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.
Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.
FOREWORD Congratulations on your purchase of a new Kawasaki motorcycle. Your new motorcycle 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 features, capabilities, and limitations.
This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold. All rights reserved. No part of this publication may be reproduced without our prior written permission. This publication includes the latest information available at the time of printing. However, there may be minor differences between the actual product and illustrations and text in this manual. All products are subject to change without prior notice or obligation.
TABLE OF CONTENTS SPECIFICATIONS............................... SERIAL NUMBER LOCATIONS......... LOCATION OF PARTS ....................... LOADING AND ACCESSORIES INFORMATION ................................ GENERAL INFORMATION................. Meter Instruments ............................ Speedometer: ............................... Digital Meter: ................................ Warning/Indicator Light:................ Key ...................................................
Stopping the Motorcycle in an Emergency ................................... Parking ............................................. Catalytic Converter........................... SAFE OPERATION............................. Safe Riding Technique ..................... Daily Safety Checks ......................... Additional Considerations for High Speed Operation .......................... MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart............. Engine Oil ........................................
8 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 2 100 mm (82.68 in.) Overall Width 760 mm (29.92 in.) Overall Height 1 100 mm (43.31 in.) Wheelbase 1 405 mm (55.31 in.) Road Clearance 140 mm (5.51 in.) Curb Mass 200 kg (441 lb) (CAL) 200.5 kg (442 lb) ENGINE Type DOHC, 4-valve, 2-cylinder, 4-stroke, liquid-cooled Displacement 649 cm3 (39.6 cu in.) Bore × Stroke 83 × 60 mm (3.27 × 2.36 in.) Compression Ratio 11.
SPECIFICATIONS 9 Firing Order 1-2 Carburetion System FI (Fuel Injection) Ignition System Battery and coil (transistorized ignition) Ignition Timing 10° BTDC @1 300 r/min (rpm) a (Electronically advanced) 34° BTDC @5 000 r/min (rpm) Spark Plugs NGK CR9EIA-9 Lubrication System Forced lubrication (semi-dry sump) Engine Oil Type : API SE, SF or SG API SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 Capacity: Coolant Capacity 2.4 L (2.5 US qt) 1.2 L (1.
10 SPECIFICATIONS Primary Reduction Ratio 2.095 (88/42) Final Reduction Ratio 3.067 (46/15) Overall Drive Ratio 5.473 (Top gear) Gear Ratio 1st 2.438 (39/16) 2nd 1.714 (36/21) 3rd 1.333 (32/24) 4th 1.111 (30/27) 5th 0.966 (28/29) 6th 0.852 (23/27) FRAME Castor 24.5° Trail 102 mm (4.0 in.) Tire Size: Rim Size: Front 120/70ZR17 M/C (58 W) Rear 160/60ZR17 M/C (69 W) Front 17 × 3.50 Rear 17 × 4.
SPECIFICATIONS 11 Fuel Tank Capacity 15.5 L (4.1 US gal) ELECTRICAL EQUIPMENT Battery 12 V 10 Ah Headlight 12 V 55 W/55 W (Hi/Lo) LED Tail/Brake Light 0.5/3.3 W CAL: California model Even if one of LED (Light Emitting Diode) tail/brake lights does not go on, consult with an authorized Kawasaki dealer. Specifications subject to change without notice.
12 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. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it. Frame No. A. Frame Number Engine No.
LOCATION OF PARTS 13 LOCATION OF PARTS 1. 2. 3. 4. Clutch Lever Left Handlebar Switches Meter Instruments Brake Fluid Reservoir (Front) 5. 6. 7. 8.
14 LOCATION OF PARTS 9. 10. 11. 12. 13. 14. 15. Wheel Headlight Turn Signal Light Spark Plugs Air Cleaner Main Fuse Battery 16. Seat 17. Tool Kit/Storage Compartments 18. Helmet Holding Cable 19. Tying Hooks 20. Seat Lock 21. Front Fork 22. 23. 24. 25. 26.
LOCATION OF PARTS 15 27. License Plate Light 28. Tail/Brake Light 29. Brake Fluid Reservoir (Rear) 30. Rear Shock Absorber 31. Spring Preload Adjuster 32. 33. 34. 35. 36. Fuel Tank Fuel Tank Cap Coolant Reserve Tank Muffler Rear Brake Light Switch 37. Rear Brake Pedal 38. Oil Level Gauge 39.
16 LOADING AND ACCESSORIES INFORMATION LOADING AND ACCESSORIES INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure that the motorcycle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories.
LOADING AND ACCESSORIES INFORMATION 17 fitting additional accessories. The following general guidelines have been prepared to assist you in making your determinations. 1. Any passenger should be thoroughly familiar with motorcycle operation. The passenger can affect control of the motorcycle by improper positioning during cornering and sudden movements. It is important that the passenger sit still while the motorcycle is in motion and not interfere with the operation of the motorcycle.
18 LOADING AND ACCESSORIES INFORMATION 6. Do not install accessories or carry baggage that impairs the performance of the motorcycle. Make sure that you have not adversely affected any lighting components, road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any other aspect of the motorcycle’s operation. 7. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in an unsafe riding condition.
GENERAL INFORMATION 19 GENERAL INFORMATION Meter Instruments A. Left Turn Signal Indicator Light B. Neutral Indicator Light C. MODE Button D. Speedometer E. RESET Button F. Right Turn Signal Indicator Light G. Coolant Temperature Warning Light H. Digital Meter I. High Beam Indicator Light J. FI Indicator Light K.
20 GENERAL INFORMATION Speedometer: The speedometer shows the speed of the vehicle. When the ignition key is turned to “ON”, the speedometer momentarily goes from the minimum to the maximum, then goes back from the maximum to the minimum reading to check its operation. If the speedometer does not operate correctly, have it checked by an authorized Kawasaki dealer. Digital Meter: The digital meter displays the following functions: the tachometer gauge, clock, odometer, trip meters A/B, fuel gauge.
GENERAL INFORMATION 21 Digital Meter A. Clock B. Odometer C. Trip Meter A D. Trip Meter B E. Push MODE Button A. Fuel Gauge B. Tachometer Gauge C. Red Zone D. Clock, Trip Meter A/B, Odometer NOTE Do not shift the digital meter display while riding for safe operation.
