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Table of Contents

   Summary of Contents for Kawasaki KLX150L 2013

  • Page 2 ENGLISH Motorcycle Owner's Manual Original instructions...
  • Page 4 SAFETY INFORMATION Quick Reference Guide GENERAL INFORMATION This Quick Reference Guide will HOW TO RIDE THE MOTORCYCLE assist you in finding the information you're looking for. MAINTENANCE AND ADJUSTMENT APPENDIX MAINTENANCE RECORD A Table of Contents is included after the Foreword.
  • Page 5 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 NOTICE THIS PRODUCT HAS BEEN MAN- UFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OP- ERATOR AND AS A VEHICLE ON-...
  • Page 7 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 8 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. Nov. 15, 2013. (1)
  • Page 9: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION ..... 10 GENERAL INFORMATION ....21 Read Owner's Manual ....... 10 Specifications ........21 Training ..........10 Serial Number Locations ....25 Daily Checks and Periodic Mainte- Location of Labels ......26 nance ..........10 Location of Parts ........
  • Page 10 Rear View Mirror ........ 51 Clutch ..........92 HOW TO RIDE THE MOTORCYCLE .. 53 Drive Chain ........94 Break-In ..........53 Brakes ..........98 Starting the Engine ......55 Brake Light Switches ......100 Jump Starting ........58 Suspension System ......102 Moving Off ..........
  • Page 11: Safety Information

    Checks section and the Periodic Main- safely. tenance section in the MAINTENANCE AND ADJUSTMENT chapter for more Training information. Kawasaki strongly recommends that all operators of this vehicle complete a suitable motorcycle rider training pro- gram to learn the proper skills and...
  • Page 12: Loading And Accessories Information

    Weight of rider, passenger, baggage, and accessories must not exceed 160 kg (352 oughly checked at an authorized Ka- lbs). wasaki dealer as soon as possible. With the exception of genuine Kawa- saki Parts and Accessories, Kawasaki has no control over the design or...
  • Page 13: Passenger

    Kawasaki Parts and Accessories eration. The passenger can affect have been specially designed for control of the motorcycle by improp- use on Kawasaki motorcycles. We er positioning during cornering and strongly recommend that all parts sudden movements. It is important...
  • Page 14: Baggage And Luggage

    SAFETY INFORMATION 4. Do not carry passengers unless security as often as possible (not passenger footpegs are installed. while the motorcycle is in motion) Instruct any passenger before rid- and adjust as necessary. ing to keep his or her feet on the 3.
  • Page 15: Other Load

    SAFETY INFORMATION of the steering assembly and can that Kawasaki cannot assume re- result in an unsafe riding condition. sponsibility for the results of such 3. Fairings, windshields, backrests, unintended use of the motorcycle. and other large items have the ca- 2.
  • Page 16: Safe Operation

    Carbon Monoxide Hazard your motorcycle may have suffered damage that is not immediately appa- DANGER rent. Have your motorcycle thoroughly checked at a Kawasaki dealer as soon Exhaust gas contains carbon as possible. monoxide, a colorless, odorless poisonous gas. Inhaling carbon...
  • Page 17: Fueling

    SAFETY INFORMATION Fueling Protective Gear and Clothing Helmet WARNING Kawasaki strongly recommends both the operator and passenger wear a Gasoline is extremely flammable helmet even if this is not a legal re- and can be explosive under cer- quirement. tain conditions.
  • Page 18: Safe Riding Techniques

    SAFETY INFORMATION Gloves Safe Riding Techniques Wear gloves which have suitable Keep Hands on Handlebars protection for your hands, especially against abrasion. When riding always keep both hands on the handlebars and both feet on the Clothing footpegs. Removing your hands from Wear protective clothing.
  • Page 19 SAFETY INFORMATION control, especially when riding in wet Riding in Wet Conditions conditions or on loose road surfaces, Rely more on the throttle to control when the ability to maneuver will be re- vehicle speed and less on the front duced.
  • Page 20: Additional Considerations For High Speed Operation

