K-Tech News Vol.12, No.3
Contents
1. Marietta OH Jamie White sco ccc Rehmert Cycle Sales Versailles OH Carlos Rodriguez nn Caribbean Kawasaki ennt Arecibo PR Cory DEVOS 2 intet be ette Vestos recenter teet eb ti ete Brigham UT Clarence Hepburn e Mark IV Kawasaki nnns Wytheville VA LEE 2h Wayne Cycle Shop sees VA Todd SI tfetje in aec tette teens Wausau Motorsports ss ssssssssssscsssssesssssessssssssssssssssssesssseessssees Wausau WI Clay Alexander ne Lakeway Power Sports eene Gillette WY2. N 8 N 6 0 0 N N N A N A N A N A 16017 1215 16017 1259 16017 1413 16017 1413 30 35 40 4 58 5 45 4 2 58 55 92064 1030 92064 1023 92064 024 92064 024 92064 1146 92064 1145 92064 1142 92064 1140 92064 1130 92064 1146 92064 1145 20 20 20 3 0 E 6 0 8 0 e 7 0 16025 1107 16025 1125 16025 1125 16025 1162 16025 1215 16025 1217 16025 1163 N A 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 113A4 14 2 13 3 3 44 6 B9EVX BIOEV me BIOEVX BROEVX BR8EVX B8EG BIOEVX 1 0 1 4 4 1 Same 4 47 50 52 49 48 47 FALL 1999 8 K TECH NEWS Digital Cameras Part 11 by John Griffin Instructional Designer Instructor In the last K Tech News Kenny Osberg explained how useful a digital cam era can be for communi cating with Kawasaki There is no need to process film you can eas ily edit pictures to improve the quality remove objects or re cen ter the picture It can save time for everyone involved but have you thought about how many other uses there are at your dealership In the Service Department Take pictures of impor tant steps in a compli cated repair as you take it apart so parts get rein stalled correctly You could even keep these on file for other technicians C to use later for training or another repair Document scratches dings and dents on customers prod ucts as they come into the shop to avoid being blamed for the damage later
3. EH T CH NEWS FALL 1999 THE KAWASAKI TECHNICAL MAGAZINE VOL 12 NO 3 INSIDE 2 Feature uci Regional ee as TAS News ROUTE LIST SERVICE 1 PARTS SALES PLEASE RETURN TO SERVICE LIBRARY The 2000 Ninjas 2 fee Upddle Seca a 4 2 Tool Corner 2 Se 5 EE Service Contest Grand Winners 5 KVF400 Crankcase 6 53 Optional Prairie Springs 6 Drive Leaks o5 e ZRX1100 Hesitation 8 Jetting Specs 0 2 Digital 9 Starter Lockout 9 Y2KX Suspension Chart 10 Generator Rotor Removal 10 Ultra 150 Power Loss AE Secure Forks ll S 2000 Ninjas by John Griffin Instructional Designer Instructor Kawasaki is entering the new millennium pre pared by introducing more new products than ever in our history The ZX 12R is primed to set new performance records to establish itself as the premier open class sport bike The ZX 9R and ZX 6R are dramatically revi talized Cruiser and tour ing customers have some sweet rides to choose from with the addition of the new Vulcan 800 Drifter and Fuel Injected versions of the Vulcan 1500 Classic and Nomad lt The ZX 12R uses a new Denso fuel injection system Retro buffs will no doubt fall in love with the new W650 In this issue we welcome the impressive new Ninjas ZX 12R The ZX 12R is pre pared to set
4. Now do the same thing on the opposite side of the rotor These alternate blows help release the High speed compression adjuster is the outside 17mm adjuster nut on the shock It has no detents All spring rates are in Kg mm rotor from the crankshaft taper Lastly hit the head of the rotor bolt with a heavy brass mallet and the rotor should come off the crankshaft You may have to repeat this proce dure FALL 1999 1 0 K TEcH NEWS Ultra 150 High Speed Power Loss by Gregg Thompson Product Support Supervisor As you may already know the JH1200 A Ultra 150 uses a jet pump that differs in design from all other Kawasaki sit down type watercraft Other Kawasaki sit down water craft use an Axial Flow jet pump This means the walls of the pump body including the impeller chamber and the guide vane chamber are rela tively parallel or straight sort of like a section of straight tube half occupied by the impeller and half by the guide vanes With this type of pump the water flows spirals straight back in an axial direction The Ultra 150 uses a Mixed Flow pump This means the walls in the pump body are not paral lel but expand through the impeller chamber and con strict through the guide vane chamber The water has some radial flow as it passes through the pump body moving outward in the impeller chamber and inward in the guide vane chamber This radial movement combined with the axial fl
