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Table of Contents

   Summary of Contents for Kawasaki VN900 Vulcan Classic 2013

  • 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 © 2013 Kawasaki Heavy Industries, Ltd. Mar. 15, 2013. (1)
  • Page 9: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS ........ 10 Brake Lever Adjusters ....... 29 LOCATION OF PARTS ......14 Fuel ............ 30 LOADING AND ACCESSORIES IN- Fuel Requirements: ....... 30 FORMATION ........17 Filling the Tank: ......32 GENERAL INFORMATION ....20 Side Stand ......... 34 Meter Instruments ......
  • Page 10 Engine Oil .......... 79 Cooling System ........86 Drive Belt ........... 92 Spark Plugs ........93 Valve Clearance ......... 93 Kawasaki Clean Air System ....94 Air Cleaner ......... 95 Throttle Control System ..... 97 Idle Speed .......... 99 Clutch ..........100 Brakes ..........102...
  • Page 11: Specifications

    SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 35 kW (48 PS) @5 700 r/min (rpm) Maximum Torque 77 N·m (8.0 kgf·m, 57.5 ft·lb) @3 700 r/min (rpm) Minimum Turning Radius 2.9 m (114 in.) DIMENSIONS Overall Length 2 465 mm (97.0 in.) Overall Width 1 005 mm (39.6 in.) Overall Height...
  • Page 12 SPECIFICATIONS Starting System Electric starter Cylinder Numbering Method Front to rear, 1-2 Firing Order Fuel System Digital fuel injection system (DFI) Ignition System Battery and coil (transistorized ignition) Ignition Timing 3.5° BTDC @1 000 r/min (rpm) ~ (Electronically advanced) 53° BTDC @5 800 r/min (rpm) Spark Plugs NGK CPR7EA-9 Lubrication System...
  • Page 13 SPECIFICATIONS Overall Drive Ratio 4.338 (Top gear) Gear Ratio 2.786 (39/14) 1.889 (34/18) 1.360 (34/25) 1.107 (31/28) 0.963 (26/27) FRAME Castor 32° Trail 160 mm (6.3 in.) Tire Size: Front 130/90-16 M/C 67H Rear 180/70-15 M/C 76H Rim Size: Front J16M/C ×...
  • Page 14 SPECIFICATIONS Specifications are subject to change without notice and may not apply to every countries.
  • Page 15: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 5. Brake Lever Adjuster 10. Right Handlebar 2. Clutch Lever Adjuster 6. Front Brake Lever Switches 3. Meter Instruments 7. Left Handlebar Switches 11. Throttle Grip 4. Brake Fluid Reservoir 8. Indicator Lights (Front) 9.
  • Page 16 LOCATION OF PARTS 12. Front Fork 19. Brake Caliper 25. Side Stand 13. Headlight 20. Wheel 26. Fuse Box 14. Turn Signal Light 21. Radiator 27. Coolant Reserve Tank 15. Horn 22. Shift Pedal 28. Rear Shock Absorber 16. Spark Plugs 23.
  • Page 17 LOCATION OF PARTS 31. Tail/Brake Light 36. Steering Lock 40. Rear Brake Light Switch 32. Seat 37. Mufflers 41. Brake Fluid Reservoir 33. Tool Kit Case/Tool Kit 38. Idle Speed Adjusting (Rear) 34. Air Cleaner Element Screw 35. Fuel Tank 39.
  • Page 18: Loading And Accessories Information

    Kawasaki Parts and Accessories ing condition. Before you ride the have been specially designed for motorcycle, make sure it is not use on Kawasaki motorcycles. We overloaded and that you have fol- strongly recommend that all parts lowed these instructions.
  • Page 19 LOADING AND ACCESSORIES 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 eration.
  • Page 20 LOADING AND ACCESSORIES 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- cle's operation.
  • Page 21: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Speedometer B. Digital Display C. Fuel Level Warning Indicator Light D. Coolant Temperature Warning Indicator Light E. Fuel Gauge F. Oil Pressure Warning Indicator Light G. Fuel Injection Warning Indicator Light H. MODE Button I.
  • Page 22: Speedometer

