ER-6f

ER-6f ABS

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 Whenever you see the symbols NOTE
shown below, heed their instructions! This note symbol indicates points of
Always follow safe operating and main- particular interest for more efficient
tenance practices. and convenient operation.
WARNING

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NOTICE

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This warning symbol identifies
special instructions or proce- THIS PRODUCT HAS BEEN

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dures which, if not correctly fol- MANUFACTURED FOR USE IN A

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lowed, could result in personal REASONABLE AND PRUDENT
MANNER BY A QUALIFIED OP-

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injury, or loss of life.
ERATOR AND AS A VEHICLE

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ONLY.
CAUTION

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This caution symbol identifies
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special instructions or proce-
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dures which, if not strictly ob-
served, could result in damage
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to or destruction of equipment.
 FOREWORD
Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-
torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety and performance.

Please read this Owner’s Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-

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tures, capabilities, and limitations. This manual offers many safe riding tips, but its
purpose is not to provide instruction in all the techniques and skills required to ride

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a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-

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cle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.

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To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-

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formation on their Kawasaki Motorcycle, a Service Manual is available for purchase

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from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-
tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.
 TABLE OF CONTENTS

SPECIFICATIONS............................... 8 Fuel Tank Cap .................................. 30

LOCATION OF PARTS ....................... 12 Fuel Tank ......................................... 31

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GENERAL INFORMATION ................. 15 Fuel Requirement: ........................ 32
Meter Instruments ............................ 15 Stand................................................ 33

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Speedometer and Tachometer: .... 16 Seat Lock ......................................... 34

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LCD (Clock, Odometer, Trip Helmet Holding Cable ...................... 36

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Meters): ..................................... 17 Tool Kit/U-Shaped lock
Warning/Indicator Lights: .............. 21 Compartment ................................ 37

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Key ................................................... 23 Tying Hooks ..................................... 38

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Ignition Switch/Steering Lock ........... 24 BREAK-IN ........................................... 39
Right Handlebar Switches................ 25 HOW TO RIDE THE MOTORCYCLE . 41

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Engine Stop Switch: ..................... 25 Starting the Engine .......................... 41
Starter Button: .............................. 26 Jump Starting ................................... 43
Left Handlebar Switches .................. Cl 27 Moving Off ........................................ 45
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Dimmer Switch: ............................ 27 Shifting Gears .................................. 46
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Turn Signal Switch:....................... 28 Braking ............................................. 47

Horn Button: ................................. 28 Anti-lock Brake System (ABS) for
Passing Button: ............................ 28 models equipped with ABS........... 49
Hazard Switch: ............................. 28 ABS Indicator Light: ...................... 50
Brake/Clutch Lever Adjusters........... 29 Stopping the Engine......................... 51
 Stopping the Motorcycle in an Engine Vacuum Synchronization ..... 86
Emergency ................................... 52 Idle Speed ........................................ 86
Parking ............................................. 53 Clutch ............................................... 88
Catalytic Converter........................... 54 Drive Chain ...................................... 90
SAFE OPERATION............................. 56 Brakes .............................................. 98
Daily Safety Checks ......................... 56 Brake Light Switches........................ 102
Additional Considerations for High Front Fork......................................... 104

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Speed Operation .......................... 58 Rear Shock Absorbers ..................... 105

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MAINTENANCE AND ADJUSTMENT 60 Wheels ............................................. 107
Periodic Maintenance Chart............. 61 Battery.............................................. 112

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Engine Oil ........................................ 70 Headlight Beam................................ 117

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Cooling System ................................ 75 Rear Turn Signal Light ..................... 119
Spark Plugs...................................... 80 Fuses ............................................... 119

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Kawasaki Clean Air System ............. 82 Cleaning Your Motorcycle ................ 121
Valve Clearance ............................... 83 STORAGE........................................... 126

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Air Cleaner ....................................... 83 ENVIRONMENTAL PROTECTION..... 129

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Throttle Control System ................... 84 LOCATION OF LABELS..................... 130
8 SPECIFICATIONS
SPECIFICATIONS

PERFORMANCE
Maximum Horsepower 53 kW (72 PS) @8 500 r/min (rpm)

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Maximum Torque 66 N·m (6.7 kgf·m, 48.7 ft·lb)

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@7 000 r/min (rpm)

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Minimum Turning Radius 2.7 m (106.3 in.)

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DIMENSIONS

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Overall Length 2 105 mm (82.87 in.)

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Overall Width 760 mm (29.92 in.)

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Overall Height 1 210 mm (47.64 in.)
Wheelbase
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Road Clearance 145 mm (5.71 in.)
Dry Weight (A) 178 kg (392 lb)
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(B) 182 kg (401 lb)

ENGINE
Type DOHC, 4-valve, 2-cylinder, 4-stroke, liquid-cooled
 SPECIFICATIONS 9

Displacement 649 cm 3 (39.6 cu in.)

Bore x Stroke 83 x 60 mm (3.27 x 2.36 in.)
Compression Ratio 11.3 : 1
Starting System Electric starter
Cylinder Numbering Method Left to right, 1-2

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Firing Order 1-2

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Carburetion System Fi (Fuel Injection)
Ignition System Battery and coil (transistorized ignition)

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Ignition Timing 10° BTDC @1 300 r/min (rpm)
(Electronically advanced) 35° BTDC @4 800 r/min (rpm)

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Spark Plugs NGK CR9EIA-9

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Lubrication System Forced lubrication (semi-dry sump)

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Engine Oil Type : API SE, SF or SG
API SH, SJ or SL with JASO MA
SAE 10W-40
Capacity : 2.4 L (2.5 US qt)
Coolant Capacity 1.2 L (1.3 US qt)
10 SPECIFICATIONS

TRANSMISSION
Transmission Type 6-speed, return shift
Clutch Type Wet, multi disc

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Driving System Chain drive

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Primary Reduction Ratio 2.095 (88/42)

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Final Reduction Ratio 3.067 (46/15)

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Overall Drive Ratio 5.473 (Top gear)

