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K-Tech News Vol.12, No.1

1. hau V gt Ge wa Q gt ha WA all a N Oo g gt E N 1 N e Read About If 1 jec ion 1 ifter Fuel In Dr O on Salt Water Protection 10 Ultra 150 Tidbits 9 Ultra 150 Oil Pump 8 ips 1 Tech T K Tech News Collections 3 News O MAAAAAAAAAAAYYYY VV x LKR N 00 AA 0090044 MA AAA N OOOO OOOO OY f OOOO YNO RAN KKK PPR RRXKX YY YP RRRAAXXXLY OH IY AY RA YY KKK AA RAAAAAKAAAAAARAAAAAR i 4 COIR ANN A I A S4 0 4 OO KAXA sewer E Viva GE Vio by w 190 08 OOK X 1 OOOO 0000 OOOO VIII AAAA AAA OOOO NY NYX RRA OO 0 yyy 00000000 00 OXY WARY XXX OO A XAANIN lt lt ONAA AOAO 0 Da N gt i THE KAWASAKI TECHNICAL MAGAZINE SPRING 1999 ECF NEWS Diesel Mule 2510 head gasket up things are quite different from gaso line engines It still uses a camshaft rocker arms and valves but combus tion is totally different Why The answer lies in the basic principles of diesel technology In the gaso line en
2. 6 inch length makes at least two wrenches and you can make four wrenches trom a 12 inch length Take the time now to make one of these 22mm wrenches You will need one for setup and service and the busy season is fast approaching Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 732 469 1221 SPRING 1999 PISCATAWAY GRAND RAPIDS IN SEARCH OF THE ELUSIVE 22MM ALLEN Several dealerships have called to ask where they can get a 22mm Allen to remove the front axle and swingarm bolts on the new ZX 7R ZX 9R and ZRX1100 Unfortu nately none of the stan dard tool companies carry this tool Here are a few ways to solve the 22mm Allen problem e The tool kit with these models includes a spark plug wrench with a 22mm Allen on the opposite end This can be used in a pinch but is not your everyday shop tool e 9 6 American bolt from your local hardware store will have a Tool Corner by Rob Taylor Supervisor Curriculum Development New special tools for the Ultra 150 See the Irvine Tacoma regional article this page for special precau tions for using these tools There are four new tools required for the JH1200 Al Flywheel Puller P N 57001 1426 Rotor Holder P N 57001 1428 Coupler Holder P N 57001 1423 and Impeller Shaft Holder P N 57001 1425 To check the throttle position sensor use Har ness Adapter P N 57001 1400 which is also used on the 98 99 ZX 9R 99
3. is affected signifi cantly by the ISC Idle Speed Control valves until the coolant tempera ture reaches about 100 degrees F By the time the by Gregg Thompson Product Support Supervisor engine is warm the ISC five seconds When this happens the unit will not restart until the ignition switch has been cycled off and back on However the starter motor will work so someone who is not aware of this could run the battery down try ing to restart it Make sure your dealership personnel and Drifter customers know about this the bottom of the thermo stat housing under the speedometer Unlike our previous fuel injection systems which sensed cylinder head tempera ture this one senses coolant temperature It will not function properly if the coolant level is low If the coolant level is low you might notice the ISC valves working overtime valves will no longer be operating and proper idle speed adjustments can be made brass dowel pins between the Fuel Injection Throttle Body and the Intake Manifold They don t fit very tight in either part Whenever you SPRING 1999 0 K TECH NEWS Engine Idle Speed Do not adjust the engine idle speed on a Vulcan 1500 Drifter cruiser with a Dowel Pins CD Drifter Accessory Load by Gregg Thompson Product Support Supervisor Please be aware and inform your customers that the Kawasaki VN1500 Drifter motorcycle has a maximum e
4. over a wide speed range just perfect for a vehicle made to work from sun up to sun down Diesel Technology The basic engine from the pistons down to the oil pan is standard auto motive technology but extra sturdy for its diesel application From the 2 K TECH NEWS The rest of the machine is based on the Mule 2510 4X4 with the same HI LOW range transmis sion and two or four wheel drive employing a limited slip front differen tial It uses the same belt driven continuously vari able transmission New Features e New coil springs over the rear shocks help increase the cargo bed load capacity from 803 Ib to 1100 Ib Larger 23 inch tires help carry the load e A new Donaldson high capacity cyclone type air cleaner has an air filter restriction indicator to monitor the air filter condition and indicate when cleaning is needed by Don Church Manager Service Training and Communications Hey Kawasaki Dealers there s anew Mule kickin in its stall and it s a whole different breed We re not ready to throw open the gate just yet so some of the following details could change but there are so many exciting new features you just gotta listen up The new Diesel Mule 2510 utility vehicle KAF950 A1 features a proven three cylinder four stroke diesel engine with a gear driven camshaft and overhead valves With a bore and stroke of 72 x 78mm it displaces 952cc and pro duces 24 5 horsepo
