Summary of Contents for Kawasaki vulcan 900 custom
Whenever you see the symbols CAUTION shown below, heed their instructions! Always follow safe operating and main- CAUTION indicates a hazardous tenance practices. situation which, if not avoided, could result in minor or moderate DANGER injury. DANGER indicates a hazardous situation which, if not avoided, NOTICE will result in death or serious in-...
FOREWORD Congratulations on your purchase of a new Kawasaki Motorcycle. Your new mo- torcycle is the product of Kawasaki's advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner's Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle's controls, its fea- tures, capabilities, and limitations.
TABLE OF CONTENTS SPECIFICATIONS ........ Brake Lever Adjusters ....... 26 LOCATION OF PARTS ......10 Fuel Tank Cap ........27 LOADING AND ACCESSORIES IN- Fuel Tank ........... 28 FORMATION ........13 Side Stand ......... 31 GENERAL INFORMATION ....16 Seat ............ 32 Meter Instruments ......
Spark Plugs ........91 Evaporative Emission Control Sys- tem (Southeast Asia and Thailand models only) ........91 Valve Clearance ......... 92 Kawasaki Clean Air System ....93 Air Cleaner ......... 94 Throttle Control System ..... 96 Idle Speed .......... 98 Clutch ..........100...
SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 37 kW (50 PS) @5 700 r/min (rpm) Maximum Torque 78 N·m (8.0 kgf·m, 57.5 ft·lb) @3 700 r/min (rpm) DIMENSIONS Overall Length 2 405 mm (94.1 in.) Overall Width 895 mm (35.2 in.) Overall Height 1 120 mm (44.1 in.) Wheelbase 1 645 mm (64.8 in.)
SPECIFICATIONS ENGINE Type SOHC, V-type 2-cylinder, 4-stroke, liquid- cooled Displacement 903 cm³ (55.1 cu in.) Bore × Stroke 88.0 × 74.2 mm (3.5 × 2.9 in.) Compression Ratio 9.5 : 1 Starting System Electric starter Cylinder Numbering Method Front to rear, 1-2 Firing Order Carburetion System Digital fuel injection system (DFI)
SPECIFICATIONS TRANSMISSION Transmission Type 5-speed, return shift Clutch Type Wet, multi disc Driving System Belt drive Primary Reduction Ratio 2.184 (83/38) Final Reduction Ratio 2.063 (66/32) Overall Drive Ratio 4.338 (Top gear) Gear Ratio 2.786 (39/14) 1.889 (34/18) 1.360 (34/25) 1.107 (31/28) 0.963 (26/27) FRAME...
SPECIFICATIONS ELECTRICAL EQUIPMENT Battery 12 V 10 Ah Headlight 12 V 60/55 W Tail/Brake Light 12 V 5/21 W (AU): Australian model Specifications subject to change without notice and may not apply to every coun- tries.
LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 7. Left Handlebar Switches 2. Clutch Lever Adjuster 8. Indicator Lights 3. Meter Instruments 9. Fuel Tank Cap 4. Brake Fluid Reservoir (Front) 10. Right Handlebar Switches 5. Brake Lever Adjuster 11.
LOCATION OF PARTS 12. Front Fork 22. Shift Pedal 13. Headlight 23. Oil Level Gauge 14. Turn Signal Light 24. Side Stand Switch 15. Horn 25. Side Stand 16. Spark Plugs 26. Fuse Box 17. Battery 27. Coolant Reserve Tank 18.
LOCATION OF PARTS 31. Tail/Brake Light 37. Mufflers 32. Seat 38. Idle Speed Adjusting Screw 33. Tool Kit Case/Tool Kit 39. Rear Brake Pedal 34. Air Cleaner Element 40. Rear Brake Light Switch 35. Fuel Tank 41. Brake Fluid Reservoir (Rear) 36.
Kawasaki Parts and Accessories ing condition. Before you ride the have been specially designed for motorcycle, make sure it is not use on Kawasaki motorcycles. We overloaded and that you have fol- strongly recommend that all parts lowed these instructions.
LOADING AND ACCESSORIES INFORMATION been prepared to assist you in making Baggage weight should also be dis- your determinations. tributed equally on both sides of the Any passenger should be thor- motorcycle. Avoid carrying baggage oughly familiar with motorcycle op- that extends beyond the rear of the eration.
