GENERAL INFORMATION Quick Reference Guide HOW TO RIDE THE MOTORCYCLE This Quick Reference Guide will SAFE OPERATION assist you in finding the information you’re looking for. MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE A Table of Contents is included after the Foreword.
NOTICE Whenever you see the symbols shown below, heed their instructions! NOTICE is used to address prac- Always follow safe operating and main- tices not related to personal in- tenance practices. jury. DANGER NOTE DANGER indicates a hazardous ○ NOTE indicates information that may situation which, if not avoided, help or guide you in the operation or will result in death or serious in-...
NOTICE WARNING Engine exhaust, some of its THIS PRODUCT BEEN constituents, and certain vehi- MANUFACTURED FOR USE IN A cle components contain or emit REASONABLE AND PRUDENT chemicals known to the State of MANNER BY A QUALIFIED OP- California to cause cancer and ERATOR AND AS A VEHICLE birth defects or other reproduc- ONLY.
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-...
TABLE OF CONTENTS SPECIFICATIONS....... Fuel Tank Cap ........31 SERIAL NUMBER LOCATIONS..12 Fuel Tank ......... 32 LOCATION OF PARTS ....... 13 Fuel Tap ........... 36 LOCATION OF LABELS..... 16 Stand..........38 LOADING INFORMATION....20 Helmet Hook ........39 GENERAL INFORMATION....23 Rear Carrier ........
Fuses ..........145 Evaporative Emission Control General Lubrication......146 System (California model only)..99 Cleaning Your Motorcycle ....149 Kawasaki Clean Air System ..... 100 Bolt and Nut Tightening....154 Valve Clearance ....... 101 STORAGE........... 156 Air Cleaner ........102 TROUBLESHOOTING GUIDE....
SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts.
LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 5. Right Handlebar Switches 2. Left Handlebar Switches 6. Front Brake Lever 3. Meter Instruments 7. Throttle Grip 4. Brake Fluid Reservoir (Front) 8. Ignition Switch/Steering Lock...
LOCATION OF PARTS 9. Turn Signal Light 15. Tool Kit/Storage 20. Brake Caliper 10. Headlight Compartments 21. Shift Pedal 11. Spark Plugs 16. Helmet Hook 22. Side Stand 12. Main Fuse 17. Tying Hooks 23. Rear Shock Absorber 13. Battery 18.
LOCATION OF PARTS 25. Tail/Brake Light 29. Fuel Tank 33. Rear Brake Pedal 26. Rear Carrier 30. Fuel Tank Cap 34. Oil Level Inspection 27. Brake Fluid Reservoir 31. Muffler Window (Rear) 32. Rear Brake Light 35. Idle Adjusting Screw 28.
Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct posi- tion. NOTE 1.
LOCATION OF LABELS 2. Brake Fluid (Rear) 3. Tire and Load Data 4. Important Drive Chain Information...
LOCATION OF LABELS 5. Vehicle Emission Control Information 6. Noise Emission Control Information *7. Vacuum Hose Routing Diagram 8. Battery Vent Hose 9. Radiator Cap Danger 10. Weight and Manufacture *: only on California model...
LOCATION OF LABELS 11. Carrier Caution 12. Battery Poison/Danger *13. Fuel Level *: only on California model...
Kawasaki Kawasaki Parts Accessories, components. Kawasaki has no control over the design or application of accessories. Because a motorcycle is sensitive to In some cases, improper installation changes in weight and aerodynamic forces, you must take extreme care...
LOADING INFORMATION 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. tributed equally on both sides of the 1. Any passenger should be thor- motorcycle.
LOADING INFORMATION affected any lighting components, be used to tow any trailer or other road clearance, banking capability vehicle. Kawasaki does not manu- (i.e., lean angle), control operation, facture sidecars or trailers for mo- wheel travel, front fork movement, torcycles and cannot predict the ef-...
GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Tachometer B. Red Zone C. Speedometer D. Odometer E. Coolant Temperature Gauge F. Neutral Indicator Light G. Trip RESET Button H. Trip Meter I. High Beam Indicator Light J. Turn Signal Indicator Light...
GENERAL INFORMATION NOTICE 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.
