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 TROUBLESHOOTING GUIDE A Table of Contents is included after the Foreword.
NOTICE Whenever you see the symbols shown below, heed their instructions! NOTICE is used to address prac- Always follow safe operating and main- tices not related to personal in- tenance practices. jury. DANGER NOTE DANGER indicates a hazardous ○ NOTE indicates information that may situation which, if not avoided, help or guide you in the operation or will result in death or serious in-...
NOTICE WARNING Engine exhaust, some of its THIS PRODUCT BEEN constituents, and certain vehi- MANUFACTURED FOR USE IN A cle components contain or emit REASONABLE AND PRUDENT chemicals known to the State of MANNER BY A QUALIFIED OP- California to cause cancer and ERATOR AND AS A VEHICLE birth defects or other reproduc- ONLY.
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-...
TABLE OF CONTENTS SPECIFICATIONS....... Horn Button: ......... 35 SERIAL NUMBER LOCATIONS..13 Fuel Tank Cap ........36 LOCATION OF PARTS ....... 14 Fuel Tank ......... 37 LOCATION OF LABELS..... 17 Fuel Requirement: ......38 LOADING INFORMATION....21 Fuel Tap ........... 41 GENERAL INFORMATION....
Cleaning Your Motorcycle ....151 Cooling System ........ 97 Bolt and Nut Tightening....157 Spark Plugs........102 STORAGE........... 159 Kawasaki Clean Air System ..... 103 TROUBLESHOOTING GUIDE.... 162 Evaporative Emission Control YOUR WARRANTY/OWNER System (California model only)..104 SATISFACTION ......163 Valve Clearance .......
SPECIFICATIONS SPECIFICATIONS PERFORMANCE Minimum Turning Radius 2.4 m (94.5 in.) DIMENSIONS Overall Length 2 200 mm (86.62 in.) Overall Width 820 mm (32.28 in.) Overall Height 1 205 mm (47.44 in.) Wheelbase 1 430 mm (56.30 in.) Road Clearance 285 mm (11.22 in.) Curb Mass 135 kg (298 lb) (CAL) 136 kg (300 lb)
SPECIFICATIONS Starting System Electric starter Carburetors KEIHIN CVK34 Ignition System 10° BTDC @1 300 r/min (rpm) ∼ 25° BTDC @5 000 Ignition Timing (Electronically advanced) r/min (rpm) Spark Plugs NGK CR8E Lubrication System Forced lubrication (wet sump) Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40...
SPECIFICATIONS Final Reduction Ratio 3.000 (42/14) Overall Drive Ratio 8.000 (Top gear) Gear Ratio 3.000 (30/10) 2.000 (30/15) 1.500 (27/18) 1.250 (25/20) 1.050 (21/20) 0.952 (20/21) FRAME Castor 26.5° Trail 105 mm (3.31 in.) Tire Size: Front 3.00-21 51P Rear 4.60-18 63P...
SPECIFICATIONS Rim Size: Front 21 × 1.60 Rear 18 × 2.15 Fuel Tank Capacity 7.7 L (2.04 US gal) ELECTRICAL EQUIPMENT Battery 12 V 6 Ah Headlight 12 V 60/55 W Tail/Brake Light 12 V 5/21 W (CAL) California model Specifications are subject to change without notice.
SERIAL NUMBER LOCATIONS 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.
LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 5. Left Handlebar Switches 2. Meter Instruments 6. Ignition Switch/Steering Lock 3. Brake Fluid Reservoir (Front) 7. Right Handlebar Switches 4. Front Brake Lever 8. Throttle Grip...
LOCATION OF PARTS 9. Front Fork 16. Rear Shock Absorber 23. Horn 10. Headlight 17. Tool Kit Bag 24. Shift Pedal 11. Turn Signal Light 18. Tool Kit 25. Side Stand 12. Fuel Tank Cap 19. Helmet Hook 26. Side Stand Switch 13.
LOCATION OF PARTS 30. License Plate Light 36. Idle Adjusting Screw 40. Rear Brake Light 31. Tail/Brake Light 37. Front Brake Light Switch 32. Muffler Switch 41. Oil Level Inspection 33. Seat 38. Radiator Cap Window 34. Air Cleaner Element 39.
Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct posi- tion. NOTE ○...
LOCATION OF LABELS 2. Important Drive Chain Information 3. Tire and Load Data 4. Brake Fluid (Rear) (For further information of label, refer to the “LABEL INFORMATION” chapter.)
