NOTE Whenever you see the symbols ○ shown below, heed their instructions! This note symbol indicates points of Always follow safe operating and main- particular interest for more efficient tenance practices. and convenient operation. WARNING NOTICE This warning symbol identifies THIS PRODUCT BEEN...
(Australian model only) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
To ensure a long, trouble-free life for your motorcycle, give it the proper care and maintenance described in this manual. For those who would like more detailed in- formation on their Kawasaki Motorcycle, a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer.
This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold. All rights reserved. No part of this publication may be reproduced without our prior written permission. This publication includes the latest information available at the time of printing.
SPECIFICATIONS ENGINE Type DOHC, 4-valve, 2-cylinder, 4-stroke, liquid-cooled Displacement 649 cm (39.6 cu in.) Bore × Stroke 83 × 60 mm (3.27 × 2.36 in.) Compression Ratio 11.3 : 1 Starting System Electric starter Cylinder Numbering Method Left to right, 1-2 Firing Order Carburetion System Fi (Fuel Injection)
SPECIFICATIONS Capacity: 2.4 L (2.5 US qt) Coolant Capacity 1.2 L (1.3 US qt) TRANSMISSION Transmission Type 6-speed, return shift Clutch Type Wet, multi disc Driving System Chain drive Primary Reduction Ratio 2.095 (88/42) Final Reduction Ratio 3.067 (46/15) Overall Drive Ratio 5.473 (Top gear) Gear Ratio 2.438 (39/16)
SPECIFICATIONS Trail 102 mm (4.0 in.) Tire Size: Front 120/70ZR17 M/C (58 W) Tubeless Rear 160/60ZR17 M/C (69 W) Tubeless Rim Size: Front 17 × 3.50 Rear 17 × 4.50 Fuel Tank Capacity 15.5 L (4.1 US gal) ELECTRICAL EQUIPMENT Battery 12 V 10 Ah Headlight...
LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 5. Right Handlebar Switches 2. Left Handlebar Switches 6. Front Brake Lever 3. Meter Instruments 7. Throttle Grip 4. Brake Fluid Reservoir (Front) 8. Ignition Switch/Steering Lock...
LOCATION OF PARTS 9. Wheel 16. Seat 22. Brake Disc 10. Headlight 17. Tool Kit/Storage 23. Brake Caliper 11. Turn Signal Light Compartments 24. Shift Pedal 12. Spark Plugs 18. Helmet Holding Cable 25. Side Stand 13. Air Cleaner 19. Tying Hooks 26.
LOCATION OF PARTS 27. License Plate Light 32. Muffler 37. Rebound Damping 28. Tail/Brake Light 33. Rear Brake Light Force Adjuster 29. Brake Fluid Reservoir Switch 38. Idle Adjusting Screw (Rear) 34. Rear Brake Pedal 39. Coolant Reserve Tank 30. Fuel Tank 35.
Incorrect loading, improper in- In selecting and using accessories, stallation or use of accessories, and in loading the motorcycle, you are or modification of your motorcy- personally responsible for your own cle may result in an unsafe rid- safety and the safety of other persons ing condition.
Make sure that the baggage tant that the passenger sit still while will not move around while you are the motorcycle is in motion and not riding. Recheck baggage security interfere with the operation of the as often as possible (not while the motorcycle.
Make 9. This motorcycle was not intended sure that you have not adversely to be equipped with a sidecar or to affected any lighting components,...
GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. MODE Button B. Neutral Indicator Light C. Left Turn Signal Indicator Light D. Tachometer E. ABS Indicator Light (Only on ER650-B) F. FI Indicator Light G. Fuel Level Warning Light H. Warning Light I.
GENERAL INFORMATION Tachometer Gauge: not operate correctly, have it inspected The tachometer shows the engine by an authorized Kawasaki dealer. speed in revolutions per minute (r/min, CAUTION rpm). On the right side of the tachome- ter face is a portion called the “red Engine r/min (rpm) should not zone”.
