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Table of Contents

   Summary of Contents for Kawasaki Z1000SX 2012

  • Page 3 ENGLISH Motorcycle Owner's Manual...
  • Page 5 GENERAL INFORMATION Quick Reference Guide HOW TO RIDE THE MOTORCYCLE This Quick Reference Guide will SAFE OPERATION assist you in finding the information you're looking for. MAINTENANCE AND ADJUSTMENT STORAGE A Table of Contents is included after the Foreword.
  • Page 7 Whenever you see the symbols NOTE ○ shown below, heed their instructions! This note symbol indicates points of Always follow safe operating and main- particular interest for more efficient tenance practices. and convenient operation. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious in- jury.
  • Page 8 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 9 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 © 2012 Kawasaki Heavy Industries, Ltd. Mar. 2012. (2)
  • Page 10: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS ........ 10 Fuel Tank Cap ........40 LOCATION OF PARTS ......14 Fuel ............ 41 LOADING AND ACCESSORIES IN- Fuel Requirements: ....... 41 FORMATION ........17 Filling the Tank: ......42 GENERAL INFORMATION ....20 Side Stand ......... 44 Meter Instruments ......
  • Page 11 ENVIRONMENTAL PROTECTION ..161 Cooling System ........95 LOCATION OF LABELS ...... 162 Spark Plugs ........100 Valve Clearance .........101 Kawasaki Clean Air System ....101 Exhaust Device ........102 Air Cleaner .........103 Throttle Control System .....105 Engine Vacuum Synchronization ..107 Idle Speed ..........108 Clutch ..........109...
  • Page 12: Specifications

    SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 101.5 kW (138 PS) @9 600 r/min (rpm) (HR) 78.2 kW (106 PS) @9 100 r/min (rpm) Maximum Torque 110 N·m (11.2 kgf·m, 81.1 ft·lb) @7 800 r/min (rpm) (HR) 95 N·m (9.7 kgf·m, 70.1 ft·lb) @7 500 r/min (rpm) Minimum Turning Radius 3.1 m (122 in.) DIMENSIONS...
  • Page 13 SPECIFICATIONS Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Fuel System FI (Fuel Injection) Ignition System Battery and coil (transistorized ignition) Ignition Timing (Electronically 10° BTDC @1 100 r/min (rpm) ~ 40.2° BTDC @5 advanced) 200 r/min (rpm) Spark Plugs NGK CR9EIA-9 Lubrication System...
  • Page 14 SPECIFICATIONS 2.600 (39/15) 1.950 (39/20) 1.600 (24/15) 1.389 (25/18) 1.238 (26/21) 1.136 (25/22) FRAME Caster 24.5° Trail 102 mm (4.0 in.) Tire Size: Front 120/70ZR17 M/C (58 W) Rear 190/50ZR17 M/C (73 W) Rim Size: Front J17M/C × MT3.50 Rear J17M/C ×...
  • Page 15 HR: with Honeycomb Catalytic Converter (Restricted model) Even if one of LED (Light Emitting Diode) tail/brake lights does not go on, consult with an authorized Kawasaki dealer. Specifications are subject to change without notice, and may not apply to every...
  • Page 16: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 7. Right Handlebar Switches 2. Left Handlebar Switches 8. Front Brake Lever 3. Spring Preload Adjuster 9. Throttle Grip 4. Rebound Damping Force Adjuster 10. Windshield Adjuster Knob 5. Meter Instruments 11.
  • Page 17 LOCATION OF PARTS 11. Turn Signal Lights 18. Tail/Brake Light 24. Brake Caliper 12. Headlight 19. License Plate Light 25. Shift Pedal 13. Spark Plugs 20. Seat Lock 26. Side Stand 14. Air Cleaner 21. Front Fork 27. Drive Chain 15.
  • Page 18 LOCATION OF PARTS 29. Brake Fluid Reservoir (Rear) 36. Rebound Damping Force Adjuster 30. Fuse Box 37. Rear Shock Absorber 31. Battery 38. Rear Brake Light Switch 32. Idle Adjusting Screw 39. Rear Brake Pedal 33. Fuel Tank Cap 40. Oil Level Inspection Window 34.
  • Page 19: Loading And Accessories Information

    Kawasaki Parts and Accessories motorcycle, make sure that the have been specially designed for motorcycle is not overloaded and use on Kawasaki motorcycles. We that you have followed these in- strongly recommend that all parts structions. and accessories you add to your mo-...
  • Page 20 LOADING AND ACCESSORIES INFORMATION prepared to assist you in making your Baggage weight should also be dis- determinations. tributed equally on both sides of the 1. Any passenger should be thor- motorcycle. Avoid carrying baggage oughly familiar with motorcycle op- that extends beyond the rear of the eration.
  • Page 21 7. Weight attached to the handlebar or that Kawasaki cannot assume re- front fork will increase the mass of sponsibility for the results of such the steering assembly and can re- unintended use of the motorcycle.
  • Page 22: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. MODE Button B. RESET Button C. Left Turn Signal Indicator Light D. Tachometer E. ABS Indicator Light (only on ABS model) F. High Beam Indicator Light G. Neutral Indicator Light H. Right Turn Signal Indicator Light I.
  • Page 23: Digital Meter

