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Owner's Manual


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  • Page 1 ENGLISH j Motorcycle Owner’s Manual...
  • Page 3 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...
  • Page 5 (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;...
  • Page 6 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.
  • Page 7 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.
  • Page 8: Table Of Contents

    Ignition Switch/Steering Lock ... 36 Air Cleaner Intake ......52 Right Handlebar Switches....38 BREAK-IN ........... 53 Engine Stop Switch: ..... 38 HOW TO RIDE THE MOTORCYCLE . 55 Starter Button: ......38 Starting the Engine ......55 START/STOP Switch (Stop Moving Off........57 Watch): ........
  • Page 9 Cooling System ........ 83 Battery..........126 Spark Plugs........89 Headlight Beam........ 130 Valve Clearance ....... 90 Fuses ..........132 Kawasaki Clean Air System ..... 91 Cleaning Your Motorcycle ....133 Exhaust Device ........ 92 STORAGE........... 138 Air Cleaner ........93 ENVIRONMENTAL PROTECTION..141 Throttle Control System ....
  • Page 10: Specifications

    SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 95.5 kW (130 PS) @14,000 r/min (rpm) (HR) 78.2 kW (106 PS) @13,000 r/min (rpm) Maximum Torque 70.5 N·m (7.2 kgf·m, 52 ft·lb) @11,500 r/min (rpm) (HR) 63 N·m (6.4 kgf·m, 46.5 ft·lb) @11,500 r/min (rpm) Minimum Turning Radius 3.3 m (130 in.) DIMENSIONS...
  • Page 11 SPECIFICATIONS ENGINE Type DOHC, 4-cylinder, 4-stroke, liquid-cooled Displacement 636 mL (38.8 cu in.) Bore x Stroke 68.0 x 43.8 mm (2.7 x 1.7 in.) 12.9 : 1 Compression Ratio Starting System Electric starter Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Carburetion System...
  • Page 12 SPECIFICATIONS TRANSMISSION Transmission Type 6-speed, constant mesh, return shift Clutch Type Wet, multi disc Driving System Chain drive Primary Reduction Ratio 1.891 (87/46) Final Reduction Ratio 2.866 (43/15) Overall Drive Ratio 6.255 (Top gear) Gear Ratio 2.923 (38/13) 2.055 (37/18) 1.666 (35/21) 1.450 (29/20) 1.272 (28/22)
  • Page 13 12 V 0.5/4.1 W Even if one of LED (Light Emitting Diode) tail/brake light is not lit, consult with an authorized Kawasaki dealer. (HR): With Honeycomb Catalytic Converter (Restricted model) Specifications subject to change without notice, and may not apply to every country.
  • Page 14: 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. Spring Preload Adjuster 8. Front Brake Lever 4. Rebound Damping Force Adjuster 9. Throttle Grip (Front Fork) 10.
  • Page 15 LOCATION OF PARTS 11. Headlight 20. License Plate Light 27. Side Stand 12. Air Cleaner Intake 21. Brake Disc 28. Shift Pedal 13. Turn Signal Light 22. Compression 29. Rebound Damping 14. Spark Plugs Damping Force Force Adjuster 15. Fuel Tank Adjuster 30.
  • Page 16 LOCATION OF PARTS 33. Tool Kit 39. Brake Fluid Reservoir (Rear) 34. Fuse Box 40. Rear Shock Absorber 35. Battery 41. Rear Brake Light Switch 36. Fuel Tank Cap 42. Rear Brake Pedal 37. Muffler 43. Oil Level Gauge 38. Swingarm...
  • Page 17: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. RESET Button B. MODE Button C. Shift-Up Indicator Light D. Tachometer E. Red Zone F. Fuel Level Warning Light G. Digital Meter H. Turn Signal Indicator Light I. High Beam Indicator Light J. Neutral Indicator Light K.
  • Page 18: Tachometer