GENERAL INFORMATION (Speedometer, Clock, Odometer, Trip Meters, Warning Symbols): The LCD (Liquid Crystal Display) lo- cated in the tachometer face is used to display the speedometer, Clock, A. Clock odometer, Trip Meters A/B, and the fol- B. Odometer C. Trip Meter A lowing Warning Symbols: oil pressure D.
GENERAL INFORMATION Digital Meter Mile/Km Display - Mile/Km Display can alternate be- tween English and metric modes (mile and km) in the digital meter. Make sure that km or mile according to local reg- ulations is correctly displayed before riding. NOTE ○...
GENERAL INFORMATION • • The km/mile display shifts by pushing The km/mile display shifts as follows. the RESET button while the MODE button pushed in. A. Mile Display B. Km Display C. Push RESET Button with MODE Button in NOTE ○...
GENERAL INFORMATION • Clock - Push the “RESET” button. To adjust the hours and minutes: hour display only flashes. Push • Turn the ignition key to “ON”. the “MODE” button to advance the • hours. Push the “MODE” button to display the clock.
GENERAL INFORMATION • Push the “RESET” button. Both the Odometer - hour and minute displays start flash- The odometer shows the total dis- ing again. tance in kilometers or miles that the ve- • hicle has been ridden. This meter can- Push the “MODE”...
GENERAL INFORMATION Trip Meter - The trip meters show the distance in kilometers (miles) traveled since they were last reset to zero. TRIP A: 0.0 ∼ 999.9 TRIP B: 0.0 ∼ 9999.9 To reset the trip meter: • Push the “MODE” button to display the trip meter A or B.
When the trip meter is reset while the vehicle is stopped, it starts counting shortly after the motorcycle starts mov- ing. If the ABS is normal, it stays off. as soon as the vehicle starts moving.
GENERAL INFORMATION A. ABS Indicator Light A. Fuel Level Warning Light B. Flash The fuel level warning light in the tachometer goes on and “FUEL” NOTE flashes in the digital meter when only ○ When pushing the MODE button 3.5 L (0.9 US gal) of fuel remains. Re- while “FUEL”...
GENERAL INFORMATION : When the headlight is on high : The oil pressure warning light in beam, the high beam indicator light is the tachometer and symbol in the LCD lit. goes on whenever the oil pressure is dangerously low or the ignition key is in the ON position with the engine not : When the turn signal switch is running, and goes off when the engine...
The indicator light also goes on whenever the troubles occur in digital fuel injection system (DFI). If the indica- tor light comes on, have the DFI system checked by an authorized Kawasaki A. FI Indicator Light dealer, B. FI Warning Symbol When the indicator light flashes, first turn the ignition key to “OFF”...
LCD goes on whenever the coolant running when the warning light temperature rises to 115°C (239°F) flashes. Prolonged engine oper- when the motorcycle is in operation. ation will result in severe dam- This warns the operator that the coolant age from overheating.
GENERAL INFORMATION Ignition Switch/Steering Lock This motorcycle has a combination This is a four-position, key-operated key, which is used for the ignition switch. The key can be removed from switch/steering lock, seat lock, and fuel the switch when it is in the OFF, LOCK, tank cap.
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.
In addition to the ignition switch, stops the engine, it does not turn off the engine stop switch must be in all the electrical circuits. Ordinarily, position for the motorcycle to the ignition switch should be used to operate. stop the engine.
When the Refer to the Starting the Engine sec- headlight is on high beam ( ), the tion of the “How to Ride the Motorcycle” high beam indicator light is lit. chapter for starting instructions. High beam..( Low beam..(...
GENERAL INFORMATION NOTE Turn Signal Switch: ○ When the turn signal switch is turned When the headlight is on high beam, both head lights are lit. When the to the left ( ) or right ( ), the corresponding turn signal flashes on headlight is on low beam, only one and off.
GENERAL INFORMATION Brake/Clutch Lever Adjusters Push in the hazard switch with the ignition switch in the ON or P (Park) There is an adjuster on both the position. All the turn signals and turn brake and clutch levers. Each adjuster signal indicator lights will flash on and has 5 positions so that the released off.
