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  • Page 3 GENERAL INFORMATION Quick Reference Guide HOW TO RIDE THE MOTORCYCLE This Quick Reference Guide will SAFE OPERATION assist you in finding the information you’re looking for. MAINTENANCE AND ADJUSTMENT STORAGE A Table of Contents is included after the Foreword.
  • Page 5 CAUTION Whenever you see the symbols shown below, heed their instructions! CAUTION indicates a hazardous Always follow safe operating and main- situation which, if not avoided, tenance practices. could result in minor or moder- ate injury. DANGER DANGER indicates a hazardous NOTICE situation which, if not avoided, will result in death or serious in-...
  • Page 7 (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 8 FOREWORD Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo- torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-...
  • Page 9 However, there may be minor differences between the actual product and illustra- tions and text in this manual. All products are subject to change without prior notice or obligation. KAWASAKI HEAVY INDUSTRIES, LTD. Consumer Products & Machinery Company © 2009 Kawasaki Heavy Industries, Ltd. Oct. 2009. (1). (M, Ke)
  • Page 10: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS....... 10 Engine Stop Switch ...... 34 LOCATION OF PARTS ....... 14 Starter Button ....... 35 LOADING AND ACCESSORIES Brake/Clutch Lever Adjusters... 35 INFORMATION ........ 17 Fuel Tank Cap ........37 GENERAL INFORMATION....20 Fuel Tank ......... 38 Meter Instruments ......
  • Page 11 Braking ..........60 Valve Clearance ....... 108 Anti-lock Brake System (ABS) for Kawasaki Clean Air System ..... 109 models equipped with ABS... 62 Air Cleaner ........110 ABS Indicator Light ....... 64 Throttle Control System ....111 Stopping the Engine......65 Engine Vacuum Synchronization ..
  • Page 12: Specifications

    SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Horsepower 47 kW (64 PS) @8 000 r/min (rpm) Maximum Torque 61 N·m (6.2 kgf·m, 45 ft·lb) @6 800 r/min (rpm) Minimum Turning Radius 2.7 m (8.9 ft) DIMENSIONS Overall Length 2 125 mm (83.7 in.) Overall Width 840 mm (33.1 in.) Overall Height...
  • Page 13 SPECIFICATIONS Displacement 649 cm (39.6 cu in.) Bore × Stroke 83.0 × 60.0 mm (3.3 × 2.4 in.) Compression Ratio 10.6:1 Starting System Electric starter Cylinder Numbering Method Left to right, 1-2 Firing Order Fuel System FI (Fuel Injection) Ignition System Battery and coil (transistorized ignition) 10°...
  • Page 14 SPECIFICATIONS 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) 1.714 (36/21) 1.333 (32/24) 1.111 (30/27) 0.966 (28/29) 0.852 (23/27)
  • Page 15 Low Beam 12 V 55 W Tail/Brake Light Even if one of LED (Light Emitting Diode) tail/brake light is not lit, consult with an authorized Kawasaki dealer. Specifications are subject to change without notice, and may not apply to every country.
  • Page 16: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 7. Spring Preload Adjuster (Front Fork) 2. Left Handlebar Switches 8. Rebound Damping Force Adjuster 3. Meter Instruments (Front Fork) 4. Ignition Switch/Steering Lock 9. Right Handlebar Switches 5. Brake Fluid Reservoir (Front) 10.
  • Page 17 LOCATION OF PARTS 1. Headlight/City Light 7. Seat 12. Brake Disc 2. Turn Signal Light 8. Helmet Holding Hook 13. Brake Caliper 3. Spark Plugs 9. Tool Kit/Storage 14. Front Fork 4. Air Cleaner Compartments 15. Shift Pedal 5. Main Fuse 10.
  • Page 18 LOCATION OF PARTS 1. License Plate Light 5. Rear Shock Absorber 10. Muffler 2. Tail/Brake Light 6. Spring Preload 11. Rear Brake Light 3. Rebound Damping Adjuster (Rear Shock Switch Force Adjuster (Rear Absorber) 12. Rear Brake Pedal Shock Absorber) 7.
  • Page 19: Loading And Accessories Information

    Kawasaki Parts Accessories, and accessories you add to your Kawasaki has no control over the motorcycle be genuine Kawasaki design or application of accessories. components. In some cases, improper installation or use of accessories, or motorcycle...
  • Page 20 LOADING AND ACCESSORIES INFORMATION in carrying cargo, passengers and/or 3. All baggage should be carried as in the fitting of additional accessories. low as possible to reduce the effect The following general guidelines have on the motorcycle center of gravity. been prepared to assist you in making Baggage weight should also be dis- your determinations.
  • Page 21 Kawasaki does not manu- (i.e., lean angle), control operation, facture sidecars or trailers for mo- wheel travel, front fork movement,...
  • Page 22: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Water Temperature Warning Indicator Light B. Oil Pressure Warning Indicator Light C. RESET Button D. Neutral Indicator Light E. MODE Button F. High Beam Indicator Light G. Left Turn Signal Indicator Light H. Tachometer I.
  • Page 23: Tachometer