LOCATION OF LABELS 5. Weight and Manufacture 6. Vehicle Emission Control Information *7. Vacuum Hose Routing Diagram 8. Noise Emission Control Information (For further information of label, refer to the “LABEL INFORMATION” chapter.) *: Only on California model...
LOCATION OF LABELS *9. Fuel Level 10. Battery Poison/Danger 11. Radiator Cap Danger (For further information of label, refer to the “LABEL INFORMATION” chapter.) *: Only on California model...
Kawasaki Parts Accessories, Kawasaki has no control over the Because a motorcycle is sensitive to design or application of accessories. changes in weight and aerodynamic In some cases, improper installation forces, you must take extreme care or use of accessories, or motorcycle...
LOADING INFORMATION been prepared to assist you in making on the motorcycle center of gravity. your determinations. Baggage weight should also be dis- 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.
LOADING INFORMATION affected any lighting components, be used to tow any trailer or other road clearance, banking capability vehicle. Kawasaki does not manu- (i.e., lean angle), control operation, facture sidecars or trailers for mo- wheel travel, front fork movement, torcycles and cannot predict the ef-...
GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. MODE Button B. RESET Button C. Tachometer D. Odometer/Trip Meter AB E. Speedometer F. Clock G. Coolant Temperature Warning Indicator Light H. High Beam Indicator Light I. Neutral Indicator Light J. Turn Signal Indicator Light K.
5000 r/min (rpm) for the ignition con- ments or tachometer does not operate trol, but this operation is not a failure. or display correctly, have it checked by an authorized Kawasaki dealer. NOTICE Tachometer: Engine r/min (rpm) should not The tachometer shows the engine be allowed to enter the red zone;...
GENERAL INFORMATION Odometer/Trip Meter AB: Odometer - This meter displays the odometer, The odometer shows the total dis- the trip meter AB, and the fuel warning tance in kilometers or miles that the ve- message. hicle has been ridden. This meter can- The odometer and the trip meter AB not be reset.
GENERAL INFORMATION • Push the MODE button to display the Mile/Km Display: trip meter A or B. Mile/Km Display can alternate be- • Push the RESET button and hold it tween English and metric modes (mph and km/h) in the meter unit. Make sure •...
GENERAL INFORMATION NOTE ○ Do not operate the vehicle with the meter unit displaying in the wrong unit (km/h or mph). Shift the km/h·mph display in the meter unit as follows. A. Km/h B. Mph • Display the odometer. C. Push RESET Button with MODE Button in •...
GENERAL INFORMATION • • Push the RESET button. The hour Push the RESET button. Both the display only blinks. Push the MODE hour and minute displays start blink- button to advance the hours. ing again. • Push the MODE button. The dis- plays stop blinking and the clock starts working.
GENERAL INFORMATION ○ When the battery is disconnected, soon after ensuring that its circuit func- the clock resets to 1:00 and starts tion properly. The warning indicator working again when the battery is light also goes on whenever the coolant connected.
GENERAL INFORMATION Keys This motorcycle has a combination key, which is used for the ignition switch, steering lock, helmet hook and fuel tank cap. Included with the key is a key number, which may be stamped on a separate plate . Record the key number in the space provided and store the number in a safe place.
LOCK position. other locks operated by that key. Contact your Kawasaki dealer to pur- chase additional spare keys either us- ing your original key as a master or us- ing the key code on the tag or your key.
GENERAL INFORMATION 2. For locking, push down the key in Engine on. All electrical equipment can be used. the OFF position and turn it to Lock position. Engine off. All electrical 3. Pull the key out. circuits off. Steering locked. Engine off. NOTE LOCK All electrical circuits off.
GENERAL INFORMATION Right Handlebar Switches Starter Button: Engine Stop Switch: The starter button operates the elec- In addition to the ignition switch, the tric starter when the transmission is in neutral. engine stop switch must be in the Refer to the Starting the Engine sec- position for the motorcycle to operate.
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 corre- with the dimmer switch. When the sponding turn signals blink on and off. headlight is on high beam , the To stop blinking, push the switch in.
GENERAL INFORMATION Fuel Tank Cap NOTE ○ To open the fuel tank cap, insert the The fuel tank cap cannot be closed ignition key into the fuel tank cap, turn without the key inserted, and the key the key to the right. cannot be removed unless the cap is To close the cap, push it down into locked properly.
GENERAL INFORMATION WARNING Fuel Tank The following octane rating gasoline Gasoline is extremely flammable is recommended in the fuel tank. Avoid and can be explosive under cer- filling the tank in the rain or where tain conditions, creating the po- heavy dust is blowing so that the fuel tential for serious burns.
