fall 1999 the kawasakitechnical magazine vol. 12, no. …

FA L L 1 9 9 9 T H E K AWA S A K I T E C H N I C A L M A G A Z I N E V O L . 1 2 , N O . 3

ROUTE LIST ❑ SERVICE ❑ PARTS ❑ SALESP L E A S E R E T U R N T O S E R V I C E L I B R A R Y

INSIDEFeature The 2000 Ninjas. . . . . . . . . . . 2Regional Update . . . . . . . . . . . . . . . . . 4News Tool Corner . . . . . . . . . . . . . . 5

Service Contest Grand Winners. 5Tech Tips KVF400 Crankcase . . . . . . . . . 6

Optional Prairie Springs . . . . . 6Drive Leaks . . . . . . . . . . . . . . 7ZRX1100 Hesitation . . . . . . . . 8Jetting Specs . . . . . . . . . . . . . 8Digital Cameras . . . . . . . . . . . 9Starter Lockout. . . . . . . . . . . . 9Y2KX Suspension Chart . . . . . 10Generator Rotor Removal . . . 10Ultra 150 Power Loss . . . . . . 11Secure Forks . . . . . . . . . . . . 11

ZX-12R

2000NINJAS2000NINJAS

ZX-12R

by John GriffinInstructionalDesigner/Instructor

Kawasaki is enteringthe new millennium pre-pared by introducingmore new products thanever in our history. TheZX-12R is primed to setnew performance recordsto establish itself as thepremier open class sport-bike. The ZX-9R and ZX-6R are dramatically revi-talized. Cruiser and tour-ing customers have somesweet rides to choosefrom with the addition ofthe new Vulcan™ 800Drifter and Fuel Injectedversions of the Vulcan1500 Classic and Nomad.

Retro buffs will no doubtfall in love with the newW650. In this issue wewelcome the impressivenew Ninjas.

ZX-12RThe ZX-12R is pre-

pared to set the motorcy-cle industry on its ear, justlike the ZX-11 did 10 yearsago. Kawasaki designedan all new 1199cc enginewith an 83mm bore and55.4mm stroke. The bore-to-stroke ratio is the sameas the ZX-9R and ZX-6R.The valves are directlyactuated by the cams, sothe valve clearance inter-vals will most likely beevery 7500 miles, with noinspection required at thefirst service. Lightweightmagnesium is used for thevalve cover, clutch cover,alternator cover, pulsercover and even the oilsump! This engine withintake and exhaust is 26.5pounds lighter than the

ZX-11s.The Denso fuel injec-

tion system uses 46mmthrottle bodies with singleinjectors. Each injector hasfour orifices for good fuelatomization like the Mit-subishi system used onthe fuel injected Vulcans.Unlike those models, theZX-12R uses a cam sensorto determine when thepistons are on the com-pression stroke to fire thestick-type ignition coilsjust once per cycle. A gear

position sensor allows theECU to calculate theeffects of the ram air sys-tem and adjust the igni-tion and fuel injectionaccordingly. The ram airsystem adds 13 horse-power at top speed.

The narrow aluminummonocoque frame is prob-ably the most unique fea-ture on this model. It fea-tures a huge stamped alu-minum section above theengine rigidly tying thesteering stem to the

FALL 1999 K-TECH NEWS

Cover Story

2

2000Ninjas®

The ZX-12R uses a new Denso fuel injection system.

All U.S. model ZX-12R, ZX-9R, and ZX-6R motorcy-cles come with a catalyzer. All ZX-12R models comewith a completely Titanium muffler. CA model ZX-9R and ZX-6R models have dual catalyzers

A scissor type primary gear on the ZX-12R elimi-nates gear lash noise by spring loading the teeth.

swingarm pivot withoutthe width of twin sparswrapping around theopen-class engine. Theframe is even home to theairbox and battery.

The ZX-12R is ready tocarve canyons with ashort wheelbase (56.7 in.),light weight (463 lb.) andtop notch suspension. Theinverted 43mm cartridgefront forks and piggybackreservoir rear shock arefully adjustable. The rearride height can beadjusted by adding shimsbetween the shock clevisand the frame. The rangeof adjustment is 10mm atthe shock, which meansabout 2 inches at the backof the bike. Specially con-structed Dunlop 207Sportmax radials wraparound new 3-spoke rims.A mammoth 200/50-ZR17

rear tire fits on a 6-inchwide rim.

