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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.
GENERAL INFORMATION
HOW TO RIDE THE MOTORCYCLE
SAFE OPERATION
MAINTENANCE AND ADJUSTMENT
STORAGE
TROUBLESHOOTING GUIDE

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Table of Contents

   Summary of Contents for Kawasaki vn900c

  • Page 1 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 3 Whenever you see the symbols NOTE ○ shown below, heed their instructions! This note symbol indicates points of Always follow safe operating and main- particular interest for more efficient tenance practices. and convenient operation. WARNING This warning symbol identifies special instructions or proce- dures which, if not correctly fol- lowed, could result in personal injury, or loss of life.
  • 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- tures, capabilities, and limitations.
  • 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. Consumer Products & Machinery Company © 2006 Kawasaki Heavy Industries, Ltd. Aug. 2006 (2) (C, K, K3)
  • Page 6: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS ........ Horn Button: ........31 SERIAL NUMBER LOCATIONS ..11 Brake Lever Adjusters ....... 31 LOCATION OF PARTS ......12 Fuel Tank Cap ........32 LOCATION OF LABELS ...... 15 Fuel Tank ........... 33 LOADING INFORMATION ....18 Side Stand .........
  • Page 7 ENVIRONMENTAL PROTECTION ..148 tem (California model only) ... 97 MAINTENANCE RECORD ....149 Valve Clearance ......... 98 LABEL INFORMATION ....... 155 Kawasaki Clean Air System ....99 Air Cleaner .........100 Throttle Control System .....102 Idle Speed ..........104 Clutch ..........106 Brakes ..........108...
  • Page 8: Specifications

    SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 2 405 mm (94.7 in.) Overall Width 895 mm (35.2 in.) Overall Height 1 120 mm (44.1 in.) Wheelbase 1 645 mm (64.8 in.) Road Clearance 140 mm (5.5 in.) Dry Weight 249 kg (549 lb) ENGINE Type SOHC, V-type 2-cylinder, 4-stroke, liquid-cooled...
  • Page 9 SPECIFICATIONS Lubrication System Forced lubrication (wet sump) Engine Oil API SE, SF or SG Type: API SH, SJ or SL with JASO MA SAE 10W-40 3.7 L (3.9 US qt) Capacity: Coolant Capacity 2.2 L (2.3 US qt) TRANSMISSION Transmission Type 5-speed, return shift Clutch Type Wet, multi disc...
  • Page 10 SPECIFICATIONS Rear 180/70-15 M/C 76H Rim Size: Front 21 × 2.15 Rear 15 × 4.50 Fuel Tank Capacity 20 L (5.3 US gal) ELECTRICAL EQUIPMENT Battery 12 V 10 Ah Headlight 12 V 60/55 W Tail/Brake Light 12 V 5/21 W Specifications subject to change without notice.
  • Page 11: 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 12: Location Of Parts

    LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 5. Brake Lever Adjuster 10. Right Handlebar 2. Clutch Lever Adjuster 6. Front Brake Lever Switches 3. Meter Instruments 7. Left Handlebar Switches 11. Throttle Grip 4. Brake Fluid Reservoir 8. Indicator Lights (Front) 9.
  • Page 13 LOCATION OF PARTS 12. Front Fork 19. Brake Caliper 26. Fuse Box 13. Headlight 20. Wheel 27. Coolant Reserve Tank 14. Turn Signal Light 21. Radiator 28. Rear Shock Absorber 15. Horn 22. Shift Pedal 29. Belt 16. Spark Plugs 23.
  • Page 14 LOCATION OF PARTS 31. Tail/Brake Light 36. Steering Lock 40. Rear Brake Light Switch 32. Seat 37. Mufflers 41. Brake Fluid Reservoir 33. Tool Kit Case/Tool Kit 38. Idle Speed Adjusting (Rear) 34. Air Cleaner Element Screw 35. Fuel Tank 39.
  • Page 15: Location Of Labels

    LOCATION OF LABELS LOCATION OF LABELS 1. Daily Safety Checks * 2. Fuel Level 3. Brake Fluid (Front) 4. Brake Fluid (Rear) (For further information of label, refer to the “LABEL INFORMATION” chap- ter.) * : only on California model...
  • Page 16 LOCATION OF LABELS 5. Tire and Load Data 6. Battery Position/Danger *7. Vacuum Hose Routing Diagram 8. Vehicle Emission Control Information (For further information of label, refer to the “LABEL INFORMATION” chap- ter.)
  • Page 17 LOCATION OF LABELS 9. Weight and Manufacture (For further information of label, refer to the “LABEL INFORMATION” chap- ter.)
  • Page 18: Loading Information

