Fall 1988 The Kawasaki Technical Magazine Vol.1 No.1

First IssueK-Tech News

by Ken Ploeser, Editor-in-chief

You may remember the Hot LineNews. But, now we call it “K-TechNews” because it will give youinformation on what’s going on in alldepartments of Technical Services.There are a lot of things to talk about, sothe folks in Technical Services, want toexpand the line of communication. Youmust provide quality services to yourcustomer and we need to work hard tosupport you.

We will be including feature articlesthat focus on the operation of aprotitable service business. Guest spotson those dealers who have made ithappen. And, of course, letters wereceive from you.

Shop Talk departments includetechnical information and explanations,special tool tips, parts news, serviceinformation, and more.

You’ll hear the inside scoop from theHot Line Specialists previewing newproduct information and keeping youup-to-date on the latest tricks.

You should file all K-Tech issues inyour Service and Warranty Binderunder the "Training" tab.

We encourage your input! If youhave a service tip you would like toshare or an article to contribute, send itin. You say yours is the top servicedepartment in your area? Tell us aboutit, you just might be in our next GUESTSPOT. Please send all yourcontributions to: K-Tech News,Kawasaki Motors Corp., U.S.A.

WHAT’SINSIDE

ENGINE CHASSIS

4x4 DrivetrainTest TankService TipsRegional News

Introduction by Tim Bean, Program Developer

KLP300-C1 Bayou for 1989. The engineKawasaki is proud to introduce the

is based on our reliable KLF300B withchanges made to the head, cams, andcab, extracting more low end torque forstump pulling power. Heavy dutyadjustable independent suspension,powerful twin piston caliper front brakesand a dual range transmission make this4x4 stand up to the toughest jobs around.

drive system with a trick limited slipdifferential up front. See the article on

The drive train is a full-time four-wheel

Page 2 of this issue for a detailed look atthe four wheel drive system. And for abrief technical look at other new modelsfor Kawasaki in ’89, check out our 1989Product Sales Guide. You will besurprised at what you’ll find. n +

Specifications

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 ccBore & Stroke.. . . . . . . . . . . . . . . . . . . 76.0 x 64.0 mmMaximum Horsepower . . . . . . . . . . . .20 @ 6500 RPMMaximum Torque . . . . . . . . . . .17.4 ft.-lb @ 5500 RPMCompression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . .8.6:1Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CVK 32Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . 2.3 Qts.Starting System . . . . . . . . . . . . . . . . . . . Electric & Recoillgnition System . . . . . . . . . . TCBI w/ Electronic AdvanceBattery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V/14AHMaximum Charging Output . . . . . . . . . . . . . . . . . 329 V/A

Front Wheel Travel . . . . . . . . . . . . . . . . . . . . . . . 4.3in.Rear Wheel Travel . . . . . . . . . . . . . . . . . . . . . . . . 4.7 in.Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.2 in.Front Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . 24/8-11Rear Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . 24/10-11Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 8.9 in.Minimum Turning Radius . . . . . . . . . . . . . . . . . . . .9.5 ft.Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . 2.9 gal.Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ShaftTrack Front/Rear . . . . . . . . . . . . . . . . . . . . . 33.2/33.1 in.Dry Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567 lb.NOTE: Specifications subject to change without notice.

The Technical Magazine ll1

SHOP TALK/TECHNICALKLF300-C1

Limited-SlipDifferentiall Maximum TractionlFull TorqueThe special tools listed below areneeded to do the following:l Sub transmission disassembly

and assembly.l Front final gear case pinion gear

removal and assembly.l Front final gear case pinion gear

preload measurement.

Four- Wheel DriveThe new KLF300-C1 4x4 is here. It

shares Kawasaki technology with the2-wheel drive B2 model. But, of course,the big news is the full-time four-wheeldrive. All wheels are driven by the twospeed subtransmission that fits up tothe left side of the transmission case. Astub shaft extends from the front andrear of the subtransmission.

Each end of the splined stub shaftdrives a front and rear driveshaft. Therear wheels are driven by the solid reardrive shaft via a bevel gear set. Nodifferential is used on the rear axle of the4x4. The front driveshaft connects to thelimited slip differential. Right and left halfshafts drive the front wheels throughconstant-velocity joints.

The limited slip front differentialprovides full traction during turning,while the steering effort at thehandlebars is greatly reduced.

Here’s thespecial toolsyou’ll need

by Jerry Heil, Program Developer

To extend engine life, thepiston-to-cylinder clearances havebeen tightened up by enlarging thepiston diameter and the top and secondring groove widths have been reduced.Other variations from the B2 modelhave helped broaden the power band.These changes include reshaping of thecombustion chamber. Squish area isenlarged and angled up slightly. Asmaller 12 mm NGK D8EA spark plugallows more metal in the valve seatarea, increasing heat dissipation. A newcam profile reduces valve lift by about0.2 mm on both intake and exhaust. Fullignition advance occurs 800 RPMsooner and is reduced 10 degrees to 30@ 3200 RPM. The result is an enginethat delivers stumppulling power over awider RPM range. Even though peakpower is reduced by less than onehorsepower, the power starts at a lowerRPM for more useable performanceideally suited for the nature of this 4x4workhorse.

