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Kawasaki Ninja ZX-6R 2010 Owner's Manual

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  Summary of Contents for Kawasaki Ninja ZX-6R 2010

  • Page 3 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.
  • Page 5 CAUTION Whenever you see the symbols shown below, heed their instructions! CAUTION indicates a hazardous Always follow safe operating and main- situation which, if not avoided, tenance practices. could result in minor or moder- ate injury. DANGER DANGER indicates a hazardous NOTICE situation which, if not avoided, will result in death or serious in-...
  • Page 6 FOREWORD Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo- torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-...
  • Page 7 However, there may be minor differences between the actual product and illustra- tions and text in this manual. All products are subject to change without prior notice or obligation. KAWASAKI HEAVY INDUSTRIES, LTD. Consumer Products & Machinery Company © 2009 Kawasaki Heavy Industries, Ltd. March 2009. (1). (D, Ke)
  • Page 8: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS....... Turn Signal Switch:....... 45 SERIAL NUMBER LOCATIONS..12 Horn Button: ......... 45 LOCATION OF PARTS ....... 13 LAP Button: ........45 LOCATION OF LABELS..... 16 Brake Lever Adjuster......46 LOADING AND ACCESSORIES Fuel Tank Cap ........47 INFORMATION ........
  • Page 9 Bolt and Nut Tightening....175 System (California model only)..112 STORAGE........... 178 Valve Clearance ....... 113 TROUBLESHOOTING GUIDE.... 181 Kawasaki Clean Air System ..... 113 OWNER SATISFACTION....182 Exhaust Device ........ 114 REPORTING SAFETY DEFECTS ..184 Air Cleaner ........115 ENVIRONMENTAL PROTECTION..
  • Page 10: Specifications

    SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 2 090 mm (82.3 in.) Overall Width 710 mm (28.0 in.) Overall Height 1 115 mm (43.9 in.) Wheelbase 1 400 mm (55.1 in.) Road Clearance 120 mm (4.7 in.) Curb Mass 191 kg (421 lb) ENGINE Type DOHC, 4-cylinder, 4-stroke, liquid-cooled...
  • Page 11 SPECIFICATIONS Firing Order 1-2-4-3 Carburetion System FI (Fuel Injection) Ignition System Battery and coil (transistorized ignition) Ignition Timing (Electronically 12.5° BTDC @1 300 r/min (rpm) ∼ 36.4° BTDC advanced) @4 800 r/min (rpm) Spark Plugs NGK CR9E Lubrication System Forced lubrication (wet sump) Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or...
  • Page 12 SPECIFICATIONS Final Reduction Ratio 2.688 (43/16) Overall Drive Ratio 6.638 (Top gear) Gear Ratio 2.714 (38/14) 2.200 (33/15) 1.850 (37/20) 1.600 (32/20) 1.421 (27/19) 1.300 (26/20) FRAME Castor 24° Trail 103 mm (4.1 in.) Tire Size: Front 120/70ZR17 M/C (58 W) Rear 180/55ZR17 M/C (73 W) Front...
  • Page 13 High beam 12 V 55 W + 65 W Low beam 12 V 55 W Tail/Brake Light Even if one of LED (Light Emitting Diode) tail/brake lights does not go on, consult with an authorized Kawasaki dealer. Specifications subject to change without notice.
  • Page 14: Serial Number Locations

    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.
  • Page 15: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 6. Brake Fluid Reservoir (Front) 2. Left Handlebar Switches 7. Right Handlebar Switches 3. Compression Damping Force 8. Front Brake Lever Adjuster (Front Fork) 9. Throttle Grip 4. Rebound Damping Force Adjuster 10.
  • Page 16 LOCATION OF PARTS 12. Headlight 21. Tail/Brake Light 29. Rebound Damping 13. Air Cleaner Intake 22. License Plate Light Force Adjuster 14. Turn Signal Light 23. Brake Disc 30. Shift Pedal 15. Spark Plugs 24. Spring Preload 31. Compression 16. Fuel Tank Adjuster Damping Force 17.
  • Page 17 LOCATION OF PARTS 34. Fuse Box 40. Rear Brake Pedal 35. Battery 41. Rear Brake Light Switch 36. Fuel Tank Cap 42. Oil Level Gauge 37. Muffler 43. Brake Fluid Reservoir (Rear) 38. Swingarm 44. Coolant Reserve Tank 39. Rear Shock Absorber...
  • Page 18: Location Of Labels

    LOCATION OF LABELS LOCATION OF LABELS 1. Brake Fluid (Front) 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.
  • Page 19 LOCATION OF LABELS 5. Noise Emission Control Information 6. Weight and Manufacture 7. Vehicle Emission Control Information 8. Battery Poison/Danger (For further information of label, refer to the “LABEL INFORMATION” chapter.)
  • Page 20 LOCATION OF LABELS 9. Daily Safety Checks *10. Vacuum Hose Routing Diagram 11. Fuel Notice *12. Fuel Level (For further information of label, refer to the “LABEL INFORMATION” chapter.) *: Only on California model...
  • Page 21: Loading And Accessories Information

    Kawasaki Kawasaki Parts Accessories, components. Kawasaki has no control over the design or application of accessories. Because a motorcycle is sensitive to In some cases, improper installation changes in weight and aerodynamic or use of accessories, or motorcycle...
  • Page 22 LOADING AND ACCESSORIES INFORMATION on the motorcycle center of gravity. following general guidelines have been 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.
  • Page 23 LOADING AND ACCESSORIES INFORMATION used to tow any trailers or other ve- affected any lighting components, road clearance, banking capability hicles. Kawasaki does not manu- (i.e., lean angle), control operation, facture sidecars or trailers for mo- wheel travel, front fork movement,...
  • Page 24: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. MODE Button B. RESET Button C. Shift-Up Indicator Light D. Tachometer E. Red Zone F. Fuel Level Indicator Light G. High Beam Indicator Light H. Neutral Indicator Light I. Turn Signal Indicator Light J.
  • Page 25: Tachometer

