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   Summary of Contents for Kawasaki klx250

  • Page 2 ENGLISH j Motorcycle Owner’s Manual Original instructions...
  • Page 4 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 6 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 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. Motorcycle & Engine Company © 2015 Kawasaki Heavy Industries, Ltd. Mar. 17, 2015. (1)
  • Page 8: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS....... Dimmer Switch: ......33 LOCATION OF PARTS ....... 13 Turn Signal Switch:....... 34 LOCATION OF LABELS..... 16 Horn Button: ......... 34 LOADING INFORMATION....19 Fuel Tank Cap ........35 GENERAL INFORMATION....22 Fuel ..........36 Meter Instruments ......22 Fuel Requirements: ......
  • Page 9 Fuses ..........132 Cooling System ........ 84 General Lubrication......133 Spark Plugs........88 Cleaning Your Motorcycle ....134 Valve Clearance ....... 90 STORAGE........... 140 Kawasaki Clean Air System ..... 90 ENVIRONMENTAL PROTECTION..143 Air Cleaner ........91 LABEL INFORMATION ...... 144...
  • Page 10: Specifications

    SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 16 kW (22 PS) @7 500 r/min (rpm) Maximum Torque 20.5 N·m (2.09 kg·m, 15.1 ft·lb) @7 000 r/min (rpm) Minimum Turning Radius 2.4 m (94.5 in.) DIMENSIONS Overall Length 2 200 mm (86.62 in.) Overall Width 820 mm (32.28 in.) Overall Height...
  • Page 11 SPECIFICATIONS Compression Ratio 11.0 : 1 Electric starter Starting System Fuel System FI (Fuel Injection) Ignition System 10° BTDC @1 300 r/min (rpm) ∼ 34° BTDC @11 000 Ignition Timing (Electronically advanced) r/min (rpm) Spark Plugs NGK CR8E Lubrication System Forced lubrication (wet sump) Engine Oil Type:...
  • Page 12 SPECIFICATIONS Primary Reduction Ratio 2.800 (84/30) Final Reduction Ratio 3.000 (42/14) Overall Drive Ratio 8.000 (Top gear) Gear Ratio 3.000 (30/10) 2.000 (30/15) 1.500 (27/18) 1.250 (25/20) 1.050 (21/20) 0.952 (20/21) FRAME Caster 26.5° Trail 105 mm (3.31 in.) Tire Size: Front 3.00-21 51P Rear...
  • Page 13 SPECIFICATIONS Rim Size: Front J21 × 1.60 Rear J18 × 2.15 Fuel Tank Capacity 7.7 L (2.04 US gal) ELECTRICAL EQUIPMENT Battery 12 V 6 Ah (10 HR) Headlight 12 V 60/55 W Brake/Tail Light 12 V 21/5 W 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 5. Left Handlebar Switches 2. Meter Instruments 6. Ignition Switch/Steering Lock 3. Brake Fluid Reservoir (Front) 7. Right Handlebar Switches 4. Front Brake Lever 8. Throttle Grip...
  • Page 15 LOCATION OF PARTS 9. Front Fork 16. Tool Kit 23. Side Stand 10. Headlight 17. Helmet Hook 24. Side Stand Switch 11. Turn Signal Light 18. Brake Disc 25. Drive Chain 12. Fuel Tank Cap 19. Brake Caliper 26. Coolant Reserve Tank 13.
  • Page 16 LOCATION OF PARTS 28. Tail/Brake Light 34. Radiator Cap 38. Rear Brake Pedal 29. Muffler 35. Brake Fluid Reservoir 39. Speedometer Lead 30. Seat (Rear) 31. Air Cleaner Element 36. Rear Brake Light 32. Idle Adjusting Screw Switch 33. Front Brake Light 37.
  • Page 17: Location Of Labels

    If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct posi- tion. 1. Brake Fluid (Front) NOTE ○...
  • Page 18 LOCATION OF LABELS 2. Important Drive Chain Information 3. Tire and Load Data 4. Brake Fluid (Rear) (For further information of label, refer to the “LABEL INFORMATION” chapter.)
  • Page 19 LOCATION OF LABELS 5. Unleaded Gasoline 6. Battery Poison/Danger 7. Radiator Cap Danger (For further information of label, refer to the “LABEL INFORMATION” chapter.)
  • Page 20: Loading Information