5. KX125 and KX250 99 ZRX1100 and the 1998 99 Vulcan 1500 Classic and Nomad cruiser models Vulcan 1500 Drifter spe cial tools now available There is one new tool for the Drifter which is Fuel Pressure Gauge Adapter P N 57001 1417 This is used with the existing Pressure Gauge P N 57001 164 10 perform a fuel pressure check on the fuel injection system Install the adapter between the main fuel filter and fuel supply block Refer to the service manual for testing procedures Hold the balancer gear NOT the flywheel sure they are seated prop erly in the pump In the electrical depart ment the Ultra 150 uses a peak voltage adapter made by KOWA SEIKI P N KEK 54 9 B that adapts to the Kawasaki analog multimeter P N 5700 1394 The adapter is required to check the pri mary voltage on the igniter and pick up coil assembly The ULTRA uses two electrical boxes The for ward box contains the igniter and coils and the rear contains the regula tor rectifier and starter relay Be careful when removing the clips hold ing the top covers on the boxes because they appear to be hinged but are not They will proba bly fall into the hull The electrical system is all new on this boat so be sure to attend the Jet Ski Electrical Troubleshooting class this autumn Rob Taylor 9950 Jeronimo Road Irvine CA 92618 949 770 0400 K TECH NEws 5 balancer drive gear not the fl
6. N 16009 1220 16009 1960 16187 1089 16187 1084 16187 1074 16187 1074 NEEDLE JET N 8 N 6 N A N A N A N A N A N A KMC P N 16017 1215 16017 1259 POWER JET N A N A N A N A 52 55 60 KMC P N 16159 1055 16159 1054 16159 1057 PILOT JET 30 58 55 45 48 45 KMC P N 92064 1030 92064 1146 92064 1145 92064 1142 92064 1143 92064 1142 SLIDE 2 0 3 0 6 0 7 0 KMC P N 16025 1107 16025 1162 16025 1215 16025 1216 AIR SCREW N A N A 1 1 2 1 1 2 1 1 2 1 1 2 1 1 3 4 TURNS OUT SPRING 1999 7 K TECH NEws idle position Adjust the carburetor cable if neces sary Then apply the throttle fully wide open throttle and make sure there is a gap between the stopper pin on the oil pump and the pulley See drawing Adjust the oil pump cable if neces sary That gap should be approx 0 5mm Gap at Full Throttle C precisely aligned and rigidly bonded espe cially important for a new boat when the fiber glass and bonding glue are in the final stages of curing Another item we want to point out is that the carburetor cable and oil pump cable must be adjusted at the same time first the carbure tor then the oil pump See the 7 procedure on pages 7 and 8 Although it seems confusing if you follow the steps you will get it right But here s another way to think of it First make sure the carburetor cable has slack with the throttle released in the Ultr
7. a 150 Assembly and Preparation will see the instruction to torque the three rear mounting plate nuts Be sure to torque them to the new torque spec as listed here and again after the first 10 hours of riding NOTE The torque spec for these nuts has been reduced to 19 6 N m 2 0 kg m 14 5 ft lb The studs go through the hull to the deck ensuring that they are by Don Church Manager Service Training and Communications How closely did you read the A amp P Supple ment P N 99931 1344 51 for the Ultra 150 If you didn t read it we d like to point out something you haven t seen before on a Jet Ski watercraft Open to page 4 and at the bottom of the second column you JH1200 A1 Ultra 150 Oil Pump Secrets by Kenny Osberg Product Support Specialist Since some of your Ultra 150 customers will be buying them for racing it won t take long before you get your first inquiry from a customer about removing the oil pump and running premixed fuel You ve been doing that for years right However this time honored and well known race secret is not a good idea on the new JH1200 engine The problem is this the oil pump doesn t just deliver oil to the carburetors but it also maintains the proper oil level in the two balancer chambers Oil that goes to the front and rear balancer chambers passes from the balancer chamber through a check valve into the front and rear crankcases The oil pump delivers less oil t
