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ENGLISH j
Motorcycle
Owner's Manual

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Table of Contents

   Summary of Contents for Kawasaki VN900 2007

  • Page 1 ENGLISH j Motorcycle Owner’s Manual...
  • Page 3 NOTE Whenever you see the symbols ○ shown below, heed their instructions! This note symbol indicates points of Always follow safe operating and main- particular interest for more efficient tenance practices. and convenient operation. WARNING NOTICE This warning symbol identifies THIS PRODUCT BEEN...
  • Page 5 (Australian model only) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
  • Page 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. Consumer Products & Machinery Company © 2006 Kawasaki Heavy Industries, Ltd. Apr. 2006 (1) (M)
  • Page 8: Table Of Contents

    TABLE OF CONTENTS Specifications ........10 Brake Lever Adjusters...... 30 Location of Parts ....... 14 Fuel Tank Cap ........31 LOADING AND ACCESSORIES Fuel Tank ......... 32 INFORMATION ........ 17 Side Stand ........34 General Information ......20 Seat..........35 Meter Instruments ......
  • Page 9 Headlight Beam........ 118 Cooling System ........ 82 Fuses ..........119 Drive Belt.......... 89 Cleaning Your Motorcycle ....122 Spark Plugs........89 Storage ..........127 Valve Clearance ....... 90 Environmental Protection....130 Kawasaki Clean Air System ..... 90 Location of Labels......131...
  • Page 10: Specifications

    SPECIFICATIONS Specifications PERFORMANCE Maximum Horsepower 37 kW (50 PS) @5 700 r/min (rpm) Maximum Torque 78 N·m (8.0 kgf·m, 57.5 ft·lb) @3 700 r/min (rpm) DIMENSIONS Overall Length 2 465 mm (97.0 in.) Overall Width 1 005 mm (39.6 in.) (AU) 980 mm (38.6 in.) Overall Height 1 065 mm (41.9 in.)
  • Page 11 SPECIFICATIONS Cylinder Numbering Method Front to rear, 1-2 Firing Order Carburetion System Digital fuel injection system (DFI) Ignition System Battery and coil (transistorized ignition) 3.5° BTDC @1 000 r/min (rpm) ∼ Ignition Timing (Electronically advanced) 53° BTDC @5 800 r/min (rpm) Spark Plugs NGK CPR7EA-9 Lubrication System...
  • Page 12 SPECIFICATIONS Final Reduction Ratio 2.063 (66/32) 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.) Front Tire Size: 130/90-16 M/C 67H Rear 180/70-15 M/C 76H Front 16 x 3.00 Rim Size:...
  • Page 13 SPECIFICATIONS ELECTRICAL EQUIPMENT Battery 12 V 10 Ah Headlight 12 V 60/55 W Tail/Brake Light 12 V 5/21 W (AU): Australian model Specifications subject to change without notice and may not apply to every coun- tries.
  • Page 14: Location Of Parts

    LOCATION OF PARTS Location of Parts 1. Clutch Lever 5. Brake Lever Adjuster 9. Fuel Tank Cap 2. Clutch Lever Adjuster 6. Front Brake Lever 10. Right Handlebar 3. Meter Instruments 7. Left Handlebar Switches 4. Brake Fluid Reservoir Switches 11.
  • Page 15 LOCATION OF PARTS 12. Front Fork 19. Brake Caliper 26. Fuse Box 13. Headlight 20. Wheel 27. Coolant Reserve Tank 14. Turn Signal Light 21. Radiator 28. Rear Shock Absorber 15. Horn 22. Shift Pedal 29. Belt 16. Spark Plugs 23.
  • Page 16 LOCATION OF PARTS 31. Tail/Brake Light 36. Steering Lock 40. Rear Brake Light 32. Seat 37. Mufflers Switch 33. Tool Kit Case/Tool Kit 38. Idle Speed Adjusting 41. Brake Fluid Reservoir 34. Air Cleaner Element Screw (Rear) 35. Fuel Tank 39.
  • Page 17: Loading And Accessories Information