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Gear Ratio 1st 2.438 (39/16)

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2nd 1.714 (36/21)
3rd 1.333 (32/24)

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4th 1.111 (30/27)
5th
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0.966 (28/29)
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6th 0.852 (23/27)
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FRAME
Castor 25°
Trail 106 mm (4.2 in.)
Tire Size: Front 120/70ZR17 M/C (58 W) Tubeless
 SPECIFICATIONS 11

Rear 160/60ZR17 M/C (69 W) Tubeless

Rim Size: Front 17 × 3.50
Rear 17 × 4.50
Fuel Tank Capacity 15.5 L (4.1 US gal)
ELECTRICAL EQUIPMENT

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Battery 12 V 10 Ah

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Headlight 12 V 55 W / 55 W (Hi/Lo)
Tail/Brake Light 12 V 5/21 W

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(A): EX650A

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(B): EX650B

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Specifications subject to change without notice, and may not apply to every country.

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12 LOCATION OF PARTS
LOCATION OF PARTS

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1. Clutch Lever 5. Right Handlebar Switches

2. Left Handlebar Switches 6. Front Brake Lever
3. Meter Instruments 7. Throttle Grip
4. Brake Fluid Reservoir (Front) 8. Ignition Switch/Steering Lock
 LOCATION OF PARTS 13

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9. Wheel 16. Seat 22. Brake Disc

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10. Turn Signal Light 17. Tool Kit/Storage 23. Brake Caliper
11. Headlight Compartments 24. Shift Pedal
12. Spark Plugs 18. Helmet Holding Cable 25. Side Stand
13. Air Cleaner 19. Tying Hooks 26. Drive Chain
14. Main Fuse 20. Seat Lock
15. Battery 21. Front Fork
14 LOCATION OF PARTS

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27. License Plate Light
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32. Muffler 37. Rebound Damping
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28. Tail/Brake Light 33. Rear Brake Light Force Adjuster
29. Brake Fluid Reservoir Switch 38. Idle Adjusting Screw
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(Rear) 34. Rear Brake Pedal 39. Coolant Reserve Tank

30. Fuel Tank 35. Oil Level Gauge
31. Fuel Tank Cap 36. Rear Shock Absorber
 GENERAL INFORMATION 15
GENERAL INFORMATION

Meter Instruments
A. Speedometer
B. Left Turn Signal Indicator
Light
C. Tachometer

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D. Red Zone
E. Right Turn Signal Indicator

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Light
F. High Beam Indicator Light

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G. Neutral Indicator Light

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H. Oil Pressure Warning Light
I. RESET Button
J. FI Indicator Light

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K. ABS Indicator Light (model

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with ABS)
L. Fuel Level Warning Light

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M. MODE Button
N. Coolant Temperature
Warning Light
O. LCD Display (Clock, Trip
Meter A/B, Odometer)
16 GENERAL INFORMATION

Speedometer and Tachometer: readings to check their operation. If the

The speedometer shows the speed speedometer and tachometer needles
of the vehicle. do not operate correctly, have them
The tachometer shows the engine inspected by an authorized Kawasaki

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speed in revolutions per minute (r/min, dealer.
rpm). On the right side of the tachome-

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ter face is a portion called the "red CAUTION

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zone". Engine r/min (rpm) in the Engine r/min (rpm) should not

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red zone is above maximum recom- be allowed to enter the red zone;
mended engine speed and is also

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operation in the red zone will
above the range for good performance. overstress the engine and may

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When ignition key is turned to “ON”, cause serious engine damage.
the speedometer and tachometer nee-

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dles momentarily point to their last
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 GENERAL INFORMATION 17

LCD (Clock, Odometer, Trip Meters): NOTE

The speedometer face contains the For safe operation do not press the
LCD (Liquid Crystal Display ). Pushing MODE button while riding.
the MODE button, shifts the display
through the following four modes: Clock -
Clock, Odometer, Trip meter A/B. To adjust the hours and minutes:
When the ignition key is turned to “ON”,
• Turn the ignition key to "ON".

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all the LCD segments are displayed for
three seconds, then the clock or me- • Push the "MODE" button to display

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the clock.
ters, depending on the mode selected,
• Push the "RESET" button for more

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will operate normally on the mode se- than two seconds. Both the hour and
lected.

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minute displays start flashing.

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A. Clock
B. Odometer
C. Trip Meter A
D. Trip Meter B
E. Push MODE Button
18 GENERAL INFORMATION

• Push the "RESET" button.

hour display only flashes.
The
Push
• Push the "RESET" button. Both the
hour and minute displays start flash-
the "MODE" button to advance the ing again.
hours. • Push the "MODE" button. The dis-

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plays stop flashing and the clock
starts working.

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NOTE

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Pushing the “MODE” button momen-

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tarily advances the hour or minute
• Push the "RESET" button. The step by step. Pushing and hold-

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hour display stops flashing and the ing the button advance the hour or
minute display starts flashing. Push minute continuously.

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the "MODE" button to advance the The clock works normally from the
minutes.
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switch is turned off.
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When the battery is disconnected,
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the clock resets to 1:00 and starts

working again when the battery is
connected.
 GENERAL INFORMATION 19

Odometer - Trip Meter -

The odometer shows the total dis- The trip meters show the distance in
tance the vehicle has been ridden. This kilometers traveled since they were last
meter cannot be reset. reset to zero.
TRIP A: 0.0 999.9
TRIP B: 0.0 9999.9
To reset the trip meter:

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• Push the “MODE” button to display
the trip meter A or B.

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• Push the “RESET” button and hold it

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NOTE in.
• After two seconds, the figure display

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The data is maintained even if the
battery is disconnected. turns to 0.0, and then starts counting

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When the figures come to 999999, when the vehicle is operated. The
meter counts until it is next reset.

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they are stopped and locked.

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20 GENERAL INFORMATION

NOTE
The data is maintained by the back
-up power if the ignition key is turned
off.

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When the trip meter is reset while the
vehicle is stopped, it starts counting

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as soon as the vehicle starts moving.