5. transmission cover removed and another one is visible with the left hand engine cover removed The hole most likely to cause this prob lem is visible from the right side Note that oil in the air box can also be caused by excessive piston ring blow by or simply an overfilled crankcase If you encounter this prob lem the first thing you should do is check the oil level and then confirm the condition of the rings by doing a leakdown test a compression test is not conclusive on this model because of the automatic compression release Don t forget that when checking oil level on a Prairie the filler cap must be threaded all the way into the filler hole to get a correct reading on the dip stick Once the oil level and engine condition are confirmed remove the right hand engine cover and inspect the three holes shown in the draw ing If no problem is found there then remove the left hand engine cover and inspect the one hole shown in the drawing FALL 1999 6 K TEcH NEWS Vulcan and Voyager Final Drive Leaks by Gregg Thompson amp Randy Davis Over the years we ve had reports of oil leaks in the pinion shaft area of the final drive on 1200 Voyagers and 1500 Vul cans The leaks are dis covered as oil comes out from the area between the swingarm and the final gear case Dealers often have trouble diag nosing the leak because they don t understand how the pinion shaft is sealed If y
6. Take pictures of the condition of internal parts of a customer s machine to improve their confi dence in your repair and help them understand the cost Send customers a quick E mail with a pic ture of their completed Kawasaki just waiting for them to pick it up Put pictures of your expensive machinery boring bars dynos test tank wheel balancers etc on your Web site In the Sales Department Use a digital camera to take pictures of your used or new vehicles and post them on your Web page or a newsletter or E mail them to interested cus tomers Use these pictures on a Web page and pick a few to be your specials of the week In the Parts Department Use the digital camera to communicate parts problems with Kawasaki Send E mails to your cus tomers with a picture of their parts inviting them to come and pick them up Take pictures of your interesting displays and save them in your com puter as a reference in the future Post pictures of special sales parts used parts or take off compo nents on your Web site or even a computer that is accessible to your in store customers Starter Lockout Problems Dual Purpose Machines by Alex Dell Product Support Specialist The Symptom The starter motor will not function when the clutch lever is pulled in If this problem is encountered on a KL650 A KLX650 C KL250 D or KL250 G Super Sherpa try adjusting the clutch switch before you get too deep i
7. front forks and piggyback reservoir rear shock are fully adjustable The rear ride height can be adjusted by adding shims between the shock clevis and the frame The range of adjustment is 10mm at the shock which means about 2 inches at the back of the bike Specially con structed Dunlop 207 Sportmax radials wrap around new 3 spoke rims A mammoth 200 50 ZR17 The new ZX 12R ZX 9R and ZX 6R use sleeveless plated aluminum cylinders This cuts weight and transfers heat much better allowing minimal pis ton to cylinder clearance for maximum power A rapid cooling open deck cylinder design is unique to the ZX 12R lt a A ae NS 4 Eun 5 m ES E NN am 2 im Note how the airbox and battery are housed inside the new frame The majority of the 5 3 gallons of fuel is carried low under the seat rear tire fits on a 6 inch power and torque A min wide rim imum of 90 octane fuel is required ZX 9R New Keihin CVRD 40 Dual headlights and an carburetors mix that fuel with air under new slides that are flat on the air box side for improved aggressive look make it plain to see that the new ZX 9R means business The new ram air system throttle response Once Scoops up the air A new this mixture is com cylinder head raises the pressed a new 16 bit compression ratio from 11 5 1 to 12 2 1 for more processor in the igniter signals the stick type coils to fire The ignite
