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Black plate (1,1)
ENGLISH
Motorcycle
Owner's Manual

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Table of Contents

   Summary of Contents for Kawasaki ZR750M

  • Page 1 Black plate (1,1) ENGLISH Motorcycle Owner's Manual...
  • Page 2 Black plate (2,1)
  • Page 3 Black plate (3,1) Whenever you see the symbols NOTE ○ shown below, heed their instructions! This note symbol indicates points of Always follow safe operating and main- particular interest for more efficient tenance practices. and convenient operation. WARNING This warning symbol identifies special instructions or proce- dures which, if not correctly fol- lowed, could result in personal...
  • Page 4 Black plate (4,1) (Australian model only) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
  • Page 5 Black plate (5,1)
  • Page 6 Black plate (6,1) 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 7 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. Consumer Products & Machinery Company © 2006 Kawasaki Heavy Industries, Ltd. Nov. 2006. (1). (C, CR, K3)
  • Page 8: Table Of Contents

    Black plate (8,1) TABLE OF CONTENTS SPECIFICATIONS ........ 10 Passing Button: ......41 LOCATION OF PARTS ......14 Brake Lever Adjuster ......42 LOADING AND ACCESSORIES IN- Fuel Tank Cap ........43 FORMATION ........17 Fuel Tank ........... 44 GENERAL INFORMATION ....20 Fuel Requirement: ......
  • Page 9 Periodic Maintenance Chart ....82 ENVIRONMENTAL PROTECTION ..154 Engine Oil .......... 90 LOCATION OF LABELS ...... 155 Cooling System ........96 Spark Plugs ........103 Valve Clearance .........104 Kawasaki Clean Air System ....104 Exhaust Device ........105 Air Cleaner .........106 Throttle Control System .....107...
  • Page 10: Specifications

    Black plate (10,1) SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Hosepower 77.7 kW (106 PS) @10 500 r/min (rpm) Maximum Torque 78.0 N·m (8.0 kgf·m, 57.5 ft·lb) @8 300 r/min (rpm) Minimum Turning Radius 3 m (118 in.) DIMENSIONS Overall Length 2 085 mm (82.1 in.) Overall Width 805 mm (31.7 in.) Overall Height...
  • Page 11 Black plate (11,1) SPECIFICATIONS ENGINE Type DOHC, 4-cylinder, 4-stroke, liquid-cooled Displacement 748 cm³ (45.6 cu in.) Bore × Stroke 68.4 × 50.9 mm (2.7 × 2.0 in.) Compression Ratio 11.3 : 1 Starting System Electric starter Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Carburetion System...
  • Page 12 Black plate (12,1) SPECIFICATIONS TRANSMISSION Transmission Type 6-speed, return shift Clutch Type Wet, multi disc Driving System Chain drive Primary Reduction Ratio 1.714 (84/49) Final Reduction Ratio 2.867 (43/15) Overall Drive Ratio 5.382 (Top gear) Gear Ratio 2.571 (36/14) 1.941 (33/17) 1.556 (28/18) 1.333 (28/21) 1.200 (24/20)
  • Page 13 High beam 12 V 55 W × 2 Low beam 12 V 55 W LED Tail/Brake Light 0.5/4.1 W M: ZR750M HR: with Honeycomb Catalytic Converter (Restricted Model) Even if one of LED (Light Emitting Diode) tail/brake light is not lit, consult with an authorized Kawasaki dealer.
  • Page 14: Location Of Parts

    Black plate (14,1) LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 7. Throttle Grip 2. Left Handlebar Switches 8. Ignition Switch/Steering Lock 3. Meter Instruments 9. Rebound Damping Force Adjuster (Front 4. Brake Fluid Reservoir (Front) Fork) 5. Right Handlebar Switches 10.
  • Page 15 Black plate (15,1) LOCATION OF PARTS 11. Turn Signal Light 18. Tail/Brake Light 25. Side Stand 12. Headlight 19. License Plate Light 26. Shift Pedal 13. Spark Plugs 20. Seat Lock 27. Drive Chain 14. Air Cleaner 21. Brake Disc 28.
  • Page 16 Black plate (16,1) LOCATION OF PARTS 29. Rebound Damping Force Adjuster (Rear 36. Swingarm Shock Absorber) 37. Rear Brake Light Switch 30. Fuse Box 38. Rear Shock Absorber 31. Battery 39. Rear Brake Pedal 32. Tool Kit 40. Oil Level Gauge 33.
  • Page 17: Loading And Accessories Information

    Kawasaki Parts and Accessories motorcycle, make sure that the have been specially designed for motorcycle is not overloaded and use on Kawasaki motorcycles. We that you have followed these in- strongly recommend that all parts structions. and accessories you add to your mo-...
  • Page 18 Black plate (18,1) LOADING AND ACCESSORIES INFORMATION been prepared to assist you in making on the motorcycle center of gravity. your determinations. Baggage weight should also be dis- Any passenger should be thor- tributed equally on both sides of the oughly familiar with motorcycle op- motorcycle.
  • Page 19 LOADING AND ACCESSORIES INFORMATION affected any lighting components, be used to tow any trailer or other 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,...
  • Page 20: General Information