    If the tachometer nee- cated in the tachometer face is used dle does not operate correctly, have it to display the Speedometer, Clock, inspected by an authorized Kawasaki Odometer, Trip Meter A/B, and Fuel dealer. Gauge. Pushing the MODE button...
  • Page 24: Digital Meter

    GENERAL INFORMATION Digital Meter A. Clock B. Odometer C. Trip Meter A D. Trip Meter B E. Push MODE Button NOTE ○ For safe operation do not press the A. Fuel Gauge MODE button while riding. B. Speedometer C. Clock, Trip Meter A/B, Odometer NOTE ○...
  • Page 25 GENERAL INFORMATION • mph·km/h Display - Display the odometer in the digital mph·km/h Display can alternate be- meter. • tween English and metric modes (mph The mph·km/h display shifts by push- and km/h) in the digital meter. Make ing the RESET button while the sure that mph or km/h is correctly dis- MODE button pushed in.
  • Page 26 GENERAL INFORMATION • • The mph·km/h display shifts as fol- Turn the ignition key to “ON”. • lows. Push the MODE button to display the clock. • Push the RESET button for more than two seconds. Both the hour and minute displays start flashing.
  • Page 27 GENERAL INFORMATION • Push the RESET button. The hour step by step. Pushing and hold- display stops flashing and the minute ing the button advance the hour or display starts flashing. Push the minute continuously. ○ MODE button to advance the min- The clock works normally from the utes.
  • Page 28 GENERAL INFORMATION NOTE ○ The data is maintained even if the battery is disconnected. ○ When the figures come to 999999, they are stopped and locked. Trip Meter - The trip meters show the distance in kilometers traveled since they were last reset to zero.
  • Page 29 GENERAL INFORMATION NOTE in the tank goes down, the segments ○ disappear one by one from F (full) to The data is maintained by the back E (empty). When only the most bot- -up power if the ignition key is turned tom segment is displayed, 5.0 L (1.3 off.
  • Page 30: Warning/indicator Lights

    GENERAL INFORMATION : When the headlight is on high beam, the high beam indicator light goes on. : When the turn signal switch is pushed to the left or right, the cor- responding turn signal indicator light flashes. : The oil pressure warning light goes on whenever the oil pressure is A.
  • Page 31 Prolonged DFI system checked by an authorized engine operation will result in Kawasaki dealer. When the indicator severe damage from overheat- light flashes, first turn the ignition key ing. to “OFF” and then back to “ON”.
  • Page 32: Key

    Motorcycle chapter. switch/steering lock, seat lock, and fuel tank cap. Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a master.
  • Page 33: 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 34: Left Handlebar Switches

    GENERAL INFORMATION ○ Left Handlebar Switches If you leave the P (Park) position on for a long time (one hour), the battery may become totally discharged. A. Dimmer Switch B. Turn Signal Switch C. Horn Button D. Passing Button E. Hazard Switch...
  • Page 35: Dimmer Switch

    GENERAL INFORMATION Dimmer Switch Horn Button High or low beam can be selected When the horn button is pushed, the with the dimmer switch. When the horn sounds. headlight is on high beam ( ), the Passing Button high beam indicator light goes on. When the passing button is pushed, High Beam···( the headlight high beam (passing...
  • Page 36: Right Handlebar Switches

    GENERAL INFORMATION NOTICE Right Handlebar Switches If you leave the switch on for a long time, the battery may be- come totally discharged. So be careful not to use the hazard lights for more than 30 minutes. A. Engine Stop Switch B.
  • Page 37: Starter Button

    GENERAL INFORMATION Brake/Clutch Lever Adjusters The engine stop switch is for emer- gency use. If some emergency re- There is an adjuster on both the quires stopping the engine, move the brake and clutch levers. Each adjuster has 5 positions so that the released engine stop switch to the position.
  • Page 38 GENERAL INFORMATION A. Adjuster A. Adjuster B. Mark B. Mark C. Brake Lever C. Clutch Lever...
  • Page 39: 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 40: Fuel Tank

    Never use gasoline with an octane rat- Do not use leaded gasoline, as ing lower than the minimum specified this will destroy the catalytic by Kawasaki to prevent severe engine converter (For further informa- damage. tion, refer to the “Catalytic Con- The octane rating of a gasoline is a verter”...
  • Page 41 GENERAL INFORMATION NOTICE Fuel Type and Octane Rating If engine “knocking” or “ping- (Except for Brazil and Thailand ing” occurs, use a different Specifications) Use clean, fresh unleaded gasoline brand of gasoline of a higher with an octane rating equal to or higher octane rating.
  • Page 42: Filling The Tank

    GENERAL INFORMATION Filling the Tank Fuel Type Unleaded Gasoline Avoid filling the tank in the rain or Ethanol where heavy dust is blowing so that the Content fuel does not get contaminated. (RON + MON) Antiknock Minimum Index Octane Rating (For Thailand Specification) Use clean, fresh unleaded gasoline with an octane rating equal to or higher...
  • Page 43 GENERAL INFORMATION NOTICE WARNING Gasoline is extremely flammable Southeast Asia and Thailand and can be explosive under cer- models only: tain conditions. Turn the igni- Never fill the tank so the fuel tion key to “OFF”. Do not smoke. level rises into the filler neck. If Make sure the area is well ven- the tank is overfilled, heat may tilated and free from any source...
  • Page 44: 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 45: Seat