GENERAL INFORMATION Fuel Tank Cap The distance from the grip to the re- leased lever is minimum at Number 5 To open the fuel tank cap, pull up the and maximum at Number 1. key hole cover. Insert the ignition key into the fuel tank cap and turn the key to the right.
GENERAL INFORMATION NOTE Fuel Tank ○ Avoid filling the tank in the rain or Do not push on the key to close the where heavy dust is blowing so that the cap, or the cap cannot be locked. fuel does not get contaminated. A.
GENERAL INFORMATION WARNING Fuel Requirement: Your Kawasaki engine is designed to Gasoline is extremely flammable use only unleaded gasoline. and can be explosive under cer- tain conditions. Turn the igni- CAUTION tion key to “OFF”. Do not smoke. Do not use leaded gasoline, as...
GENERAL INFORMATION NOTE Stand ○ The motorcycle is equipped with a If “knocking” or “pinging” occurs, use side stand. a different brand of gasoline or higher octane rating. A. Side Stand NOTE ○ When using the side stand, turn the...
Seat Lock Whenever the side stand is used, make it a practice to kick the stand fully Seat Removal up before sitting on the motorcycle. Insert the ignition key into the seat NOTE lock, located under the rear cowling. ○...
GENERAL INFORMATION NOTE Seat Installation ○ Install seats in the reverse order of If there is difficulty removing the seat, removal. be sure to insert the key all the way • Place the tabs into the matching slot and to push down strongly on the and receptacles.
GENERAL INFORMATION • Helmet Holding Cable Push down the rear part of the seat until the lock clicks. Helmets can be secured to the motor- • Pull up the rear end of the seat to cycle using the helmet holding cables make sure it is securely locked.
GENERAL INFORMATION Tool Kit/U-Shaped Lock WARNING Compartment Do not ride the motorcycle with The tool kit is stored under the seat. a helmet attached to the cable. The kit contains tools that can be help- The helmet could cause an acci-...
GENERAL INFORMATION • Install the U-shaped part and lock Fit the lock with the holes. separately and secure them each with its strap. A. Lock B. Hole A. Tool Kit B. Lock Strap C. U-Shaped Lock...
GENERAL INFORMATION Rear View Mirror CAUTION Rear View Mirror Adjustment Do not force to tighten and/or • loosen the upper hexagonal Adjust the rear view mirror by slightly area with a pair of spanners moving only the mirror portion of the or wrench.
GENERAL INFORMATION Tying Hooks When tying up light loads to the seat, use the tying hooks located on the left and right sides of the rear fairing. A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area C. Rear View Mirror A.
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 Starting the Engine NOTE • ○ Check that the engine stop switch is The motorcycle is equipped with a in the position. vehicle-down sensor, which causes • Turn the ignition key to “ON”. the engine to stop automatically and •...
HOW TO RIDE THE MOTORCYCLE NOTE CAUTION ○ 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.
HOW TO RIDE THE MOTORCYCLE Jump Starting WARNING If your motorcycle battery is “run Battery acid generates hydro- down,” it should be removed and gen gas which is flammable and charged. If this is not practical, a 12 explosive under certain con- volt booster battery and jumper cables ditions.
Do not jump start a frozen battery. It could explode. Do not reverse polarity by con- A. Motorcycle Battery Positive (+) Terminal necting positive (+) to negative B. From Booster Battery Positive (+) Terminal (–) or a battery explosion and C.
HOW TO RIDE THE MOTORCYCLE CAUTION 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 •...
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 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.
HOW TO RIDE THE MOTORCYCLE • Even in motorcycles equipped with ABS, braking during cornering may cause wheel slip. When turning a corner, it is better to limit braking to the light application of both brakes or not to brake at all. Reduce your speed before you get into the corner.
ABS is designed to help prevent or downhill surfaces, the stopping the wheels from locking up when distance of a motorcycle with ABS hard brakes are applied while running may be longer than that of an equiv- straight. The ABS automatically regu- alent motorcycle without ABS.