    “ON”, the tachometer momentarily goes from the minimum to the maxi- mum, then goes back from the maxi- mum to the minimum reading to check its operation. If the tachometer does not operate correctly, have it checked by an authorized Kawasaki dealer.
  • Page 26: Digital Meter

    GENERAL INFORMATION Digital Meter: The digital meter displays the follow- ing functions: the speedometer, clock, trip meter, odometer, coolant tempera- ture meter, stop watch, gear position, oil pressure warning symbol, and fuel A. Odometer injection warning symbol. Pushing B. Trip meter C.
  • Page 27 GENERAL INFORMATION Digital Meter Mph·km/h Display - Mph·km/h Display can alternate be- tween English and metric modes (mph and km/h) in the digital meter. Make sure that km/h or mph is correctly dis- played according to local regulations before riding. NOTE Do not operate the vehicle with the digital meter displaying in the wrong...
  • Page 28 GENERAL INFORMATION • • Display the odometer in the digital The mph·km/h (and °C/°F tempera- meter. ture) display shifts as follows. • The mph·km/h (or °C/°F tempera- ture) display shifts by pushing the RESET button while the MODE but- ton pushed in. A.
  • Page 29 GENERAL INFORMATION Gear Position - Clock - This display shows the correspond- To adjust hours and minutes: • ing gear position when the transmis- Turn the ignition key to “ON”. • sion is shifted. As the transmission Push the MODE button to display the is shifted, the corresponding gear po- odometer.
  • Page 30 GENERAL INFORMATION • NOTE Push the RESET button. The hour display stops flashing and the minute Pushing the MODE button momen- display starts flashing. Push the tarily advances the hour or minute MODE button to advance the min- step by step. Pushing and hold- utes.
  • Page 31 GENERAL INFORMATION Odometer - To reset the trip meter: • The odometer shows the total dis- Push the MODE button to display the tance in kilometers or miles that the ve- trip meter. • hicle has been ridden. This meter can- Push the RESET button and hold it not be reset.
  • Page 32 GENERAL INFORMATION NOTE Lap Counter/Coolant Temperature Meter - The data is maintained by the back The Lap counter/coolant temperature -up power if the ignition key is turned meter shows either the lap number or off. the coolant temperature. The lap num- When the trip meter reaches 999.9 ber is displayed when in the stop watch while riding, the meter is reset to 0.0...
  • Page 33 GENERAL INFORMATION • • When the coolant temperature rises If the coolant temperature rises to to above 40 °C (104 °F), the numer- above 115 °C (239 °F) and below ical value of the coolant temperature 120 °C (248 °F), the numerical value at the present state is displayed.
  • Page 34 GENERAL INFORMATION • If the coolant temperature rises to Stop Watch - above 120 °C (248 °F), “HI” is dis- The stop watch can be used in closed played and starts flashing. This course competition. warns the operator that the coolant The stop watch is operated as fol- temperature is too high.
  • Page 35 GENERAL INFORMATION • • The stop watch starts timing laps. After each lap, push the LAP button on the left handlebar switch. A. Lap Time A. Lap Button...
  • Page 36 GENERAL INFORMATION • • The stop watch starts timing the next To stop the stop watch, push the lap and the previous lap time is dis- START/STOP switch on the right played for ten seconds. handlebar switch to the left. •...
  • Page 37: Warning/Indicator Lights

    This warning light flash on with the each warning symbols: engine oil pressure warning symbol ( )/fuel injection warning symbol (FI). If the warning light flashs on with the engine running, have its cause checked by an authorized Kawasaki dealer. Refer to...
  • Page 38 ON position with the engine flashs on, have the FI system checked not running, and go off when the en- by an authorized Kawasaki dealer. gine oil pressure is high enough. Re- fer to the Maintenance and Adjustment chapter for more detailed engine oil in- formation.
  • Page 39 GENERAL INFORMATION NOTE : The fuel level indicator light goes on and “FUEL” flashes in the digital me- When pushing the MODE button ter, when only 3.5 L (3.7 US qt) of fuel while “FUEL” is displayed, the dis- remains. Refuel at the earliest oppor- play can be shifted to odometer, trip tunity when the fuel level indicator light meter, or clock mode.
  • Page 40 GENERAL INFORMATION • Shift Up Indicator Light - Push the MODE and RESET button The Shift-up indicator light can be simultaneously for more than 2 sec- used in closed course competition. Do onds. The previous shift-up engine not use the shift-up indicator during ev- speed setting will be displayed in the eryday riding.
  • Page 41 GENERAL INFORMATION • • To adjust the shift-up engine speed, To complete the adjustment, push press the RESET button and the shift the MODE button and RESET but- -up engine speed timing advances in ton simultaneously for more than two 50 r/min (rpm) increments up to 16 seconds.
  • Page 42 GENERAL INFORMATION WARNING NOTE Pushing and holding the RESET but- Failing to properly observe the ton advances the shift–up engine road ahead increases the chance speed continuously. of an accident. Do not concen- The data is maintained even if the trate on the shift-up indicator battery is disconnected.
  • Page 43: Key

