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   Also See for Kawasaki ER-6n

   Summary of Contents for Kawasaki ER-6n

  • Page 2 ENGLISH Motorcycle Owner's Manual Original instructions...
  • Page 4 Whenever you see the symbols NOTE ○ shown below, heed their instructions! NOTE indicates information that may Always follow safe operating and main- help or guide you in the operation or tenance practices. service of the vehicle. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious in- jury.
  • Page 7 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.
  • Page 8 However, there may be minor differences between the actual product and illustra- tions and text in this manual. All products are subject to change without prior notice or obligation. KAWASAKI HEAVY INDUSTRIES, LTD. Motorcycle & Engine Company © 2013 Kawasaki Heavy Industries, Ltd. Apr. 12, 2013. (1)
  • Page 9: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS ........ 10 Hazard Switch: ....... 41 LOCATION OF PARTS ......13 Brake/Clutch Lever Adjusters .... 42 LOADING AND ACCESSORIES IN- Fuel Tank Cap ........43 FORMATION ........16 Fuel ............ 44 GENERAL INFORMATION ....19 Fuel Requirement: ......44 Meter Instruments ......
  • Page 10 Periodic Maintenance Chart ....82 ENVIRONMENTAL PROTECTION ..157 Engine Oil .......... 92 LOCATION OF LABELS ...... 158 Cooling System ........98 Spark Plugs ........104 Kawasaki Clean Air System ....105 Valve Clearance .........106 Air Cleaner .........106 Throttle Control System .....108 Engine Vacuum Synchronization ..110...
  • Page 11: Specifications

    SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 53 kW (72.1 PS) @8 500 r/min (rpm) 64 N·m (6.5 kgf·m, 47.2 ft·lb) @7 000 r/min (rpm) Maximum Torque Minimum Turning Radius 2.7 m (106.3 in.) DIMENSIONS Overall Length 2 110 mm (83.07 in.) Overall Width 770 mm (30.31 in.) Overall Height...
  • Page 12 SPECIFICATIONS Fuel System FI (Fuel Injection) Ignition System Battery and coil (transistorized ignition) Ignition Timing 10° BTDC @1 300 r/min (rpm) ~ (Electronically advanced) 37° BTDC @5 000 r/min (rpm) Spark Plugs NGK CR9EIA-9 Lubrication System Forced lubrication (semi-dry sump) Engine Oil Type : API SG, SH, SJ, SL or SM with JASO MA, MA1 or...
  • Page 13 12 V 55 W/55 W (Hi/Lo) Tail/Brake Light (E): ER650E (F): ER650F Even if one of LED (Light Emitting Diode) tail/brake light is not lit, consult with an authorized Kawasaki dealer. Specifications are subject to change without notice, and may not apply to every country.
  • Page 14: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 6. Front Brake Lever 2. Left Handlebar Switches 7. Throttle Grip 3. Meter Instruments 8. Ignition Switch/Steering Lock 4. Brake Fluid Reservoir (Front) 5. Right Handlebar Switches...
  • Page 15 LOCATION OF PARTS 1. Headlight 7. Helmet Holding Hooks 13. Front Fork 2. Turn Signal Light 8. Tool Kit 14. Brake Caliper 3. Spark Plugs 9. Seat Lock 15. Shift Pedal 4. Air Cleaner 10. Passenger's Seat 16. Side Stand 5.
  • Page 16 LOCATION OF PARTS 1. License Plate Light 6. Spring Preload Adjuster 12. Rear Brake Pedal 2. Turn Signal Light 7. Fuel Tank 13. Oil Level Inspection Win- 3. Tail/Brake Light 8. Fuel Tank Cap 4. Brake Fluid Reservoir 9. Coolant Reserve Tank 14.
  • Page 17: Loading And Accessories Information

    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.
  • Page 18 LOADING AND ACCESSORIES INFORMATION prepared to assist you in making your Baggage weight should also be dis- 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.
  • Page 19 Kawasaki cannot assume re- 7. Weight attached to the handlebar or front fork will increase the mass of sponsibility for the results of such the steering assembly and can re- unintended use of the motorcycle.
  • Page 20: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Green Left Turn Signal Indi- cator Light B. Tachometer C. Yellow ABS Indicator Light (Only on ABS model) D. Yellow Engine Warning In- dicator Light E. Red Zone F. Green Right Turn Signal In- dicator Light G.
  • Page 21: Tachometer

    If the tachometer allowed to enter the red zone; op- does not operate correctly, have it eration in the red zone will over- checked by an authorized Kawasaki stress the engine and may cause dealer. serious engine damage.
  • Page 22: Multifunction Meter

