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Table of Contents

   Also See for Kawasaki Super Sherpa

   Summary of Contents for Kawasaki Super Sherpa

  • Page 2 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.
  • Page 4 CAUTION Whenever you see the symbols shown below, heed their instructions! This caution symbol identifies Always follow safe operating and main- special instructions or proce- tenance practices. dures which, if not strictly ob- served, could result in damage WARNING to or destruction of equipment. This warning symbol identifies special instructions or proce- NOTE...
  • Page 5 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 6 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 © 2008 Kawasaki Heavy Industries, Ltd. Nov. 2008. (1). (S, Ke)
  • Page 7: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS....... Fuel Tank Cap ........32 SERIAL NUMBER LOCATIONS..12 Fuel Tank ......... 33 LOCATION OF PARTS ....... 13 Fuel Requirement: ......34 LOCATION OF LABELS..... 16 Fuel Tap ........... 37 LOADING INFORMATION....19 Stand..........38 GENERAL INFORMATION....22 Helmet Hook ........
  • Page 8 SAFE OPERATION......59 Brake Light Switches......108 Safe Riding Technique ..... 59 Rear Shock Absorber....... 110 Daily Safety Checks ......61 Wheels ..........112 Additional Considerations for Off Battery..........115 Road Operation ......63 Headlight Beam........ 117 MAINTENANCE AND ADJUSTMENT Fuses ..........
  • Page 9: Specifications

    SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 2 080 mm (81.89 in.) Overall Width 780 mm (30.71 in.) Overall Height 1 190 mm (46.85 in.) Wheelbase 1 375 mm (54.13 in.) Road Clearance 270 mm (10.63 in.) Curb Mass 128 kg (282 lb) ENGINE Type DOHC, single-cylinder, 4-stroke, air-cooled...
  • Page 10 SPECIFICATIONS 10° BTDC @1 300 r/min (rpm) ∼ 30° BTDC @5 750 Ignition Timing (Electronically advanced) r/min (rpm) Spark Plugs NGK CR8E or ND U24ESR-N Lubrication System Forced lubrication (wet sump) Engine Oil Type: API SE, SF or SG API SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 Capacity: 1.5 L (1.6 US qt)
  • Page 11 SPECIFICATIONS Gear Ratio 3.090 (34/11) 2.125 (34/16) 1.500 (27/18) 1.148 (31/27) 0.962 (25/26) 0.852 (23/27) FRAME Castor 28° Trail 107 mm (4.21 in.) Tire Size: Front 2.75-21 45P Rear 4.10-18 59P Rim Size: Front 21 × 1.60 Rear 18 × 2.15 Fuel Tank Capacity 9.0 L (2.38 US gal)
  • Page 12 SPECIFICATIONS ELECTRICAL EQUIPMENT Battery 12 V 6 Ah Headlight 12 V 60/55 W Tail/Brake Light 12 V 5/21 W Specifications subject to change without notice.
  • Page 13: Serial Number Locations

    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.
  • Page 14: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 6. Left Handlebar Switches 2. Meter Instruments 7. Ignition Switch/Steering Lock 3. Choke Knob 8. Right Handlebar Switches 4. Brake Fluid Reservoir (Front) 9. Throttle Grip 5. Front Brake Lever...
  • Page 15 LOCATION OF PARTS 10. Front Fork 16. Rear Shock Absorber 22. Shift Pedal 11. Headlight 17. Battery 23. Idle Adjusting Screw 12. Turn Signal Light 18. Helmet Hook 24. Side Cover 13. Fuel Tank Cap 19. Tool Kit Case/Tool Kit 25.
  • Page 16 LOCATION OF PARTS 27. Tail/Brake Light 32. Brake Fluid Reservoir 36. Carburetor 28. Muffler (Rear) 29. Air Cleaner Element 33. Rear Brake Light 30. Seat Switch 31. Front Brake Light 34. Rear Brake Pedal Switch 35. Oil Level Gauge...
  • Page 17: Location Of Labels