    OFF, LOCK, tank cap. or P (Park) position. Blank keys are available at a Kawasaki dealers. Ask a dealer to make any additional spare keys you may need, using your original key as a master.
  • Page 44 GENERAL INFORMATION the engine immediately after turning Engine off. All electrical the ignition key to “ON”. circuits off. If you leave the P (Park) position on Engine on. All electrical for a long time (one hour), the battery equipment can be used. may become totally discharged.
  • Page 45: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches Engine Stop Switch: In addition to the ignition switch, the engine stop switch must be in position for the motorcycle to operate. The engine stop switch is for emer- gency use. If some emergency re- quires stopping the engine, move the engine stop switch to the position.
  • Page 46: Starter Button

    GENERAL INFORMATION Left Handlebar Switches Starter Button: The starter button operates the elec- Dimmer Switch: tric starter when the transmission is in High or low beam can be selected neutral. with the dimmer switch. When the Refer to the Starting the Engine sec- headlight is on high beam ( ), the tion of the “How to Ride the Motorcycle”...
  • Page 47: Turn Signal Switch

    GENERAL INFORMATION Turn Signal Switch: When the turn signal switch is turned to the left ( ) or right ( ), the corresponding turn signals flash on and off. To stop flashing, push the switch in. Horn Button: When the horn button is pushed, the horn sounds.
  • Page 48: Brake Lever Adjuster

    GENERAL INFORMATION Brake Lever Adjuster There is an adjuster on the brake lever. The adjuster has 6 positions so that the released lever position can be adjusted to suit the operator’s hands. Push the lever forward and turn the ad- juster to align the number with the mark on the lever holder.
  • Page 49: 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 50: Fuel Tank

    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 for the rain or where tain conditions. Turn the igni- heavy dust is blowing so that the fuel tion key to “OFF”.
  • Page 51: Fuel Requirement

    GENERAL INFORMATION NOTICE of a gasoline is a measure of its resis- tance to detonation or “knocking.” The California models only: Never Antiknock Index is an average of the fill the tank so the fuel level rises Research Octane Number (RON) and into the filler neck.
  • Page 52 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.
  • Page 53 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.
  • Page 54: Side Stand

    GENERAL INFORMATION NOTICE Side Stand The motorcycle is equipped with a Never store this product with side stand. “gasohol” in the fuel system. Before storage it is recom- mended that you drain all fuel from the fuel system. See the Storage section in this manual.
  • Page 55: Seats

    GENERAL INFORMATION NOTE Seats The motorcycle is equipped with a Rider’s Seat Removal side stand switch. This switch is de- • Remove the screw. signed so that the engine does not • Remove the side cover by pulling out start if the transmission is in gear and it to detach the hook and projection, the side stand is down.
  • Page 56 GENERAL INFORMATION • Remove the bolts and pull off the seat Rider’s Seat Installation • to the up and front. Place the tab on the rear of the rider’s seat into the slot in the frame and tighten the bolt. A.
  • Page 57 GENERAL INFORMATION • When installing the side cover, insert Passenger’s Seat Removal the lower side of the cover into the Remove the passenger’s seat by in- frame first, and then insert the upper serting the ignition key into the seat side of the cover into the under of the lock, and turning it clockwise.
  • Page 58 GENERAL INFORMATION NOTE When removing the passenger’s seat, pull it up while turning the key. A. Passenger’s Seat B. Pull up C. Turn the Key...
  • Page 59 GENERAL INFORMATION • Passenger’s Seat Installation Pull up the front and rear ends of the • Insert the tab on the rear of the pas- passenger’s seat to make sure they senger’s seat into the slot in the are securely locked. frame.
  • Page 60: Helmet Hooks

    GENERAL INFORMATION WARNING Helmet Hooks Helmets can be secured to the motor- Riding with helmets attached to cycle by the helmet hooks located un- the hooks could cause an ac- der the passenger’s seat. cident by distracting the oper- ator or interfering with normal vehicle operation.
  • Page 61: Tool Kit

    GENERAL INFORMATION Tool Kit Air Cleaner Intake The tool kit is located under the pas- The air cleaner intake allows air to senger’s seat. enter the fuel system. Never allow any- The kit contains tools that are help- thing to restrict the flow of air into the ful in making roadside repairs, adjust- air cleaner.
  • Page 62: Break-In

    BREAK-IN BREAK-IN The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down” instead of a “broken in” motorcycle after a few thousand kilometers.
  • Page 63 BREAK-IN WARNING New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. 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 a competent mechanic following the instructions in the Service Manual.
  • Page 64: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE • Starting the Engine Turn the ignition key to “ON”. • Check that the engine stop switch is NOTE in the position. If the ignition key is turned to “OFF” position, wait a short while (approx.
  • Page 65 HOW TO RIDE THE MOTORCYCLE • Make sure the transmission is in neu- flash when the motorcycle falls down tral. and the starter button pushed in. Af- ter righting the motorcycle, first turn the ignition key to “OFF” and then back to “ON”...
  • Page 66 HOW TO RIDE THE MOTORCYCLE NOTICE NOTE The motorcycle is equipped with a Do not let the engine idle longer starter lockout switch. This switch is than five minutes, or engine designed so that the engine does not overheating and damage may start if the transmission is in gear and occur.
  • Page 67: Jump Starting

    HOW TO RIDE THE MOTORCYCLE DANGER Jump Starting If your motorcycle battery is “run Battery acid generates hydro- down”, it should be removed and gen gas which is flammable and charged. If this is not practical, a 12 explosive under certain con- volt booster battery and jumper cables ditions.
  • Page 68 HOW TO RIDE THE MOTORCYCLE • • Connect a jumper cable from the Connect another jumper cable from positive (+) terminal of the booster the negative (–) terminal of the battery to the positive (+) terminal of booster battery to your motorcy- the motorcycle battery.
  • Page 69 HOW TO RIDE THE MOTORCYCLE • WARNING Follow the standard engine starting procedure. Batteries contain sulfuric acid that can cause burns and pro- NOTICE duce hydrogen gas which is highly explosive. Do not make Do not operate the starter con- this last connection at the car- tinuously for more than 5 sec- buretor or battery.
  • Page 70: Moving Off