For further technical informationabout the KLF300-C1, refer to theService Manual P/N 99924-1117-51.

Be sure to look on the trainingschedule for the upcoming ATV class.

2 l lK-Tech News

COMMUNICATIONS

MICRO- by "Micro" Mike Jeffers, Parts Publications

Do you realize that there is a lot of information besides part numbers included on eachmicrofiche? General specifications, tuning information, and a library of reference materialpart numbers concerning each model are but a few of the features. Also included is aparts number indexwhich lists every part number for the specified model. Bulletins or anyspecial gasket kits that may effect the product are included in a specific section at thebottom of the fiche. Reproductions of service bulletins are added during each update ofthe microfiche. Taking time to use the microfiche fully will save you time in the long run.

Beginning with 1988 models, Kawasaki street-legal vehicle parts microfiche includedecal part numbers. Prior to 1988 the decal part numbers can be found on Parts bulletinMC 86-02.

Kawasaki has microfiche decks and subscriptions especially designed for your needs.If you have any suggestions regarding microfiche, call “Micro” Mike Jeffers, KawasakiService Training and Communications Department at (714) 770-0400 ext. 2573.

BULLETINSby Ray St. John, Technical Writer

You guys make a difference! “Howcan I help,” you say? Well, Jeff Arrudafrom Clark Kawasaki of Orange,California, informed us of a problem hediscovered while doing the A & P on a1988 EX250-F2L. He questioned thelocation of the evap hoses on the fueltank. Sure enough, the hoses weremislocated and so were the color-codedstickers on the tank.The result:

MC88-01 Recall bulletin!Thanks Jeff. Good

VIDEOSV-TWIN FAMILIARIZATION (See

Service Bulletin TR88-02) This 35-minutevideo explains service and designfeatures unique to the 700-750 ccV-Twin.

JET SKI® WATERCRAFT (SeeService Bulletin TR88-02) This one-hourvideo on JET SKl® watercraftmaintenance covers technical featuresalong with general maintenance andinspection procedures on the JS550A,JS300B, and JF650A models.

ZX750-R NINJA (See Service BulletinTR88-02) Kawasaki has developed this18-minute video tape highlighting engineremoval and disassembly with helpfulhints that will reduce service time.

BONUS!As an added bonus, you will receive a

FREE video reference manual with eachtape order as a quick-reference guidewhen working in the shop. To order:call Ray at (714)770-0400 ext. 2466.

RECAP1988-FDM/FAR/RECALL

NEWVulcan 88

exploded viewengine parts posteris now available.Order it from theKawasakiTechnical ServicesDepartment. Takea look at ServiceBulletin TR88-01 tosee all the postersavailable.

BulletinNumber Model DescriptionMC88-01 EX250-F2L Vacuum Hose Routlng—

The color coded adhesive decals on the gas tanks of 1988 Californiaemissions equipped EX250-F2L models are incorrectly placed.

MC88-06 ZX1000-B1/L,B2/L Rear Wheel Hub Damper—On eligible units, the rear wheel hub damper may slip out of position andbecome damaged during hard acceleration, allowing excessive move-ment between the hub coupling (sprocket carrier) and the rear wheel hub.

MC88-07 ZX1000-A1/L,A2/L Accessory Backrest Recall—The eligible backrest is not as strong as it was intended to be. If thebackrest breaks, the passenger could fall off the motorcycle and beinjured.Kawasaki has initiated this recall campaign to remove the eligiblebackrests from the market and from customers’ motorcycles.

UV88-01 KAF450-B1 Cargo Bed Handgrips—Handgrips have been added to the KAF450-B1 cargo bed to make iteasier to tilt up and down.

PG88-01 GD700-A1/AS1 Hard Startlng—Some eligible units may have an incorrectly wound generator stator coil.This results in hard starting.

TECHNICAL TRAINING MANUALSKawasaki is making available manuals used in product support training courses. They

were created specifically for technical instruction and contain a wealth of information notfound in any other publication. Each manual is richly illustrated and covers the subjectmatter with simple, concise explanations. This material is easily understood by all skilllevels. To order, refer to Service Bulletin TR86-03, or contact: Technical Training(714)770-0400 ext. 2466.

l Electrical Fundamentalsl JET SKI Watercraft Video

Referencel High Performance Enginesl ZX900 Engine Series

Familiarizationl V-Twin Engine Familiarizationl 750 Turbol Police Motorcycle Maintenance

The Technical Magazine ll3

LETTERSCity of North Las VegasPolice DepartmentLas Vegas, Nevada

Dear Sirs:

In December, 1987, this Departmentpurchased eight KZ1000 Policemotorcycles from a local dealership,Kawasaki of Las Vegas. Since that time,we have experienced some minorproblems that were not unexpected frombrand new equipment.