8. any tendency of the hull to bounce at high speeds on smooth water Meters When the ignition is turned on all eight LCD segments of the fuel gauge light up for two seconds as part of the self check feature After that only seven of the eight seg ments will light even with the fuel tank completely full The eighth top seg ment does not light during normal operation CD Punch Mark 5 part numbers listed on the microfiche and KIC One part number is listed for early engines up to num ber 00999 and the other part number is for engine number 01000 and later They are not listed as interchangeable but the only difference is the lower exhaust manifold stud hole On the early cylinder P N 11005 3745 that stud hole extends all the way into the water jacket It requires a 66mm stud with a locking agent on the threads to prevent leakage The later cylinder P N 11005 3737 uses a 56mm stud and doesn t require a locking agent The earlier cylinder P N 11005 3745 has a 5 punched on the outer top surface of the exhaust port for easy identification Overheat Sensor The engine overheat sensor is threaded into a small cavity located in the top of the expansion chamber This cavity is filled with 10W30 engine 9 K TECH NEWS attach the lines correctly If the oil pump cable breaks or becomes discon nected from the oil pump pulley the variable orifice inside the pump becomes wide open and oil f
9. ay at the event Give everyone a ticket at the door and draw prizes all night That brings the crowd in early and keeps them interested We even managed to feed the crowd since Subway is a Supercross sponsor and they kindly donated sand wiches A lot can be done if it s a storewide event Shiver and McDonald credit Parts Manager Keith Davis for a lot of the suc cess He made sure we had plenty of the right gear and Kawasaki acces sories worked up sale prices for everything and made sure it was dis played attractively With his help we turned a stock KX into a Team Splitfire replica It didn t sell that night but it will Davis has a tip to share If it can be autographed you can sell it Have plenty of Kawasaki T shirts and ball caps on hand Hosting Team Kawasaki adds credibility to your store says McDonald Serious dirt riders want a serious ATLANTA TULSA AN Easy Way To Get More PRM That s not a typo PRM is Public Relations Mileage and if you are near an AMA Supercross Motocross Road Race Drag Race or Off Road event one of the best ways to boost your PRM is to host an Open House featuring Team Kawasaki Call Kawasaki s public relations firm Freeman McCue at 714 557 3663 to request an autograph session Millennium Kawasaki in Lilburn Ga near Atlanta has held an event with the AMA Supercross two years running Co owners Ken Shiver and Chris McDonald cite sev
10. cable Before you push the start button hold the bat tery ground cable to its battery post then hit the start button If you forget to do this you will damage Adding Electrical Accessories by John Griffin Instructional Designer Instructor How many accessories can add Can hook up an electric vest Can add grip or glove warmers What about adding a radio CB or cell phone What if just turn them on when going fast Will my battery go dead or will it be ok Adding electrical acces sories to most motorcycles can create problems but some customers demand them What should you do Conduct a break ground cable to its battery post If you forget to do this you will destroy your meter or blow its fuse SPRING 1999 tank onto the ground or drenching the operator is no easy task We recently had an opportunity to try out this redesigned test tank and were very impressed with the results It handled a JT1100 at wide open throt tle with barely a splash getting out of the tank and no pump cavitation at all We ve seen much larger custom made tanks that couldn t do that If you need a test tank we sug gest you consider this one For more information call Bresee Manufacturing 14302 Plantana Drive La Mirada CA 90638 562 944 7339 move a tremendous amount of water Design ing a compact tank that will handle this water flow continuously deliv ering smooth non aerated
11. eral benefits It s good PR because it shows your customers you care enough to bring in their heroes says Shiver It s automatically an exciting event Add a few touches to make it festive and fun and it becomes something people will remember and associate with your shop The highlight is the rid ers and their autograph session but don t stop there Make the whole 4 K TECH NEWS nominal 22mm 7 8 inch head This can be welded or brazed into an appropriate socket 10 make a better wrench than the one in the tool kit Note lf you plan to use this Allen with an air impact wrench use only an air impact socket e The impeller removal tool P N 57001 1228 also has a 22mm head and could be brazed or welded to a socket e Fora first class shop tool use 7 8 inch cold rolled steel hexagonal bar stock and a half inch drive 22mm impact socket You will need to draw file 004 inches from each flat of the 7 8 nch bar stock as it is slightly larger than 22mm Fit the stock to a 22mm impact socket and either roll pin or braze in place Round off all sharp edges with a fine file and then wire brush to smooth all the corners e f you can t find 78 inch hex bar stock locally you can order some from Blue Ridge Machinery 2905 Putnam Avenue Hurricane WV 25526 at 304 562 3538 They sell materials to the hobby industry and have six and twelve inch lengths of bar stock available for about 5 00 plus postage A
