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   Summary of Contents for Kawasaki w800

  • Page 2 ENGLISH Motorcycle Owner's Manual Original instructions...
  • Page 4 Whenever you see the symbols NOTE ○ shown below, heed their instructions! NOTE indicates information that may Always follow safe operating and main- help or guide you in the operation or tenance practices. service of the vehicle. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious in- jury.
  • Page 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- 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. Motorcycle & Engine Company © 2014 Kawasaki Heavy Industries, Ltd. Jun. 16, 2014. (1)
  • Page 9: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS ........ 10 Fuel Requirement: ......32 LOCATION OF PARTS ......13 Filling the Tank: ......34 LOADING INFORMATION ....16 Stands ..........35 GENERAL INFORMATION ....19 Seat ............ 37 Meter Instruments ......19 Helmet Hook/Holding Cable ....38 Speedometer and Tachometer ..
  • Page 10 ENVIRONMENTAL PROTECTION ..139 Engine Oil .......... 77 LOCATION OF LABELS ...... 140 Spark Plugs ........83 Kawasaki Clean Air System ....84 Valve Clearance ......... 85 Air Cleaner ......... 86 Throttle Control System ..... 90 Engine Vacuum Synchronization ..93 Idle Speed ..........
  • Page 11: Specifications

    SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 35 kW (48 PS) @6 500 r/min (rpm) 60 N·m (6.1 kgf·m, 44.3 ft·lb) @2 500 r/min (rpm) Maximum Torque Minimum Turning Radius 2.7 m (8.9 ft) DIMENSIONS Overall Length 2 190 mm (86.22 in.) Overall Width 790 mm (31.10 in.) Overall Height...
  • Page 12 SPECIFICATIONS Ignition System Battery and coil (transistorized ignition) Ignition Timing 0° BTDC @1 200 r/min (rpm) Spark Plug NGK CR8E Lubrication System Forced lubrication (wet sump) Engine Oil Type : API SG, SH, SJ, SL or SM with JASO MA, MA1 or Viscosity: SAE 10W-40 Capacity : 3.2 L (3.4 US qt) TRANSMISSION...
  • Page 13 SPECIFICATIONS Trail 108 mm (4.3 in.) Tire Size: Front 100/90-19M/C 57H Rear 130/80-18M/C 66H Rim Size: Front J19 × 2.15 Rear J18M/C × MT2.75 Fuel Tank Capacity 14 L (3.7 US gal) ELECTRICAL EQUIPMENT Battery 12 V 10 Ah (10 HR) Headlight High beam 12 V 60 W Low beam 12 V 55 W...
  • Page 14: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 6. Right Handlebar Switches 2. Left Handlebar Switches 7. Front Brake Lever 3. Starter Lockout Switch 8. Ignition Switch/Steering Lock 4. Meter Instruments 9. Throttle Grip 5. Brake Fluid Reservoir (Front)
  • Page 15 LOCATION OF PARTS 1. Front Fork 8. Seat Lock 15. Center Stand 2. Headlight 9. Helmet Hook 16. Side Stand 3. Turn Signal Lights 10. Grab Rail 17. Battery 4. Fuel Tank Cap 11. Tying Hook 18. Muffler 5. Idle Adjusting Screw 12.
  • Page 16 LOCATION OF PARTS 1. Helmet Holding Cable 7. Brake Lining Wear Indica- 11. Oil Drain Bolt 2. Tool Kit 12. Oil Filter 3. Air Cleaner Element 8. Rear Brake Light Switch 13. Horn 4. Seat 9. Oil Filler Cap 14. Brake Caliper 5.
  • Page 17: Loading Information

    Kawasaki Parts and Accessories ing condition. Before you ride the have been specially designed for motorcycle, make sure it is not use on Kawasaki motorcycles. We overloaded and that you have fol- strongly recommend that all parts lowed these instructions.
  • Page 18 LOADING INFORMATION been prepared to assist you in making Baggage weight should also be dis- your determinations. tributed equally on both sides of the Any passenger should be thor- motorcycle. Avoid carrying baggage oughly familiar with motorcycle op- that extends beyond the rear of the motorcycle.
  • Page 19 LOADING INFORMATION road clearance, banking capability vehicle. Kawasaki does not manu- (i.e., lean angle), control operation, facture sidecars or trailers for mo- wheel travel, front fork movement, torcycles and cannot predict the or any other aspect of the motorcy- effects of such accessories on han- dling or stability, but can only warn cle's operation.
  • Page 20: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Speedometer B. MODE Button C. RESET Button D. Tachometer E. Red Zone F. FI Warning Indicator Light G. Oil Pressure Warning Indi- cator Light H. Right Turn Signal Indicator Light I. Fuel Level Warning Indicator Light J.
  • Page 21: Speedometer And Tachometer