    GENERAL INFORMATION Digital Meter The digital meter displays the follow- ing functions: the speedometer, clock, trip meter AB, odometer, fuel gauge, oil pressure warning symbol, immobilizer warning symbol, coolant temperature warning symbol and fuel injection warning symbol. When the ignition key is turned to “ON”, all the LCD seg- ments are displayed for about one sec- ond, then, depending on the mode...
  • Page 24 GENERAL INFORMATION • regulations is correctly displayed be- Display the odometer. • fore riding. The km/h·mph display shifts by pushing the RESET button while the NOTE MODE button pushed in. ○ Do not operate the vehicle with the meter unit displaying in the wrong unit (km/h or mph).
  • Page 25 GENERAL INFORMATION • The km/h·mph display shifts as fol- rpm). On the top side of the tachometer face is a portion called the “red zone”. lows. Engine r/min (rpm) in the red zone is above maximum recommended gine speed and is also above the range for good performance.
  • Page 26 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 27 GENERAL INFORMATION the button advances the hour or mi- nute continuously. ○ The clock works normally by the back-up power while the ignition switch is turned off. ○ When the battery is disconnected, A. Odometer the clock is reset to 1:00 and starts B.
  • Page 28 GENERAL INFORMATION • Push the MODE button to display the trip meter A or B. • Push the RESET button and hold it • After two second, the figure display turns to 0.0, and then starts counting when the vehicle is operated. The meter counts until it is next reset.
  • Page 29: Warning/indicator Lights

    When vehicle stands with Side the wiring. Have the wiring inspected Stand, Fuel Gauge cannot show the by an authorized Kawasaki dealer im- amount of fuel in the fuel tank exactly. mediately. Stand upright the vehicle to check the Warning/Indicator Lights fuel level.
  • Page 30 If something is wrong with the ABS, checked by an authorized Kawasaki the indicator comes on and remains lit. dealer. Refer to the “Warning Symbols” When the indicator light is on, the ABS in this section for more detailed infor- does not function but if the ABS fails, mation.
  • Page 31 ) goes off the warning indicator light does not soon after it is ensured that its circuit is blink. functioning properly. If the warning indi- cator light and warning symbol blink, have the immobilizer system checked by an authorized Kawasaki dealer.
  • Page 32 “ON”, the fuel injec- tion warning symbol ( ) goes off soon after it is ensured that its circuit is functioning properly. If the warning indi- cator light and warning symbol blink, have the FI system checked by an au- thorized Kawasaki dealer.
  • Page 33: Key

    Registering additional ignition key should be done by an au- thorized Kawasaki dealer. Blank keys are available at your Kawasaki deal- ers. Ask your dealer to make any addi- tional spare keys you may need, using your original key as a master. To make...
  • Page 34 Do not put two keys of any immo- If all ignition keys are lost, an au- bilizer system on the same key thorized Kawasaki dealer will ring. have to replace the ECU and or- Do not submerge any key in der new ignition keys.
  • Page 35 GENERAL INFORMATION If an improperly coded key is used or and hold the MODE and RESET but- any incorrect communication between tons simultaneously for more than ECU and key is occurred, the engine two seconds, within twenty seconds does not start and warning indicator after turning the ignition key to the “OFF”...
  • Page 36: Ignition Switch/steering Lock

    GENERAL INFORMATION Ignition Switch/Steering Lock Engine off. Electrical circuits This is a four-position, key-operated off. switch. The key can be removed from Engine on. All electrical equip- the switch when it is in the OFF, LOCK, ment can be used. position.
  • Page 37 GENERAL INFORMATION released after starting the engine. To NOTICE avoid battery discharge, always start the engine immediately after turning When turning the handlebar all the ignition key to “ON”. the way to the right or left, the space between the handlebar holder and the ignition switch cover becomes very narrow.If an accessory such as a key ring at-...
  • Page 38: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches Dimmer Switch High or low beam can be selected with the dimmer switch. When the headlight is on high beam ( ), the high beam indicator light goes on. High beam..( Low beam..( NOTE ○ When the headlight is on high beam, both headlights go on.
  • Page 39: Horn Button

    GENERAL INFORMATION Horn Button NOTICE When the horn button is pushed, the horn sounds. Be careful not to use the hazard lights for more than 30 minutes, Passing Button otherwise the battery may be- When the passing button is pushed, come totally discharged.
  • Page 40: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches NOTE ○ Although the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine. Starter Button The starter button operates the elec- tric starter when the transmission is in neutral.
  • Page 41: Brake Lever Adjuster

    GENERAL INFORMATION Brake Lever Adjuster There is an adjuster on the brake lev- er. The adjuster has 6 positions so that the released lever position can be ad- justed to suit the operator's hands. Push the lever forward and turn the ad- juster to align the number with the mark on the lever holder.
  • Page 42: Fuel Tank Cap