• Turn the ignition key to “OFF”. function when the indicator light is on, • Support the motorcycle on a firm, but if the ABS fails, the conventional level surface with the side stand. brake system still works normally. •...
HOW TO RIDE THE MOTORCYCLE 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 fuel injection system. designed and manufactured to pro- In an emergency situation such as...
• or exhaust pipe. If parking inside a garage or other structure, be sure it is well ventilated and the motorcycle is not close to WARNING any source of flame or sparks; this includes any appliance with a pilot Gasoline is extremely flammable light.
HOW TO RIDE THE MOTORCYCLE NOTE Catalytic Converter ○ This motorcycle is equipped with When stopping near traffic at night, a catalytic converter in the exhaust you can leave the taillight on for system. Platinum and rhodium in the greater visibility by turning the igni- converter react with carbon monoxide tion key to the P (park) position.
HOW TO RIDE THE MOTORCYCLE • WARNING Use only unleaded gasoline. Never use leaded gasoline. Leaded gaso- The muffler and exhaust pipe line significantly reduces the capabil- are very hot while the engine is ity of the catalytic converter. running and just after the engine •...
SAFE OPERATION SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a Before changing lanes, look over helmet are strongly recommended.
SAFE OPERATION braking may cause the motorcycle When riding in wet conditions or to skid and lose control. on loose roadway surfaces, the abil- ity to maneuver will be reduced. All When going down long slopes, of your actions should be smooth control vehicle speed by closing under these conditions.
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.
SAFE OPERATION Drive chain ....Slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Lubricate the dive chain if dry. Nuts, bolts, fasteners .. Check that steering and suspension components, axles, and all controls are properly tightened or fastened. Steering ...... Action smooth but not loose from lock to lock. No binding of control cables.
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.
The maintenance and adjustments outlined in this chapter must be carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. The initial maintenance is vitally impor- tant and must not be neglected.
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 Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Item) Every (0.6) (7.5) (12) (15) (20) (24) • • • • Idle speed - inspect • • • • Fuel leak (fuel hose and year –...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Item) Every (0.6) (7.5) (12) (15) (20) (24) • • • • Radiator hoses installation year condition - inspect • •...
MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Every Operation (Chassis Items) (0.6) (7.5) (12) (15) (20) (24) Clutch and drive train: Clutch operation •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • Wheels/tires damage - inspect • • • Tire tread wear, abnormal wear - inspect •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • • • • • Brake fluid level - inspect 6 months Brake operation •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) Steering System: • • • • year – KSteering play - inspect •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) Chassis: • • • year – KChassis parts - lubricate Bolts and nuts tightness - •...
MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever *Odometer Reading comes first km × 1000 ( mile × 1000) Page Change/Replacement Item Every (0.6) (7.5) (15) (24) (30) K Air cleaner element # 2 year • • • • • year Engine oil # •...
Motorcycle operation with insuf- • ficient, deteriorated, or contami- If the motorcycle has just been used, nated engine oil will cause accel- wait several minutes for all the oil to erated wear and may result in en- drain down.
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.
• Remove the engine oil drain plug. immediately and find the cause. A. Drain Plug A. Oil Pressure Warning Light • Let the oil completely drain with B. Oil Pressure Warning Symbol the motorcycle perpendicular to the ground.
NOTE WARNING ○ If a torque wrench or required Motor oil is a toxic substance. Kawasaki special tool is not avail- Dispose of used oil properly. able, this item should be serviced by Contact your local authorities a Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT • • Apply a thin film of oil to the packing Fill the engine up to the upper level and tighten the cartridge to the spec- line with a good quality engine oil ified torque. specified in the table. •...
MAINTENANCE AND ADJUSTMENT Although 10W-40 engine oil is the Engine Oil Capacity recommended oil for most condi- Capacity : 1.7 L (1.8 US qt) tions, the oil viscosity may need to [when filter is not removed] be changed to accommodate atmo- 1.9 L (2.0 US qt) spheric conditions in your riding area.