    Black plate (20,1) GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. RESET Button B. MODE Button C. Left Turn Signal Indicator Light D. Tachometer E. Red Zone F. ABS Indicator Light (only on ABS model) G. High Beam Indicator Light H. Neutral Indicator Light I.
  • Page 21: Tachometer

    “ON”, the tachometer momentarily goes from the minimum to the maxi- mum, then goes back from the maxi- mum to the minimum reading to check its operation. If the tachometer does not operate correctly, have it checked by an authorized Kawasaki dealer.
  • Page 22: Digital Meter

    Black plate (22,1) GENERAL INFORMATION Digital Meter: Digital Meter The digital meter displays the follow- ing functions: the speedometer, clock, trip meter, odometer, coolant tempera- ture gauge, oil pressure warning sym- bol, and fuel injection warning symbol immobilizer warning symbol. Pushing the MODE button shifts the display in the digital meter through the following two modes: odometer, trip...
  • Page 23 Black plate (23,1) GENERAL INFORMATION • mph/km·h Display - Display the odometer in the digital mile/km Display can alternate be- meter. • tween English and metric modes (mph The km/h·mph (or °C/°F tempera- and km/h) in the digital meter. Make ture) display shifts by pushing the sure that km/h or mph according to lo- RESET button while the MODE but-...
  • Page 24 Black plate (24,1) GENERAL INFORMATION • The km/h·mile (and °C/°F tempera- Clock - ture) display shifts as follows. To adjust hours and minutes: • Turn the ignition key to “ON”. • Push the MODE button to display the odometer. • Push the RESET button for more than two seconds.
  • Page 25 Black plate (25,1) GENERAL INFORMATION • • Push the RESET button. The hour Push the RESET button. Both the display only flashes. Push the hour and minute displays start flash- MODE button to advance the hours. ing again. • Push the MODE button. The dis- plays stop flashing and the clock starts working.
  • Page 26 Black plate (26,1) GENERAL INFORMATION Odometer - Trip Meters - The odometer shows the total dis- The trip meter shows the distance in tance in kilometers or miles that the ve- kilometers or miles traveled since it hicle has been ridden. This meter was last reset to zero.
  • Page 27 Black plate (27,1) GENERAL INFORMATION • ○ After two second, the figure display When the battery is disconnected, turns to 0.0, and then starts counting the meter display resets to 0.0. when the vehicle is operated. The meter counts until it is next reset. Coolant Temperature Gauge - The coolant temperature is displayed as follows.
  • Page 28 Black plate (28,1) GENERAL INFORMATION • • When the coolant temperature rises If the coolant temperature rises to to above 40°C (104°F), the numeri- above 115°C (239°F) and below 120 cal value of the coolant temperature °C (248°F), the numerical value of at the present state is displayed.
  • Page 29: Fuel Gauge

    Black plate (29,1) GENERAL INFORMATION • If the coolant temperature rises to Fuel Gauge: above 120°C (248°F), “HI” is dis- The fuel in the fuel tank is shown by played and starts flashing. This the number of segments displayed. warns the operator that the coolant When the fuel tank is full, all the seg- temperature is too high;...
  • Page 30: Warning/indicator Lights

    Black plate (30,1) GENERAL INFORMATION : When the headlight is on high beam, the high beam indicator light is lit. : When the turn signal switch is pushed to the left or right, the corre- sponding turn signal indicator light flashes.
  • Page 31 ( )/fuel injection warning for more detailed engine oil informa- symbol (FI). If the warning light flashes tion. have its cause checked by an author- ized Kawasaki dealer. Refer to the fol- lowing each symbol instructions ), ( ) or (FI) for more detailed...
  • Page 32 If the warning light and warn- functions properly. If the warning light ing symbol flash, have the FI system and warning symbol flash on, have the checked by an authorized Kawasaki immobilizer system checked by an au- dealer. thorized Kawasaki dealer.
  • Page 33 Black plate (33,1) GENERAL INFORMATION FI indicator light flashes if the im- automatically goes off to prevent ex- properly coded key is used, or any in- cessive battery discharge. correct communication between antenna and key is occurred. However, (For models equipped with ABS) when the properly coded key can be : The ABS (Anti-lock Brake Sys- used, or the communication is clear,...
  • Page 34: Key

    To make additional user keys, take the ve- hicle along with the master key and all user keys to an authorized Kawasaki dealer to have them re-registered. Up to five user keys can be registered with...
  • Page 35 Do not put two keys of any immo- If the master key is lost, an au- bilizer system on the same key thorized Kawasaki dealer will ring. have to replace the ECU, order a Do not submerge any key in new master key, and register the water.
  • Page 36 Black plate (36,1) GENERAL INFORMATION • Master key: The master key can If an improperly coded key is used or never be duplicated. any incorrect communication between • User-keys: You can register maxi- ECU and key is occurred, the engine mum 5 user-keys at one time.
  • Page 37: Ignition Switch/steering Lock

