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Quick Reference Guide
This Quick Reference Guide will
assist you in finding the information
you're looking for.
A Table of Contents is included after
the Foreword.
SAFETY INFORMATION
GENERAL INFORMATION
HOW TO RIDE THE MOTORCYCLE
MAINTENANCE AND ADJUSTMENT
APPENDIX
MAINTENANCE RECORD
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Table of Contents

   Summary of Contents for Kawasaki Z250

  • Page 1 SAFETY INFORMATION Quick Reference Guide GENERAL INFORMATION This Quick Reference Guide will HOW TO RIDE THE MOTORCYCLE assist you in finding the information you’re looking for. MAINTENANCE AND ADJUSTMENT APPENDIX MAINTENANCE RECORD A Table of Contents is included after the Foreword.
  • Page 2 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-...
  • Page 3 NOTICE THIS PRODUCT BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OP- ERATOR AND AS A VEHICLE ONLY.
  • Page 4 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 5 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. Motorcycle & Engine Company © 2012 Kawasaki Heavy Industries, Ltd. Dec. 14, 2012. (1)
  • Page 6: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION ....GENERAL INFORMATION....19 Read Owner’s Manual ..... Specifications ........19 Training ..........Serial Number Locations....24 Daily Safety Checks and Periodic Location of Labels ......25 Maintenance ......... Location of Parts ......33 Loading and Accessories Meter Instruments ......
  • Page 7 Helmet Hooks........59 Throttle Control System ....97 Tying Hooks ........60 Idle Speed ........99 Tool Kit/Storage Compartment ..60 Clutch ..........100 Rear View Mirror ......61 Drive Chain ........102 Event Data Recorder......62 Brakes ..........106 HOW TO RIDE THE MOTORCYCLE .
  • Page 8: Safety Information

    Training WARNING Failure to perform these checks Kawasaki strongly recommends that or to correct a problem before all operators of this vehicle complete a operation may result in serious suitable motorcycle rider training pro- damage or an accident. Always...
  • Page 9: Loading And Accessories Information

    Before you ride the Kawasaki dealer as soon as possible. motorcycle, make sure it is not overloaded and that you have followed these instructions.
  • Page 10: Passenger

    Kawasaki Parts and Accessories oughly familiar with motorcycle op- have been specially designed for eration. The passenger can affect use on Kawasaki motorcycles. We control of the motorcycle by im- strongly recommend that all parts proper positioning during cornering and accessories you add to your and sudden movements.
  • Page 11: Baggage And Luggage

    SAFETY INFORMATION 4. Do not carry passengers unless will not move around while you are passenger footpegs are installed. riding. Recheck baggage security Instruct any passenger before riding as often as possible (not while the to keep his or her feet on the pas- motorcycle is in motion) and adjust senger footpegs and hold on to the as necessary.
  • Page 12: Other Load

    Kawasaki does not manu- 2. Weight attached to the handlebars facture sidecars or trailers for mo- or front fork will increase the mass...
  • Page 13: Safe Operation

    Do not run the engine in en- ent. Have your motorcycle thoroughly closed areas. Operate only in a checked at a Kawasaki dealer as soon well-ventilated area. as possible. Safe Operation The following should be carefully ob- served for safe and effective vehicle operation.
  • Page 14: Fueling

    SAFETY INFORMATION Fueling Protective Gear and Clothing Helmet WARNING Kawasaki strongly recommends both Gasoline is extremely flammable the operator and passenger wear a hel- and can be explosive under cer- met even if this is not a legal require- tain conditions. To prevent fire ment.
  • Page 15: Safe Riding Techniques

    SAFETY INFORMATION Gloves Safe Riding Techniques Wear gloves which have suitable protection for your hands, especially against abrasion. Keep Hands on Handlebars Clothing When riding always keep both hands Wear protective clothing. on the handlebars and both feet on the Wear bright, highly visible clothing footpegs.
  • Page 16 SAFETY INFORMATION Accelerate and Brake Smoothly throttle so that the engine can act as an In general your actions should be auxiliary brake. Use the front and rear smooth as sudden acceleration, brak- brakes for primary braking. ing or turning may cause loss of control, Riding in Wet Conditions especially when riding in wet conditions Rely more on the throttle to control...
  • Page 17: Additional Considerations For High Speed Operation

