GENERAL INFORMATION j

Quick Reference Guide

HOW TO RIDE THE MOTORCYCLE j
This Quick Reference Guide will SAFE OPERATION j
assist you in finding the information
you’re looking for. MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

A Table of Contents is included after

the Foreword.
 Whenever you see the symbols CAUTION
shown below, heed their instructions!
CAUTION indicates a hazardous
Always follow safe operating and main-
situation which, if not avoided,
tenance practices.
could result in minor or moder-
DANGER ate injury.

DANGER indicates a hazardous

situation which, if not avoided, NOTICE
will result in death or serious in- NOTICE is used to address prac-
jury. tices not related to personal in-
jury.
WARNING
WARNING indicates a hazardous NOTE
situation which, if not avoided, żThis note symbol indicates points of
could result in death or serious particular interest for more efficient
injury. and convenient operation.
 FOREWORD
Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-
torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety and performance.

Please read this Owner’s Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-
tures, capabilities, and limitations. This manual offers many safe riding tips, but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-
cle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-
formation on their Kawasaki Motorcycle, a Service Manual is available for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-
tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.
 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 illustra-
tions and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Consumer Products & Machinery Company

© 2009 Kawasaki Heavy Industries, Ltd. Sep. 2009. (1). (S, Ke)
 TABLE OF CONTENTS

SPECIFICATIONS............................... 7 Fuel Tank ......................................... 35

SERIAL NUMBER LOCATIONS......... 11 Fuel Requirement ......................... 36
LOCATION OF PARTS ....................... 12 Side Stand ....................................... 39
LOADING AND ACCESSORIES Seats ................................................ 40
INFORMATION ................................ 15 Tool Kit ............................................. 44
GENERAL INFORMATION................. 18 Air Cleaner Intake ............................ 44
Meter Instruments ............................ 18 Meter Unit Mounting Angle............... 45
Digital Meter ................................. 19 Rear View Mirror .............................. 46
Warning/Indicator Lights ............... 25 BREAK-IN ........................................... 47
Key ................................................... 27 HOW TO RIDE THE MOTORCYCLE . 49
Ignition Switch/Steering Lock ........... 29 Starting the Engine .......................... 49
Left Handlebar Switches .................. 31 Jump Starting ................................... 52
Dimmer Switch ............................. 31 Moving Off........................................ 55
Turn Signal Switch........................ 31 Shifting Gears .................................. 56
Horn Button .................................. 31 Braking ............................................. 58
Right Handlebar Switches................ 32 Stopping the Engine......................... 59
Engine Stop Switch ...................... 32 Stopping the Motorcycle in an
Starter Button ............................... 32 Emergency ................................... 60
Brake Lever Adjuster........................ 33 Parking ............................................. 61
Fuel Tank Cap .................................. 34 Catalytic Converter........................... 63
SAFE OPERATION............................. 65 Drive Chain ...................................... 115
Safe Riding Technique ..................... 65 Brakes .............................................. 124
Daily Safety Checks ......................... 68 Brake Light Switches........................ 128
Additional Considerations for High Front Fork......................................... 130
Speed Operation .......................... 71 Rear Shock Absorber....................... 134
MAINTENANCE AND ADJUSTMENT 73 Wheels ............................................. 137
Periodic Maintenance Chart............. 78 Battery.............................................. 143
Engine Oil ........................................ 89 Headlight Beam................................ 148
Cooling System ................................ 95 Fuses ............................................... 150
Spark Plugs...................................... 101 General Lubrication.......................... 152
Evaporative Emission Control Cleaning Your Motorcycle ................ 153
System (California model only)..... 102 Bolt and Nut Tightening.................... 159
Valve Clearance ............................... 103 STORAGE........................................... 162
Kawasaki Clean Air System ............. 104 TROUBLESHOOTING GUIDE............ 165
Exhaust Device ................................ 105 OWNER SATISFACTION.................... 166
Air Cleaner ....................................... 106 REPORTING SAFETY DEFECTS ...... 168
Throttle Control System ................... 107 ENVIRONMENTAL PROTECTION..... 169
Engine Vacuum Synchronization ..... 110 MAINTENANCE RECORD ................. 170
Idle Speed ........................................ 110 LOCATION OF LABELS..................... 174
Clutch ............................................... 112
 SPECIFICATIONS 7
SPECIFICATIONS

DIMENSIONS
Overall Length 2 095 mm (82.5 in.)
Overall Width 805 mm (32.0 in.)
Overall Height 1 085 mm (43.0 in.)
Wheelbase 1 440 mm (57.0 in.)
Road Clearance 140 mm (6.0 in.)
Curb Mass 218 kg (481 lb)
ENGINE
Type DOHC, 4-cylinder, 4-stroke, liquid-cooled
Displacement 1 043 cm³ (64.0 cu in.)
Bore × Stroke 77.0 × 56.0 mm (3.0 × 2.2 in.)
Compression Ratio 11.8:1
Starting System Electric starter
Cylinder Numbering Method Left to right, 1-2-3-4
Firing Order 1-2-4-3
8 SPECIFICATIONS

Fuel System FI (Fuel Injection)

Ignition System Battery and coil (transistorized ignition)
Ignition Timing (Electronically 10° BTDC @1 100 r/min (rpm) ∼ 40.2° BTDC @5 200
advanced) r/min (rpm)
Spark Plugs NGK CR9EIA-9
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 4.0 L (4.2 US qt)
Coolant Capacity 2.9 L (3.1 US qt)
TRANSMISSION
Transmission Type 6-speed, return shift
Clutch Type Wet, multi disc
Driving System Chain drive
Primary Reduction Ratio 1.627 (83/51)
Final Reduction Ratio 2.800 (42/15)
 SPECIFICATIONS 9

Overall Drive Ratio 5.178 @Top gear

Gear Ratio:
1st 2.600 (39/15)
2nd 1.950 (39/20)
3rd 1.600 (24/15)
4th 1.389 (25/18)
5th 1.238 (26/21)
6th 1.136 (25/22)
FRAME
Caster 24.5°
Trail 103 mm (4.1 in.)
Tire Size:
Front 120/70ZR17 M/C (58 W)
Rear 190/50ZR17 M/C (73 W)
Rim Size:
Front J17M/C × MT3.50
Rear J17M/C × MT6.00
10 SPECIFICATIONS

Fuel Tank Capacity 15.5 L (4.1 US gal)

ELECTRICAL EQUIPMENT
Battery 12 V 8 Ah
Headlight:
High Beam 12 V 55 W
Low Beam 12 V 55 W
Tail/Brake Light LED

Even if one of LED (Light Emitting Diode) tail/brake lights does not go on, consult
with an authorized Kawasaki dealer.
Specifications are subject to change without notice, and may not apply to every
country.
 SERIAL NUMBER LOCATIONS 11
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. Engine No.

A. Frame Number A. Engine Number

12 LOCATION OF PARTS
LOCATION OF PARTS

1. Clutch Lever 6. Brake Fluid Reservoir (Front)

2. Left Handlebar Switches 7. Right Handlebar Switches
3. Spring Preload Adjuster 8. Front Brake Lever
4. Rebound Damping Force Adjuster 9. Throttle Grip
5. Meter Instruments 10. Ignition Switch/Steering Lock
 LOCATION OF PARTS 13

11. Turn Signal Lights 19. Tail/Brake Light 25. Brake Caliper
12. Headlight 20. License Plate Light 26. Idle Adjusting Screw
13. Air Cleaner Intake 21. Seat Lock 27. Shift Pedal
14. Spark Plugs 22. Brake Disc 28. Side Stand
15. Air Cleaner 23. Compression 29. Drive Chain
16. Fuel Tank Damping Force 30. Chain Adjuster
17. Rider’s Seat Adjuster
18. Passenger’s Seat 24. Front Fork
14 LOCATION OF PARTS

31. Fuse Box 38. Rear Shock Absorber

32. Battery 39. Rear Brake Light Switch
33. Fuel Tank Cap 40. Rear Brake Pedal
34. Muffler 41. Oil Level Gauge
35. Brake Fluid Reservoir (Rear) 42. Oil Filter
36. Swingarm 43. Coolant Reserve Tank
37. Rebound Damping Force Adjuster
 LOADING AND ACCESSORIES INFORMATION 15
LOADING AND ACCESSORIES INFORMATION

WARNING warranty, can negatively affect per-

formance, and can even be illegal.
Incorrect loading, improper in-
In selecting and using accessories,
stallation or use of accessories,
and in loading the motorcycle, you are
or modification of your motorcy-
personally responsible for your own
cle may result in an unsafe rid-
safety and the safety of other persons
ing condition. Before you ride
involved.
the motorcycle, make sure that
the motorcycle is not overloaded NOTE
and that you have followed these
instructions.
żKawasaki Parts and Accessories
have been specially designed for
use on Kawasaki motorcycles. We
With the exception of genuine
strongly recommend that all parts
Kawasaki Parts and Accessories,
and accessories you add to your
Kawasaki has no control over the
motorcycle be genuine Kawasaki
design or application of accessories.
components.
In some cases, improper installation
or use of accessories, or motorcycle Because a motorcycle is sensitive to
modification, will void the motorcycle changes in weight and aerodynamic
forces, you must take extreme care in
16 LOADING AND ACCESSORIES INFORMATION

carrying cargo, passengers and/or in 3. All baggage should be carried as

fitting additional accessories. The fol- low as possible to reduce the effect
lowing general guidelines have been on the motorcycle center of gravity.
prepared to assist you in making your Baggage weight should also be dis-
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. The passenger can affect motorcycle.
control of the motorcycle by im- 4. Baggage should be securely at-
proper positioning during cornering tached. Make sure that the baggage
and sudden movements. It is im- will not move around while you are
portant that the passenger sits still riding. Recheck baggage security
while the motorcycle is in motion as often as possible (not while the
and not interfere with the operation motorcycle is in motion) and adjust
of the motorcycle. Do not carry ani- as necessary.
mals on your motorcycle. 5. Do not carry heavy or bulky items on
2. You should instruct any passenger a luggage rack. They are designed
before riding to keep his or her feet for light items, and overloading can
on the passenger footpegs and hold affect handling due to changes in
on to the operator or seat strap. Do weight distribution and aerodynamic
not carry a passenger unless he or forces.
she is tall enough to reach the foot-
pegs and footpegs are provided.
 LOADING AND ACCESSORIES INFORMATION 17

6. Do not install accessories or carry designed or installed items can re-

baggage that impairs the perfor- sult in an unsafe riding condition.
mance of the motorcycle. Make 9. This motorcycle is not intended to
sure that you have not adversely be equipped with a sidecar or to be
affected any lighting components, used to tow any trailers or other ve-
road clearance, banking capability hicles. Kawasaki does not manu-
(i.e., lean angle), control operation, facture sidecars or trailers for mo-
wheel travel, front fork movement, torcycles and cannot predict the ef-
or any other aspects of the motor- fects of such accessories on han-
cycle’s operation. dling or stability, but can only warn
7. Weight attached to the handlebar or that the effects can be adverse and
front fork will increase the mass of that Kawasaki cannot assume re-
the steering assembly and can re- sponsibility for the results of such
sult in an unsafe riding condition. unintended use of the motorcycle.
8. Fairings, windshields, backrests, Furthermore, any adverse effects on
and other large items have the ca- motorcycle components caused by
pability of adversely affecting stabil- the use of such accessories will not
ity and handling of the motorcycle, be remedied under warranty.
not only due to their weight, but Maximum Load
also due to the aerodynamic force
Weight of rider, passenger, baggage,
acting on these surfaces while the and accessories must not exceed 180 kg
motorcycle is in operation. Poorly (397 lb).
18 GENERAL INFORMATION
GENERAL INFORMATION

Meter Instruments
A. Left Button
B. Left Turn Signal Indicator
Light
C. Digital Meter
D. Right Turn Signal Indicator
Light
E. Right Button
F. Warning Indicator Light
G. Coolant Temperature
Warning Indicator Light
H. Neutral Indicator Light
I. High Beam Indicator Light
 GENERAL INFORMATION 19

Digital Meter
The digital meter displays the fol-
lowing functions: the speedometer,
tachometer gauge, clock, trip meter
AB, odometer, fuel gauge, oil pres-
sure warning symbol and fuel injection
warning symbol. When the ignition key
is turned to “ON”, all the LCD segments
are displayed for about one second,
then, depending on the mode selected,
the meters operate normally. A. Speedometer
B. Tachometer Gauge
C. Red Zone
D. Clock
E. Fuel Injection ( )/Oil Pressure
Warning Symbol ( )
F. Fuel Gauge
G. Odometer/Trip Meter AB

km/h·mph Display -
km/h·mph Display can alternate be-
tween metric and English modes (km/h
and mph) in the meter unit. Make sure
20 GENERAL INFORMATION

that km/h or mph according to local reg- • Display the odometer.

ulations is correctly displayed before
riding.
• ing the right button
The km/h·mph display shifts by push-
while the left but-
ton pushed in.
NOTE
żDo not operate the vehicle with
the meter unit displaying in the
wrong unit (km/h or mph). Shift
the km/h·mph display in the meter
unit as follows.

