summer 1997 the kawasakitechnical magazine vol. 10, …

S U M M E R 1 9 9 7 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 0 , N O . 2

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

POWERTO THEYOUTH

POWERTO THEYOUTH

INSIDEFeatures The ’98 KXs . . . . . . . . . . 2

Power Jet Carburetor . . . 4News New Training Center . . . . 5Regional Update . . . . . . . . . . . . . 6Tech Tips Product Sales Guides. . . . 7

Warranty Manuals . . . . . 8MULE™ Assemblies . . . . 8Warranty Registration . . . 9California Emissions . . . . 9Connecting Rods . . . . . . 101100 STX Speedometer. 111100 STX Battery . . . . . 11Gasket Kits. . . . . . . . . . 11

The ’98KXs:Powerto theYouth

The ’98KXs:Powerto theYouth

2SUMMER 1997 K-TECH NEWS

The 1998 Kawasaki KXlineup features dramaticimprovements nearlyacross the board. TheKX80 and KX100 sportdrastic engine and chassischanges that improve per-formance in all aspects.The KX125 and KX250feature engine and chassischanges that Emig andCarmichael used to winthe 1997 125cc, 250cc,

National and 250cc SXchampionships. The KX60and KX500 feature fac-tory graphics so they lookas fast as they really are.

’98 KX80 and KX100Engine

For the first time, KIPSvalves control the exhaustport height. The KX80compression ratio variesfrom 10.3:1 low speed, to

9.4:1 high speed, insteadof last year’s fixed ratio of9.4:1. The KX100 variesfrom 9.6:1 to 8.8:1, wherelast year’s was fixed at9.3:1. New cylinder headsoffer different volume,shape, and a more pol-ished finish for more effi-cient combustion and lesscarbon build-up.

These changes giveboth bikes more horse-power and torque with amuch broader power-band. The bikes are easierto ride for all levels ofriders with more low-endand mid-range power tomatch last year’s potenttop-end power. Riders canconcentrate on attackingberms and doublesinstead of worrying aboutfalling off the pipe.

The clutch featureslarger plates to handle theextra power, a newleverage ratio for lighterclutch pull, and a newdesign for quick servicing.The clutch plates are 9mm

by John GriffinInstructionalDesigner/Instructor

Cover Story

K-TECH News

Vol. 10, No. 2Summer 1997

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

WestRobert Taylor

ContributorsShannon Beeson, Dave Corey,John Griffin, Keith Pestotnik,

David Pyle

Graphics/Production

Graphic ArtGregg Thompson

PhotographyDave Corey, Rich Cox, Kevin

Wing

Copy EditorPat Shibata

ProductionDesiree Holland

©1997 Kawasaki Motors Corp.,U.S.A.

All rights reserved.Published by Kawasaki

All suggestions become the property of KMC.Sending a service suggestion gives Kawasaki

permission to publish and/or use itwithout further consideration.

Specifications subject to change without notice.

The KX100 and KX80 are basically new from the ground up.

KIPS valves on the KX80 and KX100 provide a wider spreadof power to help riders of all skill levels.


larger in diameter (110mmto 119mm), and the hubrides on roller bearingsinstead of a bushing forbetter action and dura-bility. A separate clutchcover allows access to theplates without removingthe water pump. Theclutch is now a pull-typereleasing design like thebigger KXs, so you canremove the plates withoutremoving the basket.

The clutch lever andperch come directly fromthe KX125/250.

ChassisKawasaki worked from

the wheels up, creating amore rigid and functionalchassis. New 36mm KYBupside-down cartridgeforks have large 49.5mmaluminum upper tubesand 18-way compression

damping. The swingarmshave bigger beams(50x22mm to 60x24mm)and incorporate cast alu-minum drive chainadjuster sections just likethe bigger KXs. The rearshock damping rates arerevised to work with thesechanges.

The new chassisrigidity keeps the rider oncourse through theroughest terrain. Rigidityenables the bike to gowhere you point it and getthe power to the groundby forcing all impacts tothe suspension for absorp-tion. Even the footpegsand wheels are beefed up.The footpegs are now caststeel and have largerframe brackets and pivots.Both wheels featureheavier gauge spokes, therear axle is larger in diam-

eter, and the rear hubeven has two bearings onthe drive side.

The rear brakes areimproved with a forgedaluminum pedal (insteadof steel) with two seals atthe pivot for smooth, con-trolled action. A new rearbrake disc and pads offergreat stopping powerwith less rusting. A newfront brake hose gives thebrake a solid, precise feel.

Kawasaki finished offthe bikes with detailchanges to make daily lifeeasier. The airbox hasmore room for yourhands. A new base plateand retaining bolt makeinstalling the air filter abreeze. The airbox cover is

now fastened withmachine screws instead ofself-tapping screws. Thefront number plate is heldon with one bolt insteadof three. A KX125/250fuel petcock is easier toturn on and off. Newseals and collars in theUni-Trak help keep thedirt out.

The KX80 and KX100are about as close tominiature works bikes asthey come.

’98 KX125 EngineKawasaki went all out

on this motor. Thecylinder features twoexhaust ports instead offour and a new one-valve

Cover Story

Continued on page 12

A separate clutch cover provides instant access to a largerclutch for ’98. The clutch is now a pull-type like the biggerKXs.

Kawasaki puts progressive fork and shock springs back intothe mainstream.

New for ’98‘97 ‘98

4

Feature

The 1998 KX125 andKX250 use a new KeihinPower Jet system. Thedigital igniter activates anelectric solenoid, closing anew fuel passageway inthe carburetor above9600rpm (KX125) and

8100rpm (KX250). Thesolenoid reopens the pas-sageway as the revs dropbelow 9400rpm and7900rpm, respectively.Approximately 10% lessfuel gets to the engineabove the prescribedRPMs compared to anormal carburetor. Peakpower is slightly

increased but the big ben-efit is pushing the powercurve an extra 750- to1000rpm before taperingoff.