    HOW TO RIDE THE MOTORCYCLE Moving Off NOTE • Check that the side stand is up. The motorcycle is equipped with a • Pull in the clutch lever. side stand switch. This switch is de- • Shift into 1st gear. signed so that the engine does not •...
  • Page 71: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE WARNING Shifting Gears • Close the throttle while pulling in the Downshifting to a lower gear at clutch lever. high speed causes engine r/min • Shift into the next higher or lower (rpm) to increase excessively, gear.
  • Page 72: Braking

    HOW TO RIDE THE MOTORCYCLE NOTE Braking • Close the throttle completely, leav- The transmission is equipped with a ing the clutch engaged (except when positive neutral finder. When the mo- shifting gears) so that the engine will torcycle is standing still, the transmis- help slow down the motorcycle.
  • Page 73 HOW TO RIDE THE MOTORCYCLE applying the brakes as hard as pos- sible without skidding. A. Rear Brake Pedal A. Front Brake Lever...
  • Page 74: Stopping The Engine

    Stopping the Engine Stopping the Motorcycle in an • Emergency Close the throttle completely. • Your Kawasaki Motorcycle has been Shift the transmission into neutral. • designed and manufactured to pro- Turn the ignition key to “OFF”. • vide you optimum safety and conve- Support the motorcycle on a firm, nience.
  • Page 75: Parking

    HOW TO RIDE THE MOTORCYCLE Parking 2. During removal of the air cleaner, • dirt is allowed to enter and jam the Shift the transmission into neutral fuel injection system. and turn the ignition key to “OFF”. • Support the motorcycle on a firm, In an emergency situation such as level surface with the side stand.
  • Page 76 HOW TO RIDE THE MOTORCYCLE WARNING WARNING The muffler and exhaust pipe Gasoline is extremely flammable are very hot while the engine is and can be explosive under cer- running and just after the engine tain conditions, creating the po- stops.
  • Page 77: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE WARNING Catalytic Converter This motorcycle is equipped with a The muffler and exhaust pipe catalytic converter in the exhaust sys- are very hot while the engine is tem. Palladium, platinum and rhodium running and just after the engine in the converter react with carbon stops.
  • Page 78 HOW TO RIDE THE MOTORCYCLE • Use only unleaded gasoline. Never use leaded gasoline. Leaded gaso- line significantly reduces the capabil- ity of the catalytic converter. • Do not coast the vehicle with the igni- tion switch and/or engine stop switch off.
  • Page 79: 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 80 SAFE OPERATION the throttle. Use the front and rear In general your actions should brakes for auxiliary braking. be smooth as sudden acceleration, braking or turning may cause loss In wet conditions, rely more on the of control, especially when riding in throttle to control vehicle speed and wet conditions or on loose roadway less on the front and rear brakes.
  • Page 81 SAFE OPERATION When quick acceleration is neces- sary as in passing, shift to a lower Avoiding unnecessary weaving is gear to obtain the necessary power. important to the safety of both the rider and other motorists. Do not downshift at too high an r/min (rpm) to avoid damage from overrevving to the engine.
  • Page 82: 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 83 SAFE OPERATION Front 250 kPa (2.50 kgf/cm², 36 psi) Rear 290 kPa (2.90 kgf/cm², 42 psi) Install the air valve cap. Drive chain ....Slack 30 ∼ 40 mm (1.2 ∼ 1.6 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 84 SAFE OPERATION Return spring not weak or not damaged. Refer to the “Daily Safety Checks” caution label attached to the back of left side cover.
  • Page 85: 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 86 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 87: 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 88 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 an...
  • Page 89 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...
  • Page 90 You should keep a maintenance record for your motorcycle. To assist you in keeping this record, we have provided space on pages 186 through 192 of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders,...
  • Page 91 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.
  • Page 92: Periodic Maintenance Chart

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart 1. Periodic Inspection (Engine Related Items) Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Valve clearance - •...
  • Page 93 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Fuel hoses damage - • • • • year – inspect Fuel hoses installation •...
  • Page 94 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Evaporative emission control system - • • • • • • •...
  • Page 95 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) 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, •...
  • Page 96 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Wheels and tires: Tire air pressure - • • • year inspect Wheels/tires damage •...
  • Page 97 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Brake hoses damage • • • • • • • year - inspect Brake pad wear - •...
  • Page 98 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Suspensions: Front forks/rear shock absorber 145/ • • • operation (damping and smooth stroke) - inspect Front forks/rear...
  • Page 99 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Steering system: Steering play - • • • • year – inspect Steering stem •...
  • Page 100 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Engine stop switch • • • year – operation - inspect Chassis: Chassis parts - •...
  • Page 101 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Change/Replace- Every 1 (0.6) 12 (7.5) ment Items (15) (22.5) (30) Air cleaner element # every 18 000 km (11 250 mile) (e) - replace •...
  • Page 102 • • replace 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 103: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • In order for the engine, transmission, If the oil has just been changed, start and clutch to function properly, main- the engine and run it for several min- tain the engine oil at the proper level, utes at idle speed.
  • Page 104 MAINTENANCE AND ADJUSTMENT • • Check the engine oil level through If the oil level is too high, remove the the oil level gauge. With the motor- excess oil through the oil filler open- cycle held level, the oil level should ing using a syringe or some other come up between the upper and suitable device.
  • Page 105 The oil change and oil filter replacement should be done by an authorized Kawasaki dealer. A. Oil Pressure Warning Symbol B. Warning Light A. Engine Oil Drain Plug...
  • Page 106 MAINTENANCE AND ADJUSTMENT Tightening Torque Engine Oil Drain Plug: 29 N·m (3.0 kgf·m, 21 ft·lb) Cartridge: 17 N·m (1.7 kgf·m, 13 ft·lb) Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: A.
  • Page 107 MAINTENANCE AND ADJUSTMENT Engine Oil Capacity Capacity: 2.8 L (3.0 US qt) [when filter is not removed] 3.1 L (3.3 US qt) [when filter is removed] 3.6 L (3.8 US qt) [when engine is completely dry] Although 10W-40 engine oil is the recommended oil for most condi- tions, the oil viscosity may need to be changed to accommodate atmo-...
  • Page 108: Cooling System