    Kawasaki Parts and Accessories ing condition. Before you ride the have been specially designed for motorcycle, make sure that the use on Kawasaki motorcycles. We motorcycle is not overloaded and strongly recommend that all parts that you have followed these in- and accessories you add to your mo- structions.
  • Page 19 LOADING INFORMATION been prepared to assist you in making on the motorcycle center of gravity. your determinations. Baggage weight should also be dis- Any passenger should be thor- tributed equally on both sides of the oughly familiar with motorcycle op- motorcycle.
  • Page 20 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...
  • Page 21: General Information

    GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Speedometer B. Digital Display C. Fuel Level Indicator Light D. Coolant Temperature Warning Light E. Fuel Gauge F. Oil Pressure Warning Light G. Fuel Injection Warning Light H. MODE Button I. RESET Button J.
  • Page 22: Speedometer

    GENERAL INFORMATION • Speedometer: Push the RESET button for more The speedometer shows the speed than two seconds. Both the hour and of the vehicle. minute displays start flashing. Digital Display The digital display located in the speedometer face is used to display the odometer, trip meter, and clock.
  • Page 23 GENERAL INFORMATION • Push the RESET button. The hour the button advance the hour or mi- display stops flashing and the minute nute continuously. ○ display starts flashing. Push the The clock works normally from the MODE button to advance the mi- back-up power while the ignition nutes.
  • Page 24 GENERAL INFORMATION Odometer - Trip Meters - The odometer shows the total dis- The trip meter shows the distance in tance in kilometers (miles) that the ve- kilometers (miles) traveled since it was hicle has been ridden. This meter last reset to zero. cannot be reset.
  • Page 25: Fuel Gauge

    GENERAL INFORMATION ○ When the trip meter reaches 999.9 while riding, the meter resets to 0.0 and continue counting. ○ When the battery is disconnected, the meter display resets to 0.0. Fuel Gauge: The fuel gauge shows the amount of fuel in the fuel tank.
  • Page 26: Warning/indicator Lights

    DFI system is in the ON position with the engine checked by an authorized Kawasaki not running, and goes off when the en- dealer. gine oil pressure is high enough. Refer...
  • Page 27: Keys

    Record the code from the tag with your keys here. Participating Kawasaki dealers can use the code to make a new key in the event that your original keys are lost.
  • Page 28: Ignition Switch

    GENERAL INFORMATION Ignition Switch The ignition switch is located at the left side behind the rear cylinder. This three-position, key-operated switch. The key can be removed from the switch when it is in the OFF or P (Park) position. A. Ignition Switch B.
  • Page 29: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches Engine off. All electrical circuits Engine Stop Switch: off. In addition to the ignition switch, the Engine on. All electrical equip- engine stop switch must be in the ment can be used. position for the motorcycle to operate. Engine off.
  • Page 30: Starter Button

    GENERAL INFORMATION Starter Button: Left Handlebar Switches 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 Motor-...
  • Page 31: Horn Button

    GENERAL INFORMATION Horn Button: Brake Lever Adjusters When the horn button is pushed, the There is an adjuster on the brake lev- block horn sounds. er. The adjuster has 5 positions so that the released lever position can be ad- justed to suit the operator's hands.
  • Page 32: Fuel Tank Cap

    GENERAL INFORMATION Fuel Tank Cap To open the fuel tank cap, insert the ignition key into the fuel tank cap and turn the key to the right. To close the cap, push it down into place with the key inserted. The key can be removed by turning it to the left to the original position.
  • Page 33: Fuel Tank

    GENERAL INFORMATION Fuel Tank Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. A. Ignition Key B. Fuel Tank Cap C. Key Hole Cover A. Tank Cap B. Fuel Tank C.
  • Page 34 GENERAL INFORMATION CAUTION WARNING California models only: Never fill Gasoline is extremely flammable the tank so the fuel level rises in- and can be explosive under cer- to the filler neck. If the tank is tain conditions. Turn the ignition key to “OFF”.
  • Page 35 GENERAL INFORMATION Research Octane Number (RON) and CAUTION the Motor Octane Number (MON) as If engine “knocking” or “pinging” shown in the table. occurs, use a different brand of Minimum gasoline of a higher octane rat- Octane Rating Method ing. If this condition is allowed to Rating continue it can lead to severe en- (RON + MON)
  • Page 36 15% MTBE. is approved for use. NOTE ○ 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 Never store this product with “ga- Never use gasoline with an oc- tane rating lower than the mini- sohol” in the fuel system. Before mum specified by Kawasaki. storage it is recommended that Never use “gasohol” with more you drain all fuel from the fuel than 10% ethanol, or more than system.
  • Page 38: Side Stand