A coil on the stator(similar to a lighting coil)sends power through avoltage regulator to thesolenoid. The igniter pro-vides a ground for the

solenoid at the properrpm. The igniter is nowlocated in the airbox tofurther separate it fromthe ignition coil. Shiftercart dealers take note toseparate these two com-ponents by at least a footor more. Resistor sparkplugs are mandatory.

Tuning: At rpmsbelow the activationpoint, the fuel flow of thepower jet and main jetcombined is about equalto the flow of just themain jet in normal carbu-retors. For example, the’98 KX250 uses a #158main jet and #55 powerjet, where the ’97 KX250used a #165 main jet. Only#50 and #55 power jetsare available fromKawasaki, but othersources have optional sizejets.

I believe a desert racercould install a larger mainjet and smaller power jetto retain crisp low speedresponse while keeping itrich enough on top tokeep the engine cool.Since the power jet nozzleflow is not affected by theneedle, it may preventengine seizures that occurwith the dramatic fueldrop from the needle re-entering the nozzle as therider closes the throttle.

Attend our TeamGreen ’98 training classfor more instructions onthis intricate system.�

SUMMER 1997 K-TECH NEWS

Solenoid Valve

Power Jet

Float Chamber

Power Jet Carburetor Systemby John GriffinInstructional Designer/Instructor

Power Jet Nozzle

June 1997 was animportant month forKawasaki Motors Corp.,U.S.A. It marked theopening of the first KMCtraining center outside theUnited States. Thetraining center is locatedin San Jose, Costa Rica,and is a first for themotorcycle industry inLatin America. We held atwo-week training classcovering Kawasaki motor-cycles, ATVs, Jet Skiwatercraft and Mules.Twenty-two students fromPanama, Mexico,Columbia, Costa Rica, ElSalvador, Paraguay,Puerto Rico, Argentina,Chile, Guatemala andNicaragua attended.

From the beginning, itwas clear that friendshipswere forming between thestudents. They continu-ously helped each other,went to meals together,

and supported each otherwhen needed. They tookgreat pride in representingtheir countries at the newtraining center.

Special thanks to thefollowing organizationswho helped make thisvital program possible:Purdy Motor S.A., theKawasaki distributor inCosta Rica; MotorcycleMechanics Institute inOrlando, Fla.; and the KenCook Company in Mil-

waukee, Wis. PurdyMotor generously pro-vided a building, workbenches, desks, andeverything necessary toset up a classroom andshop. MMI provided an

experienced Spanish-speaking instructor, andthe Ken Cook Companytranslated lesson plansand handouts intoSpanish.

KMC is dedicated toservice training in LatinAmerica, as well as manyother support systemsnow in development. Ilook forward to the nexttraining class and hope allthe original students willattend, as well as newtechnicians.�


News

by Rob TaylorInstructionalDesigner/Instructor, SpecialTool Coordinator

New Kawasaki Training Center in Latin America

Trained technicians play an important part in thesuccess of a dealership. All departments rely on theability of technicians to service new product or sellparts by selling service to customers. When the servicedepartment is not up to par, the whole dealership is offthe mark. Fortunately, many technicians can stay up-to-date by attending factory training schools withdealership support. Imagine if a technician had totravel thousands of miles to receive factory training,or any training at all.

Electronic Specialties Inc.Dealers often ask me, where can I get my electrical test

equipment repaired? The cost of new equipment is continu-ously rising, and many dealers have broken multimetersand CDI test equipment. In some cases, repairs are cheaperthan replacement.

If you have a bad load coil unit in your Kawasaki CDItester, which is needed to check CDI box output to the ignition coil, there is a way to replaceit. You can make one yourself by using a one ohm, eight watt resistor with an alligator clipattached to the end of the resistor. You should be able to buy the parts at an electronics store.

The other source for repairs of all types of electronic equipment is Electronic Specialties Inc.They repair all brands of multimeters, emission testers, gauges, and CDI test equipment. They have also developed ahand-held tachometer for two- and four-stroke engines. It can be used wireless, with an inductive pickup, or with acapacitive clip lead.

So, dust off your test equipment and have a busy and profitable summer. I look forward to talking with you eitheron the Hotline or at one of our training classes, which resume in the fall.�

Fred DeHart201 Circle Drive N. #107

Piscataway, NJ 08854(908) 469-1221

Very Special ToolsI would like to share my version of two very special watercraft tools. I define very special

tools as those that are not available anywhere, the ones we fabricate. The first tool is used to remove and install the 27mm nut on steering cables. If you have

ever tried to remove this nut, you will appreciate this tool. A similar tool was shown in K-Tech about 3 years ago, but there is not enough clearance to use that on the newer water-craft.

I weld a new 27mm socket to an 18" length of 1" OD steel tubing (18" is more thanneeded, but was convenient since the home improvement store sold the tubing in 36"lengths). Next, I weld an old 3/8 drive socket on the other end. To use the tool, remove the

cable end, then slide the 27mm socket over the cable up to the nut. You can use a ratchet to quickly remove the cablenut and a torque wrench to properly install the nut.

The second very special tool is used with a hoist or lift to remove an engine from the hull. I learned removingmy first JH900 engine, that it was too heavy, with too little clearance exiting the engine compartment for one person.

I make a lift ring using an eye bolt and a spark plug. I cut off the threaded part of a 1/2” shank eye bolt and grindoff the plating where it will be welded. I chip out the porcelain from an old 3/4” reach spark plug and weld the eyebolt as shown. To use this tool, I install the lift ring in the center cylinder and use a hoist to lift the engine easily, by

myself. Some technicians combine lift rings in the #1 and #3cylinders to help keep the engine flat.