8. bags fairing or other stor age areas The added weight plus the rider and passenger should not exceed the maximum load amount listed in the own ers manual The Gross Vehicle Weight Rating GVWR is also listed on the white factory sticker on the frame Loose steering head bearings can also con tribute to head shake while over tightened bear ings can cause a high speed wobble This is a delicate adjustment that should be done by an experienced technician Tires have a direct affect on steering oscilla tion Worn or cupped tires and improper tire pres Don Church congratulates Gary Bustillos sures can cause handling problems Different types of tires can affect all aspects of handling espe cially if the tires are mis matched wrong type or incorrect size and or load carrying capabilities OEM replacement tires should always be recom mended to maintain the original handling charac teristics of the motorcycle Rob Taylor 9950 Jeronimo Road Irvine CA 92618 949 770 0400 Tool Corner have spoken with several deal ers concerned about the new Kawasaki essential tool program Many wondered if their dealership would receive all the special tools required for the new model year and if there would be duplicate tools Other concerns were the cost and return policies Bulletin SP 99 01 explained the policy and procedures and was mailed to all dealers in Sep tember The policy was created
9. most demanding customers FALL 1999 1 2 News Val Horner z 8 2 winners of Contest 3 will receive a Snap On foldable palm ratchet Congratulations to the winners and thanks to all participants Dany ANIA Cf eee Smith Bro Motorsports enn Birmingham AL Mm River Valley Cydes e Russellville AR Dan Bebi ccce eet Oto EN ote Northcounty Jet Ski nn Encinitas CA Gary Bustillos e Beaumont 5 Beaumont CA RN RE Beaumont Kawasaki enne Beaumont CA David STON Cha SUN ENICE DISCS e roit te tat Thornton CO centi Sport Center Of Grand Junction Grand Junction CO rt cete Sport Center Of Grand Junction Grand Junction CO Wade Hafenstine Sun Enterprises enentennttnnttnnttnnnttnnt Thornton CO DONNY ssec tet Carrollton GA ROV SUNTITIGI Millennium Kawasaki 2 Lilburn GA Clyde Motorsports Kawasaki nnn Wichita KS Dixon DBBSOIL ccs cceticsicioci tte tint eet otii tcd Dixon s Cycle Center
10. to help dealers perform professional repairs dramatically cut the cost of essential tools and to address state warranty laws KMC receives a list of special tools from KHI at the beginning of each new model year At that time we evaluate the tools and determine which tools will be carried by KMC and which of those will be considered essential for the dealers The number of essential tools varies on the num ber of new models and the tools asso ciated with them Some criteria we use when select ing essential tools are the cost the level of importance in a service repair how often the tool will be used if it is a Kawasaki specific tool and how many models the tool will work on For example if a new motorcycle has 4 special tools associated with it and 3 are used on the final drive and one for clutch removal we would list the clutch removal tool as an essential tool and automatically ship it to the dealers The other 3 tools will be stocked by KMC as an available tool Essential tools will be charged to the dealer s parts account and cannot be returned There will be a letter sent with them stating that the tool you have received is an essential tool All special tools have a 90 day warranty covering them against defec tive materials and workmanship Con sult the Kawasaki special tool catalog P N 99960 0065 04 for complete warranty information Rob Taylor FALL 1999 5 K TECH NEws e KVF400 Cran