LOADING AND ACCESSORIES INFORMATION road clearance, banking capability vehicle. Kawasaki does not manu- (i.e., lean angle), control operation, facture sidecars or trailers for mo- wheel travel, front fork movement, torcycles and cannot predict the or any other aspect of the motorcy- effects of such accessories on han- cle's operation.
GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Speedometer B. Digital Display C. Fuel Level Indicator Light D. Coolant Temperature Warning Light E. Fuel Gauge F. Oil Pressure Warning Light G. Fuel Injection Warning Light H. MODE Button I. RESET Button J.
GENERAL INFORMATION Speedometer: Clock - The speedometer shows the speed To adjust hours and minutes: • Turn the ignition key to “ON”. of the vehicle. • Push the MODE button to display Digital Display the clock. • The digital display located in the Push the RESET button for more speedometer face is used to display than two seconds.
GENERAL INFORMATION • • Again push the RESET button. Push the RESET button. Both the When only the hour display flashes, hour and minute displays start flash- push the MODE button to advance ing again. • the hours. Push the MODE button. The dis- plays stop flashing and the clock starts working.
GENERAL INFORMATION Odometer - Trip Meters - The odometer shows the total dis- The trip meter shows the distance in tance in kilometers (miles) that the ve- kilometers (miles) traveled since it was hicle has been ridden. This meter last reset to zero. cannot be reset.
GENERAL INFORMATION Fuel Gauge: The fuel gauge shows the amount of fuel in the fuel tank. When the needle comes near the E (empty) position, re- fuel at the earliest opportunity. When vehicle stands with Side Stand, Fuel Gauge cannot show the amount of fuel in the fuel tank exactly.
DFI system is in the ON position with the engine checked by an authorized Kawasaki not running, and goes off when the en- dealer. gine oil pressure is high enough. Refer...
GENERAL INFORMATION Keys Ignition Switch This motorcycle has a combination The ignition switch is located at the key, which is used for the ignition left side behind the rear cylinder. This switch, steering lock, and fuel tank three-position, key-operated cap. switch.
GENERAL INFORMATION long time (one hour), the battery may Engine off. All electrical become totally discharged. circuits off. Engine on. All electrical equipment can be used. Engine off. Taillight and li- cence plate light on. All P (Park) other electrical circuits cut off.
GENERAL INFORMATION Right Handlebar Switches Starter Button: The starter button operates the elec- Engine Stop Switch: tric starter when the transmission is in In addition to the ignition switch, the neutral. engine stop switch must be in the Refer to the Starting the Engine sec- position for the motorcycle to op- tion of the “How to Ride the Motor- erate.
GENERAL INFORMATION Left Handlebar Switches Horn Button: When the horn button is pushed, the Dimmer Switch: horn sounds. High or low beam can be selected with the dimmer switch. When the headlight is on high beam ( ), the high beam indicator light is lit. High beam..( Low beam..( Turn Signal Switch:...
GENERAL INFORMATION Brake Lever Adjusters There is an adjuster on the brake lev- er. The adjuster has 5 positions so that the released lever position can be ad- justed to suit the operator's hands. Push the lever forward and turn the ad- juster to align the number with the ar- row mark on the lever holder.
GENERAL INFORMATION Fuel Tank Cap To open the fuel tank cap, insert the ignition key into the fuel tank cap and turn the key to the right. To close the cap, push it down into place with the key inserted. The key can be removed by turning it to the left to the original position.
GENERAL INFORMATION Fuel Tank WARNING Filling Tank: Avoid filling the tank in the rain or Gasoline is extremely flammable where heavy dust is blowing so that and can be explosive under cer- the fuel does not get contaminated. tain conditions, creating the po- tential for serious burns.
GENERAL INFORMATION Fuel Requirement NOTICE Your Kawasaki engine is designed to use only unleaded gasoline with a min- Southeast Asia and Thailand imum octane rating shown below. models only: Never fill the tank Never use gasoline with an octane rat-...
GENERAL INFORMATION Fuel Type and Octane Rating NOTICE (For Specification except for Thai- If engine “knocking" or “pinging" land Specification) Use clean, fresh unleaded gasoline occurs, use a different brand of with an octane rating equal to or higher gasoline of a higher octane rat- than that shown in the table.
GENERAL INFORMATION Side Stand NOTE ○ The motorcycle is equipped with a The motorcycle is equipped with a side stand. side stand switch. This switch is de- signed so that the engine does not start if the transmission is in gear and the side stand is down.