    LOCATION OF LABELS LOCATION OF LABELS 1. Important Break-In Instructions 2. Tire and Load Data 3. Important Drive Chain Information 4. Vehicle Emission Control Information 5. Daily Safety Checks (For further information of label, refer to the “LABEL INFORMATION” chapter.)
  • Page 18 LOCATION OF LABELS 6. Battery Poison/Danger 7. Engine Oil and Oil Filter 8. Brake Fluid (Rear) 9. Brake Fluid (Front) (For further information of label, refer to the “LABEL INFORMATION” chapter.)
  • Page 19 LOCATION OF LABELS 10. Noise Emission Control Information 11. Weight and Manufacture (For further information of label, refer to the “LABEL INFORMATION” chapter.)
  • Page 20: Loading Information

    Kawasaki Kawasaki Parts Accessories, components. Kawasaki has no control over the Because a motorcycle is sensitive to design or application of accessories. In some cases, improper installation changes in weight and aerodynamic or use of accessories, or motorcycle...
  • Page 21 LOADING INFORMATION The following general guidelines have 3. All baggage should be carried as been prepared to assist you in making low as possible to reduce the effect your determinations. on the motorcycle center of gravity. Baggage weight should also be dis- 1.
  • Page 22 Kawasaki does not manu- (i.e., lean angle), control operation, facture sidecars or trailers for mo- wheel travel, front fork movement,...
  • Page 23: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Speedometer B. Odometer/Clock C. Twin Trip Meter D. Odometer/Clock Mode Button E. Trip A/B Mode Button F. Neutral Indicator Light G. Turn Signal Indicator Light H. High Beam Indicator Light...
  • Page 24: Speedometer, Odometer/clock, And Trip Meter

    GENERAL INFORMATION Speedometer, Odometer/Clock, and Odometer - Trip Meter: The odometer shows the total dis- In the meter instruments face are tance in kilometers that the vehicle has the LCD (Liquid Crystal Display) been ridden. The meter cannot be re- speedometer, odometer/clock and trip set.
  • Page 25 GENERAL INFORMATION • • Push the TRIP A/B button with the Push the ODO/CLOCK button. The ODO/CLOCK button pushed in. Both hour display stops flashing and the the hour and minute displays start minute display starts flashing. And flashing. push the TRIP A/B button to advance the minutes.
  • Page 26 GENERAL INFORMATION • NOTE Push the TRIP A/B button and hold it Pushing the TRIP A/B button mo- • After two second, the figure display mentarily advances the hour or turns to 0.0 (TRIP A) or 0 (TRIP B), minute step by step. Pushing and and then starts counting when the ve- holding the button advance the hour hicle is operated.
  • Page 27: Indicator Lights

    GENERAL INFORMATION : When the headlight is on high beam, the high beam indicator light is lit. Indicator Lights: N : When the transmission is in neutral, the neutral indicator light is lit. : When the turn signal switch is turned to left or right, the turn signal indicator light flashes on and off.
  • Page 28: Key

    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, or using the key code on the tag with your keys.
  • Page 29: Ignition Switch/steering Lock

    GENERAL INFORMATION Ignition Switch/Steering Lock Engine on. All electrical This is a four-position, key-operated equipment can be used. switch. The key can be removed from Engine off. All electrical the switch when it is in the OFF, LOCK, circuits off. or P (Park) position.
  • Page 30: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches To lock the steering: 1. Turn the handlebar fully to the left. Engine Stop Switch: 2. With the ignition key in the OFF posi- In addition to the ignition switch, the tion, push down and release the key. engine stop switch must be in the RUN 3.
  • Page 31: Starter Button

    GENERAL INFORMATION Refer to the Starting the Engine sec- tion of the "How to Ride the Motorcycle" chapter for starting instructions. A. Engine Stop Switch B. RUN Switch C. OFF Switch D. Starter Button Starter Button: The starter button operates the elec- tric starter when pushed with the clutch lever pulled in or the transmission is in neutral.
  • Page 32: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches Turn Signal Switch: Dimmer Switch: When the turn signal switch is turned High or low beam can be selected to L (left) or R (right), the corresponding with the dimmer switch. When the turn signals flash on and off. headlight is on high beam (HI), the To stop flashing, push the switch in.
  • Page 33: Fuel Tank Cap

    GENERAL INFORMATION Fuel Tank Cap NOTE To open the fuel tank cap, insert the The fuel tank cap cannot be closed ignition key into the fuel tank cap, turn without the key inserted, and the key the key to the right. cannot be removed unless the cap is To close the cap, push it down into locked properly.
  • Page 34: Fuel Tank

