general information j quick reference guide€¦ · rear j17m/c × mt4.50 fuel tank capacity 16 l...

Quick Reference GuideGENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

This Quick Reference Guide willassist you in finding the informationyou’re looking for.

A Table of Contents is included afterthe Foreword.

Whenever you see the symbolsshown below, heed their instructions!Always follow safe operating and main-tenance practices.

DANGERDANGER indicates a hazardoussituation which, if not avoided,will result in death or serious in-jury.

WARNINGWARNING indicates a hazardoussituation which, if not avoided,could result in death or seriousinjury.

NOTICENOTICE is used to address prac-tices not related to personal in-jury.

NOTE○This note symbol indicates points ofparticular interest for more efficientand convenient operation.

(Australian model only)

TAMPERING WITH NOISE CONTROL SYSTEMPROHIBITED

Owners are warned that the law may prohibit:(a) The removal or rendering inoperative by any person other than for purposesof maintenance, repair or replacement, of any device or element of designincorporated into any new vehicle for the purpose of noise control prior toits sale or delivery to the ultimate purchaser or while it is in use; and

(b) The use of the vehicle after such device or element of design has beenremoved or rendered inoperative by any person.

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 bethoroughly familiar with the proper operation of your motorcycle’s controls, its fea-tures, capabilities, and limitations. This manual offers many safe riding tips, but itspurpose is not to provide instruction in all the techniques and skills required to ridea motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-cle enroll in a motorcycle rider training program to attain awareness of the mentaland physical requirements necessary for safe motorcycle operation.

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

Keep this Owner’s Manual aboard your motorcycle at all times so that you canrefer to it whenever you need information.

This manual should be considered a permanent part of the motorcycle and shouldremain with the motorcycle when it is sold.

All rights reserved. No part of this publication may be reproduced without ourprior 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.Motorcycle & Engine Company

© 2011 Kawasaki Heavy Industries, Ltd. Aug. 2011. (1)

TABLE OF CONTENTS

SPECIFICATIONS............................... 10LOCATION OF PARTS ....................... 14LOADING AND ACCESSORIESINFORMATION ................................ 17

GENERAL INFORMATION ................. 20Meter Instruments ............................ 20Tachometer ................................... 21

Multifunction Meter........................... 22Multifunction Display..................... 24Warning/Indicator Lights: .............. 33

Keys ................................................. 36Ignition Switch/Steering Lock........... 36Right Handlebar Switches................ 38Engine Stop Switch: ..................... 38Starter Button: .............................. 39

Left Handlebar Switches .................. 39Dimmer Switch: ............................ 39Turn Signal Switch:....................... 40Horn Button: ................................. 40Passing Button: ............................ 40

Hazard Switch: ............................. 41Brake/Clutch Lever Adjusters........... 41Fuel Tank Cap.................................. 42Fuel .................................................. 43Fuel Requirement: ........................ 43Filling the Tank:............................. 47

Stand................................................ 49Seats ................................................ 50Helmet Hooks................................... 53Tool Kit ............................................. 54Tying Hooks ..................................... 54Windshield........................................ 55

BREAK-IN ........................................... 56HOW TO RIDE THE MOTORCYCLE . 58Starting the Engine .......................... 58Jump Starting ................................... 60Moving Off........................................ 63Shifting Gears .................................. 64Braking............................................. 65

Anti-lock Brake System (ABS) formodels equipped with ABS........... 66Yellow ABS Indicator Light:........... 68

Stopping the Engine......................... 69Stopping the Motorcycle in anEmergency ................................... 70

Parking............................................. 71Catalytic Converter........................... 73

SAFE OPERATION............................. 75Safe Riding Technique ..................... 75Daily Safety Checks......................... 78Additional Considerations for HighSpeed Operation .......................... 81

MAINTENANCE ANDADJUSTMENT 83Periodic Maintenance Chart............. 84Engine Oil ........................................ 96Cooling System................................ 102Spark Plugs...................................... 110Evaporative Emission ControlSystem (Southeast Asia B1 andThailand models only) .................. 111

Kawasaki Clean Air System............. 112

Valve Clearance ............................... 113Air Cleaner ....................................... 113Throttle Control System ................... 115Engine Vacuum Synchronization ..... 118Idle Speed........................................ 119Clutch............................................... 120Drive Chain ...................................... 123Brakes.............................................. 131Brake Light Switches........................ 136Front Fork......................................... 138Rear Shock Absorber....................... 139Wheels ............................................. 142Battery.............................................. 147Headlight Beam................................ 152Fuses ............................................... 154General Lubrication.......................... 156Cleaning Your Motorcycle ................ 158

STORAGE ........................................... 164ENVIRONMENTAL PROTECTION ..... 167OWNER SATISFACTION ................. 168LOCATION OF LABELS..................... 170

10 SPECIFICATIONS

SPECIFICATIONS

PERFORMANCEMaximum Horsepower 53 kW (72.1 PS) @8 500 r/min (rpm)

(TH, SEA-B1/ B2) 52 kW (70.7 PS) @8 000 r/min (rpm)

(AU LAMS) 35 kW (47.6 PS) @8 000 r/min (rpm)Maximum Torque 64 N·m (6.5 kgf·m, 47.2 ft·lb) @7 000 r/min (rpm)

(AU LAMS) 55 N·m (5.6 kgf·m, 40.6 ft·lb) @3 800 r/min (rpm)Minimum Turning Radius 2.7 m (106.3 in.)

DIMENSIONSOverall Length 2 110 mm (83.07 in.)

Overall Width 770 mm (30.31 in.)

Overall Height 1 180 mm (46.46 in.)

Wheelbase 1 410 mm (55.51 in.)

Road Clearance 130 mm (5.12 in.)

Curb Mass (EX650E) 209 kg (461 lb)

(EX650E IN) (EX650F) 211 kg (465 lb)

SPECIFICATIONS 11

ENGINEType DOHC, 4-valve, 2-cylinder, 4-stroke, liquid-cooled

Displacement 649 cm3 (39.6 cu in.)

Bore × Stroke 83.0 × 60.0 mm (3.27 × 2.36 in.)

Compression Ratio 10.8 : 1

Starting System Electric starter

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Fuel System FI (Fuel Injection)

Ignition System Battery and coil (transistorized ignition)

Ignition Timing 10° BTDC @1 300 r/min (rpm) ∼

(Electronically advanced) 37° BTDC @5 000 r/min (rpm)

Spark Plugs NGK CR9EIA-9

Lubrication System Forced lubrication (semi-dry sump)

Engine Oil Type : API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity: SAE 10W-40

Capacity: 2.3 L (2.4 US qt)

12 SPECIFICATIONS

Coolant Capacity 1.2 L (1.3 US qt)

TRANSMISSIONTransmissionType 6-speed, return shift

Clutch Type Wet, multi disc

Driving System Chain drive

Primary Reduction Ratio 2.095 (88/42)

Final Reduction Ratio 3.067 (46/15)

Overall Drive Ratio 5.473 (Top gear)

Gear Ratio 1st 2.438 (39/16)

2nd 1.714 (36/21)

3rd 1.333 (32/24)

4th 1.111 (30/27)

5th 0.966 (28/29)

6th 0.852 (23/27)

FRAMECastor 25°

SPECIFICATIONS 13

Trail 110 mm (4.3 in.)

Tire Size: Front 120/70 ZR 17 M/C (58 W)

Rear 160/60 ZR 17 M/C (69 W)

Rim Size: Front J17M/C × MT3.50

Rear J17M/C × MT4.50Fuel TankCapacity 16 L (4.2 US gal)

ELECTRICAL EQUIPMENTBattery 12 V 10 Ah

Headlight 12 V 55 W/55 W (Hi/Lo)

Tail/Brake Light LED

SEA-B1: Southeast Asia B1 model (with Evaporative Emission Control System)SEA-B2: Southeast Asia B2 modelTH: Thailand modelIN: India modelAU LAMS: Australia Leaner Approved Motorcycle scheme modelEven if one of LED (Light Emitting Diode) tail/brake light does not go on, consultwith an authorized Kawasaki dealer.Specifications subject to change without notice, and may not apply to every country.

14 LOCATION OF PARTS

LOCATION OF PARTS

1. Clutch Lever2. Left Handlebar Switches3. Meter Instruments4. Brake Fluid Reservoir (Front)

5. Right Handlebar Switches6. Front Brake Lever7. Throttle Grip8. Ignition Switch/Steering Lock

LOCATION OF PARTS 15

1. Headlight2. Turn Signal Light3. Spark Plugs4. Air Cleaner5. Battery6. Rider’s Seat

7. Helmet HoldingHooks

8. Tool Kit9. Seat Lock10. Passenger’s Seat11. Tying Hooks

12. Brake Disc13. Front Fork14. Brake Caliper15. Shift Pedal16. Side Stand17. Drive Chain

16 LOCATION OF PARTS

1. License Plate Light2. Turn Signal Light3. Tail/Brake Light4. Brake Fluid Reservoir (Rear)5. Rear Shock Absorber6. Spring Preload Adjuster7. Fuel Tank

8. Fuel Tank Cap9. Coolant Reserve Tank10. Rear Brake Light Switch11. Muffler12. Rear Brake Pedal13. Oil Level Inspection Window14. Idle Adjusting Screw

LOADING AND ACCESSORIES INFORMATION 17LOADING AND ACCESSORIES INFORMATION

WARNINGIncorrect loading, improper in-stallation or use of accessories,or modification of your motorcy-cle may result in an unsafe ridingcondition. Before you ride themotorcycle, make sure it is notoverloaded and that you havefollowed these instructions.

With the exception of genuineKawasaki Parts and Accessories,Kawasaki has no control over thedesign or application of accessories.In some cases, improper installationor use of accessories, or motorcyclemodification, will void the motorcyclewarranty, can negatively affect per-formance, and can even be illegal.

In selecting and using accessories,and in loading the motorcycle, you arepersonally responsible for your ownsafety and the safety of other personsinvolved.

NOTE○Kawasaki Parts and Accessorieshave been specially designed foruse on Kawasaki motorcycles. Westrongly recommend that all partsand accessories you add to yourmotorcycle be genuine Kawasakicomponents.

Because a motorcycle is sensitive tochanges in weight and aerodynamicforces, you must take extreme care incarrying cargo, passengers and/or in

18 LOADING AND ACCESSORIES INFORMATION

fitting additional accessories. The fol-lowing general guidelines have beenprepared to assist you in making yourdeterminations.1. Any passenger should be thor-oughly familiar with motorcycle op-eration. The passenger can affectcontrol of the motorcycle by im-proper positioning during corneringand sudden movements. It is impor-tant that the passenger sit still whilethe motorcycle is in motion and notinterfere with the operation of themotorcycle. Do not carry animalson your motorcycle.

2. You should instruct any passengerbefore riding to keep his feet on thepassenger footpegs and hold on tothe operator or grab rail. Do notcarry a passenger unless he or sheis tall enough to reach the footpegsand footpegs are provided.

3. All baggage should be carried aslow as possible to reduce the effecton the motorcycle center of gravity.Baggage weight should also be dis-tributed equally on both sides of themotorcycle. Avoid carrying baggagethat extends beyond the rear of themotorcycle.

4. Baggage should be securely at-tached. Make sure that the baggagewill not move around while you areriding. Recheck baggage securityas often as possible (not while themotorcycle is in motion) and adjustas necessary.

5. Do not carry heavy or bulky items ona luggage rack. They are designedfor light items, and overloading canaffect handling due to changes inweight distribution and aerodynamicforces.

LOADING AND ACCESSORIES INFORMATION 19

6. Do not install accessories or carrybaggage that impairs the perfor-mance of the motorcycle. Makesure that you have not adverselyaffected any lighting components,road clearance, banking capability(i.e., lean angle), control operation,wheel travel, front fork movement,or any other aspect of the motorcy-cle’s operation.

7. Weight attached to the handlebar orfront fork will increase the mass ofthe steering assembly and can re-sult in an unsafe riding condition.

8. Fairings, windshields, backrests,and other large items have the ca-pability of adversely affecting stabil-ity and handling of the motorcycle,not only because of their weight, butalso due to the aerodynamic forcesacting on these surfaces while themotorcycle is in operation. Poorly

designed or installed items can re-sult in an unsafe riding condition.

9. This motorcycle is not intended tobe equipped with a sidecar or to beused to tow any trailer or other ve-hicle. Kawasaki does not manu-facture sidecars or trailers for mo-torcycles and cannot predict the ef-fects of such accessories on han-dling or stability, but can only warnthat the effects can be adverse andthat Kawasaki cannot assume re-sponsibility for the results of suchunintended use of the motorcycle.Furthermore, any adverse effects onmotorcycle components caused bythe use of such accessories will notbe remedied under warranty.

Maximum LoadWeight of rider, passenger, baggage,and accessories must not exceed 200 kg(441 lb).