GENERAL INFORMATION NOTICE This motorcycle has a combination Do not let the engine continue key, which is used for the ignition running when the gauge needle switch/steering lock, seat lock, helmet reaches the “H” line. Prolonged hook and fuel tank cap. engine operation will result in Included with the key is a key num- severe damage from overheat-...
If the key number is lost completely, you will need to replace the ignition switch and all other locks operated by that key. Contact your Kawasaki dealer to pur- A. Ignition Key chase additional spare keys either us- B. Tag ing your original key as a master or us- C.
GENERAL INFORMATION Ignition Switch/Steering Lock Engine off. All electrical This is a three-position, key-operated circuits off. switch. The key can be removed from Engine on. All electrical the switch when it is in the OFF or equipment can be used. LOCK position.
GENERAL INFORMATION Right Handlebar Switches NOTE ○ Engine Stop Switch: Although the engine stop switch In addition to the ignition switch, stops the engine, it does not turn off the engine stop switch must be in all the electrical circuits. Ordinarily, position for the motorcycle to the ignition switch should be used to operate.
GENERAL INFORMATION Left Handlebar Switches Starter Button: The starter button operates the elec- Dimmer Switch: tric starter when the transmission is in High or low beam can be selected neutral. with the dimmer switch. When the Refer to the Starting the Engine sec- headlight is on high beam ( ), the tion of the "How to Ride the Motorcycle"...
GENERAL INFORMATION NOTE Turn Signal Switch: ○ When the turn signal switch is turned When the headlight is on high beam, both head lights are lit. When the to the left ( ) or right ( ), the headlight is on low beam, only one corresponding turn signal flashes on and off.
GENERAL INFORMATION Fuel Tank Cap NOTE ○ To open the fuel tank cap, insert the Do not push on the key to close the ignition key into the fuel tank cap and cap, or the cap cannot be locked. turn the key to the right. To close the cap, push it down into place with the key inserted.
GENERAL INFORMATION Fuel Tank WARNING Avoid filling the tank in the rain or Gasoline is extremely flammable where heavy dust is blowing so that the and can be explosive under cer- fuel does not get contaminated. tain conditions. Turn the igni- tion key to “OFF”.
GENERAL INFORMATION NOTICE The Antiknock Index is posted on ser- vice station pumps. The octane rating California models only: Never of a gasoline is a measure of its resis- fill the tank so the fuel level rises tance to detonation or “knocking”. The into the filler neck.
GENERAL INFORMATION NOTICE Fuels Containing Oxygenates Gasoline frequently contains oxy- If engine “knocking” or “ping- genates (alcohols and ethers) espe- ing” occurs, use a different cially in areas of the U.S. and Canada brand of gasoline of a higher which are required to sell such refor- octane rating.
When operating your in unleaded gasoline include TAME Kawasaki for 30 to 60 days, mix a (up to 16.7 %) and ETBE (up to fuel stabilizer (such as STA-BIL) 17.2%). Fuel containing these oxy- with the gasoline in the fuel tank.
GENERAL INFORMATION NOTICE Fuel Tap The fuel tap has three positions: ON, Never store this product with RES (reserve), and OFF. For normal “gasohol” in the fuel system. operation, turn the tap lever to the ON Before storage it is recom- position.
GENERAL INFORMATION Turn the fuel tap lever to the OFF po- WARNING sition when the fuel tank is removed for Practice operating the fuel tap maintenance and adjustments or the with the motorcycle stopped. To motorcycle is stored for long time. prevent an accident you should NOTE be able to operate the fuel tap...
GENERAL INFORMATION Stand Do not sit on the motorcycle while it is The motorcycle is equipped with a on its side stand. Always kick the stand side stand. fully up before sitting on the motorcycle. NOTE ○ The motorcycle is equipped with a side stand switch.
GENERAL INFORMATION Helmet Hook Helmet can be secured to the motor- cycle using the 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 Riding with a helmet attached to the hook could cause an acci- dent by distracting the operator A.
GENERAL INFORMATION Rear Carrier WARNING The motorcycle is equipped with a Overloading the motorcycle and carrier on the rear. failure to adjust speed for addi- tional cargo could result in loss Vehicle Total Payload 182 kg (401 of control and an accident re- (must not exceed).