12. g the dealers and customers they must wait a short while before they can get their own Diesel Mule 2510 Cont d The diesel combustion chamber design is critical since it must control the mixing of the injected fuel with air and the uniform combustion of the mix ture The Diesel Mule engine uses a spherical auxiliary combustion chamber Air compressed by the piston enters the swirl chamber where the fuel is injected High tur bulence in the swirl cham ber helps most of the fuel to burn before it enters the main combustion cham ber through a small trans fer passage Fuel Injection Pump The Nippon Denso made Bosch VE type
13. gine the mixture of air and fuel is supplied into the cylinder then ignited by a spark plug and burned at a con trolled rate In a diesel engine air alone is sup plied into the cylinder where it is compressed to a very high pressure and temperature 500 to 700 degrees Celsius An injec tor then sprays fuel into the combustion chamber near the end of the com pression stroke and fuel particles ignite by them selves Thus combustion occurs almost simultane ously at many points within the combustion chamber producing the diesel engine s character istic knocking noise The compression ratio of the Diesel Mule 2510 is 24 8 1 with 483 psi of com pression at 300 rpm The standard Mule 2510 has a compression ratio of 10 3 1 with 206 psi of com pression at 490 rpm Cont d on page 12 a gt e Two radiators cool the new engine The second radiator is located under the seat along with a fuel priming pump that has an integrated fuel fil ter and water drain e A separate belt driven 40 amp alternator charges a heavy duty 52 amp hour battery with power to spare for acces sories Why a Diesel Mule e Economy Diesel fuel is generally less expensive than gasoline and offers better fuel economy Agricultural and indus trial users can refuel from the same tank they use for other machinery Durability and Reliabil ity There is no ignition system e Torque This unit pro duces lots of torque
14. igh tempera ture stop and go traffic The oil has a balanced lubrication package that allows the wet clutch to operate efficiently and helps to extend plate life The oil has an extremely high resistance to thermal viscosity breakdown with the ability to handle running temperatures up to 330 degrees Fahren heit and a maximum temperature of 475 degrees Fahrenheit Because of the high quality synthetic base oils when the oil is super heated in critical areas such as valves and ring grooves almost no coking deposits are left This oil uses both PAO and ester synthetic base oils The oil is polar so it sticks to iron and steel This means your engine never starts metal to metal It has up to three times more film strength than petroleum oils and up to two times that of blends It utilizes a strong anti foam additive to keep oil pressure high and heat trans fer at a maximum level Available in one quart easy pour bottles Exceeds API SG SF CD and CCMC 6 5 standards by Roger Davis Senior Product Specialist separate those two parts or the vehicle might run be careful not to drop the rich when warm dowel pins into the engine Vehicle Down Sensor If a Drifter tips over Coolant Temperature Sensor while running the fuel injection and fuel pump will shut off after about The engine tempera ture Sensor is mounted in Salt Water Protection for your PWC When a watercraft is used in salt water and not protected salt deposits f
15. lectrical accessory load capacity of 70 watts Adding too many electrical accessories can cause the battery to discharge over time This of course will depend to a great extent on how the motorcycle is ridden The more time spent on the highway the more electrical load it can handle The more time spent in town and in traffic where the engine is turning slower plus the demand from turn signals brake light and the cooling fan is much higher the less accessory load it can handle Read About It on the Internet by Steve Rice bean Product Support Specialist S00 ge Ever had a customer come into your store waving a stack of computer printouts all Internet postings all from different Internet users and all about the same problem on the same model motorcycle Of course the customer wielding the Internet postings owns the same model motorcycle If you ve had this happen you re not alone if you haven t you probably will Ah the Internet the Information Age the Age of Enlightenment Or is it the Misinformation Age the Age of Confusion The customer with the computer printouts will probably fall into one of two categories First this customer may have been complaining about the same symptoms on his motorcycle as described in the Internet stories In this case the Internet may serve a useful purpose especially if the customer s complaint has never been verified or if your repair attempts have been unsuccessful In