    SAFETY INFORMATION fuel consumption but also for long ve- Additional Considerations for hicle life and quieter operation. High Speed Operation Riding on Rough Roads Exercise caution, slow down, and grip the fuel tank with the knees for WARNING better stability. Handling characteristics of a Acceleration motorcycle at high speeds may...
  • Page 18: Electrical Equipment

    SAFETY INFORMATION Engine Oil see that they are correctly adjusted and functioning properly. To avoid engine seizure and resulting loss of control, make sure that the oil Steering level is at the upper level line. Looseness in the steering can cause Coolant loss of control.
  • Page 19: General Information

    GENERAL INFORMATION GENERAL INFORMATION Specifications PERFORMANCE Maximum (TH) 23.0 kW (31 PS) @11 000 r/min (rpm) Horsepower (ID, MY, PH) 23.5 kW (32 PS) @11 000 r/min (rpm) Maximum Torque (TH) 21.0 N·m (2.1 kgf·m, 15 ft·lb) @8 500 r/min (rpm) (ID, MY, PH) 21.0 N·m (2.1 kgf·m, 15 ft·lb) @10 000 r/min (rpm) Minimum Turning Radius...
  • Page 20 GENERAL INFORMATION Road Clearance 145 mm (5.71 in.) Curb Mass 168 kg (370 lb) ENGINE Type DOHC, 2-cylinder, 4-stroke, liquid-cooled Displacement 249 cm³ (15.2 cu in.) Bore × Stroke 62.0 × 41.2 mm (2.44 × 1.62 in.) Compression Ratio 11.3 : 1 Starting System Electric starter Cylinder Numbering Method...
  • Page 21 GENERAL INFORMATION Engine Oil: Type API SG, SH, SJ, SL, or SM with JASO MA, MA1 or Viscosity SAE 10W-40 Capacity 2.4 L (2.5 US qt) Coolant Capacity 1.5 L (1.6 US qt) TRANSMISSION Transmission Type 6-speed, return shift Clutch Type Wet, multi disc Driving System Chain drive...
  • Page 22 GENERAL INFORMATION 1.409 (31/22) 1.160 (29/25) 1.000 (27/27) 0.893 (25/28) FRAME Castor 26° Trail 82 mm (3.2 in.) Tire Size: Front 110/70-17M/C 54S Rear 140/70-17M/C 66S Rim Size: Front J17M/C × MT2.75 Rear J17M/C × MT4.00 Fuel Tank Capacity 17 L (4.5 US gal) Brake Fluid: Front DOT3 or 4...
  • Page 23 GENERAL INFORMATION Headlight: High Beam 12 V 55 W + 55 W Low Beam 12 V 55 W Tail/Brake Light 12 V 5/21 W TH: Thailand model ID: Indonesia model MY: Malaysia model PH: Philippines model Specifications are subject to change without notice, and may not apply to every country.
  • Page 24: Serial Number Locations

    GENERAL INFORMATION 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 25: Location Of Labels

    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 ○...
  • Page 26 GENERAL INFORMATION 2. Brake Fluid (Rear) 3. Battery Poison/Danger 4. Rear Shock Absorber Warning...
  • Page 27 GENERAL INFORMATION 5. Radiator Cap Danger 6. Important Drive Chain Information 7. Tire and Load Data 8. Daily Safety Checks...
  • Page 28 GENERAL INFORMATION *9. Vehicle Emission Control Information **10. Helmet Wearing **11. Vacuum Hose Routing Diagram *: Only on Philippines model **: Only on Thailand model...
  • Page 29 GENERAL INFORMATION...
  • Page 30 GENERAL INFORMATION...
  • Page 31 GENERAL INFORMATION 9) only on Philippines model 10) only on Thailand model...
  • Page 32 GENERAL INFORMATION 11) only on Thailand model...
  • Page 33: Location Of Parts

    GENERAL INFORMATION Location of Parts 1. Rear View Mirrors 6. Front Brake Lever 2. Clutch Lever 7. Left Handlebar Switches 3. Starter Lockout Switch 8. Ignition Switch/Steering Lock 4. Meter Instruments 9. Right Handlebar Switches 5. Brake Fluid Reservoir (Front) 10.
  • Page 34 GENERAL INFORMATION 1. Headlight 7. Tool Kit 13. Shift Pedal 2. Turn Signal Lights 8. Tying Hooks 14. Side Stand 3. Spark Plugs 9. License Plate Light 15. Swingarm 4. Fuel Tank 10. Front Fork 16. Drive Chain 5. Idle Adjusting Screw 11.
  • Page 35 GENERAL INFORMATION 1. Muffler 8. Fuel Tank Cap 2. Tail/Brake Light 9. Brake Discs 3. Passenger’s Seat 10. Brake Calipers 4. Brake Fluid Reservoir (Rear) 11. Rear Brake Light Switch 5. Rider’s Seat 12. Rear Brake Pedal 6. Air Cleaner 13.
  • Page 36: Meter Instruments