    GENERAL INFORMATION Side Stand NOTE ○ The motorcycle is equipped with a The motorcycle is equipped with a side stand. side stand switch. This switch is de- signed so that the engine does not start if the transmission is in gear and the side stand is down.
  • Page 39: Seat

    GENERAL INFORMATION Seat Seat Installation • To install the seat, insert the projec- Seat Removal • tion of the front on the seat into the To remove the seat, insert the igni- receptacle on the frame. tion key into the seat lock, and turn •...
  • Page 40: Tool Kit Case

    GENERAL INFORMATION • Pull the front and rear ends of the Tool Kit Case seat to make sure they are securely The tool kit case is located under the locked. seat. The kit contains tools that can be helpful in making roadside repairs, ad- justments, and some maintenance pro- cedures explained in this manual.
  • Page 41: Helmet-hook

    GENERAL INFORMATION Helmet-Hook Helmet can be secured to the motor- cycle using the helmet-hook. The hel- met hook is located under the seat. WARNING Do not ride the motorcycle with helmet attached to the hook. The helmet could cause an accident by distracting the operator or in- terfering with normal vehicle op- A.
  • Page 42: Steering Lock

    GENERAL INFORMATION Steering Lock WARNING The motorcycle is equipped with the steering lock at the right side of the Unlock the steering before start- head pipe. ing the engine. Attempting to drive with the steering locked To lock the steering: could cause an accident.
  • Page 43: Electric Accessory Connectors

    A. Electric Accessory Connectors White/Blue Under Fuel • When using the electric accessory Tank (–) Black/Yellow connectors under the fuel tank, the Maximum Current: 10 A electric accessory connection to the connectors should be done by an au- thorized Kawasaki dealer.
  • Page 44 GENERAL INFORMATION CAUTION Always install a fuse of 10 A or less in the electrical accessory circuit. The vehicle has one fuse (10 A) to protect the entire electri- cal system. If this fuse fails, the engine will not run. Do not connect more than 70 W of total load to the vehicle's elec- trical system or the battery may...
  • 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 Turn the ignition key to ON. • Check that the engine stop switch is in the position. A. Ignition Switch B. ON Position A. Engine Stop Switch B.
  • Page 48 HOW TO RIDE THE MOTORCYCLE • then back to “ON” before starting the Make sure the transmission is in neutral. engine. • Leaving the throttle grip completely closed, push the starter button. CAUTION Do not operate the starter contin- uously for more than 5 seconds, or the starter will overheat and the battery power will drop tem- porarily.
  • Page 49 HOW TO RIDE THE MOTORCYCLE NOTE CAUTION ○ The motorcycle is equipped with a Do not let the engine idle longer starter lockout switch. This switch is than five minutes, or engine over- designed so that the engine does not heating and damage may occur.
  • Page 50: Jump Starting

    HOW TO RIDE THE MOTORCYCLE Jump Starting Connecting Jumper Cables • If your motorcycle battery is “run Make sure the ignition key is turned to “OFF”. down”, it should be removed and • Remove the seat. charged. If this is not practical, a 12 •...
  • Page 51 HOW TO RIDE THE MOTORCYCLE • Connect a jumper cable from the pedal or other unpainted metal sur- positive (+) terminal of the booster face. Do not use the negative (−) ter- battery to the positive (+) terminal of minal of the battery. the motorcycle battery.
  • Page 52 HOW TO RIDE THE MOTORCYCLE ○ After installing the tool kit case, run CAUTION the seat lock cable and wires along the guide and put the connectors into Do not operate the starter contin- the original place. uously for more than 5 seconds or the starter will overheat and the battery power will drop tem- porarily.
  • Page 53: Moving Off

    HOW TO RIDE THE MOTORCYCLE Moving Off • Check that the side stand is up. • Pull in the clutch lever. • Shift into 1st gear. • Open the throttle a little, and start to let out the clutch lever very slowly. •...
  • Page 54: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE Shifting Gears • Close the throttle while pulling in the clutch lever. • Shift into the next higher or lower gear. For smooth riding, shift up or down when the motorcycle is oper- ated the speeds shown in the table below.
  • Page 55 HOW TO RIDE THE MOTORCYCLE • Open the throttle part way, while re- leasing the clutch lever. NOTE ○ The transmission is equipped with a positive neutral finder. When the mo- torcycle is standing still, the trans- mission cannot be shifted past neutral from 1st gear.
  • Page 56: Braking

    HOW TO RIDE THE MOTORCYCLE • For emergency braking, disregard Braking • downshifting, and concentrate on ap- Close the throttle completely, leaving plying the brakes as hard as possible the clutch engaged (except when 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