    MAINTENANCE AND ADJUSTMENT NOTICE Cooling System Radiator and Cooling Fan - Using high-pressure water, as Check the radiator fins for obstruc- from a car wash facility, could tion by insects or mud. Clean off damage the radiator fins and im- any obstructions with a stream of pair the radiator’s effectiveness.
  • Page 109 MAINTENANCE AND ADJUSTMENT Coolant - a period of time, the cooling system Coolant absorbs excessive heat from accumulates rust and scale in the wa- the engine and transfers it to the air ter jacket and radiator. This will clog at the radiator. If the coolant level be- up the coolant passages, and con- comes low, the engine overheats and siderably reduce the efficiency of the...
  • Page 110 MAINTENANCE AND ADJUSTMENT NOTICE NOTICE If hard water is used in the sys- Permanent types of antifreeze on tem, it causes scale accumula- the market have anti-corrosion tion in the water passages, and and anti-rust properties. When it considerably reduces the effi- is diluted excessively, it loses its ciency of the cooling system.
  • Page 111 MAINTENANCE AND ADJUSTMENT • NOTE Check the coolant level through the coolant level gauge on the reserve Check the level when the engine is tank located to the right of the engine. cold (room or atmospheric tempera- The coolant level should be between ture).
  • Page 112 Have the cooling system inspected by your authorized Kawasaki A. Reserve Tank Cap dealer. Coolant Change Have the coolant changed by an au-...
  • Page 113: Spark Plugs

    MAINTENANCE AND ADJUSTMENT 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 only by a competent mechanic follow- ing the instructions in the Service Man- ual.
  • Page 114: Evaporative Emission Control System (California Model Only)

    MAINTENANCE AND ADJUSTMENT Evaporative Emission Control System (California model only) This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no ad- justments are required, a thorough vi- sual inspection must be made at the in- tervals specified by the Periodic Main- tenance Chart.
  • Page 115: Valve Clearance

    MAINTENANCE AND ADJUSTMENT Valve Clearance Kawasaki Clean Air System Valve and valve seat wear decreases The Kawasaki Clean Air System valve clearance, upsetting valve timing. (KCA) is a secondary air suction sys- tem that helps the exhaust gases to NOTICE burn more completely.
  • Page 116: Exhaust Device

    MAINTENANCE AND ADJUSTMENT Exhaust Device Air Suction Valves - The air suction valve is essentially a This motorcycle is equipped with a check valve which allows fresh air to exhaust device system. This system flow only from the air cleaner into the controls the valve in the exhaust pipe exhaust port.
  • Page 117: Air Cleaner

    MAINTENANCE AND ADJUSTMENT NOTICE Air Cleaner A clogged air cleaner restricts the en- Do not adjust the exhaust device gine’s air intake, increasing fuel con- system by yourself. The mal- sumption, reducing engine power, and adjustment will cause the poor causing spark plug fouling.
  • Page 118 • NOTICE Remove the Rider’s seat (refer to Rider’s Seat Removal in General In- Use only the recommended air formation chapter). cleaner element (Kawasaki part • Remove the bracket bolt. number 11013-0036 or equiv- alent type). Using other air cleaner elements will wear the engine prematurely or lower the engine performance.
  • Page 119 MAINTENANCE AND ADJUSTMENT • • Raise the front of the fuel tank. Pull up the air cleaner element. • Remove the air cleaner housing cover screws and cover. A. Element B. Pull Up A. Screws B. Air Cleaner Housing Cover...
  • Page 120 MAINTENANCE AND ADJUSTMENT • • Put a clean, lint-free towel over the Element and fuel tank installation is air cleaner element duct to keep dirt performed in the reverse order of re- or other foreign material from enter- moval. • ing.
  • Page 121 MAINTENANCE AND ADJUSTMENT • WARNING Run the throttle cables and clutch ca- ble as shown in the figure. Do not pinch the cables between the bracket and the frame. Op- eration with incorrectly routed or damaged cables could result in an unsafe riding condition.
  • Page 122 MAINTENANCE AND ADJUSTMENT • Oil Draining If there is any oil in the reservoir, re- • Inspect the transparent reservoir lo- move the reservoir and drain the oil. cated on the left side of the engine to WARNING see if any oil or water has run down from the air cleaner housing.
  • Page 123: Throttle Control System

    MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check the throttle grip play each day Check that the throttle grip play is before riding the motorcycle, and carry correct by lightly turning the throttle out the maintenance and adjustments grip back and forth. in accordance with the Periodic Main- tenance Chart.
  • Page 124 MAINTENANCE AND ADJUSTMENT Throttle Grip Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • If there is improper play, adjust it. Adjustment • Loosen the locknuts at the upper of the throttle cables, and turn both throttle cable adjusters completely so as to give the throttle grip plenty of play.
  • Page 125 MAINTENANCE AND ADJUSTMENT • WARNING If the throttle cables cannot be ad- justed with the adjuster at the upper Operation with an improperly of the throttle cable, further adjust- adjusted, incorrectly routed, or ment of the throttle cables should be damaged cables could result in done only by a competent mechanic an unsafe riding condition.
  • Page 126: Engine Vacuum Synchronization

    MAINTENANCE AND ADJUSTMENT Engine Vacuum Synchronization Idle Speed Engine vacuum synchronization The idle speed adjustment should be must be checked and adjusted period- performed in accordance with the Pe- ically in accordance with the Periodic riodic Maintenance Chart or whenever Maintenance Chart only by a compe- the idle speed is disturbed.
  • Page 127 MAINTENANCE AND ADJUSTMENT • Open and close the throttle a few Idle Speed times to make sure that the idle 1 250 ∼ 1 350 r/min (rpm) speed does not change. Readjust if necessary. • With the engine idling, turn the han- dlebar to each side.
  • Page 128: Clutch

    Check that the clutch lever operates If the play is incorrect, adjust the lever properly and that the inner cable play as follows. slides smoothly. If there is any irreg- ularity, have the clutch cable checked by an authorized Kawasaki dealer.
  • Page 129 MAINTENANCE AND ADJUSTMENT • Adjustment If it cannot be done, use the nuts at • Turn the adjuster so that the clutch the lower end of the clutch cable. lever will have the proper play. WARNING Too much cable play can pre- vent clutch disengagement and cause an accident resulting in serious injury or death.
  • Page 130: Drive Chain

    MAINTENANCE AND ADJUSTMENT Drive Chain Chain Slack Inspection • The drive chain slack and lubrication Set the motorcycle up on its side must be checked each day before rid- stand. • ing the motorcycle and must be main- Rotate the rear wheel to find the po- tained in accordance with the Periodic sition where the chain is tightest, and Maintenance Chart for safety and to...
  • Page 131 MAINTENANCE AND ADJUSTMENT • If the drive chain is too tight or too Chain Slack Adjustment • loose, adjust it so that the chain slack Loosen the left and right chain ad- will be within the standard value. juster locknuts. •...
  • Page 132 MAINTENANCE AND ADJUSTMENT • If the chain is too tight, turn in the left and right chain adjusters evenly. • Turn out both chain adjusters evenly until the drive chain has the cor- rect amount of slack. To keep the chain and wheel properly aligned, the notch on the left wheel alignment indicator should align with the same...
  • Page 133 If a torque wrench is not available, checked using the straightedge or this item should be serviced by a string method. Kawasaki dealer. • Rotate the wheel, measure the chain WARNING slack again at the tightest position, and readjust if necessary.
  • Page 134 MAINTENANCE AND ADJUSTMENT WARNING NOTE When inserting the cotter pin, if the A loose axle nut can lead to an slots in the nut do not align with accident resulting in serious in- the cotter pin hole in the axle shaft, jury or death.
  • Page 135 MAINTENANCE AND ADJUSTMENT • Wear Inspection Remove the bolts and quick rivet. • • Remove the front footpeg bracket Remove the chain cover. bolts. A. Bolts B. Quick Rivet A. Front Footpeg C. Chain Cover B. Bolts...
  • Page 136 MAINTENANCE AND ADJUSTMENT NOTE Quick Rivet Installation The chain cover uses the quick rivet. The quick rivet can be removed by pushing the center pin into the quick rivets, and when installing it, pull the center pin fully up first, and then push into the center pin after inserting it.
  • Page 137 MAINTENANCE AND ADJUSTMENT • • Stretch the chain taut either by using If the length exceeds the service limit, the chain adjusters, or by hanging a the chain should be replaced. 10 kg (20 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...
  • Page 138 It is an endless type and should not be cut for installa- NOTE tion; have it installed by an au- thorized Kawasaki dealer. Install the chain cover and front foot- peg bracket in the reverse order of • Rotate the rear wheel to inspect the removal.
  • Page 139 A. Good 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.
  • Page 140: Brakes

    1 mm (0.04 in.), replace both pads in the caliper as a set. Pad replace- ment should be done by an authorized Kawasaki dealer. • If the chain is especially dirty, clean it using diesel oil or kerosine and then apply oil as described above.
  • Page 141 MAINTENANCE AND ADJUSTMENT Disc Brake Fluid - Fluid Level Inspection • In accordance with the Periodic Main- With the brake fluid reservoirs held tenance Chart, inspect the brake fluid horizontal, the brake fluid level must level in both the front and rear brake be kept between the upper and lower fluid reservoirs and change the brake level lines.
  • Page 142 MAINTENANCE AND ADJUSTMENT • If the fluid level in either reservoir is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. WARNING Mixing brands and types of brake fluid can reduce the brake system’s effectiveness...
  • Page 143 NOTE Fluid Change Have the brake fluid changed by an First, tighten until slight resistance is authorized Kawasaki dealer. felt, which indicates that the cap is seated on the reservoir body, and Front and Rear Brakes - tighten the cap an additional 1/6 turn...
  • Page 144: Brake Light Switches

    • The brake light should go on when the front brake is applied. • If it does not, ask an 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 light switch.
  • Page 145 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.
  • Page 146: Steering Damper

    When adjust- ing the damping adjuster for use in a closed course, adjustment should be done by an authorized Kawasaki dealer. The steering operation should be checked and the steering damper unit...
  • Page 147: Front Fork