    GENERAL INFORMATION Multifunction Meter The multifunction meter displays the fol- lowing functions. A. Fuel Gauge B. Economical Riding Indicator C. Speedometer D. Fuel Level Warning Symbol E. Clock F. Multifunction Display Odometer Trip meter A Trip meter B Current Mileage Average Mileage Cruising Range G.
  • Page 23 GENERAL INFORMATION NOTE Speedometer - ○ The speedometer shows the speed Do not operate the motorcycle with of the vehicle in digital values. wrong unit (mph or km/h) of the speedometer. Unit Setting - The unit setting in the meter instru- To change the meter display units in ment can be changed according to lo- the meter instrument as follows:...
  • Page 24: Multifunction Display

    GENERAL INFORMATION Multifunction Display Mileage Distance Speed Units The following display modes can be Units Units shifted by pushing the MODE button. L/100km Odometer → Trip meter A → Trip km/h meter B → Current Mileage → Aver- km/L age Mileage → Cruising Range → Od- MPG US mile ometer...
  • Page 25 GENERAL INFORMATION Odometer - Trip Meter - The odometer shows the total dis- The trip meters show the distance in tance in kilometers or miles that the ve- kilometers (miles) traveled since they hicle has been ridden. This meter were last reset to zero. cannot be reset.
  • Page 26 GENERAL INFORMATION • Push the RESET button and hold it Current Mileage - This display mode shows the current • After two seconds, the figure display mileage by numerical value. The cur- turns to 0.0, and then starts counting rent mileage display is renewed every when the vehicle is operated.
  • Page 27 GENERAL INFORMATION ○ Average Mileage - After resetting the average mileage, This display mode shows the aver- the numerical value is not displayed mileage numerical value until 5 mL (0.2 US oz.) of fuel has counted from the start of measuring to been used and 100 m (328 ft) has present time.
  • Page 28 GENERAL INFORMATION Cruising Range - The cruising range value displays "- - This display shows the cruising -" when the fuel warning symbol ( range by numerical value and indicates blinks in the multifunction meter. the cruising range from the remaining fuel in the fuel tank.
  • Page 29 GENERAL INFORMATION • Clock - Push the RESET button. The hour To adjust hours and minutes, do the display only blinks. Push the MODE followings while the motorcycle is at a button to advance the hours. stop. • Turn the ignition switch to “ON”. •...
  • Page 30 GENERAL INFORMATION • Push the RESET button. Both the Economical Riding Indicator - hour and minute displays start blink- When the operator is driving the mo- ing again. torcycle for optimum fuel-efficiency, the • Push the MODE button. The dis- economical riding indicator appears on plays stop blinking and the clock the multifunction meter to indicate fa-...
  • Page 31 If the fuel gauge is not correctly dis- injury or death. Do not concen- played, have the fuel gauge checked trate on the economical riding in- by an authorized Kawasaki dealer. dicator by taking your eyes off the road; observe using periph- eral vision.
  • Page 32 ○ The cruising range value indicate the the wiring. Have the wiring inspected “– – –” when the low fuel warning is by an authorized Kawasaki dealer im- displayed. mediately.
  • Page 33: Warning/indicator Lights

    GENERAL INFORMATION Warning/Indicator Lights: Yellow ABS Indicator Light (For N: When the transmission is in neutral, models equipped with ABS) the neutral indicator light goes on. : The ABS (Anti-lock Brake Sys- tem) indicator light goes on when the ignition switch is turned on and goes : When the headlight is on high beam, the high beam indicator light off shortly after the motorcycle starts...
  • Page 34 “How to Ride the Motor- cycle” chapter for more information. If the indicator light goes on, have the DFI system checked by an authorized Kawasaki dealer. Service Code When a failure occurs in the fuel in- jection system, the service code is...
  • Page 35 “ON” and go off after warning symbol ( starting the engine. If the warning indicator light goes on with the engine running, have its cause checked by an authorized Kawasaki dealer. Refer to the “Warning Symbols” in this section for more detailed informa- tion.
  • Page 36 ) still go ) goes on whenever the coolant on even after the battery is charged, temperature rises to 118°C (245°F) ask an authorized Kawasaki dealer for when the motorcycle is in operation. an inspection. This warns the operator that the cool- ant temperature is too high.
  • Page 37: Key

    GENERAL INFORMATION Ignition Switch/Steering Lock This motorcycle has a combination This is a four-position, key-operated key, which is used for the ignition switch. The key can be removed from switch/steering lock, seat lock, and fuel the switch when it is in the OFF, LOCK, tank cap.
  • Page 38 GENERAL INFORMATION Engine off. Electrical circuits off. Engine on. All electrical equip- ment can be used. Steering locked. Engine off. LOCK Electrical circuits off. Steering locked. Engine off. Turn signals can be used. Oth- er electrical circuits off. NOTE ○ The city, tail and license plate lights are on whenever the ignition key is in the ON position.
  • Page 39: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches NOTICE Engine Stop Switch: Do not use a metallic or heavy In addition to the ignition switch, the key ring or related accessory or engine stop switch must put other keys on the same key position for the motorcycle to ring as they could contact and operate.
  • Page 40: Starter Button