    SAFETY INFORMATION Riding on Rough Roads Additional Considerations for Exercise caution, slow down, and High Speed Operation grip the fuel tank with the knees for better stability. WARNING Acceleration Handling characteristics of a mo- When quick acceleration is neces- torcycle at high speeds may vary sary to pass another vehicle, shift to a from those you are familiar with lower gear to obtain the necessary...
  • Page 21 SAFETY INFORMATION Steering Electrical Equipment Looseness in the steering can cause Make sure that the headlight, tail/- loss of control. Check to see that the brake light, turn signals, horn, etc., all handlebars turns freely but has no work properly. play.
  • Page 22: General Information

    GENERAL INFORMATION GENERAL INFORMATION Specifications PERFORMANCE Maximum Horsepower 8.6 kW (12 PS) at 8 000 r/min (rpm) Maximum Torque 11.3 N·m (1.15 kgf·m, 100 in·lb) at 6 500 r/min (rpm) Minimum Turning Radius 2.1 m (82.7 in.) DIMENSIONS Overall Length 2 080 mm (81.9 in.) Overall Width 770 mm (30.3 in.)
  • Page 23 GENERAL INFORMATION Fuel System Carburetor KEIHIN NCV24 Ignition System DC-CDI Ignition Timing 10° BTDC at 1 400 r/min (rpm) ~ 30° BTDC at 4 000 (Electronically advanced) r/min (rpm) Spark Plug: Type NGK CR7HSA 0.6 ~ 0.7 mm (0.024 ~ 0.028 in.) Lubrication System Forced lubrication (wet sump) Engine Oil:...
  • Page 24 GENERAL INFORMATION FRAME Caster 26.5° Trail 107 mm (4.21 in.) Tire Size: Front 2.75-21 45P Rear 4.10-18 59P Rim Size: Front 21 × 1.60 Rear 18 × 1.85 Fuel Tank Capacity 7.0 L (1.8 US gal) Brake Fluid: Front DOT3 or DOT4 Rear DOT3 or DOT4 ELECTRICAL EQUIPMENT...
  • Page 25 GENERAL INFORMATION Specifications are subject to change without notice, and may not apply to every country.
  • Page 26: Serial Number Locations

    GENERAL INFORMATION Serial Number Locations The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts.
  • Page 27: Location Of Labels

    GENERAL INFORMATION 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 28 GENERAL INFORMATION 2. Brake Fluid (Rear) 3. Battery Poison/Danger 4. Rear Shock Absorber Warning...
  • Page 29 GENERAL INFORMATION 5. Fuel Notice 6. Important Drive Chain Information 7. Tire and Load Data...
  • Page 30 GENERAL INFORMATION...
  • Page 31 GENERAL INFORMATION 1. Read Owner's Manual, see page 10 2. Unleaded gasoline, see page 43 3. Octane rating of gasoline, see page...
  • Page 32 GENERAL INFORMATION 1. Read Owner's Manual, see page 10 1. Read Owner's Manual, see page 10 2. Drive chain slack, see page 94 2. Tire air pressure, see page 105 3. Front tire size and manufacture, see page 107 4. Rear tire size and manufacture, see page 107 5.
  • Page 33: Location Of Parts

    GENERAL INFORMATION Location of Parts 1. Rear View Mirrors 7. Right Handlebar Switches 2. Clutch Lever 8. Front Brake Lever 3. Left Handlebar Switches 9. Throttle Grip 4. Choke Lever 10. Ignition Switch/Steering Lock 5. Meter Instrument 11. Starter Lockout Switch 6.
  • Page 34 GENERAL INFORMATION 1. Front Fork 12. Tying Hook (Both Sides) 2. Headlight 13. Drive Chain 3. Front Turn Signal Light (Both Sides) 14. Side Stand 4. Fuel Tank Cap 15. Side Stand Switch 5. Fuel Tank 16. Idle Adjusting Screw 6.
  • Page 35 GENERAL INFORMATION 1. License Plate Light 9. Front Brake Light Switch 2. Tail/Brake Light 10. Speedometer Cable 3. Rear Turn Signal Light (Both Sides) 11. Spark Plug 4. Muffler 12. Rear Brake Pedal 5. Main/Spare Fuse 13. Oil Filler Cap/Dipstick 6.
  • Page 36: Meter Instruments