16. low goes to the maximum for the engine rpm similar to our older style non vari able pumps The engine will not be damaged but the unit will begin to smoke and use oil at a faster rate Balancer Chambers After a JH1200 engine bottom end is assembled the balancer chambers must be filled with two stroke oil the same as used in the injection tank The rear chamber takes 20cc of oil and the front chamber which also con tains the starter gears and magneto takes 200cc Cylinders There are two cylinder SPRING 1999 Ultra 150 Tidbits by Charles Yim Product Quality Engineer We recently visited Kawasaki Heavy Indus tries Ltd KHI in Japan to learn more about our new flagship PWC the Ultra 150 We learned a number of technical tidbits that I thought might inter est you Oil Pump The oil pump has five outlet fittings It is impor tant to connect each oil line to the correct fitting since oil output volume is not the same on all of them As there are no markings on the oil pump to identify them refer to the drawing in the service manual to assure you Front Balancer a KawaChem 100 Synthetic Motorcycle Engine Oil Kawasaki has just released our new 100 Synthetic Engine oil in the USA This is our top of the line premium high performance engine oil It is blended by MOTUL and primarily designed for engines used in severe applications such as all out sport bike riding or slow speed h
17. n fuel is a must for diesel fuel pumps and injectors to function prop Diesel Mule Tour by Carole Langford Media and Public Relations Coordinator injection pump delivers pressurized fuel to the injectors It is gear driven and timed to the crank shaft to deliver fuel to each cylinder on the com pression stroke Accurate timing is critical Fortu nately once timing is set it doesn t need to be read justed The injection pump has a mechanical advancer for optimum injection timing at different engine speeds It controls engine power and speed by varying fuel volume to the injectors with its built in governor connected by cable to the vehicle s throttle pedal Even the injectors are completely mechanical with pin type nozzles As SPRING 1999 2 K TECH NEWS The Diesel Mule Tour officially began with a stop in Central California January 13 1999 Since then they have made 43 stops visiting dealers and customers in Nevada Oklahoma Texas Louisiana Mississippi and Alabama By the time you read this the tour will have contin ved on through Georgia and Florida The tour has had an enthusiastic response So far 475 people have driven the Mule and Kawasaki has given away 620 hats The dealers have received the tour in a variety of ways Some demonstrated to their staff only while others invited customers and had a catered breakfast and or barbecue The only problem so far has been tellin
18. o Fuel delivery is con trolled mechanically The throttle controls the amount of fuel delivered to three injectors via the carefully designed equal length fuel pipes The injection pump incorporates a governor and timing advancer also mechanical The correct timing must be set using a dial indicator to measure plunger stroke at TDC of the number one piston erly The fuel pump is sensitive because it func tions as a distributor and throttle since there are no spark plugs or throttle butterfly plates for those of you new to diesel tech nology Contaminants and water can cause expensive damage so a fuel filter water separator and priming pump is mounted under the seat The filter element is replaceable and there is an outlet on the bottom to allow the draining of water from the system Kawasaki will be releasing more informa tion on this exciting new model as we get closer to its scheduled September 1999 release fuel from the pump rises in pressure it overcomes the spring force and pushes the needle off its seat in the nozzle body and fuel sprays into the swirl chamber Extra fuel flows through the injec tors to cool them and then returns to the fuel tank The fuel injection nozzles can be tested using a com monly available nozzle tester and disassembled and cleaned if necessary The opening pressure can be adjusted by altering the spring tension with differ ent thickness shims Requirements Clea