    GENERAL INFORMATION NOTE Starter Button: ○ The starter button operates the elec- Although the engine stop switch tric starter when the transmission is in stops the engine, it does not turn off neutral. all the electrical circuits. Ordinarily, Refer to the Starting the Engine sec- the ignition switch should be used to tion of the “How to Ride the Motor- stop the engine.
  • Page 41: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches NOTE ○ Dimmer Switch: When the headlight is on high beam, High or low beam can be selected both head lights go on. When the with the dimmer switch. When the headlight is on low beam, only one headlight is on high beam ( ), the headlight goes on.
  • Page 42: Turn Signal Switch

    GENERAL INFORMATION Turn Signal Switch: Hazard Switch: When the turn signal switch is turned If an emergency requires you to park to the left ( ) or right ( ), the on the highway shoulder, turn on the corresponding turn signal blinks on hazard lights to warn other drivers of and off.
  • Page 43: Brake/clutch Lever Adjusters

    GENERAL INFORMATION Brake/Clutch Lever Adjusters There is an adjuster on both the brake and clutch levers. Each adjuster has 5 positions so that the released lever position can be adjusted to suit the operator's hands. Push the lever forward and turn the adjuster to align the number with the mark on the lever holder.
  • Page 44: Fuel Tank Cap

    GENERAL INFORMATION Fuel Tank Cap NOTE ○ To open the fuel tank cap, pull up the Do not push on the key to close the key hole cover. Insert the ignition key cap, or the cap cannot be locked. into the fuel tank cap and turn the key clockwise.
  • Page 45: Fuel

    GENERAL INFORMATION Fuel NOTICE Fuel Requirement: If engine “knocking" or “pinging" Your Kawasaki engine is designed to use only unleaded gasoline with a min- occurs, use a different brand of imum octane rating shown below. gasoline of a higher octane rat- Never use gasoline with an octane rat- ing.
  • Page 46: Filling The Tank

    GENERAL INFORMATION equal to or higher than that shown in Filling the Tank: the table. Avoid filling the tank in the rain or where heavy dust is blowing so that Fuel Type Unleaded Gasoline the fuel does not get contaminated. Ethanol Content E10 or less Minimum Octane...
  • Page 47 GENERAL INFORMATION NOTICE WARNING Certain ingredients in gasoline Gasoline is extremely flammable may cause paint fading or dam- and can be explosive under cer- age. Be extra careful not to spill tain conditions, creating the po- fuel during refueling. tential for serious burns. When refueling, servicing fuel system, draining gasoline and/or adjust- ing the carburetor: Stop engine...
  • Page 48: Stand

    GENERAL INFORMATION Stand stand fully up before sitting on the mo- torcycle. The motorcycle is equipped with a side stand. NOTE ○ The motorcycle is equipped with a 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.
  • Page 49: Seats

    GENERAL INFORMATION Seats Rider's Seat Removal • Remove the passenger's seat. Passenger's Seat Removal • • Slide the rider's seat rearward then Insert the ignition key into the seat pull the front of seat upward to re- lock, and turn it clockwise. •...
  • Page 50 GENERAL INFORMATION Rider's Seat Installation Passenger's Seat Installation • • Slide the rider's seat rearward to po- Insert the tab under the passenger's sition it on the frame. seat into the hole in the frame. • • Slide the rider's seat forward to en- Insert the lock plate of the passeng- gage the tab under the seat with the er's seat into the slot on the frame...
  • Page 51: Helmet Hooks

    GENERAL INFORMATION Helmet Hooks Helmets can be secured to the mo- torcycle by the helmet hooks located under the passenger's seat. A. Passenger’s Seat B. Tab C. Hole D. Lock Plate E. Slot F. Projections A. Helmet Hooks G. Hole •...
  • Page 52: Tool Kit

    GENERAL INFORMATION Tool Kit WARNING The tool kit is located under the pas- senger's seat. Riding with helmets attached to The kit contains tools that are helpful the hooks could cause an acci- in making roadside repairs, adjust- dent by distracting the operator ments, and some maintenance proce- or interfering with normal vehicle dures explained in this manual.
  • Page 53: Rear View Mirror

    GENERAL INFORMATION Rear View Mirror Rear View Mirror Adjustment • Adjust the rear view mirror by slightly moving only the mirror portion of the assembly. • If the rear visibility cannot be as- sured by moving the mirror, adjust the stay position by loosening the lock nut.
  • Page 54: Tying Hooks

    GENERAL INFORMATION Tying Hooks When tying up light loads to the pas- senger's seat, use the tying hooks lo- cated on the left and right sides of the rear fender. A. Tying Hooks...
  • Page 55: Break-in

    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.
  • Page 56 During break-in, avoid sudden and maximum braking and ac- celeration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner have the initial maintenance service performed by an authorized Kawasaki dealer.
  • Page 57: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Starting the Engine • Check that the engine stop switch is in the position. • Turn the ignition key to “ON”. • Make sure the transmission is in neutral. • Without holding the throttle grip, push the starter button to start the engine.
  • Page 58 HOW TO RIDE THE MOTORCYCLE soon, there is no problem with the NOTICE motorcycle riding. ○ While the engine is cold, the fast idle Do not operate the starter contin- system automatically raises the en- uously for more than 5 seconds, gine idling speed.
  • Page 59: Jump Starting