11. 48 8 1 Bustillos at Beaumont Kawasaki in Beaumont Pt MH 4 gi Don Church congratulates Ray Sumner EA t T gt f pars fea Calif to present them with their awards for hav ing the highest cumulative scores in Kawasaki s M Service Contest quizzes As you read in the last W S y issue of K Tech News Ray and Gary tied in this 27 year s contest Along with the trophy a mini 28 Snap On tool chest Ray and Gary received a gift certificate for Kawasaki accessories Ray Sumner has been a Kawasaki technician for 20 years He has amassed a serious collection of Kawasaki memorabilia highlighted by 61 certifi cates and diplomas from the Kawasaki training courses he has attended Now that s dedication folks Gary is a two time grand award winner of the Service Contest Gary said the first quiz was the toughest since Beaumont Kawasaki doesn t carry Mules He had to visit other Kawasaki dealerships to do the research needed Obviously he did pretty well Way to go Gary amp Don Church Regional News cont d mon for the front end to wobble at low speeds when your hands are off the handlebars This somewhat happens on almost any street motor cycle Because of this tell customers to never ride their motorcycle at any speed with their hands off the handlebars Make sure that any extra items stored on the machine are evenly dis tributed by weight in the
12. 50 70 Std 0 23 70 90 90 KX65 Al 55 65 65 75 75 85 KX80 W3 75 110 Std 0 27 110 125 1254 KX100 C3 75 110 Std 0 28 110 125 1254 KX125 L2 120 140 140 165 1654 KX250 L2 130 145 145 165 165 180 KX500 E12 135 150 Std 0 39 Std 040 Stck 100mm 10 6 8 55 Stock 8 Sd 041 Heavy 100mm 10 6 8 57 Heavy 8 150 165 1654 KDX200 H6 amp KDX220 A7 135 150 Std 0 34 Sti 035 Stck 95mm 8 10 50 Stock 9 10 Sti 026 Heavy 95mm N A 8 10 52 Heavy 9 10 Sid 0 37 X 95mm N A 8 10 4 XHew 9 10 150 170 170 200 200 KLX300 A5 All Weights Std 0 38 rotor from the crankshaft taper This procedure often fails because the rotor has a very tight fit on the taper Using a puller or slide hammer will destroy the rotor If the service manual method doesn t work for you try this The rotor has two large curved iron laminated cores 180 degrees apart Position the rotor so the iron sur faces are on your right e Spring Rate Level 10mm 0 40 10mm 0 42 10mm 043 Stck 85mm 8 48 51 53 Stock 13 10 10mm 043 Stck 75mm 6 50 53 55 Heavy 12 8 Qil Reb Comp Out Out Light 130mm N A N A 3 0 125mm N A N A Light 100mm N A 8 4 6 Light 100mm N A 8 4 6 Std 0 29 Stock 100mm 8 48 Stock 8 Std 0 30 Heavy 85mm N A 8 50 Heavy 8 Li
13. d the coupler pulls off to leaking there should be a collection of dirt with a trail along the inside bot tom of the nut where oil has washed it clean A small amount of oil in this area is more likely to be from the above men tioned O rings If the seal is leaking it can be replaced without removing the large pin 0 Ring Cirdi 05 p ion bearing nut By removing the small pin ion shaft nut the pinion coupler can be removed allowing easy access to the seal There is also a large O ring behind the pin ion bearing nut This is the least likely item to leak which is good since that nut is very difficult Driveshaft Coupler to remove On the 1200 Voyager the torque on that nut is 400 ft lb On the 1500 Vulcan it s a lit tle more manageable at 180 ft Ib but beware that the nut has left hand LH threads It will take a lot more than 180 ft lb to remove the nut if you re turning it the wrong way FALL 1999 7 K TECH NEWS ZRX1100 Hesitation by Dave Langford Product Support Specialist If you have a customer complaining of a throttle hesitation or flat spot in the mid to upper RPM range check the air box cap or lid or cover reinstalled the air cleaner case To installed and tightened It Especially check this if This cover is a little install the cover correctly 15 easy to install the cover the air cleaner has been tricky to install correctly these tabs must fir
14. ght 110mm 15 Light 85mm 14 8 Light 100mm 10 6 8 5 3 light 95mm N A 8 10 44 N A 95mm N A 14 5 8 Spring Rate Out 10 4 4 4 7 4 9 02 23 is 14 sod tuts Seek Omm 041 Stck 100mm 14 8 48 51 53 Heavy 12 10 4 6 4 9 5 Reb Comp Out Comp Out Low High light N A N A N A Sd 0 25 Stock 130mm N A N A 33 Stock N A WA WA Sd 0 27 Heavy 130mm N A 37 Heavy N A WA WA Stock 33 mm 025 Heavy 125mm N A N A 35 Heavy 863 N A WA mm 025 Heavy 125 N A N A 35 Heavy 863 N A WA Pull Rods Stock 86 3 N A N A light 9 N A 1 T A Sd 029 Heavy 88mm 8 50 Hew 8 2 WA light 9 N A N A Light 12 Light 13 8 Light 8 12 light 9 10 EIE ES Lins m gt gt II gt Stock 9 12 N A Fork height is measured from top of fork tube to top of fork clamp Optional 85 3mm Pull Rods raise seat height 4 5mm over the 86 3mm Pull Rods and 9mm over stock height with the standard 87 3mm Pull Rods and left as you face the rotor and make sure the rotor bolt has Place Block Here been loosened two or three turns Take a 2x4 block of wood and set it against the iron surface and strike the block with a dead blow hammer
