Summer 1991 T h e Kawasak i T e c h n i c a l M a g a z i n e Vol. 4 No. 2

by Patrick KellyInstructional Designer/Instructor

Surely the SC’s most outstanding feature is itsunique side-by-side seating arrangement. Forthe first time in personal watercraft history, riderssit beside each other instead of fore and aft. Thisexclusive feature allows both passengers to fullyshare the riding experience-both can seewhere the craft is headed, and no longer have toshout at each other in order to communicate.

If that alone isn’t enough, Kawasaki designedthe SC so that either rider can operate the craftwithout changing seating positions! The boat’s

The JL650-A1, better known as the “Sport steering wheel can be moved to any one of threeCruiser” or “SC”, is Kawasaki’s latest entry into positions (left, right, or center) simply by stoppingthe growing two-passenger personal watercraft the craft and pulling an adjustment lever beforemarket. The SC’s innovative design proves once sliding the wheel to another position.again that Kawasaki is the leader in the personal The Sport Cruiser shares the same basic drivewatercraft industry. train as Kawasaki’s other 650 watercraft. ä

ROUTE LIST: o SERVICE o PARTS o 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

Inside:n SC explorations!

S H O P T A L K / T E C H N I C A L

CONTlNUED FROM PAGE 1

The engine is the familiar635cc two-stroke twin,with 76mm x 70mm boreand stroke. Other featuresthe SC’s engine shareswith the other 650s areCD ignition, 7.2:1 com-pression ratio, oil injection,crankcase reed induction,

and a Keihin CDK38-32carburetor with a 36mmbore. The exhaust systemfeatures a “dry” type ex-haust similar to the oneused on the TS. Water isnot mixed with the ex-haust gases in this systemuntil the water box. Thiskeeps water out of thetuned portion of the expan-sion chamber improvingperformance throughoutthe rpm range.

The SC’s exhaust sys-tem also features a stern

TECHNICALITIES

SC power steeringThe JL650-A1 SportCruiser’s jet pump steer-ing nozzle features a ver-ticle tab located in thew a t e r f l o w n e a r t h enozzle’s pivot axis. Thistab is designed to reducethe effort required to steerthe craft.

When the nozzle isturned, the force of thewater exiting the pumppushes on the inner wall of

nozzle back to a straight-ahead pos i t ion . The“balance tab” found in theSC nozzle diverts some ofthe water away from thenozzle’s inner wall. Thisreduces the high pressurearea and, as a result, sig-nificantly reduces thesteering effort.

There is a similar tab inthe steering nozzle of theJET MATE’” pump for the

the nozzle, creating a same reason: large high-pressure area - Patrick Kellywhich tries to force the

Without balance tab

2 l K-Tech News

With balance tab

exhaust outlet. This helpskeep the boat quiet byforcing the exhaust gasesto exit under the water atlow speeds. At higherspeed the exhaust exitsabove the water line butthe noise is dampened bythe wake generated by thecraft. Maximum output ofthe SC’s engine is a heal-thy 55 ps at 6000 rpm.

The jet pump is a singlestage axial flow unit likethe pumps found in ourother 650 watercraft. Theoutput nozzle diameterhas been reduced from83mm to 82mm for im-proved top speed, and thesteering nozzle has abalance tab resemblingthe one used on the JETMATE’” for easy steering.The SC pump also hasreverse for backing out ofthose tight spots. A leverunder the front of the seatengages reverse by lower-ing the reverse bucket

Another distinct featureof the SC is its hull. Unlikeother Kawasaki water-craft, the SC hull is a true15-degree V-shape. Thishull gives the SC greatturning characteristics aswell as excellent straightline stability with minimalporpoising. Although theSC hull is not designed toself right if capsized, itcan be righted easily byone person. The hull isconstructed of Sheet Mold-ing Compound (SMC) forstrength and easy repairs.

The one feature of thenew JL650-A1 that can’tbe described on paper ishow much fun it is to ride.Get your customers to tryone-and go ahead, try outa Sport Cruiser yourself.One ride is all you’ll needto be convinced thatKawasaki’s Sport Cruisertruly is a fresh new ex-perience in personalwatercraft. o

down over thenozzle, directlyreversing thefIow of waterfrom the pump.Output fromt h e S C ’ spump is agenerous 463p o u n d s o fthrust.

C O M M U N I C A T I O N S

VIDEOService manualsupplement systemThis article first appeared in K-Tech News 18 monthsago. We’ve updated the chart, however, to include newmodels and new service manual supplements -Ed.