    GENERAL INFORMATION Meter Instruments A. Green Neutral Indicator Light B. Red Battery Voltage Warning Indicator Light C. Red Oil Pressure Warning Indicator Light D. Red Coolant Temperature Warning Indicator Light E. Yellow Engine Warning Indicator Light F. Blue High Beam Indicator Light G.
  • Page 37: Tachometer

    If the tachometer does Engine r/min (rpm) should not not operate correctly, have it checked be allowed to enter the red zone; by an authorized Kawasaki dealer. operation in the red zone will overstress the engine and may cause serious engine damage.
  • Page 38: Multifunction Meter

    GENERAL INFORMATION Multifunction Meter A. Economical Riding Indicator B. Speedometer C. Clock D. Multifunction Display - Odometer - Trip Meter A - Trip Meter B E. Fuel Gauge When the ignition switch is turned on, all LCD segments are displayed with opening display functions for few seconds, then the multifunction meter turns to operational mode.
  • Page 39 GENERAL INFORMATION Speedometer NOTE ○ The speedometer shows the speed Do not operate the motorcycle with of the vehicle in digital values. wrong unit (mph or km/h) of the speedometer. Unit Setting The unit setting in the meter instru- To change the meter display unit in ment can be changed according to lo- the meter instrument as follows: •...
  • Page 40 GENERAL INFORMATION NOTE NOTE ○ ○ For safety, do not operate the instru- The data is maintained even if the ment buttons while riding the motor- battery is disconnected. ○ cycle. When the figures come to 999999, ○ The multifunction display is dis- they are stopped and locked.
  • Page 41 GENERAL INFORMATION • • Push the right button and hold it in. Push the right button for more than • After two seconds, the figure display two seconds. Both the hour and turns to 0.0, and then starts counting minute displays start blinking. when the vehicle is operated.
  • Page 42 GENERAL INFORMATION ○ When the battery is disconnected, the clock is reset to 1:00 and starts working again when the battery is connected. • Economical Riding Indicator Push the right button. Both the hour When the operator is driving the mo- and minute displays start blinking torcycle for optimum fuel-efficiency, the again.
  • Page 43 GENERAL INFORMATION WARNING the fuel gauge checked by an autho- rized Kawasaki dealer. Failing to properly observe the As the fuel level in the tank goes road ahead increases the chance down, the segments disappear one by of an accident resulting in se- one from F (full) to E (empty).
  • Page 44: Indicator Lights

    : When the turn signal switch is will blink in case of the open or short of pushed to the left or right, the cor- the wiring. Have the wiring inspected responding turn signal indicator light by an authorized Kawasaki dealer im- blinks. mediately.
  • Page 45: Warning Indicator Light

    GENERAL INFORMATION have the engine lubrication system Warning Indicator Light checked by an authorized Kawasaki dealer. Red Battery Voltage Warning NOTICE Indicator Light If the engine oil gets extremely : The battery voltage warning in- low or if the oil pump does not...
  • Page 46: Keys

    : The engine warning indicator fuel tank cap. light goes on when the ignition switch Blank keys are available at your is turned on and goes off soon after Kawasaki dealers. Ask your dealer to make any additional spare keys you...
  • Page 47: Ignition Switch/steering Lock

    GENERAL INFORMATION may need, using your original key as a master. Ignition Switch/Steering Lock This is a three-position, key-operated switch. The key can be removed from the switch when it is in the “OFF” or “LOCK” position. A. Ignition Switch/Steering Lock B.
  • Page 48 GENERAL INFORMATION NOTE ○ The tail, city and license plate lights are on whenever the ignition key is in the “ON” position. Headlights go on when the starter button is released after starting the engine. To avoid battery discharge, always start the engine immediately after turning the ignition key to “ON.”...
  • Page 49: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches The engine stop switch is for emer- gency use. If required, move the switch to the position. NOTE ○ Although the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine.
  • Page 50: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches High beam..( Low beam..( Turn Signal Switch When the turn signal switch is turned to the left ( ) or right ( ), the corresponding turn signals blink on and off. To stop blinking, push the switch in. Horn Button When the horn button is pushed, the horn sounds.
  • Page 51: Fuel Tank Cap

