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   Summary of Contents for Kawasaki Z250SL

  • Page 2 SAFETY INFORMATION Quick Reference Guide GENERAL INFORMATION This Quick Reference Guide will HOW TO RIDE THE MOTORCYCLE assist you in finding the information you’re looking for. MAINTENANCE AND ADJUSTMENT APPENDIX MAINTENANCE RECORD A Table of Contents is included after the Foreword.
  • Page 3 NOTICE Whenever you see the symbols shown below, heed their instructions! NOTICE is used to address prac- Always follow safe operating and main- tices not related to personal in- tenance practices. jury. DANGER NOTE DANGER indicates a hazardous ○ NOTE indicates information that may situation which, if not avoided, help or guide you in the operation or will result in death or serious in-...
  • Page 4 NOTICE THIS PRODUCT BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OP- ERATOR AND AS A VEHICLE ONLY.
  • Page 5 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-...
  • Page 6 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 © 2014 Kawasaki Heavy Industries, Ltd. Dec. 12, 2014. (1)
  • Page 7 TABLE OF CONTENTS SAFETY INFORMATION ....GENERAL INFORMATION....19 Read Owner’s Manual ..... Specifications ........19 Training ..........Serial Number Locations....23 Daily Checks and Periodic Location of Labels ......24 Maintenance ......... Location of Parts ......33 Loading and Accessories Meter Instruments ......
  • Page 8 Helmet Hooks........65 Throttle Control System ....106 Tying Hooks ........66 Idle Speed ........108 Tool Kit ..........66 Clutch ..........108 Drive Chain ........110 Rear View Mirror ......67 HOW TO RIDE THE MOTORCYCLE . 69 Brakes ..........114 Break-In ...........
  • Page 9: Safety Information

    WARNING Training Failure to perform these checks Kawasaki strongly recommends that or to correct a problem before all operators of this vehicle complete a operation may result in serious suitable motorcycle rider training pro- damage or an accident. Always...
  • Page 10: Loading And Accessories Information

    Before you ride the Kawasaki dealer as soon as possible. motorcycle, make sure it is not overloaded and that you have followed these instructions.
  • Page 11: Passenger

    Kawasaki Parts and Accessories oughly familiar with motorcycle op- have been specially designed for eration. The passenger can affect use on Kawasaki motorcycles. We control of the motorcycle by im- strongly recommend that all parts proper positioning during cornering and accessories you add to your and sudden movements.
  • Page 12: Baggage And Luggage

    SAFETY INFORMATION 4. Do not carry passengers unless will not move around while you are passenger footpegs are installed. riding. Recheck baggage security Instruct any passenger before riding as often as possible (not while the to keep his or her feet on the pas- motorcycle is in motion) and adjust senger footpegs and hold on to the as necessary.
  • Page 13: Other Load

    3. Fairings, backrests, and other large hicles. Kawasaki does not manu- items have the capability of ad- facture sidecars or trailers for mo- versely affecting stability and han-...
  • Page 14: Safe Operation

    DO NOT run the engine in en- - your motorcycle may have suffered closed areas. Operate only in a damage that is not immediately appar- well-ventilated area. ent. Have your motorcycle thoroughly checked at a Kawasaki dealer as soon as possible.
  • Page 15: Fueling

    Do not smoke. Make sure Helmet the area is well ventilated and Kawasaki strongly recommends both free from any source of flame or the operator and passenger wear a hel- sparks; this includes any appli- met even if this is not a legal require- ance with a pilot light.
  • Page 16: Safe Riding Techniques

    SAFETY INFORMATION Eye Protection Boots Always use eye protection. If your Wear proper protective boots that fit helmet does not have a visor installed, properly and do not interfere with gear wear goggles. shifting or braking. Gloves Safe Riding Techniques Wear gloves which have suitable protection for your hands, especially against abrasion.
  • Page 17 SAFETY INFORMATION Use Engine Brake view mirror; you may misjudge a vehi- cle’s distance and speed, or you may When going down long slopes, help not see it at all. control vehicle speed by closing the throttle so that the engine can act as an Accelerate and Brake Smoothly auxiliary brake.
  • Page 18: Additional Considerations For High Speed Operation

    SAFETY INFORMATION Ride Prudently Avoid Unnecessary Weaving Riding at the proper speed and avoid- Unnecessary weaving jeopardizes ing unnecessarily fast acceleration are the safety of both the rider and other important not only for safety and low motorists. fuel consumption but also for long ve- hicle life and quieter operation.
  • Page 19: Engine Oil

    SAFETY INFORMATION Brakes Engine Oil The importance of the brakes, es- To avoid engine seizure and resulting pecially during high speed operation, loss of control, make sure that the oil cannot be overemphasized. Check to level is at the upper level line. see that they are correctly adjusted and Coolant functioning properly.
  • Page 20: General Information