Some model Kawasakis need one service manual;some need two. Why is this?

Well, in the beginning, a single service manual includesall the information a technician needs to maintain and re-pair a given model motorcycle, watercraft, generator, etc.

Then, along comes something a little different. TheKLF300-A1, for instance, which had a comprehensive ser-vice manual all to itself, was followed by a similar all-ter-rain model, the KLF300-B1. In this sort of situation, thefactory chooses to produce only a service manual supple-ment, the latter covering only the unique features of theB1 model. So you need two books to have all the informa-tion on the KLF300-B1: the service manual for the olderAl containing all the basic information (called the basemanual), and the B1 service manual supplement. o

Supplements and base manuals MICRO-K

MODEL SUPPLEMENT BASE MANUALMOTORCYCLES AND ATVs

KX60-B6, B7 99924-1123-51 99924-1094-01

KX80-L2, L3, N2, N3 99924-1094-01 99924-1094-01

KX125-G1 99924-1116-51 99924-1101-01

KLF185-A1A, A2 99924-1076-51 99924-1056-01

EL250-B2 thru B4 99924-1093-51 99924-1066-01

EL250-E1 99924-1093-52 99924-1066-01

BASE MANUAL MODEL

KX60-B4

KX80-L1, N1

KX125-F1

KLF185-A1

EX250-E1

EX250-E1

EX250-F2 thru F4 99924-1109-51 99924-1066-01 EX250-E1KDX250-D1 99924-1143-51 99924-1114-01 KDX200-E1

KL250-D2 99924-1051-03 99924-1050-01 KL600-A1

KX250-G1 99924-1116-51 99924-1101-01 KXZ50-F1

KLF300-B1 thru B4 99924-1100-51 KLF300-A1

KLF300-C1 thru C3 99924-1117-51 KLF300-A1

EX500-A1 thru A5 99924-1082-51 EN450-A1

KX500-E1 99924-1116-51 KX500-D1

99924-1148-51 99924-1120-01 JS550-B1

99924-1122-52 99924-1069-06 JF650-A1

99924-1087-53 99924-1069-06

KX500-E2 thru E3 99924-1132-51 99924-1101-01 KX500-D1

KL600-B1 99924-1063-51 99924-1050-01 KL600-A1

ZL600-A1, A2 99924-1073-51 99924-1055-04 ZX600-A1

ZX600-C1 thru C4 99924-1081-52 99924-1055-04 ZX600-A1

KL650-A1 thru A5 99924-1080-52 99924-1050-01 KL600-A1

ZX750-H2 99924-1126-51 99924-1112-01 ZX750-H1

ZL900-A1, A2 99924-1077-51 99924-1048-05 ZX900-A1

ZL1000-A1 99924-1077-51 99924-1048-05 ZX900-A1

ZX1100-C1, C2 99924-1127-52 99924-1098-02 ZX1000-B1

ZG1200-B1 thru B5 99924-1089-52 99924-1064-01 ZG1200-A1

ZN13OO-A1 thru A6 99924-1037-03 99924-1015-05 KZ1300-A1

PERSONAL WATERCRAFT

JS300-A1 thru A5 99924-1070-51 99924-1059-02 JS300-B1

JS440-A8 thru A15 99924-1091-52 99963-0054-02 JS440-A1

JS550-A3 thru A8 99924-1075-51 999630051-01 JS500-A1

JS550-C1

JF650-B1, B2

JS650-A1 thru A4 JF650-A1

SC video now availableThe service training video covering the JL650-A1:SC isnow available. If you are on the automatic training videomailing program, you’ve probably already seen this 26-minute tape. It covers those unique features and serviceareas of the SC where it differs from other JET SKI®

watercraft models.The first section of the tape covers design features,

the second section shows how to right a capsized SC,and the third and final part concerns maintenance. Thisvideo tape is designed not only to familiarize your techni-cians with the SC, but to be used in your showroom tostir buyer interest. You can even use it to introduce thisunique watercraftt o p roud newowners, and toentertain peoplewaiting for serviceon busy days.- Ray St. John

Are you assuming?by Chuck CrawfordMicrographics Specialist

I t has recently come to my attention that many peopleworking with Micro-K parts microfiche in Kawasakidealerships assume that the reference number is al-ways the same as the function code (the first fivedigits) of the part number.

It’s true the two are usual/y the same, but they’re notalways the same. Therein lies a potential snag.