22 GENERAL INFORMATION Tachometer Gauge – The tachometer shows the engine speed in revolutions per minute (r/min, rpm). On the right side of the tachometer face is a portion called the “red zone”. Engine r/min (rpm) in the red zone is above maximum recommended engine speed and is also above the range for good performance. Clock To adjust the hours and minutes: Turn the ignition key to “ON”. Push the MODE button to display the clock. Push the RESET button for more than two seconds.
GENERAL INFORMATION 23 the RESET button. The hour • Push display stops flashing and the minute display starts flashing. Push the MODE button to advance the minutes. the RESET button. Both the • Push hour and minute displays start flash- • ing again. Push the MODE button. The displays stop flashing and the clock starts working. NOTE Pushing the MODE button momen- tarily advances the hour or minute step by step. Pushing and holding the button advance the hour or minute continuously.
24 GENERAL INFORMATION Odometer The odometer shows the total distance in kilometers or miles that the vehicle has been ridden. This meter cannot be reset. NOTE The data is maintained even if the battery is disconnected. When the figures come to 999999, they are stopped and locked. Trip Meter The trip meters show the distance in kilometers (miles) traveled since they were last reset to zero. TRIP A: 0.0 a 999.9 TRIP B: 0.0 a 9999.
GENERAL INFORMATION 25 When the battery is disconnected, the meter display resets to 0.0. Km/Mile Display Km/Mile Display can alternate between metric and English modes (km and mile) in the digital meter. Make sure that km or mile is correctly displayed according to local regulations before riding. NOTE The data is maintained by the back -up power if the ignition key is turned off. When the trip meter is without the engine operation, it starts counting as soon as the vehicle starts moving.
26 GENERAL INFORMATION the odometer in the digital • Display meter. km/mile display shifts by pushing • The the RESET button while the MODE • button pushed in. The km/mile display shifts as follows. Fuel Gauge – The fuel in the fuel tank is shown by the number of segments displayed. When the fuel tank is full, all 6 segments are displayed. If the fuel gauge is not correctly displayed, have the fuel gauge checked by an authorized Kawasaki dealer. A. Km Display B. MileDisplay C.
GENERAL INFORMATION 27 only the last 1 segment (E) is displayed in the fuel gauge, the fuel warning message “FUEL” is displayed in the digital meter, and “FUEL” and segment (E) flash. This indicates that the remaining fuel in the tank is 3.7 L (3.9 US qt). Refuel at the earliest opportunity if the fuel warning message “FUEL” is displayed in the digital meter. When vehicle stands with Side Stand, Fuel Gauge cannot show the amount of fuel in the fuel tank exactly.
28 GENERAL INFORMATION Warning/Indicator Light: N: When the transmission is in neutral, the neutral indicator light goes on. : When the headlight is on high beam, the high beam indicator light goes on. : When the turn signal switch is pushed to the left or right, the corresponding turn signal indicator light flashes.
GENERAL INFORMATION 29 CAUTION Do not let the engine continue running when the warning light flashes. Prolonged engine operation will result in severe damage from overheating. Key This motorcycle has a combination key, which is used for the ignition switch/steering lock, seat lock, and fuel tank cap. Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a master, or using the key code on the tag with your keys.
30 GENERAL INFORMATION Ignition Switch/Steering Lock This is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF, LOCK, or P (Park) position. A. Ignition Switch/Steering Lock B. ON position C. OFF position D. LOCK position E.
GENERAL INFORMATION 31 OFF Engine off. All electrical circuits off. ON Engine on. All electrical equipment can be used. LOCK Steering locked. Engine off. All electrical circuits off. Steering locked. Engine off. License plate, tail, and city P (Park) lights on and turn signals can be used. All other electrical circuits cut off. NOTE The city, tail and license plate lights are on whenever the ignition key is in the ON position.
32 GENERAL INFORMATION Right Handlebar Switches Engine Stop Switch: In addition to the ignition switch, the engine stop switch must be in position for the motorcycle to the operate. The engine stop switch is for emergency use. If some emergency requires stopping the engine, move the engine stop 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. A.
GENERAL INFORMATION 33 Starter Button: The starter button operates the electric starter when the transmission is in neutral. Refer to the Starting the Engine section of the “How to Ride the Motorcycle” chapter for starting instructions. Left Handlebar Switches Dimmer Switch: High or low beam can be selected with the dimmer switch. When the ), the headlight is on high beam ( high beam indicator light is lit. ) High beam.......( ) Low beam.......
34 GENERAL INFORMATION NOTE When the headlight is on high beam, both head lights go on. When the headlight is on low beam, only one headlight goes on. Turn Signal Switch: When the turn signal switch is turned ) or right ( ), the to the left ( corresponding turn signal flashes on and off. To stop flashing, push the switch in. Horn Button: When the horn button is pushed, the horn sounds. A. B. C. D.
GENERAL INFORMATION 35 CAUTION If you leave the switch on for a long time, the battery may become totally discharged. So be careful not to use the hazard lights for more than 30 minutes. Brake/Clutch Lever Adjusters There is an adjuster on both the brake and clutch levers. Each 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 adjuster to align the number with the mark on the lever holder.
36 GENERAL INFORMATION The distance from the grip to the released lever is minimum at Number 5 and maximum at Number 1. A. Adjuster B. Mark Fuel Tank Cap To open the fuel tank cap, pull up the key hole cover. 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 37 NOTE The fuel tank cap cannot be closed without the key inserted, and the key cannot be removed unless the cap is locked properly. Do not push on the key to close the cap, or the cap cannot be locked. Fuel Tank Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. A. B. C. D. A. Key Hole Cover B. Ignition Key C.
38 GENERAL INFORMATION WARNING Gasoline is extremely flammable and can be explosive under certain conditions. 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. Never fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vents in the tank cap.
GENERAL INFORMATION 39 the Motor Octane Number (MON) as shown in the table. Octane Rating Method Antiknock Index (RON + MON) 2 Minimum Rating 87 CAUTION If engine “knocking” or “pinging” occurs, use a different brand of gasoline of a higher octane rating. If this condition is allowed to continue it can lead to severe engine damage. Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance.