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When the trip meter reaches 999.9

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(TRIP A) or 9999.9 (TRIP B) while

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running, the meters reset to 0.0 and
continues counting.

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

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 GENERAL INFORMATION 21

Warning/Indicator Lights: NOTE

: The fuel level warning light in When pushing the MODE button
the tachometer goes on and “FUEL” while “FUEL” is displayed, the dis-
flashes in the LCD when only 3.5 L play can be shifted to odometer, trip
(0.9 US gal) of fuel remains. Refuel at meter, or clock mode.
the earliest opportunity when the fuel
level warning light goes on and “FUEL” N: When the transmission is in neutral,

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the neutral indicator light is lit.
flashes.

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: When the headlight is on high
beam, the high beam indicator light is

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lit.

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: When the turn signal switch is

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pushed to the left or right, the cor-

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responding turn signal indicator light

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flashes.

A. Fuel Level Warning Light

B. Flash
22 GENERAL INFORMATION

: The oil pressure warning light : The coolant temperature warning

goes on whenever the oil pressure is light in the speedometer goes on when-
dangerously low or the ignition key is ever the coolant temperature rises to
in the ON position with the engine not 115°C (239°F) when the motorcycle is

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running, and goes off when the engine in operation. This warns the operator
oil pressure is high enough. Refer to that the coolant temperature is too high.

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the Maintenance and Adjustment chap- If the warning light goes on, stop the

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ter for more detailed engine oil informa- engine and check the coolant level in

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tion. the reserve tank after the engine cools

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down.
FI: The fuel injection (FI) indicator light
CAUTION

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in the tachometer goes on when the ig-
nition key is turned to “ON” and goes off Do not let the engine continue

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soon after ensuring that its circuit func- running when the warning light
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tions properly. The indicator light also
goes on whenever the troubles occur
flashes. Prolonged engine oper-
ation will result in severe dam-
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in digital fuel injection system (DFI). If age from overheating.
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the indicator light comes on, have the

DFI system checked by an authorized (For models equipped with ABS)
Kawasaki dealer, : The ABS (Anti-lock Brake Sys-
When the indicator light flashes, first tem) indicator light in the tachometer
turn the ignition key to “OFF” and then comes on when the ignition switch is
back to “ON”.
 GENERAL INFORMATION 23

turned on and goes off shortly after the Key

motorcycle starts moving. If the ABS This motorcycle has a combination
is normal, it stays off. If something key, which is used for the ignition
is wrong with the ABS, the indicator switch/steering lock, seat lock, and fuel
comes on and remains lit. When the tank cap.
indicator light is on, the ABS does not Blank keys are available at your
function but if the ABS fails, the con- Kawasaki dealers. Ask your dealer to

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ventional brake system will still work make any additional spare keys you
normally. may need, using your original key as a

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For more detailed information about master.

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

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Motorcycle chapter.

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24 GENERAL INFORMATION

Ignition Switch/Steering Lock Engine off. All electrical

OFF
This is a four-position, key-operated circuits off.
switch. The key can be removed from Engine on. All electrical
the switch when it is in the OFF, LOCK, ON
equipment can be used.

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or P (Park) position.
Steering locked. Engine off.
LOCK

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All electrical circuits off.

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Steering locked. Engine off.
License plate, tail, and city

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P(Park) lights on and turn signals can

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be used. All other electrical
circuits cut off.

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NOTE
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are on whenever the ignition key is
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A. Ignition Switch/Steering Lock in the ON position. One headlight
B. ON position
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C. OFF position goes on when the starter button is

D. LOCK position released after starting the engine. To
E. P (Park) position avoid battery discharge, always start
the engine immediately after turning
the ignition key to “ON”.
 GENERAL INFORMATION 25

If you leave the P (Park) position on Right Handlebar Switches

for a long time (one hour), the battery Engine Stop Switch:
may become totally discharged. In addition to the ignition switch,
the engine stop switch must be in
the position for the motorcycle to
operate.
The engine stop switch is for emer-

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gency use. If some emergency re-

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quires stopping the engine, move the
engine stop switch to the position.

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26 GENERAL INFORMATION

NOTE Starter Button:

Although the engine stop switch The starter button operates the elec-
stops the engine, it does not turn off tric starter when the transmission is in
all the electrical circuits. Ordinarily, neutral.

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the ignition switch should be used to Refer to the Starting the Engine sec-
stop the engine. tion of the "How to Ride the Motorcycle"

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chapter for starting instructions.

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A. Engine Stop Switch

B. Starter Button
 GENERAL INFORMATION 27

Left Handlebar Switches NOTE

Dimmer Switch: When the headlight is on high beam,
High or low beam can be selected both head lights are lit. When the
with the dimmer switch. When the headlight is on low beam, only one
headlight is on high beam ( ), the headlight is lit.
high beam indicator light is lit.
High beam.......( )

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Low beam.......( )

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A. Dimmer Switch
B. Turn Signal Switch
C. Horn Button
D. Passing Button
E. Hazard
28 GENERAL INFORMATION

Turn Signal Switch: hazard lights to warn other drivers of

When the turn signal switch is turned your location.
to the left ( ) or right ( ), the Push in the hazard switch with the
corresponding turn signal flashes on ignition switch in the ON or P (Park)

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and off. position. All the turn signals and turn
To stop flashing, push the switch in. signal indicator lights will flash on and

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off.

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Horn Button:
When the horn button is pushed, the CAUTION

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horn sounds.

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If you leave the switch on for a
Passing Button: long time, the battery may be-

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When the passing button is pushed, come totally discharged. So be
the headlight high beam (passing careful not to use the hazard

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beam) comes on to signal the driver of lights for more than 30 minutes.
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the vehicle ahead that you are about to
pass him. The passing light shuts off
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as soon as the button is released.
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Hazard Switch:
If an emergency requires you to park
on the highway shoulder, turn on the
 GENERAL INFORMATION 29

Brake/Clutch Lever Adjusters The distance from the grip to the re-
There is an adjuster on both the leased lever is minimum at Number 5
brake and clutch levers. Each adjuster and maximum at Number 1.
has 5 positions so that the released
lever position can be adjusted to suit
the operator’s hands. Push the lever
forward and turn the adjuster to align

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the number with the arrow mark on the
lever holder.