A problem can occur when someone assumes the ref-erence number is the same as the first five numbers ofthe P/N, and copies down the reference number plus thelast four numbers from the part number. It’s surprisinglyeasy to write down the reference number without notic-ing that it’s not the same as the first half of the P/N.

Here’s an example of a reference number that is dif-ferent from the first five numbers of the part number:

The bot-tom line ofthe story isthis: Be care-ful not to de-pend on thereferencenumber whencopying downthe part num-ber from themicrofiche! o

The Technical Magazine l 3

G U E S T S P O T

Summer 1991Vol. 4 No. 1©1991 Kawasaki MotorsCorp., U.S.A. (KMC).All rights reserved.

K-Tech News Staff

PublisherKawasaki Tech Services

Publications ManagerDon Church

Executive EditorGary Herzog

Editor-in-ChiefGregg Thompson

Regional Editors

North and EastFred DeHart

Central and SouthWalter Rainwater

West and CorporatePatrick Kelly

Contributors

Dave Behlings, Dave CoreyChuck Crawford, Jerry Heil,Kenny Osberg, SharonWilleke, Ray St. John

Graphics/Production

Graphic ArtGregg Thompson

Copy EditorPat Shibata

ProductionNickless Communications

Published by Kawasaki. Allsuggestions become theproperty of KMC. Sending aservice suggestion givesKawasaki permission topublish and/or use it withoutfurther consideration.Specifications subject tochange without notice.

4 l K-Tech News

The Colorfile Filing Systemby Reynolds and Reynolds:by Don ChurchManager, Service Training andCommunications Dept.

Does your present sys-tem for filing service andwarranty records seem tobe a drain on the ServiceDepartments productivity?Are your ideas for a cus-tomer satisfaction follow-up program thwarted byyour present records-filingsystem?

It happens. Many dealer-ships spend unnecessaryhours retrieving, refilingand searching for lost ser-vice folders. That’s whythe Colorfile System wasdeveloped-as a solutionto your filing problems.

The end tab color-coding combined withopen shelf filing is basedon a proven techniqueused in hospitals anddoctors’ offices for 25years. The difference hereis that this particular Color-file System is based onthe last six digits of theVIN instead of “patient”name. File folders havefour other spaces for sup-plementary informationsuch as model year, dateof last visit, vehicles withGood Times ProtectionPlan coverage, etc.

Color coding is basedon the principle that thehuman eye sees andrecognizes colors and pat-terns for colors faster andat greater distances than itdoes letters or numbers.So, the Colorfile system isdesigned around a seriesof brightly colored, pres-sure sensitive mylar labelsthat are applied to the endtab of specially designed

file folders. Once theColorfile folders are inplace, the major efficien-cies become evident: Mis-files are reduced becausethey are usually obvious.Filing and searching forfolders goes faster be-cause the eye can recog-nize the proper filingsection at a glance andfrom a distance as one ap-proaches the file.

nFor quick retrievalof customer ser-

vice and warrantyrecords, this sys-

tem works!n

There are no doors andthe open shelves areangled at 55 degrees soeach file folder’s edge ex-tends beyond the previousone. This makes the color-coded folder tabs easilyvisible and accessible.

The open shelf files useonly about one-half of thefloor space required by

Besides being precise,the Colorfile System isalso extremely flexible,which means it can beadapted to handle a multi-brand and multi-productenvironment. Manufac-turer Reynolds andReynolds can help youdesign the Colorfile Sys-tem for your store. Call orwrite:

Reynolds and ReynoldsMurlin & Pine StreetsCelina, Ohio 458221-(800)-344-0996

Kawasaki is installingthe Colorfile System in theregional training centers,and will be incorporatingthis system into the Ser-vice Department Opera-tions class. We recom-

Imend this system basedon its important benefitsand its potential for in-creasing customer satis-faction with your store. o

conventional files. Betterstill, they cost up to 50 percent less than the drawer-type.

T I P S F R O M T H E S P E C I A L I S T S

TOOLS

Mule 500special tool...oopsSome KAF300-A1 engine/transmission alignmentspecial tools (P/N 57001-1341) have been shippedto dealers misassembled.The plastic centeringpieces which are screwedto the steel plate aremounted on the wrongside. Because the tool isnot symmetrical, it justwon’t work that way.

This drawing shows thetool assembled correctly. If

you have one of these inyour inventory, check itagainst the drawing.