    This checks the operation of the meter needles. So if they do not operate cor- rectly, have the function checked by an authorized Kawasaki dealer. The tachometer shows the engine speed in the revolutions per minute (r/ min, rpm). On the right side of the tach- ometer face is a portion called the “red...
  • Page 22: Lcd (clock, Odometer, Trip Meter)

    GENERAL INFORMATION LCD (Clock, Odometer, Trip Meter) The LCD (Liquid Crystal Display) lo- cated in the speedometer face is used to display the Clock, Odometer and Trip Meter. Pushing the MODE button shifts the display through the following three modes: CLOCK, ODO, and TRIP. When the ignition switch is turned to “ON”, all the LCD segments are dis- played for three seconds, then the...
  • Page 23 GENERAL INFORMATION • • Push the RESET button for more Push the RESET button. The hour than two seconds. Both the hour and display stops blinking and the minute minute displays start blinking. display starts blinking. Push the MODE button to advance the mi- nutes.
  • Page 24 GENERAL INFORMATION the button advance the hour or mi- NOTE ○ nute continuously. The data is maintained even if the ○ The clock works normally from the battery is disconnected. ○ back-up power while the ignition When the figures come to 999999, switch is turned off.
  • Page 25: Warning/indicator Lights

    GENERAL INFORMATION NOTE ○ The data is maintained even if the battery is disconnected. ○ When the trip meter reaches 9999.9 while running, the meter reset to 0.0 and continues counting. Warning/Indicator Lights : The oil pressure warning indica- tor light goes on whenever the oil pres- sure is dangerously low or the ignition switch is in the ON position with the en- gine not running, and goes off when...
  • Page 26 DFI system checked by an author- light goes on and “FUEL” blinks. ized Kawasaki dealer. When vehicle stands with side stand, fuel level warning indicator light cannot show the amount of fuel in the fuel tank exactly.
  • Page 27: Key

    GENERAL INFORMATION Ignition Switch/Steering Lock This motorcycle has a combination This is a four-position, key-operated key, which is used for the ignition switch. The key can be removed from switch/steering lock, seat lock, helmet the switch when it is in the OFF, LOCK hook and fuel tank cap.
  • Page 28 GENERAL INFORMATION Engine off. Electrical circuits off. Engine on. All electrical equip- ment can be used. Steering locked. Engine off. LOCK Electrical circuits off. Steering locked. Engine off. Tail P (Park) and city lights on. Other electri- cal circuits cut off. NOTE ○...
  • Page 29: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches NOTE ○ Engine Stop Switch: Although the engine stop switch In addition to the ignition switch, the stops the engine, it does not turn off engine stop switch must all the electrical circuits. Ordinarily, position for the motorcycle to the ignition switch should be used to operate.
  • Page 30: Starter Button

    GENERAL INFORMATION Starter Button: Left Handlebar Switches The starter button operates the elec- Dimmer Switch: tric starter when the transmission is in High or low beam can be selected neutral. with the dimmer switch. When the Refer to the Starting the Engine sec- headlight is on high beam ( ), the tion of the "How to Ride the Motor-...
  • Page 31: Turn Signal Switch

    GENERAL INFORMATION NOTE Brake/Clutch Lever Adjuster ○ There are adjusters on both the Do not allow anything to cover the brake and clutch levers. The brake lev- headlight lens when the headlight is er adjuster has 4 positions and the on.
  • Page 32: Fuel Tank Cap

    GENERAL INFORMATION Fuel Tank Cap To open the fuel tank cap, insert the ignition key into the fuel tank cap and turn the key clockwise while pushing down the fuel tank cap. To close the cap, push it down into place with the key inserted.
  • Page 33: Fuel

    Fuel ○ Fuel Requirement: Do not push on the key to close the Your Kawasaki engine is designed to cap, or the cap cannot be locked. use only unleaded gasoline with a min- imum octane rating shown below. Never use gasoline with an octane rat-...
  • Page 34 GENERAL INFORMATION equal to or higher than that shown in NOTICE the table. If engine “knocking" or “pinging" Fuel Type Unleaded Gasoline occurs, use a different brand of gasoline of a higher octane rat- Ethanol Content E10 or less ing. If this condition is allowed to Research Octane Num- Minimum continue, it can lead to severe en-...
  • Page 35: Filling The Tank