    Black plate (37,1) GENERAL INFORMATION the MODE and RESET buttons si- Ignition Switch/Steering Lock multaneously for more than two sec- This is a four-position, key-operated onds, within twenty seconds after switch. The key can be removed from turning the ignition key to the “OFF” the switch when it is in the OFF, LOCK, position, then the warning light will or P (Park) position.
  • Page 38 Black plate (38,1) GENERAL INFORMATION ○ Once the ignition key is turned to Engine off. All electrical circuits “OFF” position and when turning the off. key to “ON” position again, turn the Engine on. All electrical equip- ignition key to “ON” position after ment can be used.
  • Page 39: Right Handlebar Switches

    Black plate (39,1) GENERAL INFORMATION Starter Button: Right Handlebar Switches 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-...
  • Page 40: Left Handlebar Switches

    Black plate (40,1) GENERAL INFORMATION Turn Signal Switch: Left Handlebar Switches When the turn signal switch is turned Dimmer Switch: to the left ( ) or right ( ), the High or low beam can be selected corresponding turn signals flash on with the dimmer switch.
  • Page 41: Horn Button

    Black plate (41,1) GENERAL INFORMATION Horn Button: Passing Button: When the horn button is pushed, the When the passing button is pushed, horn sounds. the headlight high beam (passing beam) comes on to signal the driver of Hazard Switch: the vehicle ahead that you are about to If an emergency requires you to park pass him.
  • Page 42: Brake Lever Adjuster

    Black plate (42,1) GENERAL INFORMATION Brake Lever Adjuster 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 mark on the lever holder.
  • Page 43: Fuel Tank Cap

    Black plate (43,1) GENERAL INFORMATION Fuel Tank Cap To open the fuel tank cap, pull up the key hole cover. 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.
  • Page 44: Fuel Tank

    Black plate (44,1) GENERAL INFORMATION Fuel Tank WARNING The following octane rating gasoline is recommended in the fuel tank. Avoid Gasoline is extremely flammable filling the tank in the rain or where and can be explosive under cer- heavy dust is blowing so that the fuel tain conditions.
  • Page 45: Fuel Requirement

    Black plate (45,1) GENERAL INFORMATION Fuel Requirement: NOTE ○ Your Kawasaki engine is designed to If “knocking” or “pinging” occurs, use use only unleaded gasoline with a min- a different brand of gasoline or high- imum octane rating of RON 91.
  • Page 46: Side Stand

    Black plate (46,1) 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.
  • Page 47: Seat Lock

    Black plate (47,1) GENERAL INFORMATION Seat Lock Passenger's Seat Removal Remove the passenger's seat by in- serting the ignition key into the seat lock and turning it clockwise. WARNING The muffler surface is hot once the engine has been started. When operating the seat lock be careful not to touch the muffler or A.
  • Page 48 Black plate (48,1) GENERAL INFORMATION Rider's Seat Removal Rider's Seat - • • Pull the seat lock cable. Insert the tab on the front of the rid- er's seat into the slot in the tank. • Insert the left and right hooks at the rear of the rider's seat into the left and right locks on the frame.
  • Page 49 Black plate (49,1) GENERAL INFORMATION • • Push down the rear part of the rider's Push down the front part of the pas- seat until the lock clicks. senger's seat until the lock clicks. Passenger's Seat - • Insert the tab on the rear of the rid- er's seat into the slot in the frame.
  • Page 50: Helmet Holding Cables

    Black plate (50,1) GENERAL INFORMATION Helmet Holding Cables WARNING Helmets can be secured to the mo- torcycle using the helmet holding ca- Do not ride the motorcycle with bles located under the passenger's helmets attached to the hooks. seat. The helmets could cause an acci- dent by distracting the operator or interfering with normal vehicle operation.
  • Page 51: Tying Hooks

    Black plate (51,1) GENERAL INFORMATION Tying Hooks Tool Kit When tying up light loads to the seat, The tool kit is located under the rid- use the tying hooks left and right below er's seat. the passenger's seat. The kit contains tools that can be helpful in making roadside repairs, ad- justments, and some maintenance pro- cedures explained in this manual.
  • Page 52: Rear View Mirror

    Black plate (52,1) GENERAL INFORMATION Rear View Mirror CAUTION Rear View Mirror Adjustment • Do not force to tighten and/or Adjust the rear view mirror by slightly moving only the mirror portion of the loosen the upper hexagonal area assembly. with a pair of spanners or •...
  • Page 53: Air Cleaner Intake