    GENERAL INFORMATION Seat Seat Removal Insert the ignition key into the seat lock, located on the seat cover. Turn the key clockwise while pulling on the rear end of the seat. NOTE ○ If there is difficulty removing the seat, be sure to insert the key all the way and to push down strongly on the A.
  • Page 46 GENERAL INFORMATION • Seat Installation Push down the rear part of the seat Install the seat in the reverse order of until the lock clicks. • removal. Pull up the rear end of the seat to • Place the tabs into the matching slot make sure it is securely locked.
  • Page 47: Helmet Hooks

    GENERAL INFORMATION WARNING Helmet Hooks Helmets can be secured to the mo- Riding with helmets attached to torcycle using the helmet hooks located the hooks could cause an ac- under the seat. cident by distracting the oper- ator or interfering with normal vehicle operation.
  • Page 48: Tool Kit/u-shaped Lock Compartment

    GENERAL INFORMATION Tool Kit/U-Shaped Lock Compartment The tool kit is stored under the seat. The kit contains tools that can be help- ful in making roadside repairs, adjust- ments, and some maintenance proce- dures explained in this manual. Also, under the seat, there is a lock strap which can hold a U-shaped lock (not supplied).
  • Page 49: Rear View Mirror

    GENERAL INFORMATION NOTICE Rear View Mirror Rear View Mirror Adjustment Do not force to tighten and/or • Adjust the rear view mirror by slightly loosen the upper hexagonal moving only the mirror portion of the area with a pair of spanners assembly.
  • Page 50: Windshield

    GENERAL INFORMATION Windshield The windshield can be adjusted within 3 positions in height to suit the rider’s preference. Remove the bolts on the windshield. A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area C. Rear View Mirror A. Windshield B.
  • Page 51 GENERAL INFORMATION • Remove the wellnuts and rivets, and Windshield Position 1 install them in the positions to suit the rider’s preference. After adjust- ing, make sure to tighten all four bolts securely. A. Windshield B. Bolts C. Wellnuts D. Rivets A.
  • Page 52 GENERAL INFORMATION Windshield Position 2 Windshield Position 3 A. Windshield A. Windshield B. Bolts B. Bolts C. Wellnuts C. Wellnuts D. Rivets NOTE ○ Keep the uninstalled rivets in a safe place.
  • Page 53: Break-in

    BREAK-IN BREAK-IN The first 1 600 km (1 000 miles) 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 miles) 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

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Starting the Engine • Check that the engine stop switch is in the position. A. Neutral Indicator Light B. Ignition Switch C. ON Position NOTE A. Engine Stop Switch ○ The motorcycle is equipped with a B.
  • Page 56 HOW TO RIDE THE MOTORCYCLE NOTE the motorcycle, first turn the ignition ○ key to “OFF” and then back to “ON” The motorcycle is equipped with a before starting the engine. starter lockout switch. This switch is • designed so that the engine does not After the meter operation check, start if the transmission is in gear and leaving...
  • Page 57: Jump Starting

    HOW TO RIDE THE MOTORCYCLE NOTICE Jump Starting If your motorcycle battery is “run Do not let the engine idle longer down”, it should be removed and than five minutes, or engine charged. If this is not practical, a 12 overheating and damage may volt booster battery and jumper cables occur.
  • Page 58 HOW TO RIDE THE MOTORCYCLE DANGER Connecting Jumper Cables • Remove the seat (see Seat section Battery acid generates hydro- in the GENERAL INFORMATION gen gas which is flammable and chapter). explosive under certain con- • Make sure the ignition key is turned ditions.
  • Page 59 HOW TO RIDE THE MOTORCYCLE DANGER Batteries contain sulfuric acid that can cause burns and pro- duce hydrogen gas which is highly explosive. Do not make this last connection at the fuel system or battery. Take care not to touch the positive and nega- tive cables together, and do not lean over the battery when mak- A.
  • Page 60: Moving Off

    HOW TO RIDE THE MOTORCYCLE NOTICE Moving Off • Check that the side stand is up. Do not operate the starter con- • Pull in the clutch lever. tinuously for more than 5 sec- • Shift into 1st gear. onds or the starter will overheat •...
  • Page 61: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE NOTE Shifting Gears • ○ Close the throttle while pulling in the The motorcycle is equipped with a clutch lever. side stand switch. This switch is de- • Shift into the next higher or lower signed so that the engine does not gear.
  • Page 62: 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 63 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.
  • Page 64: Anti-lock Brake System (abs) For Models Equipped With Abs

    HOW TO RIDE THE MOTORCYCLE Anti-lock Brake System (ABS) must take the same care as with mo- for models equipped with torcycles not equipped with ABS. • ABS is not designed to shorten the ABS is designed to help prevent braking distance.
  • Page 65 HOW TO RIDE THE MOTORCYCLE WARNING may confuse the computers, which can extend braking distance. Use of non-recommended tires may cause malfunctioning of WARNING ABS and can lead to extended braking distance. The rider ABS cannot protect the rider could have an accident as a re- from all possible hazards and sult.
  • Page 66: Abs Indicator Light