A. km/h·mph Display
 GENERAL INFORMATION 21

• The
lows.
km/h·mph display shifts as fol- rpm). On the right side of the tachome-
ter face is a portion called the “red
zone”. Engine r/min (rpm) in the
red zone is above maximum recom-
mended engine speed and is also
above the range for good performance.

NOTICE
A. km/h
B. mph Engine r/min (rpm) should not
C. Push Right Button with Left Button in be allowed to enter the red zone;
operation in the red zone will
NOTE overstress the engine and may
żThe data is maintained even if the cause serious engine damage.
battery is disconnected.
Clock -
Speedometer - To adjust hours and minutes:
The speedometer shows the speed
of the vehicle in digital values.
• Turn the ignition key to “ON”.

Tachometer Gauge -
The tachometer shows the engine
speed in revolutions per minute (r/min,
22 GENERAL INFORMATION

• Push the right button for more than

two seconds. Both the hour and
• Push the right button. The hour dis-
play stops flashing and the minute
minute displays start flashing. display starts flashing. Push the left
button to advance the minutes.

• Push the right button. The hour dis-

play only flashes. Push the left but- • Push the right button. Both the hour
ton to advance the hours. and minute displays start flashing
again.
• Push the left button. The displays
stop flashing and the clock starts
working.

NOTE
żPushing the left button momentarily
advances the hour or minute step by
step. Pushing and holding the button
advances the hour or minute contin-
uously.
 GENERAL INFORMATION 23

żThe clock works normally by the back NOTE

-up power while the ignition switch is
turned off.
żDo not shift the odometer/trip meter
while riding for safe operation.
żWhen the battery is disconnected,
the clock is reset to 1:00 and starts Odometer
working again when the battery is The odometer shows the total dis-
connected. tance in kilometers or miles that the ve-
hicle has been ridden. This meter can-
Odometer/Trip Meter AB - not be reset.
This meter displays the odometer
and the trip meter AB.
The odometer and the trip meter AB
can be shifted pushing the left button.

A. Odometer
B. Trip Meter A
C. Trip Meter B
D. Push Left Button
24 GENERAL INFORMATION

NOTE NOTE
żThe data is maintained even if the żThe data is maintained by the back
battery is disconnected. -up power if the ignition key is turned
żWhen the figures come to 999999, off.
they are stopped and locked. żWhen the trip meter is reset while the
vehicle is stopped, it starts counting
Trip Meters AB as soon as the vehicle starts moving.
The trip meter shows the distance in żWhen the trip meter reaches 9999.9
kilometers or miles traveled since it was while riding, the meter resets to 0.0
last reset to zero. and continues counting.
żWhen the battery is disconnected,
To reset the trip meter: the meter display resets to 0.0.
• Push the left button to display the trip
meter A or B. Fuel Gauge -
• Push the right button and hold it in. The fuel in the fuel tank is shown
• After two second, the figure display
turns to 0.0, and then starts counting
by the number of segments displayed.
When the fuel tank is full, all the seg-
when the vehicle is operated. The ments are displayed. As the fuel level
meter counts until it is next reset. in the tank goes down, the segments
disappear one by one from F (full) to
E (empty). When the lowest segment
and fuel level warning symbol flash in
 GENERAL INFORMATION 25

the digital meter, only 2.5 L (0.7 US gal) Warning/Indicator Lights

of fuel remain. : When the transmission is in
Refuel at the earliest opportunity if neutral, the neutral indicator light goes
the most bottom segment of the fuel on.
gauge flashes.
When vehicle stands with Side : When the headlight is on high
Stand, Fuel Gauge cannot show the beam, the high beam indicator light
amount of fuel in the fuel tank exactly. goes on.
Stand upright the vehicle to check the
fuel level. : When the turn signal switch is
pushed to the left or right, the turn sig-
nal indicator light flashes.

: The coolant temperature warn-

ing indicator light goes on when the ig-
nition key is turned to “ON” and goes
off soon after ensuring that its circuit
function properly. The coolant temper-
ature warning indicator light also goes
on whenever the coolant temperature
A. Flash rises too high when the motorcycle is in
operation. If it stays on, stop the engine
26 GENERAL INFORMATION

and check the coolant level in the re- have its cause checked by an autho-
serve tank after the engine cools down. rized Kawasaki dealer. Refer to the
“Warning Symbols” in this section for
NOTICE more detailed information.
Do not let the engine continue Warning Symbols -
running when the coolant tem- : The warning indicator light in
perature warning indicator light the meter instrument and the oil pres-
goes on. Prolonged engine op-
eration will result in severe dam- sure warning symbol ( ) in the dig-
age from overheating. ital meter flash whenever the oil pres-
sure is dangerously low or the ignition
switch is in the ON position with the en-
Warning Indicator Light : This warn- gine not running, and go off when the
ing indicator light in the meter instru- engine oil pressure is high enough. Re-
ment has the two warning functions: fer to the Maintenance and Adjustment
oil pressure warning, fuel injection sys- chapter for more detailed engine oil in-
tem warning. This warning indicator formation.
light flashes with each warning sym-
bols: engine oil pressure warning sym- : The warning indicator light in
the meter instrument and the fuel injec-
bol ( )/fuel injection warning sym-
tion warning symbol ( ) in the dig-
bol ( ). If the warning indicator
ital meter flash whenever the ignition
light flashes with the engine running,
 GENERAL INFORMATION 27

key is turned to “ON” or trouble occurs Key

in the fuel injection system. After turn- This motorcycle has a combination
ing the ignition key to “ON”, the fuel in- key, which is used for the ignition
jection warning symbol ( ) goes off switch/steering lock, seat lock, and fuel
soon after it is ensured that its circuit is tank cap.
functioning properly. If the warning in- Blank keys are available at your
dicator light and warning symbol flash, Kawasaki dealers. Ask your dealer to
have the FI system checked by an au- make any additional spare keys you
thorized Kawasaki dealer. may need, using your original key as
a master, or using the key code on the
tag with your keys.
Record the code from the tag with
your keys here. Participating Kawasaki
dealers can use the code to make a
new key in the event that your original
keys are lost.
28 GENERAL INFORMATION

Write your key number here.

 GENERAL INFORMATION 29

Ignition Switch/Steering Lock Engine off. All electrical

OFF
This is a four-position, key-operated circuits off.
switch. The key can be removed from Engine on. All electrical
the switch when it is in the OFF, LOCK, ON
equipment can be used.
or P (Park) position.
Steering locked. Engine off.
LOCK
All electrical circuits off.
Steering locked. Engine off.
Tail and license plate lights on.
P (Park)
All other electrical circuits cut
off.

A. Ignition Switch/Steering Lock

B. ON Position
C. OFF Position
D. LOCK Position
E. P (Park) Position
30 GENERAL INFORMATION

NOTICE goes on when the starter button is

released after starting the engine. To
When turning the handlebar all
avoid battery discharge, always start
the way to the right or left, the
the engine immediately after turning
space between the handlebar
the ignition key to “ON”.
holder and the ignition switch
cover becomes very narrow.
żIf you leave the P (Park) position on
for a long time (one hour), the battery
If an accessory such as a key
may become totally discharged.
ring attached to the ignition key
is caught in the above narrow
space, it could damage ignition
switch cover or the related parts.
Avoid using a key accessory that
may be caught between the han-
dlebar holder and the ignition
switch cover.

NOTE
żThe tail, city and license plate lights
are on whenever the ignition key is
in the ON position. One headlight
 GENERAL INFORMATION 31

Left Handlebar Switches NOTE

żWhen the headlight is on high beam,
both headlights go on. When the
headlight is on low beam, only one
headlight goes on.

Turn Signal Switch

When the turn signal switch is
pushed to the left ( ) or right
( ), the corresponding turn sig-
nals flash on and off.
A. Dimmer Switch To stop flashing, push the switch in.
B. Turn Signal Switch
C. Horn Button Horn Button
When the horn button is pushed, the
Dimmer Switch
horn sounds.
High or low beam can be selected
with the dimmer switch. When the
headlight is on high beam ( ), the
high beam indicator light goes on.
High beam.......( )
Low beam.......( )
32 GENERAL INFORMATION

Right Handlebar Switches The engine stop switch is for emer-

gency use. If some emergency re-
quires stopping the engine, move the
engine stop switch to the position.
NOTE
żAlthough 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. Engine Stop Switch Starter Button

B. Starter Button
The starter button operates the elec-
Engine Stop Switch tric starter when the transmission is in
In addition to the ignition switch, neutral.
the engine stop switch must be in Refer to the Starting the Engine sec-
the position for the motorcycle to tion of the “How to Ride the Motorcycle”
operate. chapter for starting instructions.
 GENERAL INFORMATION 33

Brake Lever Adjuster

There is an adjuster on the brake
lever. The adjuster has 6 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 mark
on the lever holder. The distance from
the grip to the released lever is min-
imum at Number 6 and maximum at
Number 1. A. Adjuster
B. Mark
34 GENERAL INFORMATION

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.
NOTE
żThe fuel tank cap cannot be closed A. Key Hole Cover
B. Ignition Key
without the key inserted, and the key C. Fuel Tank Cap
cannot be removed unless the cap is
locked properly.
żDo not push on the key to close the
cap, or the cap cannot be locked.
 GENERAL INFORMATION 35

Fuel Tank WARNING

The following octane rating gaso-
Gasoline is extremely flammable
line is recommended for the fuel tank.
and can be explosive under cer-
Avoid filling the tank in the rain or where
tain conditions, creating the po-
heavy dust is blowing so that the fuel
tential for serious burns. When
does not get contaminated.
refueling, servicing fuel system,
draining gasoline and/or adjust-
ing the carburetor: Stop engine
and allow it to cool before refuel-
ing. DO NOT smoke. Make sure
the area is well ventilated and
free from any source of flame or
sparks, including the pilot light
of any appliance. DO NOT fill the
tank so the fuel level rises into
the filler neck or level surface of
A. Tank Cap level gauge. If the tank is over-
B. Fuel Tank filled, heat may cause the fuel
C. Top Level to expand and overflow through
D. Filler Neck the vents in the tank cap. Wipe
off any spilled gasoline immedi-
ately.
36 GENERAL INFORMATION

NOTICE of a gasoline is a measure of its resis-

tance to detonation or “knocking.” The
California model only: Never fill
Antiknock Index is an average of the
the tank so the fuel level rises
Research Octane Number (RON) and
into the filler neck. If the tank is
the Motor Octane Number (MON) as
overfilled, heat may cause the
shown in the table.
fuel to expand and flow into the
Evaporative Emission Control Minimum
System resulting in hard start- Octane Rating Method
ing and engine hesitation and Rating
in compliance with the emission Antiknock (RON + MON)
regulation. 90
Index 2
Fuel Requirement
Fuel Type NOTICE
Use clean, fresh unleaded gasoline Use minimum of 90 octane gaso-
with a minimum Antiknock Index of 90. line only to prevent severe en-
The Antiknock Index is posted on ser- gine damage.
vice station pumps. The octane rating
 GENERAL INFORMATION 37

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. If this condition is
mulated fuels as part of a strategy to
allowed to continue it can lead
reduce exhaust emissions.
to severe engine damage.
The types and volume of fuel oxy-
Gasoline quality is important.
genates approved for use in unleaded
Fuels of low quality or not meet-
gasoline by the U.S. Environmental
ing standard industry specifi-
Protection Agency include a broad
cations may result in unsatis-
range of alcohols and ethers, but only
factory performance. Operating
two components have seen any signif-
problems that result from the
icant level of commercial use.
use of poor quality or nonrecom-
Gasoline/Alcohol Blends - Gasoline
mended fuel may not be covered
containing up to 10% ethanol (alco-
under your warranty.
hol produced from agricultural products
such as corn), also known as “gasohol”
is approved for use.
38 GENERAL INFORMATION

NOTICE NOTICE
Avoid using blends of unleaded Never use gasoline with an oc-
gasoline and methanol (wood tane rating lower than the mini-
alcohol) whenever possible, and mum specified by Kawasaki.
never use “gasohol” contain- Never use “gasohol” with more
ing more than 5% methanol. than 10% ethanol, or more than
Fuel system damage and perfor- 5% methanol. Gasoline con-
mance problems may result. taining methanol must also be
blended with cosolvents and
Gasoline/Ether Blends - The most corrosion inhibitors.
common ether is methyl tertiary butyl Certain ingredients of gasoline
ether (MTBE). You may use gasoline may cause paint fading or dam-
containing up to 15 % MTBE. age. Be extra careful not to spill
gasoline or gasoline oxygenate
NOTE
blends during refueling.
żOther oxygenates approved for use When not 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.
genates can also be used in your Fuel stabilizer additives inhibit
Kawasaki. oxidation of the fuel which mini-
mizes gummy deposits.
 GENERAL INFORMATION 39

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.

A. Side Stand

NOTE
żWhen using the side stand, turn the
handlebar to the left.
Whenever the side stand is used,
make it a practice to kick the stand fully
up before sitting on the motorcycle.
40 GENERAL INFORMATION

NOTE Seats
żThe motorcycle is equipped with a Passenger’s Seat Removal
side stand switch. This switch is de-
signed so that the engine does not •Remove the passenger’s seat by in-
serting the ignition key into the seat
start if the transmission is in gear and lock, and turning it clockwise.
the side stand is down.
WARNING
The muffler quickly becomes
very hot soon after the engine
is started and can cause serious
burns. To avoid burns, be care-
ful not to touch the muffler when
operating the seat lock.
 GENERAL INFORMATION 41

NOTE
żWhen removing the passenger’s
seat, pull it up while turning the key.

A. Seat Lock
B. Ignition key

A. Passenger’s seat
B. Pull up
C. Turn the Key
42 GENERAL INFORMATION

Rider’s Seat Removal Rider’s Seat Installation

• Remove the bolts and pull off the seat
upward
• Insert the tabs on the front of the
rider’s seat into the slots in the frame.
• Insert the projections on the rear of
the rider’s seat into the holes on the
frame and tighten the bolts.

A. Bolts
B. Rider’s Seat
C. Pull up
A. Rider’s Seat
B. Tads
C. Slots
D. Projections
E. Holes
 GENERAL INFORMATION 43

Passenger’s Seat Installation • Push down the front part of the pas-
•Insert the tab on the rear of the pas-
senger’s seat into the slot in the
senger’s seat until the lock clicks.

frame.
•Insert the projections at the front of
the passenger’s seat into the holes
on the frame.

A. Passenger’s seat
B. Projections
C. Holes
D. Tab
E. Slot

• Pull up the front and rear ends of

the passenger’s and rider’s seats to
make sure they are securely locked.
44 GENERAL INFORMATION

Tool Kit Air Cleaner Intake

The tool kit is located under the pas- The air cleaner intake allows air to
senger’s seat. enter the fuel system. Never allow any-
The kit contains tools that are help- thing to restrict the flow of air into the
ful in making roadside repairs, adjust- air cleaner. A restricted air cleaner will
ments, and some maintenance proce- reduce performance and increase ex-
dures explained in this manual. Keep haust emissions.
the tool kit in the original place.

A. Air Cleaner Intake

A. Tool Kit
B. Band
 GENERAL INFORMATION 45

Meter Unit Mounting Angle

The meter unit can be adjusted its
• Insert the pin of the knob into the hole
of the meter unit bracket to fix the
mounting angle from 3 positions de- meter unit.
pending on the view of a rider. • Be sure the meter unit is fixed se-
curely.
Adjustment
•Hold the meter unit by the hand. NOTE
•Adjust the meter unit mounting angle
while pulling the knob located the left żThe initial position of the meter unit
side of the meter unit. mounting angle is a top hole.

WARNING
Removing your hands from the
handlebars while riding can cre-
ate an unsafe riding condition
and potential for a crash result-
ing in serious injury or death. Do
not adjust the angle of the me-
ter unit while riding; only make
this adjustment when stopped in
a safe area away from traffic.
A. Meter unit
B. Knob
C. Pull
46 GENERAL INFORMATION

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 can not be as-
sured by moving the mirror, turn the
stay by hand.

A. Stay
B. Rear View Mirror
 BREAK-IN 47
BREAK-IN

The first 1 600 km (1 000 miles) 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 pe-
riod.
Distance traveled Maximum engine speed
0 ∼ 800 km (0 ∼ 500 miles) 4 000 r/min (rpm)
800 ∼ 1 600 km (500 ∼ 1 000 miles) 6 000 r/min (rpm)

• 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.
• Do not race the engine while the transmission is in neutral.
48 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 miles) it is extremely important that

the owner has the initial maintenance service performed by a competent mechanic
following the procedures in the Service Manual.
 HOW TO RIDE THE MOTORCYCLE 49
HOW TO RIDE THE MOTORCYCLE

Starting the Engine • Turn the ignition key to “ON”.

• Check that the engine stop switch is • Make
tral.
sure the transmission is in neu-
in the position.

A. Neutral Indicator Light

A. Engine Stop Switch
B. Ignition Switch
B. Starter Button
C. ON Position
50 HOW TO RIDE THE MOTORCYCLE

NOTE NOTICE
żThe motorcycle is equipped with a Do not operate the starter con-
vehicle-down sensor, which causes tinuously for more than 5 sec-
the engine to stop automatically and onds, or the starter will overheat
the fuel injection warning symbol to and the battery power will drop
flash when the motorcycle falls down temporarily. Wait 15 seconds
and the starter button pushed in. Af- between each operation of the
ter righting the motorcycle, first turn starter to let it cool and the bat-
the ignition key to “OFF” and then tery power recover.
back to “ON” for a few seconds be-
fore starting the engine.

• After the meter operation check,

leaving the throttle completely
closed, push the starter button.
 HOW TO RIDE THE MOTORCYCLE 51

NOTE NOTICE
żThe 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.
the side stand is down. However, the
engine can be started if the clutch
lever is pulled and the side stand is
fully up.

A. Clutch Lever
B. Starter Lockout Switch
52 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. It is present within a
may be used to start the engine.
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 ar-
eas immediately with water for
at least 5 minutes. Seek medical
attention.

Connecting Jumper Cables

•Remove the rider’s seat (see Seats
section in the GENERAL INFORMA-
TION chapter).
 HOW TO RIDE THE MOTORCYCLE 53

• Make sure the ignition key is turned

to “OFF”.
• Connect another jumper cable from
the negative (–) terminal of the
booster battery to your motorcy-
• Connect a jumper cable from the
positive (+) terminal of the booster cle footpeg or other unpainted metal
battery to the positive (+) terminal of surface. Do not use the negative (–)
the motorcycle battery. terminal of the battery.

A. Motorcycle Battery Positive (+) Terminal

B. From Booster Battery Positive (+) Terminal
C. Footpeg
D. From Booster Battery Negative (–)
Terminal
54 HOW TO RIDE THE MOTORCYCLE

DANGER • Follow the standard engine starting

procedure.
Batteries contain sulfuric acid
that can cause burns and pro-
duce hydrogen gas which is NOTICE
highly explosive. Do not make Do not operate the starter con-
this last connection at the fuel tinuously for more than 5 sec-
system or battery. Take care not onds or the starter will overheat
to touch the positive and nega- and the battery power will drop
tive cables together, and do not temporarily. Wait 15 seconds
lean over the battery when mak- between each operation of the
ing this last connection. Do not starter to let it cool and the bat-
connect to a frozen battery. It tery power recover.
could explode. Do not reverse
polarity by connecting positive
(+) to negative (–), or a battery
• After the engine has started, discon-
nect the jumper cables. Disconnect
explosion and serious damage the negative (–) cable from the mo-
to the electrical system may oc- torcycle first.
cur.
• Reinstall the removed parts.
 HOW TO RIDE THE MOTORCYCLE 55

Moving Off NOTE

• Check that the side stand is up. żThe motorcycle is equipped with a
• Pull in the clutch lever. side stand switch. This switch is de-
• Shift into 1st gear. signed so that the engine does not
• Open the throttle a little, and start to
let out the clutch lever very slowly.
start if the transmission is in gear and
the side stand is down.
• As the clutch starts to engage, open żWhen the headlight is on high beam,
the throttle a little more, giving the en- two headlight beams go on, and on
gine just enough fuel to keep it from low beam, the one side of the head-
stalling. light goes on.

A. Shift Pedal
56 HOW TO RIDE THE MOTORCYCLE

Shifting Gears WARNING

• Close the throttle while pulling in the
clutch lever.
Downshifting to a lower gear at
high speed causes engine rpm
• Shift
gear.
into the next higher or lower
to increase excessively, poten-
tially damaging the engine and
• Open the throttle part way, while re-
leasing the clutch lever.
it may also cause the rear wheel
to skid and cause an accident.
• For smooth riding, each gear position
should cover the proper rate of speed
Downshifting should be done
below the vehicle speeds for
shown in the table.
each gear shown in the table.
 HOW TO RIDE THE MOTORCYCLE 57

Vehicle speed when shifting

Shifting up km/h (mph) Shifting down km/h (mph)
1st ĺ 2nd 15 ( 9) 6th ĺ 5th 30 (19)
2nd ĺ 3rd 25 (15) 5th ĺ 4th 25 (15)
3rd ĺ 4th 35 (21) 4th ĺ 3rd 20 (12)
4th ĺ 5th 45 (27) 3rd ĺ 2nd 15 ( 9)
5th ĺ 6th 55 (34) 2nd ĺ 1st 15 ( 9)

NOTE
żThe transmission is equipped with a
positive neutral finder. When the mo-
torcycle is standing still, the transmis-
sion cannot be shifted past neutral
from 1st gear. To use the positive
neutral finder, shift down to 1st gear,
then lift up on the shift pedal while
standing still. The transmission will
shift only into neutral.
58 HOW TO RIDE THE MOTORCYCLE

Braking • For emergency braking, disregard

• Close the throttle completely, leav-
ing the clutch engaged (except when
downshifting, and concentrate on
applying the brakes as hard as pos-
shifting gears) so that the engine will sible without skidding.
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 lit-
tle more than the rear. Shift down or
fully disengage the clutch as neces-
sary to keep the engine from stalling.
• Never lock the brakes, or it will cause
the tires to skid. When turning a cor- A. Front Brake Lever
ner, it is better not to brake at all. Re-
duce your speed before you get into
the corner.
 HOW TO RIDE THE MOTORCYCLE 59

Stopping the Engine

• Close the throttle completely.
• Turn the transmission
Shift the into neutral.
• Support the motorcycle“OFF”.
ignition key to
• level surface with the sideonstand.
a firm,

• Lock the steering.

NOTE
żThe motorcycle is equipped with a
A. Rear Brake Pedal vehicle-down sensor, which causes
the engine to stop automatically and
the fuel injection warning symbol to
flash when the motorcycle falls down
and the starter button is pushed in.
After righting the motorcycle, first
turn the ignition key to “OFF” and
then back to “ON” for a few seconds
before starting the engine.
60 HOW TO RIDE THE MOTORCYCLE

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 fuel injection system.
designed and manufactured to pro- In an emergency situation such as
vide you optimum safety and conve- throttle failure, your vehicle may be
nience. However, in order to fully ben- stopped by applying the brakes and
efit from Kawasaki’s safety engineering disengaging the clutch. Once this
and craftsmanship, it is essential that stopping procedure is initiated, the en-
you, the owner and operator, properly gine stop switch may be used to stop
maintain your motorcycle and become the engine. If the engine stop switch is
thoroughly familiar with its operation. used, turn off the ignition switch after
Improper maintenance can create a stopping the motorcycle.
dangerous situation known as throt-
tle failure. Two of the most common
causes of throttle failure are:
1. An improperly serviced or clogged
air cleaner may allow dirt and dust
to enter the throttle body and stick
the throttle open.
 HOW TO RIDE THE MOTORCYCLE 61

Parking WARNING
• Shift the transmission into neutral
and turn the ignition key to “OFF”.
The muffler and exhaust pipe
are very hot while the engine is
• Support the motorcycle on a firm,
level surface with the side stand.
running and just after the engine
stops. This can ignite a fire, re-
sulting in property damage or
NOTICE severe personal injury.
Do not park on a soft or steeply Do not idle or park your vehi-
inclined surface, or the motorcy- cle in an area where flammable
cle may fall over. materials such as grasses or dry
leaves may contact with muffler
• Ifstructure,
parking inside a garage or other
be sure it is well ventilated
or exhaust pipe.

and the motorcycle is not close to

any source of flame or sparks; this
includes any appliance with a pilot
light.
62 HOW TO RIDE THE MOTORCYCLE

WARNING • Lock the steering to prevent theft.