    In an emergency situation such as throttle failure, your vehicle may be Emergency stopped by applying the brakes and Your Kawasaki Motorcycle has been disengaging the clutch. Once this stop- designed and manufactured to provide ping procedure is initiated, the engine you optimum safety and convenience.
  • Page 59: Parking

    HOW TO RIDE THE MOTORCYCLE Parking • WARNING Shift the transmission into neutral and turn the ignition key to “OFF”. The muffler and exhaust pipe are • Support the motorcycle on a firm, very hot while the engine is run- level surface with the side stand.
  • Page 60: Catalytic Converter

    HOW TO RIDE THE MOTORCYCLE NOTE Catalytic Converter ○ This motorcycle is equipped with a When stopping near traffic at night, catalytic converter in the exhaust sys- you can leave the taillight, licence tem. Platinum and Rhodium in the con- plate light on for greater visibility by verter react with carbon monoxide and turning the ignition key to the P...
  • Page 61 HOW TO RIDE THE MOTORCYCLE the vehicle with the engine or any WARNING one cylinder misfiring. Under these conditions unburned air/fuel mixture The muffler and exhaust pipe are flowing out of engine excessively ac- very hot while the engine is run- celerates reaction in the converter al- ning and just after the engine lowing the converter to overheat and...
  • Page 62: 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 63 SAFE OPERATION When applying the brakes, use Riding at the proper rate of speed both the front and rear brakes. Ap- and avoiding unnecessarily fast ac- plying only one brake for sudden celeration are important not only for braking may cause the motorcycle safety and low fuel consumption but to skid and lose control.
  • Page 64 SAFE OPERATION Do not downshift at too high an r/ min (rpm) to avoid damage to the engine from overrevving. Avoiding unnecessary weaving is important to the safety of both the rider and other motorists.
  • Page 65: 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 66 SAFE OPERATION 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. Brakes ......Brake pad wear: Lining thickness more than 1 mm (0.04 in.) left.
  • Page 67: Additional Considerations For High Speed Operation

    SAFE OPERATION Additional Considerations for High Speed Operation WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills.
  • Page 68 SAFE OPERATION Coolant:To avoid overheating, check that the coolant level is at the upper level line. Electrical Equipment: Make sure that the headlight, tail/brake light, turn signals, horn, etc., all work properly. Miscellaneous: Make sure that all nuts and bolts are tight and that all safety re- lated parts are in good condition.
  • Page 69: Maintenance And Adjustment

    Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect or improper adjustment done by the owner.
  • Page 70: 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 and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicle sold in California only.
  • Page 71 MAINTENANCE AND ADJUSTMENT 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
  • Page 72 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 73 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 ele- ment of design has been removed or rendered inoperative by any person.
  • Page 74: 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 75 MAINTENANCE AND ADJUSTMENT Frequency Whichever * Odometer Reading comes km × 1 000 (mile × 1 000) first Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Engine Items) • • • • Fuel leak (fuel hose and – year pipe) - inspect •...
  • Page 76 MAINTENANCE AND ADJUSTMENT Frequency Whichever * Odometer Reading comes km × 1 000 (mile × 1 000) first Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Engine Items) Evaporative emission con- • • • • • • • trol system - function (Cal- ifornia model only) (e)
  • Page 77 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever * Odometer Reading comes km × 1 000 (mile × 1 000) first Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) Clutch and drive train: Clutch operation (play, en- •...
  • Page 78 MAINTENANCE AND ADJUSTMENT Frequency Whichever * Odometer Reading comes km × 1 000 (mile × 1 000) first Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) • • • Wheel bearings damage - – year inspect Brake system: •...
  • Page 79 MAINTENANCE AND ADJUSTMENT Frequency Whichever * Odometer Reading comes km × 1 000 (mile × 1 000) first Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) • • • • • • • Brake light switch opera- tion - inspect Suspensions: Front forks/rear shock ab-...
  • Page 80 MAINTENANCE AND ADJUSTMENT Frequency Whichever * Odometer Reading comes km × 1 000 (mile × 1 000) first Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) • Uni-trak rocker arm bear- – ings - lubricate • Uni-trak tie rods bearings - –...
  • Page 81 MAINTENANCE AND ADJUSTMENT Frequency Whichever * Odometer Reading comes km × 1 000 (mile × 1 000) first Page Every (0.6) (7.5) (12) (15) (20) (24) Operation (Chassis Items) • • • Engine stop switch opera- – year tion - inspect Chassis: •...
  • Page 82 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever * Odometer Reading comes km × 1 000 first (mile × 1 000) Page Every (0.6) (7.5) (15) (24) (30) Change/Replacement Items K Air cleaner element # (e) every 18 000 km (12 000 mile) •...
  • Page 83: Engine Oil