    Kawasaki Parts Accessories, Kawasaki has no control over the Because a motorcycle is sensitive to design or application of accessories. changes in weight and aerodynamic In some cases, improper installation forces, you must take extreme care or use of accessories, or motorcycle in carrying cargo, passengers and/or in the fitting of additional accessories.
  • Page 21 LOADING INFORMATION been prepared to assist you in making on the motorcycle center of gravity. your determinations. Baggage weight should also be dis- tributed equally on both sides of the 1. Any passenger should be thor- motorcycle. Avoid carrying baggage oughly familiar with motorcycle op- that extends beyond the rear of the motorcycle.
  • Page 22 LOADING 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, torcycles and cannot predict the ef-...
  • Page 23: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. MODE Button B. RESET Button C. Tachometer D. Odometer/Trip Meter AB/Fuel Warning Message E. Speedometer F. Clock G. Coolant Temperature Warning Indicator Light H. High Beam Indicator Light I. Neutral Indicator Light J. Turn Signal Indicator Light K.
  • Page 24: Meter Instruments

    NOTICE an authorized Kawasaki dealer. Engine r/min (rpm) should not Tachometer: be allowed to enter the red zone; The tachometer shows the engine...
  • Page 25: Speedometer

    GENERAL INFORMATION NOTE Speedometer : ○ The speedometer shows the speed Do not shift the odometer/trip meter of the vehicle in digital values. while riding for safe operation. Odometer/Trip Meter AB/Fuel Warning Message (ODO/TRIP Odometer - AB): The odometer shows the total dis- This meter displays the odometer, tance in kilometers or miles that the ve- the trip meter AB, and the fuel warning...
  • Page 26 GENERAL INFORMATION Trip Meters A/B - riding, the meter resets to 0.0 and The trip meter shows the distance in continues counting. ○ kilometers or miles traveled since it was When the battery is disconnected, last reset to zero. the trip meter resets to 0.0. To reset the trip meter: •...
  • Page 27 GENERAL INFORMATION NOTE Mile/Km Display: ○ Mile/Km Display can alternate be- Do not operate the vehicle with tween English and metric modes (mph the meter unit displaying in the and km/h) in the meter unit. Make sure wrong unit (km/h or mph). Shift that km/h or mph according to local the km/h·mph display in the meter...
  • Page 28 GENERAL INFORMATION • A. Km/h Push the RESET button. The hour B. Mph display only blinks. Push the MODE C. Push RESET Button with MODE Button in button to advance the hours. NOTE ○ The data is maintained even if the battery is disconnected.
  • Page 29: Indicator/warning Light

    GENERAL INFORMATION ○ When the battery is disconnected, the clock resets to 1:00 and starts working again when the battery is connected. Indicator/Warning Light: • Push the RESET button. Both the N : When the transmission is in neutral, hour and minute displays start blink- the neutral indicator light is lit.
  • Page 30: Warning/indicator Lights

    (0.6 US gal) of usable fuel remains. Re- have the DFI system checked by an au- fuel at the earliest opportunity when the thorized Kawasaki dealer, fuel level warning indicator light goes When the warning indicator light blinks, on and “FUEL” blinks.
  • Page 31: Key

    Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a master.
  • Page 32: Ignition Switch/steering Lock

    GENERAL INFORMATION Ignition Switch/Steering Lock Engine on. All electrical This is a three-position, key-operated equipment can be used. switch. The key can be removed from Engine off. All electrical the switch when it is in the OFF or circuits off. LOCK position.
  • Page 33: Right Handlebar Switches

    GENERAL INFORMATION NOTE Right Handlebar Switches ○ Engine Stop Switch: If the steering is hard to lock, turn the In addition to the ignition switch, the handlebar slightly to the left or the right. engine stop switch must be in the position for the motorcycle to operate.
  • Page 34: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches Dimmer Switch: High or low beam can be selected with the dimmer switch. When the headlight is on high beam , the high beam indicator light is lit. High beam..( Low beam..( NOTE ○ A. Engine Stop Switch Do not allow anything to cover the B.
  • Page 35: Turn Signal Switch

    GENERAL INFORMATION Horn Button: When the horn button is pushed, the horn sounds. A. Dimmer Switch B. Turn Signal Switch C. Horn Button Turn Signal Switch: When the turn signal switch is turned to the left or right , the corre- sponding turn signals blink on and off.
  • Page 36: Fuel Tank Cap