    GENERAL INFORMATION Meter Instruments 1. Speedometer 2. Odometer...
  • Page 37: Indicators

    GENERAL INFORMATION Indicators Turn Signal Indicator (Green) High Beam Indicator (Blue) Neutral Indicator (Green)
  • Page 38 □ : Goes on. ■ : Goes off. When the ignition switch is turned on, all indicators go on/off as shown in the table. If any indicator does not op- erate as shown, have it checked by an authorized Kawasaki dealer.
  • Page 39: Speedometer/odometer

    GENERAL INFORMATION *: The numbers in this column corre- Speedometer/Odometer sponds to reference numbers on page Indicators Indica- *No. Status tors When the turn signal switch is pushed to the left or right, this indicator blinks. When the headlight is on high beam, this indicator goes on.
  • Page 40: Keys

    GENERAL INFORMATION of 100 meter. This meter cannot be re- set. Keys This motorcycle has a combination key, which is used for the ignition switch, steering lock and fuel tank cap. Blank keys are available at your Ka- wasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a...
  • Page 41: Right Handlebar Switches

    GENERAL INFORMATION NOTE Right Handlebar Switches ○ The meter, tail, license plate and city lights are on whenever the ignition key is in the “ON” position. To avoid battery discharge, always start the engine immediately after turning the ignition key to “ON” position. ○...
  • Page 42: Left Handlebar Switches

    GENERAL INFORMATION The engine stop switch is for emer- Left Handlebar Switches gency use. If required, move the switch to the position. 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.
  • Page 43: Fuel Tank Cap

    GENERAL INFORMATION Low beam..( NOTE ○ The fuel tank cap cannot be closed Turn Signal Switch without the key inserted, and the key When the turn signal switch is turned cannot be removed unless the cap is to the left ( ) or right ( ), the locked properly.
  • Page 44: Fuel

    Fuel Requirement occurs, use a different brand of gasoline of a higher octane rat- Your Kawasaki engine is designed to ing. If this condition is allowed to use only unleaded gasoline with a min- continue, it can lead to severe en- imum octane rating shown below.
  • Page 45: Filling The Tank

    GENERAL INFORMATION equal to or higher than that shown in Filling the Tank the table. Avoid filling the tank in the rain or Fuel Type Unleaded Gasoline where heavy dust is blowing so that the fuel does not get contaminated. Ethanol Content E10 or less Minimum Octane...
  • Page 46 GENERAL INFORMATION NOTICE WARNING Certain ingredients of 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 47 GENERAL INFORMATION for maintenance and adjustments or the motorcycle is stored for long time. NOTE ○ Since riding distance is limited when on “RES”, refuel at the earliest op- portunity. ○ Make sure that the fuel tap lever is turned to “ON” position after filling up the fuel tank.
  • Page 48: Side Stand

    GENERAL INFORMATION stand fully up before sitting on the mo- Side Stand torcycle. The motorcycle is equipped with the NOTE ○ side stand. 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 49 GENERAL INFORMATION A. Bolt (Right Side) A. Bolt (Left Side) B. Projection (Right Side) B. Projection (Left Side) C. Right Side Cover C. Left Side Cover • Remove the bolt and washer, and free the seat strap. • Remove the bolt on both sides and remove the seat backward while lift- ing up the rear part of the seat.
  • Page 50 GENERAL INFORMATION A. Bolt and Washer A. Seat Hooks B. Seat Strap B. Stoppers C. Bolt (Both Sides) C. Fuel Tank D. Seat D. Frame • Install the seat strap and washer, Seat Installation • and tighten the bolt. • Insert the seat hooks into the stop- Pull up the rear end of the seat to pers of the fuel tank and the frame,...
  • Page 51: Tying Hooks