    Kawasaki dealer. and stop watch. When the ignition key is turned to “ON”, all the LCD segments are displayed for three seconds, then,...
  • Page 19 GENERAL INFORMATION Digital Meter A. Odometer B. Trip meter C. Clock D. Stop Watch E. Push MODE Button A. Speedometer B. Lap Counter/Coolant Temperature Gauge C. Clock, Trip Meter, Odometer, Stop Watch NOTE ○ Do not shift the digital meter display while riding for safe operation.
  • Page 20 GENERAL INFORMATION 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 ○ Do not operate the vehicle with the digital meter displaying in the wrong A.
  • Page 21 GENERAL INFORMATION • Push the RESET button for more than two seconds. Both the hour and minute displays start flashing. A. Km and °C Display B. Mile and °F Display C. Mile and °C Display D. Km and °F Display E.
  • Page 22 GENERAL INFORMATION ○ When the battery is disconnected, the clock resets to 1:00 and starts working again when the battery is connected. • Odometer - Push the RESET button. Both the The odometer shows the total dis- hour and minute displays start flash- tance in kilometers or miles that the ve- ing again.
  • Page 23 GENERAL INFORMATION ○ Trip Meters - When the trip meter reaches 999.9 The trip meter shows the distance in while riding, the meter resets to 0.0 kilometers or miles traveled since it was and continues counting. ○ last reset to zero. When the battery is disconnected, To reset the trip meter: the meter display resets to 0.0.
  • Page 24 GENERAL INFORMATION Lap Counter/Coolant Temperature Gauge - The Lap counter/coolant temperature gauge shows either the lap number or the coolant temperature. The lap num- ber is displayed when in the stop watch mode. The coolant temperature is displayed as follows. •...
  • Page 25 GENERAL INFORMATION temperature is too high; stop the engine and check the coolant level in the reserve tank after the engine cools down. • If the coolant temperature rises to above 115°C (239°F) and below 120 °C (248°F), the numerical value of the current coolant temperature starts flashing.
  • Page 26 GENERAL INFORMATION mode. If the coolant temperature rises above 115°C (239°F) with the Lap number displayed, the lap num- ber display automatically shifts to the coolant temperature display. Stop Watch - The stop watch can be used in closed course competition. The stop watch is operated as fol- lows;...
  • Page 27 GENERAL INFORMATION • To stop the stop watch, push the START/STOP switch on the right handlebar switch to the left. • To display each measured lap time, push the RESET button. When no lap number is displayed, the time dis- played is the total time of all timed laps.
  • Page 28: Warning/indicator Lights

    (DFI). If the indicator beam, the high beam indicator light is light comes on, have the DFI system lit. checked by an authorized Kawasaki dealer. : When the turn signal switch is pushed to the left or right, the turn sig-...
  • Page 29 GENERAL INFORMATION (For models equipped with an simultaneously for more than two immobilizer system) seconds, within twenty seconds after When the key is turned to “OFF”, the turning the ignition key to the “OFF” FI indicator light will start flashing in- position, then the FI indicator light dicating that the immobilizer system is will not flash.
  • Page 30 To select a shift-up indicator light B. “FUEL” Flashes. mode or adjust the shift-up engine speed setting in the tachometer, do NOTE the following while the motorcycle is ○ When pushing the MODE button stopped: while “FUEL” is displayed, the dis- •...
  • Page 31 GENERAL INFORMATION • To change the shift-up indicator light mode, push the MODE button and the shift-up indicator light will shift be- tween light off, light on (bright) and light on (dim). The shift-up engine speed can only be adjusted when the light is on.
  • Page 32 GENERAL INFORMATION NOTE WARNING ○ 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- ○ When the battery is disconnected, trate on the shift-up indicator the pre-set engine speed is set to 14 light by taking your eyes off the...
  • Page 33: Key