    HOW TO RIDE THE MOTORCYCLE Jump Starting If your motorcycle battery is “run down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. DANGER Battery acid generates hydrogen gas which is flammable and ex-...
  • Page 60 HOW TO RIDE THE MOTORCYCLE Connecting Jumper Cables • Remove the passenger's seat and rider's seat. • Make sure the ignition key is turned to OFF. • Connect a jumper cable from the positive (+) terminal of the booster battery to the positive (+) terminal of the motorcycle battery.
  • Page 61 HOW TO RIDE THE MOTORCYCLE NOTICE DANGER Do not operate the starter contin- Batteries contain sulfuric acid uously for more than 5 seconds that can cause burns and pro- or the starter will overheat and duce hydrogen gas which is the battery power will drop tem- highly explosive.
  • Page 62: Moving Off

    HOW TO RIDE THE MOTORCYCLE Moving Off NOTE • ○ Check that the side stand is up. The motorcycle is equipped with a • Pull in the clutch lever. side stand switch. This switch is de- • Shift into 1st gear. signed so that the engine does not •...
  • Page 63: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE Shifting Gears motorcycle is standing still, the trans- • mission cannot be shifted past neu- Close the throttle while pulling in the tral from 1st gear. To use the positive clutch lever. • neutral finder, shift down to 1st gear, Shift into the next higher or lower then lift up on the shift pedal while gear.
  • Page 64: Braking

    HOW TO RIDE THE MOTORCYCLE Braking applying the brakes as hard as pos- • sible without skidding. Close the throttle completely, leaving • Even in motorcycles equipped with the clutch engaged (except when ABS, braking during cornering may shifting gears) so that the engine will cause wheel slip.
  • Page 65: Anti-lock Brake System (abs) For Models Equipped With Abs

    HOW TO RIDE THE MOTORCYCLE Anti-lock Brake System (ABS) for models equipped with ABS is designed to help prevent the wheels from locking up when hard brakes are applied while running straight. The ABS automatically regu- lates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows sta- ble steering control while stopping.
  • Page 66 HOW TO RIDE THE MOTORCYCLE must take the same care as with mo- may confuse the computers, which torcycles not equipped with ABS. can extend braking distance. • ABS is not designed to shorten the braking distance. On loose, uneven WARNING or downhill surfaces, the stopping ABS cannot protect the rider from...
  • Page 67: Yellow Abs Indicator Light

    6 km/h or below, braking distance. The rider could you should have the ABS checked have an accident as a result. Al- by an authorized Kawasaki dealer. ways use recommended stand- ard tires for this motorcycle. Yellow ABS Indicator Light:...
  • Page 68: Stopping The Engine

    HOW TO RIDE THE MOTORCYCLE • The light goes on and stays on after Stopping the Engine • the motorcycle starts moving. Close the throttle completely. • Shift the transmission into neutral. Remember that the ABS does not • Turn the ignition key to “OFF”. function when the indicator light is on, •...
  • Page 69: Stopping The Motorcycle In An Emergency

    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.
  • Page 70: Parking

    HOW TO RIDE THE MOTORCYCLE Parking WARNING WARNING The engine and exhaust system get extremely hot during normal Operating or parking the vehicle operation and can cause serious near flammable materials can burns. cause a fire, and can result in Never touch a hot engine, ex- property damage or severe per- haust pipe, or muffler during op-...
  • Page 71 HOW TO RIDE THE MOTORCYCLE • If parking inside a garage or other NOTE ○ structure, be sure it is well ventilated When stopping near traffic at night, and the motorcycle is not close to you can leave the turn signals blink- any source of flame or sparks;...
  • Page 72: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE Catalytic Converter WARNING This motorcycle is equipped with a catalytic converter in the exhaust sys- Operating or parking the vehicle tem. The converter reacts with carbon near flammable materials can monoxide, hydrocarbons and nitrogen cause a fire, and can result in oxides to convert them into carbon di- property damage or severe per- oxide, water, nitrogen and oxygen re-...
  • Page 73 HOW TO RIDE THE MOTORCYCLE • Use only unleaded gasoline. Never use leaded gasoline. Leaded gaso- line significantly reduces the capabil- ity of the catalytic converter. • Do not operate the vehicle with the engine or any one cylinder misfiring. Under these conditions unburned air/fuel mixture flowing out of engine excessively accelerates reaction in...
  • Page 74: Safe Operation

    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.
  • Page 75 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...
  • Page 76 SAFE OPERATION Do not downshift at too high an r/min (rpm) to avoid damage from overrevving to the engine. Avoiding unnecessary weaving is important to the safety of both the rider and other motorists.
  • Page 77: Daily Checks