    GENERAL INFORMATION Fuel Tank Cap NOTE ○ To open the fuel tank cap, insert the The fuel tank cap cannot be closed ignition key into the fuel tank cap, turn without the key inserted, and the key the key to the right. cannot be removed unless the cap is To close the cap, push it down into locked properly.
  • Page 37: Fuel

    (For further infor- by Kawasaki to prevent severe engine mation, refer to the “Catalytic damage. Converter” section in the “How The octane rating of a gasoline is a to Ride the Motorcycle”...
  • Page 38 GENERAL INFORMATION NOTICE equal to or higher than that shown in the table. If engine “knocking" or “ping- ing" occurs, use a different Fuel Type Unleaded Gasoline brand of gasoline of a higher Ethanol octane rating. If this condition is E10 or less Content allowed to continue, it can lead...
  • Page 39: Filling The Tank

    GENERAL INFORMATION *E10 means fuel containing up to WARNING 10% ethanol as specified by European Gasoline is extremely flammable directive. and can be explosive under cer- Filling the Tank: tain conditions, creating the po- Avoid filling the tank in the rain or tential for serious burns.
  • Page 40: Stand

    GENERAL INFORMATION NOTICE Stand The motorcycle is equipped with a Certain ingredients in gasoline side stand. may cause paint fading or dam- age. Be extra careful not to spill fuel during refueling. A. Side Stand NOTE ○ When using the side stand, turn the handlebar to the left.
  • Page 41: Helmet Hook

    GENERAL INFORMATION NOTE Helmet Hook ○ Helmet can be secured to the motor- The motorcycle is equipped with a cycle using the helmet hook. side stand switch. This switch is de- The helmet hook can be unlocked by signed so that the engine dose not inserting the ignition key into the lock, start if the transmission is in gear and and turning the key to the right.
  • Page 42: Tool Kit Bag/tool Kit

    GENERAL INFORMATION Tool Kit Bag/Tool Kit WARNING The tool kit is stored in the tool kit Riding with a helmet attached to bag. the hook could cause an acci- The kit contains tools that can be dent by distracting the operator helpful in making roadside repairs, ad- or interfering with normal vehi- justments, and some maintenance pro-...
  • Page 43: Seat

    GENERAL INFORMATION • Seat Remove the seat band and pull the seat up and to the rear. Seat Removal • Remove the mounting bolts. A. Bolt B. Seat A. Seat C. Tandem Band B. Mounting Bolts Seat Installation • Align the front hook with the front re- ceiver and slide the seat forward.
  • Page 44: Rear View Mirror

    GENERAL INFORMATION • Rear View Mirror Slide the seat forward so that the center hook and the center receiver Rear View Mirror Adjustment engages. • Adjust the rear view mirror by slightly moving only the mirror portion of the assembly. A.
  • Page 45: 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 46 During break-in, avoid sudden and maximum braking and acceleration, 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 47: 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. A. Neutral Indicator Light B. Ignition Switch C. ON position NOTE A. Engine Stop Switch ○ The motorcycle is equipped with a B.
  • Page 48 HOW TO RIDE THE MOTORCYCLE the ignition key to “OFF” and then designed so that the engine does not back to “ON” before starting the en- start if the transmission is in gear and gine. the side stand is down. However, the engine can be started if the clutch •...
  • Page 49: Jump Starting

    HOW TO RIDE THE MOTORCYCLE NOTICE Jump Starting If your motorcycle battery is "run Do not let the engine idle longer down", it should be removed and than five minutes, or engine charged. If this is not practical, a 12 overheating and damage may volt booster battery and jumper cables occur.
  • Page 50 HOW TO RIDE THE MOTORCYCLE • DANGER Connect a jumper cable from the positive (+) terminal of the booster Battery acid generates hydro- battery to the positive (+) terminal of gen gas which is flammable and the motorcycle battery. explosive under certain con- ditions.
  • Page 51 HOW TO RIDE THE MOTORCYCLE • Connect another jumper cable from DANGER the negative (–) terminal of the Batteries contain sulfuric acid booster battery to your motorcy- that can cause burns and pro- cle foot peg or other unpainted metal duce hydrogen gas which is surface.
  • Page 52: Moving Off

    HOW TO RIDE THE MOTORCYCLE NOTICE Moving Off • Check that the side stand is up. Do not operate the starter con- • Pull in the clutch lever. tinuously for more than 5 sec- • Shift into 1st gear. onds or the starter will overheat •...
  • Page 53: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE NOTE Shifting Gears • ○ Close the throttle while pulling in the The motorcycle is equipped with a clutch lever. side stand switch. This switch is de- • Shift into the next higher or lower signed so that the engine does not gear.
  • Page 54: Braking