NOTE: When correctlyassembled, the plasticpieces should be screwedto the side of the platewith the part numberstamped in it.- Gregg Thompson

Attention KX shops: spring confusion?by Gregg ThompsonSr. Product Support Specialist

Could you use some1991 KX front fork springrate information? If youranswer is yes, here’ssome information whichmay help. It gets a littleconfusing because the fac-tory has chosen to identifythe springs for any modelas either the standardspring, or one of the twooptional springs. With this

system, none of the stand-ard springs are marked.The optional springs aremarked with one or moresmall grooves in one endof the springs.

Unfortunately, the stand-ard spring for one modelmight be the same springrate as an optional springfor another. This results ina different part number fortwo springs with apparent-ly identical specs! Also,

KX80-RI/KX80-TI

the marking on the springis not always adequate toallow you to identify justwhat spring it is.

The following tablesidentify the springs that fita certain model or groupof models by part number,spring rate, spring length,number of coils, wirediameter and markings.For standard springs (nomarkings), the model islisted. o

SPRING O.D. 28mmPART SPRING SPRING NUMBER WIRE MARKING MODEL(std.)

NUMBER RATE LENGTH OF DIAMETER(kg/mm) (mm) COILS (mm)

44026-1482 .27 482 51 3.8 I

44026-1479 .28 483 49 3.8 none KX80-RI44026-1484 .28 482 49 3.8 II44026-1480 .29 482 51 3.8 none KX80-TI44026-1483 .29 483 51 3.8 Ill44026-1485 .30 484 50 3.8 IllI

KDX200-E3SPRING O.D. 35.5mm

PART SPRING SPRING NUMBER WIRE MARKING MODEL (std.)NUMBER RATE LENGTH OF COILS DIAMETER

(kg/mm) (mm) (mm)44026-1430 .28 499 36 4.3 I44026-1401 .29 493 35 4.3 none KDX200-E344026-1431 .30 498 41 4.5 II

KXl25-H2/KDX250-D1/KX250-H2/KX500-E3SPRING O.D. 38mm

PART SPRING SPRING NUMBER WIRE MARKING MODEL(std.)NUMBER RATE LENGTH OF DIAMETER

(kg/mm) (mm) COlLS (mm)44026-1502 .34 507 36 4.6 I44026-1496 .35 508 36 4.6 none KDX250-D144026-1487 .35 515 36 4.6 I44026-1503 .36 509 38 4.7 II

44026-1492 .365 517 34 4.6 none KX125-H244026-1489 .38 517 35 4.7 III44026-1486 .39 516 35 4.7 none KX250-H2

KX500-E3

44026-1491 .40 518 37 4.8 IIIII

The Technical Magazine l 5

T I P S F R O M T H E S P E C I A L I S T S

TOOLSZX750-K carb updateby Jerry HeilTraining Development Coordinator

A sidebar in the Winter 1990 issue contained somepreliminary information on the ZX750-K’s new Keihin car-buretor (see K-Tech News Vol. 3, No. 4, pg. 3 -Ed.).Here are some additional details on a key feature. . .

The new carb’s accelerator pumps have access to fuelin the conventional manner, through inlet check-valves inthe float bowls. But the fuel solenoid, rather than control-ling fuel flow for the accelerator pumps, is the heart of anew circuit-an enricher system.

The enricher system supplies fuel, pressurized by thefuel pump, to the accelerator pump discharge nozzles.Veteran Kawasaki racing tuner Rob Muzzy, who knowsthese carbs inside and out, explains it this way: The fuelsolenoid instructs fuel to spray from the nozzle at certainthrottle opening/rpm conditions to compensate for themid-range flat spot typical of large-bore, flat-slide car-buretors.

The igniter senses engine rpm and opens the enrichersolenoid valve when the engine spins between 1500 and5000 rpm and the throttle is open more than 3/8ths. (Acam on the throttle shaft actuates a switch sending thethrottle position signal to the igniter.)

Once open, fuel passes from the solenoid, mountedbelow the main fuel supply valve, to the enricher jet fit-ting on the number one carb. Fuel then enters each ac-celerator pump chamber, opens the outlet check-valve,and squirts out the discharge nozzle.

The accelerator pump inlet check-valve prevents pres-surized fuel from entering the float bowls and floodingthe engine. o

6 l K-Tech News

Coolant pump special toolSome of our newer motor-cycles, like the ZX-6 andZX-7, have the coolantrecovery tank (reservoir)in a somewhat incon-venient location under theside cowling. To addcoolant, you must removethe side cover and tail sec-tion. This is not a hugetask but it seems likemore than what should benecessary just to add alittle coolant.