    Up to five user keys can be registered with the immobilizer sys- Immobilizer System (For models equipped with Immobilizer tem at one time. system) This motorcycle is equipped with an immobilizer system to protect your mo- torcycle from theft. This motorcycle...
  • Page 34 Do not put two keys of any immo- If the master key is lost, an au- bilizer system on the same key thorized Kawasaki dealer will ring. have to replace the ECU, order a Do not submerge any key in wa- new master key, and register the ter.
  • Page 35 GENERAL INFORMATION • Master key: When the key is turned to “OFF, ” the The master key can never be dupli- FI indicator light will start flashing in- cated. dicating that the immobilizer system is • User-keys: enabled. After 24 hours have passed, You can register maximum 5 user the FI indicator light will stop flashing, -keys at one time.
  • Page 36: Ignition Switch/steering Lock

    GENERAL INFORMATION ○ Ignition Switch/Steering Lock When the battery is connected, FI indicator light defaults to flashing This is a four-position, key-operated mode. switch. The key can be removed from ○ When the battery voltage is low (be- the switch when it is in the OFF, LOCK, low 12 V), FI indicator light flashing or P (Park) position.
  • Page 37 GENERAL INFORMATION engine immediately after turning the Engine off. All electrical 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 38: Right Handlebar Switches

    The starter button operates the elec- the ignition switch should be used to tric starter when the transmission is in stop the engine. neutral. Refer to the Starting the Engine sec- tion of the "How to Ride the Motorcycle" chapter for starting instructions.
  • Page 39: Start/stop Switch (stop Watch)

    GENERAL INFORMATION Left Handlebar Switches START/STOP Switch (Stop Watch): Refer to the Digital Meter section of Dimmer Switch: this chapter for stop watch instructions. High or low beam can be selected with the dimmer switch. When the headlight is on high beam ( ), the high beam indicator light is lit.
  • Page 40: Turn Signal Switch

    GENERAL INFORMATION To stop flashing, push the switch in. Horn Button: When the horn button is pushed, the horn sounds. LAP Button: Refer to the Digital Meter section of the this chapter for stop watch instruc- tions. A. Dimmer Switch B.
  • Page 41: Brake Lever Adjuster

    GENERAL INFORMATION Brake Lever Adjuster There is an adjuster on the brake lever. The adjuster has 5 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 42: Fuel Tank Cap

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

    GENERAL INFORMATION Fuel Tank WARNING The following octane rating gasoline Gasoline is extremely flammable is recommended in the fuel tank. Avoid and can be explosive under cer- filling the tank in the rain or where tain conditions. Turn the igni- heavy dust is blowing so that the fuel tion key to “OFF”.
  • Page 44: Fuel Requirement

    GENERAL INFORMATION Fuel Requirement: rating is the Research Octane Number Your Kawasaki engine is designed to (RON). Always use a gasoline with an use only unleaded gasoline with a min- octane rating equal to, or higher than, imum octane rating of RON 95.
  • Page 45: Side Stand

    GENERAL INFORMATION Side Stand Whenever the side stand is used, The motorcycle is equipped with a make it a practice to kick the stand fully side stand. up before sitting on the motorcycle. NOTE ○ The motorcycle is equipped with a side stand switch.
  • Page 46: Seat Lock

    GENERAL INFORMATION Seat Lock Passenger’s Seat Removal Remove the passenger’s seat by in- serting the ignition key into the seat lock, turning it clockwise, pulling up on the front of the seat with the key held in that position, then pulling the seat to the front.
  • Page 47 GENERAL INFORMATION Rider’s Seat Removal • Remove the side cover mounting screws and then pull out the rear of the side cover to disengage the projection. A. Projection B. Side Cover • Remove the seat mounting bolts and then pull off the seat to the front. A.
  • Page 48 GENERAL INFORMATION A. Bolts A. Rider’s Seat B. Seat B. Tab C. Pull to Front C. Insert D. Bracket • Seat Installation Install the cover and tighten the bolt. Install the rider’s and passenger’s seats in the reverse order of removal. NOTE ○...
  • Page 49 GENERAL INFORMATION • Push down the front part of the pas- senger’s seat until the lock clicks. A. Cover B. Rider’s Seat C. Insert A. Hook Passenger’s Seat - B. Slots • Insert the tab on the rear of the pas- C.
  • Page 50: Helmet Hooks