Radiator Hoses - Check the radiator hoses for leak- age, cracks or deterioration, and con- nections for leakage or looseness each day before riding the motorcycle, and in accordance with the Periodic Main- tenance Chart.
Check the ably reduce the efficiency of the cooling coolant level each day before riding the system. motorcycle, and in accordance with the WARNING periodic maintenance chart and replen- ish coolant if the level is low. Change...
On the mixture ratio of coolant, choose the suitable one re- Coolant Level Inspection ferring to the relation between freezing • Situate the motorcycle so that it is point and strength directed on the con- perpendicular to the ground. tainer.
MAINTENANCE AND ADJUSTMENT • • Check the coolant level if it is be- If the amount of coolant is insuffi- tween the F (Full) and L (Low) level cient, remove the right side cover lines. and add coolant into the reserve tank.
MAINTENANCE AND ADJUSTMENT • • Remove the cap from the reserve Install the cap. • tank and add coolant through the Connect the connector. • filler opening to the F (Full) level line. Fit in the projection and tab into the holes.
Maintenance Chart. correct mixture ratio by the addition Spark plug removal should be done of antifreeze concentrate as soon as by an authorized Kawasaki dealer. possible. CAUTION If coolant must be added of- ten, or the reserve tank com- pletely runs dry, there is proba- bly leakage in the system.
MAINTENANCE AND ADJUSTMENT Spark Plug Standard Plug NGK CR9EIA-9 0.8 ∼ 0.9 mm Plug Gap (0.032 ∼ 0.035 in.) Tightening 15 N·m Torque (1.5 kgf·m, 11 ft·lb) A. Plug Gap...
MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System the air suction valve is prevented from The Kawasaki Clean Air System returning. Inspect the air suction valves (KCA) is a secondary air suction sys- in accordance with the Periodic Main- tem that helps the exhaust gases to tenance Chart.
Kawasaki dealer. Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Mainte- nance Chart. Inspection and adjustment should be done by an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT • Oil Draining If there are any oil in the reservoir, • Inspect the drain hose located on the remove the plug from the lower end rear side of the engine to see if any of the drain hose and drain the oil. oil or water has run down from the air cleaner housing.
MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check the throttle grip play in accor- Check that the throttle grip play is dance with the Periodic Maintenance correct by lightly turning the throttle Chart, and adjust it if necessary. grip back and forth. Throttle Grip - The throttle grip controls the butterfly valves in the throttle body.
MAINTENANCE AND ADJUSTMENT • Adjustment Tighten the locknut. • Loosen the locknut at the upper end of the throttle cable and turn the throt- tle cable adjusting nut in completely so as to give the throttle grip plenty of play. A.
Periodic damaged cables could result in Maintenance Chart by an authorized an unsafe riding condition. Kawasaki dealer. NOTE ○ Poor engine vacuum synchronization will cause unstable idling, sluggish throttle response, and reduce engine...
MAINTENANCE AND ADJUSTMENT Idle Speed Adjustment • The idle speed check should be per- Start the engine, and warm it up thor- formed in accordance with the Peri- oughly. • odic Maintenance Chart or whenever Adjust the idle speed by turning the the idle speed is disturbed.
If handlebar movement changes the idle speed, each day before riding the motorcycle, the throttle cables may be improperly and in accordance with the Periodic adjusted or incorrectly routed, or they Maintenance Chart.
MAINTENANCE AND ADJUSTMENT Adjustment Clutch Lever Play • Loosen the locknut, and turn the 2 ∼ 3 mm (0.08 ∼ 0.12 in.) adjuster so that the clutch lever will have the proper play. WARNING Be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough ca-...
The drive chain slack and lubrica- tion must be checked each day be- fore riding the motorcycle, and in accor- dance with the Periodic Maintenance Chart for safety and to prevent exces- sive wear. If the chain becomes badly...
MAINTENANCE AND ADJUSTMENT • Chain Slack Inspection If the drive chain is too tight or too • Set the motorcycle up on its side loose, adjust it so that the chain slack stand. will be within the standard value. •...