    SAFE OPERATION Daily 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.
  • Page 78 SAFE OPERATION Up to 200 kg (441 lb) Front 225 kPa (2.25 kgf/cm², 32 psi) Load Up to 200 kg (441 lb) 250 kPa (2.50 kgf/cm², 36 psi) Rear Load Install the air valve cap. Drive chain ....Slack 25 ~ 35 mm (1.0 ~ 1.4 in.) Lubricate the dive chain if dry.
  • Page 79 SAFE OPERATION Side stand ....Returns to its fully up position by spring tension. Returns spring not weak or not damaged.
  • Page 80: Additional Considerations For High Speed Operation

    SAFE OPERATION Additional Considerations for High Speed Operation Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and func- tioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play.
  • Page 81 SAFE 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.
  • Page 82: Maintenance And Adjustment

    Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect or improper adjustment done by the owner.
  • Page 83: Periodic Maintenance Chart

    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.
  • Page 84 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1 000 (mile × 1 000) See Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Engine Items) • • • • Idle speed - in- spect Fuel leak (fuel •...
  • Page 85 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1 000 (mile × 1 000) See Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Engine Items) Radiator hoses • • • • damage - in- year spect Radiator hoses...
  • Page 86 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) See Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Clutch and drive train: Clutch operation (play, engage- •...
  • Page 87 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) See Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Drive chain • • • – guide wear - in- spect Wheels and tires: •...
  • Page 88 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) See Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Brake system: • • • • • • • Brake fluid leak - year inspect Brake hoses...
  • Page 89 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) See Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Brake operation • • • • • • • (effectiveness, year play, drag) - in- spect Brake light...
  • Page 90 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) See Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Steering System: • • • • Steering play - – year inspect Steering stem •...
  • Page 91 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) See Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Engine stop • • • – switch operation year - inspect Chassis: •...
  • Page 92 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes first * Odometer Reading km × 1 000 (mile × 1 000) See Page Every (0.6) (7.5) (15) (22.5) (30) Change/Replacement Items K Air cleaner element - replace # every 18 000 km (11 250 mile) •...
  • Page 93: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • 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.
  • Page 94 MAINTENANCE AND ADJUSTMENT • Check the engine oil level through opening using a syringe or some oth- the oil level inspection window. With er suitable device. • the motorcycle held level, the oil lev- If the oil level is too low, add the oil to el should come up between the reach the correct level.
  • Page 95 MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • Warm up the engine thoroughly, and then stop it. • Remove the under fairing and place an oil pan beneath the engine. • Remove the engine oil drain plug. A. Warning Indicator Light B.
  • Page 96 Dispose of used oil properly. item should be serviced by an au- Contact your local authorities for thorized Kawasaki dealer. approved disposal methods or possible recycling. • Remove the oil filter cartridge and re- place it with a new one.
  • Page 97 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. •...
  • Page 98 MAINTENANCE AND ADJUSTMENT provide adequate lubrication for both Although 10W-40 engine oil is the the engine and the clutch. recommended oil for most conditions, the oil viscosity may need to be Engine Oil Capacity changed to accommodate atmospheric Capacity : 1.6 L (1.7 US qt) conditions in your riding area.
  • Page 99: Cooling System

    MAINTENANCE AND ADJUSTMENT Cooling System NOTICE Radiator and Cooling Fan - Check the radiator fins for obstruc- Using high-pressure water, as tion by insects or mud. Clean off any from a car wash facility, could obstructions with a stream of low-pres- damage the radiator fins and im- sure water.
  • Page 100 MAINTENANCE AND ADJUSTMENT adjustments in accordance with the inhibitor chemicals is not used, over a Periodic Maintenance Chart. period of time, the cooling system ac- cumulates rust and scale in the water Coolant - jacket and radiator. This will clog up Coolant absorbs excessive heat from the coolant passages, and consider- the engine and transfers it to the air at...
  • Page 101 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.
  • Page 102 MAINTENANCE AND ADJUSTMENT Coolant Level Inspection • Situate the motorcycle so that it is perpendicular to the ground. • Check the coolant level if it is be- tween the F (Full) and L (Low) level lines. NOTE ○ Check the level when the engine is cold (room or atmospheric tempera- ture).
  • Page 103 MAINTENANCE AND ADJUSTMENT • Coolant Filling Remove the cap from the reserve • Remove the right side cover by re- tank and add coolant through the fill- moving the bolts. er opening to the F (Full) level line. A. Right Side Cover A.
  • Page 104 Have the cooling sys- tem inspected by your authorized Kawasaki dealer. Coolant Change Have the coolant changed by an au- A. Right Side Cover thorized Kawasaki dealer. B. Projections C. Holes NOTE ○ In an emergency you can add water...
  • Page 105: Spark Plugs

    The standard spark plug is shown in the table. The spark plugs should be replaced in accordance with the Peri- odic Maintenance Chart. Spark plug removal should be done by an authorized Kawasaki dealer. Spark Plug Standard Plug NGK CR9EIA-9 0.8 ~ 0.9 mm Plug Gap (0.031 ~ 0.035 in.)
  • Page 106: Kawasaki Clean Air System