15. kcase Vent Problems by Gregg Thompson Product Support Supervisor Vent Holes Two years ago in K Tech News Vol 10 No 3 we ran an article about KVFA00 Prairie ATV crankcases not breathing properly because of cast ing flash in the vent holes in the case halves The problem that resulted was large amounts of R H CRANKCASE crankcase oil pumping into the air box The solu tion described in the arti cle was to split the Vent Hole crankcases and clean out the casting flash in the vent holes This problem appeared briefly in the KVF400 A1 and B1 and then went away Recently it reap peared in a few KVF400 C2s The problem is the same but this time we ve L H CRANKCASE discovered that all these cast in vent holes can be Optional Prairie Springs Part 2 by John Griffin Instructional Designer Instructor In the last issue of K Tech News we listed the part numbers for the optional stiffer springs available for the Prairie models We failed to mention that the 1999 and 2000 Prairie models use a different rear spring than the 97 98 models The newer Prairie rear springs have a larger inner diameter Optional Spring Details Springs Color Part Sugg Retail 92145 1199 96 95 92145 1271 116 98 92145 1225 81 95 ea 97 98 Rear Spring Red 799 2000 Rear Spring Black 97 2000 Front Springs 2 Red accessed without splitting the cases Three are visible with the right hand
16. nto diagnosing the starter system These models are equipped with an adjustable starter lockout switch mounted on the under side of the clutch lever bracket There are two small screws hold ing the switch to the bracket and the holes in the switch case are slotted These slots allow the switch body to slide a couple millimeters in the lever bracket Try loosening these screws and sliding the switch assembly toward the handlebar This may be all that is needed to fix the problem Sometimes on older machines the contacts can become dirty causing the same condi tion The switch can be easily removed and cleaned with contact cleaner Don t forget to apply lots of dielectric grease to all the switch internals before reassembling 9 FALL 1999 9 K TECH NEWS Y2KX Suspension Specs Here are Team Green s recommenda tions for suspension set tings on all year 2000 off road bikes Note that all rebound and com pression adjustments are the number of clicks out from all the way in We recommend 5W oil in all front forks except the KX60 and KX65 which use 10W oil All optional springs are available from Kawasaki Ed PP 4000 amp 6000 Generator Rotor Removal by Fred DeHart Technical Support The Power Partner Generator service manual says to loosen the rotor bolt two or three turns then strike the head of the bolt with a brass mal let in order to loosen the Fork Rider Weight 08 Height KX60 B16
17. ou are trying to diagnose a leak in this area first make sure the oil that s leaking out is indeed final hypoid gear oil Do this simply by smelling it Gear oil has a very distinctive smell It is possible for engine oil to leak from the output shaft of the bevel gear case run all the way down the swingarm and leak out in the same place Once you ve verified the leak is gear oil check the two O rings in the driveshaft coupler Most people don t even know there are two O rings in there A small hole in the pinion shaft coupler allows oil from the final gear case to lubricate the coupler splines An O ring at each end of the driveshaft coupler one on the driveshaft splines and one on the pinion shaft coupler splines prevent that oil from leaking out Pinion i Nut t 0 4 0 Pinion Shaft Coupler M e reveal the other O ring on the end of the drive shaft These two O rings are probably the most common cause of leaks in this area Next check the pinion shaft seal for leaks With a flashlight look inside the large pinion bearing nut for evidence of a leaking seal If the seal is Seal 0 Pinion Bearing Nut m The O ring on the pin ion shaft splines is easy to see and replace but the one on the driveshaft splines is a little more challenging Getting to it requires removing the circlip and washer from inside the driveshaft coupler Once the circlip and washer are remove