    Kawasaki Parts Accessories, and accessories you add to your Kawasaki has no control over the motorcycle be genuine Kawasaki design or application of accessories. components. In some cases, improper installation or use of accessories, or motorcycle...
  • Page 18 LOADING AND ACCESSORIES INFORMATION in carrying cargo, passengers and/or 3. All baggage should be carried as in the fitting of additional accessories. low as possible to reduce the effect The following general guidelines have on the motorcycle center of gravity. been prepared to assist you in making Baggage weight should also be dis- your determinations.
  • Page 19 Kawasaki does not manu- (i.e., lean angle), control operation, facture sidecars or trailers for mo- wheel travel, front fork movement,...
  • Page 20: General Information

    GENERAL INFORMATION General Information Meter Instruments A. Speedometer B. Digital Display C. Fuel Level Indicator Light D. Coolant Temperature Warning Light E. Fuel Gauge F. Oil Pressure Warning Light G. Fuel Injection Warning Light H. MODE Button I. RESET Button J.
  • Page 21: Speedometer

    GENERAL INFORMATION Speedometer: 3. Push the RESET button for more The speedometer shows the speed than two seconds. Both the hour of the vehicle. and minute displays start flashing. Digital Display The digital display located in the speedometer face is used to display the odometer, trip meter, and clock.
  • Page 22 GENERAL INFORMATION NOTE minute display starts flashing. Push ○ the MODE button to advance the Pushing the MODE button momen- minutes. tarily advances the hour or minute step by step. Pushing and hold- ing the button advance the hour or minute continuously.
  • Page 23 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 can- last reset to zero.
  • Page 24: Fuel Gauge

    GENERAL INFORMATION ○ When the trip meter reaches 999.9 while riding, the meter resets to 0.0 and continue counting. ○ When the battery is disconnected, the meter display resets to 0.0. Fuel Gauge: The fuel gauge shows the amount of fuel in the fuel tank.
  • Page 25 DFI system is in the ON position with the engine not checked by an authorized Kawasaki running, and goes off when the engine dealer. oil pressure is high enough. Refer to...
  • Page 26: Keys

    This is a three-position, key-operated Blank keys are available at your switch. The key can be removed from Kawasaki dealers. Ask your dealer to the switch when it is in the OFF or P make any additional spare keys you (Park) position.
  • Page 27 GENERAL INFORMATION ○ If you leave the motorcycle in the P Engine off. All electrical (Park) position or in the ON position circuits off. without the motorcycle running for a Engine on. All electrical long time (one hour), the battery may equipment can be used.
  • Page 28: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches Engine Stop Switch: In addition to the ignition switch, the engine stop switch must be in the position for the motorcycle to operate. The engine stop switch is for emer- gency use. If some emergency re- quires stopping the engine, move the engine stop switch to the position.
  • Page 29: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches Turn Signal Switch: Dimmer Switch: When the turn signal switch is turned High or low beam can be selected to the left ( ) or right ( ), the with the dimmer switch. When the corresponding turn signals flash on and headlight is on high beam ( ), the...
  • Page 30: Brake Lever Adjusters

    GENERAL INFORMATION Brake Lever Adjusters There is an adjuster on the brake lever. The adjuster has 5 positions so that the released lever position can be adjusted to suit the operator’s hands. Push the lever forward and turn the ad- juster to align the number with the ar- row mark on the lever holder.
  • Page 31: 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 to the right. To close the cap, push it down into place with the key inserted. The key can be removed by turning it to the left to the original position.
  • Page 32: Fuel Tank

    GENERAL INFORMATION Fuel Tank WARNING Avoid filling the tank in the rain or Gasoline is extremely flammable where heavy dust is blowing so that the and can be explosive under cer- fuel does not get contaminated. tain conditions. Turn the igni- tion key to “OFF”.
  • Page 33 GENERAL INFORMATION Fuel Requirement rating is the Research Octane Number Your Kawasaki engine is designed to (RON). Always use a gasoline with an use only unleaded gasoline with a min- octane rating equal to, or higher than, imum octane rating of RON 91.
  • Page 34: Side Stand

    GENERAL INFORMATION Side Stand Whenever the side stand is used, The motorcycle is equipped with a make it a practice to kick the stand fully side stand. up before sitting on the motorcycle. NOTE ○ The motorcycle is equipped with a side stand switch.
  • Page 35: 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 ignition receptacle on the frame. key into the seat lock, and turn the key to the right.
  • Page 36: Tool Kit Case