MAINTENANCE AND ADJUSTMENT • Adjustment If the chain is too loose, turn in the left • Loosen the left and right chain ad- and right chain adjusting nuts evenly. • juster locknuts. If the chain is too tight, turn out the •...
MAINTENANCE AND ADJUSTMENT • NOTE To keep the chain and wheel properly ○ aligned, the value on the left wheel Wheel alignment also alignment indicator should align with checked using the straightedge or the same (left or right) edge of in- string method.
When inserting the cotter pin, if the this item should be serviced by a slots in the nut do not align with Kawasaki dealer. the cotter pin hole in the axle shaft, tighten the nut clockwise up to the •...
MAINTENANCE AND ADJUSTMENT WARNING Wear Inspection • Remove the bolts to take off the chain If the axle nut is not securely guide. tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. • Check the rear brake (see the Brakes section).
For safety, use only the standard chain. It is an endless type and should not be cut for installa- tion; have it installed by an au- thorized Kawasaki dealer. • Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links.
NOTE If there is any irregularity, have the ○ drive chain and/or the sprockets re- Sprocket wear is exaggerated for il- placed by an authorized Kawasaki lustration. See Service Manual for dealer. wear limits. Lubrication Lubrication is also necessary after riding through rain or on wet roads, or any time that the chain appears dry.
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 mentioned above.
MAINTENANCE AND ADJUSTMENT Disc Brake Fluid - Fluid Level Inspection • In accordance with the Periodic Main- The brake fluid level in the front brake tenance Chart, inspect the brake fluid fluid reservoir must be kept above level in both the front and rear brake the line (lower level line) next to the fluid reservoirs and change the brake gauge and that in the rear brake...
MAINTENANCE AND ADJUSTMENT • If the fluid level in either reservoir is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. Inside the front brake fluid reser- voir is a stepped line showing the up- per level line.
MAINTENANCE AND ADJUSTMENT NOTE WARNING ○ First, tighten until slight resistance is Do not mix two brands of brake felt indicating that the cap is seated fluid. Change the brake fluid in on the reservoir body; then, tighten the brake line completely if the the cap an additional 1/6 turn while brake fluid must be refilled but holding the brake fluid reservoir...
• If it does not, ask your authorized WARNING Kawasaki dealer to inspect the front brake light switch. If the brake lever or pedal feels mushy when it is applied, there might be air in the brake lines or the brake may be defective.
MAINTENANCE AND ADJUSTMENT • Check the operation of the rear brake Brake Pedal Travel light switch by depressing the brake 10 mm (0.4 in.) pedal. The brake light should go on after the proper pedal travel. Adjustment • Disconnect the connector. A.
MAINTENANCE AND ADJUSTMENT • Front Fork To adjust the rear brake light switch, move the switch up or down by turn- The front fork operation and oil leak- ing the switch body. age should be checked in accordance with the Periodic Maintenance Chart. Front Fork Inspection •...
Rear Shock Absorbers If any doubt about the front fork, it should be done by an authorized The rear shock absorber operation Kawasaki dealer. and oil leakage should be checked in accordance with the Periodic Mainte- nance Chart. Rear Shock Absorber Inspection •...
If any doubt about the rear shock ab- Spring Preload Adjustment sorber, it should be done by an au- The spring preload adjuster on the thorized Kawasaki dealer. rear shock absorber has 7 positions. A. Spring Preload Adjuster A. Rear Shock Absorber B.
75 kg (165 lb) Tubeless tires are installed on the with no passenger and no accessories wheels of this motorcycle. The indica- is No. 3. tions of TUBELESS on the tire side wall and the rim show that the tire and rim WARNING are specially designed for tubeless use.
MAINTENANCE AND ADJUSTMENT WARNING The tires, rims, and air valves on this motorcycle are designed only for tubeless type wheels. recommended standard tires, rims, and air valves must be used for replacement. Do not install tube-type tires on tubeless rims. The beads may not seat properly on the rim A.
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.