    GENERAL INFORMATION Fuel Tank WARNING The following octane rating gasoline Gasoline is extremely flammable is recommended in the fuel tank. Avoid and can be explosive under cer- filling the tank in the rain or where tain conditions. Turn the igni- heavy dust is blowing so that the fuel tion key to "OFF".
  • Page 35: Fuel Requirement

    GENERAL INFORMATION CAUTION Fuel Requirement: Fuel Type If engine "knocking" or "ping- ing" occurs, use a different Use clean, fresh unleaded gasoline brand of gasoline of a higher with a minimum Antiknock Index of 87. octane rating. If this condition is The Antiknock Index is posted on ser- allowed to continue it can lead vice station pumps.
  • Page 36 "gasohol" NOTE is approved for use. Other oxygenates approved for use in unleaded gasoline include TAME (up to 16.7 %) and ETBE (up to 17.2 %). Fuel containing these oxy- genates can also be used in your Kawasaki.
  • Page 37 When operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA-BIL) with the gasoline in the fuel tank. Fuel stabilizer additives inhibit oxidation of the fuel which mini-...
  • Page 38: Fuel Tap

    GENERAL INFORMATION Fuel Tap the ON position. If the fuel runs out with The fuel tap is an automatic type the tap in the ON position, turn the tap which shuts off the fuel supply when lever to PRI, leave it for a few seconds, the engine is stopped in the ON or RES and then turn it to RES.
  • Page 39: Stand

    GENERAL INFORMATION Stand WARNING The motorcycle is equipped with a Practice operating the fuel tap side stand. with the motorcycle stopped. To prevent an accident you should be able to operate the fuel tap while riding without taking your eyes off the road. Be careful not to touch the hot engine while operating the fuel tap.
  • Page 40: Helmet Hook

    GENERAL INFORMATION NOTE Helmet Hook Helmet can be secured to the motor- The motorcycle is equipped with a cycle using the helmet hook located at side stand switch. This switch is de- the front of the tool kit case. signed so that the engine dose not The helmet hook can be unlocked by start if the transmission is in gear and inserting the ignition key into the lock,...
  • Page 41: Tool Kit Case/tool Kit

    GENERAL INFORMATION Tool Kit Case/Tool Kit WARNING The tool kit is stored in the tool kit Do not ride the motorcycle with a case. helmet attached to the hook. The The kit contains tools that can be helmet could cause an accident helpful in making roadside repairs, ad- by distracting the operator or in- justments, and some maintenance pro-...
  • Page 42: Side Cover

    GENERAL INFORMATION Side Cover The left and right side covers are re- moved for battery removal or installa- tion and air cleaner element cleaning. Right and Left Side Cover Removal • To remove the right and left side cover, remove a screw of the left side cover (two screws of the right side cover), and pull out the left and right side cover.
  • Page 43 GENERAL INFORMATION A. Left Side Cover A. Right Side Cover B. Screw B. Screws...
  • Page 44: Seat

    GENERAL INFORMATION Seat Seat Removal To remove the seat, follow this step. 1. Remove the left and right side cov- ers. 2. Remove the seat mounting bolts. 3. Pull the seat up and to the rear. A. Seat B. Mounting Bolt...
  • Page 45: Break-in

    BREAK-IN BREAK-IN The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a "broken down" instead of a "broken in" motorcycle after a few thousand kilometers.
  • Page 46 BREAK-IN • Do not start moving or race the engine immediately after starting it, even if the engine is already warm. Run the engine for two or three minutes at idle speed to give the oil a chance to work up into all the engine parts. •...
  • Page 47: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Starting the Engine first turn the tap lever to PRI, leave it • for a moment, and return it to ON. Turn the fuel tap lever to "ON" posi- tion. •...
  • Page 48 HOW TO RIDE THE MOTORCYCLE • • Turn the ignition key to "ON". If the engine is cold, pull up the choke • Make certain the transmission is in knob all the way. neutral. A. Choke Knob A. Neutral Indicator Light B.
  • Page 49 HOW TO RIDE THE MOTORCYCLE • Leaving throttle completely prevents the electric starter from op- closed, push the starter button. erating when the clutch is engaged and the transmission is not in neutral. CAUTION Do not operate the starter con- tinuously for more than 5 sec- onds or the starter will overheat and the battery power will drop...
  • Page 50 HOW TO RIDE THE MOTORCYCLE choke, and push the choke knob all Ambient Choke off after the way back. temperature running for 20°C (68°F) ∼ 35°C NOTE 15 seconds (95°F) If you drive the motorcycle before Below 20°C (68°F) 1.5 minutes the engine is warmed up, return the Below 5°C (40°F) 2 minutes...
  • Page 51: Jump Starting