    HOW TO RIDE THE MOTORCYCLE • Braking For emergency braking, disregard • Close the throttle completely, leav- downshifting, and concentrate on ing the clutch engaged (except when applying the brakes as hard as pos- shifting gears) so that the engine will sible without skidding.
  • Page 55: Stopping The Engine

    HOW TO RIDE THE MOTORCYCLE Stopping the Engine • Close the throttle completely. • Shift the transmission into neutral. • Turn the ignition key to "OFF". • Support the motorcycle on a firm level surface with the side stand. • Lock the steering.
  • Page 56: Stopping The Motorcycle In An Emergency

    Stopping the Motorcycle in an 2. During removal of the air cleaner, Emergency dirt is allowed to enter and jam the Your Kawasaki Motorcycle has been fuel injection system. designed and manufactured to pro- vide you optimum safety and conve- In an emergency situation such as nience.
  • Page 57: Parking

    HOW TO RIDE THE MOTORCYCLE Parking WARNING The engine and exhaust system WARNING get extremely hot during normal Operating or parking the vehi- operation and can cause serious cle near flammable materials can burns. Never touch a hot engine, cause a fire, and can result in exhaust pipe, or muffler during property damage or severe per- operation or after stopping the...
  • Page 58: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE Catalytic Converter any source of flame or sparks; this includes any appliance with a pilot This motorcycle is equipped with a light. catalytic converter in the exhaust sys- tem. The converter reacts with car- bon monoxide, hydrocarbons and nitro- WARNING gen oxides to convert them into carbon Gasoline is extremely flammable...
  • Page 59 HOW TO RIDE THE MOTORCYCLE • WARNING Use only unleaded gasoline. Never use leaded gasoline. Leaded gaso- Operating or parking the vehi- line significantly reduces the capabil- cle near flammable materials can ity of the catalytic converter. cause a fire, and can result in •...
  • Page 60: 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. feet on the footpegs. Removing For safety, eye protection and a your hands from the handlebars or helmet are strongly recommended.
  • Page 61 SAFE OPERATION braking or turning may cause loss In wet conditions, rely more on the of control, especially when riding in throttle to control vehicle speed and wet conditions or on loose roadway less on the front and rear brakes. surfaces, when the ability to maneu- The throttle should also be used ju- ver will be reduced.
  • Page 62 SAFE OPERATION Do not downshift at too high an Avoiding unnecessary weaving is r/min (rpm) to avoid damage to the important to the safety of both the engine from overrevving. rider and other motorists.
  • Page 63: 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 64 SAFE OPERATION Tires ......Air pressure (when cold): Front – – – 150 kPa (1.50 kgf/cm², 22 psi) Up to 97.5 kg (215 lb) Rear 150 kPa (1.50 kgf/cm², 22 psi) Load 97.5 ∼ 181 kg (215 ∼ 175 kPa (1.75 kgf/cm², 25 psi) 399 lb) Load Install the air valve cap.
  • Page 65 SAFE OPERATION Electrical equipment ... All lights (Head, Tail/Brake, Turn Signal, Warning/Indica- tor) and horn work. Engine stop switch ..Stops engine. Side stands ....Return to its fully up position by spring tension. Return springs not weak or not damaged.
  • Page 66: Additional Considerations For Off Road Operation