The point of this fetter is not to dwellon the problems, but rather to commenton the service provided by Kawasaki ofLas Vegas. Whenever a motorcycle wastaken to the dealership, we receivedprompt, satisfactory service that we foundrefreshing. On some occasions,breakdowns occurred in the field.Kawasaki of Las Vegas immediately senta service mechanic to the field andrepaired the motorcycle on the spotTheir after-sale service is excellent.Everyone we have dealt with at thedealership, both in sales and service,was more than cooperative, fair andexcellent representatives of the KawasakiMotor Corporation.

GUEST SPOT

All our experiences with Kawasaki ofLas Vegas have been excellent. Wehope this letter might commend thedealership for their professional attitude.

Sincerely,

J. L. ZohnerChief of Police and Lt. K. KiphartTraffic Bureau Commander

Editor:I don’t think much of a comment is

necessary. You get the point.

Tucson Kawasaki5225 East 22nd StreetTucson, Arizona 85711Dear Sirs:

I am interested in receiving KawasakiHot Line News Publication regularly hereat our new store. Please advise as tohow I may subscribe.

Thank you.

Michael HughesService Manager

Editor:Mike, you can consider yourself a

subscriber. “K-Tech News” is a quarterlymagazine mailed automatically to allKawasaki dealers at no charge. Justcheck your regular weekly mailing fromKawasaki.

Publisher . . . . . . . . . . Kawasaki Technical ServicesPublications Manager . . . . . . . . . . . . . . . . Don ChurchExecutive Editor . . . . . . . . . . . . . . . . . . . . . . . . Gary HerzogEditor-in-Chief ........................... Ken PloeserRegional Editors

North and East . . . . . . . . . . . . . . . . . . . . . . Fred DeHartCentral and South . . . . . . . . . . Walter RainwaterWest and Corporate . . . . . . . . . . . . . . Ken Ploeser

Technical Support Specialists:Joe Nowocinski Sob EllisonRandy Davis Tevis MoffettJohn Porno Ken OsbergGregg Thompson Steve Rice

Graphics and Production:Graphic Artist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tim BeanComputer Design . . . . . . . . . . . . . . . . . . . . . . . Pat ShibataKawasaki Graphic Services Dept. StaffKAWASAKI K-Tech News©1988 Kawasaki Motors Corp., U.S.A. AlRights Reserved. Published by: Kawasaki. Allsuggestions become the property of KawasakiMotors Corp., U.S.A.. Sending a suggestiongives Kawasaki permission to publish and oruse it without further consideration.

by Don Church, Manager-Service Training and Communications

In future issues, the guest spot willfeature Kawasaki dealers who havedeveloped innovative ways of promotingand operating their service departments.To get started, take a look at thefollowing questions:

l Do you have an open house andoffer free vehicle inspections?

l Do you make customersatisfaction follow up mailings?

l Do you offer discounts to clubmembers?

l Do you do specialty work suchas painting?

l Do you have a JET SKI®watercraft test tank?

ll Do you “winterize” JET SKI®watercraft and even offer winterstorage?

Some of you can answer "yes" tothese questions, and some of you haveother ideas that work well. The GuestSpot is here for you to share yourformula for a successful (i.e., profitable)service department with other Kawasakidealers. Oh, and for those who answered"no" to these questions, be sure to readGuest Spot in the next issue.

4 llK-Tech News

ROCKY MOUNTAINKAWASAKI-

by Keith Pestotnik, R.M.K. RegionalService Manager

Rocky Mountain Kawasaki, locatedin western Nebraska, is an independentdistributor of Kawasaki productsthroughout the Rocky Mountain andhigh plains region. They first beganpurchasing Kawasaki motorcycles in1964, two years before KMC wasformed, and actually sold the firstKawasaki in the United States.

In addition to distributing Kawasakiproducts, their parent company, MasekDistributing, Inc., also distributesMariner Outboard engines, severallines of quality boats, two golf car lines,and a host of other power products.

Rocky Mountain Kawasaki hasestablished a widespread reputation forservice excellence, particularly indealing with problems relating to highaltitude. Their marine experience datesback to the 1940s and they have donean excellent job assisting their dealersthrough the explosive growth of the JETSKl® watercraft line.

Keith Pestotnik

l Technical training for dealersl Technical assistance to dealersl Consumer Servicesl Warranty Administration

Keith started his career with R.M.K.in 1984. His dealership experienceinvolved managing servicedepartments for different franchisedbrands, He always remained close tohis toolbox, with a primary focus onKawasaki products.

He can offer today’s Kawasakitechnician some very solid advice on atimely basis. RMK dealers can call Keithfor advice and technical assistance at(308)436-5818.

FEATURE

“Service: 1990”A Business: An entrepreneurial enterprise, which when well

planned, will result in the viable pursuit ofhappiness, health and profit.

EVALUATE Your Service Business by Ken Ploeser

“Service: 1990?” It’s only 1988! Did Imiss something? Well, it’s quite possible.The 1989 models are here already and1990 will be upon us before we know it.We all talk about planning, and now is thetime to do it. If ever there was a goodopportunity to get a handle on the serviceoperation of your business, now is it.