    HOW TO RIDE THE MOTORCYCLE Jump Starting WARNING If your motorcycle battery is "run Battery acid generates hydro- down", it should be removed and gen gas which is flammable and charged. If this is not practical, a 12 explosive under certain con- volt booster battery and jumper cables ditions.
  • Page 52 HOW TO RIDE THE MOTORCYCLE • Connect a jumper cable from the shift pedal or other unpainted metal positive (+) terminal of the booster surface. Do not use the negative (–) battery to the positive (+) battery ter- terminal of the battery. minal at the starter relay.
  • Page 53: Moving Off

    HOW TO RIDE THE MOTORCYCLE CAUTION Moving Off • Check that the side stand is up. Do not operate the starter con- • Pull in the clutch lever. tinuously for more than 5 sec- • Shift into 1st gear. onds or the starter will overheat •...
  • Page 54: 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 stops if the gear.
  • Page 55 HOW TO RIDE THE MOTORCYCLE Vehicle speed when shifting Shifting up km/h (mph) Shifting down km/h (mph) 15 ( 9) 30 (19) 25 (15) 25 (15) 35 (21) 20 (12) 45 (27) 15 ( 9) 55 (34) 15 ( 9)
  • Page 56: Braking

    HOW TO RIDE THE MOTORCYCLE • Braking For emergency braking, disregard • Close the throttle completely, leav- downshifting, and concentrate on applying the brakes as hard as pos- ing the clutch engaged (except when sible without skidding. shifting gears) so that the engine will help slow down the motorcycle.
  • Page 57: Stopping The Engine

    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.
  • Page 58: Stopping The Motorcycle In An Emergency

    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- vide you optimum safety and conve- In an emergency situation such as nience.
  • Page 59: Parking

    HOW TO RIDE THE MOTORCYCLE Parking WARNING • Shift the transmission into neutral Gasoline is extremely flammable and turn the ignition key to "OFF". and can be explosive under cer- • Support the motorcycle on a firm, tain conditions. level surface with the side stand. •...
  • Page 60: Safe Operation

    SAFE OPERATION SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a Before changing lanes, look over helmet are strongly recommended. your shoulder to make sure the way Gloves suitable...
  • Page 61 SAFE OPERATION braking may cause the motorcycle When riding in wet conditions or to skid and lose control. on loose roadway surfaces, the abil- ity to maneuver will be reduced. All When going down long slopes, of your actions should be smooth control vehicle speed by closing under these conditions.
  • Page 62: 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 63 SAFE OPERATION Drive chain ....Slack 35 ∼ 55 mm (1.4 ∼ 2.2 in.). Lubricate if dry Nuts, bolts, fasteners .. Check that steering and suspension components, axles, and all controls are properly tightened or fastened. Steering ...... Action smooth but not loose from lock to lock. No binding of control cables.
  • Page 64: Additional Considerations For Off Road Operation

    SAFE OPERATION Additional Considerations for Off Road Operation Brakes: The importance of reliable brakes is obvious. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play.
  • Page 65: Maintenance And Adjustment

    If you are in doubt as to any adjustment or vehicle operation, please ask your authorized Kawasaki dealer to check the motorcycle. Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect maintenance or improper adjustment done by the owner.
  • Page 66: 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. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere.
  • Page 67 Installation Instructions: High altitude adjustment requires replacement of certain carburetor components. Installation of these optional parts may be performed by an authorized Kawasaki dealer, or the consumer, following repair recommendations specified in the appro- priate Kawasaki Service Manual.
  • Page 68 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.
  • Page 69 MAINTENANCE AND ADJUSTMENT TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, re- pair, 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, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 70: Periodic Maintenance Chart