20 GENERAL INFORMATIONj GENERAL INFORMATION

Meter Instruments

A. MODE ButtonB. Green Left Turn Signal

Indicator LightC. TachometerD. Red ZoneE. Green Right Turn Signal

Indicator LightF. Yellow ABS Indicator Light

(Only on ABS model)G. Yellow Engine Warning

Indicator LightH. Red Battery Charging

System Warning IndicatorLight

I. RESET ButtonJ. Multifunction MeterK. Green Neutral Indicator

LightL. Blue High Beam Indicator

LightM. Red Coolant Temperature

Warning Indicator LightN. Red Oil Pressure Warning

Indicator Light

GENERAL INFORMATION 21jNOTE

○For safety, do not operate the instru-ment buttons while riding the motor-cycle.

TachometerThe tachometer shows the engine

speed in revolutions per minute (r/min,rpm). On the right side of the tachome-ter face is a portion called the “redzone”. Engine r/min (rpm) in thered zone is above maximum recom-mended engine speed and is alsoabove the range for good performance.

NOTICEEngine r/min (rpm) should notbe allowed to enter the red zone;operation in the red zone willoverstress the engine and maycause serious engine damage.

A. TachometerB. Red Zone

When the ignition key is turned to“ON”, the tachometer momentarilygoes from the minimum to the maxi-mum, then goes back from the maxi-mum to the minimum reading to checkits operation. If the tachometer doesnot operate correctly, have it checkedby an authorized Kawasaki dealer.

22 GENERAL INFORMATIONj Multifunction Meter

The multifunction meter displays thefollowing functions.

A. Fuel GaugeB. SpeedometerC. Economical Riding

IndicatorD. Fuel Level Warning SymbolE. Multifunction Display

OdometerTrip meter ATrip meter BCurrent MileageAverage MileageCruising Range

F. Clock

When the ignition key is turned to “ON”, all LCD segments are displayed withopening display functions for few seconds, then the multifunction meter turns tooperational mode.

GENERAL INFORMATION 23j

Speedometer -The speedometer shows the speed

of the vehicle in digital values.

Unit Setting -The unit setting in the meter instru-

ment can be changed according to lo-cal regulations. Make sure the unit set-ting is correctly displayed before riding.

A. SpeedometerB. Speed UnitC. Mileage Unit

NOTE○Do not operate the motorcycle withwrong unit (mph or km/h) of thespeedometer.

To change the meter display units inthe meter instrument as follows:• Display the odometer in the multi-function display. Refer to the Multi-function Display section.• Push the RESET button while push-ing the MODE button to select thedisplay units.L/100km (km/h) → km/L (km/h) →

MPG US (mph) → MPG UK (mph) →L/100km (km/h)...• The display units on the multifunctionmeter can be changed depending onthe selected mileage unit as shown.

24 GENERAL INFORMATIONj

MileageUnits Speed Units Distance

Units

L/100km

km/Lkm/h km

MPG US

MPG UKmph mile

Multifunction DisplayThe following display modes can be

shifted by pushing the MODE button.Odometer→ Trip meter A→ Trip me-

ter B → Current Mileage → AverageMileage→ Cruising Range→ Odome-ter...

NOTE○For safety, do not operate the instru-ment buttons while riding the motor-cycle.

○The multifunction display is dis-played in the unit depending on theunit mode setting, refer to the “UnitSetting” item in this section.


Odometer -The odometer shows the total dis-

tance in kilometers or miles that the ve-hicle has been ridden. This meter can-not be reset.

A. OdometerB. “ODO”

NOTE○The data is maintained even if thebattery is disconnected.

○When the figures come to 999999,they are stopped and locked.

Trip Meter -The trip meters show the distance in

kilometers (miles) traveled since theywere last reset to zero.TRIP A: 0.0 ∼ 9999.9TRIP B: 0.0 ∼ 9999.9

A. Trip AB. Trip B

To reset the trip meter:• Push the MODE button to display thetrip meter A or B.

26 GENERAL INFORMATIONj • Push the RESET button and hold it

in.• After two seconds, the figure displayturns to 0.0, and then starts countingwhen the vehicle is operated. Themeter counts until it is reset.

NOTE○The data is maintained by the back-up power if the ignition key is turnedoff.

○When the trip meter reaches 9999.9while running, the meters reset to 0.0and continues counting.

○When the battery is disconnected,the meter display resets to 0.0.

Current Mileage -This display mode shows the current

mileage by numerical value. The cur-rent mileage display is renewed every4 seconds.

A. Current MileageB. “km/L”

NOTE○The display unit modes can bechanged, refer to the “Unit Setting”item in this section.

○The numerical value shows “– –.–”until 4 seconds have passed and thespeedometer is rises to above 5 km/h(3 mph).


Average Mileage -This display mode shows the av-

erage mileage by numerical valuecounted from the start of measuringto present time. The average mileagedisplay is renewed every 4 ∼ 6 sec-onds.

A. Average MileageB. “AV km/L”

• While the average mileage is dis-played, push the RESET button andhold it in until the average mileagevalues resets to “– –. –”.

NOTE○The display unit modes can bechanged, refer to the “Unit Setting”item in this section.

○After resetting the average mileage,the numerical value is not displayeduntil 5 mL (0.2 US oz.) of fuel hasbeen used and 100 m (328 ft) hasbeen traveled.

○The data is maintained by back uppower if the ignition switch is turned“OFF”.

○When the battery is disconnected,the data resets to “– –.–”.


Cruising Range -This display shows the cruising range

by numerical value and indicates thecruising range from the remaining fuelin the fuel tank. This cruising rangedisplay is renewed every 20 seconds.

A. Cruising RangeB. "RANGE"

The cruising range value displays "-- -" when the fuel warning symbol ( )blinks in the multifunction meter.

A. "- - -" displayB. "RANGE"

NOTE○The display unit modes can bechanged, refer to the “Unit Setting”in this section.

○The display range for cruising rangeis 0 ~ 999.

○The cruising range value may notindicate the actual value. Use thisvalue for your reference only.


Clock -To adjust hours and minutes, do the

followings while the motorcycle is at astop.• Turn the ignition switch to “ON”.• Display the odometer in the multi-function display. Refer to the “Multi-function Display” item in this section.

• Push the RESET button for morethan 2 seconds. Both the hour andminute displays start blinking.

• Push the RESET button. The hourdisplay only blinks. Push the MODEbutton to advance the hours.

• Push the RESET button. The hourdisplay stops blinking and the minutedisplay starts blinking. Push theMODE button to advance the min-utes.

• Push the RESET button. Both thehour and minute displays start blink-ing again.

30 GENERAL INFORMATIONj • Push the MODE button. The dis-

plays stop blinking and the clockstarts working.

NOTE○Pushing the MODE button momen-tarily advances the hour or minutestep by step. Pushing and hold-ing the button advances the hour orminute continuously.

○The clock works normally by the back-up power while the ignition switch isturned “OFF”.

○When the battery is disconnected,the clock is reset to 1:00 and startsworking again when the battery isconnected.

Economical Riding Indicator -When the operator is driving the mo-

torcycle for optimum fuel-efficiency, the

economical riding indicator appears onthe multifunction meter to indicate fa-vorable fuel consumption. Monitoringthe economical riding indicator canhelp the rider maximize fuel efficiency.

A. Economical Riding Indicator

GENERAL INFORMATION 31jWARNING

Failing to properly observe theroad ahead increases the chanceof an accident resulting in se-vere injury or death. Do not con-centrate on the economical rid-ing indicator by taking your eyesoff the road; observe using pe-ripheral vision.

Fuel Gauge –The fuel in the fuel tank is shown

by the number of segments displayed.When the fuel tank is full, all 6 seg-ments are displayed.If the fuel gauge is not correctly dis-

played, have the fuel gauge checkedby an authorized Kawasaki dealer.

A. Fuel Gauge


As the fuel level in the tank goesdown, the segments disappear one byone from F (full) to E (empty). Whenonly the last 1 segment (E) is displayedin the fuel gauge, the fuel warning sym-bol ( ) and the segment (E) are blinks.

A. Fuel Warning Symbol ( )B. Segment (E)

This indicates that the remaining fuelin the tank is approximately 4 L (1.1 USgal). Refuel at the earliest opportunity

if the fuel warning symbol ( ) is dis-played in the multifunction meter.When vehicle stands with Side

Stand, Fuel Gauge cannot show theamount of fuel in the fuel tank exactly.Stand upright the vehicle to check thefuel level.All of the segments and fuel symbol

will blink in case of the open or short ofthe wiring. Have the wiring inspectedby an authorized Kawasaki dealer im-mediately.

NOTE○When pushing the MODE buttonwhile low fuel warning is displayed,the multifunction display modes canbe shifted.

○The cruising range value indicate the“– – –” when the low fuel warning isdisplayed.


Warning/Indicator Lights:

A. Green Neutral Indicator LightB. Blue High Beam Indicator LightC. Yellow ABS Indicator Light (Only on ABS

model)D. Yellow Engine Warning Indicator LightE. Red Battery Charging System Warning

Indicator LightF. Red Oil Pressure Warning Indicator LightG. Red Coolant Temperature Warning

Indicator Light

N: When the transmission is in neutral,the neutral indicator light goes on.

: When the headlight is on highbeam, the high beam indicator lightgoes on.

: When the turn signal switch ispushed to the left or right, the cor-responding turn signal indicator lightblinks.


Yellow ABS Indicator Light (Formodels equipped with ABS)

: The ABS (Anti-lock Brake Sys-tem) indicator light goes on when theignition switch is turned on and goes offshortly after the motorcycle starts mov-ing. If the ABS is normal, it stays off. Ifsomething is wrong with the ABS, theindicator goes on and stays on. Whenthe indicator light is on, the ABS doesnot function but if the ABS fails, the con-ventional brake system will still worknormally.For more detailed information about

ABS, see the Anti-lock Brake System(ABS) section in the How to Ride theMotorcycle chapter.

Yellow Engine Warning IndicatorLight

: The engine warning indicatorlight goes on when the ignition key isturned to “ON” and goes off soon afterensuring that its circuit functions prop-erly. The indicator light also goes on orblinking whenever the troubles occur indigital fuel injection system (DFI).The blinking of this indicator light indi-

cates the condition that the engine can-not be started.Refer to the Stopping the Engine sec-

tion of the “How to Ride the Motorcy-cle” chapter for more information. Ifthe indicator light goes on, have theDFI system checked by an authorizedKawasaki dealer.

Red Warning Indicator LightsIf any red warning indicator light

goes on with the engine running, have


its cause checked by an authorizedKawasaki dealer.

: This warning indicator lightshould go on whenever the ignitionswitch is turned to “ON” and go off afterstarting the engine.The oil pressure warning indicator lightgoes on whenever the oil pressure isdangerously low while the engine run-ning. Refer to the Maintenance and Ad-justment chapter for more detailed en-gine oil information.

: The coolant temperature warningindicator light goes on whenever thecoolant temperature rises to 118°C(245°F) when the motorcycle is in op-eration. This warns the operator thatthe coolant temperature is too high.If the warning indicator light goes on,stop the engine and check the coolant

level in the reserve tank after the en-gine cools down.

NOTICEDo not let the engine continuerunning when the warning indi-cator light goes on. Prolongedengine operation will result insevere damage from overheat-ing.

: The battery charging systemwarning indicator light goes on when-ever the battery voltage is less than 11V or higher than 16 V.The warning indicator light and the

battery warning indicator light still go oneven after the battery is charged, askan authorized Kawasaki dealer for aninspection.

36 GENERAL INFORMATIONj Keys

This motorcycle has a combinationkey, which is used for the ignitionswitch/steering lock, seat lock, and fueltank cap.Blank keys are available at your

Kawasaki dealers. Ask your dealer tomake any additional spare keys youmay need, using your original key as amaster.

NOTICEBe sure not to attach the key toa key chain that may damage thefinish of the motorcycle.

Ignition Switch/Steering LockThis is a four-position, key-operated

switch. The key can be removed fromthe switch when it is in the OFF, LOCK,or P (Park) position.

A. Ignition Switch/Steering LockB. ON positionC. OFF positionD. LOCK positionE. P (Park) position


OFF Engine off. All electricalcircuits off.

ON Engine on. All electricalequipment can be used.

LOCK Steering locked. Engine off.All electrical circuits off.

P (Park)

Steering locked. Engine off.License plate, tail, and citylights on and turn signals canbe used. All other electricalcircuits cut off.

NOTE○The city, tail and license plate lightsare on whenever the ignition key isin the ON position. One headlightgoes on when the starter button isreleased after starting the engine. Toavoid battery discharge, always start

the engine immediately after turningthe ignition key to “ON”.

○If you leave the P (Park) position onfor a long time (one hour), the batterymay become totally discharged.

38 GENERAL INFORMATIONj Right Handlebar Switches

Engine Stop Switch:In addition to the ignition switch,

the engine stop switch must be inthe position for the motorcycle tooperate.The engine stop switch is for emer-

gency use. If required, move the en-gine stop switch to the position.

NOTE○Although the engine stop switchstops the engine, it does not turn offall the electrical circuits. Ordinarily,the ignition switch should be used tostop the engine.