MAINTENANCE AND ADJUSTMENT Tire Wear, Damage Minimum Tread Depth As the tire tread wears down, the tire 1 mm becomes more susceptible to puncture Front (0.04 in.) and failure. An accepted estimate is that 90% of all tire failures occur during Under 130 km/h 2 mm (80 mph)
MAINTENANCE AND ADJUSTMENT WARNING bad damage. Swelling or high spots indicate internal damage, requiring To ensure safe handling and tire replacement. stability, use only the recom- • Remove any imbedded stones or mended standard tires for re- other foreign particles from the tread. placement, inflated to the stan- NOTE dard pressure.
MAINTENANCE AND ADJUSTMENT WARNING Standard Tire (Tubeless) Size: 120/70ZR17 M/C (58W) New tires are slippery and may Front DUNLOP cause loss of control and injury. SPORTMAX RADIAL D221FA A break-in period of 160 km (100 Size: 160/60ZR17 M/C (69W) miles) is necessary to estab- Rear DUNLOP lish normal tire traction.
When used regularly, charged to completely discharged in a the charging system in the motorcycle matter of days. helps keep the battery fully charged. If your motorcycle is only used occasion- ally or for short periods of time, the bat- tery is more likely to discharge.
MAINTENANCE AND ADJUSTMENT Self-discharge Current Drain Approx. Number of Days Days from Days from 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...
If the above chargers are not avail- the battery fully charged. Failure to do able, use equivalent one. so can lead to battery failure and leave For more details, ask your Kawasaki you stranded. dealer. If you are riding your vehicle infre-...
Ah battery would be 1.0 ampere. Remove the seat. • The charger will keep the battery fully charged until you are ready to re- install the battery in the motorcycle (see Battery Installation). CAUTION Never remove the sealing strip, or the battery can be damaged.
MAINTENANCE AND ADJUSTMENT • Battery Installation Cover the (+) terminal with its protec- • Place the battery in the battery case. tive cap. • • Connect the capped wire to the (+) Reinstall the parts removed . terminal, and then connect the black wire to the (–) terminal.
MAINTENANCE AND ADJUSTMENT Headlight Beam Vertical Adjustment The headlight beam is adjustable ver- Horizontal Adjustment tically. If adjusted too low, neither low The headlight beam is adjustable nor high beam will illuminate the road horizontally. If not properly adjusted far enough ahead. If adjusted too high, horizontally, the beam will point to one the high beam will fail to illuminate the side rather than straight ahead.
On high beam, the brightest point tical angle. should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper angle according to local regulations.
MAINTENANCE AND ADJUSTMENT Rear Turn Signal Light Fuses To replace the bulb of the rear turn Fuses are arranged in the fuse box signal light, remove the screw and located under the seat. The main fuse lightly twist the lens counterclockwise. is mounted on the starter relay behind the right side cover.
MAINTENANCE AND ADJUSTMENT • Remove the left side cover by remov- ing the bolt. A. Main Fuse A. Left Side Cover B. Bolt...
Covering your motorcycle with a high quality, breathable motorcycle cover will help protect its finish from harmful UV rays, pollutants, and reduce the amount of dust reaching its surfaces.
If needed, use a mild de- scratched. greaser to remove any oil or grease •...
MAINTENANCE AND ADJUSTMENT • Start the engine and let it idle for sev- rain or washing the motorcycle. To eral minutes. The heat from the en- remove the moisture, start the engine gine will help dry moist areas. and turn on the headlight. Gradually •...
Vinyl parts should be washed with the age the part’s finish. rest of the motorcycle, then treated with a vinyl treatment.
MAINTENANCE AND ADJUSTMENT WARNING The sidewalls of tires and other rub- ber components should be treated with Special care must be taken not to a rubber protectant to help prolong their get any rubber protectant on the useful life. tire’s tread surface when treat- ing tires.
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.
Reduce tire pressure by about 20%. • 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.)
STORAGE • Put a cover over the motorcycle to keep dust and dirt from collecting on it. Preparation after Storage: • Remove the plastic bags from the mufflers. • Install the battery in the motorcycle and charge the battery if necessary.
ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure.