Summary of Contents for Kawasaki Vulcan 900 Custom
GENERAL INFORMATION Quick Reference Guide HOW TO RIDE THE MOTORCYCLE This Quick Reference Guide will SAFE OPERATION assist you in finding the information you’re looking for. MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE A Table of Contents is included after the Foreword.
NOTICE Whenever you see the symbols shown below, heed their instructions! NOTICE is used to address prac- Always follow safe operating and main- tices not related to personal in- tenance practices. jury. DANGER NOTE DANGER indicates a hazardous ○ NOTE indicates information that may situation which, if not avoided, help or guide you in the operation or will result in death or serious in-...
NOTICE WARNING Engine exhaust, some of its THIS PRODUCT BEEN constituents, and certain vehi- MANUFACTURED FOR USE IN A cle components contain or emit REASONABLE AND PRUDENT chemicals known to the State of MANNER BY A QUALIFIED OP- California to cause cancer and ERATOR AND AS A VEHICLE birth defects or other reproduc- ONLY.
FOREWORD Congratulations on your purchase of a new Kawasaki Motorcycle. Your new mo- torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-...
TABLE OF CONTENTS SPECIFICATIONS....... Horn Button: ......... 33 SERIAL NUMBER LOCATIONS..12 Brake Lever Adjusters...... 34 LOCATION OF PARTS ....... 13 Fuel Tank Cap ........35 LOCATION OF LABELS..... 16 Fuel Tank ......... 36 LOADING INFORMATION....20 Side Stand ........40 GENERAL INFORMATION....
TROUBLESHOOTING GUIDE.... 157 System (California model only) ..107 YOUR WARRANTY/OWNER Valve Clearance ....... 108 SATISFACTION ......158 Kawasaki Clean Air System ..... 109 Reporting Safety Defects....164 Air Cleaner ........110 ENVIRONMENTAL PROTECTION..165 Throttle Control System ....112 MAINTENANCE RECORD ....
SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts.
LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 7. Left Handlebar Switches 2. Clutch Lever Adjuster 8. Indicator Lights 3. Meter Instruments 9. Fuel Tank Cap 4. Brake Fluid Reservoir (Front) 10. Right Handlebar Switches 5. Brake Lever Adjuster 11.
LOCATION OF PARTS 12. Front Fork 22. Shift Pedal 13. Headlight 23. Oil Level Inspection Window 14. Turn Signal Light 24. Side Stand Switch 15. Horn 25. Side Stand 16. Spark Plugs 26. Fuse Box 17. Battery 27. Coolant Reserve Tank 18.
LOCATION OF PARTS 31. Tail/Brake Light 37. Mufflers 32. Seat 38. Idle Speed Adjusting Screw 33. Tool Kit Case/Tool Kit 39. Rear Brake Pedal 34. Air Cleaner Element 40. Rear Brake Light Switch 35. Fuel Tank 41. Brake Fluid Reservoir (Rear) 36.
Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct posi- tion. NOTE *1.
LOCATION OF LABELS 3. Brake Fluid (Rear) 4. Tire and Load Data 5. Battery Position/Danger (For further information of label, refer to the “LABEL INFORMATION” chapter.)
LOCATION OF LABELS *6. Vacuum Hose Routing Diagram 7. Vehicle Emission Control Information 8. Weight and Manufacture 9. Noise Emission Control Information (For further information of label, refer to the “LABEL INFORMATION” chapter.) *: only on California model...
LOCATION OF LABELS 10. Radiator Cap Danger (For further information of label, refer to the “LABEL INFORMATION” chapter.)
Kawasaki Parts Accessories, Kawasaki has no control over the Because a motorcycle is sensitive to design or application of accessories. changes in weight and aerodynamic In some cases, improper installation forces, you must take extreme care...
LOADING INFORMATION been prepared to assist you in making Baggage weight should also be dis- your determinations. tributed equally on both sides of the 1. Any passenger should be thor- motorcycle. Avoid carrying baggage oughly familiar with motorcycle op- that extends beyond the rear of the eration.
(i.e., lean angle), control operation, vehicle. Kawasaki does not manu- wheel travel, front fork movement, facture sidecars or trailers for mo- or any other aspect of the motorcy- torcycles and cannot predict the ef- cle’s operation.
GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. Speedometer B. Digital Display C. Fuel Level Warning Indicator Light D. Coolant Temperature Warning Indicator Light E. Fuel Gauge F. Oil Pressure Warning Indicator Light G. Fuel Injection Warning Indicator Light H. MODE Button I.
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.
GENERAL INFORMATION • NOTE Push the RESET button. The hour ○ display stops flashing and the minute Pushing the MODE button momen- display starts flashing. Push the tarily advances the hour or minute MODE button to advance the min- step by step. Pushing and hold- utes.
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 can- last reset to zero.
GENERAL INFORMATION Fuel Gauge: The fuel gauge shows the amount of fuel in the fuel tank. When the nee- dle comes near the E (empty) posi- tion, refuel at the earliest opportunity. When vehicle stands with side stand, fuel gauge cannot show the amount of fuel in the fuel tank exactly.
GENERAL INFORMATION Keys : The fuel level warning indicator This motorcycle has a combination light goes on when approximately 4.0 L key, which is used for the ignition (1.0 US gal) of usable fuel remains. Re- switch, steering lock, and fuel tank fuel at the earliest opportunity when the cap.
If the key number is lost completely, you will need to replace the ignition switch and all other locks operated by that key. Contact your Kawasaki dealer to pur- A. Ignition Key chase additional spare keys either us- B. Tag ing your original key as a master or us- C.
GENERAL INFORMATION Ignition Switch Engine off. All electrical The ignition switch is located at circuits off. the left side behind the rear cylinder. Engine on. All electrical This is a three-position, key-operated equipment can be used. switch. The key can be removed from Engine off.
GENERAL INFORMATION Right Handlebar Switches Refer to the Starting the Engine sec- Engine Stop Switch: tion of the “How to Ride the Motorcycle” In addition to the ignition switch, the chapter for starting instructions. engine stop switch must be in the position for the motorcycle to operate.
GENERAL INFORMATION Left Handlebar Switches Dimmer Switch: High or low beam can be selected with the dimmer switch. When the headlight is on high beam ( ), the high beam indicator light is lit. High beam..( Low beam..( Turn Signal Switch: When the turn signal switch is turned to the left ( ) or right (...
GENERAL INFORMATION Brake Lever Adjusters There is an adjuster on the brake lever. The adjuster has 5 positions so that the released lever position can be adjusted to suit the operator’s hands. Push the lever forward and turn the ad- juster to align the number with the ar- row mark on the lever holder.
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.
GENERAL INFORMATION Fuel Tank WARNING Avoid filling the tank in the rain or Gasoline is extremely flammable where heavy dust is blowing so that the and can be explosive under cer- fuel does not get contaminated. tain conditions, creating the po- tential for serious burns.
GENERAL INFORMATION NOTICE The Antiknock Index is posted on ser- vice station pumps. The octane rating California models only: Never of a gasoline is a measure of its resis- fill the tank so the fuel level rises tance to detonation or “knocking”. The into the filler neck.
GENERAL INFORMATION NOTICE Fuels Containing Oxygenates Gasoline frequently contains oxy- If engine “knocking” or “ping- genates (alcohols and ethers) espe- ing” occurs, use a different cially in areas of the U.S. and Canada brand of gasoline of a higher which are required to sell such refor- octane rating.
When operating your in unleaded gasoline include TAME Kawasaki for 30 to 60 days, mix a (up to 16.7%) and ETBE (up to fuel stabilizer (such as STA-BIL) 17.2%). Fuel containing these oxy- with the gasoline in the fuel tank.
GENERAL INFORMATION NOTICE Side Stand The motorcycle is equipped with a Never store this product with side stand. “gasohol” in the fuel system. Before storage it is recom- mended that you drain all fuel from the fuel system. See the Storage section in this manual.
GENERAL INFORMATION NOTE Seat ○ The motorcycle is equipped with a Seat Removal • side stand switch. This switch is de- To remove the seat, insert the ignition signed so that the engine does not key into the seat lock, and turn the start if the transmission is in gear and key to the right.