    Black plate (53,1) GENERAL INFORMATION Air Cleaner Intake The air cleaner intake allows air to enter the fuel system. Never allow any- thing to restrict the flow of air into the air cleaner. A restricted air cleaner will reduce performance and increase ex- haust emissions.
  • Page 54: Break-in

    Black plate (54,1) 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 55 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 56: How To Ride The Motorcycle

    Black plate (56,1) HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Starting the Engine NOTE • ○ Check that the engine stop switch is If the ignition key is turned to “OFF” in the position. position, wait a short while (approx. 5 seconds) before turning the key to “ON”...
  • Page 57 Black plate (57,1) HOW TO RIDE THE MOTORCYCLE • Make sure the transmission is in down. After righting the motorcycle, first turn the ignition key to “OFF” neutral. and then back to “ON” before starting the engine. • After the meter operation check, leaving throttle completely...
  • Page 58 Black plate (58,1) HOW TO RIDE THE MOTORCYCLE NOTE CAUTION ○ 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.
  • Page 59: Jump Starting

    Black plate (59,1) HOW TO RIDE THE MOTORCYCLE Connecting Jumper Cables Jump Starting • If your motorcycle battery is ”run Remove the rider's and passenger's seats. down”, it should be removed and • Make sure the ignition key is turned charged.
  • Page 60 Black plate (60,1) HOW TO RIDE THE MOTORCYCLE • • Remove the seat holder bracket. Connect a jumper cable from the positive (+) terminal of the booster Be careful not to damage the motor- battery to the positive (+) terminal of cycle by the bracket.
  • Page 61 Black plate (61,1) HOW TO RIDE THE MOTORCYCLE booster battery to your motorcycle CAUTION footpeg or other unpained metal sur- face. Do not use the negative (–) ter- Do not operate the starter contin- minal of the battery. uously for more than 5 seconds or the starter will overheat and the battery power will drop tem- WARNING...
  • Page 62 Black plate (62,1) HOW TO RIDE THE MOTORCYCLE • Check the passenger's seat lock ca- NOTE ○ ble is correctly routed. Hook the projections of the cover in- to the holes. A. Passenger's Seat Lock Cable B. Seat Holder Bracket A.
  • Page 63: Moving Off

    Black plate (63,1) 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.
  • Page 64: Shifting Gears

    Black plate (64,1) HOW TO RIDE THE MOTORCYCLE Shifting Gears NOTE • ○ Close the throttle while pulling in the The transmission is equipped with a clutch lever. positive neutral finder. When the mo- • Shift into the next higher or lower torcycle is standing still, the trans- gear.
  • Page 65: Braking

    Black plate (65,1) HOW TO RIDE THE MOTORCYCLE corner, it is better to limit braking to Braking • the light application of both brakes or Close the throttle completely, leaving not to brake at all. Reduce your the clutch engaged (except when speed before you get into the corner.
  • Page 66: Anti-lock Brake System (abs) For Models Equipped With Abs

    Black plate (66,1) 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 the brakes are applied hard while running straight. The ABS automatically regu- lates brake force.
  • Page 67 Black plate (67,1) 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 Use of non-recommended tires...
  • Page 68: Abs Indicator Light

    6 km/h or be- The light does not come on when the low, you should have the ABS ignition switch is turned on. • checked by an authorized Kawasaki The light remains lit after the motor- dealer. cycle starts moving. •...
  • Page 69: Stopping The Engine

    Stopping the Motorcycle in an • Close the throttle completely. Emergency • Shift the transmission into neutral. Your Kawasaki Motorcycle has been • Turn the ignition key to “OFF”. designed and manufactured to provide • Support the motorcycle on a firm, you optimum safety and convenience.
  • Page 70: Parking

    Black plate (70,1) HOW TO RIDE THE MOTORCYCLE In an emergency situation such as Parking • throttle failure, your vehicle may be Shift the transmission into neutral and turn the ignition key to “OFF”. stopped by applying the brakes and •...
  • Page 71 Black plate (71,1) HOW TO RIDE THE MOTORCYCLE NOTE WARNING ○ When stopping near traffic at night, The muffler and exhaust pipe are you can leave the taillight on for very hot while the engine is run- greater visibility by turning the igni- ning and just after the engine tion key to the P (park) position.
  • Page 72: Catalytic Converter

    Black plate (72,1) 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-...
  • Page 73 Black plate (73,1) 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.
  • Page 74: Safe Operation

    Black plate (74,1) 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 Before changing lanes, look over helmet are strongly recommended.
  • Page 75 Black plate (75,1) SAFE OPERATION When applying the brakes, use Riding at the proper rate of speed both the front and rear brakes. Ap- and avoiding unnecessarily fast ac- plying only one brake for sudden celeration are important not only for braking may cause the motorcycle safety and low fuel consumption but to skid and lose control.
  • Page 76 Black plate (76,1) 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.
  • Page 77: Daily Safety Checks