    GENERAL INFORMATION A. Projection (Both Sides) A. Tying Hooks B. Grommet (Both Sides) C. Side Cover (Both Sides) Tool Kit Bag/Tool Kit • Tighten the bolt on both sides. The tool kit is stored in the tool kit bag. Tying Hooks The kit contains tools that can be helpful in making roadside repairs, ad- When tying up light loads to the seat,...
  • Page 52: Rear View Mirror

    GENERAL INFORMATION the upper hexagonal area (locknut) and turn the stay by hand. • Tighten the upper hexagonal area (locknut). NOTE ○ The upper hexagonal area (locknut) is left-hand threads. A. Tool Kit B. Tool Kit Bag Rear View Mirror Rear View Mirror Adjustment •...
  • Page 53 GENERAL INFORMATION A. Rear View Mirror B. Stay C. Rubber Boot D. Upper Hexagonal Area (Locknut) E. Lower Hexagonal Area...
  • Page 54: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE 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”...
  • Page 55 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 56: Starting The Engine

    HOW TO RIDE THE MOTORCYCLE Starting the Engine • Turn the fuel tap lever to “ON” posi- tion. A. Engine Stop Switch B. Starter Button • Turn the ignition key to “ON” posi- tion. • Make sure the transmission is in neutral.
  • Page 57 HOW TO RIDE THE MOTORCYCLE A. Neutral Indicator (Green) A. Choke Lever B. Ignition Switch C. ON position NOTE • ○ If the engine is cold, pull out the When the engine is already warm or choke lever all the way. on hot days [higher than 35°C (95°...
  • Page 58 HOW TO RIDE THE MOTORCYCLE clutch lever is pulled and the side NOTICE stand is fully up. Do not operate the starter contin- uously for more than 5 seconds, or the starter will overheat and the battery power will drop tem- porarily.
  • Page 59: Jump Starting

    HOW TO RIDE THE MOTORCYCLE NOTE volt booster battery and jumper cables ○ may be used to start the engine. If you drive the motorcycle before the engine is warmed up, release the DANGER choke lever as soon as you start moving.
  • Page 60 HOW TO RIDE THE MOTORCYCLE • Remove the seat (see Seat section in the GENERAL INFORMATION chapter). • Slide the cap from the positive (+) terminal (see Battery section in the MAINTENANCE ADJUST- MENT chapter). • Connect a jumper cable from the positive (+) terminal of the booster battery to the positive (+) terminal of the motorcycle battery.
  • Page 61: Moving Off

    HOW TO RIDE THE MOTORCYCLE NOTICE DANGER Do not operate the starter contin- Batteries contain sulfuric acid uously for more than 5 seconds that can cause burns and pro- or the starter will overheat and duce hydrogen gas which is the battery power will drop tem- highly explosive.
  • Page 62: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE • Open the throttle a little, and start to designed so that the engine does not let out the clutch lever very slowly. start if the transmission is in gear • As the clutch starts to engage, open and the side stand is down.
  • Page 63: Braking

    HOW TO RIDE THE MOTORCYCLE Vehicle speed when shifting WARNING Shifting down km/h (mph) Downshifting at high speed can 5th→4th 50 (31) make the rear wheel skid and 4th→3rd 40 (25) cause an accident resulting in se- 3rd→2nd 30 (19) vere injury or death, as well as cause the engine to overrev and 2nd→1st...
  • Page 64: Stopping The Engine

    HOW TO RIDE THE MOTORCYCLE necessary to keep the engine from stalling. • Never lock the brakes, or it will cause the tires to skid. When turning a cor- ner, it is better not to brake at all. Re- duce your speed before you get into the corner.
  • Page 65: Stopping The Motorcycle In An Emergency