ZX-9RDual headlights and an

aggressive look make itplain to see that the newZX-9R means business.The new ram air systemscoops up the air. A newcylinder head raises thecompression ratio from11.5:1 to 12.2:1 for more

power and torque. A min-imum of 90-octane fuel isrequired.

New Keihin CVRD 40mm carburetors mix thatfuel with air under newslides that are flat on theair box side for improvedthrottle response. Oncethis mixture is com-pressed, a new 16-bitprocessor in the ignitersignals the stick-type coilsto fire. The igniter nolonger uses a cam sensor,because a new ignitionrotor with 24 projections(from 4) offers such anaccurately timed, quick,and intense spark that thecoils can operate coolereven when fired everyrotation.

The chassis got theSupersport treatment witha stiffer frame, removablealuminum subframe, andadjustable ride height. Theframe spars are now10mm taller and the steer-ing head pipe is 12mmlonger for a rigid framethat delivers a telepathic

3FALL 1999 K-TECH NEWS

Cover Story

K-TECH NewsVol. 12, No.3

Fall 1999

K-TECH News Staff

PublisherKawasaki Tech Services

Publications ManagerDon Church

Executive EditorGary Herzog

Editor-in-ChiefGregg Thompson

Communications EditorJohn Griffin

Regional EditorsPiscataway/Grand Rapids

Fred DeHart

Atlanta/TulsaWalter Rainwater

Irvine/TacomaRobert Taylor

ContributorsDavid Behlings, Scott Buckley,

Randy Davis, Alex Dell, Dave Langford

Graphics/Production

Graphic ArtGregg Thompson

PhotographyWalter Rainwater, John Griffin

ProductionHolland Marketing Services

©1999 Kawasaki Motors Corp., U.S.A.All rights reserved.

Published by Kawasaki

All suggestions become the property ofKMC. Sending a service suggestion givesKawasaki permission to publish and/or

use it without further consideration.Specifications subject to change without notice.

Continued on pg. 12

The new ZX-12R, ZX-9R, and ZX-6R use sleevelessplated aluminum cylinders. This cuts weight andtransfers heat much better, allowing minimal pis-ton-to-cylinder clearance for maximum power. Arapid cooling open deck cylinder design is unique tothe ZX-12R.

Note how the airbox and battery are housed insidethe new frame. The majority of the 5.3 gallons offuel is carried low, under the seat.


Regional

2000 TRAINING

By the time you readthis article, I will have fin-ished my road schoolschedule with the last twoseminars being offered inGrand Rapids December 6and 7. For those attendingthe Watercraft DirectInjection seminar—don’tworry; as soon as wereceive the finalized diag-nostic software for theFICHT system, we willmail it to you. TheRegional Facilities train-ing classes will begin inJanuary 2000 and con-tinue through April.

The training schedulefor classes has beenmailed to your dealership.If you can’t locate a sched-ule, call K-FAX at (949)460-5663. The documentnumber for the trainingschedule is #1305. Thesystem will automaticallyfax the schedule to youwhen you hang up.

Make sure you gettogether with your servicemanager to determinewhich classes or seminarsyou plan to attend. Beaware that some trainingclasses are only availableonce this season. Forinstance, Team Green

Race Preparation andMaintenance will beoffered one time in boththe Piscataway, N.J. andGrand Rapids, Mich.,training centers. Enrollearly!

Keep in mind, that theinteraction between thevaried student back-grounds and the expertiseof Kawasaki TrainingInstructors always affordsyou an increased opportu-nity to upgrade your tech-nical skills that is notavailable in any othermedium. We look forwardto speaking with you atone of our classes soon!