40 GENERAL INFORMATION which are required to sell such reformulated fuels as part of a strategy to reduce exhaust emissions. The types and volume of fuel oxygenates approved for use in unleaded gasoline by the U.S. Environmental Protection Agency include a broad range of alcohols and ethers, but only two components have seen any significant level of commercial use.
GENERAL INFORMATION 41 CAUTION CAUTION Never use gasoline with an octane rating lower than the minimum specified by Kawasaki. Never use “gasohol” with more than 10% ethanol, or more than 5% methanol. Gasoline containing methanol must also be blended with solvents and corrosion inhibitors. Certain ingredients of gasoline may cause paint fading or damage. Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling.
42 GENERAL INFORMATION Stand The motorcycle is equipped with a side stand. Whenever the side stand is used, make it a practice to kick the stand fully up before sitting on the motorcycle. NOTE The motorcycle is equipped with a side stand switch. This switch is designed so that the engine does not start if the transmission is in gear and the side stand is down. A. Side Stand NOTE When using the side stand, turn the handlebar to the left.
GENERAL INFORMATION 43 Seat Seat Removal Insert the ignition key into the seat lock, located under the rear cowling. the rear end of the seat up while • Pull turning the key clockwise, and then remove the seat backward. • A. Seat Lock B. Ignition Key A. B. C. D. Turn the Key Seat Pull upward Pull backward Seat Installation Install seats in the reverse order of removal.
44 GENERAL INFORMATION • Place slots. the tabs into the matching A. Seat B. Tab C. Slots D. Hook E. Lock the hook at the rear of the seat • Insert into the lock on the frame. down the rear part of the seat • Push until the lock clicks. up the rear end of the seat to • Pull make sure it is securely locked.
GENERAL INFORMATION 45 Helmet Holding Cable Helmets can be secured to the motorcycle by the helmet holding cables located under the seat. A. Helmet Holding Cables WARNING Do not ride the motorcycle with a helmet attached to the cable. The helmet could cause an accident by distracting the operator or interfering with normal vehicle operation.
46 GENERAL INFORMATION Tool Kit/U-Shaped Lock Compartment The tool kit is stored under the seat. The kit contains tools that are helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual. Also, under the seat, there is a lock strap which can hold a U-Shaped lock (not supplied). Install the U-shaped part and lock separately and secure them with its strap. A. Tool Kit B. U-Shaped Lock (not supplied) C.
GENERAL INFORMATION 47 Some U-shaped locks cannot be stored by the size of them. Rear View Mirror Rear View Mirror Adjustment Adjust the rear view mirror by slightly moving only the mirror portion of the assembly. If the rear visibility cannot be assured by moving the mirror, adjust the stay position by loosening the lock nut. • • A. B. C. D.
48 GENERAL INFORMATION Tying Hooks When tying up light loads to the seat, use the tying hooks located on the left and right sides of the rear fairing. A.
BREAK-IN 49 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. The following rules should be observed during the break-in period. The table shows maximum recommended engine speed during the break-in period.
50 BREAK-IN WARNING New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. During break-in, avoid sudden and maximum braking and acceleration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner have the initial maintenance service performed by a competent mechanic following the instructions in the Service Manual.
HOW TO RIDE THE MOTORCYCLE 51 HOW TO RIDE THE MOTORCYCLE Starting the Engine • Check that the engine stop switch is position. in the the ignition key to “ON”. • Turn sure the transmission is in neu• Make tral. the meter operation check, • After leaving the throttle completely closed, push the starter button. A. Engine Stop Switch B. Starter Button C. Neutral Indicator Light D. Ignition Switch E.
52 HOW TO RIDE THE MOTORCYCLE NOTE The motorcycle is equipped with a vehicle-down sensor, which causes the engine to stop automatically and the Fi indicator light to flash when the motorcycle falls down. After righting the motorcycle, first turn the ignition key to “OFF” and then back to “ON” before starting the engine. NOTE The motorcycle is equipped with a starter lockout switch. This switch is designed so that the engine does not start if the transmission is in gear and the side stand is down.
HOW TO RIDE THE MOTORCYCLE 53 CAUTION Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. Jump Starting If your motorcycle battery is “run down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine.
54 HOW TO RIDE THE MOTORCYCLE WARNING Battery acid generates hydrogen gas which is flammable and explosive under certain conditions. It is present within a battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away from the battery. Wear eye protection when working with a battery. In the event of battery acid contact with skin, eyes, or clothing, wash the affected areas immediately with water for at least five minutes. Seek medical attention.
HOW TO RIDE THE MOTORCYCLE 55 booster battery to your motorcycle footpeg or other unpainted metal surface. Do not use the negative (–) terminal of the battery. the standard engine starting • Follow procedure. CAUTION Do not operate the starter continuously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover.
56 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. As the clutch starts to engage, open the throttle a little more, giving the engine just enough fuel to keep it from stalling. A. Shift Pedal NOTE The motorcycle is equipped with a side stand switch.
HOW TO RIDE THE MOTORCYCLE 57 Shifting Gears • • • • Close the throttle while pulling in the clutch lever. Shift into the next higher or lower gear. Open the throttle half way, while releasing the clutch lever. For smooth riding, each gear position should cover the proper rate of speed shown in the table. WARNING When shifting down to a lower gear, do not shift at such a high speed that the engine r/min (rpm) jumps excessively.
58 HOW TO RIDE THE MOTORCYCLE Vehicle speed when shifting Shifting up km/h (mph) Shifting down km/h (mph) 1st 2nd 15 ( 9) 6th 5th 30 (19) 2nd 3rd 25 (15) 5th 4th 25 (15) 3rd 4th 35 (21) 4th 3rd 20 (12) 4th 5th 45 (27) 3rd 2nd 15 ( 9) 5th 6th 55 (34) 2nd 1st 15 ( 9) NOTE The transmission is equipped with a positive neutral finder. When the motorcycle is standing still, the transmission cannot be shifted past neutral from 1st gear.