    SAFE OPERATION Additional Considerations for Off Road Operation Brakes: The importance of reliable brakes is obvious. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play.
  • Page 67: 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 68: 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 69 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Throttle control system • • • • year (play, smooth return, no drag) - inspect •...
  • Page 70 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • • Radiator hose damage year - inspect Radiator hoses • •...
  • Page 71 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Clutch and drive train: Clutch operation • •...
  • Page 72 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Wheels and tires: • • • Tire air pressure - year inspect • •...
  • Page 73 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Brake system: • • • • • • • Brake fluid leak - year inspect •...
  • Page 74 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • • • • • Brake light switch operation - inspect Suspensions: Front forks/rear shock •...
  • Page 75 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • Uni-trak tie rods – operation - inspect • Uni-trak tie rods –...
  • Page 76 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • Headlight aiming - year inspect • • • Side stand switch year –...
  • Page 77 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Change/Replacement Item Every (0.6) (7.5) (15) (22.5) (30) Air cleaner element # - replace 2 year • • • • •...
  • Page 78 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Every Change/Replacement Item (0.6) (7.5) (15) (22.5) (30) • Rubber parts of master cylinder – 4 years and caliper - replace • • •...
  • Page 79: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • In order for the engine, transmission, Situate the motorcycle so that it is and clutch to function properly, main- perpendicular to the ground. • tain the engine oil at the proper level, If the oil has just been changed, start and change the oil and oil filter in accor- the engine and run it for several min-...
  • Page 80 MAINTENANCE AND ADJUSTMENT • upper and lower level lines next to If the oil level is too high, remove the the oil level inspection window. excess oil through the oil filler open- ing using a syringe or same other suitable device. •...
  • Page 81 MAINTENANCE AND ADJUSTMENT • Oil and/or Oil Filter Change Let the oil completely drain with • Warm up the engine thoroughly, and the motorcycle perpendicular to the then stop it. ground. • Set the motorcycle up on its side stand. WARNING •...
  • Page 82 MAINTENANCE AND ADJUSTMENT • • If the oil filter is to be changed, re- Replace the element with a new one. move the oil filter cover bolts and take off the cover with O-ring. A. Element B. Grommet • A. Bolts Apply a little grease around the ele- B.
  • Page 83 15 N·m (1.5 kgf·m, 11 ft·lb) NOTE A. Holes ○ If a torque wrench is not available, • After the oil has completely drained this item should be serviced by a out, install the engine oil drain plug Kawasaki dealer.
  • Page 84 MAINTENANCE AND ADJUSTMENT Although 10W-40 engine oil is the Recommended Engine Oil recommended oil for most condi- Type: API SG, SH, SJ, SL or SM tions, the oil viscosity may need to with JASO MA, MA1 or MA2 be changed to accommodate atmo- Viscosity: SAE 10W-40 spheric conditions in your riding area.
  • Page 85: Cooling System

    MAINTENANCE AND ADJUSTMENT NOTICE Cooling System Radiator and Cooling Fan - Using high-pressure water, as Check the radiator fins for obstruc- from a car wash facility, could tion by insects or mud. Clean off damage the radiator fins and im- any obstructions with a stream of pair the radiator’s effectiveness.
  • Page 86 MAINTENANCE AND ADJUSTMENT Coolant - period of time, the cooling system ac- Coolant absorbs excessive heat from cumulates rust and scale in the water the engine and transfers it to the air jacket and radiator. This will clog up at the radiator. If the coolant level be- the coolant passages, and consider- comes low, the engine overheats and ably reduce the efficiency of the cooling...
  • Page 87 MAINTENANCE AND ADJUSTMENT NOTICE NOTICE If hard water is used in the sys- Permanent types of antifreeze on tem, it causes scale accumula- the market have anti-corrosion tion in the water passages, and and anti-rust properties. When it considerably reduces the effi- is diluted excessively, it loses its ciency of the cooling system.
  • Page 88 MAINTENANCE AND ADJUSTMENT • should be between the F(FULL) and If the amount of coolant is insuffi- L(LOW) level lines. cient, after removing the left side cover, unscrew the cap from the re- NOTE serve tank and add coolant through ○...
  • Page 89: Spark Plugs

    Have inspection, and resetting of the plug the cooling system inspected gap. by your authorized Kawasaki dealer. Maintenance If the plug is oily or has carbon built up on it, clean it. The plug may also...
  • Page 90 ○ If a torque wrench is not available, Standard Plug NGK CR8E this item should be serviced by a 0.7 ∼ 0.8 mm Plug Gap Kawasaki dealer. (0.028 ∼ 0.031 in.) Tightening 13 N·m NOTICE Torque (1.3 kgf·m, 115 in·lb)
  • Page 91: Valve Clearance

    The air suction valve is essentially a Inspection and adjustment should check valve which allows fresh air to be done by an authorized Kawasaki flow only from the air cleaner into the dealer. exhaust port. Any air that has passed the air suction valve is prevented from returning.
  • Page 92: Air Cleaner