    GENERAL INFORMATION Filling the Tank: WARNING Avoid filling the tank in the rain or where heavy dust is blowing so that Gasoline is extremely flammable the fuel does not get contaminated. and can be explosive under cer- tain conditions, creating the po- tential for serious burns.
  • Page 36: Stands

    GENERAL INFORMATION Stands NOTICE The motorcycle is equipped with two Certain ingredients in gasoline stands: a center stand and a side may cause paint fading or dam- stand. age. Be extra careful not to spill fuel during refueling. A. Side Stand NOTE ○...
  • Page 37 GENERAL INFORMATION Do not sit on the motorcycle while it To set the motorcycle up on the cen- is on its side stand or centre stand. Al- ter stand, step down firmly on the ways kick the stand fully up before sit- stand, and then lift the motorcycle up ting on the motorcycle.
  • Page 38: Seat

    GENERAL INFORMATION Seat Installation Seat • Insert the tab on the front of the seat Seat Removal • into the hole on the frame, and the Remove the seat by inserting the projections on the middle of the seat ignition key into the seat lock and into the hole in the frame.
  • Page 39: Helmet Hook/holding Cable

    GENERAL INFORMATION • Pull up the front and rear end of the Helmet Hook/Holding Cable seat to make sure they are securely Helmets can be secured to the mo- locked. torcycle using the helmet hook located at the left side of the motorcycle or the helmet holding cable located under the seat.
  • Page 40 GENERAL INFORMATION Helmet Holding Cable - WARNING Helmet can be secured to the motor- cycle using the helmet holding cable. Riding with helmets attached to Securely hook the helmet ring with the the hooks could cause an acci- helmet holding cable and install the dent by distracting the operator seat.
  • Page 41: Tool Kit

    GENERAL INFORMATION Tool Kit Document Compartment The tool kit is located under the seat. The document compartment is pro- The kit contains tools that are helpful vided at the rear under the seat. Use in making roadside repairs, adjust- the compartment to keep the owner's ments, and some maintenance proce- manual and any papers or documents dures explained in this manual.
  • Page 42: Tying Hooks

    GENERAL INFORMATION Tying Hooks Rear View Mirror When tying up light loads to the seat, Rear View Mirror Adjustment • use the tying hooks located on the left Adjust the rear view mirror by slightly and right sides under the seat. moving only the mirror portion of the assembly.
  • Page 43 GENERAL INFORMATION A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area C. Cover D. Rear View Mirror NOTE ○ If a torque wrench is not available, this item should be serviced by a Ka- wasaki dealer.
  • Page 44: 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 45 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 46: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Starting the Engine • Check that the engine stop switch is in the position. • Turn the ignition switch to “ON”. • Make sure the transmission is in neutral. • Without holding the throttle grip, push the starter button to start the engine.
  • Page 47 HOW TO RIDE THE MOTORCYCLE NOTE NOTICE ○ The FI warning indicator light may Do not operate the starter contin- stay on for a few seconds. However, uously for more than 5 seconds as long as it goes off soon, there is or the starter will overheat and no problem with the motorcycle rid- the battery power will drop tem-...
  • Page 48: Jump Starting

    HOW TO RIDE THE MOTORCYCLE Jump Starting If your motorcycle battery is “run down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. DANGER Battery acid generates hydrogen gas which is flammable and ex-...
  • Page 49 HOW TO RIDE THE MOTORCYCLE Connecting Jumper Cables • Remove the seat. • Make sure the ignition switch is turned to OFF. • Remove the bracket and move the ECU aside without disconnecting the connectors from the ECU. (Refer to the Battery section of the “Mainte- nance and Adjustment”...
  • Page 50 HOW TO RIDE THE MOTORCYCLE NOTICE DANGER Do not operate the starter contin- Batteries contain sulfuric acid uously for more than 5 seconds that can cause burns and pro- or the starter will overheat and duce hydrogen gas which is the battery power will drop tem- highly explosive.
  • Page 51: Moving Off

    HOW TO RIDE THE MOTORCYCLE Moving Off NOTE • ○ Check that the side stand is up. The motorcycle is equipped with a • Pull in the clutch lever. side stand switch. This switch is de- • Shift into 1st gear. signed so that the engine does not •...
  • Page 52: Shifting Gears