    Black plate (77,1) 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.
  • Page 78 Black plate (78,1) SAFE OPERATION Steering ...... Action smooth but not loose from lock to lock. No binding of control cables. Brakes ......Brake pad wear: Lining thickness more than 1 mm (0.04 in.) left. No brake fluid leakage. Throttle ......Throttle grip play 2 ~ 3 mm (0.08 ~ 0.12 in.). Clutch ......
  • Page 79: Additional Considerations For High Speed Operation

    Black plate (79,1) 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 80 Black plate (80,1) 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 81: 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 82: 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 83 Black plate (83,1) MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1 000 (mile × 1 000) Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Engine Items) • • • • Fuel leak (fuel hose and –...
  • Page 84 Black plate (84,1) MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) Clutch and drive train: Clutch operation (play, en- •...
  • Page 85 Black plate (85,1) MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) • • • Wheels/tires damage - in- spect • • •...
  • Page 86 Black plate (86,1) MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) • • • • • • • Brake operation (effective- year ness, play, drag) - inspect •...
  • Page 87 Black plate (87,1) MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) Steering system: • • • • – Steering play - inspect year •...
  • Page 88 Black plate (88,1) MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first * Odometer Reading km × 1000 (mile × 1000) Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) • • • • Bolts and nuts tightness - – inspect...
  • Page 89 Black plate (89,1) MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever * Odometer Reading comes first km × 1 000 (mile × 1 000) Page Every (0.6) (7.5) (15) (24) (30) Change/Replacement Items • Air cleaner element # • • • • • Engine oil # year •...
  • Page 90: Engine Oil

    Black plate (90,1) MAINTENANCE AND ADJUSTMENT minutes at idle speed. This fills the Engine Oil oil filter with oil. Stop the engine, In order for the engine, transmission, then wait several minutes until the oil and clutch to function properly, main- settles.
  • Page 91 Black plate (91,1) MAINTENANCE AND ADJUSTMENT • Check the engine oil level through opening using a syringe or some oth- the oil level gauge. With the motor- er suitable device. • cycle held level, the oil level should If the oil level is too low, add the oil to come up between the upper and low- reach the correct level.
  • Page 92 Black plate (92,1) 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 Symbol B.
  • Page 93 Black plate (93,1) MAINTENANCE AND ADJUSTMENT NOTE WARNING ○ If a torque wrench or required Kawa- Motor oil is a toxic substance. saki special tool is not available, this Dispose of used oil properly. item should be serviced by a Kawa- Contact your local authorities for saki dealer.
  • Page 94 Black plate (94,1) 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 line with a good quality engine oil specified torque. specified in the table. •...
  • Page 95 Black plate (95,1) MAINTENANCE AND ADJUSTMENT Engine Oil Capacity Although 10W-40 engine oil is the recommended oil for most conditions, Capacity: the oil viscosity may need to be 3.1 L (3.3 US qt) changed to accommodate atmospheric [when filter is not removed] conditions in your riding area.
  • Page 96: Cooling System

    Black plate (96,1) MAINTENANCE AND ADJUSTMENT Cooling System CAUTION Radiator and Cooling Fan - Using high-pressure water, as Check the radiator fins for obstruc- 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 97 Black plate (97,1) 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.
  • Page 98 Black plate (98,1) MAINTENANCE AND ADJUSTMENT expected weather conditions where CAUTION the motorcycle will be operated. If hard water is used in the sys- CAUTION 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 99 Black plate (99,1) MAINTENANCE AND ADJUSTMENT • Coolant Level Inspection Check the coolant level through the • Remove the rider's seat. coolant level gauge on the reserve • Position the motorcycle so that it is tank located on the rear right side of perpendicular to the ground.
  • Page 100 Black plate (100,1) MAINTENANCE AND ADJUSTMENT Coolant Filling NOTE • ○ Remove the cover (refer to the Check the level when the engine is “Jump Starting” section in the “How cold (room or atmospheric tempera- to Ride the Motorcycle” chapter). ture).
  • Page 101 Black plate (101,1) MAINTENANCE AND ADJUSTMENT • • Remove the main right side cover. Remove the bolts and rivet screws from the right side rear cowling. A. Main Right Side Cover B. Bolt A. Bolts B. Rivet Screws C. Right Side Rear Cowling...
  • Page 102 NOTE ○ In an emergency you can add water Coolant Change alone to the coolant reserve tank, Have the coolant changed by an au- however it must be returned to the thorized Kawasaki dealer. correct mixture ratio by the addition...
  • Page 103: Spark Plugs

    Maintenance Chart. shown in the table may be used Spark plug removal should be done for quicker warm-ups and more by an authorized Kawasaki dealer. efficient engine operation. How- ever, for normal temperatures an- Spark Plug d/or high speed use, the standard...
  • Page 104: Valve Clearance

    Inspection and adjustment should be flow only from the air cleaner into the carried out by an authorized Kawasaki exhaust port. Any air that has passed dealer. the air suction valve is prevented from...
  • Page 105: Exhaust Device