    GENERAL INFORMATION • Tool Kit Case Insert the hook of the middle on the seat into the holder on the frame. The tool kit case is located under the seat. The kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual.
  • Page 37: 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 Do not ride the motorcycle with helmet attached to the hook. The helmet could cause an accident by distracting the operator or in- terfering with normal vehicle op- A.
  • Page 38: Steering Lock

    GENERAL INFORMATION Steering Lock WARNING The motorcycle is equipped with the Unlock the steering before start- steering lock at the right side of the ing the engine. Attempting to head pipe. drive with the steering locked could cause an accident. To lock the steering: 1.
  • Page 39: Electric Accessory Connectors

    Seat (–) Black/Yellow When using the electric accessory connectors under the fuel tank, the White/Blue Under Fuel electric accessory connection to the Tank (–) Black/Yellow connectors should be done by an au- Maximum Current : 10 A thorized Kawasaki dealer.
  • Page 40 GENERAL INFORMATION CAUTION WARNING Always install a fuse of 10 A or Take care not to pinch any wire less in the electrical accessory between the seat and the frame circuit. The vehicle has one fuse or between other parts to avoid (10 A) to protect the entire elec- a short circuit.
  • Page 41: 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 42 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 has the initial maintenance service performed by an authorized Kawasaki dealer.
  • Page 43: 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 44 HOW TO RIDE THE MOTORCYCLE • Make sure the transmission is in neu- back to “ON” before starting the en- tral. gine. • Leaving the throttle grip completely closed, push the starter button. CAUTION Do not operate the starter con- tinuously for more than 5 sec- onds, or the starter will overheat and the battery power will drop...
  • Page 45 HOW TO RIDE THE MOTORCYCLE CAUTION engine can be started if the clutch lever is pulled and the side stand is Do not let the engine idle longer fully up. than five minutes, or engine overheating and damage may occur. A.
  • Page 46: Jump Starting

    HOW TO RIDE THE MOTORCYCLE Jump Starting WARNING If your motorcycle battery is "run Battery acid generates hydro- down", it should be removed and gen gas which is flammable and charged. If this is not practical, a 12 explosive under certain con- volt booster battery and jumper cables ditions.
  • Page 47 HOW TO RIDE THE MOTORCYCLE • • Remove the tool kit case by un- Connect a jumper cable from the screwing the helmet-hook mounting positive (+) terminal of the booster screws. battery to the positive (+) terminal of the motorcycle battery. A.
  • Page 48 HOW TO RIDE THE MOTORCYCLE • • Connect another jumper cable from Follow the standard engine starting the negative (−) terminal of the procedure. booster battery to your motorcycle shift pedal or other unpainted metal CAUTION surface. Do not use the negative (−) Do not operate the starter con- terminal of the battery.
  • Page 49 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 50: 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 51: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE • Shifting Gears Open the throttle part way, while re- • leasing the clutch lever. Close the throttle while pulling in the clutch lever. • NOTE Shift into the next higher or lower ○ gear. The transmission is equipped with a positive neutral finder.
  • Page 52 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 53: Braking

    HOW TO RIDE THE MOTORCYCLE • Braking For emergency braking, disregard • downshifting, and concentrate on Close the throttle completely, leav- ing the clutch engaged (except when applying the brakes as hard as pos- sible without skidding. shifting gears) so that the engine will help slow down the motorcycle.
  • 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 key to “OFF” . • Support the motorcycle on a firm, level surface with the side stand. •...
  • Page 55: 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 throttle body. designed and manufactured to pro- In an emergency situation such as vide you optimum safety and conve- throttle failure, your vehicle may be nience.
  • Page 56: Parking