Well, with just a few dol-lars and a few extraminutes you can build ahandy little special toolthat will allow you to ad-just the level in therecovery tank of anyvehicle without having toget to the tank itself. Withtwo 3ft sections of fuelhose (P/N 92190-3715 will

work), two straight connec-tors (brass tubing), and aKawasaki 650 TandemSport fuel primer bulb(P/N 49043-3702) youcan build a hand pumpthat will do the job nicely.

To use the pump, firstdisconnect the overflowhose from the filler neck tothe recovery tank at thefiller neck. Then, depend-ing upon whether you’readding or removingcoolant, connect the ap-propriate hose from yourpump to the overflowhose. Stick your specialpump’s other hose into abottle of 50/50 coolant mixand you’re ready to trans-fer fluid. There’s no mess,little fuss and lots of timesaved! - Kenny Osberg

Bonus Tip Bonus Tip Bonus Tip Bonusn In case you haven't discovered this already: Liquidlaundry detergent bottles with the no-drip caps workgreat for storing coolant in your shop! - Kenny Osberg

T I P S F R O M T H E S P E C I A L I S T S

AFTERMARKET

Different treads for the ZX-6The factory has tested and approved some aftermarkettires for use on the ZX600-D1/L and D2/L. What thismeans is these tires (in matched sets only) can be usedon the ZX600-D models without the rider experiencingany appreciabledeterioration in han-dling characteristics.

Check the ap-propriate ownersmanual for approvedoptional tires onother models. Re-member, the hand-ling characteristicsof any one tire willvary somewhat fromone model motor-cycle to another.- Gregg Thompson

ZX600-D1/L, -D2/L

FRONT

REAR

AS A AS ASET ONLY SET ONLY

METZELER PIRELLI120/60 ZR17 120/60 ZR17

ME1 Front Comp K MP7 Spot-lTubeless Tubeless

METZELER PIRELLI160/60 ZR17 160/60 ZR17ME1 Comp K MP7 Sport

Tubeless

AS ASET ONLY

METZELER110/70 V17 V250ME1 Front Racing

TubelessMETZELER160/60 VB17ME1 Comp K

Tubeless Tubeless

TIP

Does the battery rattle?I f you pull the bat-tery out of a newJET SKI® water-craft to fill it withacid and hearsomething rattlingaround inside,don ‘t worry!Some batteriescome from themanufacturer witha couple of anti-sulfation tablets in-side them. Thesetablets rattlearound in thereuntil electrolyte isadded.- Dave Behlings

ZX cooling systemmystery solvedby Gregg ThompsonSenior Product Support Specialist

We’ve received a handful of reports on the Hot Lineabout ZX600-Ds with confusing overheating symptoms.The engines were definitely overheating and boiling thecoolant, but the fan wouldn’t go on. And there was noth-ing wrong with the fan system.

The clue that most of these mechanics missed in theirinitial diagnosis was that the radiator was not getting hoteven when the coolant boiled over. That spells circula-tion troubles. It turned out that a plastic plug was left in-side one of the water pump pipes at the factory.

Remember this one if you ever have a new vehiclethat overheats but the fan doesn’t go on. o

ACCESSORIES

ZX-6, ZX-11 frame paintWe’ve had a lot of callson the Hot Line asking forpaint to match the silveron the ZX-6 and ZX-11frames and swingarms.Until now we haven’t hadan answer. But due topopular request, theKawasaki AccessoriesDepartment has had paintformulated to match thatsilver. It’s now available inspray cans and quarts.

The part numbers are:Spray can . . . . K61062-671CQuart can . . . . K61063-671C

The Technical Magazine l 7

T I P S F R O M T H E S P E C I A L I S T S

Crankshaft seals:Which way do they go?by Gregg ThompsonSenior Product Support Specialist

Have you ever started to put the bottom end of a JETSKI® watercraft engine back together and found youcouldn’t remember which way the seals were supposedto face?

Well, don’t feel like the Lone Ranger. It’s happened tomost of us at one time or another. The diagrams shownhere should help if you get stumped in the future. o

JS300-A, B

JS550-C1

TIP

JF650-A1, A2

All 650 models (except JF650-A1, A2)

8 l K-Tech News

JS440-A4 thru A15, JS550-A1 thru A8, JS550-B1

Don't melt the plastic!The 650 family of JETSKl® watercraft (65OSX,X-2, and TS) have plasticthrust nozzles with brassinserts that the directionalnozzle pivot screws mountto. When installing thosepivot screws, a non-perma-nent locking agent shoulde used. But removing thecrews can then be difficult.Applying heat to the

area with a torch to loosenthe locking agent will melt

the plastic-not a goodidea. The trick, of course,would be to heat just thebolt, not the plastic.