    GENERAL INFORMATION Clock - Speedometer: To adjust hours and minutes: The speedometer shows the speed • Turn the ignition key to “ON”. of the vehicle. • Push the MODE button to display Digital Display the clock. • The digital display located in the Push the RESET button for more speedometer face is used to display than two seconds.
  • Page 23 GENERAL INFORMATION • • Again push the RESET button. Push the RESET button. Both the When only the hour display flashes, hour and minute displays start flash- push the MODE button to advance ing again. • the hours. Push the MODE button. The dis- plays stop flashing and the clock starts working.
  • Page 24 GENERAL INFORMATION Odometer - Trip Meters - The odometer shows the total dis- The trip meter shows the distance in tance in kilometers (miles) that the ve- kilometers (miles) traveled since it was hicle has been ridden. This meter last reset to zero. cannot be reset.
  • Page 25: Fuel Gauge

    GENERAL INFORMATION Fuel Gauge: The fuel gauge shows the amount of fuel in the fuel tank. When the needle comes near the E (empty) position, re- fuel at the earliest opportunity. When vehicle stands with side stand, fuel gauge cannot show the amount of fuel in the fuel tank exactly.
  • Page 26 ON position with the en- comes on, have the DFI system gine not running, and goes off when checked by an authorized Kawasaki the engine oil pressure is high enough. dealer. Refer to the Maintenance and Adjust- ment chapter for more detailed engine oil information.
  • Page 27: Keys

    GENERAL INFORMATION Keys Ignition Switch This motorcycle has a combination The ignition switch is located at the key, which is used for the ignition left side behind the rear cylinder. This switch, steering lock, and fuel tank three-position, key-operated cap. switch.
  • Page 28: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches Engine off. All electrical circuits Engine Stop Switch: off. In addition to the ignition switch, the Engine on. All electrical equip- engine stop switch must be in the ment can be used. position for the motorcycle to op- Engine off.
  • Page 29: Left Handlebar Switches

    GENERAL INFORMATION Refer to the Starting the Engine sec- Left Handlebar Switches tion of the "How to Ride the Motor- Dimmer Switch: cycle" chapter for starting instructions. 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.
  • Page 30: Turn Signal Switch

    GENERAL INFORMATION Turn Signal Switch: Brake Lever Adjusters When the turn signal switch is turned There is an adjuster on the brake lev- to the left ( ) or right ( ), the er. The adjuster has 5 positions so that corresponding turn signals flash on the released lever position can be ad- and off.
  • Page 31: Fuel

    GENERAL INFORMATION Fuel Fuel Requirements: Your Kawasaki engine is designed to use only unleaded gasoline with a min- imum octane rating shown below. Never use gasoline with an octane rat- ing lower than the minimum specified by Kawasaki to prevent severe engine damage.
  • Page 32 GENERAL INFORMATION NOTICE Fuel Type Unleaded Gasoline Ethanol If engine “knocking" or “pinging" E10 or less Content occurs, use a different brand of Minimum Research Octane Number gasoline of a higher octane rat- Octane Rat- (RON) ing. If this condition is allowed to continue, it can lead to severe en- gine damage.
  • Page 33: 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 34 GENERAL INFORMATION NOTICE Certain ingredients in gasoline may cause paint fading or dam- age. Be extra careful not to spill fuel during refueling. (Fuel Tank Cap) To open the fuel tank cap, insert the ignition key into the fuel tank cap and turn the key to the right.
  • Page 35: Side Stand

    GENERAL INFORMATION Side Stand stand fully up before sitting on the mo- torcycle. The motorcycle is equipped with a side stand. NOTE ○ The motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine does not start if the transmission is in gear and the side stand is down.
  • Page 36: Seat

    GENERAL INFORMATION Seat Seat Installation • To install the seat, insert the projec- Seat Removal • tion of the front on the seat into the To remove the seat, insert the igni- receptacle on the frame. tion key into the seat lock, and turn the key to the right.
  • Page 37: Tool Kit Case

    GENERAL INFORMATION Tool Kit Case The tool kit case is located under the seat. The kit contains tools that can be helpful in making roadside repairs, ad- justments, and some maintenance pro- cedures explained in this manual. Keep the tool kit in this case. •...
  • Page 38: Helmet-hook

    GENERAL INFORMATION Helmet-Hook Helmet can be secured to the motor- cycle using the helmet-hook. The hel- met hook is located under the seat. WARNING Riding with helmet attached to the hook could cause an accident by distracting the operator or in- terfering with normal vehicle op- eration.
  • Page 39: Steering Lock