Lifting the engine by one spark plug hole will not damagethe cylinder head as long as all the threads of the tool are usedand only the engine is lifted. Do not lift the entire watercraftwith this lift ring. The engine weighs less than 200 lb., while thepressure against the spark plug when running varies between400 and 600 lb. So there is a good margin of safety.�

Walter Rainwater6110 Boat Rock Blvd. S.W.

Atlanta, GA 30378(404) 349-2000


Regional

ATLANTA/DALLAS

PISCATAWAY/GRAND RAPIDS

Contact Electronic Specialties at:

2449 Pierce DriveSpring Grove, IL 60081

Phone: 815-675-1812Fax: 815-675-2905


Special Tools Part NumbersWith the training season over, I would like to thank all of you who attended the training

classes in the West region. I met many new technicians as well as the regulars. The firstseason for the new training classes was quite successful, especially the Master level courses.We are busy adding new information and materials to the curriculum for next year'straining season as well as some new specialty courses at a new training location. I will letyou know more on this later in the season in a training bulletin. Be sure to sign up early asmany classes were full last year.

Now some current news on special tools. As many of you found out, the part number forthe flywheel holder on the 900 and 1100 Jet Ski® watercraft has changed. The old part

number T57001-1223 has changed to 57001-1403. Unfortunately, the name and purpose of the tool has changed fromflywheel holder for the JH and JT 900/1100 to flywheel puller for the KVF400 Prairie without any notice. Yes, thistool is still the same and works on both the Jet Ski and Prairie's flywheel. The tools required to assemble the Prairie'scases came from several models. One of them, P/N 57001-1092 (steering stem bearing driver adapter) was used onlate 1970's KZ-style motorcycles and was dropped when these models were discontinued. We reactivated the tool toinclude it as part of the crankcase assembly tool for the Prairie. This took some time but is now available.�

Robert Taylor9950 Jeronimo Road

Irvine, CA 92618(714) 770-0400

Regional

IRVINE/SEATTLE

By now, you havereceived the first of the1998 Product Sales Guides.If you carry motorcycles asone of your Kawasakiproduct lines, you’veprobably noticed the StreetMotorcycle Product SalesGuide has a “black-and-white” cover (with a littleyellow title box). The All-Terrain Vehicle, Off-RoadMotorcycle, and PortableGenerator books have

color covers.So, why isn’t there a

color cover on the StreetMotorcycle Sales Guide?The “black- and-white”cover means there is moreto come in the streetmotorcycle line-up. You’llsee those models in a newProduct Sales Guide at theDealer Meeting in October.

The new book will have afull-color cover and willinclude all the new prod-ucts for 1998. The 1998Watercraft and UtilityVehicle Product SalesGuides will also be pre-sented at the DealerMeeting

If you’d like to ordermore copies of any 1998

Product Sales Guide, justgive Kawasaki Tech Ser-vices a call at 714/770-0400, extension 2463 andask for Kiki. She’ll sell youthe available books for anominal charge, based onKMC’s printing costs. Noshipping. No handling.But there is sales tax formost states.�

1998 ProductSales GuidesAvailableBy Ray St. JohnSupervisor, TechnicalWriting

KeepingCurrent

8

KAF300-B/C KAF620-A/B KAF620-C

ENGINE ASSY. 70290-2176-LF 70620-2007-EG 70620-2007-EG

RR. GEAR CASE N/A 13101-1196 13101-1194

FR. GEAR CASE N/A N/A 13101-1220

by Jeff HoeppnerParts Data Coordinator

Due to the uniquedemands of utility vehiclecustomers, we now offermajor engine and drivetrain assemblies forMULEs. Although MULEutility vehicles haveproven extremely durable,in an abusive commercialenvironment where theyare used for long hours,

year round, failures areinevitable. In these cases,it is far more efficientsimply to have a spareengine or gear case handyto replace rather thanhaving the vehicle downwhile internal repairs aremade. The assemblyneeding repair can then bechecked and repairedthoroughly while stillhaving the ability to usethe MULE.�

MULE™ Engine and Gear Case Assemblies

SUMMER 1997 K-TECH NEWS

Service Tips

Here is some goodnews for those of you whocan't always carry a micro-fiche viewer around inyour pocket: Warranty FlatRate Manuals are nowavailable on paper for allKawasaki product lines.The new manuals areprinted as 8 1/2" x 11"paper booklets and areavailable from parts inven-tory.

With the new print-on-demand technologiesavailable today, it is cost-effective for us to print insmall quantities. Thismeans that we will bereprinting these manuals

several times a year andthe flat rate informationwill be updated each time.Because of this, when youorder a manual, it may notbe as current as the micro-fiche but it will not bereally out of date either.Just remember that the flatrate microfiches areupdated four times a yearand they will have themost current flat rateinformation on them.�

by Dave CoreyWriter/Producer

Kawasaki Warranty Flat Rate Manuals Now Available on Paper

Part Number Description Dlr. Cost* Pkg. Qty.

99960-0077-01 Motorcycle Warranty Flat Rate Manual $20.00 1

99960-0078-01 Jet Ski Watercraft and Marine Product Warranty Flat Rate Manual $10.00 1

99960-0079-01 ATV Warranty Flat Rate Manual $5.00 1

99960-0034-04 Utility Vehicle Warranty Flat Rate Manual $6.57 1

99960-0056-01 Portable Generator Warranty Flat Rate Manual $2.99 1

* See the Parts Retail Price Guide for latest prices.

by John GriffinInstructional Designer/Instructor

You may not live any-where close to California,but you need to knowabout the emission equip-ment Kawasaki uses there.Why? California (CA)models can be sold in theother 49 states, but 49state models cannot besold there. This meansthat Kawasaki, like mostmanufacturers, buildmore CA models than weplan to sell. It is commonfor dealers in New York orFlorida to be selling CAmodel motorcycles.