HOW TO RIDE THE MOTORCYCLE 59 Braking • • • • Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. Shift down one gear at a time so that you are in 1st gear when you come to a complete stop. When stopping, always apply both brakes at the same time. Normally the front brake should be applied a little more than the rear. Shift down or fully disengage the clutch as necessary to keep the engine from stalling.
60 HOW TO RIDE THE MOTORCYCLE Stopping the Engine the throttle completely. • Close Shift the into neutral. • Turn the transmission ignition key to • Support the motorcycle“OFF”. a firm, • level surface with the sideonstand. • Lock the steering. NOTE The A. Rear Brake Pedal motorcycle is equipped with a vehicle-down sensor, which causes the engine to stop automatically and the fuel injection indicator light to flash when the motorcycle falls down.
HOW TO RIDE THE MOTORCYCLE 61 Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to provide you optimum safety and convenience. However, in order to fully benefit from Kawasaki’s safety engineering and craftsmanship, it is essential that you, the owner and operator, properly maintain your motorcycle and become thoroughly familiar with its operation. Improper maintenance can create a dangerous situation known as throttle failure.
62 HOW TO RIDE THE MOTORCYCLE Parking • • WARNING Shift the transmission into neutral and turn the ignition key to “OFF”. Support the motorcycle on a firm, level surface with the side stand. CAUTION Do not park on a soft or steeply inclined surface, or the motorcycle may fall over. parking inside a garage or other • Ifstructure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this includes any appliance with a pilot light.
HOW TO RIDE THE MOTORCYCLE 63 NOTE When stopping near traffic at night, you can leave the taillight on for greater visibility by turning the ignition key to the P (park) position. Do not leave the ignition switch at P position too long, or the battery will discharge. Catalytic Converter This motorcycle is equipped with a catalytic converter in the exhaust system.
64 HOW TO RIDE THE MOTORCYCLE WARNING The muffler and exhaust pipe are very hot while the engine is running and just after the engine stops. This can ignite a fire, resulting in property damage or severe personal injury. Do not idle or park your vehicle in an area where flammable materials such as grasses or dry leaves may contact with muffler or exhaust pipe. only unleaded gasoline. Never • Use use leaded gasoline. Leaded gaso- • line significantly reduces the capability of the catalytic converter.
SAFE OPERATION 65 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 helmet are strongly recommended. You should be aware of and verify the applicable safety regulations in force prior to riding your motorcycle. Gloves and suitable footwear should also be used for added protection.
66 SAFE OPERATION braking may cause the motorcycle to skid and lose control. When going down long slopes, control vehicle speed by closing the throttle. Use the front and rear brakes for auxiliary braking. When riding in wet conditions or on loose roadway surfaces, the ability to maneuver will be reduced. All of your actions should be smooth under these conditions. Sudden acceleration, braking or turning may cause loss of control.
SAFE OPERATION 67 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.
68 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. No brake fluid leakage. Throttle ....................... Throttle grip play 2 a 3 mm (0.08 a 0.12 in.). Clutch .........................
SAFE OPERATION 69 Additional Considerations for High Speed Operation Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play. Tires: High speed operation is hard on tires, and good tires are crucial for riding safety.
70 SAFE OPERATION WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills.
MAINTENANCE AND ADJUSTMENT 71 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. With a basic knowledge of mechanics and the proper use of tools, you should be able to carry out many of the maintenance items described in this chapter.
72 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.
MAINTENANCE AND ADJUSTMENT 73 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. High Altitude Performance Adjustment Information High Altitude adjustment is not required.
74 MAINTENANCE AND ADJUSTMENT You should keep a maintenance record for your motorcycle. To assist you in keeping this record, we have provided space on pages 171 through 175 of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, bills, etc., as verification of this maintenance.
MAINTENANCE AND ADJUSTMENT 75 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, repair, 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
76 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. (e): Emission Related Item 1.
MAINTENANCE AND ADJUSTMENT 77 Frequency Whichever comes first Operation (Engine Items) Throttle control system (play, smooth return, no drag) inspect (e) Every year 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
78 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Operation (Engine Items) Every Fuel hoses K installation condition inspect year Coolant level - inspect year Coolant leak - inspect year Radiator hoses damage - inspect year Radiator hoses installation condition inspect year *Odometer Reading km × 1 000 (mile × 1 000) See Page 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
MAINTENANCE AND ADJUSTMENT 79 Frequency Whichever comes first Operation (Engine Items) Evaporative emission control system function (California model only) (e) Air suction system damage - inspect (e) Every *Odometer Reading km × 1 000 (mile × 1 000) See Page 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
80 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes first Operation (Chassis Items) Every *Odometer Reading km × 1000 (mile × 1000) See Page 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
MAINTENANCE AND ADJUSTMENT 81 Frequency Whichever comes first Operation (Chassis Items) K Every Drive chain guide wear - inspect *Odometer Reading km × 1000 (mile × 1000) See Page 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
82 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Operation (Chassis Items) Every *Odometer Reading km × 1000 (mile × 1000) See Page 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
MAINTENANCE AND ADJUSTMENT 83 Frequency Whichever comes first Operation (Chassis Items) Brake operation (effectiveness, play, drag) - inspect Every year Brake light switch operation - inspect *Odometer Reading km × 1000 (mile × 1000) See Page 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
84 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Operation (Chassis Items) Every *Odometer Reading km × 1000 (mile × 1000) See Page 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
MAINTENANCE AND ADJUSTMENT 85 Frequency Whichever comes first Operation (Chassis Items) Every *Odometer Reading km × 1000 (mile × 1000) See Page 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.
86 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes first Change/Replacement Items Air cleaner element # (e) replace Every year Oil filter - replace year K Fuel hoses - replace 4 years K Coolant - change 3 years Radiator hoses and O-rings replace 3 years K Brake hoses and pipe - replace 4 years Brake fluid (front and rear) change 2 years K 1 (0.6) 12 (7.5) See Page 24 36 48 (15) (22.
MAINTENANCE AND ADJUSTMENT 87 Frequency Whichever comes first Change/Replacement Items K Rubber parts of master cylinder and caliper - replace Spark plug (e) - replace Every *Odometer Reading km × 1 000 (mile × 1 000) 1 (0.6) 12 (7.5) 24 36 48 (15) (22.