GENERAL INFORMATION Seat Seat Installation • To install the seat, insert the projec- Seat Removal • tion of the front on the seat into the To remove the seat, insert the igni- receptacle on the frame. tion key into the seat lock, and turn •...
GENERAL INFORMATION • Pull the front and rear ends of the Tool Kit Case seat to make sure they are securely The tool kit case is located under the locked. seat. The kit contains tools that can be helpful in making roadside repairs, ad- justments, and some maintenance pro- cedures explained in this manual.
GENERAL INFORMATION Helmet-Hook Helmet can be secured to the motor- cycle using the helmet-hook. The hel- met hook is located under the seat. WARNING Riding with helmet attached to the hook could cause an accident by distracting the operator or in- terfering with normal vehicle op- eration.
GENERAL INFORMATION Steering Lock WARNING The motorcycle is equipped with the steering lock at the right side of the Attempting to ride with the steer- head pipe. ing locked could cause an acci- dent. Unlock the steering before To lock the steering: starting the engine.
A. Electric Accessory Connectors White/Blue Under Fuel • When using the electric accessory Tank (–) Black/Yellow connectors under the fuel tank, the Maximum Current: 10 A electric accessory connection to the connectors should be done by an au- thorized Kawasaki dealer.
GENERAL INFORMATION Rear View Mirror NOTICE Rear View Mirror Adjustment • Always install a fuse of 10 A or Adjust the rear view mirror by slightly less in the electrical accessory moving only the mirror portion of the circuit. The vehicle has one fuse assembly.
GENERAL INFORMATION NOTICE Do not force to tighten and/or loosen the upper hexagonal area with a pair of spanners or wrench. Forcible loosening an- d/or tightening may damage the upper hexagonal area and/or the turning mechanism of the stay A. Lower Hexagonal Area for Tightening B.
BREAK-IN BREAK-IN The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down” instead of a “broken in” motorcycle after a few thousand kilometers.
During break-in, avoid sudden and maximum braking and accel- eration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner has the initial maintenance service performed by an authorized Kawasaki dealer.
HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE • Starting the Engine Turn the ignition key to ON. • Check that the engine stop switch is in the position. A. Ignition Switch B. ON Position A. Engine Stop Switch B.
HOW TO RIDE THE MOTORCYCLE • then back to “ON” before starting the Make sure the transmission is in neutral. engine. • Leaving the throttle grip completely closed, push the starter button. NOTICE Do not operate the starter contin- uously for more than 5 seconds, or the starter will overheat and the battery power will drop tem- porarily.
HOW TO RIDE THE MOTORCYCLE NOTE NOTICE ○ The motorcycle is equipped with a Do not let the engine idle longer starter lockout switch. This switch is than five minutes, or engine over- designed so that the engine does not heating and damage may occur.
HOW TO RIDE THE MOTORCYCLE Jump Starting Connecting Jumper Cables • If your motorcycle battery is “run Make sure the ignition key is turned to “OFF”. down”, it should be removed and • Remove the seat. charged. If this is not practical, a 12 •...
HOW TO RIDE THE MOTORCYCLE • Connect a jumper cable from the pedal or other unpainted metal sur- positive (+) terminal of the booster face. Do not use the negative (−) ter- battery to the positive (+) terminal of minal of the battery. the motorcycle battery.
HOW TO RIDE THE MOTORCYCLE • Follow the standard engine starting NOTE ○ procedure. When installing the seat, or tool kit case, be sure not to pinch the hose, NOTICE or wires. The hose or wires should be routed as shown in the figure. Do not operate the starter contin- ○...
HOW TO RIDE THE MOTORCYCLE Moving Off • Check that the side stand is up. • Pull in the clutch lever. • Shift into 1st gear. • Open the throttle a little, and start to let out the clutch lever very slowly. •...
HOW TO RIDE THE MOTORCYCLE NOTE Shifting Gears • ○ Close the throttle while pulling in the The motorcycle is equipped with a clutch lever. side stand switch. This switch is de- • Shift into the next higher or lower signed so that the engine does not gear.
HOW TO RIDE THE MOTORCYCLE NOTE ○ The transmission is equipped with a positive neutral finder. When the mo- torcycle is standing still, the trans- mission cannot be shifted past neutral from 1st gear. To use the positive neutral finder, shift down to 1st gear, then lift up on the shift ped- al while standing still.