    ○ Do not push on the key to close the Fuel Requirements cap, or the cap cannot be locked. Your Kawasaki engine is designed to use only unleaded gasoline with a minimum octane rating shown below.
  • Page 52 NOTICE Never use gasoline with an octane rat- ing lower than the minimum specified If engine “knocking” or “ping- by Kawasaki to prevent severe engine ing” occurs, use a different damage. brand of gasoline of a higher The octane rating of a gasoline is a octane rating.
  • Page 53 GENERAL INFORMATION Fuel Type and Octane Rating (For Philippines Thailand Specification) (Except for Philippines and Thailand Use clean, fresh unleaded gasoline Specifications) with an ethanol volume content not Use clean, fresh unleaded gasoline more than 10 % and an octane rating with an octane rating equal to or higher equal to or higher than that shown in than that shown in the table.
  • Page 54: Filling The Tank

    GENERAL INFORMATION NOTICE Do not use any fuel that con- tains more ethanol or other oxy- genates than specified for E10 fuel* in this vehicle. Damage to the engine and fuel system, or engine starting and/or per- formance problems may result from the use of improper fuel.
  • Page 55 GENERAL INFORMATION NOTICE WARNING Gasoline is extremely flammable Thailand model only: and can be explosive under cer- Never fill the tank so the fuel tain conditions, creating the po- level rises into the filler neck. If tential for serious burns. Turn the tank is overfilled, heat may the ignition switch off.
  • Page 56: Side Stand

    GENERAL INFORMATION Side Stand Do not sit on the motorcycle while it is on its side stand. Always kick the stand The motorcycle is equipped with the fully up before sitting on the motorcycle. side stand. NOTE ○ Other than Indonesia model, the mo- torcycle is equipped with a side stand switch.
  • Page 57 GENERAL INFORMATION A. Side Cover (Left Side) A. Bolt and Collar (Left Side) B. Bolt and Collar B. Rider’s Seat C. Projections C. Pull Up and Rear • Remove the bolts and collars on the Rider’s Seat Installation rider’s seat, and pull off the seat to Install the rider’s seat in the reverse the up and rear.
  • Page 58 GENERAL INFORMATION • Pull up the front of seat, and remove the passenger’s seat by pushing it to the front. A. Rider’s Seat B. Tabs C. Slots D. Insert • A. Ignition Key Install the collars and tighten the B. Seat Lock bolts.
  • Page 59: Helmet Hooks

    GENERAL INFORMATION • • Insert the projection in front of the Pull up the front and rear ends of the passenger’s seat into the hole on the passenger’s seat to make sure they frame. are securely locked. Helmet Hooks Helmets can be secured to the motor- cycle using the helmet hooks.
  • Page 60: Tying Hooks

    GENERAL INFORMATION A. Helmet Hooks A. Tying Hooks Tying Hooks Tool Kit/Storage Compartment When tying up light loads to the seat, use the tying hooks located in front of The tool kit and storage compartment the rear turn signal lights and rear of the is located under the passenger’s seat.
  • Page 61: Rear View Mirror

    GENERAL INFORMATION • Keep the tool kit in the storage com- If the rear visibility can not be as- partment. sured by moving the mirror, loosen the upper hexagonal area and turn the stay by hand. NOTE ○ The upper hexagonal area (locknut) has left hand threads.
  • Page 62: Event Data Recorder

    Event Data Recorder name, gender, age). In common with many other ve- This data can help provide a better hicle manufacturers, Kawasaki has understanding for both the rider and equipped this motorcycle with an event the manufacturer of how the vehicle data recorder (EDR).
  • Page 63 EDR is required. Kawasaki will not of an accident such information as: share EDR information without obtain- • Vehicle speed, ing your consent, unless required by •...
  • Page 64: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Break-In Distance Maximum engine traveled speed The first 1 600 km (1 000 mi) that the 0 ∼ 800 km motorcycle is ridden is designated as 4 000 r/min (rpm) (0 ∼...
  • Page 65: Starting The Engine