    MAINTENANCE AND ADJUSTMENT Oil Level Inspection Engine Oil • If the oil has just been changed, start In order for the engine, transmission, the engine and run it for several mi- and clutch to function properly, main- nutes at idle speed. This fills the oil tain the engine oil at the proper level, filter with oil.
  • Page 84 MAINTENANCE AND ADJUSTMENT • • If the motorcycle has just been used, If the oil level is too high, remove the wait several minutes for all the oil to excess oil through the oil filler open- drain down. ing using a syringe or some other •...
  • Page 85 MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • Warm up the engine thoroughly, and then stop it. • Place an oil pan beneath the engine. • Remove the engine oil drain plug. A. Oil Pressure Warning Light A. Engine Oil Drain Plug •...
  • Page 86 MAINTENANCE AND ADJUSTMENT • Remove the regulator/rectifier. WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. • Remove the cover. A. Regulator/Rectifier B. Bolt A. Cover B.
  • Page 87 MAINTENANCE AND ADJUSTMENT • • Remove the bracket. Remove the oil filter cartridge and re- place it with a new one. A. Bracket B. Bolt A. Cartridge NOTE ○ If a torque wrench or required Kawa- saki special tool is not available, this item should be serviced by a Kawa- saki dealer.
  • Page 88 MAINTENANCE AND ADJUSTMENT • • Apply a thin film of oil to the packing Fill the engine up to the upper level and tighten the cartridge to the speci- line with a good quality engine oil fied torque. specified in the table. •...
  • Page 89 MAINTENANCE AND ADJUSTMENT Engine Oil Capacity Although 10W-40 engine oil is the recommended oil for most conditions, Capacity: 3.0 L (3.2 US qt) the oil viscosity may need to be [when filter is not removed] changed to accommodate atmospheric 3.2 L (3.4 US qt) conditions in your riding area.
  • Page 90: Cooling System

    MAINTENANCE AND ADJUSTMENT Cooling System CAUTION Radiator and Cooling Fin - Check the radiator fins for obstruc- Using high-pressure water, as tion by insects or mud. Clean off any from a car wash facility, could obstructions with a stream of low-pres- damage the radiator fins and im- pair the radiator's effectiveness.
  • Page 91 MAINTENANCE AND ADJUSTMENT Coolant - the coolant passages, and consider- Coolant absorbs excessive heat from ably reduce the efficiency of the cool- the engine and transfers it to the air at ing system. the radiator. If the coolant level be- WARNING comes low, the engine overheats and may suffer severe damage.
  • Page 92 MAINTENANCE AND ADJUSTMENT freezing point and strength directed on CAUTION the container. If hard water is used in the sys- CAUTION tem, it causes scale accumula- tion in the water passages, and Permanent types of antifreeze on considerably reduces the effi- the market have anti-corrosion ciency of the cooling system.
  • Page 93 MAINTENANCE AND ADJUSTMENT Coolant Level Inspection • Situate the motorcycle so that it is perpendicular to the ground. • Check the coolant level through the coolant level gauge. The coolant lev- el should be between the F (Full) and L (Low) marks. NOTE ○...
  • Page 94 MAINTENANCE AND ADJUSTMENT • Coolant Filling Remove the reservoir tank cover. • Remove the seat. • Remove the left side cover by re- moving the screw. A. Reservoir Tank Cover B. Bolt A. Screw B. Tool Kit Case...
  • Page 95 MAINTENANCE AND ADJUSTMENT • Open the cap from the reservoir NOTE ○ tank, and add coolant through the fill- When installing the left side cover, er opening to the F (Full) mark. be sure to insert the projections of the left side cover to each holes. A.
  • Page 96: Drive Belt

    Maintenance Chart. CAUTION Belt check and adjustment should be If coolant must be added often, or done by an authorized Kawasaki deal- the reserve tank completely runs dry, there is probably leakage in the system. Have the cooling sys- CAUTION...
  • Page 97: Spark Plugs

    MAINTENANCE AND ADJUSTMENT Spark Plugs Evaporative Emission Control The standard spark plug is shown in System (California model on- the table. The spark plugs should be replaced in accordance with the Peri- This system routes fuel vapors from odic Maintenance Chart. the fuel system into the running engine Spark plug removal should be done or stores the vapors in a canister when...
  • Page 98: Valve Clearance