    Helmets can be secured to the mo- torcycle using the helmet hooks located under the passenger’s seat. WARNING Do not ride the motorcycle with helmets attached to the hooks. The helmets could cause an ac- cident by distracting the opera- tor or interfering with normal ve- A.
  • Page 51: Tying Hooks

    GENERAL INFORMATION Tying Hooks Tool Kit Compartment When tying up light loads to the seat, The tool kit compartment is stored use the tying hooks located at the rear under the passenger’s seat. fairing. The kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual.
  • Page 52: Air Cleaner Intake

    GENERAL INFORMATION CAUTION Air Cleaner Intake The air cleaner intake allows air to The tool kit opening should be enter the fuel system. Never allow any- placed to the front, and the snap thing to restrict the flow of air into the fastener on the tool kit opening air cleaner.
  • Page 53: 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 54 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.
  • Page 55: How To Ride The Motorcycle

    A. Neutral Indicator Light B. Ignition Switch C. ON position NOTE A. Engine Stop Switch ○ The motorcycle is equipped with a B. Starter Button vehicle-down sensor, which causes • Turn the ignition key to “ON”. the engine to stop automatically •...
  • Page 56 Wait 15 seconds between each operation of the starter to let it cool and the bat- tery power recover. A. Clutch Lever B. Starter Lockout Switch NOTE ○ The motorcycle is equipped with a starter lockout switch. This switch is...
  • Page 57: Moving Off

    HOW TO RIDE THE MOTORCYCLE CAUTION Moving Off • Check that the side stand is up. Do not let the engine idle longer • Pull in the clutch lever. than five minutes, or engine • Shift into 1st gear. overheating and damage may •...
  • Page 58: Shifting Gears

    NOTE Shifting Gears • ○ Close the throttle while pulling in the The motorcycle is equipped with a clutch lever. side stand switch. This switch is de- • Shift into the next higher or lower signed so that the engine does not gear.
  • Page 59: 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 60 HOW TO RIDE THE MOTORCYCLE A. Front Brake Lever A. Rear Brake Pedal CAUTION In order to protect the emission control parts, do not turn off the ignition switch when the motor- cycle is in motion.
  • Page 61: Stopping The Engine

    Your Kawasaki Motorcycle has been • designed and manufactured to pro- Turn the ignition key to “OFF”. • Support the motorcycle on a firm, vide you optimum safety and conve- level surface with the side stand. nience. However, in order to fully ben- •...
  • Page 62: Parking

    • If parking inside a garage or other structure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 63: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE Catalytic Converter WARNING This motorcycle is equipped with Gasoline is extremely flammable a catalytic converter in the exhaust and can be explosive under cer- system. Platinum and rhodium in the tain conditions. converter react with harmful carbon •...
  • Page 64 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 65: Safe Operation

    SAFE OPERATION 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 66 SAFE OPERATION 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. Brakes ......Brake pad wear: Lining thickness more than 1 mm (0.04 in.) left.
  • Page 67: 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 68 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 69: Maintenance And Adjustment

    MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.
  • Page 70: Periodic Maintenance Chart

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart 1. Periodic Inspection (Engine Related Items) Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Items) Every (0.6) (7.5) (12) (15) (20) (24) K Valve clearance - inspect Every 42 000 km (26 000 mile) Throttle control system (play, •...
  • Page 71 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • • Fuel hoses installation year – condition - inspect • •...
  • Page 72 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) Clutch and drive train: Clutch operation • •...
  • Page 73 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) Wheels/tires damage - • • • inspect • • • Tire tread wear, abnormal wear - inspect •...
  • Page 74 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • • • • • Brake fluid level - inspect 6 month Brake operation •...
  • Page 75 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • Uni-trak tie rods operation - – inspect Steering system: • •...
  • Page 76 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • Engine stop switch operation year – - inspect Chassis: • •...
  • Page 77 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Items) Every (0.6) (7.5) (15) (24) (30) Air cleaner element # every 18 000 km (12 000 mile) •...
  • Page 78 • K Spark plug 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,...
  • Page 79: 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.
  • Page 80 MAINTENANCE AND ADJUSTMENT CAUTION If the engine oil gets extremely low or if the oil pump does not function properly or oil pas- sages are clogged, the oil pres- sure warning light will light. If this light stays on when the en- gine speed is above 1 300 r/min (rpm), stop the engine immedi- ately and find the cause.
  • Page 81 The oil change and oil filter replacement should be done by an authorized Kawasaki dealer. A. Oil Filter Cartridge WARNING Motor oil is a toxic substance. Dispose of used oil properly.
  • Page 82 MAINTENANCE AND ADJUSTMENT Although 10W-40 engine oil is the Tightening Torque recommended oil for most condi- Engine Oil Drain Plug: tions, the oil viscosity may need to 29 N·m (3.0 kgf·m, 22 ft·lb) be changed to accommodate atmo- Cartridge: 31 N·m (3.2 kgf·m, 23 ft·lb) spheric conditions in your riding area.
  • Page 83: Cooling System