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A. Adjuster

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B. Mark

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30 GENERAL INFORMATION

Fuel Tank Cap NOTE

To open the fuel tank cap, pull up the Do not push on the key to close the
key hole cover. Insert the ignition key cap, or the cap cannot be locked.
into the fuel tank cap and turn the key

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to the right.
To close the cap, push it down into

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place with the key inserted. The key

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can be removed by turning it to the left

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to the original position.

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NOTE
The fuel tank cap cannot be closed

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without the key inserted, and the key

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cannot be removed unless the cap is
locked properly.
Cl A. Key Hole Cover
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B. Ignition Key
C. Fuel Tank Cap
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 GENERAL INFORMATION 31

Fuel Tank WARNING

Avoid filling the tank in the rain or
Gasoline is extremely flammable
where heavy dust is blowing so that the
and can be explosive under cer-
fuel does not get contaminated.
tain conditions. Turn the igni-
tion key to “OFF”. Do not smoke.
Make sure the area is well ven-

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tilated and free from any source
of flame or sparks; this includes

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any appliance with a pilot light.
Never fill the tank so the fuel

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level rises into the filler neck. If

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the tank is overfilled, heat may
cause the fuel to expand and

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overflow through the vents in

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A. Tank Cap the tank cap.
After refueling, make sure the

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B. Fuel Tank
C. Top Level fuel tank cap is closed securely.
D. Filler Neck If gasoline is spilled on the fuel
tank, wipe it off immediately.
32 GENERAL INFORMATION

Fuel Requirement: (RON). Always use a gasoline with an

Your Kawasaki engine is designed to octane rating equal to, or higher than,
use only unleaded gasoline. RON 91.
CAUTION NOTE

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If “knocking” or “pinging” occurs, use
Do not use leaded gasoline, as

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a different brand of gasoline or higher
this will destroy the catalytic

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octane rating.
converter. (For further infor-

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mation, refer to the “Catalytic

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Converter” section in the “How
to Ride the Motorcycle” chap-

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ter.)

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Octane Rating
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The octane rating of a gasoline is a
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measure of its resistance to detona-
tion or "knocking." The term commonly
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used to describe a gasoline’s octane

rating is the Research Octane Number
 GENERAL INFORMATION 33

Stand Whenever the side stand is used,

The motorcycle is equipped with a make it a practice to kick the stand fully
side stand. up before sitting on the motorcycle.
NOTE
The motorcycle is equipped with a
side stand switch. This switch is de-

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signed so that the engine does not
start if the transmission is in gear and

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the side stand is down.

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A. Side Stand

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NOTE

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When using the side stand, turn the
handlebar to the left.
34 GENERAL INFORMATION

Seat Lock NOTE

Seat Removal If there is difficulty removing the seat,
Insert the ignition key into the seat be sure to insert the key all the way
lock, located under the rear cowling. and to push down strongly on the

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Turn the key clockwise while pulling rear end of the seat while turning the
key clockwise.

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on the rear end of the seat.

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A. Seat
B. Seat Lock
C. Ignition Key
D. Insert
 GENERAL INFORMATION 35

Seat Installation
Install seats in the reverse order of
• Insert the hook at the rear of the seat
into the lock on the frame.
removal. • Push down the rear part of the seat
• Place the tabs into the matching slot until the lock clicks.
and receptacles. • Pull up the rear end of the seat to
make sure it is securely locked.

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NOTE

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If there is difficulty removing the ig-
nition key from the seat lock, turn it

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lightly counterclockwise while pulling

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it out.

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A. Seat D. Receptacle
B. Slot E. Hook
C. Tab F. Lock
36 GENERAL INFORMATION

Helmet Holding Cable WARNING

Helmets can be secured to the motor-
Do not ride the motorcycle with
cycle using the helmet holding cables
a helmet attached to the cable.
located under the seat.
The helmet could cause an acci-

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dent by distracting the operator

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or interfering with normal vehi-
cle operation.

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A. Helmet Holding Cable Cl
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 GENERAL INFORMATION 37

Tool Kit/U-Shaped lock Install the U-shaped part and lock

Compartment separately and secure them each with
The tool kit is stored under the seat. its strap.
The kit contains tools that can be help-
ful in making roadside repairs, adjust-
ments, and some maintenance proce-
dures explained in this manual.

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Also under the seat, there is a lock
strap which holds a U-Shaped lock.

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A. Tool Kit

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B. Lock Strap
C. U-Shaped Lock

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38 GENERAL INFORMATION

• Fit the lock with the holes. Tying Hooks

When tying up light loads to the seat,
use the tying hooks located on the left
and right sides of the rear fairing.

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A. Lock

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B. Hole

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 BREAK-IN 39
BREAK-IN

The first 1,600 km (1,000 mi) that the motorcycle is ridden is designated as the
break-in period. If the motorcycle is not used carefully during this period, you may
very well end up with a "broken down" instead of a "broken in" motorcycle after a
few thousand kilometers.
The following rules should be observed during the break-in period.
•

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The table shows maximum recommended engine speed during the break-in pe-
riod.

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Distance traveled Maximum engine speed

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0 800 km (0 500 mi) 4 000 r/min (rpm)

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

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• Do not start moving or race the engine immediately after starting it, even if the

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engine is already warm. Run the engine for two or three minutes at idle speed to

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give the oil a chance to work up into all the engine parts.
• Do not race the engine while the transmission is in neutral.
40 BREAK-IN

WARNING
New tires are slippery and may cause loss of control and injury.
A break-in period of 160 km (100 miles) is necessary to establish normal
tire traction. During break-in, avoid sudden and maximum braking and

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acceleration, and hard cornering.