    5 km/h (3.1 mph) the motorcycle starts moving. or below, you should have the ABS Remember that the ABS does not checked by an authorized Kawasaki function when the indicator light is on, dealer. but if the ABS fails, the conventional brake system still works normally.
  • Page 67: Stopping The Engine

    Stopping the Motorcycle in an • Emergency Close the throttle completely. • Shift the transmission into neutral. Your Kawasaki Motorcycle has been • Turn the ignition key to “OFF”. designed and manufactured to pro- • vide you optimum safety and conve- Support the motorcycle on a firm, nience.
  • Page 68: Parking

    HOW TO RIDE THE MOTORCYCLE Parking In an emergency situation such as • throttle failure, your vehicle may be Shift the transmission into neutral stopped by applying the brakes and and turn the ignition key to “OFF”. • disengaging the clutch. Once this Support the motorcycle on a firm, stopping procedure is initiated, the en-...
  • Page 69 HOW TO RIDE THE MOTORCYCLE WARNING WARNING The muffler and exhaust pipe Gasoline is extremely flammable are very hot while the engine is and can be explosive under cer- running and just after the engine tain conditions, creating the po- stops.
  • Page 70: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE • Catalytic Converter Lock the steering to prevent theft. This motorcycle is equipped with NOTE a catalytic converter in the exhaust ○ system. Platinum and rhodium in the When stopping near traffic at night, converter react with carbon monox- you can leave the taillight on for ide, hydrocarbons and nitrogen oxides greater visibility by turning the igni-...
  • Page 71 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 •...
  • Page 72: Safe Operation

    SAFE OPERATION SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a When riding always keep both helmet are strongly recommended. hands on the handlebars and both You should be aware of and verify feet on the footpegs.
  • Page 73 SAFE OPERATION In general your actions should When going down long slopes, be smooth as sudden acceleration, control vehicle speed by closing braking or turning may cause loss the throttle. Use the front and rear of control, especially when riding in brakes for auxiliary braking.
  • Page 74 SAFE OPERATION When quick acceleration is neces- Avoiding unnecessary weaving is sary as in passing, shift to a lower important to the safety of both the gear to obtain the necessary power. rider and other motorists. Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrevving.
  • Page 75: 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 76 SAFE OPERATION Fuel ......Adequate supply in tank, no leaks. Engine Oil ....Oil level between level lines. Tires ......Air pressure (when cold): Front 225 kPa (2.25 kgf/cm², 32 psi) Rear 250 kPa (2.50 kgf/cm², 36 psi) Install the air valve cap. Drive Chain ....
  • Page 77 SAFE OPERATION Electrical Equipment ... All lights (Headlight, City Light, Tail/Brake Lights, Turn Sig- nal Lights, License Plate Light, Warning/Indicator Lights) and horn work. Engine Stop Switch ..Stops engine. Side Stand ....Return to its fully up position by spring tension. Return spring not weak or not damaged.
  • Page 78: 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 79 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 80: Maintenance And Adjustment

    Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect or improper adjustment done by the owner.
  • Page 81: Emission Control Information

    MAINTENANCE AND ADJUSTMENT EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the United States Environmental Protection Agency.
  • Page 82 MAINTENANCE AND ADJUSTMENT 3. Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low perme- ation fuel hoses and a fuel tank. 3. Evaporative Emission Control System (Southeast Asia) Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere.
  • Page 83 Owner’s Manual at your own expense. The Kawasaki Limited Emission Control System Warranty requires that you re- turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty. Please read the warranty carefully, and keep it valid by complying with the owner’s...
  • Page 84: Periodic Maintenance Chart

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart 1. Periodic Inspection (Engine Related Items) Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation Every (Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • •...
  • Page 85: Frequency Whichever Comes First

    MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation Every (Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Fuel leak (fuel • • • • year – hose and pipe) - inspect Fuel hoses •...
  • Page 86 MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation Every (Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Radiator hose • • • • year damage - inspect Radiator hoses •...
  • Page 87: Every 42 000 Km (26 250 Mile)

    MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Clutch and drive train: Clutch operation (play, •...
  • Page 88 MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Drive chain • • • – guide wear - inspect Wheels and tires: •...
  • Page 89 MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Brake system: • • • • • • • Brake fluid leak year - inspect Brake hoses...
  • Page 90 MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Brake operation • • • • • • • (effectiveness, year play, drag) - inspect Brake light...
  • Page 91 MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) Front forks/rear • • • 133, year shock absorber oil leak - inspect Steering system: •...
  • Page 92 MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Operation (Chassis Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Items) • • • Headlight year aiming - inspect Side stand • •...
  • Page 93 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever *Odometer Reading comes first km × 1 000 (mile × 1 000) Page Every Change/Replacement Items (0.6) (7.5) (15) (22.5) (30) K Air cleaner element # - replace 2 years • • •...
  • Page 94 – 4 years dampers - replace K: Should be serviced by an authorized Kawasaki dealer. *: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
  • Page 95: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • In order for the engine, transmission, If the oil has just been changed, start and clutch to function properly, main- the engine and run it for several min- tain the engine oil at the proper level, utes at idle speed.
  • Page 96 MAINTENANCE AND ADJUSTMENT • • If the motorcycle has just been used, If the oil level is too high, remove the wait several minutes for all the oil to excess oil through the oil filler open- drain down. ing using a syringe or some other •...
  • Page 97 MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • Warm up the engine thoroughly, and then stop it. • Place an oil pan beneath the engine. • Remove the engine oil drain bolt. A. Oil Pressure Warning Indicator Light A. Drain Bolt •...
  • Page 98 • Remove the oil filter and replace it with a new one. NOTE A. Oil Filter ○ If a torque wrench or required Kawasaki special tool is not avail- able, this item should be serviced by a Kawasaki dealer.
  • Page 99 MAINTENANCE AND ADJUSTMENT • NOTE Apply a thin film of engine oil to the ○ packing and tighten the oil filter to the Replace the gasket with a new one. specified torque. Tightening Torque Tightening Torque Engine Oil Drain Bolt: Oil Filter: 30 N·m (3.1 kgf·m, 22 ft·lb) 17.5 N·m (1.8 kgf·m, 13 ft·lb)
  • Page 100 MAINTENANCE AND ADJUSTMENT provide adequate lubrication for both Although 10W-40 engine oil is the the engine and the clutch. recommended oil for most condi- tions, the oil viscosity may need to Engine Oil Capacity be changed to accommodate atmo- Capacity: spheric conditions in your riding area.
  • Page 101: Cooling System

    MAINTENANCE AND ADJUSTMENT NOTICE Cooling System Radiator and Cooling Fan - Using high-pressure water, as Check the radiator fins for obstruc- from a car wash facility, could tion by insects or mud. Clean off damage the radiator fins and im- any obstructions with a stream of pair the radiator’s effectiveness.
  • Page 102 MAINTENANCE AND ADJUSTMENT Coolant - period of time, the cooling system ac- Coolant absorbs excessive heat from cumulates rust and scale in the water the engine and transfers it to the air jacket and radiator. This will clog up at the radiator. If the coolant level be- the coolant passages, and consider- comes low, the engine overheats and ably reduce the efficiency of the cooling...
  • Page 103 MAINTENANCE AND ADJUSTMENT NOTICE NOTICE If hard water is used in the sys- Permanent types of antifreeze on tem, it causes scale accumula- the market have anti-corrosion tion in the water passages, and and anti-rust properties. When it considerably reduces the effi- is diluted excessively, it loses its ciency of the cooling system.
  • Page 104 MAINTENANCE AND ADJUSTMENT NOTE Coolant Level Inspection • ○ Situate the motorcycle so that it is Check the level when the engine is perpendicular to the ground. cold (room or atmospheric tempera- • Check the coolant level through the ture). coolant level gauge on the reserve •...
  • Page 105 MAINTENANCE AND ADJUSTMENT • Coolant Filling Remove the bolts. • • Remove the seat (see Seat section Clear the projections from the grom- in the GENERAL INFORMATION mets, and remove the right middle chapter). fairing forward. • Remove the screw. •...
  • Page 106 If coolant must be added of- ten, or the reserve tank com- pletely runs dry, there is proba- bly leakage in the system. Have the cooling system inspected by your authorized Kawasaki dealer. • A. Reserve Tank Install the cap.
  • Page 107 MAINTENANCE AND ADJUSTMENT • • Install the right middle fairing as fol- Install the right side cover as follows. • lows. Fit the projections to the slots. • • Fit the projections to the slots. Fit the projections to the grommets. •...
  • Page 108: Spark Plugs

    Kawasaki dealer. the table. The spark plugs should be replaced in accordance with the Peri- odic Maintenance Chart. Spark plug removal should be done by an authorized Kawasaki dealer. Spark Plug Standard Plug NGK CR9EIA-9 0.8 ∼ 0.9 mm Plug Gap (0.031 ∼...
  • Page 109: Evaporative Emission Control System (southeast Asia Model Only)

    MAINTENANCE AND ADJUSTMENT Evaporative Emission Control System (Southeast Asia model only) This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no ad- justments are required, a thorough vi- sual inspection must be made at the in- tervals specified by the Periodic Main- tenance Chart.
  • Page 110: 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 111: Kawasaki Clean Air System

    MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System the air suction valve is prevented from The Kawasaki Clean Air System returning. Inspect the air suction valve (KCA) is a secondary air suction sys- in accordance with the Periodic Main- tem that helps the exhaust gases to tenance Chart.
  • Page 112: Air Cleaner

    In dusty, rainy, or muddy conditions, the air cleaner element should be serviced more frequently than the recom- mended interval by an authorized Kawasaki dealer. A. Drain Hose B. Plug • If there is any oil in the hose, remove the plug from the lower end of the drain hose and drain the oil.
  • Page 113: Throttle Control System