    Radiator Hoses - Check the radiator hoses for leakage, cracks or deterioration, and connec- tions for leakage, or looseness each day before riding the motorcycle, and in accordance with the Periodic Main- tenance Chart.
  • Page 84 Check the cooling system. coolant level each day before riding the WARNING motorcycle, and in accordance with the periodic maintenance chart and replen- Use coolant containing corro- ish coolant if the level is low. Change sion inhibitors made specifically...
  • Page 85 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.
  • Page 86 MAINTENANCE AND ADJUSTMENT • Check the coolant level through the coolant level gauge on the reserve tank located to the left of the engine. The coolant level should be between the F (Full) and L (Low) level lines. NOTE ○ Check the level when the engine is cold (room or atmospheric tempera- ture).
  • Page 87 MAINTENANCE AND ADJUSTMENT A. Fuel Tank A. Fuel Tank C. Reserve Tank B. Bolt B. Suitable Object • • Raise the front of the fuel tank. Remove the cap from the reserve tank and add coolant through the NOTE filler opening to the F (Full) level line. ○...
  • Page 88 MAINTENANCE AND ADJUSTMENT A. Reserve Tank Cap A. Fuel Tank B. Hose • Install the reserve tank cap. • • Install the parts removed. Install the fuel tank in the reverse or- der of removal. • NOTE When installing the fuel tank, check ○...
  • Page 89: Spark Plugs

    Maintenance Chart. bly leakage in the system. Have Spark plug removal should be done the cooling system inspected by an authorized Kawasaki dealer. by your authorized Kawasaki dealer. Spark Plug Standard NGK CR9E...
  • Page 90: Valve Clearance

    A. 0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.) ous engine damage. 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.
  • Page 91: Kawasaki Clean Air System

    MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System exhaust port. Any air that has passed The Kawasaki Clean Air System the air suction valve is prevented from (KCA) is a secondary air suction sys- returning. Inspect the air suction valves tem that helps the exhaust gases to in accordance with the Periodic Main- burn more completely.
  • Page 92: Exhaust Device

    MAINTENANCE AND ADJUSTMENT Exhaust Device This motorcycle is equipped with an exhaust device. This system controls a valve in the exhaust pipe, which stabi- lizes the engine power at low and mid- dle engine speed. This exhaust device is controlled by the ECU, and adjust- ment or maintenance should be done by an authorized Kawasaki dealer.
  • Page 93: Air Cleaner

    11013–0010 or equiva- causing spark plug fouling. lent type). Using the another air This motorcycle’s air cleaner element cleaner element will wear the en- consists of a wet paper filter, which can- gine prematurely or lower the en- not be cleaned.
  • Page 94 MAINTENANCE AND ADJUSTMENT A. Screws A. Element B. Air Cleaner Housing Cover • Put a clean, lint-free towel over the • Pull up the air cleaner element. air cleaner element slots to keep dirt or other foreign material from enter- ing.
  • Page 95 MAINTENANCE AND ADJUSTMENT WARNING Oil Draining • Inspect the transparent reservoir lo- If dirt or dust is allowed to pass cated on the left side of the engine to through into the fuel injection see if any oil or water has run down system, the throttle may become from the air cleaner housing.
  • Page 96: Throttle Control System