Gasoline is extremely flammable NOTE
and can be explosive under cer-
tain conditions, creating the po- żWhen stopping near traffic at night,
tential for serious burns. Turn you can leave the taillight on for
the ignition switch to “OFF”. Do greater visibility by turning the igni-
not smoke. Make sure the area is tion key to the P (park) position.
well-ventilated and free from any żDo not leave the ignition switch at P
source of flame or sparks; this position too long, or the battery will
includes any appliance with a pi- discharge.
lot light.
Never fill the tank completely
to the top. If the tank is filled
completely to the top, heat may
cause the fuel to expand and
overflow through the vents in
the tank cap. After refueling,
make sure the tank cap is closed
securely.
If gasoline is spilled on the fuel
tank, wipe it off immediately.
 HOW TO RIDE THE MOTORCYCLE 63

Catalytic Converter WARNING

This motorcycle is equipped with
The muffler and exhaust pipe
a catalytic converter in the exhaust
are very hot while the engine is
system. Platinum and rhodium in the
running and just after the engine
converter react with carbon monox-
stops. This can ignite a fire, re-
ide, hydrocarbons and nitrogen oxides
sulting in property damage or
to convert them into carbon dioxide,
severe personal injury.
water, nitrogen and oxygen resulting
Do not idle or park your vehi-
in much cleaner exhaust gases to be
cle in an area where flammable
discharged into the atmosphere.
materials such as grasses or dry
For proper operation of the catalytic
leaves may contact with muffler
converter, the following cautions must
or exhaust pipe.
be observed.

• Use only unleaded gasoline. Never

use leaded gasoline. Leaded gaso-
line significantly reduces the capabil-
ity of the catalytic converter.
• Do not operate the vehicle with the
engine of any one cylinder misfiring.
Under these conditions unburned
air/fuel mixture flowing out of engine
excessively accelerates reaction in
64 HOW TO RIDE THE MOTORCYCLE

the converter allowing the converter converter performance when the en-
to overheat and become damaged gine is cold.
when the engine is hot, or reduces
 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 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. Removing
the applicable safety regulations in your hands from the handlebars or
force prior to riding your motorcy- feet from the footpegs while riding
cle. Gloves and suitable footwear can be hazardous. If you remove
should also be used for added pro- even one hand or foot, you can
tection in case of a mishap. reduce your ability to control the
motorcycle.
A motorcycle does not provide
the impact protection of an auto- Before changing lanes, look over
mobile, so defensive riding in addi- your shoulder to make sure the way
tion to wearing protective apparel is clear. Do not rely solely on the
is extremely important. Do not let rear view mirror; you may misjudge
protective apparel give you a false a vehicle’s distance and speed, or
sense of security. you may not see it at all.
66 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
surfaces, when the ability to maneu- wheel from too rapid acceleration or
ver will be reduced. deceleration.

When going up steep slopes, shift Riding at the proper rate of speed
to a lower gear so that there is plenty and avoiding unnecessarily fast ac-
of power to spare rather than over- celeration are important not only for
loading the engine. safety and low fuel consumption but
also for long vehicle life and quieter
When applying the brakes, use operation.
both the front and rear brakes. Ap-
plying only one brake for sudden On rough roads, exercise caution,
braking may cause the motorcycle slow down, and grip the fuel tank
to skid and lose control. with knees for better stability.

When going down long slopes, When quick acceleration is neces-

control vehicle speed by closing sary as in passing, shift to a lower
the throttle. Use the front and rear gear to obtain the necessary power.
brakes for auxiliary braking.
 SAFE OPERATION 67

Do not downshift at too high an Avoiding unnecessary weaving is

r/min (rpm) to avoid damage from important to the safety of both the
overrevving to the engine. rider and other motorists.
68 SAFE OPERATION

Daily Safety Checks

Check the following items each day before you ride. The time required is minimal,
and habitual performance of these checks will help ensure you a safe, reliable ride.
If any irregularities are found during these checks, refer to the Maintenance and
Adjustment chapter or see your dealer for the action required to return the motor-
cycle to a safe operating condition.

WARNING
Failure to perform these checks before operation may result in serious
damage or an accident. Always perform daily safety checks before oper-
ation.

DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous
gas.
Inhaling carbon monoxide can cause serious brain injury or death.
Do not run the engine in enclosed areas. Operate only in a well-ventilated
area.
Fuel ............................. Adequate supply in tank, no leaks.
Engine Oil ................... Oil level between level lines.
 SAFE OPERATION 69

Tires ............................ Air pressure (when cold):

Front 250 kPa (2.50 kgf/cm², 36 psi)
Rear 290 kPa (2.90 kgf/cm², 42 psi)
Install the air valve cap.
Drive Chain ................. Slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.).
Lubricate when chain is dry.
Nuts, Bolts, Fasteners Check that steering and suspension components, axles,
and all controls are properly tightened or fastened.
Steering ...................... Action smooth but not loose from lock to lock.
No binding of control cables.
Steering Damper Unit: No oil leakage.
Brakes ........................ Brake pad wear: Lining thickness more than 1 mm (0.04
in.) left.
No brake fluid leakage.
Throttle ....................... Throttle grip play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).
Clutch ......................... Clutch lever play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).
Clutch lever operates smoothly.
Coolant ....................... No coolant leakage.
Coolant level between level lines (when engine is cold).
Electrical Equipment ... All lights (Headlight, Tail/Brake Lights, Turn Signal Lights,
Licence Plate Light, Warning/Indicator Lights) and horn
work.
70 SAFE OPERATION

Engine Stop Switch .... Stops engine.

Side Stand .................. Return to its fully up position by spring tension.
Return spring not weak or not damaged.

Refer to the “Daily Safety Checks” caution label attached to the back of left side
cover.
 SAFE OPERATION 71

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 func-
tioning 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. Examine their overall condition, inflate them to the proper pressure, and
check the wheel balance.
Fuel: Have sufficient fuel for the high fuel consumption during high speed oper-
ation.
Engine Oil: To avoid engine seizure and resulting loss of control, make sure that
the oil level is at the upper level line.
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 signal
lights, license plate light 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.
72 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 73
MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out 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. If you
lack proper experience or doubt your ability, all adjustments, maintenance, and
repair work should be completed by a qualified technician.
Please note that Kawasaki cannot assume any responsibility for damage result-
ing from incorrect or improper adjustment done by the owner.
74 MAINTENANCE AND ADJUSTMENT

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated
crankcase emission (1) and exhaust emission (2) control systems in compliance
with applicable regulations of the United States Environmental Protection Agency
and California Air Resources Board. Additionally, Kawasaki has incorporated an
evaporative emission control system (3) in compliance with applicable regulations
of the United States Envitonmental Protection Agency and California Air Resources
Board.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere.
Instead, the vapors are routed through an oil separator to the intake side of the
engine. While the engine is operating, the vapors are drawn into the combustion
chamber, where they are burned along with the fuel and air supplied by the fuel
injection system.

2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere
by the exhaust of this motorcycle. The fuel, ignition and exhaust systems of this
motorcycle have been carefully designed and constructed to ensure an efficient
engine with low exhaust pollutant levels. The exhaust system of this model motor-
cycle includes a catalytic converter system.
 MAINTENANCE AND ADJUSTMENT 75

3. Evaporative Emission Control System

The evaporative emission control system for this vehicle consists of low perme-
ation fuel hoses and fuel tank.
3. Evaporative Emission Control System (California)
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.
76 MAINTENANCE AND ADJUSTMENT

MAINTENANCE AND WARRANTY

Proper maintenance is necessary to ensure that your motorcycle will continue to
have low emission levels. This Owner’s Manual contains those maintenance rec-
ommendations for your motorcycle. Those items identified by the Periodic Mainte-
nance Chart are necessary to ensure compliance with the applicable standards.
As the owner of this motorcycle, you have the responsibility to make sure that
the recommended maintenance is carried out according to the instructions in this
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.
You should keep a maintenance record for your motorcycle. To assist you in
keeping this record, we have provided space on pages 170 through 173 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 77

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.

Among those acts presumed to constitute tampering are the acts listed below:
* Replacement of the original exhaust system or muffler with a component not in
compliance with Federal regulations.
* Removal of the muffler(s) or any internal portion of the muffler(s).
* Removal of the air box or air box cover.
* Modifications to the muffler(s) or air intake system by cutting, drilling, or other
means if such modifications result in increased noise levels.
78 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.
Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Valve clearance -
inspect • 103

Throttle control
system (play,
smooth return, no
year • • • • 107
drag) - inspect
Engine vacuum
synchronization -
inspect
• • • 110
 MAINTENANCE AND ADJUSTMENT 79

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Idle speed - inspect • • • • 110
Fuel leak (fuel hose
K
and pipe) - inspect
year • • • • –

Fuel hoses damage

K
- inspect
year • • • • –

Fuel hoses
K installation
condition - inspect
year • • • • –

Coolant level -
inspect • • • • 98

Coolant leak -
inspect
year • • • • 96

Radiator hoses
damage - inspect
year • • • • 96
80 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Radiator hoses
installation
condition - inspect
year • • • • 96

Evaporative
emission control
system - function
(California model
• • • • • • • 102

only)
Air suction system
damage - inspect • • • 104
 MAINTENANCE AND ADJUSTMENT 81

2. Periodic Inspection (Chassis Related Items)

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Clutch and drive train:
Clutch operation
(play, engagement,
disengagement) - • • • • 112
inspect
Drive chain
lubrication
every 600 km (400 mile) 122
condition - inspect
#
Drive chain slack - every 1 000 km (600 mile) 116
inspect #
Drive chain wear -
inspect # • • • 120
82 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Drive chain guide
K
wear - inspect • • • –

Wheels and tires:

Tire air pressure -
inspect
year • • • 138

Wheels/tires
damage - inspect • • • 139

Tire tread wear,

abnormal wear -
inspect
• • • 139

Wheel bearings
K
damage - inspect
year • • • –
 MAINTENANCE AND ADJUSTMENT 83

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Brake system:
Brake fluid leak -
inspect
year • • • • • • • 124

Brake hoses
damage - inspect
year • • • • • • • 124

Brake pad wear -

inspect # • • • • • • 124

Brake hoses
installation
condition - inspect
year • • • • • • • 124

Brake fluid level - 6

inspect months • • • • • • • 125
84 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Brake operation
(effectiveness,
play, drag) - inspect
year • • • • • • • 127

Brake light switch

operation - inspect • • • • • • • 128

Suspensions:
Front forks/rear
shock absorber
operation 130/
(damping and • • • 134
smooth stroke) -
inspect
Front forks/rear
130/
shock absorber oil
leak - inspect
year • • • 134
 MAINTENANCE AND ADJUSTMENT 85

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Uni-trak rocker arm
K
operation - inspect • • • –

Uni-trak tie rods

K
operation - inspect • • • –

Steering system:
Steering play -
K
inspect
year • • • • –

Steering stem 2
K
bearings - lubricate years • –

Electrical system:
Lights and
switches operation
- inspect
year • • • –
86 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Headlight aiming -
inspect
year • • • 148

Side stand switch

operation - inspect
year • • • –

Engine stop switch

operation - inspect
year • • • –

Chassis:
Chassis parts -
lubricate
year • • • 152

Bolts and nuts

tightness - inspect • • • • 159
 MAINTENANCE AND ADJUSTMENT 87

3. Periodic Replacement
Frequency Whichever
comes first *Odometer Reading
km × 1 000 (mile × 1 000) See
Page
1 12 24 36 48
Every
Change/Replacement Items (0.6) (7.5) (15) (22.5) (30)
Air cleaner element # - replace every 18 000 km (11 250 mile) 106
Engine oil # - change year • • • • • 92
Oil filter - replace year • • • • • 92
K Fuel hoses - replace 4 years • –

K Coolant - change 3 years • 100

Radiator hoses and O-rings -
K
replace
3 years • –

K Brake hoses - replace 4 years • –

Brake fluid (front and rear) -
K
change
2 years • • 127
88 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes first *Odometer Reading
km × 1 000 (mile × 1 000) See
Page
1 12 24 36 48
Every
Change/Replacement Items (0.6) (7.5) (15) (22.5) (30)
Rubber parts of master
K
cylinder and caliper - replace
4 years • –

Spark plug - replace • • • • 101

 MAINTENANCE AND ADJUSTMENT 89

Engine Oil Oil Level Inspection

In order for the engine, transmission,
and clutch to function properly, main-
• If the oil has just been changed, start
the engine and run it for several min-
tain the engine oil at the proper level, utes at idle speed. This fills the oil
and change the oil and replace the oil filter with oil. Stop the engine, then
filter in accordance with the Periodic wait several minutes until the oil set-
Maintenance Chart. Not only do dirt tles.
and metal particles collect in the oil, but
the oil itself loses its lubricative quality NOTICE
if used too long.
Racing the engine before the oil
WARNING reaches every part can cause en-
gine seizure.
Motorcycle operation with insuf-
ficient, deteriorated, or contam-
inated engine oil will cause ac- • Ifwait
the motorcycle has just been used,
several minutes for all the oil to
celerated wear and may result in drain down.
engine or transmission seizure,
accident, and injury. Check the
oil level before each ride and
change the oil according to the
periodic maintenance chart in
the Owner’s Manual.
90 MAINTENANCE AND ADJUSTMENT

• Check the engine oil level through

the oil level gauge. With the motor-
• Ifexcess
the oil level is too high, remove the
oil through the oil filler open-
cycle held level, the oil level should ing using a syringe or some other
come up between the upper and suitable device.
lower level lines next to the gauge. • 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.