GENERAL INFORMATION NOTICE The Antiknock Index is posted on ser- vice station pumps. The octane rating California model only: Never fill of a gasoline is a measure of its resis- the tank so the fuel level rises tance to detonation or "knocking." The into the filler neck.
GENERAL INFORMATION NOTICE Fuels Containing Oxygenates Gasoline frequently contains oxy- If engine "knocking" or "ping- genates (alcohols and ethers) espe- ing" occurs, use a different cially in areas of the U.S. and Canada brand of gasoline of a higher which are required to sell such refor- octane rating.
When operating your in unleaded gasoline include TAME Kawasaki for 30 to 60 days, mix a (up to 16.7 %) and ETBE (up to fuel stabilizer (such as STA-BIL) 17.2 %). Fuel containing these oxy- with the gasoline in the fuel tank.
GENERAL INFORMATION NOTICE Fuel Tap The fuel tap has three positions: Never store this product with OFF, ON, and RES (reserve). For no- "gasohol" in the fuel system. mal operation, turn the tap lever to the Before storage it is recom- ON position.
GENERAL INFORMATION NOTE Stand ○ The motorcycle is equipped with a Since riding distance is limited when side stand. on RES, refuel at the earliest oppor- tunity. ○ Make certain that the fuel tap lever is turned to ON (Not RES) after filling up the fuel tank.
GENERAL INFORMATION NOTE Helmet Hook ○ Helmet can be secured to the motor- The motorcycle is equipped with a cycle using the helmet hook. side stand switch. This switch is de- The helmet hook can be unlocked by signed so that the engine dose not inserting the ignition key into the lock, start if the transmission is in gear and and turning the key to the right.
GENERAL INFORMATION WARNING Tool Kit Bag/Tool Kit The tool kit is stored in the tool kit Riding with a helmet attached to bag. the hook could cause an acci- The kit contains tools that can be dent by distracting the operator helpful in making roadside repairs, ad- or interfering with normal vehi- justments, and some maintenance pro-...
GENERAL INFORMATION Seat Seat Removal • Remove the mounting bolts. A. Bolt B. Seat C. Tandem Band Seat Installation • A. Seat Align the front hook with the front re- B. Mounting Bolts ceiver and slide the seat forward. • •...
GENERAL INFORMATION Rear View Mirror Rear View Mirror Adjustment • Adjust the rear view mirror by slightly moving only the mirror portion of the assembly. A. Seat B. Front Hook C. Front Receiver D. Center Hook E. Center Receiver • Tighten the tandem band bolts.
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.
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 have the initial maintenance service performed by an authorized Kawasaki dealer.
HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE • Starting the Engine Check that the engine stop switch is • Turn the fuel tap lever to "ON". in the position. A. Fuel Tap A. Engine Stop Switch B. ON position B.
HOW TO RIDE THE MOTORCYCLE • • Turn the ignition key to "ON". If the engine is cold, pull out the • Make certain the transmission is in choke knob all the way. neutral. A. Choke Knob A. Neutral Indicator Light B.
HOW TO RIDE THE MOTORCYCLE • Leaving throttle completely the side stand is down. However, the closed, push the starter button. engine can be started if the clutch lever is pulled and the side stand is NOTICE fully up. Do not operate the starter con- tinuously for more than 5 sec- onds or the starter will overheat and the battery power will drop...
HOW TO RIDE THE MOTORCYCLE NOTE Jump Starting ○ If your motorcycle battery is "run If you drive the motorcycle before the down", it should be removed and engine is warmed up, push the choke charged. If this is not practical, a 12 knob all the way back as soon as you volt booster battery and jumper cables start moving.
HOW TO RIDE THE MOTORCYCLE DANGER Connecting Jumper Cables • Remove the left side cover. Battery acid generates hydro- • Make sure the ignition switch is gen gas which is flammable and turned "OFF". explosive under certain con- • Connect a jumper cable from the ditions.
HOW TO RIDE THE MOTORCYCLE DANGER Batteries contain sulfuric acid that can cause burns and pro- duce hydrogen gas which is highly explosive. Do not make this last connection at the fuel system or battery. Take care not to touch the positive and nega- tive cables together, and do not lean over the battery when mak- A.
HOW TO RIDE THE MOTORCYCLE NOTICE Moving Off • Check that the side stand is up. Do not operate the starter con- • Pull in the clutch lever. tinuously for more than 5 sec- • Shift into 1st gear. onds or the starter will overheat •...
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.
HOW TO RIDE THE MOTORCYCLE • Open the throttle part way, while re- leasing the clutch lever. Vehicle speed when shifting Shifting up km/h (mph) Shifting down km/h (mph) 1st → 2nd 6th → 5th 15 ( 9) 30 (19) 2nd →...