    GENERAL INFORMATION Fuel Tank Cap To open the fuel tank cap, pull up the key hole cover. Insert the ignition key into the fuel tank cap and turn the key to the right. To close the cap, push it down into place with the key inserted.
  • Page 43: Fuel

    GENERAL INFORMATION Fuel NOTICE Fuel Requirements: If engine “knocking” or “pinging” Your Kawasaki engine is designed to use only unleaded gasoline with a min- occurs, use a different brand of gasoline of a higher octane rat- imum octane rating shown below.
  • Page 44: Filling The Tank

    GENERAL INFORMATION equal to or higher than that shown in * E10 means fuel containing up to the table. 10% ethanol as specified by European directive. Fuel Type Unleaded Gasoline Filling the Tank: Ethanol Avoid filling the tank in the rain or E10 or less Content where heavy dust is blowing so that...
  • Page 45 GENERAL INFORMATION NOTICE WARNING Certain ingredients in gasoline Gasoline is extremely flammable may cause paint fading or dam- and can be explosive under cer- age. Be extra careful not to spill tain conditions, creating the po- fuel during refueling. tential for serious burns. Turn the ignition switch off.
  • Page 46: 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 47: Seats

    GENERAL INFORMATION Seats Passenger's Seat Removal • Remove the passenger’s seat by in- serting the ignition key into the seat lock, and turning it clockwise. WARNING The muffler quickly becomes very hot soon after the engine is started and can cause serious A.
  • Page 48 GENERAL INFORMATION NOTE Rider's Seat Removal • ○ Remove the bolts and pull off the When removing the passenger’s seat upward seat, pull it up while turning the key. A. Bolts A. Passenger’s Seat B. Rider’s Seat B. Pull up C.
  • Page 49 GENERAL INFORMATION • Rider's Seat Installation Insert the projection at the front of • Insert the tabs on the front of the rid- the passenger's seat into the hole on er's seat into the slots in the frame. the frame. •...
  • Page 50: Tool Kit

    GENERAL INFORMATION • Pull up the front and rear ends of the Tool Kit passenger's and rider's seats to The tool kit is located under the pas- make sure they are securely locked. senger's seat. The kit contains tools that are helpful in making roadside repairs, adjust- ments, and some maintenance proce- dures explained in this manual.
  • Page 51: Windshield

    GENERAL INFORMATION • Windshield Align the mark of the meter cover and the groove of the windshield The windshield can be adjusted with- bracket. in 3 positions in height to suit the rider's preference. Adjustment • Hold the windshield by the hand. •...
  • Page 52 GENERAL INFORMATION WARNING Removing your hand(s) from the handle- bars while riding could lead to a crash re- sulting in serious injury or death. Do not adjust the angle of the windshield while riding; stop the motorcycle before making any adjustments. Turning the handlebars while using the knob to adjust the wind- screen may pinch your hand and/or fin- gers between the knob and front fork.
  • Page 53: Break-in

    BREAK-IN BREAK-IN The first 1 600 km (1 000 miles) 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 54 During break-in, avoid sudden and maximum braking and ac- celeration, and hard cornering. In addition to the above, at 1 000 km (600 miles) it is extremely important that the owner has the initial maintenance service performed by an authorized Kawasaki dealer.
  • Page 55: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE • Turn the ignition key to “ON”. Starting the Engine • • Make sure the transmission is in Check that the engine stop switch is neutral. in the position. A. Neutral Indicator Light A.
  • Page 56 HOW TO RIDE THE MOTORCYCLE NOTE NOTICE ○ The motorcycle is equipped with a Do not operate the starter contin- vehicle-down sensor, which causes uously for more than 5 seconds, the engine to stop automatically and or the starter will overheat and the fuel injection warning symbol to the battery power will drop tem- blink when the motorcycle falls down...
  • Page 57 HOW TO RIDE THE MOTORCYCLE NOTE NOTICE ○ The motorcycle is equipped with a Do not let the engine idle longer starter lockout switch. This switch is than five minutes, or engine over- designed so that the engine does not heating and damage may occur.
  • Page 58: Jump Starting

    HOW TO RIDE THE MOTORCYCLE Jump Starting Connecting Jumper Cables • If your motorcycle battery is “run Remove the rider's seat (see Seats section in the GENERAL INFORMA- down”, it should be removed and TION chapter). charged. If this is not practical, a 12 •...
  • Page 59 HOW TO RIDE THE MOTORCYCLE • Connect a jumper cable from the footpeg or other unpainted metal sur- positive (+) terminal of the booster face. Do not use the negative (–) ter- battery to the positive (+) terminal of minal of the battery. the motorcycle battery.
  • Page 60: Moving Off