Fred DeHart201 Circle Drive N. #107

Piscataway, NJ 08854(732) 469-1221

CUSTOMER SERVICE TIPS

Many dealer customercomplaints are associatedwith the service depart-ment. There are manyways to handle customercomplaints properly sothat a satisfactory conclu-sion is attained for all con-cerned. I have a list of tipsaimed at the servicedepartment, but will helpanyone with customercomplaints.Cooling Off Hot Heads

1. Be polite , but onlyspeak after a couple ofminutes. Let themvent. Deal with emo-tions first. Logic canwait.

2. “Here’s what we’lldo...” Acknowledgetheir problem and thatyou can help them.

3. Reiterate what you willdo. Explain whatyou’re going to do andgive a time frame.

4. End the conversationpolitely and positively.Document everythingimmediately.

Phrases That DestroyCustomer Goodwill1. “I don’t know.”

Many make the mis-take of uttering thisphrase and then clamup in silent embarrass-ment. Use instead:“That’s a good ques-tion. Let me check andfind out.”

2. “We can’t do that.”This phrase is thesurest way to send acustomer to someoneelse who CAN dowhat the customerwants. Use instead:“That’s a tough one.Let’s see what we cando.”

3. “You’ll have to...”Nothing turns a cus-tomer off more thanbeing ordered around.

Give the customer thefeeling you’re in theircorner, no matter whatthe problem.

4. “No” when used at thebeginning of any sen-tence. Use instead: Thecustomer asks, “Can Iget a refund?” Insteadof simply replying,“No, I’m afraid not,”you say, “We aren’table to refund yourmoney, but we canreplace the item at nocharge.”

Good customer serviceis more than meets theeye. There are many skillsyou can learn. It keepscustomers coming back.Always remember twothings: Your job existsbecause of the customerand lastly, everyone is acustomer.

Walter Rainwater6110 Boat Rock Blvd. S.W.

Atlanta, GA 30378(404) 349-2000

STEERING OSCILLATION

We often get questionsabout steering oscillationor “head shake.”

Here are some factorsto remember when con-sidering this situation.

First, it is not uncom-

PISCATAWAY/GRAND RAPIDS

ATLANTA/TULSA

IRVINE/TACOMA

mon for the front-end towobble at low speedswhen your hands are offthe handlebars. Thissomewhat happens onalmost any street motor-cycle. Because of this, tellcustomers to never ridetheir motorcycle at anyspeed with their hands offthe handlebars.

Make sure that anyextra items stored on themachine are evenly dis-tributed by weight in thebags, fairing, or other stor-age areas. The addedweight plus the rider (andpassenger), should not

exceed the maximum loadamount listed in the own-ers manual. The GrossVehicle Weight Rating(GVWR) is also listed onthe white factory stickeron the frame.

Loose steering headbearings can also con-tribute to head shake,while over-tightened bear-ings can cause a highspeed wobble. This is adelicate adjustment thatshould be done by anexperienced technician.

Tires have a directaffect on steering oscilla-tion. Worn or cupped tiresand improper tire pres-

sures can cause handlingproblems. Different typesof tires can affect allaspects of handling, espe-cially if the tires are mis-matched, wrong type, orincorrect size and/or loadcarrying capabilities.OEM replacement tiresshould always be recom-mended to maintain theoriginal handling charac-teristics of themotorcycle.�

Rob Taylor9950 Jeronimo Road

Irvine, CA 92618(949) 770-0400


News

Service Contest Grand Award WinnersWe recently paid a visit to Ray Sumner at Mil-

lennium Cycleworks in Lilburn, Ga., and GaryBustillos at Beaumont Kawasaki in Beaumont,Calif., to present them with their awards for hav-ing the highest cumulative scores in Kawasaki’sService Contest quizzes. As you read in the lastissue of K-Tech News, Ray and Gary tied in thisyear’s contest. Along with the “trophy,” a miniSnap-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 trainingcourses he has attended. Now that’s dedication,folks!

Gary is a two-time grand award winner of theService Contest. Gary said the first quiz was thetoughest, since Beaumont Kawasaki doesn’t carryMules. He had to visit other Kawasaki dealershipsto do the research needed. Obviously, he did prettywell. Way to go, Gary!�–Don Church

I have spoken with several deal-ers concerned about the newKawasaki essential tool program.Many wondered if their dealershipwould receive all the special toolsrequired for the new model year, andif there would be duplicate tools.Other concerns were the cost andreturn policies. Bulletin SP 99-01explained the policy and proceduresand was mailed to all dealers in Sep-tember.