    MAINTENANCE AND ADJUSTMENT Valve Clearance Valve and valve seat wear de- creases valve clearance, upsetting valve timing. CAUTION If valve clearance is left unad- justed, wear will eventually cause the valves to remain partly open; which lowers performance, burns the valves and valve seats, and may cause serious engine dam- age.
  • Page 99: Kawasaki Clean Air System

    MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System in accordance with the Periodic Main- tenance Chart. Also, inspect the air The Kawasaki Clean Air System suction valves whenever stable idling (KCA) is a secondary air suction sys- cannot be obtained, engine power is...
  • Page 100: Air Cleaner

    MAINTENANCE AND ADJUSTMENT Air Cleaner Element Removal • Remove the bolts of the air cleaner A clogged air cleaner restricts the cover located on the right-side of the engine's air intake, increasing fuel con- engine. sumption, reducing engine power, and causing spark plug fouling.
  • Page 101 MAINTENANCE AND ADJUSTMENT • Remove the air cleaner screw and WARNING the air cleaner. If any part of the ele- ment is damaged, the element must If dirt or dust is allowed to pass be replaced. through into the fuel injection system, the throttle may become stuck, possibly causing accident.
  • Page 102: Throttle Control System

    MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check that there is 2 ~ 3 mm (0.08 ~ Check the throttle grip play, in ac- 0.12 in.) throttle grip play when lightly cordance with the Periodic Mainte- turning the throttle grip back and nance Chart, and adjust the throttle forth.
  • Page 103 MAINTENANCE AND ADJUSTMENT Adjustment • Loosen the locknuts at the upper ends of the throttle cables, and screw both throttle cable adjusting nuts in completely so as to give the throttle grip plenty of play. • Turn out the decelerator cable ad- justing nut until there is no play when the throttle grip is completely closed.
  • Page 104: Idle Speed

    MAINTENANCE AND ADJUSTMENT • Turn the accelerator cable adjusting Idle Speed nut until 2 ~ 3 mm (0.08 ~ 0.12 in.) of The idle adjustment should be per- throttle grip play is obtained. Tighten formed in accordance with the Periodic the locknut.
  • Page 105 MAINTENANCE AND ADJUSTMENT • Adjustment Open and close the throttle a few • Start the engine, and warm it up thor- times to make sure that the idle oughly. speed does not change. Readjust if • Wait until the idle speed drops before necessary.
  • Page 106: Clutch

    MAINTENANCE AND ADJUSTMENT Clutch Inspection • Check that the clutch lever has 2 ~ 3 Due to friction plate wear and clutch mm (0.08 ~ 0.12 in.) of play as cable stretch over a long period of use, shown in the figure. the clutch must be adjusted in accord- ance with the Periodic Maintenance Chart.
  • Page 107 MAINTENANCE AND ADJUSTMENT • Adjustment Turn the adjuster so that the clutch lever will have 2 ~ 3 mm (0.08 ~ 0.12 WARNING in.) of play. • If it cannot be done, use the nuts at Be sure the upper end of the the middle of the clutch cable.
  • Page 108: Brakes

    MAINTENANCE AND ADJUSTMENT does not slip and that it releases Brakes properly. Brake Wear Inspection ○ For minor corrections, use the ad- Inspect the brakes for wear. For each juster at the clutch lever. front and rear disc brake caliper, if the thickness of either pad is less than 1 mm (0.04 in), replace both pads in the caliper as a set.
  • Page 109 MAINTENANCE AND ADJUSTMENT Disc Brake Fluid - Fluid Level Inspection • In accordance with the Periodic The brake fluid level in the front Maintenance Chart, inspect the brake brake fluid reservoir must be kept fluid level in both the front and rear above the line (lower level line) next brake fluid reservoirs and change the to the gauge and that in the rear...
  • Page 110 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 upper level line.
  • Page 111 MAINTENANCE AND ADJUSTMENT NOTE WARNING ○ First, tighten until slight resistance is Do not mix two brands of brake felt indicating that the cap is seated fluid. Change the brake fluid in on the reservoir body; then, tighten the brake line completely if the the cap an additional 1/6 turn while brake fluid must be refilled but holding the brake fluid reservoir...
  • Page 112: Brake Light Switches

    Since it is dangerous to operate the mo- torcycle under such conditions, have the brake checked immedi- ately by an authorized Kawasaki dealer.
  • Page 113 10 mm (0.4 in.) of • If it does not, ask your authorized pedal travel. Kawasaki dealer to inspect the front brake light switch. A. Brake Pedal B. 10 mm (0.4 in.) •...
  • Page 114 MAINTENANCE AND ADJUSTMENT Adjustment • CAUTION To adjust the rear brake light switch, move the switch up or down by turn- To avoid damaging the electrical ing the adjusting nut. connections inside the switch, be sure that the switch body does not turn during adjustment.
  • Page 115: Rear Shock Absorber