    Emergency carburetor. In an emergency situation such as Your Kawasaki Motorcycle has been throttle failure, your vehicle may be designed and manufactured to provide stopped by applying the brakes and you optimum safety and convenience.
  • Page 66: Parking

    HOW TO RIDE THE MOTORCYCLE Parking WARNING The engine and exhaust system WARNING get extremely hot during normal operation and can cause serious Operating or parking the vehicle burns. near flammable materials can Never touch a hot engine, ex- cause a fire, and can result in haust pipe, or muffler during op- property damage or severe per- eration or after stopping the...
  • Page 67 HOW TO RIDE THE MOTORCYCLE • If parking inside a garage or other structure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 68: Maintenance And Adjustment

    Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect or improper adjustment made by the owner.
  • Page 69 DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area. NOTE ○ If a torque wrench is not available, the maintenance items which require a spe- cific torque value should be serviced by an authorized Kawasaki dealer.
  • Page 70: Daily Checks

    MAINTENANCE AND ADJUSTMENT Daily Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter or see your dealer for the action required to return the motorcycle to a safe operating condition.
  • Page 71 MAINTENANCE AND ADJUSTMENT Operation Page Bolts, nuts and fasteners – Check for loose and/or missing bolts, nuts and fasteners Steering – Action smooth but not loose from lock to lock – No binding of control cables Brakes Brake pad wear Brake fluid level –...
  • Page 72 MAINTENANCE AND ADJUSTMENT Operation Page Engine stop switch – Stops engine Side stand – Return to its fully up position by spring tension – Return spring not weak or not damaged Rear view mirrors – Rear view sight...
  • Page 73: Additional Considerations For Off Road Operation

    MAINTENANCE AND ADJUSTMENT Additional Considerations for Off Road Operation Brakes: The importance of reliable brakes is obvious. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebars turns freely but has no play.
  • Page 74: Periodic Maintenance

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance *A: Service at number of years shown or indicated odometer reading intervals, which- ever comes first. *B: For higher odometer readings, repeat at the frequency interval established here. *C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
  • Page 75 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) See year (*A) Page (0.6) (3.8) (7.6) (11.4) (15.2) Items Choke operation – Fuel system – Fuel hose – Valve clearance – Air suction system Clutch operation (play, engagement, disengagement) Engine oil and oil filter (*C) Tire air pressure...
  • Page 76 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) See year (*A) Page (0.6) (3.8) (7.6) (11.4) (15.2) Items : every 1 000 km (600 Drive chain slack (*C) mile) – Drive chain wear (*C) –...
  • Page 77 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) See year (*A) Page (0.6) (3.8) (7.6) (11.4) (15.2) Items 102, Suspension system – Lubrication of rear suspension – Steering play – Steering stem bearings – Electrical system Spark plug –...
  • Page 78: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • If the engine is cold, start the engine and run it for several minutes at idle speed. • Stop the engine, then wait several minutes until the oil settles. NOTICE A. Oil Filler Cap/Dipstick Racing the engine before the oil reaches every part can cause en- NOTICE...
  • Page 79 MAINTENANCE AND ADJUSTMENT between upper and lower level lines same type and brand of oil that is al- on the dipstick. ready in the engine. NOTE ○ Do not pinch the O-ring when instal- ling the dipstick on the oil filler neck. ○...
  • Page 80 MAINTENANCE AND ADJUSTMENT • If the oil filter is to be replaced, re- WARNING move the oil filter and replace it with a new one as follows. Engine oil is a toxic substance. • Remove the oil filter cover bolts, oil Dispose of used oil properly.
  • Page 81 MAINTENANCE AND ADJUSTMENT • • Be sure to install the filter with the Install the spring securely. grommet facing inside. A. O-ring B. Spring A. Grommet • B. Oil Filter Install the oil filter cover so that the arrow mark faces upward. •...
  • Page 82 ○ If a torque wrench is not available, [when filter is removed] this item should be serviced by an authorized Kawasaki dealer. Although 10W-40 engine oil is the • recommended oil for most conditions, Pour in the specified type and the oil viscosity may need to be amount of oil.
  • Page 83: Spark Plug

