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Kawasaki Motorcycle Owner's Manual

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ENGLISH j
Motorcycle
Owner's Manual

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Table of Contents

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   Summary of Contents for Kawasaki Motorcycle

  • 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

    Rear Carrier ........38 Right Handlebar Switches....24 BREAK-IN ........... 40 Engine Stop Switch ...... 24 HOW TO RIDE THE MOTORCYCLE . 42 Starter Button ....... 25 Starting the Engine ......42 Left Handlebar Switches ....26 Jump Starting ........45 Dimmer Switch ......
  • Page 9 Cooling System ........ 77 Headlight Beam........ 119 Spark Plugs........82 Fuses ..........121 Valve Clearance ....... 85 Cleaning Your Motorcycle ....122 Air Cleaner ........86 STORAGE........... 127 Kawasaki Clean Air System ..... 86 ENVIRONMENTAL PROTECTION..130 Throttle Grip ........87...
  • Page 10: Specifications

    SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 33 kW (45 PS) @8 300 r/min (rpm) Maximum Torque 41 N·m (4.2 kgf·m, 30.2 ft·lb) @7 500 r/min (rpm) Maximum Turning Radius 2.4 m (94.5 in.) DIMENSIONS Overall Length 2 215 mm (87.20 in.) Overall Width 880 mm (34.65 in.) Overall Height...
  • Page 11 SPECIFICATIONS Compression Ratio 9.8 : 1 Starting System Electric starter Cylinder Numbering Left to right, 1-2 Method Firing Order Carburetors KEIHIN CVK34 × 2 Ignition System Battery and coil (transistorized ignition) 10° BTDC @1 300 r/min (rpm) ∼ Ignition Timing (Electronically advanced) 35°...
  • Page 12 SPECIFICATIONS TRANSMISSION Transmission Type 6-speed, constant mesh, return shift Clutch Type Wet, multi disc Driving System Chain drive Primary Reduction Ratio 2.652 (61/23) Final Reduction Ratio 2.588 (44/17) Overall Drive Ratio 5.847 (Top gear) Gear Ratio 2.571 (36/14) 1.722 (31/18) 1.333 (28/21) 1.125 (27/24) 0.961 (25/26)
  • Page 13 SPECIFICATIONS FRAME Castor 27° Trail 105 mm (4.13 in.) Tire Size: Front 90/90-21 M/C 54S Rear 130/80-17 M/C 65S Rim Size: Front 21 × 1.85 Rear 17 × 2.50 Fuel Tank Capacity 15.0 L (4.0 US gal) ELECTRICAL EQUIPMENT Battery 12 V 10 Ah Headlight 12 V 55/55 W (Hi/Lo)
  • Page 14: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 6. Brake Lever Adjuster 10. Right Handlebar 2. Clutch Lever Adjuster 7. Front Brake Lever Switches 3. Starter Lockout 8. Left Handlebar 11. Throttle Grip Switch Switches 4. Meter Instruments 9. Ignition 5.
  • Page 15 LOCATION OF PARTS 12. Front Fork 19. Battery 26. Idle Adjusting Screw 13. Headlight 20. Coolant Reserve Tank 27. Shift Pedal 14. Turn Signal Light 21. Helmet Hook 28. Side Stand Switch 15. Spark Plugs 22. Brake Disc 29. Side Stand 16.
  • Page 16 LOCATION OF PARTS 31. License Plate Light 39. Fuel Tank 32. Tail/Brake Light 40. Fuel Tank Cap 33. Rear Carrier 41. Rear Shock Absorber 34. Muffler 42. Rear Brake Light Switch 35. Seat 43. Rear Brake Pedal 36. Tool Kit 44.
  • Page 17: Loading And Accessories Information

    In Incorrect loading, improper in- selecting and using accessories, and stallation or use of accessories, 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.
  • Page 18 Recheck baggage security the motorcycle is in motion and not as often as possible (not while the interfere with the operation of the motorcycle is in motion) and adjust motorcycle.
  • Page 19 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,...
  • Page 20: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Coolant Temperature Warning Light B. High Beam Indicator Light C. Oil Pressure Warning Light D. Reset Button E. Speedometer F. Odometer G. Turn Signal Indicator Light H. Neutral Indicator Light I. Tachometer J. Red Zone K.
  • Page 21: Speedometer And Tachometer