A. Engine Stop SwitchB. Starter Button


Starter Button:The starter button operates the elec-

tric starter when the transmission is inneutral.Refer to the Starting the Engine sec-

tion of the “How to Ride the Motorcycle”chapter for starting instructions.

Left Handlebar SwitchesDimmer Switch:High or low beam can be selected

with the dimmer switch. When theheadlight is on high beam ( ), thehigh beam indicator light is lit.High beam.......( )Low beam.......( )

40 GENERAL INFORMATIONj NOTE

○When the headlight is on high beam,both head lights go on. When theheadlight is on low beam, only oneheadlight goes on.

A. Dimmer SwitchB. Turn Signal SwitchC. Horn ButtonD. Hazard SwitchE. Passing Button

Turn Signal Switch:When the turn signal switch is turned

to the left ( ) or right ( ), thecorresponding turn signal blinks on andoff.To stop blinking, push the switch in.

Horn Button:When the horn button is pushed, the

horn sounds.

Passing Button:When the passing button is pushed,

the headlight high beam (passingbeam) goes on to signal the driverof the vehicle ahead that you are aboutto pass him. The passing light shutsoff as soon as the button is released.


Hazard Switch:If an emergency requires you to park

on the highway shoulder, turn on thehazard lights to warn other drivers ofyour location.Push in the hazard switch with the

ignition switch in the ON or P (Park)position. All the turn signals and turnsignal indicator lights will blink on andoff.

NOTICEIf you leave the switch on for along time, the battery may be-come totally discharged. So becareful not to use the hazardlights for more than 30 minutes.

Brake/Clutch Lever AdjustersThere is an adjuster on both the

brake and clutch levers. Each adjusterhas 5 positions so that the releasedlever position can be adjusted to suitthe operator’s hands. Push the leverforward and turn the adjuster to alignthe number with the mark on the leverholder.The distance from the grip to the re-

leased lever is minimum at Number 5and maximum at Number 1.


A. Brake Lever AdjusterB. MarkC. Clutch Lever Adjuster

Fuel Tank CapTo open the fuel tank cap, pull up the

key hole cover. Insert the ignition keyinto the fuel tank cap and turn the keyclockwise.To close the cap, push it down into

place with the key inserted. The keycan be removed by turning it coun-terclockwise to the original position.Close the key hole cover.

NOTE○The fuel tank cap cannot be closedwithout the key inserted, and the keycannot be removed unless the cap islocked properly.

GENERAL INFORMATION 43jNOTE

○Do not push on the key to close thecap, or the cap cannot be locked.

A. Key Hole CoverB. Ignition KeyC. Fuel Tank Cap

FuelFuel Requirement:Your Kawasaki engine is designed

to use only unleaded gasoline with aminimum octane rating shown below.Never use gasoline with an octane rat-ing lower than the minimum specifiedby Kawasaki to prevent severe enginedamage.The octane rating of a gasoline is a

measure of its resistance to detona-tion or “knocking”. The term commonlyused to describe a gasoline’s octanerating is the Research Octane Number(RON).

44 GENERAL INFORMATIONj NOTICE

Do not use leaded gasoline, asthis will destroy the catalyticconverter. (For further infor-mation, refer to the “CatalyticConverter” section in the “Howto Ride the Motorcycle” chap-ter.)

NOTICEIf engine “knocking" or “ping-ing" occurs, use a differentbrand of gasoline of a higheroctane rating. If this condition isallowed to continue, it can leadto severe engine damage.Gaso-line quality is important. Fuelsof low quality or not meetingstandard industry specificationsmay result in unsatisfactory per-formance. Operating problemsthat result from the use of poorquality or no recommended fuelmay not be covered under yourwarranty.


Fuel Type and Octane Rating

(Except for Australia, Brazil andThailand Specifications)Use clean, fresh unleaded gasoline

with an octane rating equal to or higherthan that shown in the table.

Fuel Type Unleaded Gasoline

MinimumOctaneRating

Research Octane Number(RON)91

NOTICEDo not use any fuel with anethanol in this vehicle. It hasnot been tested and certified foruse with such fuels. Damageto the engine and fuel system,or engine starting and/or per-formance problems may resultfrom the use of improper fuel.

(For Brazil Specification)Use clean, fresh unleaded gasoline

with an Antiknock Index equal to orhigher than that shown in the table.The Antiknock Index is posted on ser-

vice station pumps. The Antiknock In-dex is an average of the Research Oc-tane Number (RON) and the Motor Oc-tane Number (MON) as shown in thetable.


EthanolContent E25

(RON + MON)AntiknockIndex 2

MinimumOctaneRating 87


Do not use any fuel that con-tains more ethanol or other oxy-genates than specified for E25fuel* in this vehicle. Damageto the engine and fuel system,or engine starting and/or per-formance problems may resultfrom the use of improper fuel.

*E25 means fuel containing up to25% ethanol.

(For Australia and ThailandSpecification)Use clean, fresh unleaded gasoline

with an ethanol volume content notmore than 10 % and an octane ratingequal to or higher than that shown inthe table.


Ethanol Content E10 or less

Minimum OctaneRating

Research OctaneNumber (RON) 91

NOTICEDo not use any fuel that con-tains more ethanol or other oxy-genates than specified for E10fuel* in this vehicle. Damageto the engine and fuel system,or engine starting and/or per-formance problems may resultfrom the use of improper fuel.

*E10 means fuel containing up to10% ethanol.


Filling the Tank:Avoid filling the tank in the rain or

where heavy dust is blowing so that thefuel does not get contaminated.

A. Tank CapB. Fuel TankC. Top LevelD. Filler Neck

WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions, creating the po-tential for serious burns. Whenrefueling, servicing fuel system,draining gasoline and/or adjust-ing the carburetor: Stop engineand allow it to cool before refuel-ing. DO NOT smoke. Make surethe area is well-ventilated andfree from any source of flame orsparks, including the pilot lightof any appliance. DO NOT fill thetank so the fuel level rises intothe filler neck or level surface oflevel gauge. If the tank is over-filled, heat may cause the fuelto expand and overflow throughthe vents in the tank cap. Wipeoff any spilled gasoline immedi-ately.


Southeast Asia B1 and Thailandmodels only:Never fill the tank so the fuellevel rises into the filler neck. Ifthe tank is overfilled, heat maycause the fuel to expand andflow into the Evaporative Emis-sion Control System resulting inhard starting and engine hesi-tation and non compliance withthe emission regulation.

NOTICECertain ingredients in gasolinemay cause paint fading or dam-age. Be extra careful not to spillgasoline or gasoline oxygenatesblends during refueling.

GENERAL INFORMATION 49jStand

The motorcycle is equipped with aside stand.

A. Side Stand

NOTE○When using the side stand, turn thehandlebar to the left.

Do not sit on the motorcycle while it ison its side stand. Always kick the standfully up before sitting on themotorcycle.

NOTE○The motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine does notstart if the transmission is in gear andthe side stand is down.

50 GENERAL INFORMATIONj Seats

Passenger’s Seat Removal• Insert the ignition key into the seatlock, and turn it clockwise.• Remove the passenger’s seat bypulling up the front of seat while turn-ing the ignition key.

A. Seat LockB. Ignition KeyC. Passenger’s Seat

Rider’s Seat Removal• Remove the passenger’s seat.• Slide the rider’s seat rearward thenpull the front of seat upward to re-move it.

A. Rider’s SeatB. Slide Seat RearwardC. Pull Seat Upward


Rider’s Seat Installation• Slide the rider’s seat rearward to po-sition it on the frame.• Slide the rider’s seat forward to en-gage the tab under the seat with thebracket on the frame.

A. Rider’s SeatB. Slide Seat RearwardC. Slide Seat ForwardD. TabE. Bracket

Passenger’s Seat Installation• Insert the tab under the passenger’sseat into the hole in the frame.• Insert the lock plate of the passen-ger’s seat into the slot on the framewhile aligning the projection with thehole on the frame.


A. Passenger’s SeatB. TabC. HoleD. Lock PlateE. SlotF. ProjectionsG. Hole

• Push down the front part of the pas-senger’s seat until the lock clicks.

• Pull up the front and rear ends of thepassenger’s seat to make sure theyare securely locked.

GENERAL INFORMATION 53jHelmet Hooks

Helmets can be secured to themotor-cycle by the helmet hooks located un-der the passenger’s seat.

A. Helmet Hooks

WARNINGRiding with helmets attached tothe hooks could cause an ac-cident by distracting the oper-ator or interfering with normalvehicle operation. Do not ridethe motorcycle with helmets at-tached to the hooks.

54 GENERAL INFORMATIONj Tool Kit

The tool kit is located under the pas-senger’s seat.The kit contains tools that are help-

ful in making roadside repairs, adjust-ments, and some maintenance proce-dures explained in this manual. Keepthe tool kit in the original place.

A. Tool KitB. Band

Tying HooksWhen tying up light loads to the pas-

senger’s seat, use the tying hooks lo-cated on the left and right sides of therear fender.

A. Tying Hooks

GENERAL INFORMATION 55jWindshield

The windshield can be adjustedwithin 3 positions in height to suit therider’s preference.• Remove the four bolts and wind-shield.

A. WindshieldB. Bolts and Nylon Washers

• Remove the windshield bracketmounting bolts.

• Reinstall the removed parts in thewindshield positions to suit the rider’spreference.

A. Windshield BracketB. BoltsC. Low PositionD. Middle PositionE. High Position

56 BREAK-IN

BREAK-IN

The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as thebreak-in period. If the motorcycle is not used carefully during this period, you mayvery well end up with a “broken down” instead of a “broken in” motorcycle after afew 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 mi) 4 000 r/min (rpm)

800 ∼ 1 600 km (500 ∼ 1 000 mi) 6 000 r/min (rpm)

NOTE○When operating on public roadways, keep maximum speed under traffic law lim-its.

• Do not start moving or race the engine immediately after starting it, even if theengine is already warm. Run the engine for two or three minutes at idle speed togive the oil a chance to work up into all the engine parts.• Do not race the engine while the transmission is in neutral.

BREAK-IN 57

WARNINGNew tires are slippery and may cause loss of control and injury.A break-in period of 160 km (100 miles) is necessary to establish normaltire traction. During break-in, avoid sudden and maximum braking andacceleration, and hard cornering.

In addition to the above, at 1 000 km (600 mi) it is extremely important that theowner have the initial maintenance service performed by an authorized Kawasakidealer.

58 HOW TO RIDE THE MOTORCYCLE

j

HOW TO RIDE THE MOTORCYCLE

Starting the Engine• Check that the engine stop switch isin the position.• Turn the ignition key to “ON”.• Make sure the transmission is in neu-tral.• Without holding the throttle grip, pushthe starter button to start the engine.

A. Engine Stop SwitchB. Starter ButtonC. Neutral Indicator LightD. Ignition SwitchE. ON position

NOTE○The motorcycle is equipped with avehicle-down sensor which causesthe engine to stop automatically if the

HOW TO RIDE THE MOTORCYCLE 59

jmotorcycle falls down. The enginewarning indicator light ( ) blinkswhen the starter button pressed if theengine cannot be started. After right-ing the motorcycle, first turn the ig-nition key to “OFF” and then back to“ON” before starting the engine.

NOTICEDo not operate the starter con-tinuously for more than 5 sec-onds, or the starter will overheatand the battery power will droptemporarily. Wait 15 secondsbetween each operation of thestarter to let it cool and the bat-tery power recover.

NOTE○The motorcycle is equipped with astarter lockout switch. This switch is

designed so that the engine does notstart if the transmission is in gear andthe side stand is down. However, theengine can be started if the clutchlever is pulled and the side stand isfully up.

A. Clutch LeverB. Starter Lockout Switch


jNOTICE

Do not let the engine idle longerthan five minutes, or engineoverheating and damage mayoccur.

Jump StartingIf your motorcycle battery is “run

down,” it should be removed andcharged. If this is not practical, a 12volt booster battery and jumper cablesmay be used to start the engine.


jDANGER

Battery acid generates hydro-gen gas which is flammable andexplosive under certain con-ditions. It is present within abattery at all times, even in adischarged condition. Keep allflames and sparks (cigarettes)away from the battery. Wear eyeprotection when working with abattery. In the event of batteryacid contact with skin, eyes, orclothing, wash the affected ar-eas immediately with water for atleast five minutes. Seek medicalattention.

Connecting Jumper Cables• Remove the passenger’s seat andrider’s seat.• Make sure the ignition key is turnedto OFF.

• Connect a jumper cable from thepositive (+) terminal of the boosterbattery to the positive (+) terminal ofthe motorcycle battery.

A. Motorcycle Battery Positive (+) TerminalB. From Booster Battery Positive (+) TerminalC. Shift PedalD. From Booster Battery Negative (–)

Terminal

• Connect another jumper cable fromthe negative (–) terminal of thebooster battery to shift pedal or other


junpainted metal surface on your mo-torcycle. Do not use the negative (–)terminal of the battery.