HOW TO RIDE THE MOTORCYCLE • Braking For emergency braking, disregard • Close the throttle completely, leav- downshifting, and concentrate on ing the clutch engaged (except when applying the brakes as hard as pos- shifting gears) so that the engine will sible without skidding.
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. • Lock the steering.
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 carburetor. designed and manufactured to pro- vide you optimum safety and conve- In an emergency situation such as nience.
HOW TO RIDE THE MOTORCYCLE WARNING Parking The engine and exhaust system WARNING get extremely hot during normal Operating or parking the vehi- operation and can cause serious cle near flammable materials can burns. cause a fire, and can result in Never touch a hot engine, ex- property damage or severe per- haust pipe, or muffler during op-...
HOW TO RIDE THE MOTORCYCLE • and the motorcycle is not close to Turn the fuel tap lever to the OFF any source of flame or sparks; this position. includes any appliance with a pilot light. WARNING Gasoline is extremely flammable and can be explosive under cer- tain conditions, creating the po- tential for serious burns.
HOW TO RIDE THE MOTORCYCLE WARNING Catalytic Converter This motorcycle is equipped with a Operating or parking the vehi- catalytic converter in the exhaust sys- cle near flammable materials can tem. The converter reacts with car- cause a fire, and can result in bon monoxide, hydrocarbons and nitro- property damage or severe per- gen oxides to convert them into carbon...
HOW TO RIDE THE MOTORCYCLE • Use only unleaded gasoline. Never engine excessively accelerates reac- use leaded gasoline. Leaded gaso- tion in the converter allowing the con- line significantly reduces the capabil- verter to overheat and become dam- ity of the catalytic converter. aged when the engine is hot, or re- •...
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.
SAFE OPERATION When going down long slopes, In general your actions should control vehicle speed by closing be smooth as sudden acceleration, the throttle. Use the front and rear braking or turning may cause loss brakes for auxiliary braking. of control, especially when riding in In wet conditions, rely more on the wet conditions or on loose roadway throttle to control vehicle speed and...
SAFE OPERATION When quick acceleration is neces- Avoiding unnecessary weaving is sary as in passing, shift to a lower important to the safety of both the gear to obtain the necessary power. rider and other motorists. Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrevving.
SAFE OPERATION Daily Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor- cycle to a safe operating condition.
SAFE OPERATION Fuel ......Adequate supply in tank, no leaks. Engine oil ....Oil level between level lines. Tires ......Air pressure (when cold): Front – – – 150 kPa (1.50 kgf/cm², 22 psi) Up to 97.5 kg (215 lb) Rear 150 kPa (1.50 kgf/cm², 22 psi) Load...
SAFE OPERATION Coolant ....... No coolant leakage. Coolant level between level lines (when engine is cold). Electrical equipment ... All lights (Head, Tail/Brake, Turn Signal, Warning/Indica- tor) and horn work. Engine stop switch ..Stops engine. Side stands ....Return to its fully up position by spring tension. Return springs not weak or not damaged.
SAFE OPERATION 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 handlebar turns freely but has no play.
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.
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.
Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect or improper adjustment done by the owner.
MAINTENANCE AND ADJUSTMENT EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated...
When properly performed, these specified modifications only are not considered to be emissions system “tampering” and vehicle performance is generally un- changed as a result. Installation Instructions: High altitude adjustment requires replacement of certain carburetor components. Installation of these optional parts may be performed by an authorized Kawasaki...
Owner’s Manual at your own expense. The Kawasaki Limited Emission Control System Warranty requires that you re- turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty. Please read the warranty carefully, and keep it valid by complying with the owner’s obligations it contains.
MAINTENANCE AND ADJUSTMENT TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, re- pair, 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, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
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.
MAINTENANCE AND ADJUSTMENT 1. Periodic Inspection (Engine Related Items) Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Throttle control system (play, smooth • •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Coolant level - • • • • inspect • • • • year Coolant leak - inspect Radiator hose...
MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Clutch and drive train: Clutch operation (play, engagement, •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Drive chain guide • • • – wear - inspect Wheels and tires: Tire air pressure - •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Brake system: Brake fluid leak - • • • • • • •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Brake operation • • • • • • • year (effectiveness, play, drag) - inspect Brake light switch •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Uni-trak rocker arm • – bearings - lubricate Uni-trak rocker arm • •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Steering stem • – years bearings - lubricate Electrical system: Lights and switches •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Chassis: Chassis parts - • • • year lubricate Bolts and nuts •...
MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Change/Replacement Item Every (0.6) (7.5) (15) (22.5) (30) Air cleaner element - replace # 2 year • • • • •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Change/Replacement Item Every (0.6) (7.5) (15) (22.5) (30) Rubber parts of master cylinder • – 4 years and caliper - replace • • •...
MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • In order for the engine, transmission, Situate the motorcycle so that it is and clutch to function properly, main- perpendicular to the ground. • tain the engine oil at the proper level, If the oil has just been changed, start and change the oil and oil filter in accor- the engine and run it for several min-...
MAINTENANCE AND ADJUSTMENT • upper and lower level lines next to If the oil level is too high, remove the the oil level inspection window. excess oil through the oil filler open- ing using a syringe or same other suitable device. •...
MAINTENANCE AND ADJUSTMENT • Oil and/or Oil Filter Change Let the oil completely drain with • Warm up the engine thoroughly, and the motorcycle perpendicular to the then stop it. ground. • Set the motorcycle up on its side stand. WARNING •...
MAINTENANCE AND ADJUSTMENT • • If the oil filter is to be changed, re- Replace the element with a new one. move the oil filter cover bolts and take off the cover with O-ring. A. Element B. Grommet • A. Bolts Apply a little grease around the ele- B.
15 N·m (1.5 kgf·m, 11 ft·lb) NOTE A. Holes ○ If a torque wrench is not available, • After the oil has completely drained this item should be serviced by a out, install the engine oil drain plug Kawasaki dealer.
[when filter is not removed] Viscosity: SAE 10W-40 1.1 L (1.2 US qt) [when filter is removed] *Kawasaki Performance Oils and 1.3 L (1.4 US qt) Lubricants have been specifically en- [when engine is completely gineered for your vehicle. Consistent...
MAINTENANCE AND ADJUSTMENT Cooling System Radiator and Cooling Fan - 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 spins at high speed and can cause serious injuries.
MAINTENANCE AND ADJUSTMENT NOTICE 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.
MAINTENANCE AND ADJUSTMENT NOTICE jacket and radiator. This will clog up the coolant passages, and consider- If hard water is used in the sys- ably reduce the efficiency of the cooling tem, it causes scale accumula- system. tion in the water passages, and considerably reduces the effi- WARNING ciency of the cooling system.
MAINTENANCE AND ADJUSTMENT NOTICE should be between the F(FULL) and L(LOW) level lines. Permanent types of antifreeze on the market have anti-corrosion NOTE and anti-rust properties. When it ○ Check the level when the engine is is diluted excessively, it loses its cold (room or atmospheric tempera- anti-corrosion property.
F(FULL) level bly leakage in the system. Have line. the cooling system inspected • Install the cap. by your authorized Kawasaki dealer. NOTE ○ In an emergency you can add wa- Coolant Change ter alone to the coolant reserve tank,...
MAINTENANCE AND ADJUSTMENT Spark Plugs Spark Plug The standard spark plug is shown in Standard Plug NGK CR8E the table. The spark plug should be 0.7 ∼ 0.8 mm taken out in accordance with the Pe- Plug Gap (0.028 ∼ 0.031 in.) riodic Maintenance Chart for cleaning, Tightening 13 N·m...
MAINTENANCE AND ADJUSTMENT NOTE Kawasaki Clean Air System ○ The Kawasaki Clean Air System If a torque wrench is not available, (KCA) is a secondary air suction sys- this item should be serviced by a tem that helps the exhaust gases to Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT Evaporative Emission Control in accordance with the Periodic Main- System (California model tenance Chart. Also, inspect the air only) suction valves whenever stable idling cannot be obtained, engine power is This system routes fuel vapors from greatly reduced, or there are abnormal the fuel system into the running engine engine noises.
MAINTENANCE AND ADJUSTMENT Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. NOTICE If valve clearance is left un- adjusted, wear will eventually cause the valves to remain partly open, which lowers per- formance, burns the valves and valve seats, and may cause seri- ous engine damage.
MAINTENANCE AND ADJUSTMENT Air Cleaner Element Removal • A clogged air cleaner restricts the en- Remove the seat. • gine’s air intake, increasing fuel con- Unscrew the air cleaner intake cap sumption, reducing engine power, and bolts and remove the air cleaner in- causing spark plug fouling.
MAINTENANCE AND ADJUSTMENT • • Remove the wing bolt, and take out Remove the element from the frame. the element. A. Element A. Element • Put a clean, lint-free towel over the B. Wing Bolt air cleaner housing to keep dirt or other foreign material from entering.