HOW TO RIDE THE MOTORCYCLE • For emergency braking, disregard Braking • downshifting, and concentrate on ap- Close the throttle completely, leaving plying the brakes as hard as possible the clutch engaged (except when without skidding. shifting gears) so that the engine will help slow down the motorcycle.
HOW TO RIDE THE MOTORCYCLE Stopping the Engine • Close the throttle completely. • Shift the transmission into neutral. • Turn the ignition key to “OFF”. • Support the motorcycle on a firm, level surface with the side stand. • Lock the steering.
In an emergency situation such as throttle failure, your vehicle may be Emergency stopped by applying the brakes and Your Kawasaki Motorcycle has been disengaging the clutch. Once this stop- designed and manufactured to provide ping procedure is initiated, the engine you optimum safety and convenience.
HOW TO RIDE THE MOTORCYCLE Parking • WARNING Shift the transmission into neutral and turn the ignition key to “OFF”. The muffler and exhaust pipe are • Support the motorcycle on a firm, very hot while the engine is run- level surface with the side stand.
HOW TO RIDE THE MOTORCYCLE • Lock the steering to help prevent WARNING theft. Gasoline is extremely flammable NOTE and can be explosive under cer- ○ tain conditions, creating the po- When stopping near traffic at night, tential for serious burns. Turn the you can leave the taillight, licence ignition switch “OFF”.
HOW TO RIDE THE MOTORCYCLE Catalytic Converter WARNING This motorcycle is equipped with a catalytic converter in the exhaust sys- The muffler and exhaust pipe are tem. Platinum and Rhodium in the con- very hot while the engine is run- verter react with carbon monoxide and ning and just after the engine hydrocarbons to convert them into car-...
HOW TO RIDE THE MOTORCYCLE the vehicle with the engine or any one cylinder misfiring. Under these conditions unburned air/fuel mixture flowing out of engine excessively ac- celerates reaction in the converter al- lowing the converter to overheat and become damaged when the engine is hot, or reduces converter perform- ance when the engine is cold.
SAFE OPERATION SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a When riding always keep both helmet are strongly recommended. hands on the handlebars and both You should be aware of and verify feet on the footpegs.
SAFE OPERATION In general your actions should be In wet conditions, rely more on the smooth as sudden acceleration, throttle to control vehicle speed and braking or turning may cause loss less on the front and rear brakes. of control, especially when riding in The throttle should also be used ju- wet conditions or on loose roadway diciously to avoid skidding the rear...
SAFE OPERATION Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrevving. Avoiding unnecessary weaving is important to the safety of both the rider and other motorists.
SAFE OPERATION Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor- cycle to a safe operating condition.
SAFE OPERATION Tires ......Air pressure (when cold): Up to 180 kg Load (397 280 kPa (2.80 kgf/cm², 40 Front psi) Up to 97.5 kg (215 lb) 200 kPa (2.00 kgf/cm², 28 load psi) Rear 225 kPa (2.25 kgf/cm², 32 97.5 ~ 180 kg (215 ~ 397 psi) lb) load...
SAFE OPERATION Electrical equipment ... All lights (Headlight, Tail/Brake Lights, Turn Signal Lights Warning/Indicator Lights) and horn work. Engine stop switch ..Stops engine. Side stand ....Returns to its fully up position by spring tension. Return spring not weak or not damaged. Refer to the “Daily Safety Checks”...
SAFE OPERATION Additional Considerations for High Speed Operation WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills.
SAFE OPERATION Coolant: To avoid overheating, check that the coolant level is at the upper level line. Electrical Equipment: Make sure that the headlight, tail/brake light, turn signals, horn, etc., all work properly. Miscellaneous: Make sure that all nuts and bolts are tight and that all safety re- lated parts are in good condition.
MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart K : Should be serviced by an authorized Kawasaki dealer. * : For higher odometer readings, repeat at the frequency interval established here. # : Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
MAINTENANCE AND ADJUSTMENT Frequency Whichev- * Odometer Reading er comes km × 1 000 (mile × 1 000) first Page Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Operation (Engine Items) Fuel leak (fuel • • • • – hose and pipe) - year inspect •...
MAINTENANCE AND ADJUSTMENT Frequency Whichev- * Odometer Reading er comes km × 1 000 (mile × 1 000) first Page Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Operation (Engine Items) Radiator hoses in- • • • • stallation condition year - inspect •...
MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichev- * Odometer Reading er comes km × 1 000 (mile × 1 000) first Page Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Operation (Chassis Items) Clutch and drive train: Clutch operation •...
MAINTENANCE AND ADJUSTMENT Frequency Whichev- * Odometer Reading er comes km × 1 000 (mile × 1 000) first Page Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Operation (Chassis Items) Tire tread wear, • • • abnormal wear - inspect •...
MAINTENANCE AND ADJUSTMENT Frequency Whichev- * Odometer Reading er comes km × 1 000 (mile × 1 000) first Page Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Operation (Chassis Items) • • • • • • • Brake fluid level - 6 month inspect Brake operation...
MAINTENANCE AND ADJUSTMENT Frequency Whichev- * Odometer Reading er comes km × 1 000 (mile × 1 000) first Page Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Operation (Chassis Items) Front forks/rear • • • – shock absorber oil year leak - inspect •...
MAINTENANCE AND ADJUSTMENT Frequency Whichev- * Odometer Reading er comes km × 1 000 (mile × 1 000) first Page Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Operation (Chassis Items) Uni-trak tie rods • – bearings - lubri- cate Steering system: •...
MAINTENANCE AND ADJUSTMENT Frequency Whichev- * Odometer Reading er comes km × 1 000 (mile × 1 000) first Page Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Operation (Chassis Items) • • • Side stand switch – year operation - inspect Engine stop •...
MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever * Odometer Reading comes km × 1 000 first (mile × 1 000) Page Every (0.6) (7.5) (15) (22.5) (30) Change/Replacement Items K Air cleaner element # - replace every 18 000 km (12 000 mile) •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever * Odometer Reading comes km × 1 000 first (mile × 1 000) Page Every (0.6) (7.5) (15) (22.5) (30) Change/Replacement Items • • • • K Spark plug - replace...
MAINTENANCE AND ADJUSTMENT Oil Level Inspection Engine Oil • If the oil has just been changed, start In order for the engine, transmission, the engine and run it for several mi- and clutch to function properly, main- nutes at idle speed. This fills the oil tain the engine oil at the proper level, filter with oil.
MAINTENANCE AND ADJUSTMENT • • If the motorcycle has just been used, If the oil level is too high, remove the wait several minutes for all the oil to excess oil through the oil filler open- drain down. ing using a syringe or some other •...
MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • Warm up the engine thoroughly, and then stop it. • Place an oil pan beneath the engine. • Remove the engine oil drain plug. A. Oil Pressure Warning Light A. Engine Oil Drain Plug •...
MAINTENANCE AND ADJUSTMENT • Remove the regulator/rectifier. WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. • Remove the cover. A. Regulator/Rectifier B. Bolt A. Cover B.
MAINTENANCE AND ADJUSTMENT • • Remove the bracket. Remove the oil filter cartridge and re- place it with a new one. A. Bracket B. Bolt A. Cartridge NOTE ○ If a torque wrench or required Kawa- saki special tool is not available, this item should be serviced by a Kawa- saki dealer.
MAINTENANCE AND ADJUSTMENT • • Apply a thin film of oil to the packing Fill the engine up to the upper level and tighten the cartridge to the speci- line with a good quality engine oil fied torque. specified in the table. •...
MAINTENANCE AND ADJUSTMENT NOTE Although 10W-40 engine oil is the ○ recommended oil for most conditions, Do not add any chemical additive to the oil viscosity may need to be the oil. Oils fulfilling the above re- changed to accommodate atmospheric quirements are fully formulated and conditions in your riding area.
MAINTENANCE AND ADJUSTMENT Cooling System NOTICE Radiator and Cooling Fin - Check the radiator fins for obstruc- Using high-pressure water, as from a car wash facility, could tion by insects or mud. Clean off any damage the radiator fins and im- obstructions with a stream of low-pres- sure water.
MAINTENANCE AND ADJUSTMENT Coolant - the coolant passages, and consider- Coolant absorbs excessive heat from ably reduce the efficiency of the cool- the engine and transfers it to the air at ing system. the radiator. If the coolant level be- WARNING comes low, the engine overheats and may suffer severe damage.
MAINTENANCE AND ADJUSTMENT freezing point and strength directed on NOTICE the container. If hard water is used in the sys- NOTICE tem, it causes scale accumula- tion in the water passages, and Permanent types of antifreeze on considerably reduces the effi- the market have anti-corrosion ciency of the cooling system.