DANGERBatteries contain sulfuric acidthat can cause burns and pro-duce hydrogen gas which ishighly explosive. Do not makethis last connection at the fuelsystem or battery. Take care notto touch the positive and nega-tive cables together, and do notlean over the battery when mak-ing this last connection. Do notconnect to a frozen battery. Itcould explode. Do not reversepolarity by connecting positive(+) to negative (–), or a batteryexplosion and serious damageto the electrical system may oc-cur.

• Follow the standard engine startingprocedure.

NOTICEDo not operate the starter con-tinuously for more than 5 sec-onds or the starter will overheatand the battery power will droptemporarily. Wait 15 secondsbetween each operation of thestarter to let it cool and the bat-tery power recover.

• After the engine has started, discon-nect the jumper cables. Disconnectthe negative (–) cable from the mo-torcycle first.• Reinstall the removed parts.


jMoving Off• Check that the side stand is up.• Pull in the clutch lever.• Shift into 1st gear.• Open the throttle a little, and start tolet out the clutch lever very slowly.• As the clutch starts to engage, openthe throttle a little more, giving the en-gine just enough fuel to keep it fromstalling.

A. Shift Pedal

NOTE○The motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine does notstart if the transmission is in gear andthe side stand is down.

○When the headlight is on high beam,two headlight beams go on, and onlow beam, one headlight goes on.


jShifting Gears• Close the throttle while pulling in theclutch lever.• Shift into the next higher or lowergear.

WARNINGDownshifting to a lower gear athigh speed causes engine rpmto increase excessively, poten-tially damaging the engine andit may also cause the rear wheelto skid and cause an accident.Downshifting should be donebelow 5 000 rpm for each gear.

• Open the throttle half way, while re-leasing the clutch lever.

NOTE○The transmission is equipped with apositive neutral finder. When the mo-torcycle is standing still, the transmis-sion cannot be shifted past neutralfrom 1st gear. To use the positiveneutral finder, shift down to 1st gear,then lift up on the shift pedal whilestanding still. The transmission willshift only into neutral.


jBraking• Close the throttle completely, leav-ing the clutch engaged (except whenshifting gears) so that the engine willhelp slow down the motorcycle.• Shift down one gear at a time so thatyou are in 1st gear when you cometo a complete stop.• When stopping, always apply bothbrakes at the same time. Normallythe front brake should be applied a lit-tle more than the rear. Shift down orfully disengage the clutch as neces-sary to keep the engine from stalling.• Never lock the brakes, or it will causethe tires to skid. When turning a cor-ner, it is better not to brake at all. Re-duce your speed before you get intothe corner.• For emergency braking, disregarddownshifting, and concentrate on

applying the brakes as hard as pos-sible without skidding.• Even in motorcycles equipped withABS, braking during cornering maycause wheel slip. When turning acorner, it is better to limit braking tothe light application of both brakesor not to brake at all. Reduce yourspeed before you get into the corner.

A. Front Brake Lever


j

A. Rear Brake Pedal

Anti-lock Brake System (ABS)for models equipped withABS

ABS is designed to help preventthe wheels from locking up whenhard brakes are applied while runningstraight. The ABS automatically regu-lates brake force. Intermittently gaininggripping force and braking force helpsprevent wheel lock-up and allows sta-ble steering control while stopping.Brake control function is identical to

that of a conventional motorcycle. Thebrake lever is used for the front brakeand the brake pedal for the rear brake.Although the ABS provides stability

while stopping by preventing wheellock-up, remember the following char-acteristics:• ABS cannot compensate for adverseroad conditions, misjudgement or im-proper application of brakes. You


jmust take the same care as with mo-torcycles not equipped with ABS.• ABS is not designed to shorten thebraking distance. On loose, unevenor downhill surfaces, the stoppingdistance of a motorcycle with ABSmay be longer than that of an equiv-alent motorcycle without ABS. Usespecial caution in such areas.• ABS will help prevent wheel lock-upduring straight-up braking, but it can-not control wheel slip which may becaused by braking during cornering.When turning a corner, it is better tolimit braking to the light application ofboth brakes or not to brake at all. Re-duce your speed before you get intothe corner.• The computers integrated in the ABScompare vehicle speed with wheel

speed. Since non-recommendedtires can affect wheel speed, theymay confuse the computers, whichcan extend braking distance.

WARNINGABS cannot protect the riderfrom all possible hazards andis not a substitute for safe rid-ing practices. Be aware of howthe ABS system operates andits limitations. It is the rider’sresponsibility to ride at appro-priate speeds and manner forweather, road surface and trafficconditions.


jWARNING

Use of non-recommended tiresmay cause malfunctioning ofABS and can lead to extendedbraking distance. The ridercould have an accident as a re-sult. Always use recommendedstandard tires for this motorcy-cle.

NOTE○When the ABS is functioning, youmay feel a pulsing in the brake leveror pedal. This is normal. You neednot suspend applying brakes.

○ABS does not function at the speedof approx. 6 km/h or below.

○ABS does not function if the batteryis discharged.

○ABS indicator light may go on un-der motorcycle riding condition. (ex.The front or rear wheel races.) In

this case, first turn the ignition key to“OFF”, and then back to “ON”. ABSindicator light goes off by this opera-tion, but if ABS indicator light stayson after the motorcycle runs at thespeed of approx. 6 km/h or below,you should have the ABS checked byan authorized Kawasaki dealer.

Yellow ABS Indicator Light:Normally the ABS indicator light goes

on when the ignition switch is turned onand goes off shortly after the motorcy-cle starts moving.If the indicator light shows any of the

following, a fault or faults may havetaken place in the ABS. You shouldhave the ABS checked by an autho-rized Kawasaki dealer.• The light does not go on when theignition switch is turned on.• The light stays on lit after the motor-cycle starts moving.


j• The light goes on and stays on afterthe motorcycle starts moving.Remember that the ABS does not

function when the indicator light is on,but if the ABS fails, the conventionalbrake system still works normally.

Stopping the Engine• Close the throttle completely.• Shift the transmission into neutral.• Turn the ignition key to “OFF”.• Support the motorcycle on a firm,level surface with the side stand.• Lock the steering.

NOTE○The motorcycle is equipped with avehicle-down sensor which causesthe engine to stop automatically if themotorcycle falls down. The enginewarning indicator light ( ) blinkswhen the starter button pressed if theengine cannot be started. After right-ing the motorcycle, first turn the ig-nition key to “OFF” and then back to“ON” before starting the engine.


jStopping the Motorcycle in an

EmergencyYour Kawasaki Motorcycle has been

designed and manufactured to pro-vide you optimum safety and conve-nience. However, in order to fully ben-efit from Kawasaki’s safety engineeringand craftsmanship, it is essential thatyou, the owner and operator, properlymaintain your motorcycle and becomethoroughly familiar with its operation.Improper maintenance can create adangerous situation known as throt-tle failure. Two of the most commoncauses of throttle failure are:1. An improperly serviced or cloggedair cleaner may allow dirt and dustto enter the throttle body and stickthe throttle open.

2. During removal of the air cleaner,dirt is allowed to enter and jam thefuel injection system.In an emergency situation such as

throttle failure, your vehicle may bestopped by applying the brakes anddisengaging the clutch. Once thisstopping procedure is initiated, the en-gine stop switch may be used to stopthe engine. If the engine stop switch isused, turn off the ignition switch afterstopping the motorcycle.


jParking

WARNINGOperating or parking the vehi-cle near flammablematerials cancause a fire, and can result inproperty damage or severe per-sonal injury.Do not idle or park your vehiclein an area where tall or dry veg-etation, or other flammable ma-terials could come into contactwith the muffler or exhaust pipe.

WARNINGThe engine and exhaust systemget extremely hot during normaloperation and can cause seriousburns.Never touch a hot engine, ex-haust pipe, or muffler during op-eration or after stopping the en-gine.

• Shift the transmission into neutraland turn the ignition key to “OFF”.• Support the motorcycle on a firm,level surface with the side stand.

NOTICEDo not park on a soft or steeplyinclined surface, or the motorcy-cle may fall over.

• If parking inside a garage or otherstructure, be sure it is well ventilated


jand the motorcycle is not close toany source of flame or sparks; thisincludes any appliance with a pilotlight.

WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions, creating the po-tential for serious burns. Turnthe ignition switch to “OFF”. Donot smoke. Make sure the area iswell ventilated and free from anysource of flame or sparks; thisincludes any appliance with a pi-lot light.

• Lock the steering to prevent theft.

NOTE○When stopping near traffic at night,you can leave the taillight on forgreater visibility by turning the igni-tion key to the P (park) position.

○Do not leave the ignition switch at Pposition too long, or the battery willdischarge.


jCatalytic ConverterThis motorcycle is equipped with a

catalytic converter in the exhaust sys-tem. The converter reacts with car-bonmonoxide, hydrocarbons and nitro-gen oxides to convert them into carbondioxide, water, nitrogen and oxygen re-sulting in much cleaner exhaust gasesto be discharged into the atmosphere.For proper operation of the catalytic

converter, the following cautions mustbe observed.

WARNINGOperating or parking the vehi-cle near flammablematerials cancause a fire, and can result inproperty damage or severe per-sonal injury.Do not idle or park your vehiclein an area where tall or dry veg-etation, or other flammable ma-terials could come into contactwith the muffler or exhaust pipe.

WARNINGThe engine and exhaust systemget extremely hot during normaloperation and can cause seriousburns.Never touch a hot engine, ex-haust pipe, or muffler during op-eration or after stopping the en-gine.


j• Use only unleaded gasoline. Neveruse leaded gasoline. Leaded gaso-line significantly reduces the capabil-ity of the catalytic converter.• Do not operate the vehicle with theengine or any one cylinder misfiring.Under these conditions unburned

air/fuel mixture flowing out of engineexcessively accelerates reaction inthe converter allowing the converterto overheat and become damagedwhen the engine is hot, or reducesconverter performance when the en-gine is cold.

SAFE OPERATION 75

j

SAFE OPERATION

Safe Riding TechniqueThe 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 ahelmet are strongly recommended.You should be aware of and verifythe applicable safety regulations inforce prior to riding your motorcy-cle. Gloves and suitable footwearshould also be used for added pro-tection in case of a mishap.

A motorcycle does not providethe impact protection of an auto-mobile, so defensive riding in addi-tion to wearing protective apparelis extremely important. Do not letprotective apparel give you a falsesense of security.

When riding always keep bothhands on the handlebars and bothfeet on the footpegs. Removingyour hands from the handlebars orfeet from the footpegs while ridingcan be hazardous. If you removeeven one hand or foot, you canreduce your ability to control themotorcycle.

Before changing lanes, look overyour shoulder to make sure the wayis clear. Do not rely solely on therear view mirror; you may misjudgea vehicle’s distance and speed, oryou may not see it at all.

76 SAFE OPERATION

j

In general your actions shouldbe smooth as sudden acceleration,braking or turning may cause lossof control, especially when riding inwet conditions or on loose roadwaysurfaces, when the ability to maneu-ver will be reduced.

When going up steep slopes, shiftto a lower gear so that there is plentyof power to spare rather than over-loading the engine.

When applying the brakes, useboth the front and rear brakes. Ap-plying only one brake for suddenbraking may cause the motorcycleto skid and lose control.

When going down long slopes,control vehicle speed by closingthe throttle. Use the front and rearbrakes for auxiliary braking.

In wet conditions, rely more on thethrottle to control vehicle speed andless on the front and rear brakes.The throttle should also be used ju-diciously to avoid skidding the rearwheel from too rapid acceleration ordeceleration.

Riding at the proper rate of speedand avoiding unnecessarily fast ac-celeration are important not only forsafety and low fuel consumption butalso for long vehicle life and quieteroperation.

On rough roads, exercise caution,slow down, and grip the fuel tankwith the knees for better stability.

When quick acceleration is neces-sary as in passing, shift to a lowergear to obtain the necessary power.

SAFE OPERATION 77

j

Do not downshift at too high anr/min (rpm) to avoid damage fromoverrevving to the engine.

Avoiding unnecessary weaving isimportant to the safety of both therider and other motorists.

78 SAFE OPERATION

j

Daily Safety ChecksCheck 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.

WARNINGFailure to perform these checks before operation may result in seriousdamage or an accident. Always perform daily safety checks before oper-ation.

DANGERExhaust gas contains carbon monoxide, a colorless, odorless poisonousgas.Inhaling carbon monoxide can cause serious brain injury or death.Do not run the engine in enclosed areas. Operate only in a well-ventilatedarea.

Fuel ............................. Adequate supply in tank, no leaks.Engine oil .................... Oil level between level lines.Tires ............................ Air pressure (when cold):

SAFE OPERATION 79

j

Front Up to 200 kg (441 lb)Load 225 kPa (2.25 kgf/cm², 32 psi)

Rear Up to 200 kg (441 lb)Load 250 kPa (2.50 kgf/cm², 36 psi)

Install the air valve cap.Drive chain .................. Slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

Lubricate the dive chain if 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.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,

Warning/Indicator Lights) and horn work.Engine stop switch ...... Stops engine.

80 SAFE OPERATION

j

Side stand ................... Returns to its fully up position by spring tension.Returns spring not weak or not damaged.