The policy was created to helpdealers perform professional repairs,dramatically cut the cost of essentialtools and to address state warrantylaws. KMC receives a list of specialtools from KHI at the beginning ofeach new model year. At that time,we evaluate the tools and determinewhich tools will be carried by KMC,and which of those will be consideredessential for the dealers. The numberof 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, thelevel of importance in a service repair,how often the tool will be used, if it isa Kawasaki-specific tool, and howmany models the tool will work on.For example, if a new motorcycle has4 special tools associated with it, and3 are used on the final drive and onefor clutch removal, we would list theclutch removal tool as an essentialtool and automatically ship it to thedealers. The other 3 tools will bestocked by KMC as an available tool.

Essential tools will be charged tothe dealer’s parts account and cannotbe returned. There will be a letter sentwith them stating that the tool youhave received is an essential tool.

All special tools have a 90-daywarranty covering them against defec-tive materials and workmanship. Con-sult the Kawasaki special tool catalog(P/N 99960-0065-04) for completewarranty information.�—RobTaylor

CornerTool

Regional News - cont’d

Don Church congratulates Gary Bustillos.

Don Church congratulates Ray Sumner.

Tech Tips


by Gregg ThompsonProduct Support Supervisor

Two years ago, in K-Tech News, Vol. 10 No. 3,we ran an article aboutKVF400 Prairie® ATVcrankcases not breathingproperly because of cast-ing flash in the vent holesin the case halves. Theproblem that resulted waslarge amounts ofcrankcase oil pumpinginto the air box. The solu-tion described in the arti-cle was to split thecrankcases and clean outthe casting flash in thevent holes.

This problem appearedbriefly in the KVF400-A1,and B1 and then wentaway. Recently it reap-peared in a few KVF400-C2s. The problem is thesame but this time we’vediscovered that all thesecast-in vent holes can be

accessed without splittingthe cases. Three are visiblewith the right-hand(transmission) coverremoved and another oneis visible with the left-hand engine coverremoved. The hole mostlikely to cause this prob-lem is visible from theright side.

Note that oil in the air-box can also be caused byexcessive piston ringblow-by or simply anoverfilled crankcase. Ifyou encounter this prob-lem, the first thing youshould do is check the oillevel and then confirm thecondition of the rings bydoing a leakdown test (acompression test is notconclusive on this modelbecause of the automaticcompression release).Don’t forget that whenchecking oil level on aPrairie, the filler cap mustbe threaded all the wayinto the filler hole to get acorrect reading on the dip-stick. Once the oil leveland engine condition areconfirmed, remove theright-hand engine coverand inspect the threeholes shown in the draw-ing.

If no problem is foundthere, then remove theleft-hand engine coverand inspect the one holeshown in the drawing.�

KVF400 Crankcase Vent Problems

by John GriffinInstructional Designer/Instructor

In the last issue of K-Tech News, we listed the part numbers for the optional stiffer springs available for thePrairie 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 Prairie® Springs, Part 2

Vent Holes

Vent Hole

L.H. CRANKCASE

R.H. CRANKCASE

Optional Spring DetailsYear Springs Color Part # Sugg. Retail’97-98 Rear Spring Red 92145-1199 $96.95’99-2000 Rear Spring Black 92145-1271 $116.98’97-2000 Front Springs (2) Red 92145-1225 $81.95 ea.

Vulcan™ andVoyagerFinal DriveLeaksby Gregg Thompson &Randy Davis

Over the years we’vehad reports of oil leaksin the pinion shaft areaof the final drive on 1200Voyagers® and 1500 Vul-cans™. The leaks are dis-covered as oil comes outfrom the area betweenthe swingarm and thefinal gear case. Dealersoften have trouble diag-nosing the leak becausethey don’t understandhow the pinion shaft issealed.

If you are trying todiagnose a leak in thisarea, first make sure theoil that’s leaking out isindeed final (hypoid)gear oil. Do this simplyby smelling it. Gear oilhas a very distinctivesmell. It is possible forengine oil to leak fromthe output shaft of thebevel gear case, run allthe way down theswingarm, and leak outin the same place.