MAINTENANCE AND ADJUSTMENT Coolant Level Inspection NOTE • ○ Situate the motorcycle so that it is Check the level when the engine is perpendicular to the ground. • cold (room or atmospheric tempera- Check the coolant level through the ture). coolant level gauge.
MAINTENANCE AND ADJUSTMENT • Coolant Filling Remove the reservoir tank cover. • Remove the seat. • Remove the left side cover by re- moving the screw. A. Reservoir Tank Cover B. Bolt A. Screw B. Tool Kit Case...
MAINTENANCE AND ADJUSTMENT • Open the cap from the reservoir NOTE ○ tank, and add coolant through the fill- When installing the left side cover, er opening to the F (Full) mark. be sure to insert the projections of the left side cover to each holes. A.
NOTICE Maintenance Chart. Belt check and adjustment should be If coolant must be added often, or done by an authorized Kawasaki deal- the reserve tank completely runs dry, there is probably leakage in NOTICE the system. Have the cooling sys-...
MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System in accordance with the Periodic Main- tenance Chart. Also, inspect the air The Kawasaki Clean Air System suction valves whenever stable idling (KCA) is a secondary air suction sys- cannot be obtained, engine power is...
MAINTENANCE AND ADJUSTMENT Air Cleaner Element Removal • Remove the bolts of the air cleaner A clogged air cleaner restricts the cover located on the right-side of the engine's air intake, increasing fuel con- engine. sumption, reducing engine power, and causing spark plug fouling.
MAINTENANCE AND ADJUSTMENT • Remove the air cleaner screw and WARNING the air cleaner. If any part of the ele- ment is damaged, the element must If dirt or dust is allowed to pass be replaced. through into the fuel injection system, the throttle may stick or become inoperable resulting in a hazardous operating condition.
MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check that there is 2 ~ 3 mm (0.08 ~ Check the throttle grip play, in ac- 0.12 in.) throttle grip play when lightly cordance with the Periodic Mainte- turning the throttle grip back and nance Chart, and adjust the throttle forth.
MAINTENANCE AND ADJUSTMENT • Adjustment Turn out the decelerator cable ad- • Loosen the locknuts at the upper justing nut until there is no play when ends of the throttle cables, and the throttle grip is completely closed. screw both throttle cable adjusting Tighten the locknut.
Periodic cables, further adjustment of the Maintenance Chart or whenever the throttle cables should be done by an idle speed is disturbed. authorized Kawasaki dealer. WARNING Operation with an improperly ad- justed, incorrectly routed, damaged cables could result in an unsafe riding condition.
MAINTENANCE AND ADJUSTMENT • Adjustment Open and close the throttle a few • Start the engine, and warm it up thor- times to make sure that the idle oughly. speed does not change. Readjust if • Wait until the idle speed drops before necessary.
MAINTENANCE AND ADJUSTMENT Clutch Inspection • Check that the clutch lever has 2 ~ 3 Due to friction plate wear and clutch mm (0.08 ~ 0.12 in.) of play as cable stretch over a long period of use, shown in the figure. the clutch must be adjusted in accord- ance with the Periodic Maintenance Chart.
MAINTENANCE AND ADJUSTMENT • Adjustment If it cannot be done, use the nuts at • Turn the adjuster so that the clutch the middle of the clutch cable. lever will have 2 ~ 3 mm (0.08 ~ 0.12 in.) of play. WARNING Too much cable play can prevent clutch disengagement and cause...
MAINTENANCE AND ADJUSTMENT ○ For minor corrections, use the ad- Brakes juster at the clutch lever. Brake Wear Inspection Inspect the brakes for wear. For each front and rear disc brake caliper, if the thickness of either pad is less than 1 mm (0.04 in), replace both pads in the caliper as a set.
MAINTENANCE AND ADJUSTMENT Disc Brake Fluid - Fluid Level Inspection • In accordance with the Periodic The brake fluid level in the front Maintenance Chart, inspect the brake brake fluid reservoir must be kept fluid level in both the front and rear above the line (lower level line) next brake fluid reservoirs and change the to the gauge and that in the rear...
MAINTENANCE AND ADJUSTMENT • If the fluid level in either reservoir is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. Inside the front brake fluid reser- voir is a stepped line showing the upper level line.