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart K: Should be serviced by an authorized Kawasaki dealer. *: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
  • Page 71 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Throttle control system (play, smooth • • • • year return, no drag) - inspect Choke operation - •...
  • Page 72 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Fuel hoses • • • • year – installation condition - inspect Air suction system •...
  • Page 73 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Clutch and drive train: Clutch operation (play, engagement, •...
  • Page 74 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Drive chain guide • • • – wear - inspect Wheels and tires: Tire air pressure - •...
  • Page 75 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Brake system: Brake fluid leak - • • • • • • •...
  • Page 76 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Brake operation • • • • • • • year (effectiveness, play, drag) - inspect Brake light switch •...
  • Page 77 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Uni-trak rocker arm • • • – operation - inspect Uni-trak tie rods •...
  • Page 78 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Steering stem • – bearings - lubricate years Electrical system: Lights and switches •...
  • Page 79 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Chassis parts - • • • year lubricate Bolts and nuts • •...
  • Page 80 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes *Odometer Reading first km × 1000 ( mile × 1000) Page Change/Replacement Item Every (0.6) (7.5) (15) (22.5) (30) Air cleaner element # - replace 2 years • • • • •...
  • Page 81: Engine Oil

    MAINTENANCE AND ADJUSTMENT • Engine Oil If the oil has just been changed, start In order for the engine, transmission, the engine and run it for several min- and clutch to function properly, main- utes at idle speed. This fills the oil tain the engine oil at the proper level, filter with oil.
  • Page 82: Oil/filter Change

    MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • Warm up the engine thoroughly, and then stop it. • Set the motorcycle up on its side stand. • Remove the bolt of the engine guard, and take off the engine guard. A.
  • Page 83 MAINTENANCE AND ADJUSTMENT • If the oil filter is to be changed, re- move the oil filter cover bolts and take off the cover with O-ring. A. Drain Plug • Let the oil completely drain with the motorcycle perpendicular to the ground.
  • Page 84 O-ring, and install the oil fil- NOTE ter cover and tighten its bolts. If a torque wrench is not available, • After the oil has completely drained this item should be serviced by a out, install the engine oil drain plug Kawasaki dealer.
  • Page 85 MAINTENANCE AND ADJUSTMENT Although 10W-40 engine oil is the Recommended Engine Oil recommended oil for most condi- Type: API SE, SF or SG tions, the oil viscosity may need to be API SH, SJ, SL or SM with changed to accumulate atmospheric JASO MA, MA1 or MA2 conditions in your riding area.
  • Page 86: Spark Plugs

    MAINTENANCE AND ADJUSTMENT Spark Plugs Spark Plug The standard spark plug is shown in NGK CR8E, Standard Plug the table. The spark plug should be ND U24ESR-N taken out in accordance with the Pe- 0.7 ∼ 0.8 mm riodic Maintenance Chart for cleaning, Plug Gap (0.028 ∼...
  • Page 87 When installing the spark plug cap this item should be serviced by a onto the spark plug, fit the plug cap Kawasaki dealer. securely onto the spark plug, and pull the cap lightly to make sure that it is properly installed.
  • Page 88: Valve Clearance

    MAINTENANCE AND ADJUSTMENT Valve Clearance Air Cleaner Valve and valve seat wear decreases A clogged air cleaner restricts the en- valve clearance, upsetting valve timing. gine’s air intake, increasing fuel con- sumption, reducing engine power, and CAUTION causing spark plug fouling. The air cleaner element must be If valve clearance is left un- cleaned in accordance with the Peri-...
  • Page 89 MAINTENANCE AND ADJUSTMENT • Element Removal Pull out the air cleaner element from • Remove the right side cover. the air cleaner housing. • Unscrew the air cleaner element cap screws and bolt, then remove the air cleaner element cap. A.
  • Page 90 MAINTENANCE AND ADJUSTMENT • Remove the element from the frame. WARNING If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, pos- sibly causing accident. CAUTION If dirt gets through into the en- gine, excessive engine wear and possibly engine damage will oc- cur.
  • Page 91 MAINTENANCE AND ADJUSTMENT • Dry the element with compressed air Oil Draining • or by squeezing it. Inspect the transparent drain hoses • After cleaning, saturate the element located at the lower end of the air with SE, SF or SG class SAE 10W40 cleaner housing to see if any oil has motor oil, squeeze out the excess run down from the air cleaner hous-...
  • Page 92: Throttle Grip