Once you’ve verifiedthe leak is gear oil, checkthe two O-rings (*) in thedriveshaft coupler. Mostpeople don’t even knowthere are two O-rings in

there. A small hole in thepinion shaft couplerallows oil from the finalgear case to lubricate thecoupler splines. An O-ring(*) at each end of thedriveshaft coupler (oneon the driveshaft splinesand one on the pinionshaft coupler splines)prevent that oil fromleaking out.

The O-ring on the pin-ion shaft splines is easyto see and replace butthe one on the driveshaftsplines is a little morechallenging. Getting to itrequires removing thecirclip and washer frominside the driveshaftcoupler. Once the circlipand washer are removed,the coupler pulls off to

reveal the other O-ringon the end of the drive-shaft. These two O-rings(*) are probably themost common cause ofleaks in this area.

Next, check the pinionshaft seal for leaks. Witha flashlight, look insidethe large pinion-bearingnut for evidence of aleaking seal. If the seal is

leaking, there should bea collection of dirt with atrail along the inside bot-tom of the nut where oilhas washed it clean. Asmall amount of oil inthis area is more likely tobe from the above men-tioned O-rings.

If the seal is leaking, itcan be replaced withoutremoving the large pin-

ion-bearing nut. Byremoving the small pin-ion shaft nut, the pinioncoupler can be removed,allowing easy access tothe seal.

There is also a largeO-ring behind the pin-ion-bearing nut. This isthe least likely item toleak, which is good sincethat nut is very difficult

to remove. On the 1200Voyager, the torque onthat nut is 400 ft/lb. Onthe 1500 Vulcan, it’s a lit-tle more manageable at180 ft/lb., but bewarethat the nut has left-hand(LH) threads. It will takea lot more than 180 ft/lb.to remove the nut ifyou’re turning it thewrong way!�


Tech Tips

Pinion ShaftNut

O-Ring*

Pinion Shaft Coupler

Pinion-Bearing Nut

Driveshaft Coupler

Circlip

O-Ring*

Seal

ZRX1100

by Dave Langford

Product Support Specialist

If you have a customercomplaining of a throttlehesitation or flat spot inthe mid- to-upper RPMrange, check the air boxcap (or lid, or cover).Especially check this ifthe air cleaner has beeninspected or replacedrecently. It is possible thatthe cover was improperly

reinstalled. This cover is a little

tricky to install correctly.There are tabs at the bot-tom of the cover that fitinto slots in the bottom of

the air cleaner case. Toinstall the cover correctly,these tabs must first bepushed down into theslots in the case and thenthe bolts at the top can be

installed and tightened. Itis easy to install the coverwithout getting one orboth the tabs into thegrooves. Doing this willcause a lean hesitation.�

Tabs

Slots

KX60-B16 KX65-A1 KX80-W3 KX125-L2 KX250-L2 KX500-E12Stock T.G. Stock T.G. Stock T.G. Stock T.G. Stock T.G. Stock T.G.

Main Jet 200 ← 230 220 125 ← 160 ← 160 ← 168 170O/R Only

KMC P/N 92063-022 92063-025 92063-024 92063-1334 92063-1369 92063-1368 92063-1371 92063-1372Needle & Clip 5114-3 ← 5HS59-3 5HS59-4 N5HF-3 ← N7NW-3 N7NW-2 N3WE ← N82M-3 N82M-2KMC P/N 16009-1220 16187-1129 16187-1129 16009-1960 16187-1084 16187-1084 16009-1915 16009-1580 16009-1580Needle Jet N-8 N-6 O-0 O-0 N/A N/A N/A N/A N/A N/A N/A N/AKMC P/N 16017-1215 16017-1259 16017-1413 16017-1413Power Jet N/A N/A N/A N/A N/A N/A 52 42 48 ← N/A N/AKMC P/N 16159-1055 16159-1059 16159-1058Pilot Jet 30 35 40 40 58 55 45 40 52 ← 58 55KMC P/N 92064-1030 92064-1023 92064-024 92064-024 92064-1146 92064-1145 92064-1142 92064-1140 92064-1130 92064-1146 92064-1145Slide 2.0 ← 2.0 2.0 3.0 ← 6.0 ← 8.0 ← 7.0 ←KMC P/N 16025-1107 16025-1125 16025-1125 16025-1162 16025-1215 16025-1217 16025-1163Air Screw N/A N/A 1-1/2 1-1/2 1-1/2 ← 1-1/2 1-1/2 1-1/2 1-1 3/4 1-1/2 2Turns OutSpark Plug B9EG B9EVX B10EV R6252K-105 B10EVX BR9EVX ← BR8EVX ← B8EG B9EVXNGK/KMC# B10EVXC/S Sprocket 13 13 14 14 14 12 ← 13 ← 14Gearing Same SameRR Sprocket 44 46 47 50 52 49 49 48 47