Hold it! Wait a second, before youexplode out of the starting blocks. Theonly way to really plan for the future is toget a clear picture of where you’ve beenand where you are right now. So thequestion is, what is your servicebusiness? As you know, every businessprovides two things to the consumer; aproduct and a service.

Are you a tuneup shop, an overhaulshop, a body shop? Maybe you are acomplaint department, or a junkrestoration department. How does yourservice business fit into the overallbusiness plan you projected? Do you runyour service department like the rest ofyour business, or does it give you thebusiness.

By evaluating the businessactivities you have engaged Inyear-to-date, you can develop a planof action for your service department.Begin by pulling all the repair order hardcopies for the last 90 days of business,including all sales jobs, parts andaccessory internal work, and the jobsperformed to support the servicedepartment itself.

Hopefully, you write a repair order forany and every job performed by servicepersonnel.

Look at what types of jobs you aremost frequently called upon to do. Makea list of those jobs which yield the mostprofit with the least hassle. This list is thebeginning of your service menu, theservices your business sells to customers.

So, that’s a start on the type ofservices you provide.

Next, and probably most important, isto get a handle on the product you’vebeen selling through service. Take

inventory on your service product.“Physical inventory of what?” you say.Well, it may not actually be a physicalinventory, but you should know preciselywhat you are selling. The wholesale costversus the retail sales. We are talkingabout TIME. How many hours the storeis open compared to the billable hoursfrom service. Selling hours of labor. Yes,your service product is time.

From the Repair Orders you pulled upto identify your services, make a list ofthe total labor dollars sold. Compare thistotal to the technician payroll paid out inthe same time period. If you divide thepayroll (your wholesale cost of laborhours) by the total labor dollars billed out,you’ll have your percent labor cost perhour sold. This figure will not be morethan 50% in a profitable servicedepartment.

Labor PayrollLabor Dollars Sold

= 50% or less

"I thinkI’m makingprogress."

Now, compare the billable hours tothe hours the service department is openand available to the customers, you’llhave the percent of billable labor hours.This figure is either a pleasant surprise ora major cause of heart failure! In eithercase, billable hours indicate volume ofservices that have been sold. It does not,however, indicate the amount of labor

hours out in the market that are rightfullyyours to recover.

Billable Hours = ?Hours OpenBillable hours: the key to a

profitable service operation. Beforeyou say you already do that, take a checkon how well you are filling the servicelabor pipeline. You may keep good trackof hours sold and collected by work orderhard copies; you certainly know howmuch money is going toward serviceemployees’ salaries; but, are you gettingall the labor sales you should havecoming to you? What percentage of newbikes sold return for service? Are theycoming back far beyond the intervalsrecommended in the owner’s manualmaintenance schedule? Do they comeback only for the first service or never atall? Does your overall selling plan includeselling your services?

Each unit you sell, new or used,carries with it the potential labor hoursales that you should recover. When acustomer buys a unit, your service salesgo with it. How many labor hours are notreturning to your store? Realizing thepotential sellable hours you couldcapture, will aid in planning service levelsyou can provide.

Taking a look at these three factors,labor cost, billable hours and firstservice-to-sales ratios, is the first steptoward realizing the service profits youdeserve. If you were not able to attendthe Service Profit Seminar at the dealershow, be sure to see your DistrictManager or plan to attend the nextService Department Operations class fordetails.

Our next feature will focus on thedetails of the “K-BOSS” service businesssystem. So, hold on tight while we grab ahandful and Let the Good Times Roll!

The Technical Magazine ll5

SERVICE MERCHANDISING

Test Tank Updateby Ray St John, Technical Writer

Recently we’ve been seeingincreased interest in building a Jet Skidwatercraft test tank. Two articles havebeen run in two different Kawasakipublications and a number of dealershave built tanks. Their practicalexperiences showed us how we couldchange our tank design for the better. Sowe made some changes and here theyare.

Basically, our tank is twelve feet longand about eight feet wide. Suggesteddimensions are on the illustrations. Youmay want to increase dimensions to suityour own needs. It has a wall down themiddle so the water will flow around thetank in a circle. If the water circulatesaround or under the boat, the pump willcavitate and lose thrust. The walls arestrong enough to hold the weight of thewater and absorb the jet pump’s thrust.

We suggest that you build your testtank so that the bottom is below groundlevel about twelve to fourteen inches.This makes it easier to load the boat intoit, and also gets the footings below thefrost line. Of course you may have toadjust this depending on the frost linedepth in your area.

The footings and slab bottom are ofpoured concrete strengthened with 3/8"re-bar or wire mesh. If you have acontractor doing this work, make sureand tell him what you’re going to use itfor. He’ll know how much reinforcementto use. Also, be sure to put a 12"x12"footing under the center wall.

All the walls are 8"x8"x16" concreteblocks. Use 3/8" re-bar between eachcourse of blocks and at the corners asshown to reinforce the concrete cornerfillets. The walls can also be made ofpoured concrete. If so, they must bepoured at the same time as the slab andfootings, or the seam between the bottomand sides will be very hard to seal.