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In addition to the above, at 1 000 km (600 mi) it is extremely important that the

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owner have the initial maintenance service performed by an authorized Kawasaki

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dealer.

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 HOW TO RIDE THE MOTORCYCLE 41
HOW TO RIDE THE MOTORCYCLE

Starting the Engine NOTE

• Check that the engine stop switch is The motorcycle is equipped with a
in the position. vehicle-down sensor, which causes
• Make sure the transmission
Turn the ignition key to “ON”. the engine to stop automatically and
• tral. is in neu- the Fi indicator light to flash when the

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motorcycle falls down. After righting

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the motorcycle, first turn the ignition
key to “OFF” and then back to “ON”

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before starting the engine.

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CAUTION

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Do not operate the starter con-

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tinuously for more than 5 sec-

d
onds, or the starter will overheat
and the battery power will drop
temporarily. Wait 15 seconds
A. Engine Stop Switch D. Ignition Switch between each operation of the
B. Starter Button E. ON position starter to let it cool and the bat-
C. Neutral Indicator Light tery power recover.
42 HOW TO RIDE THE MOTORCYCLE

NOTE CAUTION
The motorcycle is equipped with a Do not let the engine idle longer
starter lockout switch. This switch is than five minutes, or engine
designed so that the engine does not overheating and damage may

rg
start if the transmission is in gear and occur.
the side stand is down. However, the

.o
engine can be started if the clutch

es
lever is pulled and the side stand is

cl
fully up.

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sic
as
Cl
w.
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A. Clutch Lever
B. Starter Lockout Switch
 HOW TO RIDE THE MOTORCYCLE 43

Jump Starting WARNING

If your motorcycle battery is “run
Battery acid generates hydro-
down,” it should be removed and
gen gas which is flammable and
charged. If this is not practical, a 12
explosive under certain con-
volt booster battery and jumper cables
ditions. It is present within a
may be used to start the engine.
battery at all times, even in a

Fr
discharged condition. Keep all
flames and sparks (cigarettes)

ee
away from the battery. Wear eye
protection when working with a

D
battery. In the event of battery

ow
acid contact with skin, eyes, or
clothing, wash the affected ar-

nl
eas immediately with water for at

oa
least five minutes. Seek medical
attention.

d
Connecting Jumper Cables
•Remove the seat.
•Make sure the ignition key is turned
to OFF.
44 HOW TO RIDE THE MOTORCYCLE

• Connect a jumper cable from the

positive (+) terminal of the booster
booster battery to your motorcy-
cle footpeg or other unpainted metal
battery to the positive (+) terminal of surface. Do not use the negative (–)
the motorcycle battery. terminal of the battery.

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WARNING

.o
es
Do not make this last connec-
tion at the fuel system or battery.

cl
Take care that you do not touch

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the positive and negative cables
together, and do not lean over

sic
the battery when making this last

as
connection. Do not jump start a
frozen battery. It could explode.
Cl
A. Motorcycle Battery Positive (+) Terminal
Do not reverse polarity by con-
w.
B. From Booster Battery Positive (+) Terminal necting positive (+) to negative
C. Footpeg (–) or a battery explosion and
ww

D. From Booster Battery Negative (–) serious damage to the electrical

Terminal system may occur.
• Connect another jumper cable from
the negative (–) terminal of the • Follow the standard engine starting
procedure.
 HOW TO RIDE THE MOTORCYCLE 45

CAUTION Moving Off

Do not operate the starter con- • Check that the side stand is up.
tinuously for more than 5 sec- • Shift into 1stclutch
Pull in the lever.
onds or the starter will overheat • Open the throttle a little, and start to
gear.
and the battery power will drop • let out the clutch lever very slowly.
temporarily. Wait 15 seconds
• As the clutch starts to engage, open

Fr
between each operation of the
the throttle a little more, giving the en-
starter to let it cool and the bat-
gine just enough fuel to keep it from

ee
tery power recover.
stalling.

D
• After the engine has started, discon-

ow
nect the jumper cables. Disconnect
the negative (–) cable from the mo-

nl
torcycle first.
•

oa
Reinstall the parts removed.

d
A. Shift Pedal
46 HOW TO RIDE THE MOTORCYCLE

NOTE Shifting Gears

The motorcycle is equipped with a • Close the throttle while pulling in the
clutch lever.
side stand switch. This switch is de-
signed so that the engine does not • Shift into the next higher or lower

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start if the transmission is in gear and gear.
the side stand is down.

.o
When the headlight is on high beam, WARNING

es
two headlight beams are lit, and on
When shifting down to a lower

cl
low beam, one headlight is lit.
gear, do not shift at such a high

Cy
speed that the engine r/min
(rpm) jumps excessively. Not

sic
only can this cause engine dam-

as
age, but the rear wheel may skid
and cause an accident. Down-
Cl shifting should be done below
w.
5,000 r/min (rpm) for each gear.
ww

• Open the throttle part way, while re-

leasing the clutch lever.
 HOW TO RIDE THE MOTORCYCLE 47

NOTE Braking
The transmission is equipped with a • Close the throttle completely, leav-
ing the clutch engaged (except when
positive neutral finder. When the mo-
torcycle is standing still, the transmis- shifting gears) so that the engine will
sion cannot be shifted past neutral help slow down the motorcycle.
from 1st gear. To use the positive • Shift down one gear at a time so that
you are in 1st gear when you come
neutral finder, shift down to 1st gear,

Fr
then lift up on the shift pedal while to a complete stop.
• When stopping, always apply both

ee
standing still. The transmission will
shift only into neutral. brakes at the same time. Normally

D
the front brake should be applied a lit-
tle more than the rear. Shift down or

ow
fully disengage the clutch as neces-

nl
sary to keep the engine from stalling.
• Never lock the brakes, or it will cause

oa
the tires to skid. When turning a cor-

d
ner, it is better not to brake at all. Re-
duce your speed before you get into
the corner.
• For emergency braking, disregard
downshifting, and concentrate on
applying the brakes as hard as pos-
sible without skidding.
48 HOW TO RIDE THE MOTORCYCLE