    MAINTENANCE AND ADJUSTMENT WARNING Throttle Control System Check the throttle grip play in accor- Oil on tires will make them slip- dance with the Periodic Maintenance pery and can cause an accident Chart, and adjust it if necessary. and injury. Be sure to install the plug in the drain hose after drain- Throttle Grip - ing.
  • Page 114 MAINTENANCE AND ADJUSTMENT Inspection Adjustment • • Check that the throttle grip play is Loosen the locknut at the upper end correct by lightly turning the throttle of the throttle cable, and turn the grip back and forth. throttle cable adjuster in completely so as to give the throttle grip plenty of play.
  • Page 115 MAINTENANCE AND ADJUSTMENT • • If the throttle grip play cannot be ad- Turn out the accelerator cable ad- juster until a play of 2 ∼ 3 mm (0.08 justed with the accelerator cable ad- ∼ 0.12 in.) is obtained at the throttle juster at the throttle grip, use the de- celerator cable adjuster located un- grip.
  • Page 116: Engine Vacuum Synchronization

    Peri- ically in accordance with the Periodic odic Maintenance Chart or whenever Maintenance Chart by an authorized the idle speed is disturbed. Kawasaki dealer. Adjustment • NOTE Start the engine, and warm it up thor- ○...
  • Page 117 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. Replace damaged control cables before operation. A.
  • Page 118: Clutch

    Check that the clutch lever operates properly and that the inner cable slides smoothly. If there is any irreg- ularity, have the clutch cable checked by an authorized Kawasaki dealer. A. Locknut B. Clutch Lever Play C. Adjuster Clutch Lever Play 2 ∼...
  • Page 119 MAINTENANCE AND ADJUSTMENT • Adjustment Loosen the locknut, and turn the adjuster so that the clutch lever will WARNING have the proper play. • If it cannot be done, use the nuts at Excess clutch cable play could the lower end of the clutch cable. prevent clutch disengagement and cause a crash resulting in serious injury or death.
  • Page 120 MAINTENANCE AND ADJUSTMENT WARNING DANGER To avoid a serious burn, never Exhaust gas contains carbon touch a hot engine or an exhaust monoxide, a colorless, odor- pipe during clutch adjustment. less poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. NOTE DO NOT run the engine in en- ○...
  • Page 121: Drive Chain

    MAINTENANCE AND ADJUSTMENT Drive Chain Chain Slack Inspection • The drive chain slack and lubrica- Set the motorcycle up on its side tion must be checked each day be- stand. • fore riding the motorcycle, and in accor- Rotate the rear wheel to find the po- dance with the Periodic Maintenance sition where the chain is tightest, and Chart for safety and to prevent exces-...
  • Page 122 MAINTENANCE AND ADJUSTMENT • If the drive chain is too tight or too Chain Slack Adjustment • loose, adjust it so that the chain slack Remove the cotter pin, and loosen will be within the standard value. the rear axle nut. •...
  • Page 123 MAINTENANCE AND ADJUSTMENT • If the chain is too tight, turn in the left and right chain adjusters evenly. • Turn out both chain adjusters evenly until the drive chain has the cor- rect amount of slack. To keep the chain and wheel properly aligned, the notch on the left wheel alignment indicator should align with the same...
  • Page 124 Tighten the rear axle nut to the spec- ified torque. Tightening Torque Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb) A. Cotter Pin NOTE ○ If a torque wrench is not available, this item should be serviced by a Kawasaki dealer.
  • Page 125 MAINTENANCE AND ADJUSTMENT WARNING NOTE ○ When inserting the cotter pin, if the A loose axle nut can lead to an slots in the nut do not align with accident resulting in serious in- the cotter pin hole in the axle shaft, jury or death.
  • Page 126 MAINTENANCE AND ADJUSTMENT Wear Inspection center of the 1st pin to the pin center • Remove the bolts to take off the chain of the 21st pin. Since the chain may cover. wear unevenly, take measurements at several places. • If the length exceeds the service limit, the chain should be replaced.
  • Page 127 Also inspect the sprockets for un- A. Good Teeth evenly or excessively worn teeth, B. Worn Teeth and damaged teeth. C. Damaged Teeth • If there is any irregularity, have the drive chain and/or the sprockets re- placed by an authorized Kawasaki dealer.
  • Page 128 MAINTENANCE AND ADJUSTMENT • Lubrication Apply oil to the sides of the rollers so Lubrication is also necessary after that it will penetrate to the rollers and riding through rain or on wet roads, or bushings. Apply oil to the O-rings so any time that the chain appears dry.
  • Page 129: 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. NOTICE Do not spill brake fluid onto any painted surface.
  • Page 130 MAINTENANCE AND ADJUSTMENT Fluid Level Inspection • The brake fluid level in the front brake fluid reservoir must be kept above the line (lower level line) next to the gauge and that in the rear brake fluid reservoir (located under the seat) must be kept between the upper and lower level lines (reservoirs held hor- izontal).
  • Page 131 MAINTENANCE AND ADJUSTMENT • WARNING If the fluid level in either reservoir is lower than the lower level line, check Mixing brands and types of for fluid leaks in the brake lines, and brake fluid can reduce the brake fill the reservoir to the upper level system’s effectiveness line.
  • Page 132 Have the brake C. Clockwise checked immediately by an au- D. 1/6 turn thorized Kawasaki dealer. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Front and Rear Brakes - Disc and disc pad wear is automat- ically compensated for and has no ef- fect on the brake lever or pedal action.
  • Page 133: Brake Light Switches