MAINTENANCE AND ADJUSTMENT WARNING NOTE ○ Element installation is performed in If dirt or dust is allowed to pass the reverse order of removal. through into the carburetor, the ○ When installing the element, coat the throttle may stick or become lip of the element with a thick layer of inoperable resulting in a haz- all purpose grease to assure a com-...
MAINTENANCE AND ADJUSTMENT • Element Cleaning After cleaning, saturate the element • Clean the element in a bath of a high with a high-quality foam-air-filter oil, flash-point solvent. squeeze out the excess, then wrap it in a clean towel and squeeze it as dry as possible.
MAINTENANCE AND ADJUSTMENT WARNING WARNING Gasoline and low-flash point sol- Oil on tires will make them slip- vents can be flammable and/or pery and can cause an accident explosive and cause severe and injury. Be sure to install the burns. Clean the element in a plug in the drain hose after drain- well ventilated area, and take ing.
MAINTENANCE AND ADJUSTMENT • Throttle Grip Inspect the transparent reservoir lo- cated under the rear shock absorber The throttle grip controls the throttle to see if any oil has run down from valves. If the throttle grip has exces- the air cleaner housing. sive play due to either cable stretch or maladjustment, it will cause a delay in throttle response, especially at low en-...
MAINTENANCE AND ADJUSTMENT Inspection Adjustment • • Check that there is 2 ∼ 3 mm (0.08 Loosen the locknut at the throttle ∼ 0.12 in.) throttle grip play when grip, and turn the adjuster until the lightly turning the throttle grip back proper amount of throttle grip play is and forth.
MAINTENANCE AND ADJUSTMENT grip, use the nuts located at the car- buretor. • Loosen the locknut at the throttle grip and turn in the adjuster fully. • Tighten the locknut. • Loosen the nuts at the carburetor, and screw both throttle cable nuts fully so as to give the throttle grip plenty of play.
MAINTENANCE AND ADJUSTMENT WARNING Carburetors The following procedure covers the Operation with improperly ad- idle speed adjustment, which should be justed, incorrectly routed, or performed in accordance with the Pe- damaged cables could result in riodic Maintenance Chart or whenever an unsafe riding condition.
MAINTENANCE AND ADJUSTMENT • Idle Speed 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 • Adjust the idle speed to 1 250 ∼ 1 necessary.
Check that the clutch lever operates B. Clutch Lever Play properly and that the inner cable C. Locknut D. Adjuster slides smoothly. If there is any irreg- E. Dust Cover ularity, have the clutch cable checked by an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT WARNING If the play is incorrect, adjust the lever play as follows. Too much cable play can pre- Adjustment vent clutch disengagement and • Slide the dust cover at the clutch cause an accident resulting in lever out of place. serious injury or death.
MAINTENANCE AND ADJUSTMENT • NOTE Loosen the locknut at the middle of ○ the cable, and turn the adjusting nut After the adjustment is made, start so that the clutch lever has 2 ∼ 3 mm the engine and check that the clutch (0.08 ∼...
MAINTENANCE AND ADJUSTMENT Drive Chain Chain Slack Inspection • The drive chain slack and lubrica- Set the motorcycle up on its side tion must be checked each day be- stand. fore riding the motorcycle, and in accor- • Rotate the rear wheel to find the po- dance with the Periodic Maintenance sition where the chain is tightest and Chart for safety and to prevent exces-...
MAINTENANCE AND ADJUSTMENT • If the drive chain is too tight or too loose, adjust it so that the chain slack will be within the standard value. Drive Chain Slack 35 ∼ 45 mm (1.4 ∼ 1.8 in.) Standard Chain Slack Adjustment •...
Tightening Torque Axle Nut: NOTE 110 N·m (11.0 kgf·m, 80 ft·lb) ○ Wheel alignment also checked using the straightedge or NOTE string method. ○ If a torque wrench is not available, this item should be serviced by a Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT • • Rotate the wheel, measure the chain Measure the length of 20 links on slack again at the tightest position, the straight part of the chain from pin and readjust if necessary. center of the 1st pin to pin center of •...
Also inspect the sprockets for un- evenly or excessively worn teeth, A. Good Teeth and damaged teeth. 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.
MAINTENANCE AND ADJUSTMENT Lubrication Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for sealed chains to prevent deterioration of chain seals. If the chain is especially dirty, clean it using a cleaner for sealed chains fol- lowing the instructions supplied by the chain cleaner manufacturer.
Pad replace- with dirt or water. ment should be done by an authorized Kawasaki dealer. Fluid Requirement Use heavy-duty brake fluid only from a container marked DOT3 or DOT4.