88 MAINTENANCE AND ADJUSTMENT Engine Oil In order for the engine, transmission, and clutch to function properly, maintain the engine oil at the proper level, and change the oil and replace the oil filter in accordance with the Periodic Maintenance Chart. Not only do dirt and metal particles collect in the oil, but the oil itself loses its lubricative quality if used too long.
MAINTENANCE AND ADJUSTMENT 89 the engine oil level through • Check the oil level gauge. With the motor- the oil level is too high, remove the • Ifexcess oil through the oil filler open- cycle held level, the oil level should come up between the upper and lower level lines next to the gauge. ing using a syringe or some other suitable device. If the oil level is too low, add the oil to reach the correct level. Use the same type and brand of oil that is already in the engine. • CAUTION A. B. C. D.
90 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. Drain Plug the oil completely drain with • Let the motorcycle perpendicular to the ground.
MAINTENANCE AND ADJUSTMENT 91 NOTE WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. If a torque wrench or required Kawasaki special tool is not available, this item should be serviced by a Kawasaki dealer. the oil filter cartridge and re• Remove place it with a new one. A.
92 MAINTENANCE AND ADJUSTMENT a thin film of oil to the packing • Apply and tighten the cartridge to the specified torque. the engine up to the upper level • Fill line with a good quality engine oil specified in the table. the engine. • Start • Check the oil level and oil leakage. Tightening Torque Engine Oil Drain Plug : 30 N·m (3.0 kgf·m, 22 ft·lb) Cartridge : 17.5 N·m (1.75 kgf·m, 13 ft·lb) A. Packing the drain plug with its new gas• Install ket. Tighten it to the specified torque.
MAINTENANCE AND ADJUSTMENT 93 provide adequate lubrication for both the engine and the clutch. Engine Oil Capacity Capacity : 1.7 L (1.8 US qt) [when filter is not removed] 1.9 L (2.0 US qt) [when filter is removed] 2.4 L (2.5 US qt) [when engine is completely dry] Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.
94 MAINTENANCE AND ADJUSTMENT Cooling System Radiator and Cooling Fan Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a stream of low-pressure water. WARNING Keep your hands and clothing away from the fan blades at all times. CAUTION Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator’s effectiveness.
MAINTENANCE AND ADJUSTMENT 95 Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer severe damage. Check the coolant level each day before riding the motorcycle, and carry out the maintenance and adjustments in accordance with the periodic maintenance chart. Replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart.
96 MAINTENANCE AND ADJUSTMENT CAUTION CAUTION If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Permanent types of antifreeze on the market have anti-corrosion and anti-rust properties. When it is diluted excessively, it loses its anti-corrosion property. Dilute a permanent type of antifreeze in accordance with the instructions of the manufacturer.
MAINTENANCE AND ADJUSTMENT 97 the coolant level if it is be• Check tween the F (Full) and L (Low) level lines. the amount of coolant is insuffi• Ifcient, remove the right side cover and add coolant into the reserve tank. NOTE Check the level when the engine is cold (room or atmospheric temperature). A. F (Full) Level Line B. L (Low) Level Line C. Right Side Cover Coolant Filling the right side cover by re• Remove moving the bolts. A. Right Side Cover B.
98 MAINTENANCE AND ADJUSTMENT the turn signal light con• Disconnect nector. the cap from the reserve • Remove tank and add coolant through the filler opening to the F (Full) level line. A. B. C. D. Reserve Tank F (Full) Level Line L (Low) Level Line Cap the cap. • Install Connect • tor. the turn signal light connecin the projections of the cover into • Fit the holes of the frame side. • Tighten the bolts. A. Right Side Cover B. Projections C.
MAINTENANCE AND ADJUSTMENT 99 NOTE In an emergency you can add water alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible. CAUTION If coolant must be added often, or the reserve tank completely runs dry, there is probably leakage in the system. Have the cooling system inspected by your authorized Kawasaki dealer. Coolant Change Have the coolant changed by an authorized Kawasaki dealer.
100 MAINTENANCE AND ADJUSTMENT Spark Plugs The standard spark plug is shown in the table. The spark plugs should be replaced in accordance with the Periodic Maintenance Chart. Spark plug removal should be done only by a competent mechanic following the instructions in the Service Manual. Spark Plug Standard Plug NGK CR9EIA-9 Plug Gap 0.8 a 0.9 mm (0.032 a 0.035 in.) Tightening Torque 15 N·m (1.5 kgf·m, 11 ft·lb) A.
MAINTENANCE AND ADJUSTMENT 101 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 adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart. Inspection Check that the hoses are securely connected. Replace any kinked, deteriorated, or damaged hoses.
102 MAINTENANCE AND ADJUSTMENT Kawasaki Clean Air System The Kawasaki Clean Air System (KCA) is a secondary air suction system that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust system, it is still hot enough to burn. The KCA System allows extra air into the exhaust system so that the spent fuel charge can continue to burn.
MAINTENANCE AND ADJUSTMENT 103 Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. CAUTION If valve clearance is left unadjusted, wear will eventually cause the valves to remain partly open, which lowers performance, burns the valves and valve seats, and may cause serious engine damage. Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Maintenance Chart.
104 MAINTENANCE AND ADJUSTMENT Air Cleaner A clogged air cleaner restricts the engine’s air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. The air cleaner element must be cleaned in accordance with the Periodic Maintenance Chart. In dusty, rainy, or muddy conditions, the air cleaner element should be serviced more frequently than the recommended interval only by a competent mechanic following the instructions in the Service Manual.
MAINTENANCE AND ADJUSTMENT 105 WARNING Be sure to install the plug in the drain hose after draining. Oil on tires will make them slippery and can cause an accident and injury. Throttle Control System Check the throttle grip play in accordance with the Periodic Maintenance Chart, and adjust it if necessary. Throttle Grip The throttle grip controls the butterfly valves in the throttle body.
106 MAINTENANCE AND ADJUSTMENT Inspection Check that the throttle grip play is correct by lightly turning the throttle grip back and forth. • A. Throttle Grip B. Throttle Grip Play Throttle Grip Play 2 a 3 mm (0.08 a 0.12 in.) • If there is improper play, adjust it. Adjustment Loosen the locknut at the throttle grip, and turn the adjuster until the proper amount of throttle grip play is obtained. • A. Locknut B. Adjuster C.