    HOW TO RIDE THE MOTORCYCLE Parking WARNING • Shift the transmission into neutral The muffler and exhaust pipe and turn the ignition key to “OFF”. are very hot while the engine is • Support the motorcycle on a firm, running and just after the engine level surface with the side stand.
  • Page 57: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE NOTE Catalytic Converter ○ This motorcycle is equipped with a When stopping near traffic at night, catalytic converter in the exhaust sys- you can leave the taillight, licence tem. Platinum and Rhodium in the plate light on for greater visibility by converter react with carbon monoxide turning the ignition key to the P (Park) and hydrocarbons to convert them into...
  • Page 58 HOW TO RIDE THE MOTORCYCLE • WARNING Do not coast the vehicle with the igni- tion switch and/or engine stop switch The muffler and exhaust pipe off. Do not attempt to start the en- are very hot while the engine is gine by rolling the vehicle if the bat- running and just after the engine tery is discharged.
  • Page 59: 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 Before changing lanes, look over helmet are strongly recommended. your shoulder to make sure the way You should be aware of and verify is clear.
  • Page 60 SAFE OPERATION braking may cause the motorcycle When riding in wet conditions or to skid and lose control. on loose roadway surfaces, the abil- ity to maneuver will be reduced. All When going down long slopes, of your actions should be smooth control vehicle speed by closing under these conditions.
  • Page 61: Safe Operation

    SAFE OPERATION Safe Operation Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor- cycle to a safe operating condition.
  • Page 62 SAFE OPERATION 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 63 SAFE OPERATION Side stand ....Returns to its fully up position by spring tension. Return spring not weak or not damaged. Refer to the "Daily Safety Checks" caution label attached to the back of seat.
  • Page 64: 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 65 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 related parts are in good condition.
  • Page 66: 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 67: Periodic Maintenance Chart

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart 1. Periodic Inspection (Engine Related Items) Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Items) Every (0.6) (7.5) (12) (15) (20) (24) K Valve clearance - inspect Every 42 000 km (26 000 mile) Throttle control system (play, •...
  • Page 68 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • • year – Coolant leak - inspect • • • •...
  • Page 69 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) Clutch and drive train: Clutch operation • •...
  • Page 70 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • Wheel bearings damage - year – inspect • • • • • • • Spoke tightness and rim –...
  • Page 71 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) Brake operation • • • • • • • year (effectiveness, play, drag) - inspect •...
  • Page 72 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • Uni-trak tie rods operation - – inspect • Uni-trak rocker arm bearings –...
  • Page 73 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • year Headlight aiming - inspect • • • Side stand switch operation year –...
  • Page 74 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever *Odometer Reading comes km × 1000 ( mile first Page × 1000) Operation (Chassis Items) Every (0.6) (7.5) (15) (24) (30) K Air cleaner element # every 18 000 km (12 000 mile) •...
  • Page 75 • • • • K Spark plug 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,...
  • Page 76: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • In order for the engine, transmission, If the oil has just been changed, start and clutch to function properly, main- the engine and run it for several min- tain the engine oil at the proper level, utes at idle speed.
  • Page 77 MAINTENANCE AND ADJUSTMENT CAUTION If the engine oil gets extremely low or if the oil pump does not function properly or oil pas- sages are clogged, the warning light in the speedometer will light. If this light stays on when the engine speed is above the idle speed, stop the engine im- mediately and find the cause.
  • Page 78 MAINTENANCE AND ADJUSTMENT WARNING Oil and/or Oil Filter Change • Warm up the engine thoroughly, and Motor oil is a toxic substance. then stop it. Dispose of used oil properly. • Place an oil pan beneath the engine. Contact your local authorities •...
  • Page 79 MAINTENANCE AND ADJUSTMENT • • Remove the regulator/rectifire bolt. Remove the bracket. A. Bracket A. Regulator/Rectifire B. Bolt B. Bolt...
  • Page 80 NOTE ○ If a torque wrench or required Kawasaki special tool is not avail- able, this item should be serviced by a Kawasaki dealer. A. Packing • Install the engine oil drain plug with a new gasket and tighten it to the specified torque.
  • Page 81 MAINTENANCE AND ADJUSTMENT • Fill the engine up to the upper level Engine Oil Capacity line with a good quality engine oil Capacity: 3.0 L (3.2 US qt) specified in the table. [when filter is not removed] • Start the engine. 3.2 L (3.4 US qt) •...
  • Page 82: Cooling System