18. ow of the water through the pump is where the term Mixed Flow comes from Of course these tapered pump body inner walls result in a cone shaped impeller chamber with the smaller diameter at the front end When the pump is turning and producing e shaft If there is enough movement in the shaft the impeller may contact the tapered walls of the impeller chamber That contact produces friction lots of friction If may sense nothing but a loss of power at high speeds If you have an Ultra 150 customer who complains of a loss of top speed but the engine seems to be fine thrust the impeller is always trying to move for ward inside this chamber Remember that every action produces an equal and opposite reaction Nine hundred pounds of thrust coming out the back of the pump means the same pressure pushing forward on the impeller It s this force pushing on the impeller transferred to the hull through the pump housing that you feel as you accelerate All that thrust is absorbed by the ball bear ing in the front of the pump body If that bearing becomes worn or dam aged it can allow axial movement of the impeller the bearing is worn enough the friction cre ated by the impeller con tact can actually limit the speed of the boat to 20 or 30 mph Yet the customer good compression and no signs of overheating don t forget to check the axial play in the impeller shaft If it s exces
19. r no longer uses a cam sensor because a new ignition rotor with 24 projections from 4 offers such an accurately timed quick and intense spark that the coils can operate cooler even when fired every rotation The chassis got the Supersport treatment with a stiffer frame removable aluminum subframe and adjustable ride height The frame spars are now 10mm taller and the steer ing head pipe is 12mm longer for a rigid frame that delivers a telepathic Continued on pg 12 FALL 1999 3 K TECH NEWS PISCATAWAY GRAND RAPIDS 2000 TRAINING By the time you read this article I will have fin ished my road school schedule with the last two seminars being offered in Grand Rapids December 6 and 7 For those attending the Watercraft Direct Injection seminar don t worry as soon as we receive the finalized diag nostic software for the FICHT system we will mail it to you The Regional Facilities train ing classes will begin in January 2000 and con tinue through April The training schedule for classes has been mailed to your dealership If you can t locate a sched ule call K FAX at 949 460 5663 The document number for the training schedule is 1305 The system will automatically fax the schedule to you when you hang up Make sure you get together with your service manager to determine which classes or seminars you plan to attend Be aware that some training classes are only available once thi
20. ram air system adds 13 horse power at top speed The narrow aluminum monocoque frame is prob ably the most unique fea ture on this model It fea tures a huge stamped alu minum section above the engine rigidly tying the steering stem to the FALL 1999 2 K TECH NEWS K TECH News Vol 12 No 3 Fall 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 Scott Buckley Randy Davis Alex Dell Dave Langford Graphics Production Graphic Art Gregg Thompson Photography Walter Rainwater John Griffin Production Holland Marketing Services 01999 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 swingarm pivot without the width of twin spars wrapping around the open class engine The frame is even home to the airbox and battery The ZX 12R is ready to carve canyons with a short wheelbase 56 7 in light weight 463 Ib and top notch suspension The inverted 43mm cartridge