    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 53: Braking

    HOW TO RIDE THE MOTORCYCLE • Never lock the brakes, or it will cause Braking • the tires to skid. When turning a cor- Close the throttle completely, leaving ner, it is better not be brake at all. the clutch engaged (except when Reduce your speed before you get shifting gears) so that the engine will into the corner.
  • Page 54: Stopping The Engine

    HOW TO RIDE THE MOTORCYCLE Stopping the Engine • Close the throttle completely. • Shift the transmission into neutral. • Turn the ignition switch to “OFF”. • Support the motorcycle on a firm, level surface with the side stand or center stand.
  • Page 55: Stopping The Motorcycle In An Emergency

    Stopping the Motorcycle in an throttle failure, your vehicle may be Emergency stopped by applying the brakes and Your Kawasaki Motorcycle has been disengaging the clutch. Once this stop- designed and manufactured to provide ping procedure is initiated, the engine you optimum safety and convenience.
  • Page 56: Parking

    HOW TO RIDE THE MOTORCYCLE Parking WARNING WARNING The engine and exhaust system get extremely hot during normal Operating or parking the vehicle operation and can cause serious near flammable materials can burns. cause a fire, and can result in Never touch a hot engine, ex- property damage or severe per- haust pipe, or muffler during op-...
  • Page 57 HOW TO RIDE THE MOTORCYCLE • ○ If parking inside a garage or other Do not leave the ignition switch at P structure, be sure it is well ventilated position too long, or the battery will and the motorcycle is not close to discharge.
  • Page 58: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE Catalytic Converter WARNING This motorcycle is equipped with a catalytic converter in the exhaust sys- Operating or parking the vehicle tem. The converter reacts with carbon near flammable materials can monoxide, hydrocarbons and nitrogen cause a fire, and can result in oxides to convert them into carbon di- property damage or severe per- oxide, water, nitrogen and oxygen re-...
  • Page 59 HOW TO RIDE THE MOTORCYCLE • Use only unleaded gasoline. Never use leaded gasoline. Leaded gaso- line significantly reduces the capabil- ity of the catalytic converter. • Do not operate the vehicle with the engine or any one cylinder misfiring. Under these conditions unburned air/fuel mixture flowing out of engine excessively accelerates reaction in...
  • Page 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. For safety, eye protection and a When riding always keep both helmet are strongly recommended. hands on the handlebars and both You should be aware of and verify feet on the footpegs.
  • Page 61 SAFE OPERATION In general your actions should be In wet conditions, rely more on the smooth as sudden acceleration, throttle to control vehicle speed and braking or turning may cause loss less on the front and rear brakes. of control, especially when riding in The throttle should also be used ju- wet conditions or on loose roadway diciously to avoid skidding the rear...
  • Page 62 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 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 Up to 183 kg (403 lb) Front 200 kPa (2.00 kgf/cm², 28 psi) Load Up to 97.5 kg (215 lb) 225 kPa (2.25 kgf/cm², 32 psi) Load Rear 97.5 ~ 183 kg (215 ~ 250 kPa (2.50 kgf/cm², 36 psi) 403 lb) Load Install the air valve cap.
  • Page 65 SAFE OPERATION Side stand and center stand ......Returns to their fully up position by spring tension. Re- turns springs not weak or not damaged.
  • Page 66: Additional Considerations For High Speed Operation

    SAFE OPERATION Additional Considerations for High Speed Operation Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and func- tioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play.
  • Page 67 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 68: 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 69: 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 70 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes * Odometer Reading first km × 1 000 (mile × 1 000) See Page Operation (Engine Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) • • • Engine vacuum syn- chronization - inspect •...
  • Page 71 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Which- ever comes * Odometer Reading first km × 1000 (mile × 1000) See Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Clutch and drive train: Clutch operation (play, •...
  • Page 72 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes * Odometer Reading first km × 1000 (mile × 1000) See Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Wheels and tires: • • • Tire air pressure - in- year spect •...
  • Page 73 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes * Odometer Reading first km × 1000 (mile × 1000) See Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Brake system: • • • • • • • Brake fluid leak - in- year spect •...
  • Page 74 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes * Odometer Reading first km × 1000 (mile × 1000) See Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) • • • • • • Brake lining wear - in- spect # •...
  • Page 75 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes * Odometer Reading first km × 1000 (mile × 1000) See Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Steering System: • • • • – K Steering play - inspect year •...
  • Page 76 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes * Odometer Reading first km × 1000 (mile × 1000) See Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Chassis: • • • Chassis parts - lubri- – year cate •...
  • Page 77 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichev- er comes * Odometer Reading first km × 1 000 (mile × 1 000) See Page Every (0.6) (7.5) (15) (22.5) (30) Change/Replacement Items K Air cleaner element - replace # 2 years •...
  • Page 78: Engine Oil