    GENERAL INFORMATION GENERAL INFORMATION Specifications PERFORMANCE Maximum Horsepower 20.6 kW (28 PS) @9 700 r/min (rpm) Maximum Torque 22.6 N·m (2.3 kgf·m, 17 ft·lb) @8 200 r/min (rpm) Minimum Turning Radius 2.4 m (7.9 ft) DIMENSIONS Overall Length 1 935 mm (76.18 in.) Overall Width 700 mm (27.6 in.) Overall Height...
  • Page 21 GENERAL INFORMATION Displacement 249 cm³ (15.2 cu in.) Bore × Stroke 72.0 × 61.2 mm (2.83 × 2.41 in.) Compression Ratio 11.3:1 Starting System Electric starter Fuel System FI (Fuel Injection) Ignition System Battery and coil (transistorized ignition) 10° BTDC @1 500 r/min (rpm) ∼ 32° BTDC Ignition Timing (Electronically advanced) @5 000 r/min (rpm)
  • Page 22 GENERAL INFORMATION Clutch Type Wet, multi disc Driving System Chain drive Primary Reduction Ratio 2.800 (84/30) Final Reduction Ratio 3.000 (42/14) Overall Drive Ratio 7.754 (Top gear) Gear Ratio: 3.000 (33/11) 1.933 (29/15) 1.444 (26/18) 1.217 (28/23) 1.045 (23/22) 0.923 (24/26) FRAME Caster 24.0°...
  • Page 23 GENERAL INFORMATION Rim Size: Front J17M/C × MT2.75 Rear J17M/C × MT3.50 Fuel Tank Capacity 11 L (2.9 US gal) Brake Fluid: Front DOT3 or 4 Rear DOT4 ELECTRICAL EQUIPMENT Battery 12 V 8 Ah (10 HR) Headlight: High Beam 12 V 60 W Low Beam 12 V 55 W Brake/Tail Light...
  • Page 24: Serial Number Locations

    GENERAL INFORMATION Serial Number Locations The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts.
  • Page 25: Location Of Labels

    Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct posi- tion. NOTE ○...
  • Page 26 GENERAL INFORMATION 2. Brake Fluid (Rear) 3. Battery Poison/Danger *4. Fuel Level *5. Helmet Wearing *6. Vacuum Hose Routing Diagram **7. Fuel Notice **8. Safety Riding Notice *: only on Thailand model **: only on Indonesia model...
  • Page 27 GENERAL INFORMATION **9. Coolant Notice 10. Tire and Load Data 11. Important Drive Chain Information *12. Vehicle Emission Control Information *: only on Thailand model **: only on Indonesia model...
  • Page 28 GENERAL INFORMATION ***13. Vehicle Emission Control Information ****14. Noise Test Information ***: only on Philippines model ****: only on Thailand and Malaysia models...
  • Page 29 GENERAL INFORMATION 3) Except Indonesia model 3) only on Indonesia model...
  • Page 30 GENERAL INFORMATION 4) only on Thailand model 6) only on Thailand model 5) only on Thailand model...
  • Page 31 GENERAL INFORMATION 7) only on Indonesia model 9) only on Indonesia model 8) only on Indonesia model 10) Except Indonesia and Thailand models...
  • Page 32 GENERAL INFORMATION 10) only on Thailand model 11) Except Thailand and Indonesia models 10) only on Indonesia model 11) only on Thailand model...
  • Page 33 GENERAL INFORMATION 11) only on Indonesia model 13) only on Philippines model 12) only on Thailand model 14) only on Thailand and Malaysia models...
  • Page 34: Location Of Parts

    GENERAL INFORMATION Location of Parts 1. Rear View Mirrors 6. Front Brake Lever 2. Clutch Lever 7. Left Handlebar Switches 3. Starter Lockout Switch 8. Ignition Switch/Steering Lock 4. Meter Instrument 9. Right Handlebar Switches 5. Brake Fluid Reservoir (Front) 10.
  • Page 35 GENERAL INFORMATION 1. Headlight 9. Tying Hooks 2. Turn Signal Lights 10. Front Fork 3. Spark Plug 11. Shift Pedal 4. Fuel Tank 12. Side Stand 5. Battery 13. Rear Shock Absorber 6. Seat Lock 14. Drive Chain 7. Tool Kit 15.
  • Page 36 GENERAL INFORMATION 1. License Plate Light 9. Brake Discs 2. Brake/Tail Light 10. Brake Calipers 3. Passenger’s Seat 11. Brake Fluid Reservoir (Rear) 4. Fuse Box 12. Rear Brake Light Switch 5. Rider’s Seat 13. Rear Brake Pedal 6. Air Cleaner 14.
  • Page 37: Meter Instruments