    MAINTENANCE AND ADJUSTMENT Rear Shock Absorber Spring Preload Adjustment The rear shock absorber spring pre- The rear shock absorber can be ad- load adjuster has 7 positions. justed by changing the spring preload • Remove the left side cover and res- for various riding and loading condi- ervoir tank cover (see “Cooling Sys- tions.
  • Page 116 MAINTENANCE AND ADJUSTMENT • NOTE In accordance with the following ta- ○ ble, turn the preload adjuster with the When removing the reservoir tank, wrench from the tool kit. hook the under part of the reservoir tank to the holder of the frame as shown in the figure.
  • Page 117: Wheels

    MAINTENANCE AND ADJUSTMENT with no passenger and no accessories Wheels is No. 4. Tubeless tires are installed on the wheels of this motorcycle. The indica- NOTE tions of TUBELESS on the tire side ○ This motorcycle has two hook wall and the rim show that the tire and wrenches in the tool kit.
  • Page 118: Tires

    MAINTENANCE AND ADJUSTMENT WARNING The tires, rims, and air valves on this motorcycle are designed on- ly for tubeless type wheels. The recommended standard tires, rims, and air valves must be used for replacement. Do not install tube-type tires on tubeless rims.
  • Page 119 MAINTENANCE AND ADJUSTMENT handling and performance of your mo- NOTE ○ torcycle and can result in loss of con- Measure the tire pressure when the trol. The maximum recommended load tires are cold (that is, when the mo- in addition to vehicle weight is 180 kg torcycle has not been ridden more (397 lb), including rider, passenger, than a mile during the past 3 hours).
  • Page 120 MAINTENANCE AND ADJUSTMENT • Tire Wear, Damage In accordance with the Periodic As the tire tread wears down, the tire Maintenance Chart, measure the becomes more susceptible to puncture depth of the tread with a depth and failure. An accepted estimate is gauge, and replace any tire that has that 90% of all tire failures occur during worn down to the minimum allowable...
  • Page 121 MAINTENANCE AND ADJUSTMENT Minimum Tread Depth WARNING 1 mm — Front (0.04 in.) To ensure safe handling and stability, use only the recom- Under 130 km/h 2 mm mended standard tires for re- (80 mph) (0.08 in.) Rear placement, inflated Over 130 km/h 3 mm standard pressure.
  • Page 122: Battery

    MAINTENANCE AND ADJUSTMENT Standard Tire (Tubeless) Battery The battery installed in this vehicle is 80/90-21 M/C48H • Front a sealed type, and the sealing strip DUNLOP “D404FJ” should not be removed at any time 180/70-15 M/C 76H after the specified electrolyte has been •...
  • Page 123 MAINTENANCE AND ADJUSTMENT temperature. As temperatures rise, so Current Drain does the discharge rate. Every 15°C Days from (27°F) doubles the rate. Discharg- Days from 100% 100 % Electrical accessories, such as digi- ing Am- Charged to 50% Charged to tal clocks and computer memory, also pere Discharged...
  • Page 124 If the above chargers are not avail- Battery Maintenance able, use equivalent one. It is the owner's responsibility to keep For more details, ask your Kawasaki the battery fully charged. Failure to do dealer. so can lead to battery failure and leave Battery Charging you stranded.
  • Page 125 MAINTENANCE AND ADJUSTMENT • The charger will keep the battery WARNING fully charged until you are ready to reinstall the battery in the motorcycle Battery posts, terminals and re- (see Battery Installation). lated accessories contain lead lead compounds. Wash CAUTION hands after handling.
  • Page 126 MAINTENANCE AND ADJUSTMENT • Battery Removal Pull the battery out of the motor- • Remove the seat and tool kit case cycle. • (see “Jump Starting” section in the “ Clean the battery using a solution of How to Ride the Motorcycle” chap- baking soda and water.
  • Page 127 MAINTENANCE AND ADJUSTMENT • Put a light coat of grease on the ter- minals to prevent corrosion. • Cover the (+) terminal with its protec- tive cap. • Reinstall the parts removed. NOTE ○ When installing the seat, or tool kit case, be sure not to pinch the hose, or wires.
  • Page 128: Headlight Beam

    MAINTENANCE AND ADJUSTMENT Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. • Turn the horizontal adjusting screw on the headlight rim in or out until the beam points straight ahead.
  • Page 129 MAINTENANCE AND ADJUSTMENT Vertical Adjustment The headlight beam is adjustable vertically. If adjusted too low, neither low nor high beam will illuminate the road far enough ahead. If adjusted too high, the high beam will fail to illumi- nate the road close ahead, and the low beam will blind oncoming drivers.
  • Page 130: Fuses