    HOW TO RIDE THE MOTORCYCLE • Follow the standard engine starting Moving Off • procedure. Check that the side stand is up. • Pull in the clutch lever. • NOTICE Shift into 1st gear. • Open the throttle a little, and start to Do not operate the starter contin- let out the clutch lever very slowly.
  • Page 61: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE NOTE Shifting Gears • ○ Close the throttle while pulling in the The motorcycle is equipped with a clutch lever. side stand switch. This switch is de- • Shift into the next higher or lower signed so that the engine does not gear.
  • Page 62: Braking

    HOW TO RIDE THE MOTORCYCLE motorcycle is standing still, the trans- Braking • mission cannot be shifted past neu- Close the throttle completely, leaving tral from 1st gear. To use the positive the clutch engaged (except when neutral finder, shift down to 1st gear, shifting gears) so that the engine will then lift up on the shift pedal while help slow down the motorcycle.
  • Page 63 HOW TO RIDE THE MOTORCYCLE • Even in motorcycles equipped with ABS, braking during cornering may cause wheel slip. When turning a corner, it is better to limit braking to the light application of both brakes or not to brake at all. Reduce your speed before you get into the corner.
  • Page 64: Anti-lock Brake System (abs) For Models Equipped With Abs

    HOW TO RIDE THE MOTORCYCLE Anti-lock Brake System (ABS) manner as conventional motorcycle brake system. for models equipped with • ABS cannot compensate for adverse road conditions, misjudgment or im- ABS is designed to help prevent the proper application of brakes. You wheels from locking up when the must take the same care as with mo- brakes are applied hard while running...
  • Page 65 HOW TO RIDE THE MOTORCYCLE • Same as conventional brake system, may confuse the computers, which an excessive sudden braking may can extend braking distance. cause wheel lock up that makes it harder to control a motorcycle. WARNING • During braking, ABS will not prevent Use of non-recommended tires the rear wheel lifting.
  • Page 66: Abs Indicator Light

    6 km/h or be- The light does not come on when the low, you should have the ABS ignition switch is turned on. • checked by an authorized Kawasaki The light remains lit after the motor- dealer. cycle starts moving. •...
  • Page 67: Stopping The Engine

    Stopping the Motorcycle in an • Close the throttle completely. Emergency • Shift the transmission into neutral. Your Kawasaki Motorcycle has been • Turn the ignition key to “OFF”. designed and manufactured to provide • Support the motorcycle on a firm, you optimum safety and convenience.
  • Page 68: Parking

    HOW TO RIDE THE MOTORCYCLE In an emergency situation such as Parking throttle failure, your vehicle may be WARNING stopped by applying the brakes and disengaging the clutch. Once this stop- Operating or parking the vehicle ping procedure is initiated, the engine near flammable materials can stop switch may be used to stop the cause a fire, and can result in...
  • Page 69 HOW TO RIDE THE MOTORCYCLE • If parking inside a garage or other WARNING structure, be sure it is well ventilated and the motorcycle is not close to The engine and exhaust system any source of flame or sparks; this get extremely hot during normal includes any appliance with a pilot operation and can cause serious...
  • Page 70: 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 turn signals blink- tem. The converter reacts with carbon ing for greater visibility by turning the monoxide, hydrocarbons and nitrogen ignition key to the...
  • Page 71 HOW TO RIDE THE MOTORCYCLE • Use only unleaded gasoline. Never WARNING use leaded gasoline. Leaded gaso- line significantly reduces the capabil- Operating or parking the vehicle ity of the catalytic converter. near flammable materials can • Do not operate the vehicle with the cause a fire, and can result in engine of any one cylinder misfiring.
  • Page 72: 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 73 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 74 SAFE OPERATION Do not downshift at too high an r/ min (rpm) to avoid damage from overrevving to the engine. Avoiding unnecessary weaving is important to the safety of both the rider and other motorists.
  • Page 75: Daily Safety Checks