Well, you can do justthat with a high powersoldering gun or largesoldering iron. Just holdthe heat source againstthe head of the pivotscrew until it’s hot and thescrew should come rightout! - Kenny Osberg

T I P S F R O M T H E S P E C I A L I S T S

JET SKI® watercraft pump housings: no seal, no zealby Gregg ThompsonSr. Product Support Specialist

In the Winter 1989 issueof K-Tech News, we ranan article entitled “JETSKI® Clutch Slipping?”(see Vol. 2. No. 4, pg. 8-Ed.). That article ad-dressed a problem that oc-curs when a jet pumphousing is not sufficiently

We have had somereports of new JL650-A1Sport Cruisers comingfrom the factory with in-adequate sealant.

Since this is a newmodel and we all knowhow important first impres-sions are, we suggest youcheck all SCs beforedelivering them to cus-tomers. If you don’t have

the leadingedge, thepump mustbe removeda n d r e -sealed.

To ensurea good seal,the sidesand too ofthe pump housing musthave an unbroken 1 inch

sealed to the hull. On allof our watercraft the pumphousings are sealed to thehull with clear siliconesealant. If this seal is notperfect it will allow air tobe drawn forward from theback of the craft into thepump-and any air drawninto the pump will reducethrust, especially at lowvehicle speeds. In ex-treme cases, the lack ofthrust caused by a leakcan prevent the vehiclefrom getting up on plane.

ALERT

Cooling system blockage onsome new SC & TS JET SKIs®

The boat won't be the only is plugged with sealant.thing that overheats if it Refer to Service Bulletingoes out on its maiden JS91-02, COOLING SYS-voyage and the cooling TEM BLOCKAGE.hose fitting on the jet pump

The problem is morenoticeable and thereforemore common on the big-ger JET SKI® models withthe 65Occ engine.

any water to put the boatinto, you can check it onthe bench.

To bench test the pumpseal for leaks you musthave clear access to thepump area. It’s usuallyeasiest to roll the boat upon its side. Remove the in-take grate and spray aheavy soap and water solu-tion all around the leadingedge of the pump housing.Now, with a pressurehose, blow air into the rearbetween the pump hous-ing and the hull and watchthe leading edge of thehousing for air bubbles. Ifbubbles appear anywherealong the sides or top of

wide strip of siliconemaking good contact withthe pump and hull at theleading edge of the pump.

Use only automotive-type clear RTV silicone,not the general purposehousehold silicone sealantfound at paint and hard-ware stores. Always letthe silicone dry overnightbefore putting-the boat inthe water. o

The Technical Magazine l 9

T I P S F R O M T H E S P E C I A L I S T S

Hull repairs underwarranty: do’s and don’tsby Gregg ThompsonSr. Product Support Specialist

Make sure your servicepersonnel are aware that,according to the KawasakiWarranty Policies and Pro-cedures Manual (P/N99969-0210-01), water-craft hull repairs underwarranty must be auth-orized prior to your do-ing the work.

In most cases, what theHot Line technician will re-quire is an estimate andsome pictures that showthe damage. This is impor-tant...don’t send us pic-tures that are out of focusor so over-exposed thatthe damage doesn’t show.(See “What’s Wrong WithThis Picture?", K-TechNews, Vol. 3, No. 4, pg. 7.Ed.) We have to see thedamage in order to decidewhether the estimate isreasonable.

If the repair estimate isfrom an outside bodyshop, it must include the

labor in hours andmaterial costs itemized in-dividually. On minorrepairs (under $lOO), acombined (material andlabor) dollar amount isusually OK.

When you receive aKawasaki watercraft thathas hull damage and youare considering repairingit under warranty do thefollowing:

n Work up an estimatefor in-house repairs or ob-tain a written estimate forsublet repairs.n Call the Hot Line anddiscuss the problem withthe technician.n If requested, takesome good quality photosshowing the damage andmail the photos and es-timate to the Hot Line tech-nician at KMC.n Do the repair onlyafter the Hot Line techni-cian has called you backand authorized it. o

10 l K-Tech News

DATA

Decoding Kawasakiwatercraft hull ID numbersHere’s some information you can use to make the iden-tification of Kawasaki watercraft easier:

From their introduction in 1973, Kawasaki watercrafthave come with a 12-digit Hull Identification Number(HIN). New Coast Guard regulations required a changein the HIN starting with the 1985 model year. Theoriginal 12-digit HIN can be broken down into four sec-tions of characters that are easily deciphered. The chan-ges made to the HIN for 1985 require a little moredecoding.

n Pre-1985 Hull Identification Number

K A W 12345 07 83MAKE PRODUCTION PROD. PROD.