GENERAL INFORMATION Tool Kit Container/Tool Kit Tying Hooks The tool kit container is located on When tying up light loads to the rear the rear carrier, use the container to carrier, use the tying hooks located un- keep the tool kit that should be kept with der the rear carrier.
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.
BREAK-IN WARNING New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. During break-in, avoid sudden and maximum braking and acceleration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner have the initial maintenance service performed by a competent mechanic following the procedures in the Service Manual.
HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Starting the Engine • Turn the fuel tap lever to the ON po- sition. • Check that the engine stop switch is in the position. • Turn the ignition key to “ON”. •...
HOW TO RIDE THE MOTORCYCLE • NOTE Leaving throttle completely ○ closed, push the starter button with When the engine is already warm or the clutch lever pulled in until the on hot days (35°C, 95°F or more), engine starts. open the throttle part way instead of using the choke, and then start the NOTICE...
HOW TO RIDE THE MOTORCYCLE • NOTE Gradually return the choke lever to- ○ ward the off position a little at a time If the engine is flooded, crank the en- as necessary to keep the engine gine over with the throttle fully open speed below 2 000 r/min (rpm) dur- until the engine starts.
HOW TO RIDE THE MOTORCYCLE Jump Starting Ambient choke off after If your motorcycle battery is “run temperature running for down”, it should be removed and 20°C (68°F) ∼ 35°C 15 seconds charged. If this is not practical, a 12 (95°F) volt booster battery and jumper cables may be used to start the engine.
HOW TO RIDE THE MOTORCYCLE DANGER Connecting Jumper Cables • Remove the left and right side cover Battery acid generates hydro- by unscrew the bolts. gen gas which is flammable and explosive under certain con- ditions. It is present within a battery at all times, even in a discharged condition.
HOW TO RIDE THE MOTORCYCLE • • Unscrew the bolt on both side and Connect a jumper cable from the remove the seat. positive (+) terminal of the booster battery to the positive (+) terminal of the motorcycle battery. A. Seat B.
HOW TO RIDE THE MOTORCYCLE booster battery to your motorcy- DANGER cle footpeg or other unpainted metal Batteries contain sulfuric acid surface. Do not use the negative (–) that can cause burns and pro- terminal of the battery. duce hydrogen gas which is highly explosive.
HOW TO RIDE THE MOTORCYCLE NOTICE NOTE ○ To fix the seat, place the slot into the Do not operate the starter con- tab. tinuously for more than 5 sec- onds or the starter will overheat and the battery power will drop temporarily.
HOW TO RIDE THE MOTORCYCLE Moving Off NOTE • ○ Check that the side stand is up. The motorcycle is equipped with a • Pull in the clutch lever. side stand switch. This switch is de- • Shift into 1st gear. signed so that the engine does not •...
HOW TO RIDE THE MOTORCYCLE Shifting Gears WARNING • Close the throttle while pulling in the Downshifting to a lower gear at clutch lever. high speed causes engine rpm • Shift into the next higher or lower to increase excessively, poten- gear.
HOW TO RIDE THE MOTORCYCLE • Braking For emergency braking, disregard • downshifting, and concentrate on Close the throttle completely, leav- ing the clutch engaged (except when applying the brakes as hard as pos- shifting gears) so that the engine will sible without skidding.
HOW TO RIDE THE MOTORCYCLE Stopping the Engine • Close the throttle completely. • Shift the transmission into neutral. • Turn the ignition key to “OFF”. • Support the motorcycle on a firm, level surface with the side stand. • Lock the steering.
Stopping the Motorcycle in an 2. During removal of the air cleaner, Emergency dirt is allowed to enter and jam the Your Kawasaki Motorcycle has been carburetor. designed and manufactured to pro- In an emergency situation such as vide you optimum safety and conve- throttle failure, your vehicle may be nience.
HOW TO RIDE THE MOTORCYCLE Parking WARNING The engine and exhaust system WARNING get extremely hot during normal Operating or parking the vehi- operation and can cause serious cle near flammable materials can burns. cause a fire, and can result in Never touch a hot engine, ex- property damage or severe per- haust pipe, or muffler during op-...