Set J-bolts in the side and center wailsabove the first and third courses. Thesewill hold the baffle mount angle irons inplace. Be sure the J-bolts are in a verticalline and directly across from each other.Set the eye bolts into the end walls abovethe fourth course, just at or above thewaterline.

Build the walls about eight courses tallat the high end and five at the low end.When the walls are full height, slide apiece of re-bar into each hole so it goesall the way to the foundation. Fill the

holes with poured concrete. Be sure todo the center dividing wall, too.

It’s free standing so it needs all thehelp it can get.

Cap the walls with mortar. Make it alittle rounded.

Build forms in the corners of the tankand pour concrete into them for cornerfillets. These smooth the water flowaround the corners so the larger the tank,the larger they should be. The re-barprotruding across the corners holds themin place.

Plaster the inside of the tank and ailaround the center wall. Use two 1/4"coats for best results. This is similar towaterproofing a basement. So if youknow something that works in your areato seal a basement, it’ll probably workwell here, too. Our design goes one stepfurther by coating the inside withswimming pooI sealant. Let the plastercure thoroughly before applying thesealant. Clean the tank first, and thenfollow the sealant manufacturer’sinstructions to the letter.

Roof over the tall end of the tank tokeep the water from splashing out. Braceit to withstand the expected snow load inyour area.

6 llK-Tech News

Tip:

Use these drawings to solicit bidsfrom your local contractors

NOTE:You can enlarge the tank. Just besure you keep-the proportionsconstant!

Bean

Scales to measure the thrust arereadily available. Check feed stores,agricultural implement supply houses;even bait and tackle shops may havesomething you can use. Get at least a100 pound capacity scale. Use a lever togive your scale enough of an advantageto absorb about 600 pounds of thrust. Ofcourse, you can get fancy too, and get anindustrial grade scale that can handle theentire thrust toad directly. If you build ascale-and-lever set-up like we’ve picturedhere, you can see the scale from theoperator’s position beside the boat. Thecable connecting the back of the boat tothe scale must be strong enough toabsorb shock loadings five times the totalthrust. If you plan on a maximum thrustload of 600 pounds, then the cable mustsupport 3000 pounds safety. We suggest1/4" plastic-coated stainless steel cable.This will have enough strength andflexibility to work properly and will notweaken because of corrosion.

For a bow tether 3/8" or 1/2" nylonrope is good. The bow tether keeps theboat from banging against the wallsduring testing and from crashingbackward with the water flow when thethrottle is released at the end of the testrun.

Finally, when you start using your testtank, experiment with the baffle so thewater flows smoothly around the tankwithout backing up around or under theboat. Different boats and different sizetanks may need different baffling, so takeyour time and work out the bestcombination for you. You may useconcrete blocks as we show, foradjustability, or you may decide to use analuminum plate with holes drilled in it. lfyou use concrete blocks, leave themloose. The angle irons will hold them inplace.

Many personal watercraft now havethe exhaust outlet on the right so youmight want to set up a fan to blow thefumes away from the operator.

Any electrical equipment near watermust meet special standards. Consult aprofessional electrician or contractor.

SECURITY AND SAFETY AREIMPORTANT CONSIDERATIONS.

Check local ordinances for requiredfencing or other security devices to keepsmall children from falling into the tank.Thirty inches of water is a definite safetyhazard to small children and pets. Keepthem away from your test tank. A lockingcover over the whole tank would be agood way to keep leaves and otherdebris out. It could also prevent anaccident.

Inspect all the hardware regularly forcorrosion damage. Keep everythingpainted and sealed for tightness andprotection. You will have a lot of workinvested in your test tank by the time it isfinished, but it can be a valuable tool forJet Ski® watercraft service and a realmoney maker.

The Technical Magazine ll7

INSIDE TECH SERVICES

by Joe Nowocinski,Technical Support Supervisor

We are proud to introduce our newestmember of the Product SupportSpecialist team, John Porno. Coming toKMC directly from a topnotch Kawasakidealership, John brings his 20 years oftechnical experience to add to the HotLine. John excels in the world ofmotocross, desert racing and, mostrecently, he placed first in CRC 4-StrokeEnduro in 1984 and finished second inCRC 200 cc Class Enduro in 1987.

Can he be of assistance to you? Youbet! Just call the Kawasaki dealerassistance Hot tine between the hours of7:30 am and 3:30 pm (PT).

When calling the Hot tine, theinformation needed from you will be: yourdealer number, your first name, completemodel designation, the last six digits ofthe frame or the middle five of the hullnumber, mileage (ii applicable), andfailure date.

If a problem requires you to make asecond call on the same unit, a lognumber will be given to you by the Hottine technician. When you call back, givethe log number to the Hot Line technicianfirst. Then he can recall your original filemore quickly.

John Pomo

New Computer Systemby Gary Herzog, Product Support Manager

We have a great new computerizedsystem that provides a more efficient,state-of-the-art means to log, store,update, access, and analyze productsupport related contact information.