    MAINTENANCE AND ADJUSTMENT • Start the engine. A. Spark Plug Cap • B. Spark Plug Check the oil level and oil leakage. • Unscrew the spark plug using the Spark Plug spark plug wrench included in the supplied tool kit (see Tool Kit Bag/- Spark Plug Replacement •...
  • Page 84 MAINTENANCE AND ADJUSTMENT make sure that it is properly in- stalled. ○ Check the high-tension cable is not damaged, or correctly routed. Spark Plug Standard NGK CR7HSA Plug 0.6 ~ 0.7 mm Plug Gap (0.024 ~ 0.028 in.) Tightening Torque A.
  • Page 85: Air Cleaner

    MAINTENANCE AND ADJUSTMENT • Remove the left side cover (see Seat section in the GENERAL INFORMA- TION chapter). • Remove the air cleaner element cov- er bolts and air cleaner element cov- A. 0.6 ~ 0.7 mm (0.024 ~ 0.028 in.) Air Cleaner Air Cleaner Element Replacement NOTE...
  • Page 86 MAINTENANCE AND ADJUSTMENT WARNING If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, pos- sibly causing accident. Be sure to keep the dust from entering during cleaning. NOTICE A. Wing Bolt B. Washer If dirt gets through into the en- C.
  • Page 87 MAINTENANCE AND ADJUSTMENT A. Frame A. Apply grease. • B. Air Cleaner Element Install the element and washer, and • Replace the air cleaner element with tighten the wing bolt securely. • a new one. Install the air cleaner element cover. •...
  • Page 88 MAINTENANCE AND ADJUSTMENT • Air Cleaner Element Cleaning Remove the air cleaner element (see Air Cleaner Element Replacement). • NOTE Separate the frame from the air ○ In dusty areas, the element should cleaner element (see Air Cleaner El- be cleaned more frequently than the ement Replacement).
  • Page 89 MAINTENANCE AND ADJUSTMENT WARNING Gasoline and low flash-point sol- vents are extremely flammable and may explode, causing severe burns. Do not use gasoline or a low flash-point solvent to clean the element. Clean the element in a well-ventilated area. Be sure there are no sparks or flame in the work area, including any ap- A.
  • Page 90: Throttle Control System

    A. Throttle Grip system checked by an authorized B. Throttle Grip Free Play Kawasaki dealer. • Throttle Grip Free Play Check the throttle grip free play by 2 ~ 3 mm (0.08 ~ 0.12 in.) turning back and forth.
  • Page 91: Choke Lever

    Choke Lever justment of the throttle cable should be done by an authorized Kawasaki By pulling the choke lever, the carbu- dealer. • retor provides a rich starting mixture With the engine idling, turn the han- dlebars to each side.
  • Page 92: Idle Speed

    • Check that the choke lever returns properly and that the inner cable slides smoothly. If there is any irregu- larity, have the choke cable checked by an authorized Kawasaki dealer. A. Choke Lever Idle Speed Idle Speed Adjustment •...
  • Page 93: Clutch

    If there is any irregu- necessary. • larity, have the clutch cable checked With the engine idling, turn the han- by an authorized Kawasaki dealer. dlebars to each side. If the handlebar • Check the clutch lever free play. movement changes the idle speed,...
  • Page 94 MAINTENANCE AND ADJUSTMENT • Clutch Lever Free Play Turn the adjuster so that the clutch lever will have the specified free 2 ~ 3 mm (0.08 ~ 0.12 in.) play. • Tighten the locknut. WARNING Excess clutch cable play could prevent clutch disengagement and cause a crash resulting in serious injury or death.
  • Page 95: Drive Chain