    MAINTENANCE AND ADJUSTMENT Oil Level Inspection • Engine Oil If the oil has just been changed, start In order for the engine, transmission, the engine and run it for several mi- and clutch to function properly, main- nutes at idle speed. This fills the oil tain the engine oil at the proper level, filter with oil.
  • Page 79 MAINTENANCE AND ADJUSTMENT • • Check the engine oil level through If the oil level is too high, remove the the oil level inspection window. With excess oil through the oil filler open- the motorcycle held level, the oil lev- ing using a syringe or some other el should come up between the suitable device.
  • Page 80 MAINTENANCE AND ADJUSTMENT • Remove the engine oil drain bolt. A. Oil Pressure Warning Indicator Light A. Engine Oil Drain Bolt Oil and/or Oil Filter Change • • Warm up the engine thoroughly, and Let the oil completely drain with the then stop it.
  • Page 81 MAINTENANCE AND ADJUSTMENT • If the oil filter is to be replaced, re- WARNING move the oil filter cover. Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. A.
  • Page 82 If a torque wrench or required Kawa- specified torque. saki special tool is not available, this item should be serviced by an au- thorized Kawasaki dealer. A. Packing • Install the oil filter cover. •...
  • Page 83 MAINTENANCE AND ADJUSTMENT Tightening Torque Engine Oil Capacity Engine Oil Drain Bolt: Capacity: 20 N·m (2.0 kgf·m, 15 ft·lb) 2.7 L (2.9 US qt) Oil Filter: (when filter is not removed) 18 N·m (1.8 kgf·m, 13 ft·lb) 2.9 L (3.1 US qt) Oil Filter Cover Mounting Bolts: (when filter is removed) 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 84: Spark Plugs

    The standard spark plug is shown in the table. The spark plugs should be replaced in accordance with the Peri- odic Maintenance Chart. Spark plug removal should be done only by an authorized Kawasaki deal- Spark Plug Standard Plug NGK CR8E 0.7 ~ 0.8 mm Plug Gap (0.028 ~ 0.032 in.)
  • Page 85: Kawasaki Clean Air System

    MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System The Kawasaki Clean Air System (KCA) is a secondary air suction sys- tem that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust system, it is still hot enough to burn.
  • Page 86: Valve Clearance

    Valve clearance for each valve thorized Kawasaki dealer. should be checked and adjusted in ac- cordance with the Periodic Mainte- nance Chart. Inspection and adjustment should be done only by an authorized Kawasaki dealer.
  • Page 87: Air Cleaner

    MAINTENANCE AND ADJUSTMENT • Remove the left side cover from the Air Cleaner projection by pushing the side cover A clogged air cleaner restricts the forward and pulling it outward. engine's air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. The air cleaner element must be cleaned in accordance with the Peri- odic...
  • Page 88 MAINTENANCE AND ADJUSTMENT • • Remove the screws and right side Pull out the air cleaner elements cover. from both side of the air cleaner housing. A. Right Side Cover B. Screws A. Element • Put a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering.
  • Page 89 MAINTENANCE AND ADJUSTMENT • Inspect the element material for Element Cleaning • damage. If any part of the element Clean the element in a bath of a high is damaged, the element must be re- flash-point solvent. • placed. Squeeze it dry in a clean towel. Do not wring the element or blow it dry;...
  • Page 90 MAINTENANCE AND ADJUSTMENT Oil Draining • WARNING Inspect the drain hose located on the right side of the engine to see if any Gasoline and low flash-point sol- oil or water has run down from the air vents are extremely flammable cleaner housing.
  • Page 91: Throttle Control System

    MAINTENANCE AND ADJUSTMENT Throttle Control System WARNING Check the throttle grip play in ac- cordance with the Periodic Mainte- Oil on tires will make them slip- nance Chart, and adjust it if necessary. pery and can cause an accident and injury. Be sure to install the Throttle Grip - plug in the drain hose after drain- The throttle grip controls the butterfly...
  • Page 92 MAINTENANCE AND ADJUSTMENT Inspection Adjustment • • Check that the throttle grip play is Loosen the locknuts at the upper of correct by lightly turning the throttle the throttle cables, and screw both grip back and forth. throttle cable adjusters completely so as to give the throttle grip plenty of play.
  • Page 93 Kawasaki dealer.
  • Page 94: Engine Vacuum Synchronization