19. o the outer two carburetors to compensate for the oil coming from the bal ancer chambers Removing the oil pump will eventually result in low oil level in the balancer chambers especially the rear one which has a very small capacity and cause damage to the balancer bearings You might decide to leave the oil pump on with the balancer oil lines connected and route the carburetor oil lines back to the oil tank This would ensure proper lubrication to the balancers but would result in excessive oil to the front and rear cylinders since premixing delivers the same amount of oil to all three carbure tors The bottom line is this If you decide to experiment with applying that old race modification to this new product remember that you are indeed experimenting and at your own risk And remember that all 1999 watercraft are controlled by Federal emissions regulations Modifications to the lubrication and fuel systems should only be done for use in closed course racing 8 K TECH NEWS SPRING 1999 oil This cavity only holds 0 8cc of fluid but it must be filled with oil for the sensor to function prop erly Don t loosen this sen sor unless you have to replace it because it s not that easy to refill the cav ity due to its orientation Hull There are grooves seven on each side at the bottom rear corners of the Ultra 150 hull These erooves are about 260mm long and about 2 mm wide and are designed to reduce
20. orm throughout the cool ing system and jet drive These deposits produce rapid corrosion of metal parts The salt deposits and corrosion in the cooling system can reduce the effectiveness of heat transfer causing the engine to run hotter and eventually in extreme cases engine damage Deposits and corrosion in the jet pump can cause abnormal wear and premature failures Salt Eliminator is a salt deactivator It can be used to flush cooling sys tems or as a spray on watercraft exteriors and jet pumps to remove salt deposits and protect against corrosion after the vehicle was used in salt water Once applied a protective coating stays on the surface until the next use Always rinse the craft and flush the cooling system with fresh water before applying Salt Eliminator When used to flush the cooling system concentrated Salt Eliminator is placed in a mixer device which comes with the quart size container and connected between the flush hose and the watercraft The mixer automati cally provides the proper mix to fight salt induced corrosion in the cooling system It is also available in a pre mixed spray to use on finished surfaces and jet pumps by Roger Davis Senior Product Specialist Salt Eliminator K61080 109 Dir 14 97 Ret 29 95 K61080 108 Dir 17 47 Ret 34 95 K61080 110 Dir 4 48 Ret 8 95 Quart with mixer device Gallon refill Oz spray Drifter Fuel Injection Tips cold engine The idle speed
21. s vulnerable to that same information misinformation potential A very happy customer or a very unhappy customer could decide to air his opinion pub licly on his computer Whether he s speaking the truth or not what your customer writes about you will be read and believed by lots and lots of potential customers As always word of mouth advertising is a powerful thing but now the stakes are much higher And as always an unhappy customer is much more likely to voice or post his opinion than a happy customer So pro viding good customer service treating your customers with fairness and honesty may have more effect on your future suc cess than ever before SPRING 1999 K TECH NEWS Drifter Throttle Sensor by David Behlings Parts Data Coordinator As you all know by now the Vulcan 1500 Drifter is our newest fuel injected model Some of you may have worked on our older fuel injected models like the ZX1100 A1 GPZ 1000 back in 1983 The throttle position sensor on that model was adjustable with a special tool The Drifter s throt tle sensor is incredibly sensitive and plays a large part in fuel deliv ery It should not be adjusted and is not sold separately from the throttle body Please take special care so you don t bump or damage the Drifter throttle sen sor The DM950D three cylinder diesel engine in the Diesel Mule 2510 uses a gear driven Bosch VE type injection pump made by Nippon Dens
22. the end of the Chassis section on the microfiche dated March 1999 for the KX60 B 15 KX80 W1 W2 KX125 L1 and KX250 L1 This information will appear on the next edition of KIC Volume 3 1999 which is due to dealers the end of May 3 K TECH NEws SPRING 1999 K TECH News Vol 12 No 1 Spring 1999 K TECH News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Gregg Thompson Communications Editor John Griffin Regional Editors Piscataway Grand Rapids Fred DeHart Atlanta Tulsa Walter Rainwater Irvine Tacoma Robert Taylor Contributors David Behlings Dave Corey Roger Davis Carole Langford Kenny Osberg Steve Rice Charles Yim Graphics Production Graphic Art Gregg Thompson Photography Don Church Dave Corey Randy Davis John Griffin Production Holland Marketing Services 1999 Kawasaki Motors Corp U S A All rights reserved 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 evening an event That s a big task but there is a lot of help available if you ask We had great sup port from motocross ven dors Chris McDonald says Many of them including your KMC Accessories rep will donate items you can give aw