A. Oil Level Inspection Window

B. Oil Filler Cap
C. Lower Level Line
D. Upper Level Line
 MAINTENANCE AND ADJUSTMENT 91

NOTICE
If the engine oil gets extremely
low or if the oil pump does not
function properly or oil pas-
sages are clogged, the warning
indicator light in the meter in-
strument and oil pressure warn-
ing symbol in the digital meter
will flash. If they flash on when
the engine speed is above idle,
stop the engine immediately and A. Oil Pressure Warning Symbol
B. Warning Indicator Light
have it serviced. Failure to do
so could cause serious engine
damage.
92 MAINTENANCE AND ADJUSTMENT

Oil and/or Oil Filter Change • Let the oil completely drain with
• Warm up the engine thoroughly, and
then stop it.
the motorcycle perpendicular to the
ground.
• Place an oil pan beneath the engine.
• Remove the engine oil drain bolt. WARNING
Motor oil is a toxic substance.
Dispose of used oil properly.
Contact your local authorities
for approved disposal methods
or possible recycling.

• Ifmove
the oil filter is to be replaced, re-
the oil filter cartridge and re-
place it with a new one.

A. Engine Oil Drain Bolt

 MAINTENANCE AND ADJUSTMENT 93

NOTE • Apply a thin film of oil to the packing

żIf a torque wrench or required and tighten the cartridge to the spec-
ified torque.
Kawasaki special tool is not avail-
able, this item should be serviced by
a Kawasaki dealer.

A. Packing

A. Oil Filter
• Install the drain bolt with a new gas-
ket. Tighten it to the specified torque.

NOTE
żReplace any gaskets with new ones.
94 MAINTENANCE AND ADJUSTMENT

Tightening Torque Engine Oil Capacity

Engine Oil Drain Bolt: Capacity:
30 N·m (3.1 kgf·m, 22 ft·lb) 3.2 L (3.4 US qt)
Oil Filter: (when filter is not removed)
17 N·m (1.7 kgf·m, 13 ft·lb) 3.8 L (4.0 US qt)
(when filter is removed)
Recommended Engine Oil 4.0 L (4.2 US qt)
Type: (when engine is completely dry)
API SG, SH, SJ, SL or SM with JASO
MA, MA1 or MA2
Viscosity:
SAE10W-40

NOTE
żDo not add any chemical additive to
the oil. Oils fulfilling the above re-
quirements are fully formulated and
provide adequate lubrication for both
the engine and the clutch.
 MAINTENANCE AND ADJUSTMENT 95

Although 10W-40 engine oil is the Cooling System

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.
any obstructions with a stream of
low-pressure water.

WARNING
The cooling fan spins at high
speed and can cause serious
injuries. Keep your hands and
clothing away from the cooling
fan blades at all times.
96 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.
may suffer severe damage. Check the
Do not obstruct or deflect air-
coolant level each day before riding the
flow through the radiator by
motorcycle, also carry out the mainte-
installing unauthorized acces-
nance and adjustments in accordance
sories in front of the radiator or
with the periodic maintenance chart.
behind the cooling fan. Inter-
Replenish coolant if the level is low.
ference with the radiator airflow
Change the coolant in accordance with
can lead to overheating and con-
the Periodic Maintenance Chart.
sequent engine damage.
Information for Coolant
To protect the cooling system (con-
Radiator Hoses -
sisting of the aluminum engine and
Check the radiator hoses for leakage,
radiator) from rust and corrosion, the
cracks or deterioration, and connec-
use of corrosion and rust inhibitor
tions for leakage, or looseness each
chemicals in the coolant is essential. If
day before riding the motorcycle, and
coolant containing corrosion and rust
carry out the maintenance and adjust-
inhibitor chemicals are not used, over
ments in accordance with the Periodic
a period of time, the cooling system
Maintenance Chart.
 MAINTENANCE AND ADJUSTMENT 97

accumulates rust and scale in the wa- NOTICE

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.
considerably reduces the effi-
WARNING ciency of the cooling system.

Coolant containing corrosion in- If the lowest ambient temperature en-

hitors for alminum engines and countered falls below the freezing point
radiators include harmful chem- of water, use permanent antifreeze in
icals for human body. the coolant to protect the cooling sys-
Drinking coolant can result in tem against engine and radiator freeze
serious injury or death. Use -up, as well as from rust and corrosion.
coolant in accordance with the Use a permanent type of antifreeze
instractions of the manufacturer. (soft water and ethylene glycol plus cor-
rosion and rust inhibitor chemicals for
Soft or distilled water must be used aluminum engines and radiators) in the
with the antifreeze (see below for an- cooling system. On the mixture ratio
tifreeze) in the cooling system. of coolant, choose the suitable one re-
ferring to the relation between freezing
point and strength directed on the con-
tainer.
98 MAINTENANCE AND ADJUSTMENT

NOTICE • Check the coolant level if it is be-

tween the F (Full) and L (Low) level
Permanent types of antifreeze on
lines.
the market have anti-corrosion
and anti-rust properties. When it NOTE
is diluted excessively, it loses its
anti-corrosion property. Dilute a żCheck the level when the engine is
permanent type of antifreeze in cold (room or atmospheric tempera-
accordance with the instructions ture).
of the manufacturer.

NOTE
żA permanent type of antifreeze is in-
stalled in the cooling system when
shipped. It is colored green and con-
tains ethylene glycol. It is mixed at
50% and has the freezing point of
–35°C (–31°F).

Coolant Level Inspection A. F (Full) Level Line

•Situate the motorcycle so that it is
perpendicular to the ground.
B. L (Low) Level Line
C. Right Side Cover
 MAINTENANCE AND ADJUSTMENT 99

• Ifcient,
the amount of coolant is insuffi-
remove the right fairing and
• Disconnect
nector.
the turn signal light con-

add coolant into the reserve tank. • Remove the cap from the reserve
tank and add coolant through the
Coolant Filling filler opening to the F (Full) level line.
•Remove the right fairing by removing
the bolts.

A. Reserve Tank
B. F (Full) Level Line
A. Right Fairing C. L (Low) Level Line
B. Bolts D. Cap
100 MAINTENANCE AND ADJUSTMENT

• Install the cap. NOTE

• tor. the turn signal light connec-
Connect żIn an emergency you can add wa-
ter alone to the coolant reserve tank,
• Fit the projections of the cover into
the holes of the frame side.
however it must be returned to the
correct mixture ratio by the addition
• Tighten the bolts. of antifreeze concentrate as soon as
possible.

NOTICE
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.
A. Right Fairing
B. Projections
C. Holes
Coolant Change
Have the coolant changed by an au-
thorized Kawasaki dealer.
 MAINTENANCE AND ADJUSTMENT 101

Spark Plugs
The standard spark plug is shown in
the table. The spark plugs should be
replaced in accordance with the Peri-
odic Maintenance Chart.
Spark plug removal should be done
only by a competent mechanic follow-
ing the instructions in the Service Man-
ual.
Spark Plug
Standard A. 0.8 ∼ 0.9 mm (0.032 ∼ 0.036 in.)
NGK CR9EIA-9
Plug
0.8 ∼ 0.9 mm
Plug Gap
(0.032 ∼ 0.036 in.)
Tightening
13 N·m (1.3 kgf·m, 115 in·lb)
Torque
102 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.
Inspection
• Check that the hoses are securely
connected.
• Replace any kinked, deteriorated, or
damaged hoses.
 MAINTENANCE AND ADJUSTMENT 103

Valve Clearance Inspection and adjustment should be

Valve and valve seat wear decreases carried out only by a competent me-
valve clearance, upsetting valve timing. chanic following the instructions in the
Service Manual.
NOTICE
If valve clearance is left un-
adjusted, wear will eventually
cause the valves to remain
partly open; which lowers per-
formance, burns the valves and
valve seats, and may cause seri-
ous engine damage.

Valve clearance for each valve

should be checked and adjusted in
accordance with the Periodic Mainte-
nance Chart.
104 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. Also, inspect the air
burn more completely. When the spent suction valves whenever stable idling
fuel charge is released into the ex- cannot be obtained, engine power is
haust system, it is still hot enough to greatly reduced, or there are abnormal
burn. The KCA System allows extra engine noises.
air into the exhaust system so that the Air suction valve removal and inspec-
spent fuel charge can continue to burn. tion should be carried out only by a
This continued burning action tends to competent mechanic following the in-
burn up a great deal of the normally structions in the Service Manual.
unburned gases, as well as chang-
ing a significant portion of the carbon
monoxide into carbon dioxide.
Air Suction Valves -
The air suction valve is essentially a
check valve which allows fresh air to
flow only from the air cleaner into the
exhaust port. Any air that has passed
 MAINTENANCE AND ADJUSTMENT 105

Exhaust Device NOTICE

This motorcycle is equipped with a
Do not adjust the exhaust device
exhaust device system. This system
system by yourself. The mal-
controls the valve in the exhaust pipe
adjustment will cause the poor
and produces stable engine power at
engine performance and engine
low and middle engine speed. This ex-
damage.
haust device is controlled by the ECU,
and adjustment or maintenance should
be done by an authorized Kawasaki
dealer.

A. Exhaust Device Cables

106 MAINTENANCE AND ADJUSTMENT

Air Cleaner Oil Draining

A clogged air cleaner restricts the en-
gine’s air intake, increasing fuel con-
• Inspect the transparent reservoir lo-
cated on the left side of the engine to
sumption, reducing engine power, and see if any oil or water has run down
causing spark plug fouling. from the air cleaner housing.
The air cleaner element must be
cleaned in accordance with the Pe-
riodic Maintenance Chart. In dusty,
rainy, or muddy conditions, the element
should be cleaned more frequently
than the recommended interval.
Removal and cleaning should be
done only by a competent mechanic
following the instructions in the Service
Manual.

A. Drain Hose
B. Reservoir

• Ifmove
there is any oil in the reservoir, re-
the reservoir and drain the oil.
 MAINTENANCE AND ADJUSTMENT 107

WARNING Throttle Control System

Check the throttle grip play each day
Oil on tires will make them slip-
before riding the motorcycle, and carry
pery and can cause an accident
out maintenance and adjustments in
and injury. Be sure to install the
accordance with the Periodic Mainte-
reservoir in the drain hose after
nance Chart. Adjust it if necessary.
draining.
Throttle Grip -
The throttle grip controls the butterfly
valves in the throttle body. If the throt-
tle grip has excessive play due to ei-
ther cable stretch or maladjustment, it
will cause a delay in throttle response,
especially at low engine speed. Also,
the throttle valve may not open fully at
full throttle. On the other hand, if the
throttle grip has no play, the throttle will
be hard to control, and the idle speed
will be erratic.
108 MAINTENANCE AND ADJUSTMENT

Inspection • If there is improper play, adjust it.

• Check that the throttle grip play is
correct by lightly turning the throttle Adjustment
grip back and forth. • Loosen the locknuts at the upper of
the throttle cables, and screw both
throttle cable adjusters completely so
as to give the throttle grip plenty of
play.
• Turn out the decelerator cable ad-
juster until it has no play when the
throttle grip is completely closed.
Tighten the locknut.

A. Throttle Grip
B. Throttle Grip Play
Throttle Grip Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
 MAINTENANCE AND ADJUSTMENT 109

• Turn out the accelerator cable ad-

juster until the throttle grip has the
done by a competent mechanic fol-
lowing the instructions in the Service
proper play. Tighten the locknut. Manual.
• With the engine idling, turn the han-
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 idling.