HOW TO RIDE THE MOTORCYCLE Catalytic Converter and the motorcycle is not close to any source of flame or sparks; this This motorcycle is equipped with a includes any appliance with a pilot catalytic converter in the exhaust sys- light. tem.
HOW TO RIDE THE MOTORCYCLE • WARNING Use only unleaded gasoline. Never use leaded gasoline. Leaded gaso- Operating or parking the vehi- line significantly reduces the capabil- cle near flammable materials can ity of the catalytic converter. cause a fire, and can result in •...
HOW TO RIDE THE MOTORCYCLE NOTICE In order to protect the emission control parts, do not turn off the ignition switch when the motor- cycle is in motion.
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 Gloves suitable...
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.
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.
SAFE OPERATION Daily Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor- cycle to a safe operating condition.
SAFE OPERATION Tires ......Air pressure (when cold): Front 150 kPa (1.5 kg/cm², 21 psi) Up to 97.5 kg (215 lbs) 150 kPa (1.5 kg/cm², 21 Load psi) Rear 97.5 ∼ 182 kg (215 ∼ 200 kPa (2.0 kg/cm², 28 401 lbs) Load psi) Install the air valve cap.
SAFE OPERATION Electrical equipment ... All lights (Headlight, Tail/Brake Lights, Turn Signal Lights, Indicator Lights) and horn work. Engine stop switch ..Stops engine. Side stand ....Returns to its fully up position by spring tension. Returns spring not weak or not damaged.
SAFE OPERATION Additional Considerations for OFF Road Operation Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and func- tioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play.
SAFE OPERATION WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills.
MAINTENANCE AND ADJUSTMENT EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated...
When properly performed, these specified modifications only are not considered to be emissions system “tampering” and vehicle performance is generally un- changed as a result. Installation Instructions: High altitude adjustment requires replacement of certain carburetor components. Installation of these optional parts may be performed by an authorized Kawasaki...
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 obligations it contains.
Periodic Maintenance Chart K : Should be serviced by an authorized Kawasaki dealer. * : For higher odometer readings, repeat at the frequency interval established here. # : Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
MAINTENANCE AND ADJUSTMENT 1. Periodic Inspection (Engine Related Items) Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Engine Item) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Air cleaner • • • element - clean •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Engine Item) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Fuel leak (fuel • • • • year – hose and pipe) - inspect •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Engine Item) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Radiator hoses • • • • year installation condition - inspect Evaporative emission control •...
MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Clutch and drive train: Clutch operation (play, •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • Drive chain guide – wear - inspect Wheels and tires: •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Spoke tightness • • • • • • • – and rim runout - inspect Brake system: •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • • • • • Brake fluid level - 6 month inspect Brake operation...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Front forks/rear • • • year shock absorber oil leak - inspect Uni-trak rocker •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • Swing arm pivot - – lubricate Steering system: • • •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • Side stand switch year – operation - inspect Engine stop •...
MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever *Odometer Reading comes km × 1 000 first (mile × 1 000) Page Every Change/Replacement Items (0.6) (7.5) (15) (22.5) (30) Air cleaner element - replace # 2 years • • • •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 first (mile × 1 000) Page Every Change/Replacement Items (0.6) (7.5) (15) (22.5) (30) • Rubber parts of master cylinder – 4 years and caliper - replace • • •...
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.
MAINTENANCE AND ADJUSTMENT • • Check the engine oil level through If the oil level is too high, remove the the oil level inspection window. With excess oil through the oil filler open- the motorcycle held level, the oil level ing using a syringe or some other should come up between the upper suitable device.
MAINTENANCE AND ADJUSTMENT • • Remove the engine oil drain plug. Let the oil completely drain with the motorcycle perpendicular to the ground. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
MAINTENANCE AND ADJUSTMENT • If the oil filter is to be changed, re- push the mounting pin into the ele- move the oil filter cover bolts and ment. Be careful that the grommets take off the cover with O-ring. do not slip out of place. •...
Proper torque for it is 29 N·m (3.0 kgf·m, 21 ft·lb) shown in the table. Recommended Engine Oil NOTE Type: Kawasaki Performance ○ If a torque wrench is not available, 4-Stroke Motorcycle Oil* this item should be serviced by a Kawasaki Performance Kawasaki dealer.