    GENERAL INFORMATION Meter Instruments 1. Left Button 2. Multifunction Meter 3. Right Button 4. Fuel Gauge 5. Speedometer 6. Tachometer 7. Multifunction Display - Odometer - Trip Meter A/B - Clock When the ignition switch is turned on, all LCD functions are shown for a few seconds, then the multifunction meter turns to operational mode.
  • Page 38: Indicators

    GENERAL INFORMATION Indicators Neutral Indicator (Green) Fuel Level Warning Indicator Turn Signal Indicator (Green) Coolant Temperature Warning Indicator (Red) Engine Warning Indicator (Yellow) ABS Indicator (Yellow) (ABS model) Battery Warning Indicator (Red) High Beam Indicator (Blue)
  • Page 39 When the ignition switch is turned on, all indicators go on/off as shown in the table. If any indicator does not operate as shown, have it checked by an autho- rized Kawasaki dealer.
  • Page 40 Stand the vehicle upright to check the fuel level. The fuel level warning system has malfunctioned. Have Blink (including the fuel level warning system checked by an authorized all segments) Kawasaki dealer.
  • Page 41 This indicator goes on if the battery voltage is less than 11.0 V or more than 16.0 V. If this indicator goes on, charge the battery. If this indicator still goes on after charging the battery, have the battery and/or charging system checked by an authorized Kawasaki dealer.
  • Page 42 If this happens, first turn the ignition switch off, and then back on, and ride the motorcycle at 10 km/h (6 mph) or more. The ABS indicator should then go off. If it does not, have the ABS checked by an authorized Kawasaki dealer.
  • Page 43 GENERAL INFORMATION Other Indicators *No. Indicators Status When the transmission is in neutral, this indicator goes on. When the turn signal switch is pushed to the left or right, this indicator blinks. When the headlight is on high beam, this indicator goes on.
  • Page 44: Speedometer/tachometer

    GENERAL INFORMATION the unit setting (km/h or mph) is cor- Speedometer/Tachometer rectly displayed before riding. Refer to the Unit Setting in the Dis- play Setting section. Tachometer The LCD display has tachometer function. The tachometer shows the engine speed in revolutions per minute (r/min, rpm).
  • Page 45: Multifunction Display

    If the tachome- Push the left button to select the dis- ter does not operate correctly, have play modes. The display modes can it checked by an authorized Kawasaki be shifted in the following order. dealer. NOTE ○...
  • Page 46 GENERAL INFORMATION NOTE ○ When the figures come to 999999, the display is stopped and locked. Trip Meter To reset the trip meter: A. Left Button • B. Flow when pushing left button Push the left button to select the trip meter A or B.
  • Page 47 GENERAL INFORMATION • NOTE Push the right button to select the ○ hour or minute digits. When the trip meter reaches 9999.9 • Push the left button to adjust the hour while riding, the meter resets to 0.0 or minute digits. and continues counting.
  • Page 48: Features

    GENERAL INFORMATION • Push the right button while pushing the left button to select the display unit. A. mph or km/h Display B. mile or km Display NOTE ○ Do not operate the motorcycle with wrong unit (mph or km/h) of the Features speedometer.
  • Page 49: Keys

    Blank keys are available at your A. Segments Kawasaki dealers. Ask your dealer to B. F (full) make any additional spare keys you C. E (empty) may need, using your original key as a master.
  • Page 50 GENERAL INFORMATION NOTE ○ The headlight, tail, city and license plate lights are on whenever the ig- nition key is in the “ON” position. To avoid battery discharge, always start the engine immediately after turning the ignition key to “ON” position. ○...
  • Page 51: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches The engine stop switch is for emer- gency use. If required, move the switch to the position. NOTE ○ Although the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine.
  • Page 52: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches High beam..( Low beam..( NOTE ○ Do not allow anything to cover the headlight lens when the headlight is on. If covered, heat can build up in the headlight lens causing lens dis- coloration or melting, as well as dam- age to the item covering the lens.
  • Page 53: Passing Button

    GENERAL INFORMATION Passing Button NOTE ○ When the passing button is pushed, The fuel tank cap cannot be closed the headlight high beam (passing without the key inserted, and the key beam) goes on to signal the driver cannot be removed unless the cap is of the vehicle ahead that you are about locked properly.
  • Page 54: Fuel

    Never use gasoline with an octane rat- line quality is important. Fuels ing lower than the minimum specified of low quality or not meeting by Kawasaki to prevent severe engine standard industry specifications damage. may result in unsatisfactory per- The octane rating of a gasoline is a formance.
  • Page 55 GENERAL INFORMATION Fuel Type and Octane Rating (For Philippines Thailand Specifications) (For Australia, Indonesia Use clean, fresh unleaded gasoline Malaysia Specifications) with an ethanol volume content not Use clean, fresh unleaded gasoline more than 10% and an octane rating with an octane rating equal to or higher equal to or higher than that shown in than that shown in the table.
  • Page 56: Filling The Tank