• Even in motorcycles equipped with

ABS, braking during cornering may
cause wheel slip. When turning a
corner, it is better to limit braking to

rg
the light application of both brakes
or not to brake at all. Reduce your

.o
speed before you get into the corner.

es
cl
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A. Front Brake Lever

sic
as
Cl
w.
ww

A. Rear Brake Pedal

 HOW TO RIDE THE MOTORCYCLE 49

Anti-lock Brake System (ABS) must take the same care as with mo-
for models equipped with torcycles not equipped with ABS.
ABS
ABS is designed to help prevent
• ABS is not designed to shorten the
braking distance. On loose, uneven
the wheels from locking up when or downhill surfaces, the stopping
hard brakes are applied while running distance of a motorcycle with ABS
straight. The ABS automatically regu- may be longer than that of an equiv-

Fr
lates brake force. Intermittently gaining alent motorcycle without ABS. Use
gripping force and braking force helps special caution in such areas.

ee
prevent wheel lock-up and allows sta- • ABS will help prevent wheel lock-up

D
ble steering control while stopping. during straight-up braking, but it can-
Brake control function is identical to not control wheel slip which may be

ow
that of a conventional motorcycle. The caused by braking during cornering.

nl
brake lever is used for the front brake When turning a corner, it is better to
and the brake pedal for the rear brake. limit braking to the light application of

oa
Although the ABS provides stability both brakes or not to brake at all. Re-

d
while stopping by preventing wheel duce your speed before you get into
lock-up, remember the following char- the corner.
acteristics: • The computers integrated in the ABS
• ABS cannot compensate for adverse
road conditions, misjudgement or im-
compare vehicle speed with wheel
speed. Since non-recommended
proper application of brakes. You tires can affect wheel speed, they
50 HOW TO RIDE THE MOTORCYCLE

may confuse the computers, which ABS does not function at the speed
can extend braking distance. of approx. 6 km/h or below.
ABS does not function if the battery
WARNING is discharged.

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Use of non-recommended tires ABS indicator light may come on un-

.o
may cause malfunctioning of der motorcycle riding condition. (ex.
The front or rear wheel races.) In

es
ABS and can lead to extended
braking distance. The rider this case, first turn the ignition key to

cl
could have an accident as a re- “OFF”, and then back to “ON”. ABS

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sult. Always use recommended indicator light goes off by this opera-
standard tires for this motorcy- tion, but if ABS indicator light remains

sic
cle. lit after the motorcycle runs at the
speed of approx. 6 km/h or below,

as
you should have the ABS checked by
NOTE Cl an authorized Kawasaki dealer.
When the ABS is functioning, you
w.
may feel a pulsing in the brake lever ABS Indicator Light:
Normally the ABS indicator light
ww

or pedal. This is normal. You need

comes on when the ignition switch is
not suspend applying brakes.
turned on and goes off shortly after the
Immediately after turning the ignition
switch on, you may hear a click of the motorcycle starts moving.
relay operating. This is the sound of If the indicator light shows any of the
self-checking and is quite normal. following, a fault or faults may have
 HOW TO RIDE THE MOTORCYCLE 51

taken place in the ABS. You should Stopping the Engine

have the ABS checked by an autho- • Close the throttle completely.
rized Kawasaki dealer. • Turn the transmission
Shift the into neutral.
• The light does not come on when the • Support the motorcycle“OFF”.
ignition key to
ignition switch is turned on. • level surface with the sideonstand.
a firm,
• The light remains lit after the motor-
cycle starts moving. • Lock the steering.

Fr
• The light comes on and remains lit
after the motorcycle starts moving. NOTE

ee
Remember that the ABS does not The motorcycle is equipped with a

D
function when the indicator light is on, vehicle-down sensor, which causes

ow
but if the ABS fails, the conventional the engine to stop automatically
brake system still works normally. and the fuel injection indicator light

nl
to flash when the motorcycle falls

oa
down. After righting the motorcycle,
first turn the ignition key to “OFF” and

d
then back to “ON” before starting the
engine.
52 HOW TO RIDE THE MOTORCYCLE

Stopping the Motorcycle in an 2. During removal of the air cleaner,

Emergency dirt is allowed to enter and jam the
Your Kawasaki Motorcycle has been fuel injection system.
designed and manufactured to pro- In an emergency situation such as

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vide you optimum safety and conve- throttle failure, your vehicle may be
nience. However, in order to fully ben-

.o
stopped by applying the brakes and
efit from Kawasaki’s safety engineering disengaging the clutch. Once this

es
and craftsmanship, it is essential that stopping procedure is initiated, the en-

cl
you, the owner and operator, properly gine stop switch may be used to stop
maintain your motorcycle and become

Cy
the engine. If the engine stop switch is
thoroughly familiar with its operation. used, turn off the ignition switch after

sic
Improper maintenance can create a stopping the motorcycle.
dangerous situation known as throt-

as
tle failure. Two of the most common
causes of throttle failure are:
Cl
1. An improperly serviced or clogged
w.
air cleaner may allow dirt and dust
to enter the throttle body and stick
ww

the throttle open.

 HOW TO RIDE THE MOTORCYCLE 53

Parking WARNING
• Shift the transmission into neutral
and turn the ignition key to “OFF”.
The muffler and exhaust pipe
are very hot while the engine is
• Support the motorcycle on a firm,
level surface with the side stand.
running and just after the engine
stop. This can ignite a fire, re-
sulting in property damage or
CAUTION

Fr
severe personal injury.
Do not park on a soft or steeply Do not idle or park your vehi-

ee
inclined surface, or the motorcy- cle in an area where flammable
cle may fall over. materials such as grasses or dry

D
leaves may contact with muffler

ow
• Ifstructure,
parking inside a garage or other
be sure it is well ventilated
or exhaust pipe.

nl
and the motorcycle is not close to
WARNING

oa
any source of flame or sparks; this
includes any appliance with a pilot Gasoline is extremely flammable

d
light. and can be explosive under cer-
tain conditions.