    MAINTENANCE AND ADJUSTMENT Cooling System Radiator and Cooling Fin - Check the radiator fins for obstruc- tion by insects or mud. Clean off any obstructions with a stream of low-pressure water. WARNING The cooling fan turns on auto- matically, even with the ignition switch off.
  • Page 83 MAINTENANCE AND ADJUSTMENT CAUTION Coolant - Coolant absorbs excessive heat from Using high-pressure water, as the engine and transfers it to the air from a car wash facility, could at the radiator. If the coolant level be- damage the radiator fins and im- comes low, the engine overheats and pair the radiator’s effectiveness.
  • Page 84 MAINTENANCE AND ADJUSTMENT CAUTION a period of time, the cooling system accumulates rust and scale in the wa- If hard water is used in the sys- ter jacket and radiator. This will clog tem, it causes scale accumula- up the coolant passages, and con- tion in the water passages, and siderably reduce the efficiency of the considerably reduces the effi-...
  • Page 85 MAINTENANCE AND ADJUSTMENT CAUTION Coolant Level Inspection • Situate the motorcycle so that it is Permanent types of antifreeze on perpendicular to the ground. the market have anti-corrosion • Check the coolant level through the and anti-rust properties. When it coolant level gauge.
  • Page 86 MAINTENANCE AND ADJUSTMENT Coolant Filling • Remove the seat. • Remove the left side cover by remov- ing the screw. A. F (Full) Level Line B. L (Low) Level Line C. Reserve Tank • If the amount of coolant is insuffi- cient, add coolant.
  • Page 87 MAINTENANCE AND ADJUSTMENT • • Remove the reservoir tank cover. Open the cap from the reservoir tank, and add coolant through the filler opening to the F (Full) mark. A. Reservoir Tank Cover B. Bolt A. Reserve Tank B. Reserve Tank Cap •...
  • Page 88 If coolant must be added of- ten, or the reserve tank com- pletely runs dry, there is proba- bly leakage in the system. Have the cooling system inspected by your authorized Kawasaki dealer. Coolant Change A. Projections Have the coolant changed by an au- B.
  • Page 89: Drive Belt

    Periodic Main- replaced in accordance with the Peri- tenance Chart. odic Maintenance Chart. Belt check and adjustment should Spark plug removal should be done be done by an authorized Kawasaki by an authorized Kawasaki dealer. dealer. Spark Plug CAUTION Standard...
  • Page 90: Valve Clearance

    Chart. Air Suction Valves - Inspection and adjustment should The air suction valve is essentially a be done by an authorized Kawasaki check valve which allows fresh air to dealer. flow only from the air cleaner into the exhaust port. Any air that has passed...
  • Page 91: Air Cleaner

    Maintenance Chart. This motorcycle’s tion should be done by an authorized air cleaner element consists of a wet Kawasaki dealer. paper filter, which can not be cleaned. In dusty, rainy, or on muddy conditions, the air cleaner element should be ser- viced more frequently than the recom- mended interval.
  • Page 92 MAINTENANCE AND ADJUSTMENT • Element Removal Remove the air cleaner screw and • Remove the bolts of the air cleaner the air cleaner. If any part of the ele- cover located on the right-side of the ment is damaged, the element must engine.
  • Page 93: Throttle Control System

    MAINTENANCE AND ADJUSTMENT Throttle Control System WARNING Check the throttle grip play, in accor- If dirt or dust is allowed to pass dance with the Periodic Maintenance through into the fuel injection Chart, and adjust the throttle grip play. system, the throttle may be- come stuck, possibly causing Throttle Grip - accident.
  • Page 94 MAINTENANCE AND ADJUSTMENT Inspection Adjustment • • Check that there is 2 ∼ 3 mm (0.08 Loosen the locknuts at the upper ∼ 0.12 in.) throttle grip play when ends of the throttle cables, and screw lightly turning the throttle grip back both throttle cable adjusting nuts in and forth.
  • Page 95: Idle Speed

    Kawasaki dealer. WARNING Operation with improperly ad- justed, incorrectly routed, or damaged cables could result in...
  • Page 96 MAINTENANCE AND ADJUSTMENT • Adjustment Open and close the throttle a few • Start the engine, and warm it up thor- times to make sure that the idle oughly. speed does not change. Readjust if • necessary. Wait until the idle speed drops before •...
  • Page 97: Clutch