Refer to the “Daily Safety Checks” caution label attached under the passenger’sseat.

SAFE OPERATION 81

j

Additional Considerations for High Speed OperationBrakes: 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, andcheck 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 signals,

horn, etc., all work properly.Miscellaneous: Make sure that all nuts and bolts are tight and that all safety

related parts are in good condition.

82 SAFE OPERATION

j

WARNINGHandling characteristics of a motorcycle at high speeds may vary fromthose you are familiar with at legal highway speeds. Do not attempt highspeed operation unless you have received sufficient training and have therequired skills.

MAINTENANCE AND ADJUSTMENT 83

j

MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried outand must be done in accordance with the Periodic Maintenance Chart to keep themotorcycle in good running condition. The initial maintenance is vitally impor-tant 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 youlack proper experience or doubt your ability, all adjustments, maintenance, andrepair 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.

84 MAINTENANCE AND ADJUSTMENT

j

Periodic Maintenance ChartK: 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.

1. Periodic Inspection (Engine Related Items)Frequency Whichever

comes first *Odometer Readingkm × 1 000 (mile × 1 000)

Operation(Engine Items) Every 1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

K Valve clearance- inspect every 42 000 km (26 250 mile) 113

Throttle controlsystem (play,smooth return,no drag) -inspect

year • • • • 115


j

Frequency Whichevercomes first *Odometer Reading

km × 1 000 (mile × 1 000)


(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

KEngine vacuumsynchronization- inspect

• • • 118

Idle speed -inspect • • • • 119

KFuel leak (fuelhose and pipe) -inspect

year • • • • –

KFuel hosesdamage -inspect

year • • • • –

KFuel hosesinstallationcondition -inspect

year • • • • –


j


km × 1 000 (mile × 1 000)


(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Coolant level -inspect • • • • 105

Coolant leak -inspect year • • • • 102

Radiator hosesdamage -inspect

year • • • • 102

Radiator hosesinstallationcondition -inspect

year • • • • 102


j


km × 1 000 (mile × 1 000)


(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Evaporativeemissioncontrol system- function(Southeast AsiaB1 and Thailandmodels only)

• • • • • • • 111

KAir suctionsystem damage- inspect

• • • 112


j

2. Periodic Inspection (Chassis Related Items)Frequency Whichever

comes first *Odometer Readingkm × 1000 (mile × 1000)

Operation(ChassisItems)

Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Clutch and drive train:Clutchoperation (play,engagement,disengagement)- inspect

• • • • 120

Drive chainlubricationcondition -inspect #

every 600 km (400 mile) 130

Drive chainslack - inspect # every 1 000 km (600 mile) 124

Drive chainwear - inspect # • • • 128


j


km × 1000 (mile × 1000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

KDrive chainguide wear -inspect

• • • –

Wheels and tires:Tire air pressure- inspect year • • • 143

Wheels/tiresdamage -inspect

• • • 144

Tire tread wear,abnormal wear -inspect

• • • 144

KWheel bearingsdamage -inspect

year • • • –


j


km × 1000 (mile × 1000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Brake system:Brake fluid leak- inspect year • • • • • • • 132

Brake hosesdamage -inspect

year • • • • • • • 132

Brake pad wear- inspect # • • • • • • 131

Brake hoseinstallationcondition -inspect

year • • • • • • • 132

Brake fluid level- inspect 6 months • • • • • • • 132


j


km × 1000 (mile × 1000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Brake operation(effectiveness,play, drag) -inspect

year • • • • • • • 135

Brake lightswitch operation- inspect

• • • • • • • 136

Suspensions:Front forks/rearshock absorberoperation(damping andsmooth stroke) -inspect

• • • 138,139


j


km × 1000 (mile × 1000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Front forks/rearshock absorberoil leak - inspect

year • • • 138,139

Steering System:

K Steering play -inspect year • • • • –

KSteering stembearings -lubricate

2 years • –

Electrical System:Lights andswitchesoperation -inspect

year • • • –


j


km × 1000 (mile × 1000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Headlightaiming - inspect year • • • 152

Side standswitch operation- inspect

year • • • –

Engine stopswitch operation- inspect

year • • • –

Chassis:

K Chassis parts -lubricate year • • • 156

KBolts and nutstightness -inspect

• • • • –


j

3. Periodic ReplacementFrequency Whichever

comes first *Odometer Readingkm × 1 000 (mile × 1 000)

Change/Replacement Items Every 1(0.6)

12(7.5)

24(15)

36(22.5)

48(30)

SeePage

K Air cleaner element # - replace every 18 000 km (11 250 mile) 113

Engine oil # - change year • • • • • 98

Oil filter - replace year • • • • • 98

K Fuel hoses - replace 5 years –

K Coolant - change 3 years • 109

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

K Brake hoses - replace 4 years • –

K Brake fluid (front and rear) -change 2 years • • 135


j


km × 1 000 (mile × 1 000)

Change/Replacement Items Every 1(0.6)

12(7.5)

24(15)

36(22.5)

48(30)

SeePage

K Rubber parts of mastercylinder and caliper - replace 4 years • –

K Spark plug - replace • • • • 110


j

Engine OilIn order for the engine, transmission,

and clutch to function properly, main-tain the engine oil at the proper level,and change the oil and replace the oilfilter in accordance with the PeriodicMaintenance Chart. Not only do dirtand metal particles collect in the oil, butthe oil itself loses its lubricative qualityif used too long.

WARNINGMotorcycle operation with insuf-ficient, deteriorated, or contam-inated engine oil will cause ac-celerated wear and may result inengine or transmission seizure,accident, and injury. Check theoil level before each ride andchange the oil according to theperiodic maintenance chart inthe owner’s manual.

Oil Level Inspection• If the oil has just been changed, startthe engine and run it for several min-utes at idle speed. This fills the oilfilter with oil. Stop the engine, thenwait several minutes until the oil set-tles.

NOTICERacing the engine before the oilreaches every part can cause en-gine seizure.

• If the motorcycle has just been used,wait several minutes for all the oil todrain down.


j

• Check the engine oil level throughthe oil level inspection window. Withthe motorcycle held level, the oillevel should come up between theupper and lower level lines next tothe gauge.

A. Oil Level Inspection WindowB. Upper Level LineC. Lower Level LineD. Oil Filler Cap

• If the oil level is too high, remove theexcess oil through the oil filler open-ing using a syringe or some othersuitable device.• If the oil level is too low, add the oilto reach the correct level. Use thesame type and brand of oil that isalready in the engine.

NOTICEIf the engine oil gets extremelylow or if the oil pump does notfunction properly or oil pas-sages are clogged, the warningindicator light ( ) will go on.If this warning indicator lightstays on when the engine speedis slightly above the idle speed,stop the engine immediately andfind the cause.


j

A. Red Oil Pressure Warning Indicator Light

Oil and/or Oil Filter Change• Warm up the engine thoroughly, andthen stop it.• Place an oil pan beneath the engine.• Remove the engine oil drain plug.

A. Drain Plug

• Let the oil completely drain withthe motorcycle perpendicular to theground.


j

WARNINGEngine oil is a toxic substance.Dispose of used oil properly.Contact your local authoritiesfor approved disposal methodsor possible recycling.

• Remove the right side fairing (refer tothe “Cooling System” section in thischapter).• Remove the oil filter cartridge and re-place it with a new one.

NOTE○If a torque wrench or requiredKawasaki special tool is not avail-able, this item should be serviced byan authorized Kawasaki dealer.

A. Oil Filter Cartridge


j

• Apply a thin film of oil to the packingand tighten the cartridge to the spec-ified torque.

A. Packing

• Install the drain plug with its new gas-ket. Tighten it to the specified torque.

NOTE○Replace any gaskets with new ones.

• Fill the engine up to the upper levelline with a good quality engine oilspecified in the table.• Start the engine.• Check the oil level and oil leakage.Tightening TorqueEngine Oil Drain Plug :

30 N·m (3.1 kgf·m, 22 ft·lb)Oil Filter Cartridge :

17.5 N·m (1.75 kgf·m, 13 ft·lb)

Recommended Engine OilType : API SG, SH, SJ, SL or SM

with JASO MA, MA1 orMA2

Viscosity : SAE 10W-40

NOTE○Do not add any chemical additive tothe oil. Oils fulfilling the above re-quirements are fully formulated and


j

provide adequate lubrication for boththe engine and the clutch.

Engine Oil CapacityCapacity : 1.6 L (1.7 US qt)

[when filter is not removed]1.8 L (1.9 US qt)[when filter is removed]2.3 L (2.4 US qt)[when engine is completelydry]

• Install the right side fairing (refer tothe “Cooling System” section in thischapter).

Although 10W-40 engine oil is therecommended oil for most condi-tions, the oil viscosity may need tobe changed to accommodate atmo-spheric conditions in your riding area.


j

Cooling SystemRadiator and Cooling Fan -Check the radiator fins for obstruc-

tion by insects or mud. Clean offany obstructions with a stream oflow-pressure water.

WARNINGThe cooling fan spins at highspeed and can cause seriousinjuries. Keep your hands andclothing away from the coolingfan blades at all times.

NOTICEUsing high-pressure water, asfrom a car wash facility, coulddamage the radiator fins and im-pair the radiator’s effectiveness.Do not obstruct or deflect air-flow through the radiator byinstalling unauthorized acces-sories in front of the radiator orbehind the cooling fan. Inter-ference with the radiator airflowcan lead to overheating and con-sequent engine damage.

Radiator Hoses -Check the radiator hoses for leak-

age, cracks or deterioration, and con-nections for leakage or looseness eachday before riding the motorcycle, andcarry out the maintenance and adjust-ments in accordance with the PeriodicMaintenance Chart.


j

Coolant -Coolant absorbs excessive heat from

the engine and transfers it to the airat the radiator. If the coolant level be-comes low, the engine overheats andmay suffer severe damage. Check thecoolant level each day before riding themotorcycle, and carry out the mainte-nance and adjustments in accordancewith the periodic maintenance chart.Replenish coolant if the level is low.Change the coolant in accordance withthe Periodic Maintenance Chart.

Information for CoolantTo protect the cooling system (con-

sisting of the aluminum engine andradiator) from rust and corrosion, theuse of corrosion and rust inhibitorchemicals in the coolant is essential. Ifcoolant containing corrosion and rustinhibitor chemicals is not used, over a

period of time, the cooling system ac-cumulates rust and scale in the waterjacket and radiator. This will clog upthe coolant passages, and consider-ably reduce the efficiency of the coolingsystem.

WARNINGCoolant containing corrosion in-hibitors for aluminum enginesand radiators include harmfulchemicals for human body.Drinking coolant can result inserious injury or death. Usecoolant in accordance with theinstructions of themanufacturer.

Soft or distilled water must be usedwith the antifreeze (see below for an-tifreeze) in the cooling system.


j

NOTICEIf hard water is used in the sys-tem, it causes scale accumula-tion in the water passages, andconsiderably reduces the effi-ciency of the cooling system.

If the lowest ambient temperature en-countered falls below the freezing pointof water, use permanent antifreeze inthe coolant to protect the cooling sys-tem against engine and radiator freeze-up, as well as from rust and corrosion.Use a permanent type of antifreeze

(soft water and ethylene glycol plus cor-rosion and rust inhibitor chemicals foraluminum engines and radiators) in thecooling system. On the mixture ratioof coolant, choose the suitable one re-ferring to the relation between freezingpoint and strength directed on the con-tainer.

NOTICEPermanent types of antifreeze onthe market have anti-corrosionand anti-rust properties. When itis diluted excessively, it loses itsanti-corrosion property. Dilute apermanent type of antifreeze inaccordance with the instructionsof the manufacturer.

NOTE○A permanent type of antifreeze is in-stalled in the cooling system whenshipped. It is colored green and con-tains ethylene glycol. It is mixed at50% and has the freezing point of–35°C (–31°F).


j

Coolant Level Inspection• Situate the motorcycle so that it isperpendicular to the ground.• Check the coolant level if it is be-tween the F (Full) and L (Low) levellines on the reserve tank located rightside of the radiator.

NOTE○Check the level when the engine iscold (room or atmospheric tempera-ture).

A. F (Full) Level LineB. L (Low) Level LineC. Coolant Reserve Tank

• If the amount of coolant is insuffi-cient, remove the right side fairingand add coolant into the reservetank.


j

Coolant Filling• Remove three large quick rivetson the bottom of the fairing. Thelarge quick rivets can be removed bypulling the center pin with a screwdriver.• Remove three small quick rivets be-hind the right side fairing. The smallquick rivets can be removed by push-ing the center pin into the rivet.

A. Large Quick RivetsB. Small Quick Rivets

NOTE○When installing the large quick rivet,insert them into the holes on the fair-ing and push the center pin to securethem.

○When installing the small quick riv-ets, pull the center pin fully up first,and push the center pin after insert-ing them.

A. Quick RivetB. Center PinC. Push in.


j

A. Quick RivetB. Center PinC. Pull up fully.D. Push in.

• Remove the right side fairing mount-ing bolts, nylon washers and collars.