Whet this means to you is thatwhenever you contact us, we canimmediately access more information toassist you with resolution of technical,consumer or warranty situations. It alsomeans that valuable product qualityassurance information is constantly beingextracted from your input so that productproblems are quickly identified andresolved.

While talking to a Hot tine technician,the little clicks and beeps you hear in thebackground are coming from theircomputer terminals. As you provideproduct or consumer information andcomments, they are typing the data intothe on-line, main frame computer system.The computer responds by displaying onthe terminal screen related supportinformation that can be drawn fromseveral existing banks of data. At thattime, a special notice may also appear on

8 llK-Tech News

their screen to alert them that a priorcontact has been logged about the samecustomer or vehicle. They can quicklyreference the previous information andcontinue smoothly with troubleshooting orother action that was started earlier. Thenew system allows Consumer Services,Team Green, Quality Assurance andWarranty Administration shared usage ofthe system with the Hot Line.

Warranty repair authorizations andrelated warranty information make up animportant segment of the system. Whena warranty repair is authorized, thespecific unit data has been verifiedagainst existing Kawasaki records beforethe authorization number is given to you.That means the model, frame, job codes,and warranty period have already beenverified so that necessary corrections canbe made. When the claim is submitted, itwill process quickly.

We are proud of our new system’scapabilities. We started development ofthis elaborate contact logging systemabout 18 months ago.

Many refinements and features wereconsidered, tested and added during thepast season to perfect a system that isalso “user friendly.” It is just anotherexample of Kawasaki’s goal to be“number one in the way we do business.”

Tips from the SpecialistsTEST TANK TIPS ZG1200 METER REPLACEMENTBy Kenny Osberg By Walter Rainwater and Randy Davis

1. The purpose and usage of a JET SKlwatercraft test tank are:

Here are some instructions to savetime if you ever need to replace a meteror gauge on a ZG1200.

l A test tank boosts the image of thedealership. This means thatcustomers get the impression thatthe dealer is serious about a highlevel of service and the dealer iscommitted to the JET SKI®watercraft business.

l Measuring thrust helps diagnoseengine and pump performance.

l The test tank allows simulationofreal conditions. The engine can berun without using auxiliary coolingwater supply.

l A test tank puts load on the engineso certain problems can bediagnosed property (startingdifficulties, high speed miss, coolingsystem diagnosis, etc.)

l Leakage -- water leaks can befound and repaired using a tank.

l Carburetor mixture tuningl Performance tuning for racing -

There are numerous aftermarketcompanies offeringhigh-performance parts. A dealercan use a tank to demonstrate tothe customer how these items canimprove his JET SKl® watercraft.Actual performance increases canbe measured.

2. Key points when designing:Elimination of air bubbles --prevents cavitation.

l Water current speed controll Overflowing/water splashl Exhaust gas outlet -- if possible, run

outside of tank (keeping waterclean)

l Environment impact -- noise,exhaust gas, oil

l Easyaccess into tank --water level,working platform

l Protection for boat sides and hullbottom

3. Keypoints when testing:l Simulate rider weight -- place

approximately 80 pound weight intray

l Front tie rope -- kick backprevention when throttling down

l Scale for thrustl Tachometer

Remove the meter and gaugeassembly from the brackets. You mustreplace the meter or gauge from therear of the assembly. You cannotremove the meter face plate to replace agauge or meter. Instead, remove the rearpanel by taking out all the screws on theback panel of the assembly. Leave allscrews, wires and bulbs in their originalposition in the terminals and sockets.With the screws loose, the entiresub-harness wire will easily lift off theback of the meter case. Then, removethe original meter or gauge by cutting theshaft. The original pointer is permanentlyfixed on the shaft and cannot be removed.

Install the new meter or gauge. Thereplacement unit has a threaded shaft sothe pointer can be installed with the capand retainer. The electrical connectionsat the rear panel are marked soreconnecting the wires is made easy.Replace the assembly in the bracketsand the job is complete.

QUICK TIPS

MODEL: JET SKI® watercraftl SYMPTOM: Poor top end

performance, new boatsl CAUSE: Silicone plugging exhaust

outlet in hulll CURE: Cut out with screwdriver or

knife

MODEL: JET SKI® watercraftl SYMPTOM: Premature

ring/cylinder wearl CAUSE: Hone finish on cylinder

bore too finel CURE: Use 220 grit stone when

finish-honing cylinder bore

Kawasaki Product Support

HOT LINE800 954-3900

432-7093 (Ca. Only)

CONSUMER SERVICESConsumer Services—Oh yes, the

complaint department, right? Well, notalways. As the only department withinKMC that deals directly with the retailcustomer, Consumer Services handlesquestions about every aspect of thecompany: sales, service and parts. Infact, out of the 2,000 to 3,000 contactswe receive each month, about half arefrom people who simply need a littleinformation (such as the location of localdealers, the part number for an H2 fronttire, the quarter-mile time of the ZX10,or a brochure on the KLF300) or a littlehelp (such as a lost owner’s manual, anout-of-print snowmobile manual, or asource of parts for a 1969 A7). Most ofthese customers can be helpedimmediately or within several hours. Insituations involving prices, sales, pansordering, or technical questions otherthan very simple ones, customers areusually referred to a dealer.