For 1998, Kawasakinow offers CA modelATVs and KLX300Rs. Theonly changes to thesemodels is the routing ofcrankcase and valve covervapors into the airbox.The carburetion is alsoslightly altered and nowuses emission standardjets. These jets are preci-sion manufactured andanodized for long wear.

Kawasaki sells all KXmodels as closed coursecompetition units in Cali-fornia. The ’98 KDX200and KDX220R, like theKE100, will not be sold inCalifornia. All 1998MULEs™ sold in the U.S.meet California emissionstandards.�


Service Tips

by Don ChurchManager, Service Trainingand Communications

During the busyseason, it is easy to let“paperwork” slide. Butplease, don’t put off war-ranty registrations.Entering accurate cus-tomer informationthrough K-Share is easy.It’s important to registereach Kawasaki withinthree days of retail sale forseveral reasons:

* Eligible customers getKawasaki rebate checksASAP (so they can buyaccessories).

* You get credit for anysalesperson incentives orsales promotions.

* If Kawasaki initiates arepair campaign, we mustnotify customers immedi-ately.

* You may not be able toprocess warranty requestsbecause the unit is notregistered.

Accuracy of the cus-tomer information youprovide is critical. Hereare tips based on the mostcommon errors:

* Use the customer’s pri-mary residence where theyreceive mail. Some have afew residences.

* If the customer is not theaddressee at the address,use “C/O” (in care of)after the addressee’s name.

* If the customer has a P.O.Box, it’s likely their mailis not deliverable to theirphysical address. Registerthem using the P.O. Boxnumber. Note: If it’s aP.O. Box enter P.O. Boxnot just Box. There is adifference; Box is some-times used with a Route.

* If the customer gives youa P.O. Box number andstreet address, put theP.O. Box before the streetaddress.

* Rt., CR, or GeneralDelivery are often notgood enough by them-selves; get an addressnumber or P.O. Boxnumber if possible.Here are a few more

details to watch out for:

* Verify the city and zipcode match. Use the five-digit zip and four-digitextension if possible.

* Don’t forget suite orapartment numbers.

* Add street address direc-tions—E., S.W., etc.

* Spell names and addressesaccurately.

* Split words that arehyphenated.

* Ask your customer if theyare in the process ofmoving.

* Ask your customer if theaddress they provided istheir mailing address.

By following these tips,the customer informationyou provide Kawasakiwill be processed quicklyfor everyone’s benefit.Thanks for “lending us anear.”�

Making

Warranty

Registration

a Priority

How Do California Emissions AffectMe?

On the Hotline, all ofus have gotten calls fromdealers who had disas-sembled an enginebecause of poor runningor abnormal vibration andfound a bent connectingrod. Often the dealer tech-nician has no idea whatcaused the rod to bend. Inthe case of two-strokeengines, the technicianwill sometimes take aguess that a ring caught aport and bent the rod. Idon’t think so.

For the rod to bend, thepiston has to be stoppedjust before it reaches TDC.There the crankshaft hasway more leveragepushing on the rod thanat any other place in thestroke. The ratio of crank-shaft rotation to pistontravel is very high (lots ofcrankshaft rotation, verylittle piston travel).

If you run across a bentconnecting rod in anengine you are workingon, the chances are it wascaused by a hydrauliclock—liquid in the com-bustion chamber. Theoret-ically if some large object(such as a valve head inthe case of a four-strokeengine) got into the com-bustion chamber, it couldcause a rod to bend. Butin fact, even a valve head

can be smashed andjammed into the top of apiston, but a liquidcannot. A liquid (gasolineor water/ coolant) cannotbe compressed and it dis-tributes the pressure soevenly across the pistoncrown that there is nomark of any kind left onthe piston. The volume ofliquid only needs to beslightly more than thetotal volume of the com-bustion chamber. Usuallythe cause of the eventexits the cylinder the firsttime the exhaust port is

open, leaving no trace ofitself.

In the case of our two-stroke watercraft engines,the liquid is always water.Water gets in the enginethrough the intake whenthe engine compartmentgets too full of water.Water can also enter fromthe exhaust; but in ourcurrent watercraft exhaustpipes, cooling waterenters the exhaust streamso far from the engine thatit is very unlikely any sig-nificant volume of waterwould ever make its way

back to the engine.Sometimes customers

manage to ignore the rod-bending event and subse-quent vibration and poorrunning. They continue toride the watercraft untilthe rod finally breaks. Abent rod will always breakif run long enough. Butyou can still usually tell ifthe rod was bent before itbroke.

A connecting rod thatwas bent from a hydrauliclock always ends up withthe wrist pin bore stillnearly parallel with theaxis of the crankshaft.This is because when therod bends, the pistonholds the small end of therod in its proper position.The resulting “S” bend inthe rod is usually stilldetectable even after therod has broken. If youhold the two pieces of thebroken rod together andthe rod is bent but thewrist pin bore is stillnearly parallel with thecrankshaft, it’s a prettygood bet the engine was“hydrauliced” some timeprior to the rod breakage.

Damage caused by ahydraulic lock is generallynot covered by warranty(no defect); so if you runinto one with this problemwithin its warrantyperiod, you’d better callus and discuss it beforemaking any commitmentsto the customer.�


Service Tips

by Gregg ThompsonProduct Support Supervisor

Bent/Broken Connecting Rods

“S” Bend

Bearing bores still parallel

Where’s the Battery?Where’s the Battery?Rob TaylorInstructional Designer/ InstructorSpecial Tool Coordinator


Service Tips

Back by populardemand, complete gasketsets are available forselected current models.They’re not only conve-nient, but economicaland profitable. A list ofapplicable models islisted below and we willbe adding the illustra-

tions and part numbersto the microfiche as theinformation becomesavailable. If the informa-tion is not on your micro-fiche yet, don’t panic.Parts lists, illustrations,and applications areavailable on Parts Bul-letin “MC 97-01.” �

The Hot Line hasreceived calls reportinginaccurate speedometerson the JT1100-A1.Speedometer fluctuations,inaccurate speed indica-tions, and thespeedometer droppingback to zero above a par-ticular speed are all indi-cations of this problem.Adding to the confusion isthe new digital meter andhow to troubleshoot it.Fortunately, the problem isusually the setup of thehull sensor, not the meter.