    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 76 SAFE OPERATION Tires ......Air pressure (when cold): Front 250 kPa (2.50 kgf/cm², 36 psi) 290 kPa (2.90 kgf/cm², 42 psi) Rear Install the air valve cap. Drive Chain ....Slack 20 ~ 30 mm (0.8 ~ 1.2 in.). Lubricate when chain is dry. Nuts, Bolts, Fasteners Check that steering and suspension components, axles, and all controls are properly tightened or fastened.
  • Page 77 SAFE OPERATION Engine Stop Switch ..Stops engine. Side Stand ....Return 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 left side cover.
  • Page 78: 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 79 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 80: 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 81: 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 82 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Engine Items) Engine vacuum syn- • • • chronization - in- spect •...
  • Page 83 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Engine Items) • • • • Coolant leak - in- year spect •...
  • Page 84 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Which- ever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Clutch and drive train: Clutch operation •...
  • Page 85 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) • • • Drive chain guide – wear - inspect Wheels and tires: •...
  • Page 86 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Brake system: • • • • • • • Brake fluid leak - in- year spect •...
  • Page 87 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) Brake operation (ef- • • • • • • • fectiveness, play, year drag) - inspect...
  • Page 88 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) • • • Rocker arm opera- – tion - inspect •...
  • Page 89 MAINTENANCE AND ADJUSTMENT Frequency Which- ever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) (Chassis Items) • • • Headlight aiming - year inspect • • •...
  • Page 90 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes first *Odometer Reading 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 every 18 000 km (11 250 mile) •...
  • Page 91: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • 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 92 MAINTENANCE AND ADJUSTMENT • Check the engine oil level through opening using a syringe or some oth- the oil level inspection window. With er suitable device. • the motorcycle held level, the oil lev- If the oil level is too low, add the oil to el should come up between the reach the correct level.
  • Page 93 MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • Warm up the engine thoroughly, and then stop it. • Place an oil pan beneath the engine. • Remove the engine oil drain bolt. A. Oil Pressure Warning Symbol B. Warning Indicator Light A.
  • Page 94 MAINTENANCE AND ADJUSTMENT NOTE WARNING ○ If a torque wrench or required Kawa- Engine oil is a toxic substance. saki special tool is not available, this Dispose of used oil properly. item should be serviced by a Kawa- Contact your local authorities for saki dealer.
  • Page 95 MAINTENANCE AND ADJUSTMENT • Apply a thin film of oil to the packing Tightening Torque and tighten the cartridge to Engine Oil Drain Bolt: specified torque. 29 N·m (3.0 kgf·m, 21 ft·lb) Oil Filter: 17 N·m (1.7 kgf·m, 13 ft·lb) Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO...
  • Page 96 MAINTENANCE AND ADJUSTMENT Engine Oil Capacity Although 10W-40 engine oil is the recommended oil for most conditions, Capacity: the oil viscosity may need to be 3.2 L (3.4 US qt) changed to accommodate atmospheric (when filter is not removed) 3.8 L (4.0 US qt) conditions in your riding area.
  • Page 97: 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 damage the radiator fins and im- obstructions with a stream of low-pres- sure water.
  • Page 98 MAINTENANCE AND ADJUSTMENT adjustments in accordance with the coolant containing corrosion and rust Periodic Maintenance Chart. inhibitor chemicals are not used, over a period of time, the cooling system ac- Coolant - cumulates rust and scale in the water Coolant absorbs excessive heat from jacket and radiator.
  • Page 99 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 100 MAINTENANCE AND ADJUSTMENT Coolant Level Inspection • Situate the motorcycle so that it is perpendicular to the ground. • Check the coolant level if it is be- tween the F (Full) and L (Low) level lines. NOTE ○ Check the level when the engine is cold (room or atmospheric tempera- ture).
  • Page 101 Have the cooling sys- tem inspected by your authorized Kawasaki dealer. A. Reserve Tank B. F (Full) Level Line C. L (Low) Level Line Coolant Change D. Cap • Have the coolant changed by an au- Install the cap. thorized Kawasaki dealer.
  • Page 102: 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 by an authorized Kawasaki dealer. Spark Plug Standard NGK CR9EIA-9 Plug 0.8 ~ 0.9 mm...
  • Page 103: Valve Clearance

    Inspection and adjustment should be flow only from the air cleaner into the done by an authorized Kawasaki deal- exhaust port. Any air that has passed the air suction valve is prevented from...
  • Page 104: Exhaust Device

    This ex- Air suction valve removal and in- haust device is controlled by the ECU, spection should be done by an author- and adjustment or maintenance should ized Kawasaki dealer. be done by an authorized Kawasaki dealer. A. Exhaust Device Cables...
  • Page 105: Air Cleaner

    The air cleaner element must be re- placed in accordance with the Periodic Maintenance Chart. In dusty, rainy, or muddy conditions, the air cleaner ele- ment should be serviced more fre- quently than recommended interval. Removal and cleaning should be done by an authorized Kawasaki deal-...
  • Page 106 MAINTENANCE AND ADJUSTMENT Oil Draining • WARNING Inspect the transparent reservoir lo- cated on the left side of the engine to Oil on tires will make them slip- see if any oil or water has run down pery and can cause an accident from the air cleaner housing.
  • Page 107: Throttle Control System

    MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check that the throttle grip play is Check the throttle grip play each day correct by lightly turning the throttle before riding the motorcycle, and carry grip back and forth. out maintenance and adjustments in accordance with the Periodic Mainte- nance Chart.
  • Page 108 If the throttle cables cannot be ad- justed with the adjuster at the upper of the throttle cable, further adjust- ment of the throttle cables should be done by an authorized Kawasaki dealer. • With the engine idling, turn the han-...
  • Page 109: Engine Vacuum Synchronization

    Be sure to cally in accordance with the Periodic correct any of these conditions be- Maintenance Chart by an authorized fore idling. Kawasaki dealer. NOTE WARNING ○ Poor engine vacuum synchroniza- Operation with improperly ad-...
  • Page 110: Idle Speed