Okay, we can take care of the simplethings ourselves. That brings us back tothe complaints, the problems, theunhappy customers.

by Mary Sola, Senior Consumer Analyst

We know that most consumercomplaints are resolved at thedealership level, and we never hearabout them. We also know that in mostcases we can’t solve the problems wehear about by ourselves, we need towork with you.

OUR GOAL IS TO HELP YOU MAKEAND KEEP HAPPY CUSTOMERS,

ONES WHO WILL COME BACKAGAIN AND AGAIN—FOR

PRODUCTS, SERVICE OR PARTS.

When a consumer lets us know of aproblem, we will usually contact thedealer. After all, we need your help, weneed to know what you see and whatyou think about a particular situation.Also, you will be making any repairs thatare required. Ninety percent of ourinformation about acustomer’s problemcomes from the dealer involved. Yourknowledge and opinion help us makethe best decisions we can to keep thecustomers satisfied with you andKawasaki.

The Technical Magazinell9

SERVICE TIPS

New Digital Ignitionsby Waiter Rainwater & Jerry Heil

The operation of the digital igniter issimilar to the TCBI igniter. TCBI standsfor Transistor Controlled Breakerlessignition. It replaced the “mechanicalswitch” or contact breaker pointssystems.

The transistor in a TCBI igniter is anelectric switch, a switch that is turned offand on by a small amount of electricity.In a TCBI the source for this electricity isthe pickup coil.

TCBI VERSUS DIGITAL

The major difference between TCBIand digital ignition is the addition of amicro-processor in the digital igniter. Theprocessor is placed between the pickupcoil and the transistor. The processormeasures crankshaft angle and speedinformation through the signals from thepickup coil. (See illustration, right).

Tabs on the rotor generate signalsindicating crankshaft rotation. One of thetabs is wider than the others to signalengine top dead center. Themicrocomputer first converts the analogpickup coil signals to digital pulses. Itthen measures the time between the

stored timinginformation. Thisstored information iscalled the map data.The processor thentells the transistorthe best time to turnoff and in turn firethe sparkplug.

The map data isa list of delay times.The delay time isthe time between

The pulse timingconverts directly toengine speed.

The micro-processor comesfrom the factory with

when the pickup coil generates its “fire”signal and when the transistor is told toturn off by the processor. The list has onedelay time assigned for every 50 RPMsegment of the entire range of engineRPM.

The optimum ignition timing is found inthe map data by referring to the enginespeed that was just measured. Theoptimum ignition timing map data isconverted into an elapsed time from the

TYPICAL TIMING DATA MAP

pickup coil signal. In other words, theoptimum ignition timing is figured as thetime from when the pickup coil signal isreceived and when the processor signalsthe transistor. This, of course, is when thecoil fires the spark plug.

In addition to changing spark timingwith RPM, larger displacement enginesperform better if timing is changed whendemand for power changes. Manifoldvacuum is a measure of throttle positionor “power” demand. The VN1500’s digitaligniter measures manifold vacuum boostand adjusts the timing advance accordingto vacuum map data information (seeillustration, left).

The real advantage of the digitalignition system is that any advance anglecharacteristics may be programmed in bythe factory. Advance characteristics maybe as complex as needed for standardengine operation. For example, ifknocking is liable to occur within certainRPM ranges, the advance contour maybe set to retard the spark slightly in thoseranges.

This system results in easy starting,reliable performance, great gas mileage,and low emissions. It also makes doing atuneup quick and easy. For more details,attend the next V-Twin or ElectricalSystems training class.

10 ll K-Tech News

New Accessory

Cooling Fan KitInstallation The wiring leads are run directly to the

wiring harness and to the ON/OFF switchlocated on the handlebar.by Mike Jeffers, Paris Publications

Whew, it’s hot! It must be every bit ofa 100 degrees out here. Another hour orso and we’ll have this soil turned. Man, Icould sure stand a cool breeze rightabout now.

Well, Kawasaki can't supply the thebreeze for you, but we can for yourKLF300B model BAYOU. Kawasaki isintroducing an optional electric coolingfan to increase cooling air flow for hotdays or heavy duty jobs. This isespecially helpful during low speedoperation under high temperature.

To avoid con&ant use and prolong fanlife, the fan operates at the flick of aswitch located conveniently on thehandlebar. The fan clamps on rightbehind the upper A arm portion of theframe and Is held in place by two lowerclamps and one upper clamp.(NOTE: upper clamp is supported by across brace)

Follow the detailed instructionsincluded in the fan kit. (NOTE: Coolingfan diagrams can be found in the generalinformation [1-10] section of the KLF300:BAYOU Service Manual Supplement[P/N 99924-1100-51]).

The kit is available throughKawasaki’s Accessory division. Follownormal accessory ordering procedures orcall the Accessory division426-8208 (CA) or(800) 423-5726 forassistance.