GENERAL INFORMATION • Seat Installation Pull the front and rear ends of the • To install the seat, insert the projec- seat to make sure they are securely tion of the front on the seat into the locked. receptacle on the frame. •...
GENERAL INFORMATION Tool Kit Case The tool kit case is located under the seat. The kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual. Keep the tool kit in this case. •...
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 Riding with helmet attached to the hook could cause an acci- dent by distracting the operator or interfering with normal vehi- cle operation.
GENERAL INFORMATION Steering Lock WARNING The motorcycle is equipped with the Attempting to ride with the steer- steering lock at the right side of the ing locked could cause an acci- head pipe. dent. Unlock the steering before To lock the steering: starting the engine.
A. Electric Accessory Connectors White/Blue • Under Fuel When using the electric accessory Tank (–) Black/Yellow connectors under the fuel tank, the electric accessory connection to the Maximum Current: 10 A connectors should be done by an au- thorized Kawasaki dealer.
GENERAL INFORMATION NOTICE Rear View Mirror The vehicle has an electrical ac- Rear View Mirror Adjustment • cessory circuit (10 A fuse) for the Adjust the rear view mirror by slightly socket and connectors. Always moving only the mirror portion of the install a fuse 10 A or less in the assembly.
A. Stay A. Lower Hexagonal Area for Tightening B. Rear View Mirror B. Upper Hexagonal Area C. Rear View Mirror D. Rubber Boots NOTE ○ If a torque wrench is not available, this item should be serviced by a Kawasaki dealer.
BREAK-IN BREAK-IN The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down” instead of a “broken in” motorcycle after a few thousand kilometers.
BREAK-IN • 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. •...
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.
HOW TO RIDE THE MOTORCYCLE • ○ Make sure the transmission is in neu- The motorcycle is equipped with a tral. vehicle-down sensor, which causes the engine to stop automatically when the motorcycle falls down. Af- ter righting the motorcycle, first turn the ignition key to “OFF”...
HOW TO RIDE THE MOTORCYCLE NOTICE NOTE ○ The motorcycle is equipped with a Do not let the engine idle longer starter lockout switch. This switch is than five minutes, or engine designed so that the engine does not overheating and damage may start if the transmission is in gear and occur.
HOW TO RIDE THE MOTORCYCLE Jump Starting DANGER 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.
HOW TO RIDE THE MOTORCYCLE • Connecting Jumper Cables Connect a jumper cable from the • Make sure the ignition key is turned positive (+) terminal of the booster to “OFF”. battery to the positive (+) terminal of • Remove the seat. the motorcycle battery.
HOW TO RIDE THE MOTORCYCLE • shift pedal or other unpainted metal Follow the standard engine starting surface. Do not use the negative (−) procedure. terminal of the battery. NOTICE DANGER Do not operate the starter con- tinuously for more than 5 sec- Batteries contain sulfuric acid onds or the starter will overheat that can cause burns and pro-...
HOW TO RIDE THE MOTORCYCLE NOTE ○ When installing the seat, or tool kit case, be sure not to pinch the hose, or wires. The hose or wires should be routed as shown in the figure. ○ After installing the tool kit case, run the seat lock cable and wires along the guide and put the connectors into the original place.
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. •...
HOW TO RIDE THE MOTORCYCLE • Shifting Gears Open the throttle part way, while re- • leasing the clutch lever. Close the throttle while pulling in the clutch lever. • NOTE Shift into the next higher or lower ○ gear. For smooth riding, shift up or The transmission is equipped with a down when the motorcycle is oper- positive neutral finder.
HOW TO RIDE THE MOTORCYCLE Vehicle speed when shifting Shifting up km/h (mph) Shifting down km/h (mph) 1st → 2nd 5th → 4th 20 (12) 40 (25) 2nd → 3rd 4th → 3rd 30 (19) 30 (19) 3rd → 4th 3rd →...