    Air suction valve removal and inspec- cleaned in accordance with the Peri- tion should be carried out by an autho- odic Maintenance Chart. In dusty ar- rized Kawasaki dealer. eas, the element should be cleaned more frequently than the recom- mended interval. After riding through rain or on muddy roads, the element should be cleaned immediately.
  • Page 93 MAINTENANCE AND ADJUSTMENT • Element Removal Remove the wing bolt, and take out • Remove the seat. the element. • Unscrew the air cleaner intake cap bolts and remove the air cleaner in- take cap. A. Element B. Wing Bolt A.
  • Page 94 MAINTENANCE AND ADJUSTMENT • Remove the element from the frame. damaged, the element must be re- placed. WARNING If dirt or dust is allowed to pass through into the fuel injection system, the throttle may stick or become inoperable resulting in a hazardous operating condition.
  • Page 95 MAINTENANCE AND ADJUSTMENT NOTE Element Cleaning • ○ Clean the element in a bath of a high Element installation is performed in flash-point solvent. the reverse order of removal. ○ When installing the element, coat the lip of the element with a thick layer of all purpose grease to assure a com- plete seal against the air cleaner el- ement base.
  • Page 96 MAINTENANCE AND ADJUSTMENT • Squeeze it dry in a clean towel. Do WARNING not wring the element or blow it dry; Gasoline and low flash-point sol- the element can be damaged. vents are extremely flammable • After cleaning, saturate the element and may explode, causing se- with a high-quality foam-air-filter oil, vere burns.
  • Page 97 MAINTENANCE AND ADJUSTMENT • WARNING Inspect the transparent reservoir lo- cated under the rear shock absorber Oil on tires will make them slip- to see if any oil has run down from pery and can cause an accident the air cleaner housing. any injury.
  • Page 98: Throttle Grip

    MAINTENANCE AND ADJUSTMENT Throttle Grip Inspection • Check that there is 2 ∼ 3 mm (0.08 The throttle grip controls the throttle ∼ 0.12 in.) throttle grip play when valves. If the throttle grip has exces- sive play due to either cable stretch or lightly turning the throttle grip back maladjustment, it will cause a delay in and forth.
  • Page 99 MAINTENANCE AND ADJUSTMENT • of the throttle cable. Turn both ad- Turn out the accelerator cable ad- juster until a play of 2 ∼ 3 mm (0.08 juster in completely so as to give the ∼ 0.12 in.) is obtained at the throttle throttle grip plenty of play.
  • Page 100: Idle Speed

    MAINTENANCE AND ADJUSTMENT Idle Speed Adjustment • The idle speed adjustment should be Start the engine, and warm it up thor- performed in accordance with the Pe- oughly. • Adjust the idle speed to 1 250 ∼ 1 riodic Maintenance Chart or whenever idle speed is disturbed.
  • Page 101: Clutch

    Inspection • Check that the clutch lever operates properly and that the inner cable slides smoothly. If there is any irreg- ularity, have the clutch cable checked by an authorized Kawasaki dealer.
  • Page 102 MAINTENANCE AND ADJUSTMENT • Side the dust cover. If the play is incorrect, adjust the lever • Check the clutch lever play as shown play as follows. in the figure. Adjustment • Clutch Lever Play Slide the dust cover at the clutch 2 ∼...
  • Page 103 Tighten the locknut. • Do not run the engine in en- Slide the dust cover back into place. • closed areas. Operate only in a If it cannot be done, have the clutch well-ventilated area. cable adjusted by an authorized Kawasaki dealer.
  • Page 104: Drive Chain

    MAINTENANCE AND ADJUSTMENT Drive Chain Chain Slack Inspection • The drive chain slack and lubrica- Set the motorcycle up on its side tion must be checked each day be- stand. • fore riding the motorcycle, and in accor- Rotate the rear wheel to find the po- dance with the Periodic Maintenance sition where the chain is tightest and Chart for safety and to prevent exces-...
  • Page 105 MAINTENANCE AND ADJUSTMENT • • If the drive chain is too tight or too Loosen the left and right chain ad- loose, adjust it so that the chain slack juster locknuts. will be within the standard value. Drive Chain Slack 35 ∼...
  • Page 106 MAINTENANCE AND ADJUSTMENT • NOTE Turn in the left and right chain ad- ○ justers evenly to obtain the standard Wheel alignment also chain slack. To keep the chain and checked using the straightedge or wheel properly aligned, the notch on string method.
  • Page 107 Check the rear brake (see the Brakes ○ section). If a torque wrench is not available, this item should be serviced by a Kawasaki dealer. WARNING • Rotate the wheel, measure the chain A loose axle nut can lead to an...
  • Page 108 It is an endless type and the chain should be replaced. should not be cut for installa- tion; have it installed by an au- thorized Kawasaki dealer. • Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links.
  • Page 109 Wipe off any excess lubricant. 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 110: 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. • Wipe off any lubricant that gets on the tire surface.
  • Page 111 MAINTENANCE AND ADJUSTMENT NOTICE Brake Fluid - In accordance with the Periodic Main- Do not spill brake fluid onto any tenance Chart, inspect the brake fluid painted surface. level in both the front and rear brake Do not use fluid from a container fluid reservoir and change the brake that has been left open or that fluid.
  • Page 112 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 must be kept between the upper and lower level lines (reser- voirs held horizontal).
  • Page 113 Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. A. Front Brake Fluid Reservoir Front and Rear Brakes - B. Upper Level Line Disc and disc pad wear is automat- ically compensated for and has no ef- fect on the brake lever or pedal action.
  • Page 114: Brake Light Switches