“Offeras a specialfor the month”

P/N 99995-1012

New ProductsSTA-BIL

When added to gasoline,Sta-Bil will prevent theformation of gum and varnishin the fuel system of storedvehicles and equipment for upto one year. Squirt therecommended amount ofSta-Bil in the fuel tank. Drainthe fuel from the float chamber,then allow the treated fuel torefill the bowls. Run the enginefor a short time to get theSta-Bil through the jets in thecarburetor. It is a good idea tofully service your customer’sKawasaki before storage.Consider offering a winterizingservice to help boost servicelabor sales in the off season.Sta-Bil comes in packagequantity of 1, P/N 1104.

ALUMA-COOLA full-strength engine

coolant formulated withT-Triazole for maximumcorrosion protection inaluminum coolingsystems. Aluma-Coolalso contains foam andrust inhibitors. Designedprimarily for use inaluminum engines with acooling system operatingaround 15 psi,Aluma-Cool protectsbetween minus 84° Fand plus 265° F whenusing a 50/50 mix ratio.Packaged in quantities of12, one quart,convenient, easy-pourbottles. P/N K61081-004.

The Technical Magazine ll 11

REGIONAL NEWS lntroduction by Don Church

Please let us introduce to you the regional editors of “K-TechNews.” Do they look familiar to you? Sure. Many of you knowthem as your regional training instructors. Take a look at theircredentials. These gentlemen have a tremendous amount ofknowledge to share with you about Kawasaki and the industry weare in. So, who could serve better as editors of a service-orientedpublication like this?

NORTH & EASTWhat makes one service technician or

service manager better than another? I’msure each of us has our own ideas onthis subject. Here are some of the keyingredients I came up with:l Fast, safe, reliable work the first

time around.l Efficient diagnosis of mechanical

and electrical problems.l Up-to-date product knowledge.l An ability to communicate with the

customer.l A working knowledge of service

department operations.l The ability to communicate with the

manufacturers representatives.

We want you to get to know these professionals. So read on.And if you have any questions about your service business orsomething technical, give them a call. Or better yet, come to oneof their classes.

How about some tips for “K-Tech News”? Send your tips toK-Tech News, Kawasaki Motors Corp., U.S.A., P.O. Box 25252,Santa Ana, CA 92799-5252. We really want to hear from you.

l A desire to keep on learning.This last point is extremely important.

The day we feel we know enough is theday we take a step backward. So take aself-check, how do you stack up?K-Tech News is just one of the tools youcan use to enhance your knowledge.

Make plans to attend the servicetraining classes starting again thisOctober. I hope to be talking with yousoon.

EXPERIENCE:l 23 years as motorcycle mechanicl Started with Kawasaki in 1973l Service Training Instructor Fred DeHartll Hot Line Support Office: 201 Circle Dr. No., #107l Warranty Assistance Piscataway N.J. 08854 l (201) 469-1221

CENTRAL & SOUTHThis summer I had the opportunity to.

work on the Hot tine. I knew what theHot tine responsibilities were, but I didn’tknow exactly what to expect because ofthe comments made by some students insome of my classes.

I noticed there was a lot of wastedtime when a dealer did not have all thenecessary information ready when hecalled the Hot Line. With the new HotLine computer system, we must enter allthe information before the log can beclosed or any warranty authorizationgiven,

If you are calling for warrantyauthorization, you should also have all

the job codes ready, as well as the claimnumber and parts used. Part numbersare not needed.

Occasionally, a dealer forgets that theHOT LINE is for dealers only and not forconsumers. When a consumer gets onthe HOT LINE, considerable time iswasted. The phone number forconsumers to call is (714) 770-0400.

With a little help from you, the HOTLINE can be quicker and more beneficialto all Kawasaki dealers.

EXPERIENCE:l Over 16 years with Kawasakil Service Training Instructorl Warranty Assistancel Hot Line Support

Walter RainwaterOffice: 6110 Boat Rock Blvd. S.W.

Atlanta, GA. 30378 l (464) 349-2000

WEST REGIONThe demand on the dealer technician

to keep up with changes in today’stechnology is no easy task. And, whatabout the new guy? The person justgetting started with Kawasaki has thetoughest job. Especially difficult is gettinga handle on the operations of a profitableservice department.

I’m reminded of my experiencesteaching Service Department Operationsin NDO. I have realized that dealers needa great deal more training for theirservice managers -the guys who actuallyrun things on a day-today basis. So, Ihave drawn on my background as aService Manager and other sources

within the Technical Services Departmentto upgrade the Service DepartmentOperations class. After 12 weeks ofintensive work on this project, we canprovide you with a realistic approach tooperating your service department. Not abunch of notebooks and blank forms thatbury you in paperwork.

I urge you to sign up for the upcomingService Department Operations course.Look for the October 1988 courseschedule in the weekly mailing.

EXPERIENCE:l 20 years motorcycle mechanicl With KMC since February 1986l Service Training Instructorl New Dealer Trainingl Hot Line Support

Ken PloeserOffice: 9950 Jeronimo Rd.

Irvine, CA. 92718 l (714) 770-0400

12 llK-Tech News