Capacity : 1.9 L (2.0 US qt) [when filter is not removed] 2.0 L (2.1 US qt) [when filter is removed] 2.1 L (2.2 US qt) *Kawasaki Performance Oils and [when engine is completely dry] Lubricants have been specifically en- gineered for your vehicle. Consistent...
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.
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...
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.
MAINTENANCE AND ADJUSTMENT • Check the coolant level if it is be- Coolant Filling • tween the F (Full) and L (Low) level If the amount of coolant is insuffi- lines. cient, remove the right shroud by un- screwing the bolts and add coolant NOTE into the reserve tank.
MAINTENANCE AND ADJUSTMENT • removing the shroud, push the top of Remove the cap from the reserve shroud to the front. tank and add coolant through the filler opening to the F (Full) level line. • Remove the reserve tank cover by removing the screws.
NOTICE 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.
MAINTENANCE AND ADJUSTMENT Spark Plugs The standard spark plug is shown in the table. The spark plugs should be replaced in accordance with the Peri- odic Maintenance Chart. Spark plug removal should be done only by a competent mechanic follow- ing the instructions in the service man- ual.
MAINTENANCE AND ADJUSTMENT Evaporative Emission Control System (California model only) This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no ad- justments are required, a thorough vi- sual inspection must be made at the in- tervals specified by the Periodic Main- tenance Chart.
MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System the air suction valve is prevented from The Kawasaki Clean Air System returning. Inspect the air suction valves (KCA) is a secondary air suction sys- in accordance with the Periodic Main- tem that helps the exhaust gases to tenance Chart.
MAINTENANCE AND ADJUSTMENT Valve Clearance following the instructions in the Service Valve and valve seat wear decreases Manual. valve clearance, upsetting valve timing. NOTICE If valve clearance is left un- adjusted, wear will eventually cause the valves to remain partly open, which lowers per- formance, burns the valves and valve seats, and may cause seri- ous engine damage.
MAINTENANCE AND ADJUSTMENT Air Cleaner Element Removal • A clogged air cleaner restricts the en- Remove the right side cover and gine’s air intake, increasing fuel con- seat. • sumption, reducing engine power, and Unscrew the air cleaner cover screw causing spark plug fouling.
MAINTENANCE AND ADJUSTMENT • • Remove the wing bolt, and take out Remove the element from the frame. the element. A. Element B. Frame A. Element • B. Wing Bolt Put a clean, lint-free towel over the air cleaner housing to keep dirt or other foreign material from entering.
MAINTENANCE AND ADJUSTMENT WARNING Element Cleaning • Clean the element in a bath of a high If dirt or dust is allowed to pass flash-point solvent. through into the carburetor, the • Squeeze it dry in a clean towel. Do throttle may stick or become not wring the element or blow it dry;...
MAINTENANCE AND ADJUSTMENT WARNING Oil Draining • Inspect the transparent reservoir be- Gasoline and low flash-point sol- low the swingarm pivot section on the vents are extremely flammable right side of the motorcycle to see and may explode, causing se- if any oil has run down from the air vere burns.
MAINTENANCE AND ADJUSTMENT Throttle Control System WARNING 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 - The throttle grip controls the throttle...
MAINTENANCE AND ADJUSTMENT Inspection Adjustment • • Check that the throttle grip play is Turn out the decelerator cable adjust- correct by lightly turning the throttle ing nut until there is no play when grip back and forth. the throttle grip is completely closed. Tighten the locknut.
MAINTENANCE AND ADJUSTMENT throttle grip play is obtained. Tighten the locknut. NOTE ○ If the throttle cables cannot be ad- justed by using the cable adjusting nuts at the upper end of the throttle cables, use the cable adjusters at the lower end of the throttle cables (at the carburetor).
MAINTENANCE AND ADJUSTMENT WARNING the throttle cables may be improperly adjusted or incorrectly routed, or they Too much cables play can pre- may be damaged. Be sure to correct vent throttle operation any of these conditions before riding. cause an accident resulting in serious injury or death.
If starting difficulty or rich fuel mixture Periodic Maintenance Chart have trouble occurs, inspect the choke lever, the choke cable checked by an au- and adjust it if necessary. thorized Kawasaki dealer. A. Choke Lever...