    • The brake light should go on when the front brake is applied. • If it does not, ask an authorized Kawasaki dealer to inspect the front brake light switch. A. Brake Pedal B. 10 mm (0.39 in.) • If it does not, adjust the rear brake light switch.
  • Page 134 MAINTENANCE AND ADJUSTMENT • Adjustment To adjust the rear brake light switch, • Disconnect the connector. move the switch up or down by turn- ing the switch body. A. Connector A. Rear Brake Light Switch B. Adjusting Nut C. Lights sooner D.
  • Page 135: Front Fork

    Visually inspect the front fork for oil leakage, scoring or scratches on the A. Inner Tube outer surface of the inner tube. • If there is any doubt about the front fork, it should be checked by an au- thorized Kawasaki dealer.
  • Page 136 MAINTENANCE AND ADJUSTMENT On the top of each front fork leg is Spring Preload Adjustment • a spring preload adjuster and on the Turn the spring preload adjuster into spring preload adjuster of the right the nut to increase spring force and front fork leg is a rebound damping out to decrease spring force.
  • Page 137 MAINTENANCE AND ADJUSTMENT Spring Preload 7 turns out* Adjuster Rebound Damping Force 1 3/4 turns out* Adjuster *: Counterclockwise from the fully seated position NOTICE Do not force to turn the rebound A. Screwdriver B. Rebound Damping Force Adjuster damping force adjuster from the fully seated position, as the ad- The standard setting positions of the justing mechanism may be dam-...
  • Page 138: Rear Shock Absorber

    If there is any doubt about the rear The rear shock absorber operation shock absorber, it should be checked and oil leakage should be checked in by an authorized Kawasaki dealer. accordance with the Periodic Mainte- nance Chart. Rear Shock Absorber Inspection •...
  • Page 139 MAINTENANCE AND ADJUSTMENT NOTICE Be careful not to damage the motorcycle parts when adjust- ing the spring preload. Rebound Damping Force Adjustment The rebound damping force adjuster is located at the lower end of the rear shock absorber. A. Spring Preload Adjuster B.
  • Page 140: Wheels

    MAINTENANCE AND ADJUSTMENT • Wheels Turn the rebound damping force ad- juster towards the H mark to make Tubeless tires are installed on the the damping force greatest. wheels of this motorcycle. The indica- • Turn the adjuster towards the S mark tions of TUBELESS on the tire side wall to decrease damping force.
  • Page 141 MAINTENANCE AND ADJUSTMENT WARNING Installing a tube inside a tube- less-type tire can create exces- sive heat build up that can dam- age the tube and cause rapid deflation. The tires, rims, and air valves on this motorcycle are designed only for tubeless type wheels.
  • Page 142 MAINTENANCE AND ADJUSTMENT ○ Tires - Tire pressure is affected by changes in ambient temperature and altitude, Payload and Tire Pressure and so the tire pressure should be Failure to maintain proper inflation checked and adjusted when your rid- pressures or observe payload limits for ing involves wide variations in tem- your tires may adversely affect han- perature or altitude.
  • Page 143 MAINTENANCE AND ADJUSTMENT • Tire Wear, Damage In accordance with the Periodic As the tire tread wears down, the tire Maintenance Chart, measure the becomes more susceptible to puncture depth of the tread with a depth and failure. An accepted estimate is gauge, and replace any tire that that 90% of all tire failures occur during has worn down to the minimum al-...
  • Page 144 MAINTENANCE AND ADJUSTMENT WARNING Minimum Tread Depth 1 mm Tires that have been punctured — Front (0.04 in.) and repaired do not have the Under 130 km/h 2 mm same capabilities as undam- (80 mph) (0.08 in.) aged tires and can suddenly fail, Rear causing an accident resulting Over 130 km/h...
  • Page 145 MAINTENANCE AND ADJUSTMENT ○ When operating on public roadways, Replacement Tire (Tubeless) KLE650C Model only keep maximum speed under traffic law limits. Make, Type: PIRELLI, SCORPION Standard Tire (Tubeless) Front SYNC FRONT Make, Type: Size: DUNLOP, SPORTMAX 120/70 ZR17 M/C (58W) Front RADIAL D221FAG Make, Type:...
  • Page 146: Battery