    MAINTENANCE AND ADJUSTMENT Clutch Inspection • Check that the clutch lever has 2 ∼ 3 Due to friction plate wear and clutch mm (0.08 ∼ 0.12 in.) of play as shown cable stretch over a long period of use, the clutch must be adjusted in accor- in the figure.
  • Page 98 MAINTENANCE AND ADJUSTMENT • Adjustment If it cannot be done, use the nuts at • Turn the adjuster so that the clutch the middle of the clutch cable. lever will have 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play. WARNING Be sure the upper end of the clutch outer cable is fully seated...
  • Page 99: 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. Lining Thickness B. 1 mm (0.04 in.) Disc Brake Fluid -...
  • Page 100 MAINTENANCE AND ADJUSTMENT Fluid Requirement Fluid Level Inspection • Use heavy-duty brake fluid only from The brake fluid level in the front brake a container marked DOT4 . fluid reservoir must be kept above the line (lower level line) next to the CAUTION gauge and that in the rear brake fluid reservoir (located near the brake...
  • Page 101 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 reser- voir is a stepped line showing the up- per level line.
  • Page 102 MAINTENANCE AND ADJUSTMENT WARNING Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser- voir are unidentified.
  • Page 103: Brake Light Switches

    • If it does not, ask your authorized If the brake lever or pedal feels Kawasaki dealer to inspect the front mushy when it is applied, there brake light switch. might be air in the brake lines or the brake may be defective.
  • Page 104 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 105: 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 preload adjuster has 7 positions. • Remove the left side cover and reser- voir tank cover (see “Cooling Sys- A.
  • Page 106 MAINTENANCE AND ADJUSTMENT A. Reservoir Tank A. Under Part of Reservoir Tank B. Bolt B. Holder • NOTE In accordance with the following ta- ○ 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 107 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 ad- juster by using the suitable hook wrenches. A. Spring Preload Adjuster B. Wrench Position —→...
  • Page 108: 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 securely installed. Failure to maintain proper inflation pressures or observe payload limits for your tires may adversely affect han- dling and performance of your motorcy-...
  • Page 109 MAINTENANCE AND ADJUSTMENT NOTE Tire Wear, Damage ○ As the tire tread wears down, the tire Measure the tire pressure when the becomes more susceptible to puncture tires are cold (that is, when the mo- and failure. An accepted estimate is torcycle has not been ridden more that 90% of all tire failures occur during than a mile during the past 3 hours).
  • Page 110 MAINTENANCE AND ADJUSTMENT • In accordance with the Periodic Minimum Tread Depth Maintenance Chart, measure the Front 1 mm depth of the tread with a depth (0.04 in.) gauge, and replace any tire that has worn down to the minimum al- Rear Under 130 km/h 2 mm...
  • Page 111 MAINTENANCE AND ADJUSTMENT WARNING Standard Tire (Tubeless) 130/90-16M/C 67H To ensure safe handling and Front • DUNLOP "D404FP” stability, use only the recom- mended standard tires for re- 180/70-15M/C 76H Rear placement, inflated to the stan- • DUNLOP "D404” dard pressure. Tires that have been punctured WARNING and repaired do not have the...
  • Page 112: Battery