    MAINTENANCE AND ADJUSTMENT Front Fork Steering Damping Adjuster Standard Setting The front fork operation and oil leak- age should be checked in accordance 18 clicks* with the Periodic Maintenance Chart. : Fully turned to the softer direction Front Fork Inspection •...
  • Page 148 If any doubt about the front fork, it so that the spring force and damping should be done by an authorized force can be adjusted for different rid- Kawasaki dealer. ing and loading conditions. Weaker spring force and damping force are...
  • Page 149 MAINTENANCE AND ADJUSTMENT NOTICE Spring Preload Adjustment • Turn the spring preload adjuster all Do not force to turn the rebound the way counterclockwise with the and compression damping force hexagon wrench to make the spring adjuster from the fully seated po- force weakest.
  • Page 150 MAINTENANCE AND ADJUSTMENT Compression Damping Force Adjuster Rebound Damping Force Adjuster Adjustment • Turn the adjuster all the way clock- wise with a screwdriver to make the damping force greatest. • Turn the adjuster counterclockwise to decrease damping force. Be sure to turn both adjusters by the same number of turns.
  • Page 151 MAINTENANCE AND ADJUSTMENT WARNING The standard setting positions of the spring preload adjuster, rebound If both spring preload adjusters damping force adjuster and compres- and both rebound and compres- sion damping force adjuster for an sion damping force adjusters average-build rider of 68 kg (150 lb) are not adjusted equally, han- with no passenger and no accessories dling may be impaired and haz-...
  • Page 152: Rear Shock Absorber

    If there is any doubt about the rear The rear shock absorber operation shock absorber, it should be checked and oil leakage should be checked in by an authorized Kawasaki dealer. accordance with the Periodic Mainte- nance Chart. Rear Shock Absorber Inspection •...
  • Page 153 If the spring action feels too soft or too stiff, have it adjusted by an authorized • Turn the rebound damping force ad- Kawasaki dealer. juster all the way clockwise with a screwdriver to make the damping force greatest. •...
  • Page 154 MAINTENANCE AND ADJUSTMENT Compression Damping Force to decrease high speed compression Adjustment damping. The compression damping force ad- juster is located on the gas reservoir at the upper end of the rear shock ab- sorber. • The compression damping adjuster has both high and low speed com- pression damping adjusters.
  • Page 155: Wheels

    MAINTENANCE AND ADJUSTMENT Wheels low speed adjuster setting position dose not change. Tubeless tires are installed on the wheels of this motorcycle. The indica- The standard setting positions of the tions of TUBELESS on the tire side wall rebound damping force adjuster and and the rim show that the tire and rim compression damping force adjuster are specially designed for tubeless use.
  • Page 156 MAINTENANCE AND ADJUSTMENT WARNING Installing a tube inside a tube- less-type tire can create exces- sive heat build up that can dam- age the tube and cause rapid deflation. The tires, rims, and air valves on this motorcycle are designed only for tubeless type wheels.
  • Page 157 MAINTENANCE AND ADJUSTMENT Tires - Tire pressure is affected by changes in ambient temperature and altitude, Payload and Tire Pressure and so the tire pressure should be Failure to maintain proper inflation checked and adjusted when your rid- pressures or observe payload limits for ing involves wide variations in tem- your tires may adversely affect han- perature or altitude.
  • Page 158 MAINTENANCE AND ADJUSTMENT • In accordance with the Periodic Tire Air Pressure (when cold) Maintenance Chart, measure the Front 250 kPa (2.50 kgf/cm², 36 psi) depth of the tread with a depth Rear 290 kPa (2.90 kgf/cm², 42 psi) gauge, and replace any tire that has worn down to the minimum al- Tire Wear, Damage lowable tread depth.
  • Page 159 MAINTENANCE AND ADJUSTMENT WARNING Minimum Tread Depth 1 mm Tires that have been punctured Front — (0.04 in.) and repaired do not have the 2 mm same capabilities as undam- Under 130 km/h (80 mph) (0.08 in.) aged tires and can suddenly fail, Rear causing an accident resulting Over 130 km/h...
  • Page 160 MAINTENANCE AND ADJUSTMENT WARNING Standard Tire (Tubeless) Size: 120/70ZR17 M/C (58 W) New tires are slippery and may • cause loss of control and injury. Front BRIDGESTONE A break-in period of 160 km (100 “BATLAX BT016F L” miles) is necessary to estab- lish normal tire traction.
  • Page 161: Battery

    MAINTENANCE AND ADJUSTMENT Battery Due to their internal composition, bat- The battery installed in this motorcy- teries continually self discharge. The cle is a sealed type, so it is not nec- discharge rate depends on the type of essary to check the battery electrolyte battery and ambient temperature.
  • Page 162 MAINTENANCE AND ADJUSTMENT Self-discharge Current Drain Approx. Number of Days Days form Days form From 100% Charged to 100% 100% Discharging 100% discharged charged to charged to Ampere Temperature 100% Lead Lead Discharged Discharged -Antimony -Calcium 7 mA 60 Days 119 Days Battery Battery...
  • Page 163 12.8 volts, the battery should be tion is not warrantable. charged using an appropriate charger (check with a Kawasaki dealer). you will not be using the motorcy- cle for longer than two weeks, the battery should be charged using an appropriate charger.
  • Page 164 Battery Mate 150–9 battery in this motorcycle, or the If the above chargers are not avail- electrical system cannot work able, use equivalent one. properly. For more details, ask a Kawasaki dealer. NOTE Battery Charging If you charge the sealed battery, •...
  • Page 165 MAINTENANCE AND ADJUSTMENT • Battery Removal Take the battery out of the case. • • Remove the rider’s seat (refer to Clean the battery using a solution of Rider’s Seat Removal in General baking soda and water. Be sure that Information chapter).
  • Page 166: Headlight Beam