SEQUENCE MONTH YEAR

Beginning with the 1985 model year, the productionmonth and production year sections were combined intoa single two-digit code. A two-digit model year wasadded to the end of the sequence. These changesproduced the 12-digit HIN we still use today.

n 1985-present Hull Identification Number

K A W 12345 C5 91MODELYEAR

MONTH AND YEAROF MANUFACTURE*

PRODUCTION SEQUENCE

IDENTIFIES KAWASAKI AS THE MANUFACTURER

*KEY TO MONTH AND YEAR:

C 5INDICATES MONTH INDICATES YEAROF MANUFACTURE OF MANUFACTURE

A = JANUARY 1985B = FEBRUARY 1986C = MARCH 1987D = APRIL 1988etc.

The HIN is always located on the starboard side of thecraft, near or on the stern.

For additional model identification information, referto the following publications:oWatercraft Chronology Service Bulletin: publishedeach year, lists all models produced since 1973.oParts Catalog Microfiche: provides HIN and enginenumber ranges, colors and publication part numbers.

In our next issue, we’ll crack the code on Vehicle Iden-tification Numbers (VINs). - Dave Corey

C O M M U N I C A T I O N S

TOOLS

Two-strokepressuretestingBefore you tear down thetop end of any two-strokeengine with low compres-sion, consider what mighthave caused the poorcompression readings. Ifyou believe the enginemay have been seized,don’t remove the headand cylinder until youhave pressure and vac-uum tested the engine.

One of the most com-mon causes of seizures intwo-stroke engines is anair leak. An air leak in acrankshaft seal, crank-case seam, intake tractgasket, or the base gasket.can lean out the engine tothe point of seizing.

“

Obviously you want toperform this test beforeyou take the engine apart;you don ‘t want to rebuildthe top end and then findout a crankshaft seal isleaking. Also, determiningthe cause of a seizure andeliminating that is just asimportant as fixing thedamage.

If you don ‘t alreadyhave a crankcase pres-sure tester, Kawasaki hasone for you (P/N T96000-001). As you use this kit onvarious engines, you’ll findyou have to make someplates and buy some ex-pandable freeze plugs. Buteventually you’ll have every-thing you need to pressuretest all the engines you nor-mally work on.

Remember: An ounce ofprevention (diagnostic test-ing) is worth tonof cure (wrenching).- Gregg Thompson

Part 3:Don’t let them goaway mad

by Sharon WillekeCustomer ServiceRepresentative

Our last article focusedon repeat business and of-fered several good tips forencouraging the customerto return to your store.

This time we presentthe flip side and show youtypes of behavior that candrive customers out thedoor, possibly never toreturn.

Just as everything youdo for a customer willeventually get a return foryou, everything you do notdo for a customer willstunt the growth of yourbusiness. We have all en-countered service person-nel who have helped usdecide to “take our busi-ness elsewhere.” They arethe rude, the crude andthe indifferent, and theycan destroy an organiza-tion. Hopefully they arenot working at your dealer-ship!

Try to eliminate the fol-lowing behaviors when-ever you recognize themin your store:

1. APATHY - an attitudethat tells the customer youcould not care less aboutserving him. ComedianGeorge Carlin calls thisthe “DILLIGAD” look-theone that says, “Do I LookLike I Give A Damn?”

Take a genuine interestin your customer’s con-cerns. As minor as theymay seem to you, they arequite major to your cus-tomers.

2. RUDENESS - coldness,hostility, unfriendliness-any behavior that says tothe customer, “You arebothering me; please goaway.”

We all learned commoncourtesy as children. Getback to basics.

3. “GOING BY THEBOOK” - hiding behind aset of company policiesthat leave no room for dis-cretion in the name of cus-tomer satisfaction.

Increasing yourknowledge andawareness will

give you more con-fidence in handling

customerproblems. When

problems arehandled well, cus-

tomers don’t goaway mad.

”Know when to bend

rules. Use your commonsense to decide what isthe best solution to eachset of circumstances.