    MAINTENANCE AND ADJUSTMENT Idle Speed The idle speed adjustment should be performed in accordance with the Peri- odic Maintenance Chart or whenever the idle speed is disturbed. Adjustment • Start the engine, and warm it up thor- oughly. • Adjust the idle speed by turning the idle adjusting screw.
  • Page 111: 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 operation should be checked WARNING each day before riding the motorcycle, Operation with damaged cables and must be adjusted in accordance could result in an unsafe riding...
  • Page 112 If the play is incorrect, adjust the lev- slides smoothly. If there is any irregu- er play as follows. larity, have the clutch cable checked by an authorized Kawasaki dealer. Adjustment • • Check the clutch lever play as shown Loosen the locknut at the clutch lev- in the figure.
  • Page 113: Drive Chain

    MAINTENANCE AND ADJUSTMENT NOTE Drive Chain ○ The drive chain slack and lubrication After the adjustment is made, start must be checked each day before rid- the engine and check that the clutch ing the motorcycle and must be main- does not slip and releases properly.
  • Page 114 MAINTENANCE AND ADJUSTMENT Chain Slack Inspection • WARNING Set the motorcycle up on its side stand. Misalignment of the wheel will re- • Check the wheel alignment. Confirm sult in abnormal wear, and may that the notch on the swingarm and result in an unsafe riding condi- the mark on the chain adjuster are at tion.
  • Page 115 MAINTENANCE AND ADJUSTMENT • Rotate the rear wheel to find the po- Drive Chain Slack sition where the chain is tightest, and Standard: 20 ~ 30 mm (0.8 ~ 1.2 in.) measure the maximum chain slack by pulling up and pushing down the Chain Slack Adjustment •...
  • Page 116 MAINTENANCE AND ADJUSTMENT • Tighten the chain adjuster clamp NOTE ○ bolts to the specified torque. • If a torque wrench is not available, Rotate the wheel, measure the chain this item should be serviced by a Ka- slack again at the tightest position, wasaki dealer.
  • Page 117 MAINTENANCE AND ADJUSTMENT • Turn the right chain adjuster with the NOTE ○ allen wrench so that the notch on the The wheel alignment adjustment can swingarm and the mark on the chain adjust at left chain adjuster also. ○ adjuster are at the same position on If a torque wrench is not available, the left and right sides.
  • Page 118 MAINTENANCE AND ADJUSTMENT • • Remove the bolts. Stretch the chain taut either by using • Remove the chain cover. the chain adjusters, or by hanging a 10 kg (22 lb) weight on the chain. • Measure the length of 20 links on the straight part of the chain from pin center of the 1st pin to pin center of the 21st pin.
  • Page 119 For safety, use only the standard chain. It is an endless type and should not be cut for installation; have it installed by an authorized Kawasaki dealer. • Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links.
  • Page 120 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. Lubrication • Lubrication is also necessary after If the chain is especially dirty, clean it...
  • Page 121: Brakes

    MAINTENANCE AND ADJUSTMENT Brakes Brake Fluid - In accordance with the Periodic Brake Wear Inspection Maintenance Chart, inspect the brake Inspect the brakes for wear. For each fluid level in both the front and rear front and rear disc brake caliper, if the brake fluid reservoirs and change the thickness of either pad is less than 1 brake fluid.
  • Page 122 MAINTENANCE AND ADJUSTMENT Fluid Level Inspection • With the brake fluid reservoirs held horizontal, the brake fluid level must be kept between the upper and lower level lines. A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line •...
  • Page 123 MAINTENANCE AND ADJUSTMENT NOTE WARNING ○ First, tighten until slight resistance is Mixing brands and types of brake felt, which indicates that the cap is fluid can reduce the brake sys- seated on the reservoir body, and tem’s effectiveness and cause an tighten the cap an additional 1/6 turn accident resulting in injury or while holding the brake fluid reser-...
  • Page 124: Brake Light Switches