    GENERAL INFORMATION CAUTION Speedometer and Tachometer The speedometer shows the speed Engine r/min (rpm) should not of the vehicle. In the speedometer be allowed to enter the red zone; face are the odometer and trip meter. operation in the red zone will The odometer shows the total distance overstress the engine and may that the vehicle has been ridden.
  • Page 22: Key

    The warning light also goes on whenever the coolant temperature rises to 120°C or higher when the motorcycle is in operation. If it stays on, stop the engine and check the coolant level in the reserve tank after...
  • Page 23: Ignition Switch/steering Lock

    GENERAL INFORMATION Ignition Switch/Steering Lock Engine off. All electrical This is a four-position, key-operated circuits off. switch. The key can be removed from Engine on. All electrical the switch when it is in the OFF, LOCK, equipment can be used. or P (Park) position.
  • Page 24: Right Handlebar Switches

    In addition to the ignition switch, the engine stop switch must be in the To operate the ignition switch; position for the motorcycle to operate. The engine stop switch is for emer- gency use. If some emergency re-...
  • Page 25: Starter Button

    GENERAL INFORMATION Refer to the Starting the Engine sec- tion of the "How to Ride the Motorcycle" chapter for starting instructions. A. Engine Stop Switch B. Starter Button Starter Button The starter button operates the elec- tric starter when pushed with the clutch lever pulled in or the transmission in neutral.
  • Page 26: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches Dimmer Switch 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. High beam..( Low beam..( NOTE ○ A.
  • Page 27: Horn Button

    GENERAL INFORMATION Brake/Clutch Lever Adjusters Horn Button When the horn button is pushed, the There is an adjuster on both the horn sounds. brake and clutch levers. The brake lever adjuster has 4 positions and the Passing Button clutch lever adjuster has 5 positions so When the passing button is pushed, that the released lever position can be the headlight high beam (passing...
  • Page 28: Fuel Tank Cap

    GENERAL INFORMATION Fuel Tank Cap To open the fuel tank cap, pull up the key hole cover. Insert the ignition switch key into the lock and turn the key to the right. To close the cap, push it down into place with the key inserted.
  • Page 29: Fuel Tank

    GENERAL INFORMATION Fuel Tank Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. A. Key Hole Cover B. Ignition Switch Key C. Fuel Tank Cap...
  • Page 30 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 ignition CAUTION key to “OFF.” Do not use leaded gasoline, as Do not smoke.
  • Page 31: Fuel Tap

    GENERAL INFORMATION NOTE Fuel Tap ○ The fuel tap is an automatic type If “knocking” or “pinging” occurs, use which shuts off the fuel supply when a different brand of gasoline or higher the engine is stopped in the ON or RES octane rating.
  • Page 32 PRI, leave it for a few Practice operating the fuel tap seconds, and then turn it to RES. with the motorcycle stopped. To The last 3.4 L (0.9 US gal) of fuel can prevent an accident you should be used by turning the fuel to RES.
  • Page 33: Stand

    GENERAL INFORMATION 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 34: Helmet Hook

    The helmet hook can be unlocked by inserting the ignition switch key into the lock, and turning the key to the right. WARNING Do not ride the motorcycle with helmet attached to the hook. The helmet could cause an accident A. Helmet Hook B.
  • Page 35: Side Covers

    GENERAL INFORMATION Side Covers Right Side Cover Removal: Remove the left and right side covers To remove the right side cover, insert for the brake fluid and coolant refilling, the ignition switch key into the lock, turn and seat removal. the key to the right, and take off the right side cover with the ignition switch key.
  • Page 36 GENERAL INFORMATION A. Projection A. Projection B. Guide B. Hole • Fit in the projection into the hole.
  • Page 37: Tool Kit