• Lock
theft.
the steering to help prevent
54 HOW TO RIDE THE MOTORCYCLE

NOTE Catalytic Converter

When stopping near traffic at night, This motorcycle is equipped with
you can leave the taillight on for a catalytic converter in the exhaust
greater visibility by turning the igni- system. Platinum and rhodium in the

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tion key to the P (park) position. converter react with carbon monoxide
Do not leave the ignition switch at P and hydrocarbons to convert them into

.o
position too long, or the battery will carbon dioxide and water resulting in

es
discharge. much cleaner exhaust gases to be dis-

cl
charged into the atmosphere.
For proper operation of the catalytic

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converter, the following cautions must

sic
be observed.

as
Cl
w.
ww
 HOW TO RIDE THE MOTORCYCLE 55

WARNING • Do not coast the vehicle with the igni-

tion switch and/or engine stop switch
The muffler and exhaust pipe
off. Do not attempt to start the en-
are very hot while the engine is
gine by rolling the vehicle if the bat-
running and just after the engine
tery is discharged. Do not operate
stop. This can ignite a fire, re-
the vehicle with the engine or any
sulting in property damage or
one cylinder misfiring. Under these

Fr
severe personal injury.
conditions unburned air/fuel mixture
Do not idle or park your vehi-
flowing out of engine excessively ac-

ee
cle in an area where flammable
celerates reaction in the converter al-
materials such as grasses or dry

D
lowing the converter to overheat and
leaves may contact with muffler
become damaged when the engine

ow
or exhaust pipe.
is hot, or reduces converter perfor-

nl
• Use only unleaded gasoline. Never
mance when the engine is cold.

oa
use leaded gasoline. Leaded gaso-
line significantly reduces the capabil-

d
ity of the catalytic converter.
56 SAFE OPERATION
SAFE OPERATION

Daily Safety Checks

Check the following items each day before you ride. The time required is minimal,

rg
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

.o
Adjustment chapter or see your dealer for the action required to return the motor-

es
cycle to a safe operating condition.

cl
WARNING

Cy
Failure to perform these checks every day before you ride may result in

sic
serious damage or a severe accident.

as
Fuel ............................. Adequate supply in tank, no leaks.
Cl
Engine oil .................... Oil level between level lines.
Tires ............................ Air pressure (when cold):
w.
Front Up to 180 kg (397 lb) 225 kPa (2.25 kg/cm², 32 psi)
ww

Load
Rear Up to 180 kg (397 lb) 250 kPa (2.50 kg/cm², 36 psi)
Load
Install the air valve cap.
 SAFE OPERATION 57

Drive chain .................. Slack 30 40 mm (1.2 1.6 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

Fr
in.) left.
No brake fluid leakage.

ee
Throttle ....................... Throttle grip play 2 3 mm (0.08 0.12 in.).

D
Clutch ......................... Clutch lever play 2 3 mm (0.08 0.12 in.).
Clutch lever operates smoothly.

ow
Coolant ....................... No coolant leakage.

nl
Coolant level between level lines (when engine is cold).
Electrical equipment ... All lights (Headlight, Tail/Brake Lights, Turn Signal Lights,

oa
Warning/Indicator Lights) and horn work.

d
Engine stop switch ...... Stops engine.
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 to the tool kit/U-shaped
lock compartment.
58 SAFE OPERATION

Additional Considerations for High Speed Operation

Brakes: The importance of the brakes, especially during high speed operation,
cannot be overemphasized. Check to see that they are correctly adjusted and func-
tioning properly.

rg
Steering: Looseness in the steering can cause loss of control. Check to see that
the handlebar turns freely but has no play.

.o
Tires: High speed operation is hard on tires, and good tires are crucial for riding

es
safety. Examine their overall condition, inflate them to the proper pressure, and

cl
check the wheel balance.
Fuel: Have sufficient fuel for the high fuel consumption during high speed oper-

Cy
ation.

sic
Engine Oil: To avoid engine seizure and resulting loss of control, make sure that
the oil level is at the upper level line.

as
Coolant: To avoid overheating, check that the coolant level is at the upper level
line.
Cl
Electrical Equipment: Make sure that the headlight, tail/brake light, turn signals,
w.
horn, etc., all work properly.
Miscellaneous: Make sure that all nuts and bolts are tight and that all safety
ww

related parts are in good condition.

 SAFE OPERATION 59

WARNING
Handling characteristics of a motorcycle at high speeds may vary from
those you are familiar with at legal highway speeds. Do not attempt high
speed operation unless you have received sufficient training and have the
required skills.

Fr
ee
D
ow
nl
oa
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60 MAINTENANCE AND ADJUSTMENT
MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out
and must be done in accordance with the Periodic Maintenance Chart to keep the

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motorcycle in good running condition. The initial maintenance is vitally impor-
tant and must not be neglected.

.o
With a basic knowledge of mechanics and the proper use of tools, you should be

es
able to carry out many of the maintenance items described in this chapter. If you

cl
lack proper experience or doubt your ability, all adjustments, maintenance, and
repair work should be completed by a qualified technician.