    Brake Light Switches Have the brake fluid changed by an When either the front or rear brake is authorized Kawasaki dealer. applied, the brake light goes on. The front brake light switch requires no ad- Front and Rear Brakes -...
  • Page 125 MAINTENANCE AND ADJUSTMENT Inspection • Turn the ignition key to ON. • The brake light should go on when the front brake is applied. • If it does not, ask an authorized Ka- wasaki dealer to inspect the front brake light switch. •...
  • Page 126 MAINTENANCE AND ADJUSTMENT • Adjustment To adjust the rear brake light switch, • Remove the right front footpeg move the switch up or down by turn- bracket bolts. ing the adjusting nut. • Pull the footpeg bracket a little bit outward.
  • Page 127: 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 For various riding or load conditions not turn during adjustment.
  • Page 128 • If any doubt about the front fork, it hexagon wrench. • should be checked by an authorized To decrease preload and soften the Kawasaki dealer. suspension, turn the preload adjust- er counterclockwise. A. Inner Tube A. Spring Preload Adjuster...
  • Page 129 MAINTENANCE AND ADJUSTMENT Spring Preload Setting ← → Adjuster Position 7 turns in** 15 turns in** ← → Spring Action Weak Standard Strong ← → Setting Soft Standard Hard ← → Load Light Standard Heavy ← → Road Good Standard ←...
  • Page 130 MAINTENANCE AND ADJUSTMENT Rebound Damping Force Adjuster Ad- justment The rebound damping force adjuster are located on top of each front fork leg. • Turn the adjuster clockwise with a screw driver to increase damping force. • Turn the adjuster counterclockwise to decrease damping force.
  • Page 131 MAINTENANCE AND ADJUSTMENT Rebound Damping Force Setting Adjuster Rebound ← → 2 turn out** 3 1/2 turns out** Position Damping ← → Damping Force Strong Standard Weak ← → Setting Hard Standard Soft ← → Load Heavy Standard Light ← →...
  • Page 132 MAINTENANCE AND ADJUSTMENT Compression Damping Force Adjuster The compression damping force ad- juster are located at the lower end of each front fork leg. • Turn the adjuster clockwise with a screw driver to increase damping force. • Turn the adjuster counterclockwise to decrease damping force.
  • Page 133 MAINTENANCE AND ADJUSTMENT Compression Damping Force Setting Adjuster Compression ← 1 1/4 turns out** → 3 turns out** Position Damping ← → Damping Force Strong Standard Weak ← → Setting Hard Standard Soft ← → Load Heavy Standard Light ← →...
  • Page 134 MAINTENANCE AND ADJUSTMENT Standard Setting Position (Front Fork) Spring Preload Adjuster 7 turns in* Rebound Damping Adjuster 2 turns out** 1 1/4 turns out** Compression Damping Adjuster In from the fully seated position (turned fully counterclockwise) Out from the fully seated position (turned fully clockwise)
  • Page 135: Rear Shock Absorber

    If there is any doubt about the rear Rear Shock Absorber shock absorber, it should be in- The rear shock absorber should be spected by an authorized Kawasaki checked for operation and oil leakage dealer. in accordance with the Periodic Main- tenance Chart.
  • Page 136 MAINTENANCE AND ADJUSTMENT Spring Preload Adjustment Spring preload can be adjusted by turning the ring on the rear shock ab- sorber with the tool provided. To in- crease spring preload and stiffen the suspension, turn the adjusting ring clockwise. To decrease preload and soften the suspension, turn the ring counterclockwise.
  • Page 137 MAINTENANCE AND ADJUSTMENT Spring Preload Setting ← → Adjuster Position 4 turns in** 10 turns in** ← → Spring Action Weak Standard Strong ← → Setting Soft Standard Hard ← → Load Light Standard Heavy ← → Road Good Standard ←...
  • Page 138 MAINTENANCE AND ADJUSTMENT NOTICE Rebound Damping Force Adjustment The rebound damping force adjuster Do not turn the rebound damping is located at the lower end of the rear force adjuster beyond the fully shock absorber. seated position or the adjusting mechanism may be damaged.
  • Page 139 MAINTENANCE AND ADJUSTMENT Rebound Damping Force Setting Adjuster Rebound ← 1 1/4 turn out** → 2 1/2 turns out** Position Damping ← → Damping Force Strong Standard Weak ← → Setting Hard Standard Soft ← → Load Heavy Standard Light ←...
  • Page 140: Wheels

    MAINTENANCE AND ADJUSTMENT Wheels Tubeless tires are installed on the wheels of this motorcycle. The indica- tions of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. TUBELESS Mark The tire and rim form a leakproof unit by making airtight contacts at the tire chamfers and the rim flanges instead...
  • Page 141 MAINTENANCE AND ADJUSTMENT Tires - WARNING Payload and Tire Pressure Failure to maintain proper inflation Installing a tube inside a tube- pressures or observe payload limits for less-type tire can create exces- your tires may adversely affect han- sive heat build up that can dling and performance of your motor- damage the tube and cause rapid cycle and can result in loss of control.
  • Page 142 MAINTENANCE AND ADJUSTMENT ○ Tire pressure is affected by changes Tire Wear, Damage in ambient temperature and altitude, As the tire tread wears down, the tire and so the tire pressure should be becomes more susceptible to puncture checked and adjusted when your rid- and failure.
  • Page 143 MAINTENANCE AND ADJUSTMENT • In accordance with the Periodic Minimum Tread Depth Maintenance Chart, measure the 1 mm Front – depth of the tread with a depth (0.04 in.) gauge, and replace any tire that has Under 130 km/h 2 mm worn down to the minimum allowable (80 mph) (0.08 in.)
  • Page 144 MAINTENANCE AND ADJUSTMENT ○ When operating on public roadways, WARNING keep maximum speed under traffic law limits. Tires that have been punctured and repaired do not have the Standard Tire (Tubeless) same capabilities as undamaged Make, Type: tires and can suddenly fail, caus- BRIDGESTONE, ing an accident resulting in seri- Front...
  • Page 145: Battery