As with any compo-nent attached to the hull,alignment is critical. If thespeedometer sensor ismounted so it protrudesbelow the hull line, or is

too high, the speedometerwill not operate correctly.The left bottom corner ofthe sensor body must beeven with the bottom sur-face of the hull. To alignthe sensor, loosen the boltsattaching the sensor bodyto the mounting bracket,move the sensor until it isflush with the hull. Besure to use a non-perma-nent locking agent on themounting bolts. Also,remove any debris or ironbuildup on the paddlewheel.�

Have you ever gonesearching for the hourmeter’s backup battery onthe 1100 STX Jet Skiwatercraft? Apparently,some technicians havedone just that. Afterhunting for a while (espe-cially in the meterassembly), the battery was

never found. Thisprompted quite a few callsto the Hot Line. So whereis the battery? There is nobattery!

The system uses a read-write memory chip that islocated in the meterassembly. The memorychip is continuouslyupdated as the watercraftis operated. If the batteryever goes dead or is dis-connected, the chip storesthe latest informationbefore power is lost. If thehour meter does not retainthe information when thebattery is disconnectedand then reconnected, itcan only be one thing: thememory chip. Unfortu-nately, the complete meterassembly must bereplaced.�

1100 STXSpeedometerErrorsby Rob TaylorInstructionalDesigner/Instructor Special Tool Coordinator

Gasket Kits for Select Models

MODEL YEAR KIT PART NO.

VN1500-D ..................1996 & UP............................99995-1393

VN800-A ....................1995 & UP............................99995-1394

VN800-B ....................1996 & UP............................99995-1394

ZX1100-D ..................1993 & UP............................99995-1396

ZX1100-E ....................1995 & UP............................99995-1396

ZX1100-F ....................1996 & UP............................99995-1396

ZX600-F ......................1995 & UP............................99995-1397

KX250-K ....................1994 & UP............................99995-1399

Gasket Kits Are Backby Jeff HoeppnerParts Data Coordinator


KIPS that works like aKX250 center valve. Thenew KIPS alters portheight 6mm, compared to5mm in ’97. The con-necting rod is 2mmshorter for better primarycompression. The piston is7 grams lighter (130g to123g) for quicker responseand it has an intakewindow for more top-end.

Other big news is theaddition of the Power JetCarburetor (see sidebar).The carburetor bore is also1mm larger (35mm to36mm) for more top-endpower. New ignition andmagneto increase outputfor the power jet system.

’98 KX250 EngineThe designers extracted

one more horsepower outof the motor this year by

revising the exhaust portlayout and adding aPower Jet Carburetor. Thecenter exhaust port andKIPS valve are now wider(41mm to 43mm), and thesub-exhaust ports androtary KIPS valves aresmaller (21mm to 17mm).Since the center KIPSvalve is the most effectiveport-altering device, alarger center valveimproves power acrossthe board.

A more powerful igni-tion uses a much smaller(and lighter) rotor to ener-gize the power jet. Aheavier crank nearly off-sets the loss, for a slightreduction in overall fly-wheel effect versus the’97. This change results inquicker engine response,less vibration, and longermain bearing life. Theconnecting rod offersimproved lubricationthrough a larger oilgroove on the big end andan additional oil hole onthe small end. The piston-

to-ring tolerances aretighter for improved ringseal and more power.

’98 KX 125/250 ChassisThe chassis (and center

of gravity) is 5mm lowerfor improved corneringand traction. This changewas accomplished byraising the forks 5mm inthe triple clamps andshortening the lowershock clevis 1.5mm. Sus-pension travel has notbeen affected.

It has been over adecade since anyone hasused progressive springson modern motocrossers,but Kawasaki re-intro-duces them for ’98. Therear shock spring is triplerate, while the fork

springs offer a steady pro-gressive winding. Newdamping rates work withthe springs to provideplush action with muchmore resistance to bot-toming.

The 1998 Kawasaki KXmodels feature an infu-sion of technology learnedfrom winning thetoughest championships.Our reputation stands for:great bikes right out of thebox; balanced bikes thatturn great and arestable;plush suspension,and outright performance.It doesn’t matter whatclass you race, Kawasakiis the bike to own in ’98.�

Power tothe YouthContinued from page 3

The KX125 cylinder features only two exhaust ports regu-lated by one center KIPS valve.

The KX250 motor is massaged with revised exhaust ports,KIPS system, more powerful ignition, new crankshaft, dif-ferent reed valve, and stronger engine cases.