    MAINTENANCE AND ADJUSTMENT Throttle Control System WARNING Check the throttle grip play in accor- Be sure to install the reservoir in dance with the Periodic Maintenance the drain hose after draining. Oil Chart, and adjust it if necessary. on tires will make them slippery and can cause an accident and Throttle Grip - injury.
  • Page 97 MAINTENANCE AND ADJUSTMENT • Turn out the decelerator cable ad- juster until there is no play when the throttle grip is completely closed. Tighten the locknut against the ad- juster. A. Throttle Grip B. Throttle Grip Play Throttle Grip Play 2 ∼...
  • Page 98: Engine Vacuum Synchronization

    If handlebar movement changes the idle speed, Maintenance Chart by an authorized the throttle cables may be improp- Kawasaki dealer. erly adjusted or in correctly routed, NOTE or they may be damaged. Be sure ○ Poor engine vacuum synchronization...
  • Page 99: Idle Speed

    MAINTENANCE AND ADJUSTMENT Idle Speed The idle speed adjustment should be performed in accordance with the Pe- riodic Maintenance Chart or whenever the idle speed is disturbed. Adjustment • Start the engine, and warm it up thor- oughly. • Adjust the idle speed to by turning the idle adjusting screw.
  • Page 100: Clutch

    Periodic Maintenance Chart. WARNING To avoid a serious burn, never touch a hot engine or an exhaust pipe during clutch adjustment.
  • Page 101 Clutch Lever Play justed with the cable adjuster, further 2 ∼ 3 mm (0.08 ∼ 0.12 in.) adjustment should be done by an au- thorized Kawasaki dealer. WARNING Be sure the upper end of the clutch outer cable is fully seated...
  • Page 102: Drive Chain

    Periodic Maintenance chain midway between the engine Chart for safety and to prevent exces- sprocket and rear wheel sprocket.
  • Page 103 MAINTENANCE AND ADJUSTMENT • If the chain is too loose, turn out the Drive Chain Slack left and right chain adjusters evenly. Standard: 30 ∼ 35 mm (1.2 ∼ 1.4 in.) • If the chain is too tight, turn in the left and right chain adjusters evenly.
  • Page 104 D. Adjuster NOTE E. Locknut ○ If a torque wrench is not available, this item should be serviced by a NOTE ○ Kawasaki dealer. Wheel alignment also • checked using the straightedge or Rotate the wheel, measure the chain string method.
  • Page 105 MAINTENANCE AND ADJUSTMENT • ○ Install a new cotter pin through the It should be within 30 degree. ○ axle nut and axle, and spread its Loosen once and tighten again when ends. the slot goes past the nearest hole. A.
  • Page 106 MAINTENANCE AND ADJUSTMENT • • Check the rear brake (see the Brakes Measure the length of 20 links on section). the straight part of the chain from pin center of the 1st pin to pin center of Wear Inspection the 21st pin. Since the chain may •...
  • Page 107 If there is any irregularity, have the loose pins and links. • drive chain and/or the sprockets re- Also inspect the sprockets for un- placed by an authorized Kawasaki evenly or excessively worn teeth, dealer. and damaged teeth. NOTE NOTE ○...
  • Page 108 MAINTENANCE AND ADJUSTMENT • Apply oil to the sides of the rollers so that it will penetrate to the rollers and bushings. Apply oil to the O-rings so that the O-rings will be coated with oil. Wipe off any excess oil. A.
  • Page 109: Brakes

    1 mm (0.04 in.), replace both pads changed if it becomes contaminated in the caliper as a set. Pad replace- with dirt or water. ment should be done by an authorized Kawasaki dealer. Fluid Requirement Use heavy-duty brake fluid only from a container marked DOT4. CAUTION Do not spill brake fluid onto any painted surface.
  • Page 110 MAINTENANCE AND ADJUSTMENT Fluid Level Inspection • With the brake fluid reservoirs held horizontal, the brake fluid level must be kept between the upper and lower level lines. A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line D.
  • Page 111 1/6 turn while holding Fluid Change the brake fluid reservoir body. Have the brake fluid changed by an authorized Kawasaki dealer. Front and Rear Brakes - Disc and disc pad wear is automat- ically compensated for and has no ef-...
  • Page 112: Brake Light Switches