    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...
  • Page 107: Valve Clearance

    Periodic Mainte- cleaner element (Kawasaki part nance Chart. number 11013-0713). Using the Inspection and adjustment should be any other air cleaner element will done by an authorized Kawasaki deal- wear the engine prematurely or lower the engine performance.
  • Page 108 MAINTENANCE AND ADJUSTMENT Oil Draining • WARNING Inspect the drain hose located on the left side of the engine to see if any oil Oil on tires will make them slip- or water has run down from the air pery and can cause an accident cleaner housing.
  • Page 109: Throttle Control System

    MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check that the throttle grip play is Check the throttle grip play in ac- correct by lightly turning the throttle cordance with the Periodic Mainte- grip back and forth. nance Chart, and adjust it if necessary. Throttle Grip - The throttle grip controls the butterfly valves in the throttle body.
  • Page 110 MAINTENANCE AND ADJUSTMENT • Adjustment If the throttle grip play cannot be ad- • Loosen the locknut at the throttle justed with the accelerator cable ad- grip, and turn the adjuster until the juster at the throttle grip, use the proper amount of throttle grip play is decelerator cable adjuster located obtained.
  • Page 111: Engine Vacuum Synchronization

    Periodic • Tighten the locknut. Maintenance Chart by an authorized • With the engine idling, turn the han- Kawasaki dealer. dlebar to each side. If handlebar NOTE movement changes the idle speed, ○ Poor engine vacuum synchroniza-...
  • Page 112: Idle Speed

    MAINTENANCE AND ADJUSTMENT Idle Speed The idle speed check should be per- formed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed. Adjustment • Start the engine, and warm it up thor- oughly. • Adjust the idle speed by turning the idle adjusting screw.
  • Page 113: Clutch

    MAINTENANCE AND ADJUSTMENT correct any of these conditions be- Clutch fore riding. Due to friction plate wear and clutch cable stretch over a long period of use, the clutch operation should be checked WARNING each day before riding the motorcycle, Operation with damaged cables and carry out the maintenance and ad- could result in an unsafe riding...
  • Page 114 MAINTENANCE AND ADJUSTMENT irregularity, have the clutch cable If the play is incorrect, adjust the lev- checked by an authorized Kawasaki er play as follows. dealer. • Adjustment • Check the clutch lever play as shown Loosen the locknut, and turn the ad- in the figure.
  • Page 115: Drive Chain

    MAINTENANCE AND ADJUSTMENT • If it cannot be done, have the clutch Drive Chain cable adjusted by an authorized Ka- The drive chain slack and lubrication wasaki dealer. must be checked each day before rid- ing the motorcycle, and must be main- NOTE tained in accordance with the Periodic ○...
  • Page 116 MAINTENANCE AND ADJUSTMENT • Chain Slack Inspection If the drive chain is too tight or too • Set the motorcycle up on its side loose, adjust it so that the chain stand. slack will be within the standard val- • Rotate the rear wheel to find the po- sition where the chain is tightest, and Drive Chain Slack...
  • Page 117 MAINTENANCE AND ADJUSTMENT • Chain Slack Adjustment If the chain is too tight, turn in the left • Loosen the left and right chain ad- and right chain adjusters evenly. • juster locknuts. Turn out both chain adjusters evenly • Remove the cotter pin, and loosen until the drive chain has the correct the axle nut.
  • Page 118 MAINTENANCE AND ADJUSTMENT WARNING Misalignment of the wheel will re- sult in abnormal wear, and may result in an unsafe riding condi- tion. Align the rear wheel using the marks on the swingarm or measuring the distance between the center of the axle and swing- arm pivot.
  • Page 119 When inserting the cotter pin, if the this item should be serviced by an slots in the nut do not align with the authorized Kawasaki dealer. cotter pin hole in the axle shaft, tight- • en the nut clockwise up to the next Rotate the wheel, measure the chain alignment.
  • Page 120 MAINTENANCE AND ADJUSTMENT Wear Inspection • WARNING Remove the bolts and chain cover. A loose axle nut can lead to an accident resulting in serious in- jury or death. Tighten the axle nut to the proper torque and install a new cotter pin.
  • Page 121 MAINTENANCE AND ADJUSTMENT • Stretch the chain taut either by using the chain adjusters, or by hanging a 10 kg (22 lb) weight on the chain. • Measure the length of 20 links on the straight part of the chain from pin center of the 1st pin to pin center of the 21st pin.
  • Page 122 Also inspect the sprockets for un- evenly or excessively worn teeth, and damaged teeth. A. Good Teeth B. Worn Teeth C. Damaged Teeth • If there is any irregularity, have the drive chain and/or the sprockets re- placed by an authorized Kawasaki dealer.
  • Page 123 MAINTENANCE AND ADJUSTMENT Lubrication Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for sealed chains to prevent deterioration of chain seals. If the chain is especially dirty, clean it us- ing a cleaner for sealed chains follow- ing the instructions supplied by the chain cleaner manufacturer.
  • Page 124: Brakes