Cover Story

44 KAWASAKIEATONTON, GA

A ACTION MOTOR SPORTSGREELEY, CO

A.J. FOYT KAWASAKIHOUSTON, TX

ACTION SPORTS KAWASAKICOLLEGE STATION, TX

ACTION JET SKI WESTVENICE, FL

ACTION KAWASAKISHAWNEE, OK

ADAMS MOTORSPORTS KAWASAKIMONTGOMERY, AL

AINSWORTH KAWASAKIAINSWORTH, NE

AL GASKILL KAWASAKIEAST POINTE, MI

ALAMO CYCLE-PLEX KAWASAKISAN ANTONIO, TX

ALCOA GOOD TIMES KAWASAKIALCOA, TN

ALEX CYCLE SHOPWARREN, OH

ALFORDS SPORT CENTERMCCOMB, MS

ALL AMERICAN KAWASAKISANTA CRUZ, CA

ALL SEASONS SPORTSROCK SPRINGS, WY

ALLSPORT KAWASAKIDECATUR, AL

ANAHEIM KAWASAKIANAHEIM, CA

ANDERSON SALES & SERVICE, INC.BLOOMFIELD HILLS, MI

APEX SPORTS, INC.COLORADO SPRINGS, CO

ARIZONA JET SKIPHOENIX, AZ

ART'S KAWASAKIZEPHYR HILLS, FL

B & B CYCLE, INC.NORFOLK, NE

BABBITT'S SPORT CENTERMUSKEGON, MI

BAY AREA KAWASAKIHAYWARD, CA

BEAUMONT KAWASAKIBEAUMONT, CA

BENTLEY YAMAHA SUZUKICANONSBURG, PA

BERT'S KAWASAKIAZUSA, CA

BIG RED KAWASAKIEATONTOWN, NJ

BIKE WORLD KAWASAKISUNNYVALE, CA

BLOCKER KAWASAKIPARRYVILLE, PA

BOB THOMAS' KAWASAKINORTH HUNTINGDON, PA

BOB'S MARINE & JET SKIBELLEVUE, IA

BOONE ACTION KAWASAKIBOONE, NC

BREWER KAWASAKIHENDERSON, NC

BURBANK KAWASAKIBURBANK, CA

BUTCH'S JET SKI SHOPGRAND RAPIDS, MI

CAL COAST MOTORSPORTS KAWASAKIVENTURA, CA

CAMRODNEW YORK, NY

CAPITOL KAWASAKICOLUMBIA, SC

CARL'S CYCLE SALESBOISE, ID

CASINO BEACH MARINA KAWASAKISTORM LAKE, IA

CASTAIC SKI & SPORT KAWASAKICASTAIC, CA

CENTRAL NEW YORK KAWASAKIELBRIDGE, NY

CENTRAL VERMONT KAWASAKIRUTLAND, VT

CHAMPION KAWASAKICOSTA MESA, CA

CHARLOTTE KAWASAKIMATTHEWS, NC

CHEYENNE SPORT CENTERCHEYENNE, WY

CHICO JET SKICHICO, CA

CLEAR LAKE KAWASAKIFREMONT, IN

CLIFF'S CYCLE CENTERBREMERTON, WA

COAST CYCLESGULFPORT, MS

COLBOCH HARLEY-DAVIDSON SALESMORRISTOWN, TN

COLUMBIA TRACTOR, INC.CLAVERACK, NY

COMMONWEALTH CYCLESARLINGTON, MA

CONCORD KAWASAKICONCORD, CA

CORVALLIS FORD NEW HOLLANDCORVALLIS, OR

CRAIG'S KAWASAKIBOUNTIFUL, UT

CRAIG'S JET SKISANTA FE SPRINGS, CA

CUNNINGHAM CYCLE WORLD FAYETTEVILLE, NC

CUNNINGHAM GOLF CAR CO.LOUISVILLE, KY

CYCLE SPORTS KAWASAKISALEM, OR

CYCLE SPORT CENTERORLANDO, FL

CYCLE CENTER OF FREMONTFREMONT, CA

CYCLE CITY KAWASAKIHEYBURN, ID

CYCLE SPORTS & SERVICEMT. PLEASANT, PA

CYCLE CENTERGLOBE, AZ

CYCLE MOTION KAWASAKIMIDDLETOWN, NY

CYCLE WORLD KAWASAKISAVANNAH, GA

CYCLES OF PALM BEACH KAWASAKIWEST PALM BEACH, FL

CYCLES OF BOULDER, INC.BOULDER, CO

DAL-KAWA CYCLE SALESHENDERSONVILLE, NC

DAVIS CYCLE SALESBUTLER, PA

DOUG'S CYCLE SHOPSALISBURY, MO

DUFF SHELLEY KAWASAKIAMERICAN FORK, UT

EAST END JET SKIHAMPTON BAYS, NY

EDDIE HILL'S KAWASAKIWICHITA FALLS, TX

ELK CITY KAWASAKIELK CITY, OK

ELLIOTT KAWASAKIMANDEVILLE, LA

ELYS KAWASAKIHUTCHINSON, KS

ENUMCLAW KAWASAKIENUMCLAW, WA

EXCEL MOTORCYCLES & WATERCRAFTDENVER, CO

F & R SPORTS CENTERDODGE CITY, KS

FAIRFIELD KAWASAKIFAIRFIELD, CA

FAY MYERS KAWASAKIDENVER, CO

FORSYTH KAWASAKIWINSTON-SALEM, NC

FREEWHEELING CYCLEKENMORE, NY

FUN BIKE CENTERSAN DIEGO, CA

G.N. GONZALES KAWASAKIGONZALES, LA

G.N. GONZALES KAWASAKIBATON ROUGE, LA

GARBER KAWASAKIHESSTON, KS

GARBERS HONDAFAIRBURY, NE

GARTON TRACTOR & KAWASAKITURLOCK, CA

GATTO KAWASAKITARENTUM, PA

GOLD COUNTRY KAWASAKIAUBURN, CA

GOODTIMES KAWASAKISACRAMENTO, CA

GRAND HAVEN KAWASAKIGRAND HAVEN, MI

GRAND LAKE MOTOR SPORTSGRAND LAKE, CO

GRANDVIEW TRACTOR & KAWASAKIGRANDVIEW, WA

GREAT BEND HONDAGREAT BEND, KS

GULFSIDE KAWASAKIORANGE BEACH, AL

HACIENDA MOTORCYCLESSAFFORD, AZ

HAMME KAWASAKIGASTONIA, NC

HARRISON'S MARINE & KAWASAKIWAYLAND, MI

HEBELER SALES & SERVICEPENDLETON, NY

HIGH COUNTRY CONNECTIONSALIDA, CO

HILLSBORO KAWASAKIHILLSBORO, OR

HILLSIDE MOTORSPORTS KAWASAKIENFIELD, NH

HILTON HEAD KAWASAKIBLUFFTON, SC

HONDA SUZUKI KAWASAKI WESTTAMPA, FL

HOOKSETT KAWASAKIHOOKSETT, NH

HOUSE OF KAWASAKISAN DIEGO, CA

HUDSON KAWASAKIHUDSON, NH

INDUSTRIAL VEHICLE SALESPONTIAC, MI

ITHACA REC. SPORTS KAWASAKINEWFIELD, NY

JENKINS MACHINERY CO.CONCORD, CA

JIM BENNETT KAWASAKIIUKA, MS

JIM MURRAY'S KAWASAKI SALESSCRANTON, PA

JIM'S MARINE & CYCLE, INC.SHERIDAN, WY

JOHNSON'S CYCLE & AUTOFREMONT, NE

JONES KAWASAKI SALES & SERVICELAUREL, MS

JORGY'S KAWASAKI REC CENTERSTOCKTON, CA

K & H KAWASAKILITTLE YORK, NY

K & N KAWASAKIWICHITA, KS

KAWASAKI OF HOLLYWOODHOLLYWOOD, CA

KAWASAKI BIG BOYS TOYS, INC.OGDEN, UT

KAWASAKI OF DURHAMDURHAM, NC

KAWASAKI OF OCALAOCALA, FL

KAWASAKI OF PHILLIPSBURG/EASTNPHILLIPSBURG, NJ

KAWASAKI OF JONESVILLEJONESVILLE, LA

We want to officially thank all of the

dealers who participated in Kawasaki’s ’97

Service Training Program. We appreciate

your commitment to excellent service and

the sacrifices you made to send technicians to our classes. We are confident your cus-

tomers benefit from the knowledge your technicians gain through factory training.

Look for our ’98 Training Schedule at the Dealer Meeting in Orlando (Oct. 9-12).

The 1998 models offer new technology, which means important new training mate-

rial. Lastly, prepare for a ’98 Service Update Seminar coming to a location near you.