    A. Engine Stop Switch that the owner has the initial mainte- B. Starter Button nance service performed by an autho- • Turn the ignition key to “ON” position. rized Kawasaki dealer. • Make sure the transmission is in neu- tral.
  • Page 66 HOW TO RIDE THE MOTORCYCLE if the engine cannot be started. Af- ter righting the motorcycle, first turn the ignition key to “OFF” position and then back to “ON” position before starting the engine. • Without holding the throttle grip, push the starter button to start the engine.
  • Page 67: Jump Starting

    HOW TO RIDE THE MOTORCYCLE NOTICE designed so that the engine does not start if the transmission is in gear and Do not let the engine idle longer the side stand is down. However, the than five minutes, or engine engine can be started if the clutch overheating and damage may lever is pulled and the side stand is...
  • Page 68 HOW TO RIDE THE MOTORCYCLE • DANGER Remove the side covers and the rider’s seat. Battery acid generates hydro- • Remove the battery cover. Refer to gen gas which is flammable and the Battery section in the MAINTE- explosive under certain con- NANCE AND ADJUSTMENT chap- ditions.
  • Page 69 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 70: Moving Off

    HOW TO RIDE THE MOTORCYCLE NOTICE Moving Off • Do not operate the starter con- Check that the side stand is up. • tinuously for more than 5 sec- Pull in the clutch lever. • onds or the starter will overheat Shift into 1st gear.
  • Page 71: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE NOTE WARNING ○ Other than Indonesia model, the mo- Downshifting to a lower gear at torcycle is equipped with a side stand high speed causes engine rpm switch. This switch is designed so to increase excessively, poten- that the engine does not start if the tially damaging the engine and transmission is in gear and the side...
  • Page 72: Braking

    HOW TO RIDE THE MOTORCYCLE • standing still. The transmission will For emergency braking, disregard shift only into neutral. downshifting, and concentrate on applying the brakes as hard as pos- sible without skidding. Braking • Close the throttle completely, leav- ing the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle.
  • Page 73: Stopping The Engine

    Emergency • Shift the transmission into neutral. • Turn the ignition key to “OFF” posi- Your Kawasaki Motorcycle has been tion. designed and manufactured to pro- • Support the motorcycle on a firm, vide you optimum safety and conve- level surface with the side stand.
  • Page 74: Parking

    HOW TO RIDE THE MOTORCYCLE you, the owner and operator, properly the engine. If the engine stop switch is maintain your motorcycle and become used, turn off the ignition switch after thoroughly familiar with its operation. stopping the motorcycle. Improper maintenance can create a Parking dangerous situation known as throt- tle failure.
  • Page 75 HOW TO RIDE THE MOTORCYCLE • WARNING If parking inside a garage or other structure, be sure it is well ventilated The engine and exhaust system and the motorcycle is not close to get extremely hot during normal any source of flame or sparks; this operation and can cause serious includes any appliance with a pilot burns.
  • Page 76: Maintenance And Adjustment

    Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect or improper adjustment made by the owner.
  • Page 77 The cooling fan spins at high speed and can cause serious injuries. Keep your hands and clothing away from the cooling fan blades at all times. NOTE ○ If a torque wrench is not available, the maintenance items which require a specific torque value should be serviced by an authorized Kawasaki dealer.
  • Page 78: Daily Safety Checks

    MAINTENANCE AND ADJUSTMENT 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 motorcycle to a safe operating condition.
  • Page 79 MAINTENANCE AND ADJUSTMENT Operation Page Lubricate if dry Bolts, nuts and fasteners – Check for loose and/or missing bolts, nuts and fasteners Steering – Action smooth but not loose from lock to lock – No binding of control cables Brakes Brake pad wear Brake fluid level –...
  • Page 80 MAINTENANCE AND ADJUSTMENT Operation Page Coolant – No coolant leakage Coolant level between level lines (when engine is cold) Electrical equipment – All lights (head, tail/brake, turn signal, warning/indicator) and horn work Engine stop switch – Stops engine Side stand –...
  • Page 81: Periodic Maintenance

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first. *B: For higher odometer readings, repeat at the frequency interval established here. *C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
  • Page 82 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Air cleaner element (*C) Idle speed Throttle control system (play, smooth return, no drag) – Engine vacuum synchronization –...
  • Page 83 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) : every 36 000 km – Coolant, water hoses and O-rings (22 500 mile) – Valve clearance –...
  • Page 84 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) : every 1 000 km Drive chain slack (*C) (600 mile) – Drive chain wear (*C) – Drive chain guide wear –...
  • Page 85 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Brake light switch operation – Suspension system – Lubrication of rear suspension – Steering play – Steering stem bearings –...
  • Page 86: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • If the engine is cold, start the engine and run it for several minutes at idle speed. • Stop the engine, then wait several minutes until the oil settles. NOTICE A. Oil Level Inspection Window Racing the engine before the oil B.
  • Page 87: Oil And/or Oil Filter Change

    MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • The oil change and oil filter replace- ment should be done by an autho- rized Kawasaki dealer. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods A.
  • Page 88 MAINTENANCE AND ADJUSTMENT NOTE ○ Do not add any chemical additive to the oil. Oils fulfilling the above re- quirements are fully formulated and provide adequate lubrication for both the engine and the clutch. Engine Oil Capacity Capacity: 2.0 L (2.1 US qt) [when filter is not removed] A.
  • Page 89: Coolant

    MAINTENANCE AND ADJUSTMENT A. F (Full) Level Line Coolant B. L (Low) Level Line C. Reserve Tank Coolant Level Inspection NOTE • Position the motorcycle so that it is ○ Check the level when the engine is perpendicular to the ground. •...
  • Page 90 MAINTENANCE AND ADJUSTMENT Coolant Filling • Remove the right side cover. Refer to the Seat section in the GENERAL INFORMATION chapter. • Remove the screw, bolt and collar on the right knee grip cover. • Clear the projections and tabs on the right knee grip cover.
  • Page 91 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. • Install the reserve tank cap. •...
  • Page 92 G. Holes cooling system. On the mixture ratio of coolant, choose the suitable one re- Coolant Change ferring to the relation between freezing Have the coolant changed by an au- point and strength directed on the con- thorized Kawasaki dealer. tainer.
  • Page 93: Air Cleaner

    MAINTENANCE AND ADJUSTMENT • NOTICE Unscrew the air cleaner element cap mounting screws, then remove the If hard water is used in the sys- air cleaner element cap. tem, it causes scale accumula- tion in the water passages, and considerably reduces the effi- ciency of the cooling system.
  • Page 94 MAINTENANCE AND ADJUSTMENT A. Element A. Element B. Frame • Remove the element from the frame. • Put a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering. • Inspect the element material for dam- age.
  • Page 95 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 throttle body • Squeeze it dry in a clean towel. Do assembly, the throttle may be- not wring the element or blow it dry;...
  • Page 96 MAINTENANCE AND ADJUSTMENT WARNING Gasoline and low flash-point sol- vents are extremely flammable and may explode, causing se- vere burns. Do not use gaso- line or a low flash-point solvent to clean the element. Clean the element in a well-ventilated area. Be sure there are no sparks or flame in the work area, including A.
  • Page 97: Throttle Control System

    2 ∼ 3 mm (0.08 ∼ 0.12 in.) steering positions. • • If the throttle grip does not return If there is improper play, adjust it. properly, have the throttle control system checked by an authorized Kawasaki dealer.
  • Page 98 Throttle Grip Free Play Adjustment • Loosen the locknut at the throttle justment of the throttle cables should grip, and turn the adjuster until the be done by an authorized Kawasaki proper amount of throttle grip play is dealer. • obtained.
  • Page 99: Idle Speed

    MAINTENANCE AND ADJUSTMENT • Idle Speed Open and close the throttle a few times to make sure that the idle speed does not change. Readjust if Idle Speed Adjustment • necessary. Start the engine, and warm it up thor- • With the engine idling, turn the han- oughly.
  • Page 100: 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. • Check the clutch lever play as shown. Clutch Lever Play A.
  • Page 101 MAINTENANCE AND ADJUSTMENT WARNING Too much cable play can pre- vent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replac- ing the cable, be sure the up- per end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creat- A.
  • Page 102: Drive Chain

    MAINTENANCE AND ADJUSTMENT Drive Chain Drive Chain Lubrication Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for sealed chains to prevent deterioration of chain seals. If the chain is especially dirty, clean it using a cleaner for sealed chains fol- lowing the instructions supplied by the...
  • Page 103 MAINTENANCE AND ADJUSTMENT chain midway between the engine Drive Chain Slack Adjustment • sprocket and rear wheel sprocket. Loosen the left and right chain ad- juster locknuts. • Remove the cotter pin, and loosen the axle nut. A. Chain Slack •...
  • Page 104 MAINTENANCE AND ADJUSTMENT • If the chain is too tight, turn out the left and right chain adjusting nuts evenly. • Turn out both chain adjusting nuts evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch on the left wheel alignment in- dicator should align with the same...
  • Page 105 If a torque wrench is not available, NOTE this item should be serviced by an ○ When inserting the cotter pin, if the authorized Kawasaki dealer. slots in the nut do not align with the cotter pin hole in the axle shaft,...
  • Page 106: Brakes