    GENERAL INFORMATION Tool Kit Seat The tool kit is located inside the right To remove the seat, follow this step. side cover under the seat. 1. Remove the left and right side cov- Store the tool kit in this compartment. ers (right with the ignition switch The kit contains tools that can be help- key).
  • Page 38: Seat Installation

    Rear Carrier Seat Installation: • Place the tab on the front of the riders The motorcycle is equipped with a seat into the slot in the bracket and carrier on the rear. tighten the seat mounting bolts. Vehicle Total Payload 180 kg (must not exceed).
  • Page 39 GENERAL INFORMATION WARNING Never exceed the rear carrier load limit of 10 kg (22 lb). It is designed for light items, and overloading can affect handling due to changes in weight distri- bution and aerodynamic forces. Do not exceed the vehicle speed of 130 km/h (80 mph) when car- rying a load of more than 5 kg (11 lb) on the carrier.
  • Page 40: 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 41 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 42: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE • Starting the Engine Make certain the transmission is in • neutral or the clutch is disengaged. Turn the fuel tap to the ON position. A. Engine Stop Switch A. ON position B.
  • Page 43 If the engine is flooded, crank the en- gine over with the throttle fully open until the engine starts. ○ The motorcycle is equipped with a starter lockout switch. This switch prevents the electric starter from op- A. Choke Lever erating when the clutch is engaged •...
  • Page 44 HOW TO RIDE THE MOTORCYCLE choke, return the choke lever all the way back. NOTE ○ If you drive the motorcycle before the engine is warmed up, return the choke to the off position as soon as your start moving. CAUTION A.
  • Page 45: Jump Starting

    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.
  • Page 46 HOW TO RIDE THE MOTORCYCLE • Connect a jumper cable from the rear brake pedal or other unpainted positive (+) terminal of the booster metal surface. Do not use the nega- battery to the positive (+) battery ca- tive (−) terminal of the battery.
  • Page 47: Moving Off

    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 •...
  • Page 48: 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 stops if the gear.
  • Page 49: 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 50 HOW TO RIDE THE MOTORCYCLE A. Front Brake Lever A. Rear Brake Pedal...
  • Page 51: 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 52: 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 53 HOW TO RIDE THE MOTORCYCLE • WARNING Lock the steering to help prevent theft. The muffler and exhaust pipe NOTE are very hot while the engine is ○ running and just after the engine When stopping near traffic at night, stops.
  • Page 54: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE Catalytic Converter WARNING This motorcycle is equipped with The muffler and exhaust pipe a catalytic converter in the exhaust are very hot while the engine is system. Platinum and rhodium in the running and just after the engine converter react with carbon monoxide stops.
  • Page 55 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 56: 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 Before changing lanes, look over helmet are strongly recommended.
  • Page 57 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.
  • Page 58: 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 59 SAFE OPERATION 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. No brake fluid leakage. Throttle ....... Throttle grip play 2 ∼ 3 mm (0.08 ∼ 0.12 in.). Clutch ......
  • Page 60: Additional Considerations For Off Road Operation

    SAFE OPERATION Additional Considerations for Off Road Operation Brakes: The importance of reliable brakes is obvious. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play.
  • Page 61: 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 62: 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 Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • K Air cleaner element - clean •...
  • Page 63 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Items) Every (0.6) (7.5) (12) (15) (20) (24) • • • • Fuel leak (fuel hose and year – pipe) - inspect •...
  • Page 64 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Items) Every (0.6) (7.5) (12) (15) (20) (24) Liquid cooled carburetor year (before winter) coolant filter - cleaning • • •...
  • Page 65 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) 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) Clutch and drive train: Clutch operation •...
  • Page 66 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 •...
  • Page 67 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 hose installation • • • • • • • year condition - inspect •...
  • Page 68 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) Uni-trak rocker arm bearings • – - lubricate • • • Uni-trak rocker arm operation –...
  • Page 69 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) Electrical system: • • • Lights and switches year – operation - inspect •...
  • Page 70 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever *Odometer Reading comes km × 1 000 (mile first × 1 000) Page Change/Replacement Items Every (0.6) (7.5) (15) (24) (30) K Air cleaner element # 2 year • • • • • year Engine oil # •...
  • Page 71 • • • • 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 72: 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 73 MAINTENANCE AND ADJUSTMENT CAUTION If the engine oil gets extremely low or if the oil pump or oil pas- sages clog up or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the en- gine speed is above 1 500 r/min (rpm), stop the engine immedi- ately and find the cause.
  • Page 74 MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • Set the motorcycle up on its side stand. • Remove the engine guard. A. Drain Plug • Let the oil completely drain with the motorcycle perpendicular to the ground. A. Engine Guard WARNING •...
  • Page 75 A. Cartridge • Apply a thin film of oil on the gasket NOTE and tighten the cartridge to the spec- ○ If a torque wrench is not available, ified torque. this item should be serviced by a Kawasaki dealer.
  • Page 76 MAINTENANCE AND ADJUSTMENT • Fill the engine up to the upper level Engine Oil Capacity with a good quality motor oil specified Capacity: 2.8 L (3.0 US qt) in the table. [when filter is not removed] • Start the engine. 3.0 L (3.2 US qt) •...
  • Page 77: Cooling System