    Inspection • Since it is dangerous to operate Turn the ignition key to ON. • the motorcycle under such con- The brake light should go on when ditions, have the brake checked the front brake is applied. • immediately by an authorized If it does not, ask your authorized Kawasaki dealer.
  • Page 113 MAINTENANCE AND ADJUSTMENT CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. A. Brake Pedal B. 10 mm (0.4 in.) • If it does not, adjust the rear brake light switch.
  • Page 114: Front Fork

    On top of each front fork leg are a should be done by an authorized spring preload adjuster and a rebound Kawasaki dealer. damping force adjuster, and on the lower portion of each front fork leg is a compression damping force adjuster...
  • Page 115 MAINTENANCE AND ADJUSTMENT be increased for high speed riding or riding on rough roads. A. Compression Damping Force Adjuster Spring Preload Adjustment A. Spring Preload Adjuster • B. Rebound Damping Force Adjuster Turn the spring preload adjusters into the nut to increase spring force and CAUTION out to decrease spring force using the wrench.
  • Page 116 MAINTENANCE AND ADJUSTMENT preload adjuster with a screwdriver. This makes the damping force great- est. • Turn out the adjuster to decrease damping force. Be sure to turn both adjusters by the same number of turns. A. Spring Preload Adjuster B.
  • Page 117 MAINTENANCE AND ADJUSTMENT Compression Damping Force The standard setting positions of Adjustment the spring preload adjuster, rebound • Turn the compression damping force damping force adjuster and compres- sion damping force adjuster for an adjuster all the way clockwise with a screwdriver to make the damping average-build rider of 68 kg (150 lb) force greatest.
  • Page 118: Rear Shock Absorber

    If any doubt about the rear shock ab- justed by changing the spring preload sorber, it should be done by an au- and rebound and compression damp- thorized Kawasaki dealer. ing force for various riding and loading conditions. Before making any adjustments,...
  • Page 119 If the spring action feels too soft or too • Turn the rebound damping force ad- stiff, have it adjusted by an authorized juster all the way clockwise with a Kawasaki dealer. screwdriver to make the damping Rebound Damping Force Adjustment force greatest. •...
  • Page 120 MAINTENANCE AND ADJUSTMENT at the upper end of the rear shock ab- compression damping force adjuster sorber. for an average-build rider of 68 kg (150 • Turn the compression damping force lb) with no passenger and no acces- adjuster all the way clockwise with sories are as follows: a screwdriver to make the damping force greatest.
  • Page 121: Wheels

    MAINTENANCE AND ADJUSTMENT Wheels Tubeless tires are installed on the wheels of this motorcycle. The indica- tions of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. TUBELESS Mark...
  • Page 122 The tires, rims, and air valves cle and can result in loss of control. The on this motorcycle are designed maximum recommended load in addi- only for tubeless type wheels. tion to vehicle weight is 180 kg (397 lb),...
  • Page 123 MAINTENANCE AND ADJUSTMENT checked and adjusted when your rid- Tire Wear, Damage ing involves wide variations in tem- As the tire tread wears down, the tire perature or altitude. becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 124 MAINTENANCE AND ADJUSTMENT WARNING To ensure safe handling and stability, use only the recom- mended standard tires for re- placement, inflated to the stan- dard pressure. Tires that have been punctured and repaired do not have the same capabilities as undam- aged tires.
  • Page 125 MAINTENANCE AND ADJUSTMENT WARNING Standard Tire (Tubeless) Size: 120/65ZR17 M/C (56 W) New tires are slippery and may Front • BRIDGESTONE “BT014F RA- cause loss of control and injury. DIAL J” A break-in period of 160 km (100 miles) is necessary to estab- Size: 180/55ZR17 M/C (73 W) lish normal tire traction.
  • Page 126: Battery