    GENERAL INFORMATION NOTICE Do not use any fuel that con- tains more ethanol or other oxy- genates than specified for E10 fuel* in this vehicle. Damage to the engine and fuel system, or engine starting and/or per- formance problems may result from the use of improper fuel.
  • Page 57 GENERAL INFORMATION NOTICE WARNING Gasoline is extremely flammable Thailand model only: and can be explosive under cer- Never fill the tank so the fuel tain conditions, creating the po- level rises into the filler neck. If tential for serious burns. Turn the tank is overfilled, heat may the ignition switch off.
  • Page 58: Side Stand

    GENERAL INFORMATION Side Stand Do not sit on the motorcycle while it is on its side stand. Always kick the stand The motorcycle is equipped with the fully up before sitting on the motorcycle. side stand. Seats Passenger’s Seat Removal •...
  • Page 59 GENERAL INFORMATION A. Ignition Key A. Grommet B. Seat Lock • Insert the tab at the rear of the pas- C. Passenger’s Seat senger’s seat under the seat bracket. • Insert the hook and projection at the Passenger’s Seat Installation •...
  • Page 60 GENERAL INFORMATION • Remove the screw and quick rivets (both sides). A. Tab B. Seat Bracket C. Hook D. Projection A. Screw (both sides) E. Slot B. Quick Rivets (both sides) F. Grommet • Pull up the front and rear ends of the NOTE passenger’s seat to make sure they ○...
  • Page 61 GENERAL INFORMATION Quick Rivet Removal Quick Rivet Installation A. Quick Rivet A. Quick Rivet B. Center Pin B. Center Pin C. Push in. C. Pull up fully. D. Push in. • Clear the hooks outward while push- ing the upper hook (both sides).
  • Page 62 GENERAL INFORMATION A. Push A. Projections B. Hooks B. Projection (only on left seat cover) C. Tabs • Pull the seat cover outward to clear D. Seat Cover the projections and tabs, and remove E. Pull outward. the seat cover (both sides). •...
  • Page 63 GENERAL INFORMATION A. Bolt (both sides) A. Grommets B. Seat Pin (both sides) • Insert the pins on the seat bracket C. Rider’s Seat into the holes of the rider’s seat. D. Pull up and rear. Rider’s Seat Installation • Check that the grommets are in place on the rider’s seat.
  • Page 64 GENERAL INFORMATION A. Pins A. Seat Pin B. Holes B. Bolt • • Install the seat pin and tighten the Pull up the front and rear ends of the bolt (both sides) securely. rider’s seat to make sure they are securely locked.
  • Page 65 GENERAL INFORMATION A. Tabs A. Hooks B. Slots • Install the quick rivets and tighten the C. Projection (only on left seat cover) screw (both sides) securely. D. Projections E. Grommets • Insert the hooks into the slots (both sides).
  • Page 66: Helmet Hooks

    GENERAL INFORMATION WARNING Riding with helmets attached to the hooks could cause an ac- cident by distracting the oper- ator or interfering with normal vehicle operation. Do not ride the motorcycle with helmets at- tached to the hooks. A. Quick Rivets (both sides) B.
  • Page 67: Tying Hooks

    GENERAL INFORMATION Tying Hooks The kit contains tools that can be helpful in making roadside repairs, When tying up light loads to the seat, adjustments, and some maintenance use the tying hooks located in front of procedures explained in this manual. the rear turn signal lights and rear of the Keep the tool kit in the original place.
  • Page 68: 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 can not be as- sured by moving the mirror, loosen the upper hexagonal area and turn the stay by hand.
  • Page 69 GENERAL INFORMATION NOTE ○ If a torque wrench is not available, this item should be serviced by a Kawasaki dealer. A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area C. Rear View Mirror D. Rubber Boots...
  • Page 70: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Break-In Maximum engine Distance traveled speed The first 1 600 km (1 000 mile) that 0 ∼ 800 km (0 ∼ 500 the motorcycle is ridden is designated 4 000 r/min (rpm) mile) as the break-in period.
  • Page 71: Starting The Engine

    (600 mile) it is extremely important A. Engine Stop Switch that the owner has the initial mainte- B. Starter Button nance service performed by an autho- • Turn the ignition switch on. rized Kawasaki dealer. • Make sure the transmission is in neu- tral.
  • Page 72 HOW TO RIDE THE MOTORCYCLE motorcycle falls down. The engine warning indicator ( ) blinks when the starter button is pressed if the en- gine cannot be started. After righting the motorcycle, first turn the ignition switch off and then back to on before starting the engine.
  • Page 73: Jump Starting