    Peri- cally in accordance with the Periodic odic Maintenance Chart or whenever Maintenance Chart by an authorized the idle speed is disturbed. Kawasaki dealer. Adjustment • NOTE Start the engine, and warm it up thor- ○...
  • Page 95 MAINTENANCE AND ADJUSTMENT • With the engine idling, turn the han- WARNING dlebar to each side. If handlebar movement changes the idle speed, The engine gets extremely hot the throttle cables may be improperly during normal operation and can adjusted or incorrectly routed, or cause serious burns.
  • Page 96: Clutch

    If there is any irregu- A. Adjuster larity, have the clutch cable checked B. Locknut C. Clutch Lever Play by an authorized Kawasaki dealer. • Check the clutch lever play as shown If the play is incorrect, adjust the lev- in the figure.
  • Page 97: Drive Chain

    MAINTENANCE AND ADJUSTMENT Drive Chain WARNING The drive chain slack and lubrication must be checked each day before rid- Too much cable play can prevent ing the motorcycle, and in accordance clutch disengagement and cause with the Periodic Maintenance Chart an accident resulting in serious for safety and to prevent excessive injury or death.
  • Page 98 MAINTENANCE AND ADJUSTMENT • Chain Slack Inspection If the drive chain is too tight or too • Set the motorcycle up on its side loose, adjust it so that the chain stand. slack will be within the standard val- • Rotate the rear wheel to find the po- sition where the chain is tightest, and Drive Chain Slack...
  • Page 99 MAINTENANCE AND ADJUSTMENT • • Remove the cotter pin, and loosen If the chain is too tight, turn in the left the rear axle nut. and right chain adjusting bolts evenly. • Turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack.
  • Page 100 MAINTENANCE AND ADJUSTMENT • To keep the chain and wheel prop- NOTE ○ erly aligned, the notch on the left Wheel alignment also wheel alignment indicator should checked using the straightedge or align with the same swingarm mark string method. that the right indicator notch aligns with.
  • Page 101 MAINTENANCE AND ADJUSTMENT NOTE ○ If a torque wrench is not available, this item should be serviced by an authorized Kawasaki dealer. • Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary. •...
  • Page 102 MAINTENANCE AND ADJUSTMENT Wear Inspection • Remove the bolts and washers to take off the chain cover. A. Turning Clockwise WARNING A. Chain Cover A loose axle nut can lead to an B. Bolts and Washers accident resulting in serious in- •...
  • Page 103 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 104 Wipe off any A. Good Teeth excess lubricant. 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 105: Brakes

    Inspect the front disc brake pads for wear. If the thickness of either pad is less than 1 mm (0.04 in.), replace both pads as a set. Pad replacement should be done by an authorized Kawasaki dealer. • Wipe off any lubricant that gets on the tire surface.
  • Page 106 In this case, the brake shoes must be replaced, and the drum and other brake parts examined by an authorized A. Rear Brake Panel Kawasaki dealer. B. USABLE RANGE C. Brake Lining Wear Indicator Front Disk Brakes - Disc and disc pad wear is automati- cally compensated for and has no ef- fect on the brake lever or pedal action.
  • Page 107 Check for fluid leakage around thorized Kawasaki dealer. the fittings. Check brake hose for damage. Brake Fluid - In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in the front brake fluid reser- voir and change the brake fluid.
  • Page 108 MAINTENANCE AND ADJUSTMENT • Fluid Level Inspection If the fluid level in front brake fluid • With the front brake fluid reservoir reservoir is lower than the lower level held horizontal, the brake fluid level line, check for fluid leaks in the brake in the front brake fluid reservoir must lines, and fill the reservoir to the be kept above the lower level line...
  • Page 109 Fluid Change A. Brake Pedal Have the brake fluid changed by an B. Pedal Play authorized Kawasaki dealer. Pedal Play Rear Drum Brake - 20 ~ 30 mm (0.8 ~ 1.2 in.) In accordance with the Periodic •...
  • Page 110: Brake Light Switch

    • correct pedal play. 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. Adjusting Nut...
  • Page 111 MAINTENANCE AND ADJUSTMENT • Check the operation of the rear Adjustment • brake light switch by depressing the To adjust the rear brake light switch, brake pedal. The brake light should move the switch up or down by turn- go on after the proper pedal travel. ing the adjusting nut.
  • Page 112: Front Fork