    MAINTENANCE AND ADJUSTMENT Cooling System Radiator and Cooling Fan: Check the radiator fins for obstruc- tion by insects or mud. Clean off any obstructions with a stream of low-pressure water. WARNING The cooling fan turns on auto- matically, even with the ignition switch off.
  • Page 78 Check the Do not obstruct or deflect air- coolant level each day before riding the flow through the radiator by motorcycle, and replenish coolant if the installing unauthorized acces- level is low. Change the coolant in...
  • Page 79 MAINTENANCE AND ADJUSTMENT CAUTION jacket and radiator. This will clog up the coolant passages, and consider- If hard water is used in the sys- ably reduce the efficiency of the cooling tem, it causes scale accumula- system. tion in the water passages, and considerably reduces the effi- WARNING ciency of the cooling system.
  • Page 80 Permanent types of antifreeze on the market have anti-corrosion Coolant Level Inspection and anti-rust properties. When it • Situate the motorcycle so that it is is diluted excessively, it loses its perpendicular to the ground. anti-corrosion property. Dilute a •...
  • Page 81 D. L (Low) Mark bly leakage in the system. Have E. Left Side Cover the cooling system inspected • by your authorized Kawasaki If the amount of coolant is insuffi- dealer. cient, remove the left side cover, unscrew the cap from the reserve...
  • Page 82: Spark Plugs

    Before the winter season starts, have The standard spark plug is shown in the coolant filter cleaned by an autho- the table. The spark plugs should be rized Kawasaki dealer. replaced in accordance with the Peri- odic Maintenance Chart. Maintenance...
  • Page 83 MAINTENANCE AND ADJUSTMENT • ○ Carefully pull the spark plug cap from Fit the plug cap securely onto the the spark plug. spark plug, and pull the cap lightly to make sure that it is properly installed. Shroud Installation: Insert the projection to the hole and tighten the screws.
  • Page 84 ○ If a torque wrench is not available, A. 0.6 ~ 0.7 mm (0.024 ~ 0.028 in.) this item should be serviced by a Kawasaki dealer. CAUTION For cold weather and/or low speed riding, a hotter spark plug shown in the table may be used for quicker warm-ups and more efficient engine operation.
  • Page 85: Valve Clearance

    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 86: Air Cleaner

    MAINTENANCE AND ADJUSTMENT Air Cleaner Kawasaki Clean Air System A clogged air cleaner restricts the en- The Kawasaki Clean Air System gine’s air intake, increasing fuel con- (KCA) is a secondary air suction sys- sumption, reducing engine power, and tem that helps the exhaust gases to causing spark plug fouling.
  • Page 87: Throttle Grip

    Also, the throttle valves tion should be done by an authorized may not open fully at full throttle. On Kawasaki dealer. the other hand, if the throttle grip has no play, the throttle will be hard to con- trol, and the idle speed will be erratic.
  • Page 88 If the throttle cables can not be ad- proper amount of throttle grip play is justed by using the cable adjuster at obtained. the upper end of the throttle cable, grip, have it checked by an autho- rized Kawasaki dealer.
  • Page 89: Choke Lever