MAINTENANCE AND ADJUSTMENT Idle Speed The idle speed should be performed in accordance with the Periodic Main- tenance Chart or whenever the idle speed is disturbed. Adjustment • Start the engine, and warm it up thor- oughly. • Adjust the idle speed by turning the idle adjusting screw.
Check that the clutch lever operates C. Adjuster properly and that the inner cable If the play is incorrect, adjust the lever slides smoothly. If there is any irreg- play as follows. ularity, have the clutch cable checked by an authorized Kawasaki dealer.
If it cannot be done, have the • Loosen the locknut, and turn the clutch cable adjusted by authorized adjuster so that the clutch lever will Kawasaki dealer. have the proper play. NOTE ○ After the adjustment is made, start...
MAINTENANCE AND ADJUSTMENT Spark Arrester Spark Arrester Cleaning This motorcycle is equipped with a WARNING spark arrester approved for off-road use by the U.S. Forest Service. It must The muffler can become ex- be properly maintained to ensure its tremely hot during normal op- efficiency.
MAINTENANCE AND ADJUSTMENT • • Remove the drain plugs on the muf- Raise and lower engine speed while fler. tapping on the muffler with a rub- ber mallet until carbon particles are purged from the muffler. DANGER Exhaust gas contains carbon monoxide, a colorless, odor- less poisonous gas.
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 dance with the Periodic Maintenance position where the chain is tightest.
MAINTENANCE AND ADJUSTMENT • • If the drive chain is too tight or too Remove the cotter pin, and loosen loose, adjust it so that the chain slack the axle nut. will be within the standard value. Drive Chain Slack 35 ∼...
MAINTENANCE AND ADJUSTMENT • NOTE Turn out both chain adjusters evenly ○ until the drive chain has the cor- Wheel alignment also rect amount of slack. To keep the checked using the straightedge or chain and wheel properly aligned, string method. the notch on the left wheel alignment indicator should align with the same WARNING...
98 N·m (10 kgf·m, 72 ft·lb) NOTE ○ If a torque wrench is not available, this item should be serviced by a Kawasaki dealer. • Rotate the wheel, measure the chain A. Cotter Pin slack again at the tightest position, and readjust if necessary.
MAINTENANCE AND ADJUSTMENT Wear Inspection • Remove the bolts to take off the chain cover. A. Turning Clockwise WARNING A. Chain Guide A loose axle nut can lead to an B. Bolts accident resulting in serious in- • jury or death. Tighten the axle Stretch the chain taut either by using nut to the proper torque and in- the chain adjusters, or by hanging a...
It is an endless type and the chain should be replaced. 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.
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 necessary after riding through rain or on wet roads, or any...
1 mm (0.04 in.), replace both pads in the caliper as a set. Pad replace- ment should be done by an authorized Kawasaki dealer. A. Lining Thickness B. 1 mm (0.04 in.)
MAINTENANCE AND ADJUSTMENT Disc Brake Fluid - Fluid Level Inspection • In accordance with the Periodic Main- The brake fluid level in the front brake tenance Chart, inspect the brake fluid fluid reservoir must be kept above level in both the front and rear brake the line (lower level line) next to the fluid reservoirs and change the brake gauge and that in the rear brake fluid...
MAINTENANCE AND ADJUSTMENT • If the fluid level in either reservoir is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. Inside the front brake fluid reser- voir is a stepped line showing the up- per level line.
Have the brake unidentified. checked immediately by an au- 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.
• The brake light should go on when the front brake is applied. • If it does not, ask your authorized Kawasaki dealer to inspect the front brake light switch. A. Brake Pedal B. Pedal Travel • If it does not, adjust the rear brake light switch.
MAINTENANCE AND ADJUSTMENT NOTICE Adjustment • To adjust the rear brake light switch, To avoid damaging the electrical move the switch up or down. connections inside the switch, be sure that the switch body does not turn during adjustment. A. Rear Brake Light Switch B.
Periodic Maintenance Chart by and rebound damping force for various an authorized Kawasaki dealer. riding and loading conditions. Before marking any adjustments, however, read the following proce-...