    HOW TO RIDE THE MOTORCYCLE NOTICE NOTE ○ The motorcycle is equipped with a Do not let the engine idle longer starter lockout switch. This switch than five minutes, or engine is designed so that the engine does overheating and damage may not start if the transmission is in gear.
  • Page 74 HOW TO RIDE THE MOTORCYCLE • DANGER Remove the rider’s seat (see Seats section in the GENERAL INFORMA- Battery acid generates hydro- TION chapter). gen gas which is flammable and • Slide the red cap from the positive explosive under certain con- (+) terminal (see Battery section in ditions.
  • Page 75 HOW TO RIDE THE MOTORCYCLE DANGER Batteries contain sulfuric acid that can cause burns and pro- duce hydrogen gas which is highly explosive. • Do not make this last connec- tion at the fuel system or bat- tery. • Take care not to touch the pos- itive and negative cables to- A.
  • Page 76: Moving Off

    HOW TO RIDE THE MOTORCYCLE • • Follow the standard engine starting Pull in the clutch lever. • procedure. Shift into 1st gear. • Open the throttle a little, and start to NOTICE let out the clutch lever very slowly. •...
  • Page 77: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE Shifting Gears Braking • • Close the throttle while pulling in the Close the throttle completely, leav- clutch lever. ing the clutch engaged (except when • Shift into the next higher or lower shifting gears) so that the engine will gear.
  • Page 78: Anti-lock Brake System (abs)

    HOW TO RIDE THE MOTORCYCLE applying the brakes as hard as pos- sible without skidding. • Even in motorcycles equipped with ABS, braking during cornering may cause wheel slip. When turning a corner, it is better to limit braking to the light application of both brakes or not to brake at all.
  • Page 79 HOW TO RIDE THE MOTORCYCLE prevent wheel lock-up and allows sta- or downhill surfaces, the stopping ble steering control while stopping. distance of a motorcycle with ABS Brake control function is identical to may be longer than that of an equiv- that of a conventional motorcycle.
  • Page 80 HOW TO RIDE THE MOTORCYCLE WARNING WARNING ABS cannot protect the rider Use of non-recommended tires from all possible hazards and may cause malfunctioning of is not a substitute for safe rid- ABS and can lead to extended ing practices. Be aware of how braking distance.
  • Page 81: Stopping The Engine

    Stopping the Motorcycle in an Emergency • Close the throttle completely. • Shift the transmission into neutral. Your Kawasaki Motorcycle has been • Turn the ignition switch off. designed and manufactured to pro- • Support the motorcycle on a firm, vide you optimum safety and conve- level surface with the side stand.
  • Page 82: Parking

    HOW TO RIDE THE MOTORCYCLE Parking 2. During removal of the air cleaner, dirt is allowed to enter and jam the fuel injection system. WARNING In an emergency situation such as Operating or parking the vehi- throttle failure, your vehicle may be cle near flammable materials can stopped by applying the brakes and cause a fire, and can result in...
  • Page 83 HOW TO RIDE THE MOTORCYCLE • WARNING If parking inside a garage or other structure, be sure it is well ventilated The engine and exhaust system and the motorcycle is not close to get extremely hot during normal any source of flame or sparks; this operation and can cause serious includes any appliance with a pilot burns.
  • Page 84: Maintenance And Adjustment

    Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect or improper adjustment made by the owner.
  • Page 85 The cooling fan spins at high speed and can cause serious injuries. Keep your hands and clothing away from the cooling fan blades at all times. NOTE ○ If a torque wrench is not available, the maintenance items which require a specific torque value should be serviced by an authorized Kawasaki dealer.
  • Page 86: Daily Checks

    MAINTENANCE AND ADJUSTMENT 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 motorcycle to a safe operating condition.
  • Page 87 MAINTENANCE AND ADJUSTMENT Operation Page Bolts, nuts and fasteners – Check for loose and/or missing bolts, nuts and fasteners Steering – Action smooth but not loose from lock to lock – No binding of control cables Brakes Brake pad wear Brake fluid level –...
  • Page 88 MAINTENANCE AND ADJUSTMENT Operation Page Coolant level between level lines (when engine is cold) Electrical equipment – All lights (head, city, brake/tail, turn signal, warning/indicator) and horn work Engine stop switch – Stops engine Side stand – Return to its fully up position by spring tension –...
  • Page 89: Periodic Maintenance

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first. *B: For higher odometer readings, repeat at the frequency interval established here. *C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
  • Page 90 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Air cleaner element (*C) Idle speed Throttle control system (play, smooth return, no drag) – Fuel system –...
  • Page 91 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) – Valve clearance – Air suction system Clutch operation (play, engagement, disengagement) Engine oil and oil filter (*C) Tire air pressure Wheels and tires –...
  • Page 92 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) – Drive chain wear (*C) – Drive chain guide wear – Brake system Brake operation (effectiveness, play, –...
  • Page 93 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Brake light switch operation – Suspension system – Lubrication of rear suspension – Steering play – Steering stem bearings –...
  • Page 94: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • If the engine is cold, start the engine and run it for several minutes at idle speed. • Stop the engine, then wait several minutes until the oil settles. NOTICE A. Oil Level Inspection Window Racing the engine before the oil B.
  • Page 95 MAINTENANCE AND ADJUSTMENT • NOTE If the oil level is too high, remove the ○ excess oil through the oil filler open- To avoid damaging the right frame ing using a syringe or some other cover, push the rear brake pedal suitable device.
  • Page 96 MAINTENANCE AND ADJUSTMENT A. Engine Oil Drain Bolt A. Oil Filter Cap Bolts B. Oil Filter Cap • Let the oil completely drain with • Replace the oil filter with a new one. the motorcycle perpendicular to the ground. • If the oil filter is to be replaced, re- move the oil filter cap bolts and oil fil- ter cap with O-ring.
  • Page 97 MAINTENANCE AND ADJUSTMENT NOTICE If the filter is put in the wrong di- rection, it blocks oil from flowing to the engine and causes an en- gine seizure. A. Oil Filter • Apply grease to the spring so that it may stay in place without falling off from the oil filter.
  • Page 98 If a torque wrench is not available, C. Oil Passage Holes this item should be serviced by an D. Clutch Cover authorized Kawasaki dealer. • Tighten the oil filter cap bolts to the • Fill the engine up to the upper level specified torque.
  • Page 99 MAINTENANCE AND ADJUSTMENT Although 10W-40 engine oil is the Recommended Engine Oil recommended oil for most condi- Type: tions, the oil viscosity may need to API SG, SH, SJ, SL or SM with JASO be changed to accommodate atmo- MA, MA1 or MA2 rating Viscosity: spheric conditions in your riding area.
  • Page 100: Coolant

    MAINTENANCE AND ADJUSTMENT Coolant Coolant Level Inspection • Position the motorcycle so that it is perpendicular to the ground. • Check the coolant level through the coolant level gauge on the reserve tank located to the behind of the right middle fairing.
  • Page 101 MAINTENANCE AND ADJUSTMENT up first, and then push into the center Coolant Filling • Remove the quick rivets. pin after inserting it. ○ The middle fairing uses the quick rivet (screw type). The quick rivet can be removed by loosening the center screw, and when installing it, tighten the center screw after insert- ing it.
  • Page 102 MAINTENANCE AND ADJUSTMENT Quick Rivet (Pin Type) Installation A. Right Middle Fairing B. Projections A. Quick Rivet C. Pull outward. B. Center Pin • Remove the cap from the reserve C. Pull up fully. D. Push in. tank and add coolant through the •...
  • Page 103 If coolant must be added of- ten, or the reserve tank com- pletely runs dry, there is proba- bly leakage in the system. Have the cooling system inspected by your authorized Kawasaki A. Cap dealer. B. Reserve Tank C. F (Full) Level Line •...
  • Page 104 MAINTENANCE AND ADJUSTMENT A. Reserve Tank A. Right Middle Fairing B. Reserve Tank Hose B. Projections C. Grooves C. Grommets • • Insert the projections of the right mid- Install the quick rivets. dle fairing into the grommets.
  • Page 105 Have the coolant changed by an au- aluminum engines and radiators) in the thorized Kawasaki dealer. cooling system. On the mixture ratio of coolant, choose the suitable one re- ferring to the relation between freezing point and strength directed on the con- tainer.
  • Page 106: Air Cleaner

    If there is any oil in the transparent Cleaning and inspection of the air drain cap, remove the cap from the cleaner element should be done by an left lower end of the air cleaner hous- authorized Kawasaki dealer. ing and drain the oil.
  • Page 107: Throttle Control System

    2 ∼ 3 mm (0.08 ∼ 0.12 in.) steering positions. • • If the throttle grip does not return If there is improper play, adjust it. properly, have the throttle control system checked by an authorized Kawasaki dealer.
  • Page 108 MAINTENANCE AND ADJUSTMENT Throttle Grip Free Play Adjustment WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch a hot engine or an exhaust pipe during throt- tle grip adjustment. • Loosen the locknuts at the upper end A.
  • Page 109: Idle Speed

    If there is any irreg- The idle speed inspection should be ularity, have the clutch cable checked performed in accordance with the Peri- by an authorized Kawasaki dealer. • odic Maintenance chart. Check the clutch lever free play as This motorcycle is equipped with the shown.
  • Page 110 If it cannot be done, have the clutch If the free play is incorrect, adjust the lever free play adjusted by an autho- lever free play as follows. rized Kawasaki dealer. Clutch Lever Free Play Adjustment • Loosen the locknut at the clutch...
  • Page 111: Drive Chain

    MAINTENANCE AND ADJUSTMENT NOTE coated with lubricant. Wipe off any ○ excess lubricant. After the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly. Drive Chain Drive Chain Lubrication Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry.
  • Page 112 MAINTENANCE AND ADJUSTMENT measure the maximum chain slack Drive Chain Slack Adjustment • by pulling up and pushing down the Remove the cotter pin, and loosen chain midway between the engine the axle nut. • sprocket and rear wheel sprocket. Loosen the left and right chain ad- juster locknuts.
  • Page 113 MAINTENANCE AND ADJUSTMENT • If the chain is too tight, turn out the left and right chain adjusting nuts evenly. • Turn out both chain adjusting nuts evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch on the left wheel alignment in- dicator should align with the same...
  • Page 114 If a torque wrench is not available, NOTE this item should be serviced by an ○ When inserting the cotter pin, if the authorized Kawasaki dealer. slots in the nut do not align with the cotter pin hole in the axle shaft,...
  • Page 115: Brakes

    • Check the rear brake (see Brakes section). Brakes If you feel there is something wrong when applying the brakes, have the brake system checked by an autho- rized Kawasaki dealer immediately. A. Turn Clockwise...
  • Page 116 Have the brake checked immediately by an au- A. Front Brake Fluid Reservoir thorized Kawasaki dealer. B. Lower Level Line • With the rear brake fluid reservoir Brake Fluid Level Inspection •...
  • Page 117 1.5 mm (0.06 in.), replace both pads in the caliper as a set. Pad re- placement should be done by an autho- rized Kawasaki dealer. A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line •...
  • Page 118: Brake Light Switches

    MAINTENANCE AND ADJUSTMENT • If it does not, ask your authorized Kawasaki dealer to inspect the front brake light switch. • Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go on after the proper pedal travel.
  • Page 119: Suspension System

    MAINTENANCE AND ADJUSTMENT NOTICE Brake Pedal Travel 10 mm (0.39 in.) To avoid damaging the electrical connections inside the switch, be sure that the switch body Brake Light Switch Adjustment • does not turn during adjustment. To adjust the rear brake light switch, move the switch up or down by turn- ing the adjusting nut.
  • Page 120 MAINTENANCE AND ADJUSTMENT • NOTE Identify wrench marked ○ “R30·UP” and wrench B marked The wrench A and B are designed for “R30”. The wrench A is used for turning the adjuster only one direc- increase the spring preload, and the tion.
  • Page 121 MAINTENANCE AND ADJUSTMENT To Increase the Spring Preload • Insert the wrench A with its “R30·UP” mark facing up between the tie-rod and shock absorber from the left side, just under the drive chain. • Securely fit the tip of the wrench A into the recess at rear of the adjuster.
  • Page 122 MAINTENANCE AND ADJUSTMENT • Insert the handle to the wrench B and turn the adjuster counterclock- wise to decrease the spring preload and soften the suspension. A. Wrench B B. Handle C. Frame Bracket D. Spring Preload Adjuster E. Recess...
  • Page 123: Setting Tables

    MAINTENANCE AND ADJUSTMENT Setting Tables Rear Shock Absorber Spring Preload Setting Softest setting limit Standard Hardest setting limit Adjuster Position ←→ Spring Action Weak Strong ←→ Setting Soft Hard ←→ Load Light Heavy ←→ Road Good ←→ Speed High...
  • Page 124: Wheels

    MAINTENANCE AND ADJUSTMENT Wheels Tire Pressure Inspection • Remove the air valve cap. • Check the tire pressure often, using an accurate gauge. • Make sure to install the air valve cap securely. NOTE ○ Measure the tire pressure when the A.
  • Page 125 MAINTENANCE AND ADJUSTMENT So it is false economy and unsafe to Minimum Tread Depth use the tires until they are bald. — Front 1 mm (0.04 in.) Tire Wear Inspection Under 130 km/h • 2 mm (0.08 in.) Measure the depth of the tread with (80 mph) Rear a depth gauge, and replace any tire...
  • Page 126 MAINTENANCE AND ADJUSTMENT WARNING Tires that have been punctured and repaired do not have the same capabilities as undam- aged tires and can suddenly fail, causing an accident resulting in serious injury or death. Re- place damaged tires as soon as possible.
  • Page 127: Battery

    MAINTENANCE AND ADJUSTMENT ○ When operating on public roadways, WARNING keep maximum speed under traffic New tires are slippery and may law limits. cause loss of control and injury. A break-in period of 160 km (100 Standard Tire (Tubeless) miles) is necessary to estab- Make, Type: lish normal tire traction.
  • Page 128: Battery Maintenance

    Kawasaki-recommended chargers are: quently, inspect the battery voltage Battery Mate 150-9 weekly using a voltmeter. If it drops OptiMate 4 below 12.8 volts, the battery should be Yuasa MB-2040/2060 Christie C10122S charged using an appropriate charger (check with your Kawasaki dealer).
  • Page 129 MAINTENANCE AND ADJUSTMENT If the above chargers are not avail- DANGER able, use equivalent one. Battery acid generates hydro- For more details, ask your Kawasaki gen gas which is flammable and dealer. explosive under certain con- ditions. It is present within a Battery Charging •...
  • Page 130 MAINTENANCE AND ADJUSTMENT • Remove the rider’s seat. Refer to the Seats section in the GENERAL INFORMATION chapter. • Slide the red cap from the positive (+) terminal. • Disconnect the cables from the bat- tery, first from the (–) terminal and then the (+) terminal.
  • Page 131: Headlight

    • Connect the (+) cable to the (+) ter- Headlight aiming should be done by minal, and then connect the (–) cable an authorized Kawasaki dealer. to the (–) terminal. Horizontal Adjustment NOTICE The headlight beam is adjustable horizontally.
  • Page 132 MAINTENANCE AND ADJUSTMENT in or out to adjust the headlight verti- cally. NOTE ○ On high beam, the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper angle according to local regulations.
  • Page 133: Fuses

    If the fuse fails repeatedly, there is something wrong with the electrical system. Have the motorcycle checked A. Fuse Boxes B. Fuses by an authorized Kawasaki dealer. C. Spare Fuses The main fuse removal should be D. Main Fuse done by an authorized Kawasaki E.
  • Page 134: General Lubrication

    MAINTENANCE AND ADJUSTMENT General Lubrication WARNING Lubricate the points shown below, Substituting fuses can cause with either engine oil or regular grease, wiring to overheat, catch fire in accordance with the Periodic Main- and/or fail. Do not use any sub- tenance Chart or whenever the vehicle stitute for the standard fuse.
  • Page 135: Cleaning Your Motorcycle

    Cleaning Your Motorcycle General Precautions Frequent and proper care of your Apply grease to the following Kawasaki motorcycle will enhance points its appearance, optimize overall per- • (K) Clutch Inner Cable Upper End formance, and extend its useful life.
  • Page 136 MAINTENANCE AND ADJUSTMENT • WARNING Be sure the engine and exhaust are cool before washing. Build-up of debris or flammable • Avoid applying degreaser to seals, material in and around the vehi- brake pads, and tires. cle chassis, engine, and exhaust •...
  • Page 137: Washing Your Motorcycle

    MAINTENANCE AND ADJUSTMENT • Avoid spraying water in delicate detergent can damage parts of your areas such as in air intakes, fuel sys- motorcycle). • tem, brake components, electrical Use a soft cloth to dry your motorcy- components, muffler outlet, and fuel cle.
  • Page 138 MAINTENANCE AND ADJUSTMENT NOTICE water as it accelerates the chemical reaction of the salt. After drying, Using high-pressure water, as apply a corrosion protection spray from a car wash facility, could on all metal and chrome surfaces to damage the radiator fins and im- prevent corrosion.
  • Page 139 MAINTENANCE AND ADJUSTMENT • NOTICE If any doubt, consult an authorized Kawasaki dealer. Plastic parts may deteriorate and break if they come in con- Other Plastic Parts tact with chemical substances After washing use a soft cloth to or household cleaning products gently dry plastic parts.
  • Page 140 MAINTENANCE AND ADJUSTMENT should be washed with a mild neu- The sidewalls of tires and other rub- tral detergent and finished with a spray ber components should be treated with polish. Aluminum wheels, both painted a rubber protectant to help prolong their and unpainted can be cleaned with useful life.
  • Page 141: Appendix

    APPENDIX APPENDIX 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 engine oil. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recy- cling.
  • Page 142 APPENDIX WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. Turn the ignition switch off. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 143 APPENDIX • Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or in the brakes. • Lubricate the drive chain and all the cables. • Remove the battery, and store it where it will not be exposed to direct sunlight, moisture, or freezing temperatures.
  • Page 144: Troubleshooting Guide

    APPENDIX Troubleshooting Guide Engine Does Not Start Starter Motor Won’t Turn • Engine stop switch off • Transmission not in neutral • Fuse blown • Battery cables do not make good electrical contact with battery terminals • Battery discharged Engine Cranks, But Won’t Start •...
  • Page 145: Environmental Protection

    Con- sult 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 146: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Owner Name..................Address ....................Phone Number ................... Engine Number .................. Vehicle Number.................. Key Code .................... Selling Dealer Name ................Phone Number ................... Warranty Start Date ................Note: Keep this information and a spare key in a secure location. Odometer Date Dealer Name...
  • Page 147 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 148 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 149 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 150 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 151 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...

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Z250sl abs

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