    MAINTENANCE AND ADJUSTMENT Throttle Grip WARNING The throttle grip controls the throttle Be sure to install each plug in valves. If the throttle grip has exces- the drain hose after draining. Oil sive play due to either cable stretch or on tires will make them slippery maladjustment, it will cause a delay in and can cause an accident and...
  • Page 93 MAINTENANCE AND ADJUSTMENT Inspection Adjustment • Check that there is 2 ∼ 3 mm (0.08 • Loosen the locknut at the upper end ∼ 0.12 in.) throttle grip play when of the throttle cable, and turn the lightly turning the throttle grip back adjuster until the proper amount of and forth.
  • Page 94 MAINTENANCE AND ADJUSTMENT use the upper and lower nuts at the lower ends of the throttle cables. • Loosen the locknut at the upper end of the throttle cable and turn in the adjuster fully. • Tighten the locknut. • Turn the upper and lower nuts at the lower end of the decelerator cable until there is no play when the throttle...
  • Page 95: Carburetors

    MAINTENANCE AND ADJUSTMENT Carburetors WARNING The following procedure covers the Operation with improperly ad- idle speed adjustment, which should be justed, incorrectly routed, or performed in accordance with the Pe- damaged cables could result in riodic Maintenance Chart or whenever an unsafe riding condition.
  • Page 96: Clutch

    MAINTENANCE AND ADJUSTMENT Clutch may be damaged. Be sure to correct any of these conditions before riding. Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart.
  • Page 97 MAINTENANCE AND ADJUSTMENT • Turn the adjuster at the upper end of the cable so that the clutch lever will have 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play. WARNING Be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough ca- A.
  • Page 98 MAINTENANCE AND ADJUSTMENT • NOTE Loosen the locknut at the middle of the clutch cable, and turn the adjust- After the adjustment is made, start ing nut so that the clutch lever has 2 the engine and check that the clutch ∼...
  • Page 99: Drive Chain

    MAINTENANCE AND ADJUSTMENT • Drive Chain Rotate the rear wheel to find the po- The drive chain must be checked, sition where the chain is tightest and adjusted, and lubricated in accordance measure the maximum chain slack with the Periodic Maintenance Chart by pulling up and pushing down the for safety and to prevent excessive chain midway between the engine...
  • Page 100 MAINTENANCE AND ADJUSTMENT Drive Chain Slack 35 ∼ 55 mm (1.4 ∼ 2.2 in.) Standard Chain Slack Adjustment • Remove the cotter pin, and loosen the axle nut. • Rotate the chain adjuster at each end of the swingarm to obtain the stan- dard chain slack.
  • Page 101 MAINTENANCE AND ADJUSTMENT • WARNING Check the rear brake (see the Brakes section). Misalignment of the wheel will result in abnormal wear, and may WARNING result in an unsafe riding condi- tion. If the axle nut is not securely tightened or the cotter pin is not •...
  • Page 102 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.
  • Page 103 SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrica- tion. • If there is any irregularity, have the drive chain and/or the sprockets re- placed by an authorized Kawasaki dealer.
  • Page 104: Brakes

    MAINTENANCE AND ADJUSTMENT • Brakes Apply oil to the sides of the rollers so that it will penetrate to the rollers and Disc and disc pad wear is automat- bushings. Apply oil to the O-rings so ically compensated for and has no ef- that the O-rings will be coated with fect on the brake lever or pedal action.
  • Page 105 MAINTENANCE AND ADJUSTMENT A. Brake Lever A. Brake Lever B. 2 ∼ 5 mm (0.08 ∼ 0.20 in.) B. Adjuster C. Locknut WARNING If the brake lever or pedal feels mushy when it is applied, there might be air in the brake lines or the brake may be defective.
  • Page 106 Pad changed if it becomes contaminated replacement should be done by an au- with dirt or water. thorized Kawasaki dealer. Fluid Requirement Use heavy-duty brake fluid only from a container marked DOT3 or DOT4.
  • Page 107 MAINTENANCE AND ADJUSTMENT CAUTION Fluid Level Inspection • The brake fluid level in the front brake Do not spill brake fluid onto any fluid reservoir must be kept above painted surface. the line (lower level line) next to the Do not use fluid from a container gauge and that in the rear brake fluid that has been left open or that reservoir (located under the right side...
  • Page 108 MAINTENANCE AND ADJUSTMENT • If the fluid level in ether 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.
  • Page 109: Brake Light Switches