23. the best tips along with your dealership name and location in future issues of K Tech News Send your tips to Attention John Griffin Kawasaki Motors Corp U S A 9950 Jeronimo Rd Irvine CA 92618 2084 articles from the very first issue right up to Volume 10 Number 4 There are now six K Tech News compilations available including Street Motorcycles Off Road craft Utility Vehi cles ATVs and Genera tors You can purchase any of these handy reference man uals from Kawasaki s Technical Services Department for only 6 50 each You will find these and many other useful publi cations listed for sale on page 18 of the Kawasaki Technical Services Depart ment Catalog of Resource Materials To order contact Tech nical Publications at 949 770 0400 ext 2472 or fax us at 949 460 5629 K Tech News Collections by Dave Corey Writer Producer nN This year along with the usual updates to the K Tech News compilations we decided it was time to add a street motorcycle volume For the first time you can have access to every article related to Kawasaki street motorcy cles ever published in K Tech News Included are New Optional Parts Grid on KX Microfiche by David Behlings Parts Data Coordinator Kawasaki has added a new microfiche grid called Optional Parts which shows the top end rebuild kit with all included parts and quantities You can find this grid at
24. this case the information the customer discovered on the Internet could serve to legitimize his complaint or even provide your service department with some clues as to the solution This is good the Age of Enlightenment The second category includes two possible scenarios Either the customer has never complained of this problem before but now he says he has had the problem all along or he doesn t claim to have experienced the problem but is sure he will and wants his bike fixed before he does This is not so good the Age of Confusion or Fear These situations the good scenarios as well as the bad are often made much more difficult by the fact that these Internet postings are frequently riddled with incorrect or misleading information After all there are no minimum requirements for intel ligence education experience communication skills or honesty that someone must meet before posting a story on the Inter net And there is no way fo know for sure what motivated a person to post a story This is important for your dealership to remember when dealing with one of these customers Anyone can post anything they want for any reason This is why all Inter net postings should be viewed with a healthy dose of skepticism If you have any doubts about your customer s claims or sto ries on the Internet call our Technical Hotline and discuss the situation Also be aware that millions of people worldwide read the Internet and that your dealership i
25. tlanta GA 30378 404 349 2000 IRVINE TACOMA Uira 150 FEATURES The all new Ultra 150 Jet Ski watercraft has many new features Some can be a technician s nightmare if a little pre caution is not used As stated in Tool Corner this page there are four new special tools required to service the JH1200 A1 To remove the flywheel mounting bolt hold the horn or turn signals or the cooling fan comes on the engine will have to rev higher for the charging system to reach the break even point Likewise the more electrical accessories you power the higher the rpm needed to achieve the break even point Ask the customer what type of rid ing they do such as in town or highway or some combination of both Try to determine at what rpm they typically ride On Vulcan motorcycles you may need to use a digital tachometer to get some idea what rpm that is since the customer will only know the speed and gear If a unit never reaches the break even point or reaches it at too high an rpm there are a couple options The customer can choose to remove some of the accessories or you can wire accessories with a separate ON OFF switch so the user can activate them only when riding above the determined break even rpm or the customer can Once running pull the battery ground cable away from the negative post This bike is charging the battery with 6 7 amps at idle your meter or blow i
26. ts fuse Once the unit is run ning pull the battery eround cable away from the post The multimeter now functions as your ground connection and reads the flow of amper age to or from the battery If the needle moves to the left you have a nega tive flow of amperage This means the battery is actually discharging As the engine rpm increases the charging output should increase from a negative flow to the break even point which is the rpm at which the bat tery is neither charging nor discharging In other words when the charging system output is just enough to power all the electrical equipment in use Write down the break even rpm Above this rpm positive or charging current will begin to flow The positive flow of amperage will con tinue to increase with rpm until the voltage regulator kicks in If you increase the electrical load by acti vating the high beam 6 K TECH NEws even test on their unit to determine if the electrical output is sufficient to power that accessory Use the ammeter function of the Kawasaki multimeter P N 57001 1394 This function is included on most multimeters To conduct this test turn the key off switch the meter dial to 20A or the equivalent on your meter plug the red lead into the DC20A outlet and attach it to the negative battery post not the cable Plug the black lead into the common outlet on your meter and connect it to the battery end of the ground