4. THE RUNAROUND -sending the frustrated cus-tomer on a wild goosechase from one party toanother, often with the cus-tomer returning to Point Awhere he explodes—andtakes others with him.

Take the time to learnmore about how your or-ganization operates andoffer to go the extra milefor the customer. Don’tsay, “It’s not my job.”

These unfortunate be-haviors can be modifiedby actively listening toyour customer anddemonstrating a willing-ness to help. Increasingyour knowledge andawareness will give youmore confidence in han-dling customer problems.When problems are hand-led well, customers don’tgo away mad.

Summer is here and it istime to dust off thoseKawasaki ExceptionalCustomer Servicematerials and put yourskills to work!

Remember, the “Mo-ment of Truth” is any situa-tion in which a customercomes in contact with yourorganization and forms animpression. Let’s avoid the“turnoffs” listed in this ar-ticle because you neverget a second chance tomake a first impression.Have a great summer! o

A victim of the runaround.

The Technical Magazine l 11

R E G I O N A L N E W S

WEST NORTH & EAST

Burning themidnight oilby Patrick Kelly9950 Jeronimo RoadIrvine, CA 92718(714) 770-0400

I t’s that time of year al-ready: The training seasonis over and summer ac-tivities are in full swing.For you, that means busi-ness is booming. We hereat KMC are plenty busy,too. Work on the ProductSales Guide highlightingall the information on thenew models for ’92 will bein full swing by the timeyou read this. So will workon other projects-a newgenerator sales manual, anew flat-rate microfiche,reference manuals forsome of our latest trainingvideos, plus revisions tothe training classes.

SOUTH & CENTRAL

A major project we’ll betackling is a completelynew Parts DepartmentOperations class to helpyou maximize the profitpotential of your partsdepartment.

The busier you get, ofcourse, the busier the per-

12 l K-Tech News

sonnel on the Hot Line be-come. So busy, in fact,that the training instructorsfrom each region will behelping man the lines fromtime to time to assist withthe extra-large volume ofdealer calls.

Rest assured that whileyou are working diligentlyto serve your customers’needs, we’ll be burning themidnight oil to help serveyour needs better too! o

Planning forsuccessby Walter Rainwater611O Boat Rock Blvd. S.W.Atlanta, GA 30378(404) 349-2000

The prime objective of anew dealership is to makea profit as soon as pos-sible. The ways newowners go about achiev-ing this often leave mewondering “Why didn’t Ithink of that?”

One business plan that Iadmire for being so wellthought out was con-ceived by Vince VonEberstein, the owner ofthe just-opened Gulf

Coast Kawasaki located inOrange Beach, Alabama.

Von Eberstein had a lotof good ideas. For one, hearranged for his servicemanager, George Istre, toattend Kawasaki TechnicalTraining classes beforehis shop was open forbusiness. For another, hehosted a “Demo Days”promotion for our JETSKI® watercraft productafter only being open twoweeks!.

Von Eberstein was ablyassisted by servicemanager lstre andKawasaki DistrictManager Chris Ousley.The Demo Days promo-tion was held on a Satur-day and Sunday at theoceanfront where hedemonstrated the SportCruiser, Tandem Sportand JET MATE as well asthe X-2 and 650SXmodels.

The bottom line? Vinceattributes the sale of 11JET SKI® watercraft andeight trailers to DemoDays. And his servicedepartment was well-trained, ready to prep andmaintain all those boatsfrom the start. o

TrainingScheduleEast RegionNorth RegionCentral RegionSouth RegionWest Region

KMC instructors are work-ing now on the 1992 Train-ing Program schedule.Classes will begin again inOctober. All dealers willreceive a copy of thewinter class schedule, butdon’t forget to watch thisspace in the Fall andWinter issues of K-TechNews.

Be sure to signup early!by Fred DeHart201 Circle Drive N., #1O7Piscataway, NJ 08854(201) 469-1221

Kawasaki Technical Train-ing classes run from Oc-tober to May, so by thetime you read this column,our 1990-91 training sea-son will have ended.

Our new trainingschedule for the 1991-92season should be arrivingat your dealership some-time in September. Besure to sign up early!

I will be working on theHot Line for two-week ses-sions during the months ofJuly, August and Septem-ber. I hope to be talkingwith some of you duringthat time. Be sure to call ifyou have questions wecan help you with.

I can also be reached atthe East Region office anytime you need assistance.

Please keep in touchduring the busy summermonths. I hope to be talk-ing with you soon! Have agreat summer season! o