21. rase and then clam up in silent embarrass ment Use instead That s a good ques tion Let me check and find out 2 We can t do that This phrase is the surest way to send a customer to someone else who CAN do what the customer wants Use instead That s a tough one Let s see what we can do 3 You ll have to Nothing turns a cus tomer off more than being ordered around Give the customer the feeling you re in their corner no matter what the problem 4 No when used at the beginning of any sen tence Use instead The customer asks Can I get a refund Instead of simply replying No I m afraid not you say We aren t able to refund your money but we can replace the item at no charge Good customer service is more than meets the eye There are many skills you can learn It keeps customers coming back Always remember two things Your job exists because of the customer and lastly everyone is a customer Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 STEERING OSCILLATION IRVINE TACOMA We often get questions about steering oscillation or head shake Here are some factors to remember when con sidering this situation First it is not uncom FALL 1999 4 K TECH NEws Service Contest Grand Award Winners V Va We recently paid a visit to Ray Sumner at lennium Cydeworks in Lilburn Ga and Gary T 718 e
22. s season For instance Team Green Race Preparation and Maintenance will be offered one time in both the Piscataway N J and Grand Rapids Mich training centers Enroll early Keep in mind that the interaction between the varied student back grounds and the expertise of Kawasaki Training Instructors always affords you an increased opportu nity to upgrade your tech nical skills that is not available in any other medium We look forward to speaking with you at one of our classes soon Fred DeHart 201 Circle Drive 107 Piscataway NJ 08854 732 469 1221 CUSTOMER SERVICE TIPS ATLANTA TULSA Many dealer customer complaints are associated with the service depart ment There are many ways to handle customer complaints properly so that a satisfactory conclu sion is attained for all con cerned I have a list of tips aimed at the service department but will help anyone with customer complaints Cooling Off Hot Heads 1 Be polite but only speak after a couple of minutes Let them vent Deal with emo tions first Logic can wait 2 Here s what we ll do Acknowledge their problem and that you can help them 3 Reiterate what you will do Explain what you re going to do and give a time frame 4 End the conversation politely and positively Document everything immediately Phrases That Destroy Customer Goodwill 1 I don t know Many make the mis take of uttering this ph
23. sis new fork offset 6 inch rear rim and more power cal cylinder head is a copy of our World Superbike engine and it allows a lofty 12 8 1 compression ratio The top of the piston actually protrudes out of the cylinder into the head The new ZX 6R is 11 pounds lighter and has even more power with a sky high 12 8 1 compression ratio requiring a minimum of 90 octane fuel like the ZX 9R New valves valve springs and crowned valve tappets add durabil ity The dramatic weight loss was accomplished even with an additional headlight wider rear tire 180 55 ZR17 and taller front tire 120 65 ZR17 A new magnesium clutch cover valve cover oil pump cover and sump pan cut weight New plated aluminum cylin ders stick type ignition coils and an internally braced swingarm cut about five pounds The chassis is more focused for increased rider feedback with 2mm less fork offset 28mm and a 5mm wider fork pitch 210mm Damping rates have been revised front and rear A new rear link offers a more linear progressive rate that is stiffer throughout the range than last year New front brake calipers have different size pistons and new pads for improved feel and bite These new Ninjas are leading the brigade of new products from Kawasaki They reach new performance levels while still setting the stan dard for riding comfort They have been engi neered to the highest stan dards to satisfy the
24. sive check the impeller shaft Simple Way to Hold Up Forks by Scott Buckley Product Services Technician How do you secure fork tubes when you are checking the oil level This can be tricky Mounting the bot tom of the fork in the vise means you may have to stand on some thing to check the oil level Setting the fork on the ground invites the opportunity for i hod lo fall over especially on the current KX forks which are not flat on the bottom Try this Insert the axle into the axle clamps and bolt the two forks together like those in the accompanying picture Fat 1999 1 News 2000 Ninjas Cont d ride The fork offset is changed from 35mm to 30mm to increase trail to complement the wider 6 inch rim with190 55 ZR17 rear tire and new frame Comfort and control are improved with revised suspension settings front and rear A new rear link offers a more linear rate that is stiffer initially then softer at the end of the stroke New 310mm front brake rotors are 10mm larger than last year for stop on a dime braking power New instrument gauges are a classy black on white and the coolant temperature is now dis played numerically ZX oR The ZX 6R is ready for more racing glory with more power and 11 less pounds to carry around A new semi hemispheri The ZX 9R is still comfortable to ride but underneath the skin everything got more serious with a stiffer chas