    GENERAL INFORMATION Steering Lock WARNING The motorcycle is equipped with the steering lock at the right side of the Attempting to ride with the steer- head pipe. ing locked could cause an acci- dent. Unlock the steering before To lock the steering: •...
  • Page 40: Electric Accessory Connectors

    A. Electric Accessory Connectors • White/Blue Under Fuel When using the electric accessory Tank connectors under the fuel tank, the (–) Black/Yellow electric accessory connection to the Maximum Current : 10 A connectors should be done by an au- thorized Kawasaki dealer.
  • Page 41: Rear View Mirror

    GENERAL INFORMATION Rear View Mirror NOTICE Rear View Mirror Adjustment • The vehicle has an electrical ac- Adjust the rear view mirror by slightly cessory circuit (10 A fuse) for the moving only the mirror portion of the connectors. Always install a fuse assembly.
  • Page 42 GENERAL INFORMATION A. Stay A. Lower Hexagonal Area for Tightening B. Rear View Mirror B. Upper Hexagonal Area C. Rear View Mirror D. Rubber Boots NOTE ○ If a torque wrench is not available, this item should be serviced by a Ka- wasaki dealer.
  • Page 43: 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 44 During break-in, avoid sudden and maximum braking and accel- eration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner has the initial maintenance service performed by an authorized Kawasaki dealer.
  • Page 45: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE • Starting the Engine Turn the ignition key to ON. • Check that the engine stop switch is in the position. A. Ignition Switch B. ON Position A. Engine Stop Switch B.
  • Page 46 HOW TO RIDE THE MOTORCYCLE • then back to ”ON” before starting the Make sure the transmission is in neutral. engine. • Without holding the throttle grip, push the starter button to start the engine. NOTICE Do not operate the starter contin- uously for more than 5 seconds, or the starter will overheat and the battery power will drop tem-...
  • Page 47: Jump Starting

    HOW TO RIDE THE MOTORCYCLE and the side stand is down. How- Jump Starting ever, the engine can be started if the If your motorcycle battery is "run clutch lever is pulled and the side down", it should be removed and stand is fully up.
  • Page 48 HOW TO RIDE THE MOTORCYCLE • Connecting Jumper Cables Connect a jumper cable from the • Make sure the ignition key is turned positive (+) terminal of the booster to "OFF". battery to the positive (+) terminal of • Remove the seat. the motorcycle battery.
  • Page 49 HOW TO RIDE THE MOTORCYCLE • pedal or other unpainted metal sur- Follow the standard engine starting face. Do not use the negative (−) procedure. terminal of the battery. NOTICE DANGER Do not operate the starter contin- uously for more than 5 seconds Batteries contain sulfuric acid or the starter will overheat and that can cause burns and pro-...
  • Page 50 HOW TO RIDE THE MOTORCYCLE NOTE ○ After installing the tool kit case, run the seat lock cable and wires along the guide. A. Harness B. Guide A. Seat Lock Cable B. Guide...
  • 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 HOW TO RIDE THE MOTORCYCLE Vehicle speed when downshifting Shifting down km/h (mph) 5th → 4th 40 (25) 4th → 3rd 30 (19) 3rd → 2nd 20 (12) 2nd → 1st 15 (9)
  • Page 54: Braking

    HOW TO RIDE THE MOTORCYCLE applying the brakes as hard as pos- Braking • sible without skidding. Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. • Shift down one gear at a time so that you are in 1st gear when you come to a complete stop.
  • 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. •...
  • Page 56: Stopping The Motorcycle In An Emergency

    In an emergency situation such as throttle failure, your vehicle may be Emergency stopped by applying the brakes and Your Kawasaki Motorcycle has been disengaging the clutch. Once this designed and manufactured to provide stopping procedure is initiated, the en- you optimum safety and convenience.
  • Page 57: 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. 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 HOW TO RIDE THE MOTORCYCLE and the motorcycle is not close to NOTE ○ any source of flame or sparks; this When stopping near traffic at night, includes any appliance with a pilot you can leave the taillight, licence light. plate light on for greater visibility by turning the ignition key to the P WARNING...
  • Page 59: 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 react 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 60 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 61: 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 62 SAFE OPERATION Before changing lanes, look over When applying the brakes, use your shoulder to make sure the way both the front and rear brakes. Ap- is clear. Do not rely solely on the plying only one brake for sudden rear view mirror;...
  • Page 63 SAFE OPERATION Riding at the proper rate of speed and avoiding unnecessarily fast ac- celeration are important not only for safety and low fuel consumption but also for long vehicle life and quieter operation. On rough roads, exercise caution, slow down, and grip the fuel tank with the knees for better stability.
  • Page 64: Daily Checks