A. Bolts (Black) and Nylon WashersB. Bolt and CollarC. Bolt, Nylon Washer and Collar


j

• Slide the upper edge of the right sidefairing rearward carefully to detachall tabs from the holes on the fairings.• Disconnect the right turn signal lightconnector and remove the right sidefairing.

A. TabsB. HolesC. Right Side Fairing

• Remove the cap from the reservetank and add coolant through thefiller opening to the F (Full) level line.

A. Reserve TankB. F (Full) Level LineC. Cap

• Position the right side fairing aligningthe tabs with the holes carefully.• Install the three small quick rivets be-hind the right side fairing and threelarge quick rivets at the bottom of thefairing.


j

• Install the mounting bolts, nylonwashers and collars to secure rightside fairing.

A. Right Side FairingB. Small Quick RivetsC. Large Quick RivetsD. Bolts (Black) and Nylon WashersE. Bolt and CollarF. Bolt, Nylon Washer and Collar

NOTE○In an emergency you can add wa-ter alone to the coolant reserve tank,however it must be returned to thecorrect mixture ratio by the additionof antifreeze concentrate as soon aspossible.

NOTICEIf coolant must be added of-ten, or the reserve tank com-pletely runs dry, there is proba-bly leakage in the system. Havethe cooling system inspectedby your authorized Kawasakidealer.

Coolant ChangeHave the coolant changed by an au-

thorized Kawasaki dealer.


j

Spark PlugsThe standard spark plug is shown in

the table. The spark plugs should bereplaced in accordance with the Peri-odic Maintenance Chart.Spark plug removal should be done

by an authorized Kawasaki dealer.Spark PlugStandard Plug NGK CR9EIA-9

Plug Gap 0.8 ∼ 0.9 mm(0.032 ∼ 0.035 in.)

TighteningTorque

15 N·m(1.5 kgf·m, 11 ft·lb)

A. Plug Gap


j

Evaporative Emission ControlSystem (Southeast Asia B1and Thailand models only)

This system routes fuel vapors fromthe fuel system into the running engineor stores the vapors in a canister whenthe 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 securelyconnected.• Replace any kinked, deteriorated, ordamaged hoses.


j

Kawasaki Clean Air SystemThe Kawasaki Clean Air System

(KCA) is a secondary air suction sys-tem that helps the exhaust gases toburn more completely. When the spentfuel charge is released into the ex-haust system, it is still hot enough toburn. The KCA System allows extraair into the exhaust system so that thespent fuel charge can continue to burn.This continued burning action tends toburn up a great deal of the normallyunburned gases, as well as chang-ing a significant portion of the carbonmonoxide into carbon dioxide.

Air Suction Valves -The air suction valve is essentially a

check valve which allows fresh air toflow only from the air cleaner into theexhaust port. Any air that has passed

the air suction valve is prevented fromreturning. Inspect the air suction valvesin accordance with the Periodic Main-tenance Chart. Also, inspect the airsuction valves whenever stable idlingcannot be obtained, engine power isgreatly reduced, or there are abnormalengine noises.Air suction valve removal and inspec-

tion should be done by an authorizedKawasaki dealer.


j

Valve ClearanceValve and valve seat wear decreases

valve clearance, upsetting valve timing.

NOTICEIf valve clearance is left un-adjusted, wear will eventuallycause the valves to remainpartly open, which lowers per-formance, burns the valves andvalve seats, and may cause seri-ous engine damage.

Valve clearance for each valveshould be checked and adjusted inaccordance with the Periodic Mainte-nance Chart.Inspection and adjustment should

be done by an authorized Kawasakidealer.

Air CleanerA clogged air cleaner restricts the en-

gine’s air intake, increasing fuel con-sumption, reducing engine power, andcausing spark plug fouling.The air cleaner element must be re-

placed in accordance with the PeriodicMaintenance Chart. This motorcycle’sair cleaner element consists of a wetpaper filter, which cannot be cleaned.In dusty, rainy, or on muddy conditions,the air cleaner element should be ser-viced more frequently than the recom-mended interval.


j

NOTICEUse only the recommended aircleaner element (Kawasaki partnumber 11013-0713 or equiva-lent type). Using the any otherair cleaner element will wear theengine prematurely or lower theengine performance.

Oil Draining• Inspect the drain hose located on theleft side of the engine to see if any oilor water has run down from the aircleaner housing.

A. Drain HoseB. Plug

• If there is any oil in the hose, removethe plug and drain the oil.


j

WARNINGOil on tires will make them slip-pery and can cause an accidentand injury. Be sure to install theplug in the drain hose after drain-ing.

Throttle Control SystemCheck the throttle grip play in accor-

dance with the Periodic MaintenanceChart, and adjust it if necessary.

Throttle Grip -The throttle grip controls the butterfly

valves in the throttle body. If the throt-tle grip has excessive play due to eithercable stretch or maladjustment, it willcause a delay in throttle response, es-pecially at low engine speed. Also, thethrottle valve may not open fully at fullthrottle. On the other hand, if the throt-tle grip has not play, the throttle will behard to control, and the idle speed willbe erratic.


j

Inspection• Check that the throttle grip play iscorrect by lightly turning the throttlegrip back and forth.

A. Throttle GripB. Throttle Grip Play

Throttle Grip Play2 ∼ 3 mm (0.08 ∼ 0.12 in.)

• If there is improper play, adjust it.

Adjustment• Loosen the locknut at the throttlegrip, and turn the adjuster until theproper amount of throttle grip play isobtained.

A. LocknutB. AdjusterC. Throttle Cable (Accelerator Cable)


j

• If the throttle grip play cannot be ad-justed with the accelerator cable ad-juster at the throttle grip, use the de-celerator cable adjuster located un-der the fuel tank.• Remove the right side fairing (refer tothe “Cooling System” section in thischapter).• Turn out the decelerator cable adjust-ing nut until there is no play when thethrottle grip is completely closed.• Tighten the locknut. A. Adjuster

B. LocknutC. Throttle Cable (Decelerator Cable)

• Turn the accelerator cable adjustingnut until a play of 2 ∼ 3 mm (0.08 ∼0.12 in.) is obtained at the throttlegrip.• Tighten the locknut.• With the engine idling, turn the han-dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improperly


j

adjusted or incorrectly routed, or theymay be damaged. Be sure to correctany of these conditions before idling.

WARNINGOperation with improperly ad-justed, incorrectly routed, ordamaged cables could result inan unsafe riding condition. Besure the control cables are ad-justed and routed correctly, andare free from damage.


Engine Vacuum SynchronizationEngine vacuum synchronization

must be checked and adjusted period-ically in accordance with the PeriodicMaintenance Chart by an authorizedKawasaki dealer.

NOTE○Poor engine vacuum synchronizationwill cause unstable idling, sluggishthrottle response, and reduce enginepower and performance.


j

Idle SpeedThe idle speed check should be per-

formed in accordance with the Peri-odic Maintenance Chart or wheneverthe idle speed is disturbed.

Adjustment• Start the engine, and warm it up thor-oughly.• Adjust the idle speed by turning theidle adjusting screw.

Idle Speed1 250 ∼ 1 350 r/min (rpm)

A. Idle Adjusting Screw

• Open and close the throttle a fewtimes to make sure that the idlespeed does not change. Readjust ifnecessary.• With the engine idling, turn the han-dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improperlyadjusted or incorrectly routed, or theymay be damaged. Be sure to correctany of these conditions before riding.


j

WARNINGOperation with damaged cablescould result in an unsafe ridingcondition. Replace damagedcontrol cables before operation.

ClutchDue to friction plate wear and clutch

cable stretch over a long period of use,the clutch operation should be checkedeach day before riding the motorcycle,and carry out the maintenance and ad-justments in accordance with the Peri-odic Maintenance Chart.

WARNINGThe engine and exhaust systemget extremely hot during normaloperation and can cause seriousburns. Never touch a hot engineor an exhaust pipe during clutchadjustment.


j

Inspection• Check that the clutch lever operatesproperly and that the inner cableslides smoothly. If there is any irreg-ularity, have the clutch cable checkedby an authorized Kawasaki dealer.• Check the clutch lever play as shownin the figure.

Clutch Lever Play2 ∼ 3 mm (0.08 ∼ 0.12 in.)

A. LocknutB. Clutch Lever PlayC. Adjuster

If the play is incorrect, adjust the leverplay as follows.

Adjustment• Loosen the locknut, and turn theadjuster so that the clutch lever willhave the proper play.


j

WARNINGToo much cable play can pre-vent clutch disengagement andcause an accident resulting inserious injury or death. Whenadjusting the clutch or replac-ing the cable, be sure the up-per end of the clutch outer cableis fully seated in its fitting, or itcould slip into place later, creat-ing enough cable play to preventclutch disengagement.

• If it cannot be done, use the adjusterat the lower end of the clutch cable.• Remove the right side fairing (refer tothe “Cooling System” section in thischapter).• Loosen the locknut and turn the ad-juster to adjust the clutch lever play.• Tighten the locknut while holding theadjuster with a wrench.

A. AdjusterB. LocknutC. Clutch Cable


j

NOTE○After the adjustment is made, startthe engine and check that the clutchdoes not slip and releases properly.

○For minor corrections, use the ad-juster at the clutch lever.


Drive ChainThe drive chain slack and lubrication

must be checked each day before rid-ing the motorcycle, and must be main-tained in accordance with the PeriodicMaintenance Chart for safety and toprevent excessive wear. If the chainbecomes badly worn or maladjusted -either too loose or too tight - the chaincould jump off the sprockets or break.

WARNINGA chain that breaks or jumps offthe sprockets could snag on theengine sprocket or lock the rearwheel, severely damaging themotorcycle and causing it to goout of control. Inspect the chainfor damage and proper adjust-ment before each ride.


j

Chain Slack Inspection• Set the motorcycle up on its sidestand.• Rotate the rear wheel to find the po-sition where the chain is tightest, andmeasure the maximum chain slackby pulling up and pushing down thechain midway between the enginesprocket and rear wheel sprocket.

A. Chain Slack

• If the drive chain is too tight or tooloose, adjust it so that the chain slackwill be within the standard value.

Drive Chain SlackStandard 25 ∼ 35 mm (1.0 ∼ 1.4 in.)


j

Chain Slack Adjustment• Loosen the left and right chain ad-juster locknuts.• Remove the cotter pin, and loosenthe axle nut.

A. Axle NutB. Cotter PinC. AdjusterD. Locknut

• If the chain is too loose, turn out theleft and right chain adjusters evenly.• If the chain is too tight, turn in the leftand right chain adjusters evenly.• Turn out both chain adjusters evenlyuntil the drive chain has the cor-rect amount of slack. To keep thechain and wheel properly aligned,the notch on the left wheel alignmentindicator should align with the sameswingarm mark that the right indica-tor notch aligns with.


j

A. MarksB. NotchC. IndicatorD. AdjusterE. Locknut

NOTE○Wheel alignment can also bechecked using the straightedge orstring method.

WARNINGMisalignment of the wheel willresult in abnormal wear, andmayresult in an unsafe riding con-dition. Align the rear wheel us-ing the marks on the swingarmor measuring the distance be-tween the center of the axle andswingarm pivot.

• Tighten both chain adjuster locknuts.• Tighten the rear axle nut to the spec-ified torque.

Tightening TorqueAxle Nut:108 N·m (11 kgf·m, 80 ft·lb)

NOTE○If a torque wrench is not available,this item should be serviced by anauthorized Kawasaki dealer.


j

• Rotate the wheel, measure the chainslack again at the tightest position,and readjust if necessary.• Install a new cotter pin through therear axle nut and axle, and spread itsends.

A. Cotter Pin

NOTE○When inserting the cotter pin, if theslots in the nut do not align withthe cotter pin hole in the axle shaft,tighten the nut clockwise up to thenext alignment.

○It should be within 30 degrees.○Loosen once and tighten again whenthe slot goes past the nearest hole.

A. Turning Clockwise


j

WARNINGA loose axle nut can lead to anaccident resulting in serious in-jury or death. Tighten the axlenut to the proper torque and in-stall a new cotter pin.

• Check the rear brake (see the Brakessection).

Wear Inspection• Remove the bolts and chain cover.

A. BoltsB. Chain Cover

• Stretch the chain taut either by usingthe chain adjusters, or by hanging a10 kg (22 lb) weight on the chain.• Measure the length of 20 links onthe straight part of the chain from pincenter of the 1st pin to pin center ofthe 21st pin. Since the chain may


j

wear unevenly, take measurementsat several places.• If the length exceeds the service limit,the chain should be replaced.

A. MeasureB. Weight

Drive Chain 20-Link Length

Service Limit: 323 mm (12.7 in.)

WARNINGFor safety, use only the standardchain. It is an endless type andshould not be cut for installa-tion; have it installed by an au-thorized Kawasaki dealer.