SpecialThanks

KAWASAKI SPORTS CENTERLAKE FOREST, CA

KAWASAKI OF NEW BERNNEW BERN, NC

KAWASAKI OF ST. GEORGEST. GEORGE, UT

KAWASAKI OF TWIN FALLSTWIN FALLS, ID

KAWASAKI OF YAKIMAYAKIMA, WA

KAWASAKI OF OCEANSIDEOCEANSIDE, CA

KAWASAKI OF CARROLLTONCARROLLTON, TX

KAWASAKI OF ROANOKE RAPIDSROANOKE RAPIDS, NC

KAWASAKI OF RAMSEYRAMSEY, NJ

KAWASAKI EASTINDIANAPOLIS, IN

KAWASAKI OF RALEIGHRALEIGH, NC

KAWASAKI OF WEST SWANZEYKEENE, NH

KAWASAKI HOUSE OF CYCLESNATCHEZ, MS

KAWASAKI OF POMPANO BEACHPOMPANO BEACH, FL

KAWASAKI OF SENECASENECA, SC

KAWASAKI POWERSPORTSVALLEJO, CA

KAWASAKI OF YUMAYUMA, AZ

KAWASAKI SPORT MOTORSPOCATELLO, ID

KAWASAKI OF STATESVILLESTATESVILLE, NC

KAWASAKI OF OAKLANDOAKLAND, CA

KAWASAKI OF SANTA BARBARAGOLETA, CA

KAWASAKI OF HICKORYHICKORY, NC

KAWASAKI OF RENORENO, NV

KAWASAKI EXPRESSWARNER ROBBINS, GA

KAWASAKI OF MONTEREYMONTEREY, CA

KAWASAKI OF ROCKY MOUNTROCKY MOUNT, NC

KAWASAKI SPORT CENTERPOMPTON PLAINS, NJ

KAWASAKI TERRITORYSTUART, FL

KAWASAKI OF BOUND BROOKBOUND BROOK, NJ

KELLY'S KAWASAKIMESA, AZ

KENT KAWASAKIKENT, WA

KEYSTONE KAWASAKIDUNCANSVILLE, PA

KLAMATH MOTORSPORTS KAWASAKIKLAMATH FALLS, OR

KREHBIELS COUNTRY STOREABERDEEN, ID

LAKE CHARLES KAWASAKILAKE CHARLES, LA

LAKE POWELL KAWASAKIPAGE, AZ

LAKEVIEW MARINA JET SKISNOBLESVILLE, IN

LAKEWAY POWER SPORTSGILLETTE, WY

LANTZ RENTAL & OUTDOOR EQUIP.CODY, WY

LARRY'S KAWASAKIPARKERSBURG, WV

LAUREL HIGHLANDS KAWASAKILEMONT FURNACE, PA

LEBANON KAWASAKILEBANON, MO

LINTON KAWASAKILINTON, IN

LIVERPOOL KAWASAKILIVERPOOL, NY

LONG BEACH KAWASAKILONG BEACH, CA

LYNNWOOD KAWASAKILYNNWOOD, WA

M & M CYCLEKALAMAZOO, MI

M & R KAWASAKIROOSEVELT, UT

MAC'S CYCLECLARKSTON, WA

MARK'S OUTDOOR SPORTSALAMOSA, CO

MATTOON KAWASAKIMATTOON, IL

MICHAEL'S KAWASAKICARSON CITY, NV

MID CITIES KAWASAKIPARAMOUNT, CA

MILLENNIUM CYCLEWORKS KAWASAKILILBURN, GA

MOSES LAKE KAWASAKIMOSES LAKE, WA

MOTION KAWASAKIHAMMONTON, NJ

MOTIONS KAWASAKIMARIETTA, GA

MOTOSPORTS OF UKIAHUKIAH, CA

NEWGATE KAWASAKIOGDEN, UT

NORTH WASHINGTON IMPLEMENT CO.LYNDEN, WA

NORTH COUNTY JET SKIENCINITAS, CA

NORTH BAY KAWASAKISANTA ROSA, CA

NORTHLAND KAWASAKIFLAGSTAFF, AZ

ONEKAMA JET SKIONEKAMA, MI

ORANGE COAST FORD TRACTOR, INC.ORANGE, CA

ORLANDO KAWASAKIORLANDO, FL

OUTDOOR SPORT, INC.GRAND ISLAND, NE

PALMETTO KAWASAKIHIALEAH, FL

PASCO CYCLEPORT RICHEY, FL

PAW PAW KAWASAKIPAW PAW, MI

PEMBINE KAWASAKIPEMBINE, WI

PIEDMONT KAWASAKISALISBURY, NC

PIONEER MOTORSPORT KAWASAKISARDINIA, NY

PLANO KAWASAKIPLANO, TX

POINT CYCLE KAWASAKIPITTSBURGH, PA