    MAINTENANCE AND ADJUSTMENT NOTE ○ After the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly. Drive Chain Drive Chain Lubrication Lubrication is necessary after riding • through rain or on wet roads, or any Wipe off any lubricant that gets on time that the chain appears dry.
  • Page 96 MAINTENANCE AND ADJUSTMENT chain midway between the swingarm Drive Chain Slack Adjustment • Remove the axle cap. pivot and rear axle. • Remove the cotter pin, and loosen the rear axle nut. • Loosen the left and right chain ad- juster locknuts.
  • Page 97 MAINTENANCE AND ADJUSTMENT standard chain slack. To keep the NOTE ○ chain and wheel properly aligned, Wheel alignment also the notch on the right wheel align- checked using the straightedge or ment indicator should align with the string method. same swingarm mark that the left in- dicator notch align with.
  • Page 98 When inserting the cotter pin, if the this item should be serviced by an slots in the nut do not align with the authorized Kawasaki dealer. cotter pin hole in the axle shaft, tight- • en the nut clockwise up to the next Rotate the wheel, measure the chain alignment.
  • Page 99: Brakes

    If you feel there is something wrong With the front brake fluid reservoir when applying the brakes, have the held horizontal, the brake fluid level brake system checked by an author- must be above the lower level line. ized Kawasaki dealer immediately.
  • Page 100 In this case, have the lower level lines. brake system inspected by an au- thorized Kawasaki dealer. Brake Pad Wear Inspection Inspect the brakes for wear. For each front and rear disc brake caliper, if the...
  • Page 101: Brake Light Switches

    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. Rear Brake Pads B. Lining Thickness C. 1 mm (0.04 in.) Brake Light Switches A.
  • Page 102 MAINTENANCE AND ADJUSTMENT • Brake Pedal Travel If it does not, ask your authorized Kawasaki dealer to inspect the front 10 mm (0.39 in.) brake light switch. • Check the operation of the rear Brake Light Switch Adjustment • brake light switch by depressing the To adjust the rear brake light switch, brake pedal.
  • Page 103: Suspension System

    After riding through muddy or dusty outer surface of the inner tube. roads, the front inner tube should be • If any doubt about the front fork, it cleaned immediately. should be done by an authorized Kawasaki dealer.
  • Page 104: Rear Shock Absorber

    MAINTENANCE AND ADJUSTMENT NOTICE Sticking muds or dusts on the sliding surface of the rear shock absorber could damage to the oil seal, leading to an oil leak. Clean the sliding surface after each ride. A. Inner Tube B. Fork Boot (Both Sides) Rear Shock Absorber The rear shock absorber operation and oil leakage should be checked in...
  • Page 105: Wheels

    If there is any doubt about the rear If the spring action feels too soft or shock absorber, it should be done by too stiff, have it adjusted by an author- an authorized Kawasaki dealer. ized Kawasaki dealer. Wheels Tire Air Pressure Inspection •...
  • Page 106 MAINTENANCE AND ADJUSTMENT Tire Air Pressure (when cold) more than a mile during the past 3 hours). Front 150 kPa (1.50 kgf/cm², 22 psi) ○ Tire air pressure is affected by Rear 150 kPa (1.50 kgf/cm², 22 psi) changes in ambient temperature and altitude, and so the tire air pressure Tire Wear, Damage should be checked and adjusted...
  • Page 107 MAINTENANCE AND ADJUSTMENT A. Tire Depth Gauge A. Crack or Cut B. Nail Minimum Tread Depth C. Swelling or High Spot D. Stone Front 2 mm (0.08 in.) • Remove any imbedded stones or Rear 2 mm (0.08 in.) • other foreign particles from the tread.
  • Page 108 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 same capabilities as undamaged Make, Type: tires and can suddenly fail, caus- IRC, GP-21F Front ing an accident resulting in seri-...
  • Page 109: Battery