    • Check the rear brake (see the Brakes section). Brakes Brake Operation Inspection • If you feel there is something wrong when applying the brakes, have the brake system checked by an autho- A. Turn Clockwise rized Kawasaki dealer immediately.
  • Page 107 Have the brake checked immediately by an au- A. Front Brake Fluid Reservoir thorized Kawasaki dealer. B. Lower Level Line • With the rear brake fluid reservoir Brake Fluid Level Inspection •...
  • Page 108 In this case, have the brake system inspected by an au- thorized Kawasaki dealer. Brake Pad Wear Inspection A. Front Brake Pads Inspect the brakes for wear. For each B.
  • Page 109: Brake Light Switches

    MAINTENANCE AND ADJUSTMENT • If it does not, ask your authorized Kawasaki dealer to inspect the front brake light switch. • Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go on after the proper pedal travel.
  • Page 110: Suspension System

    MAINTENANCE AND ADJUSTMENT NOTICE Brake Pedal Travel 10 mm (0.4 in.) To avoid damaging the electrical connections inside the switch, be sure that the switch body Brake Light Switch Adjustment • does not turn during adjustment. To adjust the rear brake light switch, move the switch up or down by turn- ing the adjusting nut.
  • Page 111 MAINTENANCE AND ADJUSTMENT A. Chain Cover A. Bolts B. Bolts • Turn the adjuster counterclockwise to increase spring preload and stiffen the suspension. • Turn the adjuster clockwise to de- crease preload and soften the sus- pension.
  • Page 112 MAINTENANCE AND ADJUSTMENT A. Spring Preload Adjuster B. Wrench • Install the chain cover in the reverse order of removal.
  • Page 113: Setting Table

    MAINTENANCE AND ADJUSTMENT Setting Table Rear Shock Absorber Spring Preload Setting Hardest setting Softest setting limit Standard limit Adjuster Position ←→ Weak Spring Action Strong ←→ Hard Setting Soft ←→ Load Light Heavy ←→ Road Good ←→ Speed High...
  • Page 114: Wheels

    MAINTENANCE AND ADJUSTMENT Wheels Tire Pressure Inspection • Remove the air valve cap. • Check the tire pressure often, using an accurate gauge. • Make sure to install the air valve cap securely. NOTE ○ Measure the tire pressure when the A.
  • Page 115 MAINTENANCE AND ADJUSTMENT So it is false economy and unsafe to Minimum Tread Depth use the tires until they are bald. — Front 1 mm (0.04 in.) Tire Wear Inspection Under 130 km/h • 2 mm (0.08 in.) Measure the depth of the tread with (80 mph) Rear a depth gauge, and replace any tire...
  • Page 116 MAINTENANCE AND ADJUSTMENT WARNING Tires that have been punctured and repaired do not have the same capabilities as undam- aged tires and can suddenly fail, causing an accident resulting in serious injury or death. Re- place damaged tires as soon as possible.
  • Page 117 MAINTENANCE AND ADJUSTMENT ○ When operating on public roadways, WARNING keep maximum speed under traffic Mixing tire brands and types can law limits. adversely affect handling and cause an accident resulting in Standard Tire (Tubeless) injury or death. Always use the Make, Type: same manufacturer’s tires on IRC, ROAD WINNER RX-01F...
  • Page 118: Battery

    The battery installed in this motorcy- charged using an appropriate charger cle is a sealed type, so it is not nec- (check with your Kawasaki dealer). essary to check the battery electrolyte If you will not be using the motorcy- level or add distilled water.
  • Page 119 If the above chargers are not avail- away from the battery. Wear eye able, use equivalent one. protection when working with a For more details, ask your Kawasaki battery. In the event of battery dealer. acid contact with skin, eyes, or...
  • Page 120 MAINTENANCE AND ADJUSTMENT Seats section in the GENERAL IN- FORMATION chapter. • Unscrew the cover screw and pull up the battery cover with the relay assy. A. (+) Terminal B. (–) Terminal • Take the battery out of the case. •...
  • Page 121 MAINTENANCE AND ADJUSTMENT NOTICE Installing the (–) cable to the (+) terminal of the battery or the (+) cable to the (–) terminal of the battery can seriously damage the electrical system. • Put a light coat of grease on the ter- minals to prevent corrosion.
  • Page 122: Headlight