POMONA VALLEY KAWASAKIONTARIO, CA

PORT ANGELES KAWASAKIPORT ANGELES, WA

POWAY KAWASAKIPOWAY, CA

QUINSEY KAWASAKIEL CAJON, CA

R & R JET SKIHOLLYWOOD, FL

R & R JET SKI SOUTHNORTH MIAMI BEACH, FL

RAY C'SLAPEER, MI

REDWOOD CITY KAWASAKIREDWOOD CITY, CA

RIVERFRONT KAWASAKIYUBA CITY, CA

RIVERHEAD KAWASAKIRIVERHEAD, NY

ROCKFORD KAWASAKIROCKFORD, MI

ROMERO'S LAWN MOWER SALESNEW IBERIA, LA

RON GREENE KAWASAKIMT. PLEASANT, UT

ROSENAU POWERSPORTS KAWASAKIDEARBORN HEIGHTS, MI

SAN JUAN JET SKI & MARINEFLORA VISTA, NM

SAN DIEGO TURFSAN DIEGO, CA

SANDERS KAWASAKINEW CASTLE, PA

SATCH SALESMENANDS, NY

SCOTT'S KAWASAKILAS CRUCES, NM

SECORD LAKE MARINA JET SKIGLADWIN, MI

SIERRA CYCLESSIERRA VISTA, AZ

SIGMUND'S KAWASAKICENTRAL CITY, PA

SISTER LAKES KAWASAKISISTER LAKES, MI

SKAGIT VALLEY KAWASAKIBURLINGTON, WA

SMITH POWER EQUIP. & KAWASAKIHAYESVILLE, NC

SMITTY'S KAWASAKI CYCLEIMPERIAL BEACH, CA

SONOMA KAWASAKIWINNEMUCCA, NV

SOUTH BAY KAWASAKINATIONAL CITY, CA

SOUTH VALLEY KAWASAKIDRAPER, UT

SOUTHERN CYCLE KAWASAKIKENNER, LA

SPORT CENTER OF GRAND JUNCTIONGRAND JUNCTION, CO

SPRUILL KAWASAKIMT. PLEASANT, TX

ST. AUGUSTINE CYCLE CENTERST. AUGUSTINE, FL

ST. CHARLES JET SKIST. CHARLES, MO

STAR CITY MOTOR SPORTS, INC.LINCOLN, NE

STEVENS MOTOR SPORTS,INC.OMAHA, NE

STOCKTON FORD NEW HOLLANDSTOCKTON, CA

STORR TRACTOR CO.SOMERVILLE, NJ

STREIT'S KAWASAKIGAINESVILLE, FL

SUBURBAN JET SKIWARRINGTON, PA

SUN ENTERPRISESTHORNTON, CO

SUN SPORTS UNLIMITED, INC.GUNNISON, CO

SURBURBAN SALES & RENTAL CNTRCOCKEYSVILLE, MD

TEAM SAVAGE KAWASAKICLEARWATER, FL

TEAM BOZEMANBOZEMAN, MT

TEXAS CITY KAWASAKITEXAS CITY, TX

THE FIRST TURNCROWLEY, LA

TIME RENTAL SALES & SERVICENO. LOGAN, UT

TOMS RIVER JET SKITOMS RIVER, NJ

TREASURE COAST KAWASAKIFT. PIERCE, FL

TRI-COUNTY EQUIPMENT CO.POSEYVILLE, IN

TUCSON CYCLE & SKI KAWASAKIMARANA, AZ

TUCSON KAWASAKITUCSON, AZ

TWIGG CYCLESHAGERSTOWN, MD

TWO WHEEL WORLDWOODBURY HEIGHTS, NJ

VALLEY KAWASAKIPHOENIX, AZ

VESCO'S KAWASAKIBRIGHAM CITY, UT

VICKERY MOTORSPORTS INC.DENVER, CO

WATERTOWN KAWASAKIWATERTOWN, NY

WENATCHEE CYCLE CENTERWENATCHEE, WA

WEST COAST KAWASAKIPASO ROBLES, CA

WHITTIER KAWASAKIWHITTIER, CA

WILD RIDE SPORTS KAWASAKIGRENADA, MS

WILDCAT KAWASAKICOLORADO SPRINGS, CO

WINDHAM KAWASAKIWINDHAM, NH

WOLFE CYCLE SPORTS, INCHASTINGS, NE

WOODBRIDGE KAWASAKILINDEN, NJ

WOODS KAWASAKI FUN CENTERAUSTIN, TX

Z'S MOTOR SPORTSCRAIG, CO

summer 1997 the kawasakitechnical magazine vol. 10, …

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