• Install the chain cover and bolts.• Rotate the rear wheel to inspect thedrive chain for damaged rollers, andloose pins and links.• Also inspect the sprockets for un-evenly or excessively worn teeth,and damaged teeth.


j

NOTE○Sprocket wear is exaggerated for il-lustration. See Service Manual forwear limits.

A. Good TeethB. Worn TeethC. Damaged Teeth

• If there is any irregularity, have thedrive chain and/or the sprockets re-placed by an authorized Kawasakidealer.

LubricationLubrication is also necessary after

riding through rain or on wet roads, orany time that the chain appears dry. Aheavy oil such as SAE 90 is preferredto a lighter oil because it will stay on thechain longer and provide better lubrica-tion.


j

• Apply oil to the sides of the rollers sothat it will penetrate to the rollers andbushings. Apply oil to the O-rings sothat the O-rings will be coated withoil. Wipe off any excess oil.

• If the chain is especially dirty, clean itusing diesel oil or kerosine and thenapply oil as mentioned above.

BrakesBrake Wear InspectionInspect the brakes for wear. For each

front and rear disc brake caliper, if thethickness of either pad is less than1 mm (0.04 in.), replace both padsin the caliper as a set. Pad replace-ment should be done by an authorizedKawasaki dealer.

A. Lining ThicknessB. 1 mm (0.04 in.)


j

Brake Fluid -In accordance with the Periodic Main-

tenance Chart, inspect the brake fluidlevel in both the front and rear brakefluid reservoirs and change the brakefluid. The brake fluid should also bechanged if it becomes contaminatedwith dirt or water.

Fluid RequirementUse heavy-duty brake fluid only from

a container marked DOT4.

NOTICEDo not spill brake fluid onto anypainted surface.Do not use fluid from a containerthat has been left open or thathas been unsealed for a longtime.Check for fluid leakage aroundthe fittings.Check brake hose for damage.

Fluid Level Inspection• The brake fluid level in the front brakefluid reservoir must be kept abovethe line (lower level line) next to thegauge and that in the rear brake fluidreservoir (located under the rider’sseat) must be kept between the up-per and lower level lines (reservoirsheld horizontal).

A. Front Brake Fluid ReservoirB. Lower Level Line


j

A. Rear Brake Fluid ReservoirB. Upper Level LineC. Lower Level Line

• If the fluid level in either reservoir islower than the lower level line, checkfor fluid leaks in the brake lines, andfill the reservoir to the upper levelline. Inside the front brake fluid reser-voir is a stepped line showing the up-per level line.

A. Front Brake Fluid ReservoirB. Upper Level Line


j

WARNINGMixing brands and types ofbrake fluid can reduce the brakesystem’s effectiveness andcause an accident resulting ininjury or death. Do not mix twobrands of brake fluid. Changethe brake fluid in the brake linecompletely if the brake fluidmust be refilled but the typeand brand of the brake fluid thatis already in the reservoir areunidentified.

NOTE○First, tighten until slight resistance isfelt, which indicates that the cap isseated on the reservoir body; then,tighten the cap an additional 1/6 turnwhile holding the brake fluid reservoirbody.

A. ReservoirB. CapC. ClockwiseD. 1/6 turn


j

Fluid ChangeHave the brake fluid changed by an

authorized Kawasaki dealer.

Front and Rear Brakes -Disc and disc pad wear is automat-

ically compensated for and has no ef-fect on the brake lever or pedal action.So there are no parts that require ad-justment on the front brakes and rearbrakes.

WARNINGAir in the brake lines diminishbraking performance and cancause an accident resulting ininjury or death. If the brake leveror pedal feels mushy when itis applied, there might be air inthe brake lines or the brake maybe defective. Have the brakechecked immediately by an au-thorized Kawasaki dealer.


j

Brake Light SwitchesWhen either the front or rear brake is

applied, the brake light goes on. Thefront brake light switch requires no ad-justment, but the rear brake light switchshould be adjusted in accordance withthe Periodic Maintenance Chart.

Inspection• Turn the ignition key to “ON”.• The brake light should go on whenthe front brake is applied.• If it does not, ask your authorizedKawasaki dealer to inspect the frontbrake light switch.

• Check the operation of the rear brakelight switch by depressing the brakepedal. The brake light should go onafter the proper pedal travel.

A. Brake PedalB. Pedal Travel

• If it does not, adjust the rear brakelight switch.

Brake Pedal Travel10 mm (0.4 in.)


j

Adjustment• To adjust the rear brake light switch,remove bolt and the right frame sidecover.

A. BoltB. Right Frame Side Cover

• Move the switch up or down by turn-ing the switch body.

A. Rear Brake Light SwitchB. Adjusting NutC. Lights soonerD. Lights later

• Reinstall the right frame side coverand bolt.


j

NOTICETo avoid damaging the electricalconnections inside the switch,be sure that the switch bodydoes not turn during adjustment.

Front ForkThe front fork operation and oil leak-

age should be checked in accordancewith the Periodic Maintenance Chart.

Front Fork Inspection• Holding the brake lever, pump thefront fork up and down several timesto inspect smooth stroke.• Visually inspect the front fork for oilleakage, scoring or scratches on theouter surface of the inner tube.

• If any doubt about the front fork, itshould be checked by an authorizedKawasaki dealer.


j

A. Inner Tube

Rear Shock AbsorberThe rear shock absorber should be

checked operation and oil leakage inaccordance with the Periodic Mainte-nance Chart.

Rear Shock Absorber Inspection• Press down on the seat several timesto check if the rear shock absorberstroke is smooth.• Visually inspect the rear shock ab-sorber for oil leaks.

• If there is any doubt about the rearshock absorber, it should be in-spected by an authorized Kawasakidealer.


j

A. Rear Shock Absorber

The rear shock absorber can be ad-justed by changing the spring preloadand rebound damping force for variousriding and loading conditions.

Spring Preload AdjustmentThe spring preload adjuster on the

rear shock absorber has 7 positions.

A. Spring Preload AdjusterB. Wrench

• In accordance with the following ta-ble, turn the preload adjuster with thewrench from the tool kit.


j

Spring Preload SettingAdjusterPosition 1 2 3 4 5 6 7

Spring Action Weak ← Standard → Strong

Setting Soft ← Standard → Hard

Load Light ← Standard → Heavy

Road Good ← Standard → Bad

Speed Low ← Standard → High


j

WheelsTubeless tires are installed on the

wheels of this motorcycle. The indica-tions of TUBELESS on the tire side walland the rim show that the tire and rimare specially designed for tubeless use.

A. TUBELESS Mark

A. TUBELESS Mark

The tire and rim form a leakproof unitby making airtight contacts at the tirechamfers and the rim flanges insteadof using an inner tube.


j

WARNINGInstalling a tube inside a tube-less-type tire can create exces-sive heat build up that can dam-age the tube and cause rapiddeflation. The tires, rims, andair valves on this motorcycle aredesigned only for tubeless typewheels. The recommended stan-dard tires, rims, and air valvesmust be used for replacement.Do not install tube-type tires ontubeless rims. The beads maynot seat properly on the rimcausing tire deflation. Do notinstall a tube inside a tubelesstire. Excessive heat build-upmay damage the tube causingtire deflation.

Tires -Payload and Tire PressureFailure to maintain proper inflation

pressures or observe payload limits foryour tires may adversely affect han-dling and performance of your motorcy-cle and can result in loss of control. Themaximum recommended load in addi-tion to vehicle weight is 200 kg (441 lb),including rider, passenger, baggage,and accessories.• Remove the air valve cap.• Check the tire pressure often, usingan accurate gauge.• Make sure to install the air valve capsecurely.

NOTE○Measure the tire pressure when thetires are cold (that is, when the mo-torcycle has not been ridden morethan a mile during the past 3 hours).


j

○Tire pressure is affected by changesin ambient temperature and altitude,and so the tire pressure should bechecked and adjusted when your rid-ing involves wide variations in tem-perature or altitude.

A. Tire Pressure Gauge

Tire Air Pressure (when cold)Front 225 kPa (2.25 kgf/cm², 32 psi)Rear 250 kPa (2.50 kgf/cm², 36 psi)

Tire Wear, DamageAs the tire tread wears down, the tire

becomes more susceptible to punctureand failure. An accepted estimate isthat 90% of all tire failures occur duringthe last 10% of tread life (90 % worn).So it is false economy and unsafe touse the tires until they are bald.• In accordance with the PeriodicMaintenance Chart, measure thedepth of the tread with a depthgauge, and replace any tire thathas worn down to the minimum al-lowable tread depth.

Minimum Tread Depth

Front 1 mm(0.04 in.)

Up to 130 km/h(80 mph)

2 mm(0.08 in.)Rear

Over 130 km/h(80 mph)

3 mm(0.12 in.)


j

A. Tire Depth Gauge

• Visually inspect the tire for cracksand cuts, replacing the tire in case of

bad damage. Swelling or high spotsindicate internal damage, requiringtire replacement.• Remove any imbedded stones orother foreign particles from the tread.

NOTE○Most countries may have their ownregulations requiring a minimum tiretread depth; be sure to follow them.

○Have the wheel balance inspectedwhenever a new tire is installed.


j

WARNINGTires that have been puncturedand repaired do not have thesame capabilities as undam-aged tires and can suddenly fail,causing an accident resultingin serious injury or death. Re-place damaged tires as soon aspossible. To ensure safe han-dling and stability, use only therecommended standard tires forreplacement, inflated to the stan-dard pressure. If it is necessaryto ride on a repaired tire, do notexceed 100 km/h (60 mph) untilthe tire is replaced.

NOTE○When operating on public roadways,keep maximum speed under trafficlaw limits.

Standard Tire (Tubeless)

FrontSize: 120/70ZR17 M/C (58W)DUNLOPROADSMART II J

RearSize: 160/60ZR17 M/C (69W)DUNLOPROADSMART II J

WARNINGMixing tire brands and types canadversely affect handling andcause an accident resulting ininjury or death. Always use thesame manufacturer’s tires onboth front and rear wheels.


j

WARNINGNew tires are slippery and maycause loss of control and injury.A break-in period of 160 km (100miles) is necessary to estab-lish normal tire traction. Duringbreak-in, avoid sudden and max-imum braking and acceleration,and hard cornering.

BatteryThe battery installed in this motorcy-

cle is a sealed type, so it is not nec-essary to check the battery electrolytelevel or add distilled water.The sealing strip should not be pulled

off once the specified electrolyte hasbeen installed in the battery for initialservice.However, in order to maximize bat-

tery life and ensure that it will providethe power needed to start the motor-cycle you must properly maintain thebattery’s charge. When used regularly,the charging system in the motorcyclehelps keep the battery fully charged. Ifyour motorcycle is only used occasion-ally or for short periods of time, the bat-tery is more likely to discharge.Due to their internal composition,

batteries continually self discharge.The discharge rate depends on the


j

type of battery and ambient temper-ature. As temperature rises, so doesthe discharge rate. Every 15°C (27°F)doubles the rate.Electrical accessories, such as digi-

tal clocks and computer memory, alsodraw current from the battery evenwhen the key is switched off. Due toa combination of such “key-off” drawsand hot temperature, a battery can gofrom fully charged to completely dis-charged in a matter of days.

Self-discharge

Approx. Number of DaysFrom 100% Charged to100% dischargedLead-Antimony

Lead-Calcium

Temperature

Battery Battery

40°C(104°F) 100 Days 300 Days

25°C (77°F) 200 Days 600 Days

0°C (32°F) 550 Days 950 Days


j

Current Drain

DischargingAmpere

Days from100%charged to50%Discharged

Days from100%charged to100%Discharged

7 mA 60 Days 119 Days





In extremely cold weather the fluid inan inadequately charged battery caneasily freeze, which can crack the caseand buckle the plates. A fully chargedbattery can withstand sub-freezingtemperature with no damage.

Battery SulfationA common cause of battery failure is

sulfation.

Sulfation occurs when the battery isleft in a discharged condition for an ex-tended time. Sulfate is a normal byproduct of the chemical reactions withina battery. But when continuous dis-charge allows the sulfate to crystallizein the cells, the battery plates becomepermanently damaged and will not holda charge. Battery failure due to sulfa-tion is not warrantable.

Battery MaintenanceIt is the owner’s responsibility to keep

the battery fully charged. Failure to doso can lead to battery failure and leaveyou stranded.If you are riding your vehicle infre-

quently, inspect the battery voltageweekly using a voltmeter. If it dropsbelow 12.8 volts, the battery should becharged using an appropriate charger(check with an authorized Kawasakidealer). If you will not be using the


j

motorcycle for longer than two weeks,the battery should be charged using anappropriate charger. Do not use an au-tomotive-type quick charger that mayovercharge the battery and damage it.

Kawasaki-recommended chargersare:Battery Mate 150-9OptiMate 4Yuasa MB-2040/2060Christie C10122SIf the above chargers are not avail-

able, use equivalent one.For more details, ask your Kawasaki

dealer.

Battery Charging• Remove the battery from the motor-cycle (see Battery Removal).• Attach the leads from the chargerand charge the battery at a rate (am-perage × hours) that is indicated on

the battery. If it is not possible to readthe rate, charge the battery at an am-perage that is about 1/10th of the bat-tery capacity.• The charger will keep the battery fullycharged until you are ready to re-install the battery in the motorcycle(see Battery Installation).