WARNING
Operation with improperly ad-
A. Decelerator Cable
justed, incorrectly routed or
B. Accelerator Cable damaged cables could result
C. Adjuster in an unsafe riding condition.
D. Locknuts Follow the service manual to
be make sure to correct any of
• Ifjusted
the throttle cables cannot be ad-
with the adjuster at the upper these conditions.
of the throttle cable, further adjust-
ment of the throttle cables should be
110 MAINTENANCE AND ADJUSTMENT

Engine Vacuum Synchronization Idle Speed

Engine vacuum synchronization The idle speed adjustment should be
must be checked and adjusted period- performed in accordance with the Pe-
ically in accordance with the Periodic riodic Maintenance Chart or whenever
Maintenance Chart by a competent the idle speed is disturbed.
mechanic following the instructions in
Adjustment
the Service Manual.
NOTE
•Start the engine, and warm it up thor-
oughly.
żPoor engine vacuum synchronization •Adjust the idle speed by turning the
idle adjusting screw.
will cause unstable idling, sluggish
throttle response, and reduce engine Idle Speed
power and performance. 1 050 ∼ 1 150 r/min (rpm)
 MAINTENANCE AND ADJUSTMENT 111

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. Replace damaged
control cables before operation.
A. Idle Adjusting Screw

• Open and close the throttle a few

times to make sure that the idle
speed does not change. Readjust if
necessary.
• With the engine idling, turn the han-
dlebar to each side. If handlebar
movement changes the idle speed,
the throttle cables may be improperly
112 MAINTENANCE AND ADJUSTMENT

Clutch Inspection
Due to friction plate wear and clutch
cable stretch over a long period of use,
• Check that the clutch lever operates
properly and that the inner cable
the clutch operation should be checked slides smoothly. If there is any irreg-
each day before riding the motorcycle, ularity, have the clutch cable checked
and must be adjusted in accordance by an authorized Kawasaki dealer.
with the Periodic Maintenance Chart.
• Check the clutch lever play as shown
in the figure.

A. Adjuster
B. Locknut
C. Clutch Lever Play
 MAINTENANCE AND ADJUSTMENT 113

Clutch Lever Play WARNING

2 ∼ 3 mm (0.08 ∼ 0.12 in.) Excess clutch cable play could
prevent clutch disengagement
If the play is incorrect, adjust the lever and cause a crash resulting in
play as follows. serious injury or death. When
Adjustment adjusting the clutch cable, be
•Loosen the locknut at the clutch
lever.
sure the upper end of the outer
cable is fully seated in its fitting
•Turn the adjuster so that the clutch
lever will have the proper play.
so that it doesn’t slip into place
later and create excessive cable
Tighten the locknut. play.
114 MAINTENANCE AND ADJUSTMENT

• Iftheit lower
cannot be done, use the nuts at NOTE
end of the clutch cable. żAfter the adjustment is made, start
the engine and check that the clutch
does not slip and releases properly.
żFor minor corrections, use the ad-
juster at the clutch lever.

DANGER
Exhaust gas contains carbon
monoxide, a colorless, odor-
less poisonous gas. Inhaling
carbon monoxide can cause
A. Nuts serious brain injury or death.
B. Clutch Cable DO NOT run the engine in en-
closed areas. Operate only in a
WARNING well-ventilated area.
To avoid a serious burn, never
touch a hot engine or an exhaust
pipe during clutch adjustment.
 MAINTENANCE AND ADJUSTMENT 115

Drive Chain WARNING

The drive chain slack and lubrication
A chain that breaks or jumps off
must be checked each day before rid-
the sprockets could snag on the
ing the motorcycle and must be main-
engine sprocket or lock the rear
tained in accordance with the Periodic
wheel, severely damaging the
Maintenance Chart for safety and to
motorcycle and causing it to go
prevent excessive wear. If the chain
out of control. Inspect the chain
becomes badly worn or maladjusted -
for damage and proper adjust-
either too loose or too tight - the chain
ment before each ride.
could jump off the sprockets or break.
116 MAINTENANCE AND ADJUSTMENT

Chain Slack Inspection WARNING

•Set the motorcycle up on its side
stand.
Misalignment of the wheel will
result in abnormal wear, and may
• Check the wheel alignment. Confirm
that the notch on the swingarm and
result in an unsafe riding con-
dition. Align the rear wheel us-
the mark on the chain adjuster are ing the marks on the swingarm
at the same position on the left and or measuring the distance be-
right sides. If they are different, ad- tween the center of the axle and
just the wheel alignment (see Wheel swingarm pivot.
Alignment Adjustment).

A. Notch
B. Marks
 MAINTENANCE AND ADJUSTMENT 117

• Rotate the rear wheel to find the po-

sition where the chain is tightest, and
• Ifloose,
the drive chain is too tight or too
adjust it so that the chain slack
measure the maximum chain slack will be within the standard value.
by pulling up and pushing down the Drive Chain Slack
chain midway between the engine
Standard: 20 ∼ 30 mm (0.8 ∼ 1.2 in.)
sprocket and rear wheel sprocket.

A. Chain Slack
118 MAINTENANCE AND ADJUSTMENT

Chain Slack Adjustment • Rotate the wheel, measure the chain

•Loosen the chain adjuster clamp
bolts on the left and right sides.
slack again at the tightest position,
and readjust if necessary.
• Turn the chain adjuster with the allen
wrench until the drive chain has the WARNING
correct amount of slack. A loose clamp bolts can lead
to an accident resulting in seri-
ous injury or death. Tighten the
clamp bolts to the proper torque.

• Check the wheel alignment.

• section the
Check rear brake (see Brakes
in this chapter).
Tightening Torque
Chain Adjuster Clamp Bolts:
64 N·m (6.5 kgf·m, 47 ft·lb)
A. Clamp Bolt
B. Chain Adjuster
C. Allen Wrench NOTE
• Tighten the chain adjuster clamp żIf a torque wrench is not available,
bolts to the specified torque. this item should be serviced by a
Kawasaki dealer.
 MAINTENANCE AND ADJUSTMENT 119

Wheel Alignment Adjustment adjuster are at the same position on

•Remove the right retaining ring, and the left and right sides.
loosen the axle nut. • Tighten the axle nut to the specified
torque.
• Loosen the right clamp bolt. • Install the retaining ring.

WARNING
A loose axle nut can lead to an
accident resulting in serious in-
jury or death. Tighten the axle
nut to the proper torque and in-
stall a retaining ring.

• Check the rear brake (see Brakes

section in this chapter).
A. Retaining Ring
B. Axle Nut Tightening Torque
C. Clamp Bolt Axle Nut: 98 N·m (10 kgf·m, 72 ft·lb)

• Turn the right chain adjuster with the

allen wrench so that the notch on the NOTE
swingarm and the mark on the chain żThe wheel alignment adjustment can
adjust at left chain adjuster also.
120 MAINTENANCE AND ADJUSTMENT

żIf a torque wrench is not available, • Remove the bolts and quick rivet.
this item should be serviced by a
Kawasaki dealer.
• Remove the chain cover.

Wear Inspection
• Slide the clip to the back.

A. Bolt
B. Quick Rivet
C. Chain Cover

NOTE
żPull up the core of the quick rivet by
A. Clip
B. Slide to back
the flat-head screwdriver.
 MAINTENANCE AND ADJUSTMENT 121

• Stretch the chain taut either by using

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. Since the chain may
wear unevenly, take measurements
at several places.
• Ifthethechain
length exceeds the service limit,
should be replaced. A. Measure
B. Weight

Drive Chain 20-Link Length

Service Limit: 319 mm (12.56 in.)

122 MAINTENANCE AND ADJUSTMENT

WARNING
For safety, use only the standard
chain. It is an endless type and
should not be cut for installa-
tion; have it installed by an au-
thorized Kawasaki dealer.

• Rotate the rear wheel to inspect the

drive chain for damaged rollers, and
loose pins and links.
• Also inspect the sprockets for un-
evenly or excessively worn teeth,
A. Good Teeth
B. Worn Teeth
and damaged teeth. C. Damaged Teeth

NOTE • Ifdrive
there is any irregularity, have the
chain and/or the sprockets re-
żSprocket wear is exaggerated for il- placed by an authorized Kawasaki
lustration. See Service Manual for dealer.
wear limits.
Lubrication
Lubrication is also necessary after
riding through rain or on wet roads, or
any time that the chain appears dry. A
 MAINTENANCE AND ADJUSTMENT 123

heavy oil such as SAE 90 is preferred

to a lighter oil because it will stay on the
• Ifusing
the chain is especially dirty, clean it
diesel oil or kerosine and then
chain longer and provide better lubrica- apply oil as described above.
tion.
• Apply oil to the sides of the rollers so
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.
124 MAINTENANCE AND ADJUSTMENT

Brakes Disc Brake Fluid -

In accordance with the Periodic Main-
Brake Wear Inspection
tenance Chart, inspect the brake fluid
Inspect the brakes for wear. For each
level in both the front and rear brake
front and rear disc brake caliper, if the
fluid reservoirs and change the brake
thickness of either pad is less than
fluid. The brake fluid should also be
1 mm (0.04 in.), replace both pads
changed if it becomes contaminated
in the caliper as a set. Pad replace-
with dirt or water.
ment should be done by an authorized
Kawasaki dealer. Fluid Requirement
Use heavy-duty brake fluid only from
a container marked DOT4.
NOTICE
Do not spill brake fluid onto any
painted surface.
Do not use fluid from a container
that has been left open or that
has been unsealed for a long
time.
A. Lining Thickness Check for fluid leakage around
B. 1 mm (0.04 in.) the fittings.
Check brake hose for damage.
 MAINTENANCE AND ADJUSTMENT 125

Fluid Level Inspection

• With the brake fluid reservoirs held
horizontal, the brake fluid level must
be kept between the upper and lower
level lines.

A. Rear Brake Fluid Reservoir

B. Upper Level Line
C. Lower Level Line

• Iflower
the fluid level in either reservoir is
than the lower level line, check
for fluid leaks in the brake lines, and
A. Front Brake Fluid Reservoir
B. Upper Level Line fill the reservoir to the upper level
C. Lower Level Line line.
126 MAINTENANCE AND ADJUSTMENT

WARNING NOTE
Mixing brands and types of żFirst, tighten until slight resistance is
brake fluid can reduce the brake felt, which indicates that the cap is
system’s effectiveness and seated on the reservoir body, and
cause an accident resulting in tighten the cap an additional 1/6 turn
injury or death. Do not mix two while holding the brake fluid reservoir
brands of brake fluid. Change body.
the brake fluid in the brake line
completely if the brake fluid
must be refilled but the type
and brand of the brake fluid that
is already in the reservoir are
unidentified.

A. Reservoir
B. Cap
C. Clockwise
D. 1/6 turn
 MAINTENANCE AND ADJUSTMENT 127

Fluid Change WARNING

Have the brake fluid changed by an
Air in the brake lines diminish
authorized Kawasaki dealer.
braking performance and can
Front and Rear Brakes - cause an accident resulting in
Disc and disc pad wear is automat- injury or death. If the brake lever
ically compensated for and has no ef- or pedal feels mushy when it
fect on the brake lever or pedal action. is applied, there might be air in
So there are no parts that require ad- the brake lines or the brake may
justment on the front and rear brakes. be defective. Have the brake
checked immediately by an au-
thorized Kawasaki dealer.
128 MAINTENANCE AND ADJUSTMENT

Brake Light Switches

When either the front or rear brake is
• Check the operation of the rear brake
light switch by depressing the brake
applied, the brake light goes on. The pedal. The brake light should go on
front brake light switch requires no ad- after the proper pedal travel.
justment, but the rear brake light switch
should be adjusted in accordance with
the Periodic Maintenance Chart.
Inspection
• Turn the ignition key to ON.
• The brake light should go on when
the front brake is applied.
• If it does not, ask an authorized
Kawasaki dealer to inspect the front
brake light switch.
A. Brake Pedal
B. 10 mm (0.4 in.)

• Iflightit does not, adjust the rear brake

switch.
Brake Pedal Travel
10 mm (0.4 in.)
 MAINTENANCE AND ADJUSTMENT 129

Adjustment • To adjust the rear brake light switch,

•Remove the right front footpeg
bracket bolts.
move the switch up or down by turn-
ing the adjusting nut.
•Pull the footppeg bracket a little bit
outward.

A. Rear Brake Light Switch

B. Adjusting Nut
A. Bolts C. Lights sooner
B. Right Front Footpeg Bracket D. Lights later
130 MAINTENANCE AND ADJUSTMENT

NOTICE Front Fork

The front fork operation and oil leak-
To avoid damaging the electrical
age should be checked in accordance
connections inside the switch,
with the Periodic Maintenance Chart.
be sure that the switch body
does not turn during adjustment. Front Fork Inspection
• Holding the brake lever, pump the
• Reinstall
bracket.
the right front footpeg front fork up and down several times
to inspect smooth stroke.
Tightening Torque • Visually inspect the front fork for oil
leakage, scoring or scratches on the
Front Footpeg Bracket Bolts:
outer surface of the inner tube.
25 N·m (2.5 kgf·m, 18 ft·lb)

NOTE
żIf a torque wrench is not available,
this item should be serviced by a
Kawasaki dealer.
 MAINTENANCE AND ADJUSTMENT 131

• Iffork,
there is any doubt about the front
it should be checked by an au-
so that the spring force and damping
force can be adjusted for different rid-
thorized Kawasaki dealer. ing and loading conditions. Weaker
spring force and damping force are
for comfortable riding, but they should
be increased for high speed riding or
riding on rough roads.