    MAINTENANCE AND ADJUSTMENT Battery WARNING The battery installed in this motor- cycle is a sealed type, so it is not nec- Some replacement tires may ad- essary to check the battery electrolyte versely affect handling and cause level or add distilled water. an accident resulting in serious The sealing strip should not be injury or death.
  • Page 146 MAINTENANCE AND ADJUSTMENT temperature. As temperature rises, so Current Drain does the discharge rate. Every 15°C Days from Days from (59°F) doubles the rate. 100% 100% Electrical accessories, such as digi- Discharging charged to charged to tal clocks and computer memory, also Ampere 50% dis- 100% dis-...
  • Page 147 12.8 volts, the battery should be Battery Mate 150-9 charged using an appropriate charger OptiMate 4 (check with a Kawasaki dealer). If you Yuasa MB-2040/2060 will not be using the motorcycle for lon- Christie C10122S ger than two weeks, the battery should...
  • Page 148 MAINTENANCE AND ADJUSTMENT If the above chargers are not avail- NOTICE able, use equivalent one. For more details, ask a Kawasaki Never remove the sealing strip, dealer. or the battery can be damaged. Do not install a conventional bat- Battery Charging - •...
  • Page 149 MAINTENANCE AND ADJUSTMENT • Battery Removal Take the battery out of the case. • • Remove the rider's seat (see Seats Clean the battery using a solution of section in the GENERAL INFORMA- baking soda and water. Be sure that TION chapter).
  • Page 150: Headlight Beam

    MAINTENANCE AND ADJUSTMENT • Headlight Beam Turn the vertical adjuster in or out to adjust the headlight vertically. Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. •...
  • Page 151: Fuses

    MAINTENANCE AND ADJUSTMENT Fuses NOTICE Fuses are arranged in the fuse box When handling the quartz-halo- located under the rider's seat. The gen bulbs, never touch the glass main fuse is located under the fuel portion with bare hands. Always tank.
  • Page 152 MAINTENANCE AND ADJUSTMENT The main fuse removal should be done by an authorized Kawasaki deal- A. Main Fuse WARNING A. Fuse Boxes Substituting fuses can cause wir- ing to overheat, catch fire and/or fail. Do not use any substitute for the standard fuse.
  • Page 153: General Lubrication

    MAINTENANCE AND ADJUSTMENT General Lubrication Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Main- tenance Chart or whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.
  • Page 154 MAINTENANCE AND ADJUSTMENT • Front Brake Lever (K): Should be serviced by an author- • ized Kawasaki dealer. Rear Brake Pedal NOTE Lubricate the following cables with ○ a pressure cable lubber - After connecting the cables, adjust • (K) Clutch Inner Cable them.
  • Page 155: Cleaning Your Motorcycle

    MAINTENANCE AND ADJUSTMENT Cleaning Your Motorcycle WARNING General Precautions Frequent and proper care of your Ka- Build-up of debris or flammable wasaki motorcycle will enhance its ap- material in and around the ve- pearance, optimize overall hicle chassis, engine, and ex- performance, and extend its useful life.
  • Page 156 MAINTENANCE AND ADJUSTMENT • • Be sure the engine and exhaust are Avoid spraying water in delicate cool before washing. areas such as in air intakes, fuel sys- • Avoid applying degreaser to seals, tem, brake components, electrical brake pads, and tires. components, muffler outlets, and fuel •...
  • Page 157 MAINTENANCE AND ADJUSTMENT • • If the boot is damaged, replace it Mix a mild neutral detergent (de- with a new one. If the boot is not signed for motorcycles or automo- positioned in the groove correctly, re- biles) and water in a bucket. Use a place it in the correct position.
  • Page 158 • If any doubt, consult an authorized immediately wash your motorcycle Kawasaki dealer. with cold water. Do not use warm water as it accelerates the chemical Windshield and Other Plastic Parts reaction of the salt. After drying, ap-...
  • Page 159 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 160 MAINTENANCE AND ADJUSTMENT 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. Do not apply rubber protectant to any tread area.
  • Page 161: 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 162 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 163: 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 164: 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 165 LOCATION OF LABELS 2. Important Drive Chain Information 3. Tire and Load Data 4. Brake Fluid (Rear) 5. Fuel Notice...
  • Page 166 LOCATION OF LABELS 6. Battery Poison/Danger 7. Windshield Warning...
  • Page 167 LOCATION OF LABELS...
  • Page 168 LOCATION OF LABELS 1. Read Owner’s Manual 2. Drive chain slack, see page 112...
  • Page 169 LOCATION OF LABELS 1. Read Owner's Manual 2. Tire Pressure, see page 139 3. Front tire size and manufacture, see page 142 4. Rear tire size and manufacture, see page 142 5. Maximum load, see page 139...
  • Page 170 LOCATION OF LABELS 1. Read Owner's Manual 2. Unleaded gasoline, see page 41 3. Octane rating of gasoline, see page...
  • Page 171 LOCATION OF LABELS...
  • Page 172 LOCATION OF LABELS...

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