    • Check that the choke lever returns properly and that the inner cable slides smoothly. If there is any ir- regularity, have the choke cable checked by an authorized Kawasaki dealer. • Push the choke lever back all the way.
  • Page 90 MAINTENANCE AND ADJUSTMENT lever travel is the amount of cable play. A. Choke Lever B. 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Adjustment A. Starter Plunger Lever • B. Stater plunger Loosen the locknut at the upper of • the choke cable, and turn the ad- The proper amount of play is 2 ∼...
  • Page 91: Carburetors

    Maintenance Chart or whenever the idle speed is disturbed. The following procedure covers the idle speed adjustment. Carburetor syn- chronization should be done by an au- thorized Kawasaki dealer. NOTE A. Adjuster B. Locknut ○ Poor carburetor synchronization will •...
  • Page 92 MAINTENANCE AND ADJUSTMENT adjusted or incorrectly routed, or they may be damaged. Be sure to correct any of these conditions before riding. WARNING Operation with damaged cables could result in an unsafe riding condition. A. Idle Adjusting Screw • Open and close the throttle a few times to make sure that the idle speed does not change.
  • Page 93: Clutch

    MAINTENANCE AND ADJUSTMENT Clutch Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING To avoid serious burn, never touch a hot engine or exhaust pipe during clutch adjustment.
  • Page 94 MAINTENANCE AND ADJUSTMENT • Turn the adjuster so that the clutch lever will have 10 ∼ 20 mm (0.4 ∼ 0.8 in.) of 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- ble play to prevent clutch dis- A.
  • Page 95: Drive Chain

    A. Chain Slack • 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.
  • Page 96 MAINTENANCE AND ADJUSTMENT Drive Chain Slack 35 ∼ 45 mm (1.4 ∼ 1.8 in.) Standard Chain Slack Adjustment • Remove the cap on the cotter pin and end of locknut. • Loosen the left and right chain ad- juster locknuts. •...
  • Page 97 MAINTENANCE AND ADJUSTMENT NOTE the notch on the left wheel alignment ○ indicator should align with the same Wheel alignment also swing arm mark that the right indica- checked using the straightedge or tor notch aligns with. string method. WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condi-...
  • Page 98 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 •...
  • Page 99 MAINTENANCE AND ADJUSTMENT WARNING If the axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. • Check the rear brake (see the Brakes section). Wear Inspection • Remove the bolts to take off the chain A.
  • Page 100 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.
  • Page 101 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. Lubrication Lubrication is also necessary after riding through rain or on wet roads, or...
  • Page 102: Brakes

    1 mm (0.04 in.), replace both pads in the caliper as a set. Pad replacement should be done by an au- thorized Kawasaki dealer. A. Lining Thickness B. 1 mm (0.04 in.)
  • Page 103 MAINTENANCE AND ADJUSTMENT Disc Brake Fluid: Fluid Level Inspection • In accordance with the Periodic Main- With the front and rear brake fluid tenance Chart, inspect the brake fluid reservoirs held horizontal, the brake level in both the front and rear brake fluid level in the front brake fluid fluid reservoir and change the brake reservoir must be kept above the line...
  • Page 104 MAINTENANCE AND ADJUSTMENT A. Rear Brake Fluid Reservoir A. Front Brake Fluid Reservoir B. Upper Level Line B. Upper Level Line C. Lower Level Line • If the fluid level in each reservoir is WARNING lower than the lower level line, check Do not mix two brands of brake for fluid leaks in the brake lines, and fluid.
  • Page 105 Since it is dangerous to operate the motorcycle under such con- A. Reservoir ditions, have the brake checked B. Cap immediately by an authorized C.
  • Page 106: Brake Light Switches

    A. Brake Pedal the front brake is applied. • B. 10 mm (0.4 in.) If it does not, ask your authorized Kawasaki dealer to inspect the front • brake light switch. If it does not, adjust the rear brake •...
  • Page 107: Front Fork