NOTICENever remove the sealing strip,or the battery can be damaged.Do not install a conventionalbattery in this motorcycle, or theelectrical system cannot workproperly.

NOTE○If you charge the sealed battery,never fail to observe the instructionsshown in the label on the battery.


j

Battery Removal• Remove the passenger’s seat andrider’s seat.

• Disconnect the cables from the bat-tery, first from the (–) terminal andthen the (+) terminal.• Remove the bolts and bracket, thentake the battery out of the case.• Clean the battery using a solution ofbaking soda and water. Be sure thatthe cable connections are clean. A. (+) Terminal

B. (–) TerminalC. BoltsD. Bracket

Battery Installation• Place the battery in the battery case.• Connect the capped cable to the (+)terminal, and then connect the blackcable to the (–) terminal.


j

NOTE○Install the battery in the reverse orderof the Battery Removal.

NOTICEInstalling the (–) cable to the (+)terminal of the battery or the (+)cable to the (–) terminal of thebattery can seriously damagethe electrical system.

• Put a light coat of grease on the ter-minals to prevent corrosion.• Cover the (+) terminal with its protec-tive cap.• Reinstall the removed parts.

Headlight BeamHorizontal AdjustmentThe headlight beam is adjustable

horizontally. If not properly adjustedhorizontally, the beam will point to oneside rather than straight ahead.• Turn the horizontal adjuster clock-wise or counterclockwise until thebeam points straight ahead.

A. Horizontal AdjusterB. Vertical Adjuster


j

Vertical AdjustmentThe headlight beam is adjustable ver-

tically. If adjusted too low, neither lownor high beam will illuminate the roadfar enough ahead. If adjusted too high,the high beam will fail to illuminate theroad close ahead, and the low beamwill blind oncoming drivers.• Turn the vertical adjuster clockwiseor counterclockwise to adjust its ver-tical angle.

NOTE○On high beam, the brightest pointshould be slightly below horizontalwith the motorcycle on its wheels andthe rider seated. Adjust the headlightto the proper angle according to localregulations.


j

FusesFuses are arranged in the fuse boxes

located under the fuel tank cover andthe left frame cover for ABSmodel. Themain fuse is mounted on the starter re-lay under the rider’s seat. If a fusefails during operation, inspect the elec-trical system to determine the cause,and then replace it with a new fuse ofproper amperage.

A. Fuse BoxesB. Main Fuse

A. Fuse Box (for models equipped with ABS)

WARNINGSubstituting fuses can causewiring to overheat, catch fireand/or fail. Do not use any sub-stitute for the standard fuse.Replace the blown fuse with anew one of the correct capacity,as specified on the junction boxand main fuse.


j

• To access the fuse boxes, removethe bolts and slide each side of thetank front cover forwards then pull upthe front of the cover to remove it.

A. BoltsB. Tank Front CoverC. Pull Up CoverD. Slide Cover Forward

• To access the fuse box for ABS, re-move the left frame side cover by re-moving the bolt.

A. BoltB. Left Frame Side Cover


j

A. NormalB. Failed

General LubricationLubricate the points shown below,

with either motor oil or regular grease,in accordance with the Periodic Main-tenance Chart or whenever the vehiclehas been operated under wet or rainyconditions.Before lubricating each part, clean off

any rusty spots with rust remover andwipe off any grease, oil, dirt, or grime.

NOTE○A few drops of oil are effective tokeep bolts and nuts from rusting andsticking. This makes removal easier.Badly rusted nuts, bolts, etc., shouldbe replaced with new ones.


j

Apply engine oil to the followingpivots -○Side Stand○Clutch Lever○Front Brake Lever○Rear Brake PedalLubricate the following cables with apressure cable lubber -○(K) Clutch Inner Cable○(K) Throttle Inner Cables

Apply grease to the following points-○(K) Clutch Inner Cable Upper End○(K) Throttle Inner Cable Upper Ends(K): Should be serviced by an authorized

Kawasaki dealer.

NOTE○After connecting the cables, adjustthem.


j

Cleaning Your MotorcycleGeneral PrecautionsFrequent and proper care of your

Kawasaki motorcycle will enhanceits appearance, optimize overall per-formance, and extend its useful life.Covering your motorcycle with a highquality, breathable motorcycle coverwill help protect its finish from harmfulUV rays, pollutants, and reduce theamount of dust reaching its surfaces.

WARNINGBuild-up of debris or flammablematerial in and around the vehi-cle chassis, engine, and exhaustcan cause mechanical problemsand increase the risk of fire.When operating the vehicle inconditions that allow debris orflammable material to collect inand around the vehicle, inspectthe engine, electrical componentand exhaust areas frequently. Ifdebris or flammable materialshave collected, park the vehi-cle outside and stop the engine.Allow the engine to cool, thenremove any collected debris. Donot park or store the vehicle inan enclosed space prior to in-specting for build-up of debrisor flammable materials.


j

• Be sure the engine and exhaust arecool before washing.• Avoid applying degreaser to seals,brake pads, and tires.• Always use non-abrasive wax andcleaner/polisher.• Avoid all harsh chemicals, solvents,detergents, and household cleaningproducts such as ammonia-basedwindow cleaners.• Gasoline, brake fluid, and coolantwill damage the finish of painted andplastic surfaces: wash them off im-mediately.• Avoid wire brushes, steel wool, andall other abrasive pads or brushes.• Use care when washing the wind-shield, headlight cover, and otherplastic parts as they can easily bescratched.

• Avoid using pressure washers; wa-ter can penetrate seals and electricalcomponents and damage your mo-torcycle.• Avoid spraying water in delicateareas such as in air intakes, fuelsystem, brake components, electri-cal components, muffler outlets, andfuel tank openings.


j

Washing Your Motorcycle• Rinse your bike with cold water froma garden hose to remove any loosedirt.• Mix a mild neutral detergent (de-signed for motorcycles or automo-biles) and water in a bucket. Usea soft cloth or sponge to wash yourmotorcycle. If needed, use a mild de-greaser to remove any oil or greasewhich build up.• After washing, rinse your motorcy-cle thoroughly with clean water to re-move any residue (residue from thedetergent can damage parts of yourmotorcycle).• Use a soft cloth to dry your motorcy-cle. As you dry, inspect your motor-cycle for chips and scratches. Do notlet the water air dry as this can dam-age the painted surfaces.

• Start the engine and let it idle for sev-eral minutes. The heat from the en-gine will help dry moist areas.• Carefully ride your motorcycle at aslow speed and apply the brakesseveral times. This helps the brakesdry and restores its normal operatingperformance.• Lubricate the drive chain to preventrusting.

NOTE○After riding in an area where theroads are salted or near the ocean,immediately wash your motorcyclewith cold water. Do not use warmwater as it accelerates the chemicalreaction of the salt. After drying,apply a corrosion protection sprayon all metal and chrome surfaces toprevent corrosion.

○Condensation may form on the insideof the headlight lens after riding in the


j

rain or washing the motorcycle. Toremove themoisture, start the engineand turn on the headlight. Graduallythe condensation on the inside of thelens will clear off.

Semi-gloss FinishTo clean the semi-gloss finish;• When washing the motorcycle, al-ways use a mild neutral detergentand water.• The semi-gloss finish effect may belost when the finish is excessivelyrubbed.• If any doubt, consult an authorizedKawasaki dealer.

Painted SurfacesAfter washing your motorcycle, coat

painted surfaces, both metal and plas-tic, with a commercially available mo-torcycle/automotive wax. Wax should

be applied once every three months oras conditions require. Avoid surfaceswith “satin” or “flat” finishes. Alwaysuse non-abrasive products and applythem according to the instructions onthe container.

Windshield and Other Plastic PartsAfter washing use a soft cloth to gen-

tly dry plastic parts. When dry, treatthe windshield, headlight lens, andother non-painted plastic parts withan approved plastic cleaner/polisherproduct.


j

NOTICEPlastic parts may deteriorateand break if they come in con-tact with chemical substancesor household cleaning productssuch as gasoline, brake fluid,window cleaners, thread-lockingagents, or other harsh chemi-cals. If a plastic part comes incontact with any harsh chemicalsubstance, wash it off immedi-ately with water and a mild neu-tral detergent, and then inspectfor damage. Avoid using abra-sive pads or brushes to cleanplastic parts, as they will dam-age the part’s finish.

Chrome and AluminumChrome and uncoated aluminum

parts can be treated with a chrome/alu-minum polish. Coated aluminumshould be washed with a mild neu-tral detergent and finished with a spraypolish. Aluminum wheels, both paintedand unpainted can be cleaned withspecial non-acid based wheel spraycleaners.

Leather, Vinyl, and RubberIf your motorcycle has leather ac-

cessories, special care must be taken.Use a leather cleaner/treatment toclean and care for leather accessories.Washing leather parts with detergentand water will damage them, shorten-ing their life.Vinyl parts should be washed with the

rest of the motorcycle, then treated witha vinyl treatment.


j

The sidewalls of tires and other rub-ber components should be treated witha rubber protectant to help prolong theiruseful life.

WARNINGRubber protectants can be slip-pery and, if used on the treadarea, cause loss of traction re-sulting in accident causing in-jury or death. Do not apply rub-ber protectant to any tread area.

164 STORAGE

j

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 theengine oil.

WARNINGEngine oil is a toxic substance. Dispose of used oil properly. Contactyour local authorities for approved disposal methods or possible recy-cling.

• Put in fresh engine oil.• Empty the fuel from the fuel tank by the pump or siphon.

STORAGE 165

j

WARNINGGasoline is extremely flammable and can be explosive under certain con-ditions, creating the potential for serious burns. Turn the ignition key to“OFF”. Do not smoke. Make sure the area is well-ventilated and free fromany source of flame or sparks; this includes any appliance with a pilotlight. Gasoline is a toxic substance. Dispose of gasoline properly. Con-tact 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%.• Set themotorcycle on a box or stand so that both wheels are raised off the ground.(If this cannot be done, put boards under the front and rear wheels to keep damp-ness away from the tire rubber.)• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil onrubber 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 slowcharge (one ampere or less) about once a month. Keep the battery well chargedespecially during cold weather.• Tie plastic bags over the mufflers to prevent moisture from entering.

166 STORAGE

j

• 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.• Install the battery in the motorcycle and charge the battery if necessary.• Fill the fuel tank with fuel.• Check all the points listed in the Daily Safety Checks section.• Lubricate the points listed in the General Lubrication section.

ENVIRONMENTAL PROTECTION 167ENVIRONMENTAL PROTECTION

To help preserve the environment, properly discard used batteries, tires, oils andfluids, or other vehicle components that you might dispose of in the future. Con-sult your authorized Kawasaki dealer or local environmental waste agency for theirproper disposal procedure. This also applies to disposal of the entire vehicle at theend of its life.

168 OWNER SATISFACTION

OWNER SATISFACTION

(For Products Sold in Australia Only)

Your satisfaction is important to your authorized Kawasaki dealer and to KawasakiMotors Pty., Ltd. If you have a problem concerning warranty or service, please takethe 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. TheOWNER of the dealership is an independent business person and is concernedwith your satisfaction and your future business. For this reason the owner is in thebest position to assist you. Also, all warranty and service matters are handled andresolved through the authorized Kawasaki dealer network.

If you are unsatisfied after working with your Kawasaki dealer and feel you stillrequire further assistance, WRITE to the address below. Please be certain to pro-vide themodel, product identification number, mileage or hours of use, accessories,dates that events occurred and what action has been taken by both you and yourdealer. Include the name and address of the dealership. To assist us in resolvingyour inquiry, please include copies of related receipts and any other pertinent infor-mation including the names of the dealership personnel with whom you have beenworking in the resolution of your problem.

OWNER SATISFACTION 169

Upon receipt of your WRITTEN correspondence we will contact the dealership andwork with them in resolving your problem.

In order to provide a permanent record, all warranty and service resolutions takeplace only through WRITTEN correspondence.

Please send your correspondence to:

Customer Relations:Technical Service DepartmentKAWASAKI MOTORS Pty., Ltd.Private Mail Bag 24RYDALMERER N.S.W. 2116A.C.N.: 002 840 315

170 LOCATION OF LABELS

LOCATION OF LABELS

1. Brake Fluid (Front)2. Brake Fluid (Rear)3. Important Drive Chain Information

LOCATION OF LABELS 171

4. Tire and Load Data5. Battery Poison/Danger6. Daily Safety Checks


*7. Fuel Level**8. Stationary Noise Test Information*9. Vacuum Hose Routing Diagram

*: Only on Southeast Asia B1 andThailand models

**: Only on Australian model


(1) (2)


(3)

(4)


(5)


(6)


(7) only on Southeast Asia B1 andThailand models

(8) only on Australian model

(9) only on Southeast Asia B1 andThailand models

general information j quick reference guide€¦ · rear j17m/c × mt4.50 fuel tank capacity 16 l...

Documents