25. snnt Scott City KS Shirley Beeson cocto e Duc Dixon s Cycle Center nennt Scott City KS David Lemmo 2 20222 5 Brockton Cycle ees Brockton MA NS Classic Motor Sports eee Ira Verse City MI Mark Paw Paw Paw Paw MI DOUG NOC e tuc Northern Kawasaki nnns Cloquet MN Jason Clymer Gase corte tr tet t etes cott Jackson MN Larry attt ette itte ete Jackson Cycle eee Jackson MN PRO Cycle 2 ROCES ter MN David 2 Springfield Kawasaki 00020012200 Springfield MO Jeff Red DIC ace tete eitis Valley Park MO DOOM Sports City CUCIBIW Great Falls MT Tom Vandergrinten enn Spons Great Falls MT Dean Bueckel eee Action Cycle eeenttttnttttntttnnnnttnnc Minot ND Robert Rilo Action CV LE Minot ND Action Cyde sentent ND David Southern Ocean Cycle Center 21 4 Manahawkin NJ AYER IIT NER OO PARENT cn MER Marietta OH Grog nin tur aee Big 4
26. st be without getting one or inspected or replaced There are tabs at the bot pushed down into the both the tabs into the recently It is possible that tom of the cover that fit slots in the case and then grooves Doing this will the cover was improperly into slots in the bottom of the bolts at the top cause a lean hesitation Y2KX Jetting Specs Now that the year 2000 KXs have been out for a while Team Green has had a chance to test them extensively and offers some recommended jetting specifications These carburetor settings were developed using Trick Racing Gas and Bel Ray oil premixed at a 40 1 ratio They are recommended for sea level to 3000 ft Your results will vary with the use of different gasolines oils and mixing ratios Jetting needs will also vary with changes in temperature humidity and altitude Team Green does not recommend the use of pump gas aviation fuels or octane boosters Ed KX60 B 16 65 1 KX80 W3 KX125 L2 KX250 L2 KX500 E12 Stock T G Stock T G Stock T G Stock T G Stock T G T G 0 5114 3 lt 50559 3 54994 NSHF 3 lt N7NW 3 N7NW 2 N3WE lt N82M 3 N82M 2 16009 1220 16187 1129 16187 1129 16009 1960 16187 1084 16187 1084 16009 1915 16009 1580 16009 1580 EN N A 2 4 16159 1055 16159 1059 16159 1058 mnm 2 Stock 200 lt 230 220 125 g 160 160 168 170 0 R Only 92063 022 92063 025 92063 024 02063 1334 92063 1369 92063 1368 92063 1371 92063 1372 n
27. the motorcy cle industry on its ear just like the ZX 11 did 10 years ago Kawasaki designed an all new 1199cc engine with an 82mm bore and 55 4mm stroke The bore to stroke ratio is the same as the ZX 9R and ZX 6R The valves are directly actuated by the cams so the valve clearance inter vals will most likely be every 7500 miles with no inspection required at the first service Lightweight magnesium is used for the valve cover clutch cover alternator cover pulser cover and even the oil sump This engine with intake and exhaust is 26 5 pounds lighter than the gt A scissor type primary gear the ZX 12R elimi nates gear lash noise by spring loading the teeth s ZX 11s The Denso fuel injec tion system uses 46mm throttle bodies with single injectors Each injector has four orifices for good fuel atomization like the Mit subishi system used on the fuel injected Vulcans Unlike those models the ZX 12R uses a cam sensor to determine when the pistons are on the com pression stroke to fire the stick type ignition coils just once per cycle A gear All U S model ZX 12R ZX 9R and ZX 6R motorcy cles come with a catalyzer All ZX 12R models come with a completely Titanium muffler CA model ZX 9R and ZX 6R models have dual catalyzers position sensor allows the ECU to calculate the effects of the ram air sys tem and adjust the igni tion and fuel injection accordingly The
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