HOW TO RIDE THE MOTORCYCLE • Braking For emergency braking, disregard • downshifting, and concentrate on Close the throttle completely, leav- ing the clutch engaged (except when applying the brakes as hard as pos- shifting gears) so that the engine will sible without skidding.
HOW TO RIDE THE MOTORCYCLE Stopping the Engine • Close the throttle completely. • Shift the transmission into neutral. • Turn the ignition key to “OFF”. • Support the motorcycle on a firm, level surface with the side stand. • Lock the steering.
Stopping the Motorcycle in an 2. During removal of the air cleaner, Emergency dirt is allowed to enter and jam the Your Kawasaki Motorcycle has been throttle body. designed and manufactured to pro- In an emergency situation such as vide you optimum safety and conve- throttle failure, your vehicle may be nience.
HOW TO RIDE THE MOTORCYCLE Parking WARNING The engine and exhaust system WARNING get extremely hot during normal Operating or parking the vehi- operation and can cause serious cle near flammable materials can burns. cause a fire, and can result in Never touch a hot engine, ex- property damage or severe per- haust pipe, or muffler during op-...
HOW TO RIDE THE MOTORCYCLE • • If parking inside a garage or other Lock the steering to help prevent structure, be sure it is well ventilated theft. and the motorcycle is not close to NOTE any source of flame or sparks; this ○...
HOW TO RIDE THE MOTORCYCLE Catalytic Converter WARNING This motorcycle is equipped with a Operating or parking the vehi- catalytic converter in the exhaust sys- cle near flammable materials can tem. The converter reacts with car- cause a fire, and can result in bon monoxide, hydorocarbons and ni- property damage or severe per- trogen oxides to convert them into car-...
HOW TO RIDE THE MOTORCYCLE • Use only unleaded gasoline. Never air/fuel mixture flowing out of engine use leaded gasoline. Leaded gaso- excessively accelerates reaction in line significantly reduces the capabil- the converter allowing the converter ity of the catalytic converter. to overheat and become damaged •...
SAFE OPERATION SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a When riding always keep both helmet are strongly recommended. hands on the handlebars and both You should be aware of and verify feet on the footpegs.
SAFE OPERATION In general your actions should In wet conditions, rely more on the be smooth as sudden acceleration, throttle to control vehicle speed and braking or turning may cause loss less on the front and rear brakes. of control, especially when riding in The throttle should also be used ju- wet conditions or on loose roadway diciously to avoid skidding the rear...
SAFE OPERATION Do not downshift at too high an Avoiding unnecessary weaving is r/min (rpm) to avoid damage to the important to the safety of both the engine from overrevving. rider and other motorists.
SAFE OPERATION Daily Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor- cycle to a safe operating condition.
SAFE OPERATION Up to 180 kg (397 lb) Front 280 kPa (2.80 kgf/cm², 40 psi) Load Up to 97.5 kg (215 lb) Rear 200 kPa (2.00 kgf/cm², 28 psi) Load 97.5 ∼ 180 kg 225 kPa (2.25 kgf/cm², 32 psi) (215 ∼...
SAFE OPERATION Side stand ....Returns to its fully up position by spring tension. Return spring not weak or not damaged.
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.
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 related parts are in good condition.
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...
MAINTENANCE AND ADJUSTMENT 3. Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low per- meation fuel hoses and a fuel tank. 3. Evaporative Emission Control System (California) Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere.
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.
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.
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.
MAINTENANCE AND ADJUSTMENT 1. Periodic Inspection (Engine Related Items) Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • Valve clearance - inspect (e) Throttle control system •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • • Coolant level - inspect • • • •...
MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Clutch and drive train: Clutch operation •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • Wheels/tires damage - inspect Tire tread wear, • •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Brake hose • • • • • • • year installation condition - inspect •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Suspensions: Front forks/rear shock absorber • • • – operation (damping and smooth stroke) - inspect Front forks/rear...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • Uni-trak rocker arm – bearings - lubricate • Uni-trak tie rods –...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 (mile × 1 000) first Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • Side stand switch year – operation - inspect •...
MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever *Odometer Reading comes km × 1 000 first (mile × 1 000) Page Every Change/Replacement Items (0.6) (7.5) (15) (22.5) (30) Air cleaner element - replace # every 18 000 km (12 000 mile) •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever *Odometer Reading comes km × 1 000 first (mile × 1 000) Page Every Change/Replacement Items (0.6) (7.5) (15) (22.5) (30) • Rubber parts of master cylinder – 4 years and caliper - replace • • •...
MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • In order for the engine, transmission, If the oil has just been changed, start and clutch to function properly, main- the engine and run it for several min- tain the engine oil at the proper level, utes at idle speed.
MAINTENANCE AND ADJUSTMENT • • 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 •...
MAINTENANCE AND ADJUSTMENT A. Oil Pressure Warning Indicator Light A. Engine Oil Drain Plug • Let the oil completely drain with Oil and/or Oil Filter Change the motorcycle perpendicular to the • Warm up the engine thoroughly, and ground. then stop it. •...
MAINTENANCE AND ADJUSTMENT • • Remove the cover. Remove the regulator/rectifier. A. Cover A. Regulator/Rectifier B. Bolt B. Bolt...
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 Kawasaki special tool is not avail- able, this item should be serviced by an authorized Kawasaki dealer.
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 spec- line with a good quality engine oil ified torque. specified in the table. •...
JASO MA, MA1, MA2 rating 3.2 L (3.4 US qt) Viscosity: SAE 10W-40 [when filter is removed] *Kawasaki Performance Oils and 3.7 L (3.9 US qt) Lubricants have been specifically en- gineered for your vehicle. Consistent [when engine is completely...
MAINTENANCE AND ADJUSTMENT Cooling System Although 10W-40 engine oil is the recommended oil for most condi- Radiator and Cooling Fan - tions, the oil viscosity may need to Check the radiator fins for obstruc- be changed to accommodate atmo- tion by insects or mud. Clean off spheric conditions in your riding area.
MAINTENANCE AND ADJUSTMENT NOTICE Coolant - Coolant absorbs excessive heat from Using high-pressure water, as the engine and transfers it to the air from a car wash facility, could at the radiator. If the coolant level be- damage the radiator fins and im- comes low, the engine overheats and pair the radiator’s effectiveness.
MAINTENANCE AND ADJUSTMENT NOTICE accumulates rust and scale in the wa- ter jacket and radiator. This will clog If hard water is used in the sys- up the coolant passages, and con- tem, it causes scale accumula- siderably reduce the efficiency of the tion in the water passages, and cooling system.
MAINTENANCE AND ADJUSTMENT NOTICE Coolant Level Inspection • Situate the motorcycle so that it is Permanent types of antifreeze on perpendicular to the ground. the market have anti-corrosion • Check the coolant level through the and anti-rust properties. When it coolant level gauge.
MAINTENANCE AND ADJUSTMENT Coolant Filling • Remove the seat. • Remove the left side cover by remov- ing the screw. A. F (Full) Level Line B. L (Low) Level Line C. Reserve Tank • If the amount of coolant is insuffi- cient, add coolant.
MAINTENANCE AND ADJUSTMENT • • Remove the reserve tank cover. Open the cap from the reserve tank, and add coolant through the filler opening to the F (Full) mark. A. Reserve Tank Cover B. Bolt A. Reserve Tank B. Reserve Tank Cap •...
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. Coolant Change A. Projections Have the coolant changed by an au- B.
Peri- tenance Chart. odic Maintenance Chart. Belt check and adjustment should Spark plug removal should be done be done by an authorized Kawasaki by a competent mechanic following the dealer. instructions in the Service Manual. NOTICE...
MAINTENANCE AND ADJUSTMENT Evaporative Emission Control System (California model only) This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no ad- justments are required, a thorough vi- sual inspection must be made at the in- tervals specified by the Periodic Main- tenance Chart.
MAINTENANCE AND ADJUSTMENT Valve Clearance Inspection and adjustment should be Valve and valve seat wear decreases done by a competent mechanic follow- valve clearance, upsetting valve timing. ing the instructions in the Service Man- ual. NOTICE If valve clearance is left un- adjusted, wear will eventually cause the valves to remain partly open;...
MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System the air suction valve is prevented from The Kawasaki Clean Air System returning. Inspect the air suction valves (KCA) is a secondary air suction sys- in accordance with the Periodic Main- tem that helps the exhaust gases to tenance Chart.
MAINTENANCE AND ADJUSTMENT Air Cleaner Element Removal • A clogged air cleaner restricts the en- Remove the bolts of the air cleaner gine’s air intake, increasing fuel con- cover located on the right-side of the sumption, reducing engine power, and engine.
MAINTENANCE AND ADJUSTMENT • Remove the air cleaner screw and WARNING the air cleaner. If any part of the ele- If dirt or dust is allowed to pass ment is damaged, the element must through into the fuel injection be replaced. system, the throttle may stick or become inoperable resulting in a hazardous operating condition.
MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check that there is 2 ∼ 3 mm (0.08 Check the throttle grip play, in accor- ∼ 0.12 in.) throttle grip play when dance with the Periodic Maintenance Chart, and adjust the throttle grip play. lightly turning the throttle grip back and forth.
MAINTENANCE AND ADJUSTMENT • both throttle cable adjusting nuts in Turn the accelerator cable adjusting nut until 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of completely so as to give the throttle grip plenty of play. throttle grip play is obtained. Tighten •...
MAINTENANCE AND ADJUSTMENT Idle Speed The idle adjustment should be per- formed in accordance with the Peri- odic Maintenance Chart or whenever the idle speed is disturbed. Adjustment • Start the engine, and warm it up thor- oughly. • Wait until the idle speed drops before making the following adjustment.
MAINTENANCE AND ADJUSTMENT Clutch WARNING Due to friction plate wear and clutch Operation with damaged cables cable stretch over a long period of use, could result in an unsafe riding the clutch must be adjusted in accor- condition. Replace damaged dance with the Periodic Maintenance control cables before operation.
2 ∼ 3 mm (0.08 ∼ 0.12 C. 2 ∼ 3 mm (0.08 ∼ 0.12 in.) in.) of play. • If the play is incorrect, adjust the lever If it cannot be done, have the clutch play as follows. cable adjusted by an authorized Kawasaki dealer.
1 mm (0.04 in), replace both pads in the caliper as a set. Pad replace- ment should be done by an authorized Kawasaki dealer. A. Lining Thickness B. 1 mm (0.04 in.)
MAINTENANCE AND ADJUSTMENT Brake Fluid - Fluid Level Inspection • In accordance with the Periodic Main- The brake fluid level in the front brake tenance Chart, inspect the brake fluid fluid reservoir must be kept above level in both the front and rear brake the line (lower level line) next to the fluid reservoirs and change the brake gauge and that in the rear brake fluid...
MAINTENANCE AND ADJUSTMENT • If the fluid level in either reservoir is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. Inside the front brake fluid reser- voir is a stepped line showing the up- per level line.
Fluid Change ○ Have the brake fluid changed by an First, tighten until slight resistance is authorized Kawasaki dealer. felt indicating that the cap is seated on the reservoir body; then, tighten the cap an additional 1/6 turn while holding the brake fluid reservoir...
If the brake lever If it does not, ask your authorized or pedal feels mushy when it Kawasaki dealer to inspect the front is applied, there might be air in brake light switch. the brake lines or the brake may be defective.
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.
MAINTENANCE AND ADJUSTMENT NOTICE Rear Shock Absorber The rear shock absorber can be ad- To avoid damaging the electrical justed by changing the spring preload connections inside the switch, for various riding and loading condi- be sure that the switch body tions.
MAINTENANCE AND ADJUSTMENT tank to the holder of the frame as shown in the figure. A. Reserve Tank B. Bolt NOTE A. Under Part of Reserve Tank ○ B. Holder When removing the reserve tank, hook the under part of the reserve...
MAINTENANCE AND ADJUSTMENT • In accordance with the following ta- The standard setting position for an ble, turn the preload adjuster with the average-build rider of 68 kg (150 lb) wrench from the tool kit. with no passenger and no accessories is No.