MAINTENANCE AND ADJUSTMENT 107 the throttle grip play cannot be ad• Ifjusted with the accelerator cable ad- • • juster at the throttle grip, use the decelerator cable adjuster located under the fuel tank. Turn out the decelerator cable adjusting nut until there is no play when the throttle grip is completely closed. Tighten the locknut. out the accelerator cable adjust• Turn ing nut until a play of 2 a 3 mm (0.08 • • a 0.12 in.) is obtained at the throttle grip. Tighten the locknut.
108 MAINTENANCE AND ADJUSTMENT Engine Vacuum Synchronization Idle Speed Engine vacuum synchronization must be checked and adjusted periodically in accordance with the Periodic Maintenance Chart only by a competent mechanic following the instructions in the Service Manual. The idle speed check should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed.
MAINTENANCE AND ADJUSTMENT 109 Idle Speed 1 250 a 1 350 r/min (rpm) the engine idling, turn the han• With dlebar to each side. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or they may be damaged. Be sure to correct any of these conditions before riding. WARNING Operation with damaged cables could result in an unsafe riding condition. A.
110 MAINTENANCE AND ADJUSTMENT Clutch Clutch Lever Play Due to friction plate wear and clutch cable stretch over a long period of use, the clutch operation should be checked each day before riding the motorcycle, and carry out the maintenance and adjustments in accordance with the Periodic Maintenance Chart. 2 a 3 mm (0.08 a 0.12 in.) WARNING To avoid a serious burn, never touch a hot engine or an exhaust pipe during clutch adjustment.
MAINTENANCE AND ADJUSTMENT 111 Adjustment Loosen the locknut, and turn the adjuster so that the clutch lever will have the proper play. • WARNING Be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement, resulting in a hazardous riding condition. be done, use the adjuster • Ifatitthecannot lower end of the clutch cable. A. Adjuster B. Locknut C.
112 MAINTENANCE AND ADJUSTMENT Drive Chain The drive chain slack and lubrication must be checked each day before riding the motorcycle, and must be maintained in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the chain becomes badly worn or maladjusted either too loose or too tight - the chain could jump off the sprockets or break.
MAINTENANCE AND ADJUSTMENT 113 Drive Chain Slack 25 a 35 mm Standard (1.0 a 1.4 in.) Adjustment Loosen the left and right chain adjuster locknuts. Remove the cotter pin, and loosen the rear axle nut. • • A. B. C. D. Axle Nut Cotter Pin Adjusting Nut Locknut chain is too loose, turn in the left • Ifandtheright chain adjusting nuts evenly. If the chain tight, turn out the • left and rightis too chain adjusting nuts evenly.
114 MAINTENANCE AND ADJUSTMENT keep the chain and wheel prop• To erly aligned, the left wheel alignment indicator should align with the same swingarm mark that the right indicator aligns with. NOTE Wheel alignment can also be checked using the straightedge or string method. WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. both chain adjuster locknuts. • Tighten Tighten the rear axle nut to the spec• ified torque. A. B. C. D.
MAINTENANCE AND ADJUSTMENT 115 NOTE NOTE If a torque wrench is not available, When inserting the cotter pin, if the this item should be serviced by a Kawasaki dealer. the wheel, measure the chain • Rotate slack again at the tightest position, • and readjust if necessary. Install a new cotter pin through the rear axle nut and axle, and spread its ends. slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise up to the next alignment.
116 MAINTENANCE AND ADJUSTMENT WARNING If the axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result. the rear brake (see the Brakes • Check section). Wear Inspection Remove the bolts and quick rivet to take off the chain cover. • A. Bolts B. Quick Rivet C. Chain Cover NOTE The chain cover uses the quick rivet.
MAINTENANCE AND ADJUSTMENT 117 Quick Rivet Removal Quick Rivet Installation A. Quick Rivet B. Center Pin C. Push in. A. B. C. D. Quick Rivet Center Pin Pull up fully. Push in. the chain taut either by using • Stretch the chain adjusters, or by hanging a • 10 kg (20 lb) weight on the chain. Measure the length of 20 links on the straight part of the chain from pin center of the 1st pin to pin center of the 21st pin.
118 MAINTENANCE AND ADJUSTMENT • wear unevenly, take measurements at several places. If the length exceeds the service limit, the chain should be replaced. A. Measure B. Weight Drive Chain 20-Link Length Service Limit 323 mm (12.7 in.) installing the chain cover, in• When sert the projections of the chain cover into the holes. A. Projection B. Hole C.
MAINTENANCE AND ADJUSTMENT 119 NOTE WARNING For safety, use only the standard chain. It is an endless type and should not be cut for installation; have it installed by an authorized Kawasaki dealer. Sprocket wear is exaggerated for illustration. See Service Manual for wear limits. the rear wheel to inspect the • Rotate drive chain for damaged rollers, and • loose pins and links. Also inspect the sprockets for unevenly or excessively worn teeth, and damaged teeth. A. Good Teeth B. Worn Teeth C.
120 MAINTENANCE AND ADJUSTMENT Lubrication Lubrication is also necessary after riding through rain or on wet roads, or any time that the chain appears dry. A heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. oil to the sides of the rollers so • Apply that it will penetrate to the rollers and bushings. Apply oil to the O-rings so that the O-rings will be coated with oil. Wipe off any excess oil.
MAINTENANCE AND ADJUSTMENT 121 Brakes Brake Wear Inspection Inspect the brakes for wear. For each 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. Pad replacement should be done by an authorized Kawasaki dealer. Disc Brake Fluid In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in both the front and rear brake fluid reservoirs and change the brake fluid.
122 MAINTENANCE AND ADJUSTMENT Fluid Level Inspection The brake fluid level in the front brake fluid reservoir must be kept above the line (lower level line) next to the gauge and that in the rear brake fluid reservoir (located under the seat) must be kept between the upper and lower level lines (reservoirs held horizontal). • A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line A. Front Brake Fluid Reservoir B.