    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.
  • Page 127 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 128 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-...
  • Page 129 The charger will keep the battery fully must be removed. The battery re- charged until you are ready to re- moval and installation should be install the battery in the motorcycle done by an authorized Kawasaki (see Battery Installation). dealer.
  • Page 130: Headlight Beam

    MAINTENANCE AND ADJUSTMENT Headlight Beam Horizontal Adjustment To adjust the headlight beam, the The headlight beam is adjustable left and right inner covers must be re- horizontally. If not properly adjusted moved. horizontally, the beam will point to one • Remove the bolts.
  • Page 131 NOTE ○ On high beam, the brightest point 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.
  • Page 132: Fuses

    The main fuse removal should be done by an authorized Kawasaki dealer. A. Main Fuse B. Spare Fuse WARNING Do not use any substitute for the standard fuse.
  • Page 133: Cleaning Your Motorcycle

    Frequent and proper care of your Kawasaki motorcycle will enhance its appearance, optimize overall per- formance, and extend its useful life. Covering your motorcycle with a high quality, breathable motorcycle cover will help protect its finish from harmful UV rays, pollutants, and reduce the A.
  • Page 134 • Use care when washing the wind- motorcycle. If needed, use a mild de- shield, headlight cover, and other greaser to remove any oil or grease plastic parts as they can easily be build up.
  • Page 135 MAINTENANCE AND ADJUSTMENT • brakes and restores them to normal When washing the motorcycle, al- operating performance. ways use a mild neutral detergent • Lubricate the drive chain to prevent and water. • The semi-gloss finish effect may be rusting.
  • Page 136 Vinyl parts should be washed with the plastic parts, as they will dam- rest of the motorcycle, then treated with age the part’s finish. a vinyl treatment. The sidewalls of tires and other rub-...
  • Page 137 MAINTENANCE AND ADJUSTMENT WARNING Special care must be taken not to get any rubber protectant on the tire’s tread surface when treat- ing tires. This may decrease the tire’s ability to maintain contact with the road surface causing the rider to lose control.
  • Page 138: Storage

    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 139 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.)
  • Page 140 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.
  • Page 141: 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 142: Location Of Labels

    LOCATION OF LABELS LOCATION OF LABELS 1. Brake Fluid (Front) 2. Fuel Caution 3. Unleaded Gasoline 4. Daily Safety Checks 5. Engine Oil and Oil Filter...
  • Page 143 LOCATION OF LABELS 6. Important Drive Chain Information *7. Tire and Load Data 8. Brake Fluid (Rear) **9. Stationary Noise Test Information *: only on Australia and Malaysia model **: only on Australia model...
  • Page 144 LOCATION OF LABELS 10. Battery Poison/Danger...
  • Page 145 LOCATION OF LABELS 1)/8) 1)/8)
  • Page 146 LOCATION OF LABELS...
  • Page 147 LOCATION OF LABELS...
  • Page 148 LOCATION OF LABELS 7) only on Australia and Malaysia model 8) only on Australia model...
  • Page 149 LOCATION OF LABELS...
  • Page 150: Additional Information

    ADDITIONAL INFORMATION ADDITIONAL INFORMATION 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.
  • Page 151 Raise the rear end of the fuel tank. • Make sure the ignition key is turned to “OFF”. • Connect a jumper cable from the positive (+) terminal of the booster battery to the positive (+) terminal of the motorcycle battery.
  • Page 152 ○ Be careful not to drop the fuel tank. A. Motorcycle Battery Positive (+) Terminal B. From Booster Battery Positive (+) Terminal C. Unpainted Metal Surface D. From Booster Battery Negative (–) Terminal E.
  • Page 153 ADDITIONAL INFORMATION • WARNING Follow the standard engine starting procedure. Do not make this last connec- tion at the fuel system or battery. CAUTION Take care that you do not touch the positive and negative cables Do not operate the starter con- together, and do not lean over tinuously for more than 5 sec- the battery when making this last...

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