    This ex- Air suction valve removal and in- haust device is controlled by the ECU, spection should be carried out by an and adjustment or maintenance should authorized Kawasaki dealer. be done by an authorized Kawasaki dealer. A. Exhaust Device Cables...
  • Page 106: Air Cleaner

    Black plate (106,1) MAINTENANCE AND ADJUSTMENT Air Cleaner CAUTION A clogged air cleaner restricts the Do not adjust the exhaust device engine's air intake, increasing fuel system by yourself. The malad- consumption, reducing engine power, justment will cause the poor en- and causing spark plug fouling.
  • Page 107: Throttle Control System

    Black plate (107,1) MAINTENANCE AND ADJUSTMENT Throttle Control System Check the throttle grip play each day before riding the motorcycle, and in ac- cordance with the Periodic Mainte- nance Chart, and adjust it if necessary. Throttle Grip - The throttle grip controls the butterfly valves in the throttle body.
  • Page 108 Black plate (108,1) MAINTENANCE AND ADJUSTMENT A. Throttle Grip A. Adjusters B. Throttle Grip Play B. Locknuts C. Decelerator Cable Throttle Grip Play D. Accelerator Cable • 2 ~ 3 mm (0.08 ~ 0.12 in.) If the throttle cable can not be ad- •...
  • Page 109 Black plate (109,1) MAINTENANCE AND ADJUSTMENT • Loosen the locknuts above the en- gine, and screw both throttle cable adjusters in fully so as to give the throttle grip plenty of play. • Turn out the decelerator cable ad- justing nut until there is no play when the throttle grip is completely closed.
  • Page 110: Engine Vacuum Synchronization

    Periodic adjusted or in correctly routed, or Maintenance Chart by an authorized they may be damaged. Be sure to Kawasaki dealer. correct any of these conditions be- NOTE fore riding. ○...
  • Page 111: Idle Speed

    Black plate (111,1) MAINTENANCE AND ADJUSTMENT Idle Speed The idle speed adjustment should be performed in accordance with the Peri- odic Maintenance Chart or whenever the idle speed is disturbed. Adjustment • Start the engine, and warm it up thor- oughly.
  • Page 112: Clutch

    Operation with damaged cables Check that the clutch lever operates could result in an unsafe riding properly and that the inner cable condition. slides smoothly. If there is any irregu- larity, have the clutch cable checked by an authorized Kawasaki dealer.
  • Page 113 Black plate (113,1) MAINTENANCE AND ADJUSTMENT • Check the clutch lever play as shown Adjustment • in the figure. Turn the adjuster so that the clutch lever will have the proper play. WARNING Be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable...
  • Page 114: Drive Chain

    Black plate (114,1) MAINTENANCE AND ADJUSTMENT • If it cannot be done, use the nuts at Drive Chain the lower end of the clutch cable. The drive chain slack and lubrication must be checked each day before rid- ing the motorcycle, and in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear.
  • Page 115 Black plate (115,1) MAINTENANCE AND ADJUSTMENT • Rotate the rear wheel to find the po- Drive Chain Slack sition where the chain is tightest, and Standard 30 ~ 40 mm (1.2 ~ 1.6 in.) measure the maximum chain slack by pulling up and pushing down the Chain Slack Adjustment •...
  • Page 116 Black plate (116,1) MAINTENANCE AND ADJUSTMENT • If the chain is too loose, turn in the left and right chain adjusters evenly. • If the chain is too tight, turn out the left and right chain adjusters evenly. • Turn out both chain adjusters evenly until the drive chain has the correct amount of slack.
  • Page 117 Black plate (117,1) MAINTENANCE AND ADJUSTMENT • Install a new cotter pin through the WARNING axle nut and axle, and spread its ends. Misalignment of the wheel will re- sult in abnormal wear, and may result in an unsafe riding condi- tion.
  • Page 118 Black plate (118,1) MAINTENANCE AND ADJUSTMENT • ○ It should be within 30 degree. Check the rear brake (see the ○ Loosen once and tighten again when Brakes section). the slot goes past the nearest hole. Wear Inspection • Remove the bolts. •...
  • Page 119 It is an endless type and it, the chain should be replaced. should not be cut for installation; have it installed by an authorized Kawasaki dealer. • Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links.
  • Page 120 Wipe off any excess oil. C. Damaged Teeth • If there is any irregularity, have the drive chain and/or the sprockets re- placed by an authorized Kawasaki dealer. NOTE ○ When installing the chain cover, in- sert the projection to the hole, and...
  • Page 121: Brakes