    MAINTENANCE AND ADJUSTMENT WARNING Battery The battery installed in this motorcy- New tires are slippery and may cle is a sealed type, so it is not nec- cause loss of control and injury. essary to check the battery electrolyte A break-in period of 160 km (100 level or add distilled water.
  • Page 147 MAINTENANCE AND ADJUSTMENT type of battery and ambient temper- Self-discharge ature. As temperature rises, so does Approx. number of days the discharge rate. Every 15°C (27°F) from 100% charged to doubles the rate. 100% discharged Tempera- Electrical accessories, such as digi- ture Lead Lead...
  • Page 148 If it drops battery can withstand sub-freezing below 12.8 volts, the battery should be temperature with no damage. charged using an appropriate charger Battery Sulfation - (check with a Kawasaki dealer). A common cause of battery failure is sulfation.
  • Page 149 Do not install a conventional If the above chargers are not avail- battery in this motorcycle, or the able, use equivalent one. electrical system cannot work For more details, ask a Kawasaki properly. dealer. Battery Charging - NOTE •...
  • Page 150 MAINTENANCE AND ADJUSTMENT • Battery Removal Clean the battery using a solution of • Remove the seat (see Seat section baking soda and water. Be sure that in the GENERAL INFORMATION the cable connections are clean. chapter). • Battery Installation Slide the red cap.
  • Page 151: 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 152: Fuses

    MAINTENANCE AND ADJUSTMENT NOTE Fuses ○ Fuses are arranged in the fuse box On high beam, the brightest point located under the seat. The main fuse should be slightly below horizontal is mounted on the starter relay behind with the motorcycle on its wheels and the left side cover.
  • Page 153 MAINTENANCE AND ADJUSTMENT • • Remove the bolt. Remove the cover by removing the • Clear the projections from the grom- bolt. mets, and remove the left frame cover upward. A. Cover B. Bolt A. Left Frame Cover B. Bolt C.
  • Page 154 MAINTENANCE AND ADJUSTMENT • • Disconnect the connector. Install the left frame cover as follows. • Fit the projection to the slot. • Fit the projections to the grommets. • Tighten the bolt. A. Main Fuse B. Spare Fuse C. Connector A.
  • Page 155 MAINTENANCE AND ADJUSTMENT WARNING Substituting fuses can cause wiring to overheat, catch fire and/or fail. Do not use any sub- stitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse box and main fuse.
  • Page 156: Cleaning Your Motorcycle

    General Precautions plastic surfaces: wash them off im- Frequent and proper care of your mediately. Kawasaki motorcycle will enhance • Avoid wire brushes, steel wool, and its appearance, optimize overall per- all other abrasive pads or brushes.
  • Page 157 MAINTENANCE AND ADJUSTMENT • Washing Your Motorcycle After cleaning your motorcycle, • Rinse your bike with cold water from check the rubber boot covering the a garden hose to remove any loose shift pedal ball joint for correct instal- dirt. lation.
  • Page 158 MAINTENANCE AND ADJUSTMENT • If the boot is damaged, replace it with several times. This helps the brakes a new one. If the boot is not posi- dry and restores its normal operating tioned in the groove correctly, place performance. •...
  • Page 159 MAINTENANCE AND ADJUSTMENT headlight. Gradually the condensa- an approved plastic cleaner/polisher tion on the inside of the lens will clear product. off. NOTICE Painted Surfaces Plastic parts may deteriorate After washing your motorcycle, coat and break if they come in con- painted surfaces, both metal and plas- tact with chemical substances tic, with a commercially available mo-...
  • Page 160 MAINTENANCE AND ADJUSTMENT Chrome and Aluminum Vinyl parts should be washed with the Chrome and uncoated aluminum rest of the motorcycle, then treated with parts can be treated with a chrome/alu- a vinyl treatment. minum polish. Coated aluminum The sidewalls of tires and other rub- should be washed with a mild neu- ber components should be treated with tral detergent and finished with a spray...
  • Page 161: Storage

    STORAGE STORAGE Preparation for Storage • Clean the entire vehicle thoroughly. • Run the engine for about five minutes to warm the oil, shut it off, and drain the engine oil. WARNING Motorcycle oil is a toxic substance. Dispose of used oil properly. Con- tact your local authorities for approved disposal methods or possible re- cycling.
  • Page 162 STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. Turn the ignition key to “OFF”. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 163 STORAGE • Put a cover over the motorcycle to keep dust and dirt from accumulating on it. Preparation after Storage • Remove the plastic bags from the muffler. • Install the battery in the motorcycle and charge the battery if necessary. •...
  • Page 164: 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 165: Location Of Labels

    LOCATION OF LABELS LOCATION OF LABELS *1. Unleaded Gasoline **2. Fuel Level 3. Brake Fluid (Front) 4. Brake Fluid (Rear) *: Except for Brazil, Southeast Asia, Malaysia and Australia models **: only on Southeast Asia model...
  • Page 166 LOCATION OF LABELS 5. Daily Safety Checks 6. Tire and Load Data 7. Important Drive Chain Informa- tion *8. Noise Emission Control Informa- tion 9. Battery Poison/Danger *: only on Australia model...
  • Page 167 LOCATION OF LABELS *10. Vacuum Hose Routing Diagram *: only on Southeast Asia model...
  • Page 168 LOCATION OF LABELS (1) Except for Brazil, Southeast Asia, Malaysia and Australia models (2) only on Southeast Asia model...
  • Page 169 LOCATION OF LABELS...
  • Page 170 LOCATION OF LABELS...
  • Page 171 LOCATION OF LABELS...
  • Page 172 LOCATION OF LABELS (8) only on Australia model...
  • Page 173 LOCATION OF LABELS...
  • Page 174 LOCATION OF LABELS (10) only on Southeast Asia model...

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