    The brake light should go on when Fluid Change the front brake is applied. Have the brake fluid changed by an • If it does not, ask your authorized authorized Kawasaki dealer. Kawasaki dealer to inspect the front brake light switch.
  • Page 110 MAINTENANCE AND ADJUSTMENT • Check the operation of the rear brake Adjustment • light switch by depressing the brake To adjust the rear brake light switch, pedal. The brake light should go on move the switch up or down by turn- after about 10 mm (0.4 in.) of pedal ing the adjusting nut.
  • Page 111: Rear Shock Absorber

    If the spring action feels too soft or too B. Adjusting Nut stiff, have it adjusted by an authorized C. Lights sooner Kawasaki dealer. D. Lights later Rebound Damping Force Adjustment The rebound damping force adjuster at the lower end of the rear shock ab- sorber has 20 adjustment clicks.
  • Page 112 MAINTENANCE AND ADJUSTMENT • Turn the adjuster counterclockwise Rebound Damping 7 turns out* to decrease damping force. Force Adjuster * out from the fully seated position A. Rebound Damping Adjuster B. Mark The standard setting position of the rebound damping force adjuster for an average-build rider of 68kg (150 lb) with no passenger and no accessories are as follows.
  • Page 113: Wheels

    MAINTENANCE AND ADJUSTMENT Wheels Tire pressure is affected by changes in ambient temperature and altitude, Tires - and so the tire pressure should be checked and adjusted when your rid- Payload and Tire Pressure ing involves wide variations in tem- Failure to maintain proper inflation perature or altitude.
  • Page 114 MAINTENANCE AND ADJUSTMENT • In accordance with the Periodic Tire Air Pressure (when cold) Maintenance Chart, measure the Up to 165 kg 150 kPa (1.50 Front depth of the tread with a depth (364 lb) Load kgf/cm², 21 psi) gauge, and replace any tire that Up to 97.5 kg 150 kPa (1.50 Rear...
  • Page 115 MAINTENANCE AND ADJUSTMENT • Visually inspect the tire for cracks Standard Tire and cuts, replacing the tire in case of Front Size: 2.75-21 45P bad damage. Swelling or high spots BRIDGESTONE “TRAIL indicate internal damage, requiring WING-301” tire replacement. • Rear Size: 4.10-18 59P Remove any imbedded stones or...
  • Page 116: Battery

    MAINTENANCE AND ADJUSTMENT Battery WARNING 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 117 MAINTENANCE AND ADJUSTMENT NOTE Battery Removal • Remove the left side cover. If you charge the sealed battery, • Disconnect the leads from the bat- never fail to observe the instructions tery, first from the (–) terminal and shown in the label on the battery. then the (+) terminal.
  • Page 118: Headlight Beam

    MAINTENANCE AND ADJUSTMENT • Headlight Beam Clean the battery using a solution of baking soda and water. Be sure that Horizontal Adjustment the lead connections are clean. The headlight beam is adjustable horizontally. If not properly adjusted Battery Installation horizontally, the beam will point to one •...
  • Page 119 MAINTENANCE AND ADJUSTMENT NOTE Vertical Adjustment The headlight beam is adjustable ver- On high beam, the brightest point tically. If adjusted too low, neither low should be slightly below horizontal. nor high beam will illuminate the road The proper angle is 0.4 degrees be- far enough ahead.
  • Page 120: Fuses

    MAINTENANCE AND ADJUSTMENT CAUTION Fuses The main fuse is mounted on the When handling quartz starter relay located to the left side of -halogen bulbs, never touch the the battery. The fuse case is located to glass portion with bare hands. the left side of the starter relay.
  • Page 121 MAINTENANCE AND ADJUSTMENT WARNING Do not use any substitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse case. A. Normal B. Failed A. Normal B. Failed...
  • Page 122: General Lubrication

    MAINTENANCE AND ADJUSTMENT General Lubrication Apply motor oil to the following Lubricate the points shown below, pivots - with either motor oil or regular grease, Side Stand in accordance with the Periodic Main- Clutch Lever tenance Chart or whenever the vehicle Front Brake Lever has been operated under wet or rainy Rear Brake Pedal...
  • Page 123: Cleaning Your Motorcycle