    Periodic Maintenance Chart by be sure that the switch body an authorized Kawasaki dealer. does not turn during adjustment. A. Front Fork The standard air pressure in the front A.
  • Page 108 MAINTENANCE AND ADJUSTMENT • NOTE Park the vehicle on level ground. • ○ Take the air valve caps off the tops of Addition of air pressure is not rec- the fork legs. ommended since atmospheric pres- sure is the most suitable setting for all ranges of riding.
  • Page 109: Rear Shock Absorber

    A. Rear Shock Absorber The rear shock absorber can be ad- justed by changing the spring preload for various riding and loading condi- tions. If the spring action feels too soft or too stiff, have it adjusted by an au- thorized Kawasaki dealer.
  • Page 110: Wheels

    MAINTENANCE AND ADJUSTMENT • Wheels Make sure to install the air valve cap securely. Tires: Payload and Tire Pressure NOTE Failure to maintain proper inflation ○ Measure the tire pressure when the pressures or observe payload limits for tires are cold (that is, when the mo- your tires may adversely affect han- torcycle has not been ridden more dling and performance of your motorcy-...
  • Page 111 MAINTENANCE AND ADJUSTMENT and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90 % worn). So it is false economy and unsafe to use the tires until they are bald. •...
  • Page 112 MAINTENANCE AND ADJUSTMENT NOTE ○ Most countries may have their own regulations requiring a minimum tire tread depth; be sure to follow them. ○ Have the wheel balance inspected whenever a new tire is installed. WARNING To ensure safe handling and stability, use only the recom- A.
  • Page 113 MAINTENANCE AND ADJUSTMENT WARNING Standard Tire Front Size: 90/90-21 M/C 54S Use the same manufacturer’s DUNLOP TRAIL MAX tires on both front and rear Size: 90/90-21 54S wheels. METZELER ENDURO 3 SAHARA Size: 90/90-21 54H WARNING BRIDGESTONE TRAIL WING-101 New tires are slippery and may MICHELINE T66 cause loss of control and injury.
  • Page 114: 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 115 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 116 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 117 The charger will keep the battery fully ers. • charged until you are ready to re- Remove the seat. • install the battery in the motorcycle Remove the I.C igniter holder with I.C (see Battery Installation). igniter. CAUTION Never remove the sealing strip, or the battery can be damaged.
  • Page 118 MAINTENANCE AND ADJUSTMENT • Connect the capped wire to the (+) terminal, and then connect the black wire to the (−) terminal. NOTE ○ Install the battery in the reverse order of the Battery Removal. CAUTION Installing the (–) cable to the (+) A.
  • Page 119: Headlight Beam

    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.
  • Page 120 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 121: Fuses

    MAINTENANCE AND ADJUSTMENT Fuses Fuses are arranged in the junction box located inside the left side cover. The main fuse is mounted on the starter relay inside the right side cover. a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 122: 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 123 If needed, use a mild de- scratched. greaser to remove any oil or grease •...
  • Page 124 • tic, with a commercially available mo- Carefully ride your motorcycle at a slow speed and apply the brakes torcycle/automotive wax. Wax should several times. This helps dry the...
  • Page 125 Vinyl parts should be washed with the age the part’s finish. rest of the motorcycle, then treated with a vinyl treatment. The sidewalls of tires and other rub- Chrome and Aluminum...
  • Page 126 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 127: 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 Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
  • Page 128 STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions. Turn the ignition switch 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 129 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 130: 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 procedure.
  • Page 131: Location Of Labels

    LOCATION OF LABELS LOCATION OF LABELS 1. Brake Fluid (Front) 2. Brake Fluid (Rear) 3. Daily safety Checks 4. Engine Oil and Oil Filter 5. Rear Carrier/Warning...
  • Page 132 LOCATION OF LABELS 6. Important Drive Chain Information 7. Battery Poison/Danger...
  • Page 133 LOCATION OF LABELS...
  • Page 134 LOCATION OF LABELS...
  • Page 135 LOCATION OF LABELS...
  • Page 136 LOCATION OF LABELS...
  • Page 137 LOCATION OF LABELS...

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