Tech Tips

Y2KX Jetting SpecsNow 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 H1R oil premixed at a 40:1 ratio. They are recommended for sealevel 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.

Hesitation

by John GriffinInstructionalDesigner/Instructor

In the last K-Tech News,Kenny Osberg explainedhow useful a digital cam-era can be for communi-cating with Kawasaki.There is no need toprocess film, you can eas-

ily edit pictures toimprove the quality,remove objects, or re-cen-ter the picture. It can savetime for everyoneinvolved, but have youthought about how manyother uses there are atyour dealership?

In the Service Department

Take pictures of impor-tant steps in a compli-cated repair as you take itapart so parts get rein-stalled correctly. Youcould even keep these onfile for other technicians

to use later for training oranother repair. Documentscratches, dings, anddents on customers’ prod-ucts as they come into theshop to avoid beingblamed for the damagelater.

Take pictures of thecondition of internal partsof a customer’s machineto improve their confi-dence in your repair, andhelp them understand thecost. Send customers aquick E-mail with a pic-ture of their completedKawasaki just waiting forthem to pick it up. Putpictures of your expensivemachinery (boring bars,dynos, test tank, wheelbalancers, etc.) on yourWeb site.

In the Sales Department

Use a digital camera totake pictures of your used

or new vehicles and postthem on your Web pageor a newsletter, or E-mailthem to interested cus-tomers. Use these pictureson a Web page and pick afew to be your “specials ofthe week.”

In theParts Department

Use the digital camerato communicate partsproblems with Kawasaki.Send E-mails to your cus-tomers with a picture oftheir parts, inviting themto come and pick themup. Take pictures of yourinteresting displays andsave them in your com-puter as a reference in thefuture. Post pictures ofspecial sales parts, usedparts, or take-off compo-nents on your Web site oreven a computer that isaccessible to your in-storecustomers.�


Tech Tips

DigitalCameras(Part II)

Starter Lockout Problems on Dual Purpose Machines?by Alex DellProduct 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 into 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.�


Tech Tips

Y2KXSuspensionSpecs

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 & 6000Generator RotorRemoval

by Fred DeHartTechnical Support

The Power PartnerGenerator service manualsays to loosen the rotorbolt two or three turns,then strike the head ofthe bolt with a brass mal-let in order to loosen the

rotor from the crankshafttaper. This procedureoften fails because therotor has a very tight fiton the taper. Using apuller or slide hammerwill destroy the rotor.

If the service manualmethod doesn’t work foryou, try this. The rotorhas two large curvediron-laminated cores, 180degrees apart. Positionthe rotor so the iron sur-faces are on your right

and left as youface the rotor andmake sure therotor bolt hasbeen loosenedtwo or threeturns. Take a 2x4block of wood and set itagainst the iron surfaceand strike the block witha dead blow hammer.Now do the same thingon the opposite side ofthe rotor. These alternateblows help release the

rotor from the crankshafttaper. Lastly, hit the headof the rotor bolt with aheavy brass mallet andthe rotor should come offthe crankshaft. You mayhave to repeat this proce-dure.�

*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.

***High speed compression adjuster is the outside 17mm adjuster nut on the shock. It has no detents.All spring rates are in Kg/mm.