    MAINTENANCE AND ADJUSTMENT Brakes Brake Fluid - In accordance with the Periodic Brake Wear Inspection Maintenance Chart, inspect the brake Inspect the brakes for wear. For each fluid level in both the front and rear front and rear disc brake caliper, if the brake fluid reservoirs and change the thickness of either pad is less than 1 brake fluid.
  • Page 125 MAINTENANCE AND ADJUSTMENT Fluid Level Inspection • The brake fluid level in the front brake fluid reservoir must be kept above the line (lower level line) next to the gauge and that in the rear brake fluid reservoir (located under the rider's seat) must be kept be- tween the upper and lower level lines (reservoirs held horizontal).
  • Page 126 MAINTENANCE AND ADJUSTMENT • If the fluid level in either reservoir is WARNING lower than the lower level line, check for fluid leaks in the brake lines, and Mixing brands and types of brake fill the reservoir to the upper level fluid can reduce the brake sys- line.
  • Page 127 Fluid Change ○ Have the brake fluid changed by an First, tighten until slight resistance is authorized Kawasaki dealer. felt, which indicates that the cap is seated on the reservoir body; then, Front and Rear Brakes - tighten the cap an additional 1/6 turn...
  • Page 128: Brake Light Switches

    • If it does not, ask your authorized justment, but the rear brake light switch Kawasaki dealer to inspect the front should be adjusted in accordance with brake light switch. the Periodic Maintenance Chart.
  • Page 129 MAINTENANCE AND ADJUSTMENT Adjustment • To adjust the rear brake light switch, remove bolt and the right frame side cover. A. Brake Pedal B. Pedal Travel • If it does not, adjust the rear brake light switch. Brake Pedal Travel A.
  • Page 130 MAINTENANCE AND ADJUSTMENT • Move the switch up or down by turn- NOTICE ing the adjusting nut. To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. A. Rear Brake Light Switch B.
  • Page 131: Front Fork

    • Visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tube. • If any doubt about the front fork, it should be checked by an authorized Kawasaki dealer. A. Inner Tube...
  • Page 132: Rear Shock Absorber

    Periodic Mainte- • Visually inspect the rear shock ab- nance Chart. sorber for oil leaks. • If there is any doubt about the rear shock absorber, it should be in- spected by an authorized Kawasaki dealer.
  • Page 133 MAINTENANCE AND ADJUSTMENT Spring Preload Adjustment The spring preload adjuster on the rear shock absorber has 7 positions. A. Rear Shock Absorber The rear shock absorber can be ad- justed by changing the spring preload A. Spring Preload Adjuster for various riding and loading condi- B.
  • Page 134 MAINTENANCE AND ADJUSTMENT Spring Preload Setting Adjuster Posi- tion ← → Spring Action Weak Standard Strong ← → Setting Soft Standard Hard ← → Load Light Standard Heavy ← → Road Good Standard ← → Speed Standard High...
  • Page 135: Wheels

    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...
  • Page 136 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.
  • Page 137 MAINTENANCE AND ADJUSTMENT ○ Tire pressure is affected by changes Tire Wear, Damage in ambient temperature and altitude, As the tire tread wears down, the tire and so the tire pressure should be becomes more susceptible to puncture checked and adjusted when your rid- and failure.
  • Page 138 MAINTENANCE AND ADJUSTMENT NOTE ○ Most countries may have their own regulations requiring a minimum tire tread depth; be sure to follow them. ○ Have the wheel balance inspected whenever a new tire is installed. A. Tire Depth Gauge • Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage.
  • Page 139 MAINTENANCE AND ADJUSTMENT Standard Tire (Tubeless) WARNING Size: 120/70ZR17 M/C (58W) Front DUNLOP Tires that have been punctured ROADSMART II J and repaired do not have the same capabilities as undamaged Size: 160/60ZR17 M/C (69W) tires and can suddenly fail, caus- Rear DUNLOP ing an accident resulting in seri-...
  • Page 140: Battery

    MAINTENANCE AND ADJUSTMENT Battery WARNING The battery installed in this motor- cycle is a sealed type, so it is not nec- New tires are slippery and may essary to check the battery electrolyte cause loss of control and injury. level or add distilled water. A break-in period of 160 km (100 The sealing strip should not be miles) is necessary to establish...
  • Page 141 MAINTENANCE AND ADJUSTMENT temperature. As temperature rises, so Current Drain does the discharge rate. Every 15°C Days from Days from (59°F) doubles the rate. 100% 100% Electrical accessories, such as digi- Discharging charged to charged to tal clocks and computer memory, also Ampere 100% draw current from the battery even...
  • Page 142 12.8 volts, the battery should be Battery Mate 150-9 charged using an appropriate charger OptiMate 4 (check with an authorized Kawasaki Yuasa MB-2040/2060 dealer). If you will not be using the mo- Christie C10122S torcycle for longer than two weeks, the...
  • Page 143 MAINTENANCE AND ADJUSTMENT If the above chargers are not avail- NOTICE able, use equivalent one. For more details, ask your Kawasaki Never remove the sealing strip, dealer. or the battery can be damaged. Do not install a conventional bat- Battery Charging •...
  • Page 144 MAINTENANCE AND ADJUSTMENT Battery Removal • Remove the passenger's seat and rider's seat. • Disconnect the cables from the bat- tery, first from the (–) terminal and then the (+) terminal. • Remove the bolts and bracket, then take the battery out of the case. •...
  • Page 145: Headlight Beam