    C. Battery Cover Headlight A. Horizontal Adjuster B. Vertical Adjuster Headlight aiming should be done by an authorized Kawasaki dearer. 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.
  • Page 123: Fuses

    MAINTENANCE AND ADJUSTMENT the high beam will fail to illuminate the road close ahead, and the low beam will blind oncoming drivers. • Turn the vertical adjuster in or out to adjust the headlight vertically. NOTE ○ On high beam, the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated.
  • Page 124 MAINTENANCE AND ADJUSTMENT system. Have the motorcycle checked WARNING by an authorized Kawasaki dealer. Substituting fuses can cause The main fuse removal should be wiring to overheat, catch fire done by an authorized Kawasaki and/or fail. Do not use any sub- dealer.
  • Page 125: General Lubrication

    Clutch Lever (K) Throttle Inner Cable Upper Ends • Front Brake Lever • Rear Brake Pedal (K): Should be serviced by an authorized Kawasaki dealer. Lubricate the following cables with a pressure cable luber NOTE • ○ (K) Clutch Inner Cable After connecting the cables, adjust •...
  • Page 126: Cleaning Your Motorcycle

    Frequent and proper care of your and increase the risk of fire. Kawasaki motorcycle will enhance When operating the vehicle in its appearance, optimize overall per- conditions that allow debris or formance, and extend its useful life.
  • Page 127: Washing Your Motorcycle

    MAINTENANCE AND ADJUSTMENT • • Be sure the engine and exhaust are Avoid spraying water in delicate cool before washing. areas such as in air intakes, fuel sys- • Avoid applying degreaser to seals, tem, brake components, electrical brake pads, and tires. components, muffler outlet, and fuel •...
  • Page 128 MAINTENANCE AND ADJUSTMENT detergent can damage parts of your immediately wash your motorcycle motorcycle). with cold water. Do not use warm • Use a soft cloth to dry your motorcy- water as it accelerates the chemical cle. As you dry, inspect your motor- reaction of the salt.
  • Page 129 Do not obstruct or deflect air- • If any doubt, consult an authorized flow through the radiator by Kawasaki dealer. installing unauthorized acces- sories in front of the radiator or Other Plastic Parts behind the cooling fan. Inter-...
  • Page 130 MAINTENANCE AND ADJUSTMENT NOTICE should be washed with a mild neu- tral detergent and finished with a spray Plastic parts may deteriorate polish. Aluminum wheels, both painted and break 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 131 MAINTENANCE AND ADJUSTMENT WARNING Rubber protectants can be slip- pery and, if used on the tread area, cause loss of traction re- sulting in accident causing in- jury or death. Do not apply rub- ber protectant to any tread area.
  • Page 132: Appendix

    APPENDIX APPENDIX 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.
  • Page 133 APPENDIX WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. Turn the ignition key 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. Gasoline is a toxic substance.
  • Page 134 APPENDIX • Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or in the brakes. • Lubricate the drive chain and all the cables. • Remove the battery, and store it where it will not be exposed to direct sunlight, moisture, or freezing temperatures.
  • Page 135: Troubleshooting Guide

    APPENDIX Troubleshooting Guide Engine Does Not Start Starter Motor Won’t Turn • Engine stop switch off • Transmission not in neutral • Fuse blown • Battery leads do not make good electrical contact with battery terminals • Battery discharged Engine Cranks, But Won’t Start •...
  • Page 136: Environmental Protection

    Con- sult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure. This also applies to disposal of the entire vehicle at the...
  • Page 137: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Owner Name..................Address ....................Phone Number ................... Engine Number .................. Vehicle Number.................. Key Code .................... Selling Dealer Name ................Phone Number ................... Warranty Start Date ................Note: Keep this information and a spare key in a secure location. Odometer Date Maintenance Performed...
  • Page 138 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 139 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 140 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 141 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 142 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...

Comments to this Manuals

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  • Ken Mar 10, 2019 09:01:
    How do I change the speedo from mph to Klm/ hr
  • Ken Mar 10, 2019 09:01:
    How do I change the speedo from mph to Klm/ hr