MAINTENANCE AND ADJUSTMENT 123 the fluid level in either reservoir is • Iflower 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 reservoir is a stepped line showing the upper level line. A. Front Brake Fluid Reservoir B. Upper Level Line WARNING Do not mix two brands of brake fluid.
124 MAINTENANCE AND ADJUSTMENT NOTE First, tighten until slight resistance is felt, which indicates that the cap is seated on the reservoir body; then, tighten the cap an additional 1/6 turn while holding the brake fluid reservoir body. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Front and Rear Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action.
MAINTENANCE AND ADJUSTMENT 125 Brake Light Switches When either the front or rear brake is applied, the brake light goes on. The front brake light switch requires no adjustment, but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart. the operation of the rear brake • Check light switch by depressing the brake pedal. The brake light should go on after the proper pedal travel. Inspection Turn the ignition key to “ON”.
126 MAINTENANCE AND ADJUSTMENT Adjustment To adjust the rear brake light switch, move the switch up or down by turning the switch body. • A. B. C. D. Rear Brake Light Switch Adjusting Nut Lights sooner Lights later CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
MAINTENANCE AND ADJUSTMENT 127 Front Fork The front fork operation and oil leakage should be checked in accordance with the Periodic Maintenance Chart. there is any doubt about the front • Iffork, it should be checked by an authorized Kawasaki dealer. Front Fork Inspection Holding the brake lever, pump the front fork up and down by several times for inspection of smooth stroke. Visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tube. • • A.
128 MAINTENANCE AND ADJUSTMENT Rear Shock Absorbers The rear shock absorber operation and oil leakage should be checked in accordance with the Periodic Maintenance Chart. any doubt about the rear shock ab• Ifsorber, it should be done by an authorized Kawasaki dealer. Rear Shock Absorber Inspection Press down on the seat several times to check if the rear shock absorber stroke is smooth. Visually inspect the rear shock absorber for oil leakage. • • A.
MAINTENANCE AND ADJUSTMENT 129 Spring Preload Adjustment The spring preload adjuster on the rear shock absorber has 7 positions. Position Spring Action 1 2 3 4 5 6 7 Stronger —— The standard setting position for an average-build rider of 75 kg (165 lb) with no passenger and no accessories is No. 4. WARNING A. Spring Preload Adjuster B. Wrench with the following ta• Inble,accordance turn the preload adjuster with the wrench from the tool kit. This unit contains high pressure nitrogen gas.
130 MAINTENANCE AND ADJUSTMENT Wheels Tubeless tires are installed on the wheels of this motorcycle. The indications of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. TUBELESS Mark The tire and rim form a leakproof unit by making airtight contacts at the tire chamfers and the rim flanges instead of using an inner tube. A.
MAINTENANCE AND ADJUSTMENT 131 WARNING The tires, rims, and air valves on this motorcycle are designed only 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. The beads may not seat properly on the rim causing tire deflation. Do not install a tube inside a tubeless tire. Excessive heat build-up may damage the tube causing tire deflation.
132 MAINTENANCE AND ADJUSTMENT checked and adjusted when your riding involves wide variations in temperature or altitude. Tire Wear, Damage As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90 % worn). So it is false economy and unsafe to use the tires until they are bald.
MAINTENANCE AND ADJUSTMENT 133 Minimum Tread Depth 1 mm (0.04 in.) Front Rear Under 130 km/h (80 mph) Over 130 km/h (80 mph) 2 mm (0.08 in.) 3 mm (0.12 in.) inspect the tire for cracks • Visually and cuts, replacing the tire in case of • bad damage. Swelling or high spots indicate internal damage, requiring tire replacement. Remove any imbedded stones or other foreign particles from the tread. NOTE Have the wheel balance inspected whenever a new tire is installed. A.
134 MAINTENANCE AND ADJUSTMENT WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. Tires that have been punctured and repaired do not have the same capabilities as undamaged tires. Do not exceed 100 km/h (60 mph) within 24 hours after repair, and 180 km/h (110 mph) at any time after that. NOTE When operating on public roadways, keep maximum speed under traffic law limits.
MAINTENANCE AND ADJUSTMENT 135 WARNING New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. During break-in, avoid sudden and maximum braking and acceleration, and hard cornering. Battery The battery installed in this motorcycle is a sealed type, so it is not necessary to check the battery electrolyte level or add distilled water.
136 MAINTENANCE AND ADJUSTMENT Due to their internal composition, batteries continually self discharge. The discharge rate depends on the type of battery and ambient temperature. As temperature rises, so does the discharge rate. Every 15°C (27°F) doubles the rate. Electrical accessories, such as digital clocks and computer memory, also draw current from the battery even when the key is switched off.
MAINTENANCE AND ADJUSTMENT 137 Current Drain Discharging Ampere Days from 100% charged to 50% Discharged Days from 100% charged to 100% Discharged 7 mA 60 Days 119 Days 10 mA 42 Days 83 Days 15 mA 28 Days 56 Days 20 mA 21 Days 42 Days 30 mA 14 Days 28 Days In extremely cold weather the fluid in an inadequately charged battery can easily freeze, which can crack the case and buckle the plates. A fully charged battery can withstand sub-freezing temperature with no damage.
138 MAINTENANCE AND ADJUSTMENT charged using an appropriate charger (check with a Kawasaki dealer). If you will not be using the motorcycle for longer than two weeks, the battery should be charged using an appropriate charger. Do not use an automotive-type quick charger that may overcharge the battery and damage it. Kawasaki-recommended chargers are: OptiMate Yuasa 1.5 Amp Automatic charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
MAINTENANCE AND ADJUSTMENT 139 NOTE If you charge the sealed battery, never fail to observe the instructions shown in the label on the battery. WARNING Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Battery Removal Remove the seat. Disconnect the wires from the battery, first from the (–) terminal and then the (+) terminal. Take the battery out of the case. Clean the battery using a solution of baking soda and water.
140 MAINTENANCE AND ADJUSTMENT CAUTION Installing the (–) cable to the (+) terminal of the battery or the (+) cable to the (–) terminal of the battery can seriously damage the electrical system. a light coat of grease on the ter• Put minals to prevent corrosion. the (+) terminal with its protec• Cover tive cap. • Reinstall the removed parts. Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally.