    1 mm (0.04 in.), replace both pads in the caliper as a set. Pad replace- ment should be done by an authorized Kawasaki dealer. • If the chain is especially dirty, clean it using diesel oil or kerosine and then apply oil as described above.
  • Page 122 Black plate (122,1) MAINTENANCE AND ADJUSTMENT Disc Brake Fluid - Fluid Level Inspection • In accordance with the Periodic With the brake fluid reservoirs held Maintenance Chart, inspect the brake horizontal, the brake fluid level must fluid level in both the front and rear be kept between the upper and lower brake fluid reservoirs and change the level lines.
  • Page 123 Black plate (123,1) MAINTENANCE AND ADJUSTMENT WARNING Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser- voir are unidentified.
  • Page 124 Since it is dangerous to operate the mo- torcycle under such conditions, have the brake checked immedi- A. Reservoir ately by an authorized Kawasaki B. Cap dealer. C. Clockwise D. 1/6 turn Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer.
  • Page 125: Brake Light Switches

    • The brake light should go on when the front brake is applied. • If it does not, ask your authorized Kawasaki dealer to inspect the front brake light switch. A. Brake Pedal B. 10 mm (0.4 in.) • If it does not, adjust the rear brake light switch.
  • Page 126 Black plate (126,1) MAINTENANCE AND ADJUSTMENT Adjustment • CAUTION To adjust the rear brake light switch, move the switch up or down by turn- To avoid damaging the electrical ing the adjusting nut. connections inside the switch, be sure that the switch body does not turn during adjustment.
  • Page 127: Front Fork

    Black plate (127,1) MAINTENANCE AND ADJUSTMENT • If any doubt about the front fork, it Front Fork should be done by an authorized Ka- The front fork operation and oil leak- wasaki dealer. age should be checked in accordance with the Periodic Maintenance Chart. Front Fork Inspection •...
  • Page 128 Black plate (128,1) MAINTENANCE AND ADJUSTMENT Weaker spring force and damping CAUTION force are for comfortable riding, but they should be increased for high Do not force to turn the rebound speed riding or riding on rough roads. and compression damping force adjuster from the fully seated po- sition, as the adjusting mecha- nism may be damaged.
  • Page 129 Black plate (129,1) MAINTENANCE AND ADJUSTMENT • Turn out the adjuster to decrease damping force. Be sure to turn both adjusters by the same number of turns. A. Spring Preload Adjuster B. Wrench C. 4 ~ 19 mm (0.2 ~ 0.7 in.) D.
  • Page 130: Rear Shock Absorber

    Black plate (130,1) MAINTENANCE AND ADJUSTMENT Rear Shock Absorber WARNING The rear shock absorber operation and oil leakage should be checked in If both spring preload adjusters accordance with the Periodic Mainte- and both rebound and compres- nance Chart. sion damping force adjusters are not adjusted equally, handling Rear Shock Absorber Inspection •...
  • Page 131 If any doubt about the rear shock ab- Before making any adjustments, sorber, it should be done by an au- however, read the following proce- thorized Kawasaki dealer. dures: CAUTION Do not force to turn the rebound and compression damping force...
  • Page 132 Black plate (132,1) MAINTENANCE AND ADJUSTMENT with no passenger and no accessories is No. 4. Rebound Damping Force Adjustment The rebound damping force adjuster is located at the lower end of the rear shock absorber. A. Spring Preload Adjuster B. Wrench •...
  • Page 133: Wheels

    Black plate (133,1) MAINTENANCE AND ADJUSTMENT • Turn the adjuster counterclockwise Wheels to decrease damping force. Tubeless tires are installed on the wheels of this motorcycle. The indica- The standard setting positions of the tions of TUBELESS on the tire side rebound damping force adjuster for an wall and the rim show that the tire and average-build rider of 68 kg (150 lb)
  • Page 134 Black plate (134,1) MAINTENANCE AND ADJUSTMENT WARNING The tires, rims, and air valves on this motorcycle are designed on- ly for tubeless type wheels. The recommended standard tires, rims, and air valves must be used for replacement. Do not install tube-type tires on tubeless rims.
  • Page 135 Black plate (135,1) MAINTENANCE AND ADJUSTMENT handling and performance of your mo- torcycle and can result in loss of con- trol. The maximum recommended load in addition to vehicle weight is 180 kg (397 lb), including rider, passenger, baggage, and accessories. •...
  • Page 136 Black plate (136,1) 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...
  • Page 137 Black plate (137,1) MAINTENANCE AND ADJUSTMENT Minimum Tread Depth WARNING 1 mm — Front (0.04 in.) To ensure safe handling and stability, use only the recom- Under 130 km/h 2 mm mended standard tires for re- (80 mph) (0.08 in.) Rear placement, inflated...
  • Page 138: Battery