    SAFE OPERATION Daily Checks Check the following items each day before you ride. The time required is mini- mal, 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 65 SAFE OPERATION Tires ......Air pressure (when cold): Up to 180 kg Load Front 200 kPa (2.00 kgf/cm², 28 psi) (397 lb) Up to 97.5 kg (215 lb) 200 kPa (2.0 kgf/cm², 28 psi) load Rear 97.5 ~ 180 kg (215 ~ 225 kPa (2.25 kgf/cm², 32 psi) 397 lb) load Install the air valve cap.
  • Page 66 SAFE OPERATION Engine stop switch ..Stops engine. Side stand ....Returns to its fully up position by spring tension. Return spring not weak or not damaged.
  • Page 67: Additional Considerations For High Speed Operation

    SAFE OPERATION Additional Considerations for High Speed 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 SAFE OPERATION Coolant:To avoid overheating, check that the coolant level is at the upper level line. Electrical Equipment: Make sure that the headlight, tail/brake light, turn signals, horn, etc., all work properly. Miscellaneous: Make sure that all nuts and bolts are tight and that all safety re- lated parts are in good condition.
  • Page 69: 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 70: Periodic Maintenance Chart

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart 1. Periodic Inspection (Engine Related Items) Frequency Which- ever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Valve clearance - in- Every 42 000 km (26 000 mile) spect Throttle control system...
  • Page 71 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • • Coolant level - inspect • • • •...
  • Page 72 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Which- ever 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) Clutch and drive train: Clutch operation (play, •...
  • Page 73 MAINTENANCE AND ADJUSTMENT Frequency Which- ever 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) • • • Tire tread wear, abnor- mal wear - inspect •...
  • Page 74 MAINTENANCE AND ADJUSTMENT Frequency Which- ever 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 hose installation year condition - inspect •...
  • Page 75 MAINTENANCE AND ADJUSTMENT Frequency Which- ever 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) Front forks/rear shock • • • – absorber oil leak - in- year spect •...
  • Page 76 MAINTENANCE AND ADJUSTMENT Frequency Which- ever 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) Steering system: • • • • – K Steering play - inspect year •...
  • Page 77 MAINTENANCE AND ADJUSTMENT Frequency Which- ever 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) Chassis: • • • Chassis parts - lubri- year cate • •...
  • Page 78 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever *Odometer Reading comes first km × 1000 ( mile × Page 1000) Operation (Chassis Items) Every (0.6) (7.5) (15) (22.5) (30) K Air cleaner element # - replace every 18 000 km (12 000 mile) •...
  • Page 79 MAINTENANCE AND ADJUSTMENT 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...
  • Page 80: 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 81 MAINTENANCE AND ADJUSTMENT NOTICE If the engine oil gets extremely low or if the oil pump does not function properly or oil passages are clogged, the warning indica- tor light in the speedometer will light. If this light stays on when the engine speed is above the idle speed, stop the engine imme- diately and find the cause.
  • Page 82 MAINTENANCE AND ADJUSTMENT A. Oil Pressure Warning Indicator Light A. Engine Oil Drain Plug • Let the oil completely drain with the Oil and/or Oil Filter Change • motorcycle perpendicular to the Warm up the engine thoroughly, and ground. then stop it. •...
  • Page 83 MAINTENANCE AND ADJUSTMENT • • Remove the cover. Remove the regulator/rectifire bolt. A. Cover A. Regulator/Rectifire B. Bolt B. Bolt...
  • Page 84 Remove the oil filter cartridge and re- place it with a new one. NOTE ○ If a torque wrench or required Kawa- saki special tool is not available, this item should be serviced by an au- thorized Kawasaki dealer. A. Bracket B. Bolt A. Cartridge...
  • Page 85 MAINTENANCE AND ADJUSTMENT • • Apply a thin film of oil to the packing Fill the engine up to the upper level and tighten the cartridge to the speci- line with a good quality engine oil fied torque. specified in the table. •...
  • Page 86 MAINTENANCE AND ADJUSTMENT NOTE ○ Do not add any chemical additive to the oil. Oils fulfilling the above re- quirements are fully formulated and provide adequate lubrication for both the engine and the clutch. Engine Oil Capacity Capacity: 3.0 L (3.2 US qt) [when filter is not removed] 3.2 L (3.4 US qt) [when filter is removed]...
  • Page 87: Cooling System