    MAINTENANCE AND ADJUSTMENT NOTE Headlight Beam ○ Horizontal Adjustment Install the battery in the reverse or- The headlight beam is adjustable der of the Battery Removal. horizontally. If not properly adjusted horizontally, the beam will point to one NOTICE side rather than straight ahead. •...
  • Page 146 MAINTENANCE AND ADJUSTMENT Vertical Adjustment NOTE ○ The headlight beam is adjustable On high beam, the brightest point vertically. If adjusted too low, neither should be slightly below horizontal low nor high beam will illuminate the with the motorcycle on its wheels road far enough ahead.
  • Page 147: Fuses

    MAINTENANCE AND ADJUSTMENT Fuses Fuses are arranged in the fuse boxes located under the fuel tank cov- er and the left frame cover for ABS model. The main fuse is mounted on the starter relay under the rider's seat. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 148 MAINTENANCE AND ADJUSTMENT • • To access the fuse boxes, remove To access the fuse box for ABS, re- the bolts and slide each side of the move the left frame side cover by re- tank front cover forwards then pull moving the bolt.
  • Page 149: General Lubrication

    MAINTENANCE AND ADJUSTMENT General Lubrication Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Main- tenance Chart or whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.
  • Page 150 (K) Throttle Inner Cable Upper Ends • Front Brake Lever • (K): Should be serviced by an author- Rear Brake Pedal ized Kawasaki dealer. Lubricate the following cables with NOTE a pressure cable luber - • ○ (K) Clutch Inner Cable After connecting the cables, adjust •...
  • Page 151: Cleaning Your Motorcycle

    MAINTENANCE AND ADJUSTMENT Cleaning Your Motorcycle WARNING General Precautions Frequent and proper care of your Ka- Build-up of debris or flammable wasaki motorcycle will enhance its ap- material in and around the ve- pearance, optimize overall hicle chassis, engine, and ex- performance, and extend its useful life.
  • Page 152 MAINTENANCE AND ADJUSTMENT • • Be sure the engine and exhaust are Avoid spraying water in delicate cool before washing. areas such as in air intakes, fuel sys- • Avoid applying degreaser to seals, tem, brake components, electrical brake pads, and tires. components, muffler outlets, and fuel •...
  • Page 153 • If any doubt, consult an authorized with cold water. Do not use warm Kawasaki dealer. water as it accelerates the chemical reaction of the salt. After drying, ap- ply a corrosion protection spray on...
  • Page 154 MAINTENANCE AND ADJUSTMENT Painted Surfaces NOTICE After washing your motorcycle, coat painted surfaces, both metal and plas- Plastic parts may deteriorate and tic, with a commercially available mo- break if they come in contact with torcycle/automotive wax. Wax should chemical substances or house- be applied once every three months or hold cleaning products such as as conditions require.
  • Page 155 MAINTENANCE AND ADJUSTMENT chrome/aluminum polish. Coated alu- The sidewalls of tires and other rub- minum should be washed with a mild ber components should be treated with neutral detergent and finished with a a rubber protectant to help prolong spray polish. Aluminum wheels, both their useful life.
  • Page 156: Storage

    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 Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
  • Page 157 STORAGE • Empty the fuel system by running the engine at idle speed until the engine stalls. (If left in for a long time, the fuel will break down and could clog the fuel system.) • Reduce tire pressure by about 20%. •...
  • Page 158: Environmental Protection

    To help preserve the environment, properly discard used batteries, tires, oils and fluids, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure. This also applies to disposal of the entire vehicle at the...
  • Page 159: Location Of Labels

    LOCATION OF LABELS LOCATION OF LABELS All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may op- erate your vehicle.
  • Page 160 LOCATION OF LABELS 2. Brake Fluid (Rear) 3. Important Drive Chain Information 4. Tire and Load Data...
  • Page 161 LOCATION OF LABELS 5. Battery Poison/Danger 6. Unleaded Gasoline 7. Radiator Cap Danger...
  • Page 162 LOCATION OF LABELS...
  • Page 163 LOCATION OF LABELS 1. Read Owner’s Manual 1. Read Owner’s Manual 2. Drive chain slack, see page 115 2. Tire Pressure, see page 135 3. Front tire size and manufacture, see page 138 4. Rear tire size and manufacture, see page 138 5.
  • Page 164 LOCATION OF LABELS 1. Read Owner’s Manual 2. Unleaded gasoline, see page 44...

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