PlaceBlockHere


Tech Tips

Ultra 150 High-Speed Power Lossby Gregg ThompsonProduct Support Supervisor

As you may alreadyknow, the JH1200-A Ultra150 uses a jet pump thatdiffers in design from allother Kawasaki sit-downtype watercraft. OtherKawasaki sit-down water-craft use an Axial Flow jetpump. This means thewalls of the pump body(including the impellerchamber and the guidevane chamber) are rela-tively parallel or straight—sort of like a section ofstraight tube half occupiedby the impeller and halfby the guide vanes. Withthis type of pump thewater flows (spirals)straight back in an axialdirection.

The Ultra 150 uses aMixed Flow pump. Thismeans the walls in thepump body are not paral-lel but expand through theimpeller chamber and con-strict through the guidevane chamber. The waterhas some radial flow as itpasses through the pumpbody, moving outward inthe impeller chamber andinward in the guide vanechamber. This radialmovement combined withthe axial flow of the waterthrough the pump iswhere the term “MixedFlow” comes from.

Of course these taperedpump body inner wallsresult in a cone-shapedimpeller chamber with thesmaller diameter at thefront end. When the pumpis turning and producing

thrust, the impeller isalways trying to move for-ward inside this chamber.

Remember that everyaction produces an equaland opposite reaction.Nine hundred pounds ofthrust coming out the backof the pump means thesame pressure pushingforward on the impeller.It’s this force pushing onthe impeller (transferred tothe hull through the pumphousing) that you feel asyou accelerate.

All that thrust isabsorbed by the ball bear-ing in the front of thepump body. If that bearingbecomes worn or dam-aged, it can allow axialmovement of the impeller

shaft. If there is enoughmovement in the shaft, theimpeller may contact thetapered walls of theimpeller chamber. Thatcontact producesfriction...lots of friction. If

the bearing is wornenough, the friction cre-ated by the impeller con-tact can actually limit thespeed of the boat to 20 or30 mph. Yet the customer

may sense nothing but aloss of power at highspeeds.

If you have an Ultra 150customer who complainsof a loss of top speed, butthe engine seems to be fine

(good compression and nosigns of overheating),don’t forget to check theaxial play in the impellershaft. If it’s excessive,check the impeller shaft

Simple Way to Hold Up Forksby Scott BuckleyProduct Services Technician

How do you secure fork tubeswhen you are checking the oil level?This can be tricky. Mounting the bot-tom of the fork in the vise meansyou may have to stand on some-thing to check the oil level. Settingthe fork on the ground invites the opportunity for the fork to 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 forkstogether, like those in the accompanying picture.”�

Cover


ride. The fork offset ischanged from 35mm to30mm to increase trail tocomplement the wider 6-inch rim with190/55-ZR17 rear tire and newframe.

Comfort and controlare improved with revisedsuspension settings frontand rear. A new rear linkoffers a more linear ratethat is stiffer initially, thensofter at the end of thestroke. New 310mm frontbrake rotors are 10mmlarger than last year for“stop on a dime” brakingpower. New instrumentgauges are a classy blackon white and the coolanttemperature is now dis-played numerically.

ZX-6RThe ZX-6R is ready for

more racing glory withmore power and 11 lesspounds to carry around.A new semi-hemispheri-

cal cylinder head is a copyof our World Superbikeengine and it allows alofty 12.8:1 compressionratio. The top of the pistonactually protrudes out ofthe cylinder into the head.

New valves, valvesprings, and crownedvalve tappets add durabil-ity.

The dramatic weightloss was accomplishedeven with an additionalheadlight, wider rear tire(180/55-ZR17), and tallerfront tire (120/65-ZR17).A new magnesium clutchcover, valve cover, oilpump cover, and sumppan cut weight. Newplated aluminum cylin-ders, stick type ignitioncoils, and an internallybraced swingarm cutabout five pounds.

The chassis is morefocused for increasedrider feedback with 2mmless fork offset (28mm)and a 5mm wider fork

pitch (210mm). Dampingrates have been revisedfront and rear. A new rearlink offers a more linearprogressive rate that isstiffer throughout therange than last year. Newfront brake calipers havedifferent size pistons andnew pads for improvedfeel and bite.