    MAINTENANCE AND ADJUSTMENT Cooling System NOTICE Radiator and Cooling Fan - Check the radiator fins for obstruc- Using high-pressure water, as tion by insects or mud. Clean off any from a car wash facility, could obstructions with a stream of low-pres- damage the radiator fins and im- sure water.
  • Page 88 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 89 MAINTENANCE AND ADJUSTMENT freezing point and strength directed on NOTICE the container. If hard water is used in the sys- NOTICE tem, it causes scale accumula- tion in the water passages, and Permanent types of antifreeze on considerably reduces the effi- the market have anti-corrosion ciency of the cooling system.
  • Page 90 MAINTENANCE AND ADJUSTMENT Coolant Level Inspection • Situate the motorcycle so that it is perpendicular to the ground. • Check the coolant level through the coolant level gauge. The coolant level should be between the F (Full) and L (Low) marks. NOTE ○...
  • Page 91 MAINTENANCE AND ADJUSTMENT • Coolant Filling Remove the reservoir tank cover. • Remove the seat. • Remove the left side cover by re- moving the screw. A. Reservoir Tank Cover B. Bolt • Open the cap from the reservoir tank, and add coolant through the fill- A.
  • Page 92 MAINTENANCE AND ADJUSTMENT A. Reserve Tank A. Projections B. Reserve Tank Cap B. Left Side Cover • Install the cap after filling coolant. • NOTE Install the parts removed. ○ In an emergency you can add water alone to the coolant reserve tank, NOTE ○...
  • Page 93: Drive Belt

    Maintenance Chart. the system. Have the cooling Belt check and adjustment should be system inspected by your author- done by an authorized Kawasaki deal- ized Kawasaki dealer. NOTICE Coolant Change Improper drive belt deflection can Have the coolant changed by an au- result in belt damage.
  • Page 94: Spark Plugs

    Periodic Mainte- ○ nance Chart. Fit the plug cap securely onto the Inspection and adjustment should be spark plug, and pull the cap lightly to done by an authorized Kawasaki deal- make sure that it is properly in- stalled.
  • Page 95: Kawasaki Clean Air System

    MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System in accordance with the Periodic Main- tenance Chart. Also, inspect the air The Kawasaki Clean Air System suction valves whenever stable idling (KCA) is a secondary air suction sys- cannot be obtained, engine power is...
  • Page 96: Air Cleaner

    MAINTENANCE AND ADJUSTMENT Air Cleaner Element Removal • Remove the bolts of the air cleaner A clogged air cleaner restricts the cover located on the right-side of the engine's air intake, increasing fuel con- engine. sumption, reducing engine power, and causing spark plug fouling.
  • Page 97 MAINTENANCE AND ADJUSTMENT • Remove the air cleaner screw and WARNING the air cleaner. If any part of the ele- ment is damaged, the element must If dirt or dust is allowed to pass be replaced. through into the fuel injection system, the throttle may stick or become inoperable resulting in a hazardous operating condition.
  • Page 98: Throttle Control System

    MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check that there is 2 ~ 3 mm (0.08 ~ Check the throttle grip play, in ac- 0.12 in.) throttle grip play when lightly cordance with the Periodic Mainte- turning the throttle grip back and nance Chart, and adjust the throttle forth.
  • Page 99 Tighten the locknut. authorized Kawasaki dealer. WARNING Operation with improperly ad- justed, incorrectly routed, damaged cables could result in an unsafe riding condition.
  • Page 100: Idle Speed

    MAINTENANCE AND ADJUSTMENT Idle Speed The idle adjustment should be per- formed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed. Adjustment • Start the engine, and warm it up thoroughly. • Wait until the idle speed drops before making the following adjustment.
  • Page 101: Clutch