    Black plate (138,1) MAINTENANCE AND ADJUSTMENT Standard Tire (Tubeless) Battery The battery installed in this motor- Size: 120/70ZR17 M/C (58 W) • Front cycle is a sealed type, so it is not nec- DUNLOP “Qualifier PTL” essary to check the battery electrolyte Size: 180/55ZR17 M/C (73 W) level or add distilled water.
  • Page 139 Black plate (139,1) MAINTENANCE AND ADJUSTMENT temperature. As temperatures rise, so Current Drain does the discharge rate. Every 15°C Days from Days from (27°F) doubles the rate. 100% 100% Electrical accessories, such as digi- Discharging charged to charged to tal clocks and computer memory, also Ampere 50% Dis- 100% Dis-...
  • Page 140 If the above chargers are not avail- Battery Maintenance able, use equivalent one. It is the owner's responsibility to keep For more details, ask your Kawasaki the battery fully charged. Failure to do dealer. so can lead to battery failure and leave Battery Charging you stranded.
  • Page 141 Black plate (141,1) MAINTENANCE AND ADJUSTMENT • The charger will keep the battery Battery Removal • fully charged until you are ready to Remove the rider's and passenger's reinstall the battery in the motorcycle seat. • (see Battery Installation). Remove the cover. CAUTION Never remove the sealing strip, or the battery can be damaged.
  • Page 142 Black plate (142,1) MAINTENANCE AND ADJUSTMENT • • Remove the seat holder bracket. Disconnect the wire from the battery, first from the (–) terminal and then Be careful not to damage the motor- the (+) terminal. cycle by the bracket. Make sure the fuse box or cable is attached to the bracket.
  • Page 143 Black plate (143,1) MAINTENANCE AND ADJUSTMENT • Battery Installation Reinstall the seat holder bracket and • Place the battery in the original cover. Tighten the bolts securely. • place. Check the passenger's seat lock ca- • Connect the red capped wire to the ble is correctly routed.
  • Page 144: Headlight Beam

    Black plate (144,1) MAINTENANCE AND ADJUSTMENT NOTE Headlight Beam ○ Horizontal Adjustment Hook the projections of the cover in- The headlight beam is adjustable to the holes. horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. •...
  • Page 145 Black plate (145,1) MAINTENANCE AND ADJUSTMENT • Turn the vertical adjuster in or out to CAUTION adjust the headlight vertically. When handling the quartz-halo- gen bulbs, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamina- tion from hands or dirty rags can reduce bulb life or cause the bulb to explode.
  • Page 146: Fuses

    Black plate (146,1) MAINTENANCE AND ADJUSTMENT Fuses Main and other fuses are arranged in the fuse box located under the pas- senger's and 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 prop- er amperage.
  • Page 147: Cleaning Your Motorcycle

    Black plate (147,1) MAINTENANCE AND ADJUSTMENT Cleaning Your Motorcycle General Precautions Frequent and proper care of your Ka- wasaki motorcycle will enhance its ap- pearance, optimize overall performance, and extend its useful life. Covering your motorcycle with a high quality, breathable motorcycle cover will help protect its finish from harmful UV rays, pollutants, and reduce the amount of dust reaching its surfaces.
  • Page 148 Black plate (148,1) MAINTENANCE AND ADJUSTMENT • Avoid wire brushes, steel wool, and motorcycle. If needed, use a mild de- all other abrasive pads or brushes. greaser to remove any oil or grease • Use care when washing the wind- build up.
  • Page 149 Black plate (149,1) MAINTENANCE AND ADJUSTMENT nonpainted plastic parts with an ap- NOTE ○ proved plastic cleaner/polisher prod- After riding in an area where the uct. roads are salted or near the ocean, immediately wash your motorcycle CAUTION with cold water. Do not use warm Plastic parts may deteriorate and water as it accelerates the chemical break if they come in contact with...
  • Page 150 Black plate (150,1) MAINTENANCE AND ADJUSTMENT Chrome and Aluminum a rubber protectant to help prolong Chrome and uncoated aluminum their useful life. parts can be treated with a chrome/alu- WARNING minum polish. Coated aluminum should be washed with a mild neutral Special care must be taken not to detergent and finished with a spray get any rubber protectant on the...
  • Page 151: Storage

    Black plate (151,1) 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 Motorcycle oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recy- cling.
  • Page 152 Black plate (152,1) STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions. Turn the ignition key to “OFF”. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this in- cludes any appliance with a pilot light.
  • Page 153 Black plate (153,1) STORAGE • 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. • Install the battery in the motorcycle and charge the battery if necessary. •...
  • Page 154: Environmental Protection

    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 procedures.
  • Page 155: Location Of Labels

    Black plate (155,1) LOCATION OF LABELS LOCATION OF LABELS 1. Brake Fluid (Front) 2. Important Drive Chain Information 3. Tire and Load Data 4. Brake Fluid (Rear)
  • Page 156 Black plate (156,1) LOCATION OF LABELS 5. Daily Safety Checks 6. Battery Poison/Danger 7. Unleaded Gasoline...
  • Page 157 Black plate (157,1) LOCATION OF LABELS 1)/4)
  • Page 158 Black plate (158,1) LOCATION OF LABELS...
  • Page 159 Black plate (159,1) LOCATION OF LABELS...
  • Page 160 Black plate (160,1) LOCATION OF LABELS...
  • Page 161 Black plate (161,1) LOCATION OF LABELS...

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