MAINTENANCE AND ADJUSTMENT NOTE WARNING ○ First, tighten until slight resistance is Mixing brands and types of brake felt indicating that the cap is seated fluid can reduce the brake sys- on the reservoir body; then, tighten tem’s effectiveness and cause an the cap an additional 1/6 turn while accident resulting in injury or holding the brake fluid reservoir...
• If it does not, ask your authorized Air in the brake lines diminish Kawasaki dealer to inspect the front braking performance and can brake light switch. cause an accident resulting in in- jury or death. If the brake lever or...
MAINTENANCE AND ADJUSTMENT • Check the operation of the rear Adjustment • brake light switch by depressing the To adjust the rear brake light switch, brake pedal. The brake light should move the switch up or down by turn- go on after about 10 mm (0.4 in.) of ing the adjusting nut.
MAINTENANCE AND ADJUSTMENT Rear Shock Absorber NOTICE The rear shock absorber can be ad- To avoid damaging the electrical justed by changing the spring preload connections inside the switch, be for various riding and loading condi- sure that the switch body does tions.
MAINTENANCE AND ADJUSTMENT Spring Preload Adjustment NOTE ○ The rear shock absorber spring pre- When removing the reservoir tank, load adjuster has 7 positions. • hook the under part of the reservoir Remove the left side cover and res- tank to the holder of the frame as ervoir tank cover (see “Cooling Sys- shown in the figure.
MAINTENANCE AND ADJUSTMENT • In accordance with the following ta- with no passenger and no accessories ble, turn the preload adjuster with the is No. 4. wrench from the tool kit. NOTE ○ This motorcycle has two hook wrenches in the tool kit. When changing the spring preload of the rear shock absorber, turn the adjust- er by using the suitable hook...
MAINTENANCE AND ADJUSTMENT Wheels Tubeless tires are installed on the wheels of this motorcycle. The indica- tions of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. TUBELESS Mark The tire and rim form a leakproof unit by making airtight contacts at the tire chamfers and the rim flanges instead...
MAINTENANCE AND ADJUSTMENT Tires - WARNING Payload and Tire Pressure Failure to maintain proper inflation Installing a tube inside a tube- pressures or observe payload limits for less-type tire can create exces- your tires may adversely affect han- sive heat build up that can dling and performance of your motor- damage the tube and cause rapid cycle and can result in loss of control.
MAINTENANCE AND ADJUSTMENT • Remove the air valve cap. motorcycle has not been ridden • Check the tire pressure often, using more than a mile during the past 3 an accurate gauge. hours). • ○ Make sure that the air valve cap is Tire pressure is affected by changes securely installed.
MAINTENANCE AND ADJUSTMENT • Tire Wear, Damage In accordance with the Periodic As the tire tread wears down, the tire Maintenance Chart, measure the becomes more susceptible to puncture depth of the tread with a depth and failure. An accepted estimate is gauge, and replace any tire that has that 90% of all tire failures occur during worn down to the minimum allowable...
MAINTENANCE AND ADJUSTMENT Minimum Tread Depth WARNING — Front 1 mm (0.04 in.) Tires that have been punctured and repaired do not have the Rear Under 130 km/h 2 mm same capabilities as undamaged (80 mph) (0.08 in.) tires and can suddenly fail, caus- Over 130 km/h 3 mm ing an accident resulting in seri-...
MAINTENANCE AND ADJUSTMENT ○ Most counters may have their own WARNING regulations requiring a minimum tire thread depth; be sure to follow them. New tires are slippery and may cause loss of control and injury. Standard Tire (Tubeless) A break-in period of 160 km (100 80/90-21M/C 48H miles) is necessary to establish •...
MAINTENANCE AND ADJUSTMENT Battery temperature. As temperatures rise, so does the discharge rate. Every 15°C The battery installed in this vehicle is (27°F) doubles the rate. a sealed type, and the sealing strip Electrical accessories, such as digi- should not be removed at any time tal clocks and computer memory, also after the specified electrolyte has been draw current from the battery even...
12.6 volts, the battery should be temperatures with no damage. charged using an appropriate charger Battery Sulfation (check with your Kawasaki dealer). If A common cause of battery failure is you will not be using the motorcycle for sulfation.
Do not install a conventional bat- tery is this vehicle, or the electri- If the above chargers are not avail- cal system cannot work properly. able, use equivalent one. For more details, ask your Kawasaki dealer. NOTE ○ Battery Charging If you charge the sealed battery, •...