MAINTENANCE AND ADJUSTMENT Wheels Tubeless tires are installed on the wheels of this motorcycle. The indica- tions of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. Hook Wrench B.
MAINTENANCE AND ADJUSTMENT WARNING Installing a tube inside a tube- less-type tire can create exces- sive heat build up that can dam- age the tube and cause rapid deflation. The tires, rims, and air valves on this motorcycle are designed only for tubeless type wheels.
MAINTENANCE AND ADJUSTMENT • Tires - Remove the air valve cap. • Check the tire pressure often, using Payload and Tire Pressure an accurate gauge. Failure to maintain proper inflation • Make sure that the air valve cap is pressures or observe payload limits for securely installed.
MAINTENANCE AND ADJUSTMENT NOTE Tire Wear, Damage ○ As the tire tread wears down, the tire Measure the tire pressure when the becomes more susceptible to puncture tires are cold (that is, when the mo- and failure. An accepted estimate is torcycle has not been ridden more that 90% of all tire failures occur during than a mile during the past 3 hours).
MAINTENANCE AND ADJUSTMENT • In accordance with the Periodic Minimum Tread Depth Maintenance Chart, measure the 1 mm — Front depth of the tread with a depth (0.04 in.) gauge, and replace any tire that Under 130 km/h 2 mm has worn down to the minimum al- (80 mph) (0.08 in.)
MAINTENANCE AND ADJUSTMENT WARNING Standard Tire (Tubeless) 80/90-21 M/C 48H Tires that have been punctured Front • and repaired do not have the DUNLOP “D404FJ” same capabilities as undam- 180/70-15 M/C 76H aged tires and can suddenly fail, Rear • causing an accident resulting DUNLOP “D404”...
MAINTENANCE AND ADJUSTMENT Battery WARNING The battery installed in this vehicle New tires are slippery and may is a sealed type, and the sealing strip cause loss of control and injury. should not be removed at any time af- A break-in period of 160 km (100 ter the specified electrolyte has been miles) is necessary to estab- installed in the battery for initial service.
MAINTENANCE AND ADJUSTMENT the discharge rate. Every 15°C (59°F) Current Drain doubles the rate. Days from Days from 100 Dis- Electrical accessories, such as digi- 100% Charged % Charged charging tal clocks and computer memory, also to 50% to 100 % Ampere draw current from the battery even Discharged...
Sulfation occurs when the battery is charged using an appropriate charger left in a discharged condition for an ex- (check with your Kawasaki dealer). tended time. Sulfate is a normal by If you will not be using the motorcy- product of the chemical reactions within cle for longer than two weeks, the a battery.
If the above chargers are not avail- Never remove the sealing stirp, able, use equivalent one. or the battery can be damaged. For more details, ask your Kawasaki Do not install a conventional bat- dealer. tery is this vehicle, or the elec-...
MAINTENANCE AND ADJUSTMENT WARNING Battery Removal • Remove the seat and tool kit case Battery posts, terminals and re- (see “Jump Starting” section in the “ lated accessories contain lead How to Ride the Motorcycle” chap- and lead compounds, chemicals ter).
MAINTENANCE AND ADJUSTMENT • • Clean the battery using a solution of Put a light coat of grease on the ter- baking soda and water. Be sure that minals to prevent corrosion. • the cable connections are clean. Cover the (+) terminal with its protec- tive cap.
MAINTENANCE AND ADJUSTMENT A. Seat Lock Cable A. Wires B. Guide B. Guide C. Connectors...
MAINTENANCE AND ADJUSTMENT Headlight Beam Vertical Adjustment The headlight beam is adjustable ver- Horizontal Adjustment tically. If adjusted too low, neither low The headlight beam is adjustable nor high beam will illuminate the road horizontally. If not properly adjusted far enough ahead. If adjusted too high, horizontally, the beam will point to one the high beam will fail to illuminate the side rather than straight ahead.
MAINTENANCE AND ADJUSTMENT Fuses The fuses are arranged in the fuse box located behind left side cover. The main fuse is mounted on the starter relay behind right side cover. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
MAINTENANCE AND ADJUSTMENT • • Remove the seat. Remove the screw • Remove the left side cover (see “Cooling System” section in this chapter). A. Screw B. Right Side Cover A. Fuse Box B. Spare Fuse...