A. Inner Tube

On the top of each front fork leg are a

spring preload adjuster and a rebound
damping force adjuster, and on the A. Spring Preload Adjuster
lower portion of each front fork leg is B. Rebound Damping Force Adjuster
a compression damping force adjuster
132 MAINTENANCE AND ADJUSTMENT

NOTICE
Do not force to turn the rebound
and compression damping force
adjuster from the fully seated po-
sition, or the adjusting mecha-
nism may be damaged.

Spring Preload Adjustment

•Turn the spring preload adjusters in
to increase spring force and out to
A. Compression Damping Force Adjuster
decrease spring force. The adjusting
range is as follows.
Adjusting Range
15 turns
 MAINTENANCE AND ADJUSTMENT 133

Rebound Damping Force Adjustment Compression Damping Force

•Turn the rebound damping force Adjustment
adjuster all the way into the spring
preload adjuster with a screwdriver.
•Turn the compression damping force
adjuster all the way clockwise with
This makes the damping force great- a screwdriver to make the damping
est. force greatest.
• Turn out the adjuster to decrease •Turn the adjuster counterclockwise
to decrease damping force. Be sure
damping force. Be sure to turn both
adjusters by the same number of to turn both adjusters by the same
turns. number of turns.

WARNING
If both spring preload adjusters
and both rebound and compres-
sion damping force adjusters
are not adjusted equally, han-
dling may be impaired and haz-
ardous condition may result.
Always adjust the suspension
components equally.

A. Rebound Damping Force Adjuster

B. Screwdriver
134 MAINTENANCE AND ADJUSTMENT

The standard setting positions of Rear Shock Absorber

the spring preload adjuster, rebound The rear shock absorber operation
damping force adjuster and compres- and oil leakage should be checked in
sion damping force adjuster for an accordance with the Periodic Mainte-
average-build rider of 68 kg (150 lb) nance Chart.
with no passenger and no accessories
are as follows:

Spring Preload
5 turns in*
Adjuster
Rebound Damping
2 turns out**
Force Adjuster
Compression
Damping Force 1.75 turns out**
Adjuster

*: in from the fully loosed position

**: out from the fully tightened position
 MAINTENANCE AND ADJUSTMENT 135

Rear Shock Absorber Inspection and rebound and compression damp-

•Press down on the seat several times
to inspect the stroke.
ing force for various riding and loading
conditions.
•Visually inspect the rear shock ab-
sorber for oil leakage.
Before making any adjustments,
however, read the following proce-
dures:
• Ifshock
there is any doubt about the rear
absorber, it should be checked NOTICE
by an authorized Kawasaki dealer.
Do not force to turn the rebound
and compression damping force
adjuster from the fully seated po-
sition or the adjusting mecha-
nism may be damaged.

Spring Preload Adjustment

The spring adjusting nut on the rear
shock absorber can be adjusted.
If the spring action feels too soft or too
stiff, have it adjusted by an authorized
A. Rear Shock Absorber Kawasaki dealer.
The rear shock absorber can be ad-
justed by changing the spring preload
136 MAINTENANCE AND ADJUSTMENT

Rebound Damping Force Adjustment

The rebound damping force adjuster
• Turn the adjuster counterclockwise
to decrease damping force.
is located at the lower end of the rear The standard setting positions of the
shock absorber. rebound damping force adjuster for an
average-build rider of 68 kg (150 lb)
with no passenger and no accessories
are as follows:

1.75 turns
Rebound Damping Adjuster
out*

*: out from the fully tightened position

A. Rebound Damping Force Adjuster

• Turn the rebound damping force ad-

juster all the way clockwise with a
screwdriver to make the damping
force greatest.
 MAINTENANCE AND ADJUSTMENT 137

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. 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. TUBELESS Mark
138 MAINTENANCE AND ADJUSTMENT

WARNING Tires -
Installing a tube inside a tube- Payload and Tire Pressure
less-type tire can create exces- Failure to maintain proper inflation
sive heat build up that can dam- pressures or observe payload limits for
age the tube and cause rapid your tires may adversely affect han-
deflation. The tires, rims, and dling and performance of your motorcy-
air valves on this motorcycle are cle and can result in loss of control. The
designed only for tubeless type maximum recommended load in addi-
wheels. The recommended stan- tion to vehicle weight is 180 kg (397 lb),
dard tires, rims, and air valves including rider, passenger, baggage,
must be used for replacement. and accessories.
Do not install tube-type tires on • Remove the air valve cap.
tubeless rims. The beads may
not seat properly on the rim
• Check the tire pressure often, using
an accurate gauge.
causing tire deflation. Do not
install a tube inside a tubeless
• Make sure to install the air valve cap
securely.
tire. Excessive heat build-up
may damage the tube causing NOTE
tire deflation. żMeasure the tire pressure when the
tires are cold (that is, when the mo-
torcycle has not been ridden more
than a mile during the past 3 hours).
 MAINTENANCE AND ADJUSTMENT 139

żTire pressure is affected by changes Tire Air Pressure (when cold)

in ambient temperature and altitude, Front 250 kPa (2.50 kgf/cm², 36 psi)
and so the tire pressure should be
Rear 290 kPa (2.90 kgf/cm², 42 psi)
checked and adjusted when your rid-
ing involves wide variations in tem-
perature 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.

A. Tire Pressure Gauge

140 MAINTENANCE AND ADJUSTMENT

• InMaintenance
accordance with
Chart,
the Periodic
measure the
Minimum Tread Depth
1 mm
depth of the tread with a depth Front –
(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.)
lowable tread depth. Rear
Over 130 km/h 3 mm
(80 mph) (0.12 in.)

• Visually inspect the tire for cracks

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
A. Tire Depth Gauge
żHave the wheel balance inspected
whenever a new tire is installed.
 MAINTENANCE AND ADJUSTMENT 141

WARNING Standard Tire (Tubeless)

Tires that have been punctured Make, Type:
and repaired do not have the DUNLOP D210F J
Size:
same capabilities as undam- 120/70ZR17 M/C (58W)
aged tires and can suddenly fail, Front
causing an accident resulting Make, Type:
in serious injury or death. Re- PIRELLI DIABLO ROSSO K
Size:
place damaged tires as soon as
120/70ZR17 M/C (58W)
possible. To ensure safe han-
dling and stability, use only the Make, Type:
recommended standard tires for DUNLOP D210
replacement, inflated to the stan- Size:
190/50ZR17 M/C (73W)
dard pressure. If it is necessary Rear
to ride on a repaired tire, do not Make, Type:
exceed 100 km/h (60 mph) until PIRELLI DIABLO ROSSO K
the tire is replaced. Size:
190/50ZR17 M/C (73W)

NOTE
żWhen operating on public roadways,
keep maximum speed under traffic
law limits.
142 MAINTENANCE AND ADJUSTMENT

WARNING WARNING
Some replacement tires may New tires are slippery and may
adversely affect handling and cause loss of control and injury.
cause an accident resulting in A break-in period of 160 km (100
serious injury or death. To en- miles) is necessary to estab-
sure proper handling and stabil- lish normal tire traction. During
ity, use only the recommended break-in, avoid sudden and max-
standard tires for replacement, imum braking and acceleration,
inflated to the standard pres- and hard cornering.
sure.
 MAINTENANCE AND ADJUSTMENT 143

Battery Due to their internal composition,

The battery installed in this motorcy- batteries continually self discharge.
cle is a sealed type, so it is not nec- The discharge rate depends on the
essary to check the battery electrolyte type of battery and ambient temper-
level or add distilled water. ature. As temperature rises, so does
The sealing strip should not be pulled the discharge rate. Every 15°C (27°F)
off once the specified electrolyte has doubles the rate.
been installed in the battery for initial Electrical accessories, such as digi-
service. tal clocks and computer memory, also
However, in order to maximize bat- draw current from the battery even
tery life and ensure that it will provide when the key is switched off. Due to
the power needed to start the motor- a combination of such “key-off” draws
cycle you must properly maintain the and hot temperature, a battery can go
battery’s charge. When used regularly, from fully charged to completely dis-
the charging system in the motorcycle charged in a matter of days.
helps keep the battery fully charged. If
your motorcycle is only used occasion-
ally or for short periods of time, the bat-
tery is more likely to discharge.
144 MAINTENANCE AND ADJUSTMENT

Self-discharge Current Drain

Approx. number of days Days from Days from
from 100% charged to 100% 100%
Discharging
100% discharged charged charged
Ampere
Temperature to 50% to 100%
Lead Lead
discharged discharged
-Antimony -Calcium
7 mA 60 Days 119 Days
Battery Battery
10 mA 42 Days 83 Days
40°C
100 Days 300 Days
(104°F) 15 mA 28 Days 56 Days
25°C (77°F) 200 Days 600 Days 20 mA 21 Days 42 Days
0°C (32°F) 550 Days 950 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.
Battery Sulfation -
A common cause of battery failure is
sulfation.
 MAINTENANCE AND ADJUSTMENT 145

Sulfation occurs when the battery is you will not be using the motorcy-
left in a discharged condition for an ex- cle for longer than two weeks, the
tended time. Sulfate is a normal by battery should be charged using an
product of the chemical reactions within appropriate charger. Do not use an au-
a battery. But when continuous dis- tomotive-type quick charger that may
charge allows the sulfate to crystallize overcharge the battery and damage it.
in the cells, the battery plates become
permanently damaged and will not hold
NOTE
a charge. Battery failure due to sulfa- żLeaving the battery connected
tion is not warrantable. causes the electrical components
(clock etc) to make the battery dis-
Battery Maintenance - charged, resulting the over discharge
It is the owner’s responsibility to keep of the battery. In this case, the repair
the battery fully charged. Failure to do or replacement of the battery is not
so can lead to battery failure and leave included in the warranty. If you do
you stranded. not drive for four weeks or more, dis-
If you are riding your vehicle infre- connect the battery from the vehicle.
quently, inspect the battery voltage
weekly using a voltmeter. If it drops Kawasaki-recommended chargers
below 12.8 volts, the battery should be are:
charged using an appropriate charger OptiMate ǿǿǿ
(check with a Kawasaki dealer). If Yuasa 1.5 Amp Automatic charger
Battery Mate 150-9
146 MAINTENANCE AND ADJUSTMENT

NOTICE
If the above chargers are not avail-
Never remove the sealing strip,
able, use equivalent one.
or the battery can be damaged.
For more details, ask a Kawasaki
Do not install a conventional
dealer.
battery in this motorcycle, or the
Battery Charging - electrical system cannot work
•Remove the battery from the motor-
cycle (see Battery Removal).
properly.

•Attach the leads from the charger to

the battery and charge the battery at
NOTE
a rate that is 1/10th of the battery żIfyou charge the sealed battery,
capacity. For example, the charging never fail to observe the instructions
rate for a 10 Ah battery would be 1.0 shown in the label on the battery.
ampere.
•The charger will keep the battery fully
charged until you are ready to re-
WARNING
install the battery in the motorcycle Lead is a toxic substance. Bat-
(see Battery Installation). tery posts, terminals and related
accessories contain lead and
lead compounds. Wash hands
after handling.
 MAINTENANCE AND ADJUSTMENT 147

Battery Removal • Take the battery out of the case.

•Remove the rider’s seat (see Seats
section in the GENERAL INFORMA-
• bakingthe
Clean battery using a solution of
soda and water. Be sure that
TION chapter). the wire connections are clean.
•Remove the red cap form the (+) ter-
minal. Battery Installation

• Disconnect the cables from the bat- •Place the battery in the battery case.
tery, first from the (–) terminal and •Connect the (+) cable to the (+) ter-
minal, and then connect the (–) cable
then the (+) terminal.
to the (–) terminal.

NOTICE
Installing the (–) cable to the (+)
terminal of the battery or the (+)
cable to the (–) terminal of the
battery can seriously damaged
the electrical system.

• Put a light coat of grease on the ter-

minals to prevent corrosion.
A. (+) Terminal
B. (–) Terminal
148 MAINTENANCE AND ADJUSTMENT

• Cover
cap.
the (+) terminal with the red Headlight Beam
Horizontal Adjustment
• Reinstall the removed parts. The headlight beam is adjustable
horizontally. If not properly adjusted
horizontally, the beam will point to one
side rather than straight ahead.
• Turn the horizontal adjuster in or out
until the beam points straight ahead.