    MAINTENANCE AND ADJUSTMENT NOTICE WARNING Never remove the sealing strip, New tires are slippery and may or the battery can be damaged. cause loss of control and injury. Do not install a conventional bat- A break-in period of 160 km (100 tery in this motorcycle, or the miles) is necessary to establish electrical system cannot work...
  • Page 110 MAINTENANCE AND ADJUSTMENT (check with your Kawasaki dealer). If If the above chargers are not avail- you will not be using the motorcycle for able, use equivalent one. longer than two weeks, the battery For more details, ask your Kawasaki should be charged using an appropri- dealer.
  • Page 111 MAINTENANCE AND ADJUSTMENT • Remove the seat (see Seat section DANGER in the GENERAL INFORMATION chapter). Battery acid generates hydrogen • Remove the bolts and battery holder. gas which is flammable and ex- plosive under certain conditions. It is present within a battery at all times, even in a discharged con- dition.
  • Page 112: Headlight

    Clean the battery using a solution of Headlight baking soda and water. Be sure that the cable connections are clean. Headlight aiming should be done by an authorized Kawasaki dealer. Battery Installation • Put the battery onto the battery dampers.
  • Page 113 MAINTENANCE AND ADJUSTMENT Vertical Adjustment NOTE ○ The headlight beam is adjustable On high beam, the brightest point vertically. If adjusted too low, neither should be slightly below horizontal low nor high beam will illuminate the with the motorcycle on its wheels road far enough ahead.
  • Page 114: Fuses

    A. Main Fuse by an authorized Kawasaki dealer. B. Spare Fuse The main fuse removal should be done by an authorized Kawasaki deal- WARNING Substituting fuses can cause wir- ing to overheat, catch fire and/or fail. Do not use any substitute for the standard fuse.
  • Page 115: General Lubrication

    MAINTENANCE AND ADJUSTMENT Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. Apply motor oil to the following pivots • Side Stand • Clutch Lever • Front Brake Lever •...
  • Page 116: Cleaning Your Motorcycle

    (K) Clutch Inner Cable Upper End • UV rays, pollutants, and reduce the (K) Throttle Inner Cable Upper Ends amount of dust reaching its surfaces. (K): Should be serviced by an author- ized Kawasaki dealer.
  • Page 117 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- • Avoid all harsh chemicals, solvents, hicle chassis, engine, and ex- detergents, and household cleaning haust...
  • Page 118: Washing Your Motorcycle

    MAINTENANCE AND ADJUSTMENT components, muffler outlet, and fuel not let the water air dry as this can tank openings. damage the painted surfaces. • Start the engine and let it idle for sev- Washing Your Motorcycle eral minutes. The heat from the en- •...
  • Page 119 • If any doubt, consult an authorized age. Avoid using abrasive pads Kawasaki dealer. or brushes to clean plastic parts, as they will damage the part's fin- Other Plastic Parts ish. After washing use a soft cloth to gen-...
  • Page 120 MAINTENANCE AND ADJUSTMENT Chrome and Aluminum The sidewalls of tires and other rub- ber components should be treated with Chrome and uncoated aluminum a rubber protectant to help prolong parts can be treated with a chrome/alu- their useful life. minum polish.
  • Page 121: Appendix

    APPENDIX APPENDIX 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 122 APPENDIX WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. Turn the ignition key 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. Gasoline is a toxic substance.
  • Page 123 APPENDIX • 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 dampness away from the tire rubber.) •...
  • Page 124: Troubleshooting Guide

    APPENDIX Troubleshooting Guide Engine Does Not Start Starter Motor Won't Turn • Engine stop switch off • Transmission not in neutral • Fuse blown • Battery cables do not make good electrical contact with battery terminals • Battery discharged Engine Cranks, But Won't Start •...
  • Page 125: 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 126: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Owner Name ..................Address ....................Phone Number ..................Engine Number ..................Vehicle Number ................... Key Code ....................Selling Dealer Name ................Phone Number ..................Warranty Start Date ................Note: Keep this information and a spare key in a secure location. Odometer Date Maintenance Performed...
  • Page 127 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 128 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 129 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 130 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 131 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...

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