MAINTENANCE AND ADJUSTMENT • • Remove the bracket bolts and take When changing the adjuster position out the separator (California model). from 1st to 5th in numerical order (1st→2nd→3rd→4th→5th), turn the adjusting bolt clockwise. • When changing the adjuster position from 5th to 1st in numerical order (5th→4th→3rd→2nd→1st), turn the adjusting bolt counterclockwise.
MAINTENANCE AND ADJUSTMENT Rebound Damping Force Adjustment The rebound damping force adjuster is located at the lower end of the rear shock absorber. A. Adjusting Bolt B. 1st Position C. 5th Position D. Turn Clockwise E. Turn Counterclockwise F. Rear Shock Absorber A.
MAINTENANCE AND ADJUSTMENT Wheels The standard setting positions of the spring preload adjuster and rebound Tires - damping force adjuster for an average Payload and Tire Pressure -build rider of 68 kg (150 lb) with no pas- Failure to maintain proper inflation senger and no accessories are as fol- pressures or observe payload limits for lows:...
MAINTENANCE AND ADJUSTMENT NOTE ○ Measure the tire pressure when the tires are cold (that is, when the mo- torcycle has not been ridden more than a mile during the past 3 hours). ○ Tire pressure is affected by changes in ambient temperature and altitude, and so the tire pressure should be checked and adjusted when your rid-...
MAINTENANCE AND ADJUSTMENT Tire Wear, Damage As the tire tread wears down, the tire 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). So it is false economy and unsafe to use the tires until they are bald.
MAINTENANCE AND ADJUSTMENT WARNING Standard Tire DUNLOP 90/90-21 M/C 54S Tires that have been punctured Front K750 and repaired do not have the same capabilities as undam- DUNLOP 130/80-17 M/C 65S Rear K750 aged tires and can suddenly fail, causing an accident resulting in serious injury or death.
MAINTENANCE AND ADJUSTMENT Battery WARNING New tires are slippery and may Battery Electrolyte Level Inspection cause loss of control and injury. The battery electrolyte level must be A break-in period of 160 km (100 kept between the upper and lower level miles) is necessary to estab- lines.
MAINTENANCE AND ADJUSTMENT NOTICE Add only distilled water to the battery. Ordinary tap water is not a substitute for distilled wa- ter and will shorten the life of the battery. Battery Charging • Remove the battery from the motor- cycle (see Battery Removal). A.
MAINTENANCE AND ADJUSTMENT • Before charging, check the elec- DANGER trolyte level in each cell. If the elec- Batteries produce hydrogen trolyte level is low in any cell, fill to gas which can cause an ex- above the lower level line but not up plosion.
MAINTENANCE AND ADJUSTMENT • Charge the battery at a rate that is 1/10th of the battery capacity. For example, the charging rate for a 10 Ah battery would be 1.0 ampere. A. Battery Charger B. Filler Caps C. (+) terminal D.
MAINTENANCE AND ADJUSTMENT NOTICE Make Siam Furukawa Type FB14L-A2 Do not use a high rate battery charger, as is typically employed • After charging, check the electrolyte at automotive service stations, level in each cell. If the level has unless the charging rate can be fallen, add distilled water to bring it reduced to the level required for back up to the upper level line.
MAINTENANCE AND ADJUSTMENT • Battery Removal Take the battery out. • • Remove the side covers. Clean the battery using a solution of • Remove the seat. baking soda and water. Be sure that • Disconnect the leads from the bat- the lead connections are clean.
MAINTENANCE AND ADJUSTMENT NOTICE Make sure the battery vent hose is kept away from the drive sys- tem and exhaust system. Bat- tery electrolyte can corrode and dangerously weaken the drive system. Do not let the vent hose become folded, pinched, or melted by the exhaust sys- tem.
MAINTENANCE AND ADJUSTMENT Rear Turn Signal Light The proper angle is 0.4 degrees be- low horizontal. This is a 50 mm (2.0 To replace the bulb of the rear turn in.) drop at 7.6 m (25 ft) measured signal light, remove the screw and from the center of the headlight, with lightly twist the lens counterclockwise.