A. Horizontal Adjusters
B. Vertical Adjuster
 MAINTENANCE AND ADJUSTMENT 149

Vertical Adjustment NOTICE

The headlight beam is adjustable ver-
When handling the quartz
tically. If adjusted too low, neither low
-halogen bulbs, never touch the
nor high beam will illuminate the road
glass portion with bare hands.
far enough ahead. If adjusted too high,
Always use a clean cloth. Oil
the high beam will fail to illuminate the
contamination from hands or
road close ahead, and the low beam
dirty rags can reduce bulb life or
will blind oncoming drivers.
cause the bulb to explode.
• Turn the vertical adjuster in or out to
adjust the headlight vertically.

NOTE
żOn high beam, the brightest point
should be slightly below horizontal.
The proper angle is 0.4 degrees be-
low horizontal. This is a 50 mm (2.0
in.) drop at 7.6 m (25 ft) measured
from the center of the headlight, with
the motorcycle on its wheels and the
rider seated.
150 MAINTENANCE AND ADJUSTMENT

Fuses
Fuses are arranged in the fuse box
located under the rider’s seat. The
main fuse is located under the fuel tank.
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 main fuse removal should be
done by an authorized Kawasaki
A. 50 mm (2.0 in.) dealer.
B. Center of Brightest Spot
C. 7.6 m (25 ft)
D. Height of Headlight Center

A. Fuse Boxes
 MAINTENANCE AND ADJUSTMENT 151

A. Main Fuse A. Normal

B. Failed

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 fuse boxes
and main fuse.
152 MAINTENANCE AND ADJUSTMENT

General Lubrication Apply motor oil to the following

Lubricate the points shown below, pivots -
with either motor oil or regular grease, żSide Stand
in accordance with the Periodic Main- żClutch Lever
tenance Chart or whenever the vehicle żFront Brake Lever
has been operated under wet or rainy żRear Brake Pedal
conditions.
Before lubricating each part, clean off Lubricate the following cables with a
any rusty spots with rust remover and pressure cable lubber -
wipe off any grease, oil, dirt, or grime. ż(K) Clutch Inner Cable
NOTE
ż(K) Throttle Inner Cables
żA few drops of oil are effective to
keep bolts and nuts from rusting and
sticking. This makes removal easier.
Badly rusted nuts, bolts, etc., should
be replaced with new ones.
 MAINTENANCE AND ADJUSTMENT 153

Apply grease to the following Cleaning Your Motorcycle

points -
ż(K) Clutch Inner Cable Upper End General Precautions
ż(K) Throttle Inner Cable Upper Ends Frequent and proper care of your
Kawasaki motorcycle will enhance
(K): Should be serviced by an authorized its appearance, optimize overall per-
Kawasaki dealer. formance, and extend its useful life.
Covering your motorcycle with a high
NOTE quality, breathable motorcycle cover
will help protect its finish from harmful
żAfter connecting the cables, adjust UV rays, pollutants, and reduce the
them. amount of dust reaching its surfaces.
• Be sure the engine and exhaust are
cool before washing.
• Avoid applying degreaser to seals,
brake pads, and tires.
• Avoid all harsh chemicals, solvents,
detergents, and household cleaning
products such as ammonia-based
window cleaners.
• Gasoline, brake fluid, and coolant
will damage the finish of painted and
154 MAINTENANCE AND ADJUSTMENT

plastic surfaces: wash them off im-

mediately.
• After cleaning your motorcycle,
check the rubber boot covering the
• Avoid wire brushes, steel wool, and
all other abrasive pads or brushes.
shift pedal ball joint for correct instal-
lation. Be sure the sealing lip of the
• Use care when washing the wind-
shield, headlight cover, and other
rubber boot fits into the groove of the
ball joint.
plastic parts as they can easily be
scratched.
• Avoid using pressure washers; wa-
ter can penetrate seals and electrical
components and damage your mo-
torcycle.
• Avoid spraying water in delicate
areas such as in air intakes, fuel
system, brake components, electri-
cal components, muffler outlets, and
fuel tank openings.
A. Boots
 MAINTENANCE AND ADJUSTMENT 155

• Ifa the boot is damaged, replace it with

new one. If the boot is not po-
• Mix a mild neutral detergent (de-
signed for motorcycles or automo-
sitioned in the groove correctly, re- biles) and water in a bucket. Use
place it in the correct position. a soft cloth or sponge to wash your
motorcycle. If needed, use a mild de-
greaser to remove any oil or grease
which build up.
• After washing, rinse your motorcy-
cle thoroughly with clean water to re-
move any residue (residue from the
detergent can damage parts of your
motorcycle).
• Use a soft cloth to dry your motorcy-
cle. As you dry, inspect your motor-
cycle for chips and scratches. Do not
A. Wrongly set lip not in the correct position let the water air dry as this can dam-
B. Lip set correctly in the groove age the painted surfaces.

Washing Your Motorcycle • Start the engine and let it idle for sev-
eral minutes. The heat from the en-
•Rinse your bike with cold water from
a garden hose to remove any loose
gine will help dry moist areas.
dirt. • Carefully ride your motorcycle at a
slow speed and apply the brakes
156 MAINTENANCE AND ADJUSTMENT

several times. This helps the brakes żCondensation may form on the inside
dry and restores its normal operating of the headlight lens after riding in the
performance. rain, washing the motorcycle or hu-
• Lubricate the drive chain to prevent
rusting.
mid weather. To remove the mois-
ture, start the engine and turn on the
headlight. Gradually the condensa-
NOTE tion on the inside of the lens will clear
żAfter riding in an area where the off.
roads are salted or near the ocean,
immediately wash your motorcycle Other Plastic Parts
with cold water. Do not use warm After washing use a soft cloth to
water as it accelerates the chemical gently dry plastic parts. When dry,
reaction of the salt. After drying, treat the headlight lens and other non-
apply a corrosion protection spray painted plastic parts with an approved
on all metal and chrome surfaces to plastic cleaner/polisher product.
prevent corrosion.
 MAINTENANCE AND ADJUSTMENT 157

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
cleaners.
such as gasoline, brake fluid,
window cleaners, thread-locking Leather, Vinyl, and Rubber
agents, or other harsh chemi- If your motorcycle has leather ac-
cals. If a plastic part comes in cessories, special care must be taken.
contact with any harsh chemical Use a leather cleaner/treatment to
substance, wash it off immedi- clean and care for leather accessories.
ately with water and a mild neu- Washing leather parts with detergent
tral detergent, and then inspect and water will damage them, shorten-
for damage. Avoid using abra- ing their life.
sive pads or brushes to clean Vinyl parts should be washed with the
plastic parts, as they will dam- rest of the motorcycle, then treated with
age the part’s finish. a vinyl treatment.
The sidewalls of tires and other rub-
ber components should be treated with
Chrome and Aluminum
a rubber protectant to help prolong their
Chrome and uncoated aluminum
useful life.
parts can be treated with a chrome/alu-
minum polish. Coated aluminum
158 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.
 MAINTENANCE AND ADJUSTMENT 159

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. Clutch Lever Holder Bolts

2. Steering Stem Head Nut
3. Handlebar Clamp Bolts
4. Front Fork Clamp Bolts
5. Brake Lever Mounting
Bolts
160 MAINTENANCE AND ADJUSTMENT

6. Front Fender Mounting

Bolts
7. Engine Mounting Bolts
and Nuts
8. Rear Frame Mounting Bolts
9. Brake Disc Mounting Bolts
10. Front Axle Clamp Bolt
11. Front Axle Nut
12. Caliper Mounting Bolts
13. Side Stand Bolt
14. Uni-trak Tie-Rod Nuts
15. Swingarm Pivot Shaft Nut
16. Footpeg Mounting Bolt
17. Rear Shock Absorber
Mounting Bolts
18. Rear Axle Nut
19. Rear Sprocket Nuts
 MAINTENANCE AND ADJUSTMENT 161

20. Silencer Mounting Bolt

21. Brake Pedal Bolt
22. Exhaust Pipe Mounting
Nuts
162 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
Motorcycle oil is a toxic substance. Dispose of used oil properly. Con-
tact your local authorities for approved disposal methods or possible re-
cycling.

• Put in fresh engine oil.

• Empty the fuel from the fuel tank by the pump or siphon.
 STORAGE 163

WARNING
Gasoline is extremely flammable and can be explosive under certain con-
ditions. 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.

• Empty the fuel system by running the engine at idle speed until the engine stalls
(If left in for a long time, the fuel will break down and could clog the fuel system.).
• Reduce tire pressure by about 20%.
• (If this cannot be done,
Set the motorcycle on a box or stand so that both wheels are raised off the ground
put boards under the front and rear wheels to keep damp-
ness away from the tire rubber.).
• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on
rubber parts or in the brakes.
• Lubricate the drive chain and all the cables.
• Remove the battery, and store it where it will not be exposed to direct sunlight,
moisture, or freezing temperature. During storage it should be given a slow
charge (one ampere or less) about once a month. Keep the battery well charged
especially during cold weather.
• Tie plastic bags over the mufflers to prevent moisture from entering.
164 STORAGE

• Put a cover over the motorcycle to keep dust and dirt from accumulating on it.
Preparation after Storage
• Remove the plastic bags from the mufflers.
• Fill the fuelbattery
Install the in the motorcycle and charge the battery if necessary.
• Check all the points listed
tank with fuel.
• Lubricate the pivots, bolts,inand
the Daily Safety Checks section.
• nuts.
 TROUBLESHOOTING GUIDE 165
TROUBLESHOOTING GUIDE

Engine Does Not Start - • Incorrect valve clearance

Starter Motor Won’t Turn • No first turning the ignition key to
Battery discharged
• Engine stop switch off • “OFF” when the motorcycle falls
• Transmission not in neutral
• Fuse blown down.
• Battery leads do not make good elec-
trical contact with battery terminals Engine Stalls -
• Battery discharged Just When Shifting Into 1st Gear
• Side stand has been left down
Engine Cranks, But Won’t Start • Clutch does not properly disengage

•No fuel in tank

•Fuel line clogged While Riding
•Fuel broken down •No fuel in tank
•Engine flooded •Fuel tank air vent is obstructed
•Spark plugs not in good contact •Overheating
•Spark plugs fouled or wet •Battery discharged
•Incorrect spark plug gap
166 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. The
OWNER of the dealership is concerned with your satisfaction and your future busi-
ness. For this reason the owner is in the best position to assist you. Also, all
warranty and service matters are handled and resolved through the authorized
Kawasaki dealer network.

If you are unsatisfied after working with your Kawasaki dealer and feel you still re-
quire further assistance, write to the address below. Please be certain to provide
the model, product identification number, mileage or hours of use, accessories,
dates that events occurred and what action has been taken by both you and your
dealer. Include the name and address of the dealership. To assist us in resolving
 OWNER SATISFACTION 167

your inquiry, please include copies of related receipts and any other pertinent infor-
mation 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.

Please send your correspondence to:

CONSUMER RELATIONS
KAWASAKI MOTORS CORP., U.S.A.
P. O. Box 25252
SANTA ANA, CA. 92799-5252
(949) 460–5688
168 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 Corpora-
tion, U.S.A.

If NHTSA receives similar complaints, it may open an investigation, and if it finds

that a safety defect exists in a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems be-
tween you, your dealer, or Kawasaki Motors Corporation, U.S.A.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800
-424-9393 (or 366-0123 in Washington, D.C. area) or write to: NHTSA, U.S. De-
partment of Transportation, Washington, D.C. 20590. You can also obtain other
information about motor vehicle safety from the Hotline.
 ENVIRONMENTAL PROTECTION 169
ENVIRONMENTAL PROTECTION

To protect our environment, properly discard used batteries, tires, engine oil, or
other vehicle components that you might dispose of in the future. Consult your
authorized Kawasaki dealer or local environmental waste agency for their proper
disposal procedures.
170 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 Dealer Address
Reading
 MAINTENANCE RECORD 171

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading
172 MAINTENANCE RECORD

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading
 MAINTENANCE RECORD 173

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading
174 LOCATION OF LABELS
LOCATION OF LABELS

1. Brake Fluid (Front)

2. Important Drive Chain Information
3. Tire and Load Data
4. Brake Fluid (Rear)
 LOCATION OF LABELS 175

5. Noise Emission Control Information

6. Weight and Manufacture
*7. Vehicle Emission Control Information
*8. Vacuum Hose Routing Diagram

*: only on California model

176 LOCATION OF LABELS

9. Battery Poison/Danger
10. Daily Safety Checks
*11. Fuel Level
12. Fuel Notice

*: only on California model

 LOCATION OF LABELS 177

1)

2)
178 LOCATION OF LABELS

3)
 LOCATION OF LABELS 179

4) 5)

6)
180 LOCATION OF LABELS

7)
 LOCATION OF LABELS 181

7) only on California model

182 LOCATION OF LABELS

8) only on California model

 LOCATION OF LABELS 183

9)
184 LOCATION OF LABELS

10)
 LOCATION OF LABELS 185

11) only on California model 12)