    MAINTENANCE AND ADJUSTMENT Front Fork NOTICE The front fork operation and oil leak- To avoid damaging the electrical age should be checked in accordance connections inside the switch, be with the Periodic Maintenance Chart. sure that the switch body does Front Fork Inspection •...
  • Page 113: Rear Shock Absorber

    MAINTENANCE AND ADJUSTMENT • If any doubt about the front fork, it Rear Shock Absorber should be done by an authorized Ka- The rear shock absorbers should be wasaki dealer. checked for operation and oil leakage in accordance with the Periodic Main- tenance Chart.
  • Page 114 If there is any doubt about the rear Spring Preload Adjustment shock absorber, it should be in- Spring preload can be adjusted by spected by an authorized Kawasaki turning the preload adjuster on the rear dealer. shock absorber with the screwdriver bit.
  • Page 115 MAINTENANCE AND ADJUSTMENT WARNING If both spring preload adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. Set all sus- pension adjusters equally to the recommended settings. NOTE ○ Be sure to turn back the preload ad- juster to the left from position 5 when softening the spring action.
  • Page 116 MAINTENANCE AND ADJUSTMENT Spring Preload Setting Adjuster Position ← → Spring Action Weak Standard Strong ← → Setting Soft Standard Hard ← → Load Light Standard Heavy ← → Road Good Standard ← → Speed Standard High...
  • Page 117: Wheels

    MAINTENANCE AND ADJUSTMENT motorcycle has not been ridden Wheels more than a mile during the past 3 Tires - hours). ○ Payload and Tire Pressure Tire pressure is affected by changes Failure to maintain proper inflation in ambient temperature and altitude, pressures or observe payload limits for and so the tire pressure should be your tires may adversely affect han-...
  • Page 118 MAINTENANCE AND ADJUSTMENT Tire Air Pressure (when cold) worn down to the minimum allowable tread depth. Up to 183 kg 200 kPa (2.00 Front (403 lb) Load kgf/cm², 28 psi) Minimum Tread Depth Up to 97.5 kg 225 kPa (2.25 1 mm Front (215 lb) Load...
  • Page 119 MAINTENANCE AND ADJUSTMENT • Visually inspect the tire for cracks WARNING and cuts, replacing the tire in case of bad damage. Swelling or high spots Tires that have been punctured indicate internal damage, requiring and repaired do not have the tire replacement.
  • Page 120: Spoke And Rim

    Spoke tightness and rim runout Mixing tire brands and types can should be inspected by an authorized adversely affect handling and Kawasaki dealer in accordance with cause an accident resulting in in- the Periodic Maintenance Chart. jury or death. Always use the same manufacturer's tires on both front and rear wheels.
  • Page 121: Battery

    MAINTENANCE AND ADJUSTMENT temperature. As temperatures rise, so Battery does the discharge rate. Every 15°C The battery installed in this motor- (59°F) doubles the rate. cycle is a sealed type, so it is not nec- Electrical accessories, such as digi- essary to check the battery electrolyte tal clocks and computer memory, also level or add distilled water.
  • Page 122 12.8 volts, the battery should be temperatures with no damage. charged using an appropriate charger Battery Sulfation (check with your Kawasaki dealer). If A common cause of battery failure is you will not be using the motorcycle for sulfation.
  • Page 123 If the above chargers are not avail- ate charger. Do not use an automotive- able, use equivalent one. type quick charger that may over- For more details, ask your Kawasaki charge the battery and damage it. dealer. Battery Charging NOTE •...
  • Page 124 MAINTENANCE AND ADJUSTMENT Battery Removal NOTICE • Make sure the ignition switch is turned to OFF. Never remove the sealing strip, • Remove the seat and tool kit. or the battery can be damaged. • Remove the screw and move the Do not install a conventional bat- ECU aside without disconnecting the tery in this motorcycle, or the...
  • Page 125 MAINTENANCE AND ADJUSTMENT • • Disconnect the cables from the bat- Disconnect the ground connector of tery, first from the (-) terminal and the battery (–) cables. • then the (+) terminal. Remove the left side cover (see Air Cleaner section). •...
  • Page 126 MAINTENANCE AND ADJUSTMENT Battery Installation NOTICE • Clean the battery using a solution of baking soda and water. Be sure that Do not give the battery holder a the cable connections are clean. strong pull, or the leads may be- •...
  • Page 127: Headlight Beam