MAINTENANCE AND ADJUSTMENT • Battery Removal Pull the battery out of the motor- • Remove the seat and tool kit case cycle. • (see “Jump Starting” section in the “ Clean the battery using a solution of How to Ride the Motorcycle” chap- baking soda and water.
MAINTENANCE AND ADJUSTMENT • Put a light coat of grease on the ter- minals to prevent corrosion. • Cover the (+) terminal with its protec- tive cap. • Reinstall the parts removed. NOTE ○ When installing the seat, or tool kit case, be sure not to pinch the hose, or wires.
MAINTENANCE AND ADJUSTMENT Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. • Turn the horizontal adjusting screw on the headlight rim in or out until the beam points straight ahead.
MAINTENANCE AND ADJUSTMENT Vertical Adjustment The headlight beam is adjustable vertically. If adjusted too low, neither low nor high beam will illuminate the road far enough ahead. If adjusted too high, the high beam will fail to illumi- nate the road close ahead, and the low beam will blind oncoming drivers.
MAINTENANCE AND ADJUSTMENT • Fuses Remove the left side cover (see “Cooling System” section in this The fuses are arranged in the fuse chapter). box located behind left side cover. The main fuse is mounted on the starter relay behind right side cover. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new...
MAINTENANCE AND ADJUSTMENT • • Remove the screw. Pull out the right side cover and then inspect the main fuse. A. Screw B. Right Side Cover A. Main Fuse...
MAINTENANCE AND ADJUSTMENT • When installing the right side cover, WARNING be sure to insert the projections of the right side cover. Substituting fuses can cause wir- ing to overheat, catch fire and/or fail. Do not use any substitute for the standard fuse.
MAINTENANCE AND ADJUSTMENT Cleaning Your Motorcycle plastic surfaces: wash them off im- mediately. General Precautions • Avoid wire brushes, steel wool, and Frequent and proper care of your Ka- all other abrasive pads or brushes. wasaki motorcycle will enhance its ap- •...
MAINTENANCE AND ADJUSTMENT A. Rubber Boot A. Not position • B. Correct position If the boot is damaged, replace it with a new one. If the boot is not Washing Your Motorcycle • positioned in the groove correctly, re- Rinse your bike with cold water from place it in the correct position.
MAINTENANCE AND ADJUSTMENT degreaser to remove any oil or NOTE ○ grease build up. • After riding in an area where the After washing, rinse your motorcycle roads are salted or near the ocean, thoroughly with clean water to re- immediately wash your motorcycle move any residue (residue from the with cold water.
MAINTENANCE AND ADJUSTMENT motorcycle/automotive wax. NOTICE should be applied once every three months or as conditions require. Avoid Plastic parts may deteriorate and surfaces with “satin” or “flat” finishes. break if they come in contact with Always use nonabrasive products and chemical substances or house- apply them according to the instruc- hold cleaning products such as...
MAINTENANCE AND ADJUSTMENT chrome/aluminum polish. Coated alu- WARNING minum should be washed with a mild neutral detergent and finished with a Rubber protectants can be slip- spray polish. Aluminum wheels, both pery and, if used on the tread painted and unpainted can be cleaned area, cause loss of traction re- with special non-acid based wheel sulting in accident causing injury...
STORAGE STORAGE Preparation for Storage: • Clean the entire vehicle thoroughly. • Run the engine for about five minutes to warm the oil, shut it off and drain the en- gine oil. WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
STORAGE • Empty the fuel system by running the engine at idle speed until all fuel in the fuel system is used up (If left in for a long time, the fuel will break down and clog the fuel system). WARNING An air/oil mist may be forcibly ejected from the spark plug holes and could get into your eyes.
STORAGE • Tie plastic bags over the mufflers to prevent moisture from entering. • Put a cover over the motorcycle to keep dust and dirt from collecting on it. Preparation after Storage: • Remove the plastic bags from the mufflers. •...
To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your au- thorized Kawasaki dealer or local environmental waste agency for their proper dis- posal procedure.
LOCATION OF LABELS LOCATION OF LABELS 1. Daily Safety Checks *2. Unleaded Gasoline 3. Brake Fluid (Front) **4. Fuel Level 5. Brake Fluid (Rear) *: only on European model **: only on Southeast Asia and Thailand models...
LOCATION OF LABELS 6. Battery Position/Danger 7. Tire and Load Data **8. Vacuum Hose Routing Diagram **: only on Southeast Asia and Thailand models...