MAINTENANCE AND ADJUSTMENT 141 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 illuminate the road close ahead, and the low beam will blind oncoming drivers. Turn the vertical adjuster clockwise or counterclockwise to adjust its vertical angle. • A. Vertical Adjuster NOTE On high beam, the brightest point should be slightly below horizontal.
142 MAINTENANCE AND ADJUSTMENT Fuses Fuses are arranged in the fuse box located under the seat. The main fuse is mounted on the starter relay behind the left 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. the left side cover by remov• Remove ing the bolt. A. Left Side Cover B. Bolt A.
MAINTENANCE AND ADJUSTMENT 143 WARNING Do not use any substitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the junction box and main fuse. A. Main Fuse B. Spare Fuse A. Normal B.
144 MAINTENANCE AND ADJUSTMENT General Lubrication Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. NOTE A few drops of oil are effective to keep bolts and nuts from rusting and sticking. This makes removal easier.
MAINTENANCE AND ADJUSTMENT 145 Apply grease to the following points (K) Clutch Inner Cable Upper End (K) Throttle Inner Cable Upper Ends (K): Should be serviced by an authorized Kawasaki dealer. NOTE After them. connecting the cables, adjust Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its useful life.
146 MAINTENANCE AND ADJUSTMENT brake fluid, and coolant • Gasoline, will damage the finish of painted and • • • • plastic surfaces: wash them off immediately. Avoid wire brushes, steel wool, and all other abrasive pads or brushes. Use care when washing the windshield, headlight cover, and other plastic parts as they can easily be scratched. Avoid using pressure washers; water can penetrate seals and electrical components and damage your motorcycle.
MAINTENANCE AND ADJUSTMENT 147 the engine and let it idle for sev• Start eral minutes. The heat from the engine will help dry moist areas. ride your motorcycle at a • Carefully slow speed and apply the brakes • several times. This helps the brakes dry and restores its normal operating performance. Lubricate the drive chain to prevent rusting. NOTE After riding in an area where the roads are salted or near the ocean, immediately wash your motorcycle with cold water.
148 MAINTENANCE AND ADJUSTMENT an approved plastic cleaner/polisher product. CAUTION Plastic parts may deteriorate and break if they come in contact with chemical substances or household cleaning products such as gasoline, brake fluid, window cleaners, thread-locking agents, or other harsh chemicals. If a plastic part comes in contact with any harsh chemical substance, wash it off immediately with water and a mild neutral detergent, and then inspect for damage.
MAINTENANCE AND ADJUSTMENT 149 The sidewalls of tires and other rubber components should be treated with a rubber protectant to help prolong their useful life. 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.
150 MAINTENANCE AND ADJUSTMENT 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. 1. Front Fender Mounting Bolts 2. Front Fork Clamp Bolts 3. Handlebar Clamp Bolts 4. Clutch Lever Holder Bolts 5. Steering Stem Head Bolt 6. Steering Stem Nut 7. Pivot Shaft Bolt 8.
MAINTENANCE AND ADJUSTMENT 151 16. Front Brake Master Cylinder Clamp Bolt 17. Rear Shock Absorber Mounting Bolts 18. Front Axle Clamp Bolt 19. Front Axle Shaft 20. Brake Pedal Mounting Bolt 21.
152 STORAGE STORAGE Preparation for Storage: the entire vehicle thoroughly. • Clean Run the • engine oil.engine for about five minutes to warm the oil, shut it off, and drain the WARNING Motorcycle oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. in fresh engine oil. • Put Empty the fuel from the fuel tank by the pump or siphon.
STORAGE 153 WARNING Gasoline is extremely flammable and can be explosive under certain conditions. 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. Gasoline is a toxic substance. Dispose of gasoline properly. Contact your local authorities for approved disposal methods. the fuel system by running the engine at idle speed until the engine stalls.
154 STORAGE • Put a cover over the motorcycle to keep dust and dirt from accumulating on it. Preparation after Storage: the plastic bags from the mufflers. • Remove Install the in the motorcycle and charge the battery if necessary. • Fill the fuelbattery with fuel. • Check all thetank listed in the Daily Safety Checks section. • Lubricate the points pivots, bolts, and nuts.
TROUBLESHOOTING GUIDE 155 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 No fuel in tank Fuel line clogged Fuel broken down Engine flooded Spark plugs not in good contact Spark plugs fouled or wet • • • • • • spark plug gap • Incorrect Incorrect valve clearance • Battery discharged • No fi
156 OWNER SATISFACTION OWNER SATISFACTION (For Products Sold in the Continental United States of America Only) Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Corp., U.S.A. If you have a problem concerning warranty or service, please take the following action: Contact the owner and/or service manager of your authorized Kawasaki dealer. Fully explain your problem and ask for assistance in resolving the situation.
OWNER SATISFACTION 157 your inquiry, please include copies of related receipts and any other pertinent information including the names of the dealership personnel with whom you have been working in the resolution of your problem. Upon receipt of your correspondence we will contact the dealership and work with them in resolving your problem. In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence.
158 REPORTING SAFETY DEFECTS REPORTING SAFETY DEFECTS (For Products Sold in the Continental United States of America Only) 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 Corporation, U.S.A.
160 LOCATION OF LABELS LOCATION OF LABELS *1. 2. 3.
LOCATION OF LABELS 161 4. 5. 6. 7. 8. *9.
162 LOCATION OF LABELS 10. Weight and Manufacture 11.
LOCATION OF LABELS 163 (1) Only on California model (2) (3)
164 LOCATION OF LABELS (4) (5)
LOCATION OF LABELS 165 (6)
166 LOCATION OF LABELS (6) Only on California model
LOCATION OF LABELS 167 (7)
168 LOCATION OF LABELS (8) (9) Only on California model
LOCATION OF LABELS 169 (10)
170 LOCATION OF LABELS (11)
MAINTENANCE RECORD 171 MAINTENANCE RECORD Owner Name....................................................................................... Address .............................................................................................. Phone Number ................................................................................... Engine Number .................................................................................. Vehicle Number............................................................
172 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
MAINTENANCE RECORD 173 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
174 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
MAINTENANCE RECORD 175 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address