MAINTENANCE AND ADJUSTMENT • • Pull out the right side cover and then When installing the right side cover, inspect the main fuse. be sure to insert the projections of the right side cover. A. Main Fuse A. Projections B. Right Side Cover...
MAINTENANCE AND ADJUSTMENT WARNING Substituting fuses can cause wiring to overheat, catch fire and/or fail. Do not use any sub- stitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the junction box and main fuse.
MAINTENANCE AND ADJUSTMENT • General Lubrication Clutch Lever • Lubricate the points shown below, Front Brake Lever • with either motor oil or regular grease, Rear Brake Pedal in accordance with the Periodic Main- Lubricate the following cables with a tenance Chart or whenever the vehicle pressure cable luber - has been operated under wet or rainy...
(K) Clutch Inner Cable Upper Ends Frequent and proper care of your • (K) Throttle Inner Cable Upper Ends Kawasaki motorcycle will enhance its appearance, optimize overall per- (K): Should be serviced by an authorized formance, and extend its useful life.
MAINTENANCE AND ADJUSTMENT • WARNING Be sure the engine and exhaust are cool before washing. Build-up of debris or flammable • Avoid applying degreaser to seals, material in and around the vehi- brake pads, and tires. cle chassis, engine, and exhaust •...
MAINTENANCE AND ADJUSTMENT • • Avoid spraying water in delicate If the boot is damaged, replace it with areas such as in air intakes, fuel a new one. If the boot is not po- system, brake components, electri- sitioned in the groove correctly, re- cal components, muffler outlets, and place it in the correct position.
MAINTENANCE AND ADJUSTMENT • Mix a mild neutral detergent (de- several times. This helps dry the signed for motorcycles or automo- brakes and restores them to normal biles) and water in bucket. operating performance. a soft cloth or sponge to wash your NOTE motorcycle.
After washing use a soft cloth to gen- • If any doubt, consult an authorized tly dry plastic parts. When dry, treat Kawasaki dealer. the headlight lens and non-painted plastic parts with an approved plastic Painted Surfaces cleaner/polisher product.
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...
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.
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.
STORAGE STORAGE Preparation for Storage: • Clean the entire vehicle thoroughly. • Run the engine for about five minutes to warm the oil, shut it off and drain the engine oil. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recy- cling.
STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. Turn the ignition key to “OFF”. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
STORAGE • Set the motorcycle on a box or stand so that both wheels are raised off the ground. (If this cannot be done, put boards under the front and rear wheels to keep damp- ness away from the tire rubber.) •...
TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE • Engine Does Not Start: Incorrect spark plug gap • Starter Motor Won’t Turn No first turning the ignition key to • Engine stop switch off “OFF” when the motorcycle falls • Transmission not in neutral down.
You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale. The warranty does not cover the cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such as tires, brake pads, transmission drive belts, chains, sprockets, etc.
Much of the warranty coverage offered by the limited warranty can be extended by purchasing Kawasaki’s Good Time™ Protection Plan (GTPP). See your Kawasaki dealer or go to Kawasaki.com for more information if you don’t already have the GTPP. What Am I Responsible For? You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner’s manual.
Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the Maintenance Record section of this Owner’s Manual.
Kawasaki if the repair is one that will be covered by the limited warranty. The dealership will also file all necessary paperwork. The dealership is responsible for correctly completing any necessary repairs, whether they are covered by the lim- ited warranty or not.
YOUR WARRANTY/OWNER SATISFACTION Kawasaki will work with your dealer to resolve any warranty issues. No autho- rization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer. What if I am not Satisfied With My Warranty Service? If you aren’t satisfied with your dealership’s repair work or operations, it is best to...
Want to Contact Kawasaki? This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you.
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Kawasaki Motors Corpora- tion, U.S.A.
MAINTENANCE RECORD MAINTENANCE RECORD Owner Name..................Address ....................Phone Number ................... Engine Number .................. Vehicle Number.................. 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...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...