MAINTENANCE AND ADJUSTMENT NOTICE Fluid Level Inspection • The brake fluid level in the front brake Do not spill brake fluid onto any fluid reservoir must be kept above painted surface. the line (lower level line) next to the Do not use fluid from a container gauge and that in the rear brake fluid that has been left open or that reservoir must be kept between the...
MAINTENANCE AND ADJUSTMENT • If the fluid level in ether 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 reservoir is a stepped line showing the upper level line.
Have the brake is already in the reservoir are checked immediately by an au- unidentified. thorized Kawasaki dealer. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Front and Rear Brakes - Disc and disc pad wear is automat- ically compensated for and has no ef- fect on the brake lever or pedal action.
• The brake light should go on when the front brake is applied. • If it does not, ask your authorized Kawasaki dealer to inspect the front brake light switch. A. Brake Pedal B. 10 mm (0.4 in.) • If it does not, adjust the rear brake...
MAINTENANCE AND ADJUSTMENT NOTICE Adjustment • To adjust the rear brake light switch, To avoid damaging the electrical move the switch up or down by turn- connections inside the switch, ing the adjusting nut. be sure that the switch body does not turn during adjustment.
If any doubt about the front fork, it The front fork operation and oil leak- should be done by an authorized age should be checked in accordance Kawasaki dealer. with the Periodic Maintenance Chart. After riding through muddy or dusty roads, the front inner tube should be cleaned immediately.
MAINTENANCE AND ADJUSTMENT • Compression Damping Adjustment To adjust compression damping, turn • Using the jack under the frame, sta- the adjuster on the front fork cylinder bilize the motorcycle. valve with the blade of a screwdriver • Place a stand or block under the en- until you feel a click.
MAINTENANCE AND ADJUSTMENT WARNING Rear Shock Absorber The rear shock absorber operation If both damping force adjusters and oil leakage should be checked in are not adjusted equally, han- accordance with the Periodic Mainte- dling may be impaired and a nance Chart.
• If any doubt about the rear shock ab- sorber, it should be done by an au- thorized Kawasaki dealer. A. Rebound Damping Adjuster B. Mark A. Rear Shock Absorber...
Spring Preload Adjustment The rear shock absorber can be ad- justed by changing the spring preload for various riding and loading condi- tions. If the spring action feels too soft or too stiff, have it adjusted by an au- thorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT • Wheels Remove the air valve cap. • Check the tire pressure often, using Tires - an accurate gauge. • Make sure to install the air valve cap Payload and Tire Pressure Failure to maintain proper inflation securely installed.
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).
MAINTENANCE AND ADJUSTMENT • In accordance with the Periodic Minimum Tread Depth Maintenance Chart, measure the Front 2 mm (0.08 in.) depth of the tread with a depth Rear 2 mm (0.08 in.) gauge, and replace any tire that has worn down to the minimum al- •...
MAINTENANCE AND ADJUSTMENT WARNING Standard Tire Front Size: 3.00-21 51P Tires that have been punctured and repaired do not have the DUNLOP D605FG same capabilities as undam- Rear Size: 4.60-18 63P aged tires and can suddenly fail, DUNLOP D605 G causing an accident resulting in serious injury or death.
MAINTENANCE AND ADJUSTMENT WARNING Battery The battery installed in this motorcy- New tires are slippery and may cle is a sealed type, so it is not nec- cause loss of control and injury. essary to check the battery electrolyte A break-in period of 160 km (100 level or add distilled water.
MAINTENANCE AND ADJUSTMENT type of battery and ambient temper- Self-discharge ature. As temperatures rise, so does Approx. Number of Days the discharge rate. Every 15°C (59°F) From 100% Charged to doubles the rate. 100% discharged Electrical accessories, such as digi- Temperature Lead Lead...
MAINTENANCE AND ADJUSTMENT Battery Sulfation Current Drain A common cause of battery failure is Days from Days from sulfation. 100% 100% Discharging Sulfation occurs when the battery is charged charged Ampere left in a discharged condition for an ex- to 50% to 100% tended time.
If the above chargers are not avail- causes the electrical components able, use equivalent one. (clock etc) to make the battery dis- For more details, ask your Kawasaki charged, resulting the over discharge dealer. of the battery. In this case, the repair...
MAINTENANCE AND ADJUSTMENT NOTE Battery Charging ○ • Remove the battery from the motor- If you charge the sealed battery, cycle (see Battery Removal). never fail to observe the instructions • Attach the leads from the charger shown in the label on the battery. and charge the battery at a rate (am- perage×hours) that is indicated on WARNING...