    General Precautions Clutch Inner Cable Upper End Frequent and proper care of your Throttle Inner Cable Upper Ends Kawasaki motorcycle will enhance its appearance, optimize overall per- * Grease the lower part of the inner formance, and extend its useful life.
  • Page 124 MAINTENANCE AND ADJUSTMENT • • Gasoline, brake fluid, and coolant Mix a mild neutral detergent (de- will damage the finish of painted and signed for motorcycles or automo- plastic surfaces: wash them off im- biles) and water in bucket. mediately. a soft cloth or sponge to wash your •...
  • Page 125 MAINTENANCE AND ADJUSTMENT brakes and restores them to normal Painted Surfaces operating performance. After washing your motorcycle, coat • Lubricate the drive chain to prevent painted surfaces, both metal and plas- rusting. tic, with a commercially available mo- torcycle/automotive wax. Wax should NOTE be applied once every three months or as conditions require.
  • Page 126 MAINTENANCE AND ADJUSTMENT CAUTION should be washed with a mild neu- tral detergent and finished with a spray Plastic parts may deteriorate polish. Aluminum wheels, both painted and brake if they come in con- and unpainted can be cleaned with tact with chemical substances special non-acid based wheel spray or household cleaning products...
  • Page 127 MAINTENANCE AND ADJUSTMENT WARNING Special care must be taken not to get any rubber protectant on the tire’s tread surface when treat- ing tires. This may decrease the tire’s ability to maintain contact with the road surface causing the rider to lose control.
  • Page 128: Bolt And Nut Tightening

    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.
  • Page 129 MAINTENANCE AND ADJUSTMENT 13. Muffler Mounting Bolts 14. Brake Lever Holder Bolt 15. Rear Axle Nut 16. Exhaust Pipe Holder Nuts 17. Front Axle Nut...
  • Page 130: Storage

    STORAGE STORAGE Preparation for Storage: • Clean the entire vehicle thoroughly. • Run the engine for about five minutes to warm the oil, shut it off and drain the engine oil. WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
  • Page 131 • Remove the spark plugs and spray fogging oil, such as Kawasaki K-Kare Fogging Oil (part number K61030-002), directly into each cylinder. Turn the engine over several times with the starter button to coat the cylinder walls. Install the spark...
  • Page 132 STORAGE WARNING Do not lean over the engine when performing this procedure. An air/oil mist may be forcibly ejected from the spark plug hole and could get into your eyes. if you do get some in your eyes, wash your eyes immediately with liberal amounts of clean, fresh water.
  • Page 133 STORAGE Preparation after Storage: • Remove the plastic bag from the muffler. • Install the battery in the motorcycle and charge the battery if necessary. • Make sure the spark plug is tight. • Fill the fuel tank with fuel. •...
  • Page 134: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE • Engine Does Not Start - Spark plugs fouled or wet • Starter Motor Won’t Turn Incorrect spark plug gap • • Engine stop switch off Battery discharged • Clutch lever not pulled in and trans- Engine Stalls - mission not in neutral •...
  • Page 135: Owner Satisfaction

    Kawasaki dealer network. If you are unsatisfied after working with your Kawasaki dealer and feel you still re- quire further assistance, write to the address below. Please be certain to provide...
  • Page 136 In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence. Please send your correspondence to: CONSUMER RELATIONS KAWASAKI MOTORS CORP., U.S.A. P. O. Box 25252 SANTA ANA, CA. 92799-5252 (949) 460–5688...
  • Page 137: Reporting Safety Defects

    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.
  • Page 138: 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 139: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Owner Name..................Address ....................Phone Number ................... Engine Number .................. Vehicle Number.................. Selling Dealer Name ................Phone Number ................... Warranty Start Date ................Note: Keep this information and a spare key in a secure location. Odometer Date Maintenance Performed Dealer Name...
  • Page 140 MAINTENANCE RECORD Odometer Date Dealer Name Dealer Address Maintenance Performed Reading...
  • Page 141 MAINTENANCE RECORD Odometer Date Dealer Name Dealer Address Maintenance Performed Reading...
  • Page 142 MAINTENANCE RECORD Odometer Date Dealer Name Dealer Address Maintenance Performed Reading...
  • Page 143 MAINTENANCE RECORD Odometer Date Dealer Name Dealer Address Maintenance Performed Reading...
  • Page 144: Label Information

    LABEL INFORMATION LABEL INFORMATION...
  • Page 145 LABEL INFORMATION...
  • Page 146 LABEL INFORMATION...
  • Page 147 LABEL INFORMATION...
  • Page 148 LABEL INFORMATION...
  • Page 149 LABEL INFORMATION...
  • Page 151 LABEL INFORMATION (8)/(9) (11) (10)

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