    MAINTENANCE AND ADJUSTMENT • Put a light coat of grease on the ter- Headlight Beam minals to prevent corrosion. Horizontal Adjustment • Cover the (+) terminal with its protec- The headlight beam is adjustable tive cap. horizontally. If not properly adjusted •...
  • Page 128 MAINTENANCE AND ADJUSTMENT Vertical Adjustment NOTE ○ The headlight beam is adjustable On high beam, the brightest point vertically. If adjusted too low, neither should be slightly below horizontal low nor high beam will illuminate the with the motorcycle on its wheels road far enough ahead.
  • Page 129: Fuses

    MAINTENANCE AND ADJUSTMENT • Remove the seat. Fuses • Remove the left side cover (see Air Fuses are arranged in the junction Cleaner section). box located inside the left side cover. The main fuse is mounted on the start- er relay located inside the left side cov- If a fuse fails during operation, inspect the electrical system to deter- mine the cause, and then replace it...
  • Page 130 MAINTENANCE AND ADJUSTMENT A. Junction Box A. Normal B. Fuses B. Failed C. Spare Fuses WARNING Substituting fuses can cause wir- ing to overheat, catch fire and/or fail. Do not use any substitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the junction box and main fuse.
  • Page 131: General Lubrication

    MAINTENANCE AND ADJUSTMENT • Front Brake Lever General Lubrication • Rear Brake Pedal Lubricate the points shown below, with either motor oil or regular grease, Lubricate the following cables with in accordance with the Periodic Main- a pressure cable luber - tenance Chart or whenever the vehicle •...
  • Page 132: Cleaning Your Motorcycle

    MAINTENANCE AND ADJUSTMENT (K): Should be serviced by an author- Cleaning Your Motorcycle ized Kawasaki dealer. General Precautions Frequent and proper care of your Ka- NOTE wasaki motorcycle will enhance its ap- ○ pearance, optimize overall After connecting the cables, adjust performance, and extend its useful life.
  • Page 133 MAINTENANCE AND ADJUSTMENT • Be sure the engine and exhaust are WARNING cool before washing. • Avoid applying degreaser to seals, Build-up of debris or flammable brake pads, and tires. material in and around the ve- • Always use non-abrasive wax and hicle chassis, engine, and ex- cleaner/polisher.
  • Page 134 MAINTENANCE AND ADJUSTMENT • • Avoid spraying water in delicate Use a soft cloth to dry your motor- areas such as in air intakes, throttle cycle. As you dry, inspect your mo- body, brake components, electrical torcycle for chips and scratches. Do components, muffler outlets, and fuel not let the water air dry as this can tank openings.
  • Page 135 • plastic parts with an approved plastic 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 136 MAINTENANCE AND ADJUSTMENT Chrome and Aluminum NOTICE Chrome and uncoated aluminum parts can be treated with a chrome/alu- Plastic parts may deteriorate and minum polish. Coated aluminum break if they come in contact with should be washed with a mild neutral chemical substances or house- detergent and finished with a spray hold cleaning products such as...
  • Page 137 MAINTENANCE AND ADJUSTMENT The sidewalls of tires and other rub- ber components should be treated with a rubber protectant to help prolong their useful life. WARNING Rubber protectants can be slip- pery and, if used on the tread area, cause loss of traction re- sulting in accident causing injury or death.
  • Page 138: Storage

    STORAGE STORAGE Preparation for Storage: • Clean the entire vehicle thoroughly. • Run the engine for about five minutes to warm the oil, shut it off, and drain the en- gine oil. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
  • Page 139 STORAGE • Empty the fuel system by running the engine at idle speed until the engine stalls. (If left in for a long time, the fuel will break down and could clog the fuel system.) • Reduce tire pressure by about 20%. •...
  • Page 140: Environmental Protection

    To help preserve the environment, properly discard used batteries, tires, oils and fluids, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure. This also applies to disposal of the entire vehicle at the...
  • Page 141: Location Of Labels

    LOCATION OF LABELS LOCATION OF LABELS All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may op- erate your vehicle.
  • Page 142 LOCATION OF LABELS 2. Tire and Load Data 3. Important Drive Chain Information 4. Battery Poison/Danger...
  • Page 143 LOCATION OF LABELS 5. Unleaded Gasoline...
  • Page 144 LOCATION OF LABELS 1. Read Owner's Manual 2. Tire Pressure, see page 117 3. Front tire size and manufacture, see page 119 4. Rear tire size and manufacture, see page 119 5. Maximum load, see page 18...
  • Page 145 LOCATION OF LABELS 1. Read Owner's Manual 2. Drive Chain Slack, see page 97...
  • Page 146 LOCATION OF LABELS 1. Read Owner's Manual 2. Unleaded gasoline, see page 33...

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