MAINTENANCE AND ADJUSTMENT • Fuses Remove the cover by unscrewing the Fuses are located under the seat. screw. The main fuse is mounted on the starter relay behind the cover. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
MAINTENANCE AND ADJUSTMENT General Lubrication WARNING Lubricate the points shown below, Substituting fuses can cause with either motor oil or regular grease, wiring to overheat, catch fire in accordance with the Periodic Main- and/or fail. Do not use any sub- tenance Chart or whenever the vehicle stitute for the standard fuse.
Rear Brake Pedal • Rear Brake Rod Joint (K): Should be serviced by an authorized Lubricate the following cables Kawasaki dealer. with a pressure cable luber: *: Grease the lower part of the inner • (K)Clutch Inner Cable cable sparigly.
MAINTENANCE AND ADJUSTMENT in the tongue of the speedometer pin- ion. A. Grease NOTE ○ After connecting the cables, adjust them. ○ Insert the speedometer inner cable into the speedometer gear housing while turning the wheel so that the slot in the end of the cable will seat...
General Precautions Build-up of debris or flammable Frequent and proper care of your material in and around the vehi- Kawasaki motorcycle will enhance cle chassis, engine, and exhaust its appearance, optimize overall per- can cause mechanical problems formance, and extend its useful life.
MAINTENANCE AND ADJUSTMENT • Be sure the engine and exhaust are components and damage your mo- cool before washing. torcycle. • • Avoid applying degreaser to seals, Avoid spraying water in delicate brake pads, and tires. areas such as in air intakes, fuel •...
After riding in an area where the rubbed. roads are salted or near the ocean, • If any doubt, consult an authorized immediately wash your motorcycle Kawasaki dealer. with cold water. Do not use warm...
MAINTENANCE AND ADJUSTMENT NOTICE Painted Surfaces After washing your motorcycle, coat Plastic parts may deteriorate painted surfaces, both metal and plas- and break if they come in con- tic, with a commercially available mo- tact with chemical substances torcycle/automotive wax. Wax should or household cleaning products be applied once every three months or such as gasoline, brake fluid,...
MAINTENANCE AND ADJUSTMENT should be washed with a mild neu- a rubber protectant to help prolong their tral detergent and finished with a spray useful life. polish. Aluminum wheels, both painted WARNING and unpainted can be cleaned with special non-acid based wheel spray Rubber protectants can be slip- cleaners.
In accordance with the Periodic Maintenance Chart, it is very important to check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki dealer for torque values.
MAINTENANCE AND ADJUSTMENT 16. Front Axle Nut 17. Spoke Nipples 18. Brake Pedal Mounting Bolt 19. Rear Axle Nut 20. UNI TRACK Lever Rod Nuts 21. Front Axle Clamp Bolts 22. Rear Shock Absorber Mounting Nut 23. Exhaust Pipe Holder Nuts 24.
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 Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recy- cling.
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.
STORAGE • 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.) •...
You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale. The warranty does not cover the cost of regularly-scheduled maintenance. The warranty also does not ap- ply to the normal wear of items such as tires, brake pads, transmission drive belts, chains, sprockets, etc.
Much of the warranty coverage offered by the limited warranty can be extended by purchasing Kawasaki’s Good Time™ Protection Plan (GTPP). See your Kawasaki dealer or go to Kawasaki.com for more information if you don’t already have the GTPP. What Am I Responsible For? You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner’s manual.
Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the Maintenance Record section of this Owner’s Manual.
Kawasaki if the repair is one that will be covered by the limited warranty. The dealership will also file all necessary paperwork. The dealership is responsi- ble for correctly completing any necessary repairs, whether they are covered by the limited warranty or not.
YOUR WARRANTY/OWNER SATISFACTION Kawasaki will work with your dealer to resolve any warranty issues. No autho- rization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer. What if I am not Satisfied With My Warranty Service? If you aren’t satisfied with your dealership’s repair work or operations, it is best to...
Want to Contact Kawasaki? This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you.
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Kawasaki Motors Corpora- tion, U.S.A.
MAINTENANCE RECORD MAINTENANCE RECORD Owner Name..................Address ....................Phone Number ................... Engine Number .................. Vehicle Number.................. Key Number ..................Selling Dealer Name ................Phone Number ................... Warranty Start Date ................Note: Keep this information and a spare key in a secure location. Odometer Date Dealer Name...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...