    • be defective. Have the brake If it does not, ask your authorized checked immediately by an au- Kawasaki dealer to inspect the front thorized Kawasaki dealer. brake light switch.
  • Page 115 MAINTENANCE AND ADJUSTMENT • Check the operation of the rear brake Adjustment • light switch by depressing the brake To adjust the rear brake light switch, pedal. The brake light should go on move the switch up or down by turn- after about 10 mm (0.4 in.) of pedal ing the adjusting nut.
  • Page 116: Front Fork

    MAINTENANCE AND ADJUSTMENT NOTICE Front Fork The front fork operation and oil leak- To avoid damaging the electrical age should be checked in accordance connections inside the switch, with the Periodic Maintenance Chart. be sure that the switch body After riding through muddy or dusty does not turn during adjustment.
  • Page 117 If any doubt about the front fork, it as the fork heats up, so the fork action should be done by an authorized will get stiffer as the vehicle operation Kawasaki dealer. progresses. Compression Damping Adjustment • Using the jack under the frame, sta- bilize the motorcycle.
  • Page 118 MAINTENANCE AND ADJUSTMENT • To adjust compression damping, turn WARNING the adjuster on the front fork cylinder If both damping force adjusters valve with the blade of a screwdriver are not adjusted equally, han- until you feel a click. Adjust the com- dling may be impaired and a pression damping to suit your prefer- hazardous condition may result.
  • Page 119: Rear Shock Absorber

    If any doubt about the rear shock ab- should be cleaned immediately. sorber, it should be done by an au- thorized Kawasaki dealer. NOTICE Sticking muds or dusts on the sliding surface of the rear shock absorber could damage to the oil seal, leading to an oil leak.
  • Page 120 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjustment Compression Damping Adjustment To adjust shock rebound damping, To adjust compression damping, turn turn the rebound damping adjuster on the compression damping adjuster on the rear shock absorber lower end with the gas reservoir with the blade of a the blade of a screwdriver until you feel screwdriver until you feel a click.
  • Page 121: Wheels

    Spring Preload Adjustment The rear shock absorber can be ad- justed by changing the spring preload for various riding and loading condi- tions. If the spring action feels too soft or too stiff, have it adjusted by an au- thorized Kawasaki dealer.
  • Page 122 MAINTENANCE AND ADJUSTMENT • NOTE Remove the air valve cap. • ○ Check the tire pressure often, using Measure the tire pressure when the an accurate gauge. tires are cold (that is, when the mo- • Make sure to install the air valve cap torcycle has not been ridden more securely installed.
  • Page 123 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 that 90% of all tire failures occur during has worn down to the minimum al-...
  • Page 124 MAINTENANCE AND ADJUSTMENT • Visually inspect the tire for cracks WARNING and cuts, replacing the tire in case of Tires that have been punctured bad damage. Swelling or high spots and repaired do not have the indicate internal damage, requiring same capabilities as undam- tire replacement.
  • Page 125 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. Standard Tire A break-in period of 160 km (100 miles) is necessary to estab- Front Size: 3.00-21 51P lish normal tire traction.
  • Page 126: Battery