    MAINTENANCE AND ADJUSTMENT correct any of these conditions be- Clutch fore riding. Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accord- WARNING ance with the Periodic Maintenance Operation with damaged cables Chart.
  • Page 102 MAINTENANCE AND ADJUSTMENT Inspection Adjustment • • Check that the clutch lever has 2 ~ 3 Turn the adjuster so that the clutch mm (0.08 ~ 0.12 in.) of play as lever will have 2 ~ 3 mm (0.08 ~ 0.12 shown in the figure.
  • Page 103: 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. A. Locknut B. Clutch Cable C. Adjuster NOTE ○...
  • Page 104 MAINTENANCE AND ADJUSTMENT Disc Brake Fluid - Fluid Level Inspection • In accordance with the Periodic The brake fluid level in the front Maintenance Chart, inspect the brake brake fluid reservoir must be kept fluid level in both the front and rear above the line (lower level line) next brake fluid reservoirs and change the to the gauge and that in the rear...
  • Page 105 MAINTENANCE AND ADJUSTMENT • If the fluid level in either reservoir is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. Inside the front brake fluid res- ervoir is a stepped line showing the upper level line.
  • Page 106 D. 1/6 turn reservoir are unidentified. Fluid Change Have the brake fluid changed by an NOTE authorized Kawasaki dealer. ○ First, tighten until slight resistance is Front and Rear Brakes - felt indicating that the cap is seated Disc and disc pad wear is automati- on the reservoir body;...
  • Page 107: Brake Light Switches

    Have brake The brake light should go on when checked immediately by an au- the front brake is applied. • thorized Kawasaki dealer. If it does not, ask your authorized Kawasaki dealer to inspect the front brake light switch.
  • Page 108 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 about 10 mm (0.4 in.) of ing the adjusting nut.
  • Page 109: Rear Shock Absorber

    MAINTENANCE AND ADJUSTMENT Rear Shock Absorber The rear shock absorber can be ad- justed by changing the spring preload for various riding and loading condi- tions. Spring Preload Adjustment The rear shock absorber spring pre- load adjuster has 7 positions. •...
  • Page 110 MAINTENANCE AND ADJUSTMENT A. Reservoir Tank A. Under Part of Reservoir Tank B. Bolt B. Holder • In accordance with the following ta- NOTE ble, turn the preload adjuster with the ○ When removing the reservoir tank, wrench from the tool kit. hook the under part of the reservoir tank to the holder of the frame as shown in the figure.
  • Page 111 MAINTENANCE AND ADJUSTMENT NOTE ○ This motorcycle has two hook wrenches in the tool kit. When changing the spring preload of the rear shock absorber, turn the adjust- er by using the suitable hook wrenches. A. Spring Preload Adjuster B. Wrench Position —→...
  • Page 112: Wheels

    MAINTENANCE AND ADJUSTMENT • Wheels Remove the air valve cap. • Check the tire pressure often, using Tires - an accurate gauge. Payload and Tire Pressure • Make sure that the air valve cap is Failure to maintain proper inflation securely installed.
  • Page 113 MAINTENANCE AND ADJUSTMENT motorcycle has not been ridden that 90% of all tire failures occur during more than a mile during the past 3 the last 10% of tread life (90% worn). hours). So it is false economy and unsafe to ○...
  • Page 114 MAINTENANCE AND ADJUSTMENT Minimum Tread Depth WARNING Front 1 mm Tires that have been punctured (0.04 in.) and repaired do not have the Rear Under 130 km/h 2 mm same capabilities as undamaged (80 mph) (0.08 in.) tires and can suddenly fail, caus- ing an accident resulting in seri- Over 130 km/h 3 mm...
  • Page 115 MAINTENANCE AND ADJUSTMENT ○ Most counters may have their own WARNING regulations requiring a minimum tire thread depth; be sure to follow them. New tires are slippery and may cause loss of control and injury. Standard Tire (Tubeless) A break-in period of 160 km (100 130/90-16M/C 67H miles) is necessary to establish Front...
  • Page 116: Battery

    MAINTENANCE AND ADJUSTMENT Battery temperature. As temperatures rise, so does the discharge rate. Every 15°C The battery installed in this vehicle is (59°F) doubles the rate. a sealed type, and the sealing strip Electrical accessories, such as digi- should not be removed at any time tal clocks and computer memory, also after the specified electrolyte has been draw current from the battery even...
  • Page 117 MAINTENANCE AND ADJUSTMENT Battery Sulfation Current Drain A common cause of battery failure is Days from sulfation. Discharg- Days from 100% 100 % Sulfation occurs when the battery is ing Am- Charged to 50% Charged to left in a discharged condition for an ex- pere Discharged 100 % Dis-...
  • Page 118 MAINTENANCE AND ADJUSTMENT (check with your Kawasaki dealer). If OptiMate 4 you will not be using the motorcycle for Yuasa MB-2040/2060 longer than two weeks, the battery Christie C10122S should be charged using an appropri- If the above chargers are not avail- ate charger.
  • Page 119 MAINTENANCE AND ADJUSTMENT Battery Removal NOTICE • Remove the seat and tool kit case (see “Jump Starting” section in the “ Never remove the sealing stirp, How to Ride the Motorcycle” chap- or the battery can be damaged. ter). Do not install a conventional bat- •...
  • Page 120 MAINTENANCE AND ADJUSTMENT • • Pull the battery out of the motor- Put a light coat of grease on the ter- cycle. minals to prevent corrosion. • • Clean the battery using a solution of Cover the (+) terminal with its protec- baking soda and water.
  • Page 121: Headlight Beam