    MAINTENANCE AND ADJUSTMENT Battery The discharge rate depends on the The battery installed in this vehicle type of battery and ambient temper- is a sealed type, and the sealing strip ature. As temperatures rise, so does should not be removed at any time af- the discharge rate.
  • Page 113 MAINTENANCE AND ADJUSTMENT Self-discharge Current Drain Approx. Number of Days Days from From 100% Charged to Dis- Days from 100% 100 % 100% discharged charging Charged to 50% Charged Tempera- Ampere Discharged to 100 % Lead Lead ture Discharged -Antimony -Calcium 7 mA 60 Days...
  • Page 114 If the above chargers are not avail- It is the owner’s responsibility to keep able, use equivalent one. the battery fully charged. Failure to do For more details, ask your Kawasaki so can lead to battery failure and leave dealer. you stranded.
  • Page 115 MAINTENANCE AND ADJUSTMENT • CAUTION Attach the leads from the charger and charge the battery at a rate that Never remove the sealing stirp, is 1/10th of the battery capacity. For or the battery can be damaged. example, the charging rate for a 10 Do not install a conventional bat- Ah battery would be 1.0 ampere.
  • Page 116 MAINTENANCE AND ADJUSTMENT • Battery Removal Clean the battery using a solution of • Remove the seat and tool kit case baking soda and water. Be sure that (see “Jump Starting” section in the “ the wire connections are clean. How to Ride the Motorcycle”...
  • Page 117 MAINTENANCE AND ADJUSTMENT • NOTE Cover the (+) terminal with its protec- ○ tive cap. When installing the seat, or tool kit • Reinstall the parts removed. case, be sure not to pinch the hose, or wires. The hose or wires should be routed as shown in the figure.
  • Page 118: Headlight Beam

    MAINTENANCE AND ADJUSTMENT Headlight Beam Vertical Adjustment The headlight beam is adjustable ver- Horizontal Adjustment tically. If adjusted too low, neither low The headlight beam is adjustable nor high beam will illuminate the road horizontally. If not properly adjusted far enough ahead. If adjusted too high, horizontally, the beam will point to one the high beam will fail to illuminate the side rather than straight ahead.
  • Page 119: 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 120 MAINTENANCE AND ADJUSTMENT • • Remove the seat. Remove the screw • Remove the left side cover (see “Cooling System” section in this chapter). A. Screw A. Fuse Box B. Spare Fuse...
  • Page 121 MAINTENANCE AND ADJUSTMENT • • Pull out the right side cover and then When installing the right side cover, inspect the main fuse. be sure to insert the projections of the right side cover. A. Main Fuse A. Projections B. Right Side Cover...
  • Page 122: Cleaning Your Motorcycle

    General Precautions standard fuse. Frequent and proper care of your Replace the blown fuse with a Kawasaki motorcycle will enhance new one of the correct capacity its appearance, optimize overall per- as specified on the fuse box and formance, and extend its useful life.
  • Page 123 MAINTENANCE AND ADJUSTMENT • • Gasoline, brake fluid, and coolant Mix a mild neutral detergent (de- will damage the finish of painted and signed for motorcycles or automo- plastic surfaces: wash them off im- biles) and water in bucket. mediately. a soft cloth or sponge to wash your •...
  • Page 124 MAINTENANCE AND ADJUSTMENT brakes and restores them to normal Painted Surfaces operating performance. After washing your motorcycle, coat painted surfaces, both metal and plas- NOTE tic, with a commercially available mo- ○ torcycle/automotive wax. Wax should After riding in an area where the be applied once every three months or roads are salted or near the ocean, as conditions require.
  • Page 125 MAINTENANCE AND ADJUSTMENT CAUTION Chrome and Aluminum Chrome and uncoated aluminum Plastic parts may deteriorate parts can be treated with a chrome/alu- and break if they come in con- minum polish. Coated aluminum tact with chemical substances should be washed with a mild neu- or household cleaning products tral detergent and finished with a spray such as gasoline, brake fluid,...
  • Page 126 MAINTENANCE AND ADJUSTMENT Vinyl parts should be washed with the rest of the motorcycle, then treated with a vinyl treatment. The sidewalls of tires and other rub- ber components should be treated with a rubber protectant to help prolong their useful life.
  • Page 127: 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 Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
  • Page 128 STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions. Turn the ignition key to “OFF”. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 129 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 130: Environmental Protection

    Environmental Protection To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure.
  • Page 131: Location Of Labels

    LOCATION OF LABELS Location of Labels 1. Daily Safety Checks 2. Unleaded Gasoline 3. Brake Fluid (Front) 4. Brake Fluid (Rear)
  • Page 132 LOCATION OF LABELS 5. Tire and Load Data 6. Battery Position/Danger...
  • Page 133 LOCATION OF LABELS...
  • Page 134 LOCATION OF LABELS (3)/(4)
  • Page 135 LOCATION OF LABELS...
  • Page 136 LOCATION OF LABELS...

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