    MAINTENANCE AND ADJUSTMENT Battery Due to their internal composition, The battery installed in this motorcy- batteries continually self discharge. cle is a sealed type, so it is not nec- The discharge rate depends on the essary to check the battery electrolyte type of battery and ambient temper- level or add distilled water.
  • Page 127 MAINTENANCE AND ADJUSTMENT Self-discharge Current Drain Approx. Number of Days Days from Days from From 100% Charged to 100% 100% Discharging 100% discharged charged charged Ampere Temperature to 50% to 100% Lead Lead Discharged Discharged -Antimony -Calcium 7 mA 60 Days 119 Days Battery Battery...
  • Page 128 A common cause of battery failure is charged using an appropriate charger sulfation. (check with your Kawasaki dealer). Sulfation occurs when the battery is If you will not be using the motorcy- left in a discharged condition for an ex-...
  • Page 129 If the above chargers are not avail- the rate, charge the battery at an am- able, use equivalent one. perage that is about 1/10th of the bat- For more details, ask your Kawasaki tery capacity. dealer. • The charger will keep the battery fully...
  • Page 130 MAINTENANCE AND ADJUSTMENT Make Furukawa Battery Type FTX7L-BS NOTE ○ If you charge the sealed battery, never fail to observe the instructions shown in the label on the battery. Battery Removal • Remove the left side cover. A. (–) Terminal •...
  • Page 131: Headlight Beam

    MAINTENANCE AND ADJUSTMENT Headlight Beam Battery Installation • Put the battery in the battery case. Horizontal Adjustment • Connect the capped cable to the (+) The headlight beam is adjustable terminal, and then connect the black horizontally. If not properly adjusted cable to the (–) terminal.
  • Page 132 MAINTENANCE AND ADJUSTMENT NOTE Vertical Adjustment ○ The headlight beam is adjustable ver- On high beam, the brightest point tically. If adjusted too low, neither low should be slightly below horizontal nor high beam will illuminate the road with the motorcycle on its wheels and far enough ahead.
  • Page 133: Fuses

    MAINTENANCE AND ADJUSTMENT Fuses WARNING The main fuse is mounted on the Substituting fuses can cause starter relay located under the seat. wiring to overheat, catch fire The fuse case is located under the and/or fail. Do not use any sub- seat.
  • Page 134: General Lubrication

    MAINTENANCE AND ADJUSTMENT General Lubrication Apply motor oil to the following Lubricate the points shown below, pivots - • with either motor oil or regular grease, Side Stand • in accordance with the Periodic Main- Clutch Lever • tenance Chart or whenever the vehicle Front Brake Lever •...
  • Page 135: Cleaning Your Motorcycle

    (K) Clutch Inner Cable Upper End Frequent and proper care of your • (K) Throttle Inner Cable Upper Ends Kawasaki motorcycle will enhance its appearance, optimize overall per- (K): Should be serviced by an authorized 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 MAINTENANCE AND ADJUSTMENT • • Avoid spraying water in delicate Use a soft cloth to dry your motorcy- areas such as in air intakes, fuel cle. As you dry, inspect your motor- system, brake components, electri- cycle for chips and scratches. Do not cal components, muffler outlets, and let the water air dry as this can dam- fuel tank openings.
  • Page 138 • The semi-gloss finish effect may be cleaner/polisher product. lost when the finish is excessively rubbed. • If any doubt, consult an authorized Kawasaki dealer.
  • Page 139 MAINTENANCE AND ADJUSTMENT NOTICE should be washed with a mild neu- tral detergent and finished with a spray Plastic parts may deteriorate polish. Aluminum wheels, both painted and brake if they come in con- and unpainted can be cleaned with tact with chemical substances special non-acid based wheel spray or household cleaning products...
  • Page 140 MAINTENANCE AND ADJUSTMENT WARNING Rubber protectants can be slip- pery and, if used on the tread area, cause loss of traction re- sulting in accident causing in- jury or death. Do not apply rub- ber protectant to any tread area.
  • Page 141: 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 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 STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. 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 includes any appliance with a pilot light.
  • Page 143 STORAGE • Set the motorcycle on a box or stand so that both wheels are raised off the ground. (If this cannot be done, put boards under the front and rear wheels to keep damp- ness away from the tire rubber.) •...
  • Page 144: 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 145: Label Information

    LABEL INFORMATION LABEL INFORMATION 1. Read Owner’s Manual 2. Drive chain slack, see page 103 3. Safety alert symbol...
  • Page 146 LABEL INFORMATION 1. Read Owner’s Manual 2. Tire Pressure, see page 121 3. Front tire size and manufacture, see page 124 4. Rear tire size and manufacture, see page 124 5. Maximum load, see page 121 6. Safety alert symbol 1.

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