27. water to the jet pump without draining the test The improved design does a much better job of managing the water flow of today s high perfor mance large displacement personal watercraft At wide open throttle these big personal watercraft Personal Watercraft Test Tank by Gregg Thompson Product Support Supervisor A few years ago we ran an article encouraging watercraft dealers to pur chase a test tank In that article we also recom mended a supplier Bresee Manufacturing who we felt offered a good quality tank at a reasonable price Since then Bresee Manu facturing has improved their tank significantly 1999 KX Jetting Recommendations Here are Team Green s latest recommendations for jetting on the 1999 KX models These specs are for Sea Level up to 2500f and moderate weather conditions You may remember we published some jetting recommendations for the KX125 and 250 in a previous issue Fall 98 but these are different from those The Team Green technicians continued to experiment with different jetting and found calibrations that worked even better We suggest you use these specs as a starting point when fine tuning carburetors Ed KX JETTING KX60 B 15 KX80 W2 KX125 L1 KX250 L 1 Stock T G Stock T G Stock T G Stock T G MAIN JET 200 125 158 158 155 KMC P N 92063 022 92063 1334 92063 1367 92063 1367 92063 1366 NEEDLE amp CLIP 5114 3 NSHF 3 N7PW 3 N7NW 3 N3YK 4 N3YK 3 KMC P
28. wer at 3600rpm with a maxi mum torque of 34 4 ft lb at 2600rpm E gt A Where s the combustion chamber Answer With a compression ratio of 24 8 to 1 there isn t one Seri ously the removable plug in the head is part of the swirl type auxiliary combustion chamber where fuel is injected and first ignited Combustion exits the bat wing hole in the plug into the pocket in the piston and the main combustion chamber SPRING 1999 Share Your Customer Service Tips The importance of customer service can never be overstated You may fix it right on time and at the right price but it may not be enough If an employee had bad attitude the product was returned dirty the customer had to wait forever for help or just did not perceive any value in your service they may not be back Dealers come up with inge nious ways to take care of cus tomers A dealer close to a movie theater bowling alley restaurant or deli could give out free passes or meal tickets they purchased at a discount to cus tomers waiting for extended repairs tune ups or new vehicle assembly These customers receive a special benefit and are no longer looking over the tech nician s shoulder Customers wait ing for shorter periods are encouraged 10 walk around your store to add potential sales K Tech News would like to invite Kawasaki dealers to share your customer service ideas with us We will put
29. y wheel with Rotor Holder P N 57001 1428 Do not use the Band Fly wheel Holder P N 57001 1313 or any other holder on the fly wheel because it is thin and can easily be dam aged Use the Flywheel Puller P N 57001 1426 which screws onto the fly Wheel hub to remove the flywheel Once again do not hammer or pry on the flywheel Use Coupler Holder P N 57001 1423 to remove the new couplers Be sure to apply a small amount of silicone sealant on the coupler s threads before torquing The new mixed flow pump uses a different impeller and impeller shaft which require the use of Impeller Holder P N 57001 1425 to hold the shaft during impeller removal The JH1100 JT1100 Impeller Wrench P N 57001 1228 is also used on this model If the impeller or bear ings are removed make sure they are installed properly After torquing the impeller the impeller and shaft should rotate with 26 in lb of force or less If not check the con dition of the pump hous ing bearings and make SPRING 1999 Regional News cont d shop they want to know you re into it Bringing in the pros sends that mes sage Millennium esti mates a crowd of 350 to 450 at this year s Open House but says Shiver don t judge the success just by the day s receipts Have a good event spend time with the crowd and you ll see these people again over the next weeks and months Walter Rainwater 6110 Boat Rock Blvd S W A

K-Tech News Vol.12, No.1

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