MAINTENANCE AND ADJUSTMENT • Battery Removal Clean the battery using a solution of • Remove the left side cover. baking soda and water. Be sure that • Disconnect the cables from the bat- the wire connections are clean. tery, first from the (–) terminal and Battery Installation then the (+) terminal.
MAINTENANCE AND ADJUSTMENT • Headlight Beam Put a light coat of grease on the ter- minals to prevent corrosion. Horizontal Adjustment • Cover the (+) terminal with its protec- The headlight beam is adjustable tive cap. horizontally. If not properly adjusted •...
MAINTENANCE AND ADJUSTMENT Vertical Adjustment the motorcycle on its wheels and the The headlight beam is adjustable ver- rider seated. tically. If adjusted too low, neither low nor high beam will illuminate the road far enough ahead. If adjusted too high, the high beam will fail to illuminate the road close ahead, and the low beam will blind oncoming drivers.
MAINTENANCE AND ADJUSTMENT NOTICE Fuses The main fuse is mounted on the When handling quartz starter relay located under the seat. -halogen bulbs, never touch the The fuse case is located under the glass portion with bare hands. seat. If a fuse fails during operation, Always use a clean cloth.
MAINTENANCE AND ADJUSTMENT WARNING Substituting fuses can cause wiring to overheat, catch fire and/or fail. Do not use any sub- stitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the junction box and main fuse.
MAINTENANCE AND ADJUSTMENT General Lubrication Apply motor oil to the following Lubricate the points shown below, pivots - • with either motor oil or regular grease, Side Stand • in accordance with the Periodic Main- Clutch Lever • tenance Chart or whenever the vehicle Front Brake Lever •...
(K) Clutch Inner Cable Upper End Frequent and proper care of your • (K) Throttle Inner Cable Upper Ends Kawasaki motorcycle will enhance its appearance, optimize overall per- (K): Should be serviced by an authorized formance, and extend its useful life.
MAINTENANCE AND ADJUSTMENT • WARNING Be sure the engine and exhaust are cool before washing. Build-up of debris or flammable • Avoid applying degreaser to seals, material in and around the vehi- brake pads, and tires. cle chassis, engine, and exhaust •...
MAINTENANCE AND ADJUSTMENT • • Avoid spraying water in delicate ar- Use a soft cloth to dry your motorcy- eas such as in air intakes, carbu- cle. As you dry, inspect your motor- retors, brake components, electrical cycle for chips and scratches. Do not components, muffler outlets, and fuel let the water air dry as this can dam- tank openings.
• If any doubt, consult an authorized Kawasaki dealer. Painted Surfaces After washing your motorcycle, coat painted surfaces, both metal and plas- tic, with a commercially available mo- torcycle/automotive wax. Wax should...
MAINTENANCE AND ADJUSTMENT NOTICE should be washed with a mild neu- tral detergent and finished with a spray Plastic parts may deteriorate polish. Aluminum wheels, both painted and brake if they come in con- and unpainted can be cleaned with tact with chemical substances special non-acid based wheel spray or household cleaning products...
MAINTENANCE AND ADJUSTMENT WARNING Rubber protectants can be slip- pery and, if used on the tread area, cause loss of traction re- sulting in accident causing in- jury or death. Do not apply rub- ber protectant to any tread area.
In accordance with the Periodic Maintenance Chart, it is very important to check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki dealer for torque values.
MAINTENANCE AND ADJUSTMENT 14. Rear Axle Nut 15. Muffler Mounting Bolts and Nuts...
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 Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recy- cling.
STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. 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.
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.) •...
You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale. The warranty does not cover the cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such as tires, brake pads, transmission drive belts, chains, sprockets, etc.
Much of the warranty coverage offered by the limited warranty can be extended by purchasing Kawasaki’s Good Time™ Protection Plan (GTPP). See your Kawasaki dealer or go to Kawasaki.com for more information if you don’t already have the GTPP. What Am I Responsible For? You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner’s manual.
Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the Maintenance Record section of this Owner’s Manual.
Kawasaki if the repair is one that will be covered by the limited warranty. The dealership will also file all necessary paperwork. The dealership is responsible for correctly completing any necessary repairs, whether they are covered by the lim- ited warranty or not.
YOUR WARRANTY/OWNER SATISFACTION Kawasaki will work with your dealer to resolve any warranty issues. No autho- rization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer. What if I am not Satisfied With My Warranty Service? If you aren’t satisfied with your dealership’s repair work or operations, it is best to...
Want to Contact Kawasaki? This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you.
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Kawasaki Motors Corpora- tion, U.S.A.
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...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...