These new Ninjas areleading the brigade ofnew products fromKawasaki. They reachnew performance levels,while still setting the stan-dard for riding comfort.They have been engi-neered to the highest stan-dards to satisfy the mostdemanding customers.�

2000 Ninjas -Cont’d

The new ZX-6R is 11 pounds lighter and has evenmore power with a sky-high 12.8:1 compressionratio requiring a minimum of 90 octane fuel like theZX-9R.

The ZX-9R is still comfortable to ride, but underneath the skin everything gotmore serious with a stiffer chassis, new fork offset, 6-inch rear rim and morepower.

Danny Aldridge ............................................................Smith Bro Motorsports ................................................................Birmingham, ALCraig Faith ......................................................................River Valley Cycles......................................................................Russellville, ARDan Bebieff ....................................................................Northcounty Jet Ski ........................................................................Encinitas, CAGary Bustillos ................................................................Beaumont Kawasaki......................................................................Beaumont, CARusty Hadley..................................................................Beaumont Kawasaki......................................................................Beaumont, CADavid Stluka ......................................................................Sun Enterprises ..........................................................................Thornton, COMike White ............................................................Sport Center Of Grand Junction......................................................Grand Junction, COTerry Brown ..........................................................Sport Center Of Grand Junction......................................................Grand Junction, COWade Hafenstine................................................................Sun Enterprises ..........................................................................Thornton, CODanny Barclay......................................................................Cycle Works ..........................................................................Carrollton , GARay Sumner ..................................................................Millennium Kawasaki ........................................................................Lilburn, GA Clyde Denslow ..............................................................Motorsports Kawasaki ........................................................................Wichita, KSDixon Beeson ................................................................Dixon’s Cycle Center ......................................................................Scott City, KSShirley Beeson ..............................................................Dixon’s Cycle Center ......................................................................Scott City, KSDavid Lemmo ....................................................................Brockton Cycle ..........................................................................Brockton, MAAlan Bush ......................................................................Classic Motor Sports ..................................................................Traverse City, MIMark Garrison ....................................................................Paw Paw Cycle............................................................................Paw Paw, MIDoug Engie ....................................................................Northern Kawasaki ........................................................................Cloquet, MNJason Clymer ......................................................................Jackson Cycle ............................................................................Jackson, MNLarry Clymer ......................................................................Jackson Cycle ............................................................................Jackson, MNTed Danga..............................................................................Cycle City..............................................................................Rochester, MNDavid Myers ..................................................................Springfield Kawasaki ..................................................................Springfield, MOJeff Reddick..................................................................St. Louis Power Sports ................................................................Valley Park, MOScott Dailey ....................................................................Sports City Cyclery......................................................................Great Falls, MTTom Vandergrinten ..........................................................Sports City Cyclery......................................................................Great Falls, MTDean Bueckel ......................................................................Action Cycle ..................................................................................Minot, NDRobert Richter ......................................................................Action Cycle ................................................................................Minot, NDVal Horner............................................................................Action Cycle ................................................................................Minot, NDDavid Thayer ..........................................................Southern Ocean Cycle Center ..........................................................Manahawkin, NJChris Adams ......................................................................Big 4 Kawasaki ..........................................................................Marietta, OHGreg Becker ......................................................................Big 4 Kawasaki ..........................................................................Marietta, OHJamie White ..................................................................Rehmert Cycle Sales ......................................................................Versailles, OHCarlos Rodriguez ............................................................Caribbean Kawasaki..........................................................................Arecibo, PRCory Devries ....................................................................Vescos Kawasaki ..........................................................................Brigham, UTClarence Hepburn ............................................................Mark IV Kawasaki ......................................................................Wytheville, VAJim Tribou ......................................................................Wayne Cycle Shop ....................................................................Waynesboro, VATodd Stagege..................................................................Wausau Motorsports ........................................................................Wausau, WIClay Alexander ............................................................Lakeway Power Sports........................................................................Gillette, WY

K-TECH

CONTEST

#3 WINNERS

The winners of Contest #3 will receive aSnap-On foldable palm ratchet.

Congratulations to the winners and thanksto all participants.