    MAINTENANCE AND ADJUSTMENT Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. • Turn the horizontal adjusting screw on the headlight rim in or out until the beam points straight ahead.
  • Page 122 MAINTENANCE AND ADJUSTMENT Vertical Adjustment The headlight beam is adjustable vertically. If adjusted too low, neither low nor high beam will illuminate the road far enough ahead. If adjusted too high, the high beam will fail to illumi- nate the road close ahead, and the low beam will blind oncoming drivers.
  • Page 123: Fuses

    MAINTENANCE AND ADJUSTMENT Fuses The fuses are arranged in the fuse box located behind left side cover. The main fuse is mounted on the starter relay behind right side cover. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 124 MAINTENANCE AND ADJUSTMENT • • Remove the screw Pull out the right side cover and then inspect the main fuse. A. Screw A. Main Fuse...
  • Page 125 MAINTENANCE AND ADJUSTMENT • When installing the right side cover, WARNING be sure to insert the projections of the right side cover. Substituting fuses can cause wir- ing to overheat, catch fire and/or fail. Do not use any substitute for the standard fuse.
  • Page 126: General Lubrication

    MAINTENANCE AND ADJUSTMENT • General Lubrication Front Brake Lever • 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 127: 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 128 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 129 MAINTENANCE AND ADJUSTMENT • • Avoid spraying water in delicate If the boot is damaged, replace it areas such as in air intakes, fuel sys- with a new one. If the boot is not tem, brake components, electrical positioned in the groove correctly, re- components, muffler outlets, and fuel place it in the correct position.
  • Page 130 MAINTENANCE AND ADJUSTMENT • Mix a mild neutral detergent (de- brakes and restores them to normal signed for motorcycles or automo- operating performance. biles) and water in bucket. Use a soft NOTE cloth or sponge to wash your motor- ○ cycle.
  • Page 131 The semi-gloss finish effect may be lost when the finish is excessively rubbed. • If any doubt, consult an authorized Kawasaki dealer. Painted Surfaces After washing your motorcycle, coat painted surfaces, both metal and plas- tic, with a commercially available mo- torcycle/automotive wax.
  • Page 132 MAINTENANCE AND ADJUSTMENT chrome/aluminum polish. Coated alu- NOTICE minum should be washed with a mild neutral detergent and finished with a Plastic parts may deteriorate and spray polish. Aluminum wheels, both break if they come in contact with painted and unpainted can be cleaned chemical substances or house- with special non-acid based wheel hold cleaning products such as...
  • Page 133 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 injury or death. Do not apply rubber protectant to any tread area.
  • Page 134: 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 135 STORAGE • Empty the fuel system by running the engine at idle speed until all fuel in the fuel system is used up (If left in for a long time, the fuel will break down and clog the fuel system). WARNING An air/oil mist may be forcibly ejected from the spark plug holes and could get into your eyes.
  • Page 136 STORAGE • Tie plastic bags over the mufflers to prevent moisture from entering. • 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. •...
  • Page 137: 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 138: 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 139 LOCATION OF LABELS 3. Brake Fluid (Rear) 4. Tire and Load Data 5. Battery Position/Danger...
  • Page 140 LOCATION OF LABELS 6. Radiator Cap Danger...
  • Page 141 LOCATION OF LABELS (2)/(3) 1. Read Owner's Manual 2. Unleaded gasoline, see page 31...
  • Page 142 LOCATION OF LABELS 1. Read Owner's Manual 2. Tire Pressure, see page 112 3. Front tire size and manufacture, see page 114 4. Rear tire size and manufacture, see page 114 5. Maximum load, see page 19...
  • Page 143 LOCATION OF LABELS...
  • Page 144 LOCATION OF LABELS...

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