    MAINTENANCE AND ADJUSTMENT • Fuses Remove the seat. • Remove the left side cover (see The fuses are arranged in the fuse “Cooling System” section in this box located behind left side cover. chapter). The main fuse is mounted on the starter relay behind right side cover.
  • Page 131 MAINTENANCE AND ADJUSTMENT • • Remove the screw Pull out the right side cover and then inspect the main fuse. A. Screw B. Right Side Cover A. Main Fuse...
  • Page 132 MAINTENANCE AND ADJUSTMENT • When installing the right side cover, WARNING be sure to insert the projections of the right side cover. 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 box and main fuse.
  • Page 133: General Lubrication

    MAINTENANCE AND ADJUSTMENT ○ General Lubrication Front Brake Lever ○ Rear Brake Pedal Lubricate the points shown below, with either motor oil or regular grease, Lubricate the following cables with in accordance with the Periodic Main- a pressure cable lubber - tenance Chart or whenever the vehicle ○...
  • Page 134: Cleaning Your Motorcycle

    MAINTENANCE AND ADJUSTMENT (K): Should be serviced by an author- Cleaning Your Motorcycle ized Kawasaki dealer. General Precautions Frequent and proper care of your Ka- NOTE wasaki motorcycle will enhance its ap- ○ pearance, optimize overall After connecting the cables, adjust performance, and extend its useful life.
  • Page 135 MAINTENANCE AND ADJUSTMENT plastic surfaces: wash them off im- cloth or sponge to wash your motor- mediately. cycle. If needed, use a mild degreas- • Avoid wire brushes, steel wool, and er to remove any oil or grease build all other abrasive pads or brushes. •...
  • Page 136 MAINTENANCE AND ADJUSTMENT NOTE motorcycle/automotive wax. ○ should be applied once every three After riding in an area where the months or as conditions require. Avoid roads are salted or near the ocean, surfaces with “satin” or “flat” finishes. immediately wash your motorcycle Always use nonabrasive products and with cold water.
  • Page 137 MAINTENANCE AND ADJUSTMENT aluminum polish. Coated aluminum CAUTION should be washed with a mild neutral detergent and finished with a spray Plastic parts may deteriorate and polish. Aluminum wheels, both painted break if they come in contact with and unpainted can be cleaned with chemical substances or house- special non-acid based wheel spray hold cleaning products such as...
  • Page 138 MAINTENANCE AND ADJUSTMENT WARNING Special care must be taken not to get any rubber protectant on the tire's tread surface when treating tires. This may decrease the tire's ability to maintain contact with the road surface causing the rider to lose control.
  • Page 139: 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 140 MAINTENANCE AND ADJUSTMENT 14. Muffler Mounting Bolts 15. Brake Lever Holder Clamp Bolts 16. Pivot Shaft Bolt 17. Brake Pedal Mounting Bolts 18. Rear Shock Absorber Mounting Nuts...
  • Page 141: 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 en- gine 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 142 STORAGE • Empty the fuel system by running the engine at idle speed until all fuel in the fuel system is used up (If left in for a long time, the fuel will break down and clog the fuel system). WARNING Do not lean over the engine when performing this procedure.
  • Page 143 STORAGE • Tie plastic bags over the mufflers to prevent moisture from entering. • Put a cover over the motorcycle to keep dust and dirt from collecting on it. Preparation after Storage: • Remove the plastic bags from the mufflers. •...
  • Page 144: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Engine Does Not Start: Engine Stalls: Starter Motor Won't Turn Just When Shifting Into 1st Gear • • Engine stop switch off Side stand has been left down • • Transmission not in neutral Clutch does not properly disengage •...
  • Page 145: 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 146 OWNER SATISFACTION 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 147: 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 148: 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 au- thorized Kawasaki dealer or local environmental waste agency for their proper dis- posal procedure.
  • Page 149: 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...
  • Page 150 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 151 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 152 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 153 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 154 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 155: Label Information

    LABEL INFORMATION LABEL INFORMATION...
  • Page 156 LABEL INFORMATION (2) only on California model (3)/(4)
  • Page 157 LABEL INFORMATION...
  • Page 158 LABEL INFORMATION...
  • Page 159 LABEL INFORMATION (7) only on California model...
  • Page 160 LABEL INFORMATION...
  • Page 161 LABEL INFORMATION (8) only on California model...
  • Page 162 LABEL INFORMATION...

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