    MAINTENANCE AND ADJUSTMENT NOTICE Headlight Beam Installing the (–) wire to the (+) Horizontal Adjustment terminal of the battery or the (+) The headlight beam is adjustable wire to the (–) terminal of the bat- horizontally. If not properly adjusted tery can seriously damaged the horizontally, the beam will point to one electrical system.
  • Page 167 MAINTENANCE AND ADJUSTMENT NOTICE Vertical Adjustment The headlight beam is adjustable ver- When handling quartz tically. If adjusted too low, neither low -halogen bulbs, never touch the nor high beam will illuminate the road glass portion with bare hands. far enough ahead. If adjusted too high, Always use a clean cloth.
  • Page 168: Fuses

    The main fuse removal should be done by an authorized Kawasaki dealer. A. 50 mm (2.0 in.) B. Center of Brightest Spot C.
  • Page 169 MAINTENANCE AND ADJUSTMENT A. Main Fuse A. Normal B. Failed 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 fuse box and main fuse.
  • Page 170: General Lubrication

    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 has been operated under wet or rainy Rear Brake Pedal...
  • Page 171: Cleaning Your Motorcycle

    (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.
  • Page 172 MAINTENANCE AND ADJUSTMENT • Gasoline, brake fluid, and coolant Washing Your Motorcycle • will damage the finish of painted and Rinse your bike with cold water from plastic surfaces: wash them off im- a garden hose to remove any loose mediately.
  • Page 173 MAINTENANCE AND ADJUSTMENT • • After cleaning your motorcycle, If the boot is damaged, replace it with check the rubber boot covering the a new one. If the boot is not po- shift pedal ball joint for correct instal- sitioned in the groove correctly, re- lation.
  • Page 174 MAINTENANCE AND ADJUSTMENT • NOTE Start the engine and let it idle for sev- eral minutes. The heat from the en- After riding in an area where the gine will help dry moist areas. roads are salted or near the ocean, •...
  • Page 175 MAINTENANCE AND ADJUSTMENT NOTICE Windshield and Other Plastic Parts After washing use a soft cloth to Plastic parts may deteriorate gently dry plastic parts. When dry, and break if they come in con- treat the windshield, headlight lens, tact with chemical substances and other nonpainted plastic parts with or household cleaning products an approved plastic cleaner/polisher...
  • Page 176 MAINTENANCE AND ADJUSTMENT Chrome and Aluminum Vinyl parts should be washed with the Chrome and uncoated aluminum rest of the motorcycle, then treated with parts can be treated with a chrome/alu- a vinyl treatment. minum polish. Coated aluminum The sidewalls of tires and other rub- should be washed with a mild neu- ber components should be treated with tral detergent and finished with a spray...
  • Page 177: Bolt And Nut Tightening

    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.
  • Page 178 MAINTENANCE AND ADJUSTMENT 6. Front Fender Mounting Bolts 7. Engine Mounting Bolts and Nuts 8. Rear Frame Mounting Bolts 9. Brake Disc Mounting Bolts 10. Front Axle Clamp Bolt 11. Front Axle 12. Caliper Mounting Bolts 13. Side Stand Bolt 14.
  • Page 179 MAINTENANCE AND ADJUSTMENT 19. Footpeg Mounting Bolts 20. Silencer Mounting Bolt 21. Brake Pedal Bolt 22. Muffler Mounting Bolts...
  • Page 180: Storage

    STORAGE STORAGE Preparation for Storage - • Clean the entire vehicle thoroughly. • Run the engine for about five minutes to warm the oil, shut it off, and drain the engine oil. WARNING Motorcycle oil is a toxic substance. Dispose of used oil properly. Con- tact your local authorities for approved disposal methods or possible re- cycling.
  • Page 181 STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions. Turn the ignition key to “OFF”. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 182 STORAGE • Put a cover over the motorcycle to keep dust and dirt from accumulating on it. Preparation after Storage - • Remove the plastic bags from the mufflers. • Install the battery in the motorcycle and charge the battery if necessary. •...
  • Page 183: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE • Engine Does Not Start - Incorrect valve clearance • Starter Motor Won’t Turn Battery discharged • • Engine stop switch off No first turning the ignition key to • Transmission not in neutral “OFF” when the motorcycle falls •...
  • Page 184: Owner Satisfaction

    Kawasaki dealer network. If you are unsatisfied after working with your Kawasaki dealer and feel you still re- quire further assistance, write to the address below. Please be certain to provide...
  • Page 185 In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence. Please send your correspondence to: CONSUMER RELATIONS KAWASAKI MOTORS CORP., U.S.A. P. O. Box 25252 SANTA ANA, CA. 92799-5252 (949) 460–5688...
  • Page 186: Reporting Safety Defects

    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.
  • Page 187: Environmental Protection

    ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedures.
  • Page 188: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Owner Name..................Address ....................Phone Number ................... Engine Number .................. Vehicle Number.................. Selling Dealer Name ................Phone Number ................... Warranty Start Date ................Note: Keep this information and a spare key in a secure location. Odometer Date Maintenance Performed Dealer Name...
  • Page 189 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 190 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 191 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 192 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 193 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 194 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 195: Label Information

  • Page 199 LABEL INFORMATION 7) Only California model...
  • Page 202 LABEL INFORMATION 10) Only on California model 12) Only on California model...