Cy
Please note that Kawasaki cannot assume any responsibility for damage result-

sic
ing from incorrect or improper adjustment done by the owner.

as
Cl
w.
ww
 MAINTENANCE AND ADJUSTMENT 61

Periodic Maintenance Chart

1. Periodic Inspection (Engine Related Items)
Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)

Fr
1 6 12 18 24 30 36
Operation (Engine Item) Every
(0.6) (4) (7.5) (12) (15) (20) (24)

ee
K Air cleaner element - clean • • • 83

D
K Valve clearance - inspect Every 42 000 km (26 000 mile) 83

ow
Throttle control system
(play, smooth return, no year • • • • 84

nl
drag) - inspect

oa
K
Engine vacuum
• • • 86

d
synchronization - inspect
Idle speed - inspect • • • • 86

K
Fuel leak (fuel hose and
pipe) - inspect
year • • • • –
62 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)

rg
1 6 12 18 24 30 36
Operation (Engine Items) Every

.o
(0.6) (4) (7.5) (12) (15) (20) (24)

es
K
Fuel hoses damage -
inspect
year • • • • –

cl
• • • •

Cy
Fuel hoses installation year –
K
condition - inspect

• • • •

sic
Coolant level - inspect 78

• • • •
as
Coolant leak - inspect year 76
Radiator hose damage -
inspect
Cl
year • • • • 76
w.
Radiator hoses installation
• • • •
ww

year 76
condition - inspect

K
Air suction system damage
- inspect • • • 82
 MAINTENANCE AND ADJUSTMENT 63

2. Periodic Inspection (Chassis Related Items)

Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)

1 6 12 18 24 30 36
Operation (Chassis Items) Every

Fr
(0.6) (4) (7.5) (12) (15) (20) (24)
Clutch and drive train:

ee
Clutch operation
• • • •

D
(play, engagement, 88

ow
disengagement) - inspect
Drive chain lubrication

nl
every 600 km (400 mile) 97
condition - inspect #

oa
Drive chain slack - inspect # every 1 000 km (600 mile) 90

• • •

d
Drive chain wear - inspect # 95

K
Drive chain guide wear -
inspect • • • –

Wheels and tires:

Tire air pressure - inspect year • • • 108
64 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)

rg
1 6 12 18 24 30 36
Operation (Chassis Items) Every

.o
(0.6) (4) (7.5) (12) (15) (20) (24)

es
Wheels/tires damage -
inspect • • • 109

cl
• • •

Cy
Tire tread wear, abnormal
109
wear - inspect

sic
K
Wheel bearings damage -
inspect
year • • • –

as
Brake system:
Brake fluid leak - inspect Cl
year • • • • • • • 98
w.
Brake hoses and pipe year • • • • • • • 98
ww

damage - inspect
Brake pad wear - inspect # • • • • • • 98
Brake hose installation
condition - inspect
year • • • • • • • 98
 MAINTENANCE AND ADJUSTMENT 65

Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)

1 6 12 18 24 30 36
Operation (Chassis Items) Every
(0.6) (4) (7.5) (12) (15) (20) (24)

Fr
Brake fluid level - inspect
6
months • • • • • • • 99

ee
Brake operation
(effectiveness, play, drag) - year • • • • • • • 101

D
inspect

ow
Brake light switch operation
• • • • • • • 102

nl
- inspect

oa
Suspensions:
Front forks/rear shock

d
absorber operation
(damping and smooth • • • 104,105

stroke) - inspect
Front forks/rear shock
absorber oil leak - inspect
year • • • 104,105
66 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)

rg
1 6 12 18 24 30 36
Operation (Chassis Items) Every

.o
(0.6) (4) (7.5) (12) (15) (20) (24)

es
Steering System:

• • • •

cl
KSteering play - inspect year –

Cy
K
Steering stem bearings -
lubricate
2
years • –

sic
Electrical System:

as
Lights and switches
operation - inspect
year
Cl • • • –

• • •
w.
Headlight aiming - inspect year 117

• • •
ww

Side stand switch operation year –

- inspect
Engine stop switch operation year
- inspect • • • –
 MAINTENANCE AND ADJUSTMENT 67

Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)

1 6 12 18 24 30 36
Operation (Chassis Items) Every
(0.6) (4) (7.5) (12) (15) (20) (24)

Fr
Chassis:

• • •

ee
KChassis parts - lubricate year –
Bolts and nuts tightness -
• • • •

D
K –
inspect

ow
nl
oa
d
68 MAINTENANCE AND ADJUSTMENT

3. Periodic Replacement
Frequency Whichever See
comes first *Odometer Reading
Page
km × 1000 ( mile × 1000)

rg
1 12 24 36 48

.o
Change/Replacement Item Every
(0.6) (7.5) (15) (24) (30)

es
K Air cleaner element # 2 year 83

cl
Engine oil # year • • • • • 72

Cy
Oil filter year • • • • • 72

sic
K Fuel hoses 4 year • –

as
K Coolant 3 years • 80
K Radiator hoses and O-rings Cl
3 years • –
w.
K Brake hoses and pipe 4 years • –
ww

K Brake fluid (front and rear) 2 years • • 101

K
Rubber parts of master cylinder
and caliper
4 years • –

K Spark plug • • • • 80
 MAINTENANCE AND ADJUSTMENT 69

K: Should be serviced by an authorized Kawasaki dealer.

*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions: dusty, wet, muddy,
high speed, or frequent starting/stopping.

Fr
ee
D
ow
nl
oa
d
70 MAINTENANCE AND ADJUSTMENT

Engine Oil Oil Level Inspection

In order for the engine, transmission,
and clutch to function properly, main-
• If the oil has just been changed, start
the engine and run it for several min-
tain the engine oil at the proper level, utes at idle speed. This fills the oil

rg
and change the oil and replace the oil filter with oil. Stop the engine, then
filter in accordance with the Periodic wait several minutes until the oil set-

.o
Maintenance Chart. Not only do dirt tles.

es
and metal particles collect in the oil, but

cl
the oil itself loses its lubricative quality CAUTION
if used too long.

Cy
Racing the engine before the oil
reaches every part can cause en-

sic
WARNING
gine seizure.
Motorcycle operation with insuf-

as
ficient, deteriorated, or contami-
Cl
nated engine oil will cause accel-
• Ifwaittheseveral
motorcycle has just been used,
minutes for all the oil to
erated wear and may result in en-
w.
drain down.
gine or transmission seizure, ac-
ww

cident, and injury.

 MAINTENANCE AND ADJUSTMENT 71

• Check the engine oil level through

the oil level gauge. With the motor-
• Ifexcess
the oil level is too high, remove the
oil through the oil filler open-
cycle held level, the oil level should ing using a syringe or some other
come up between the upper and suitable device.
lower level lines next to the gauge. • If the oil level is too low, add the oil
to reach the correct level. Use the
same type and brand of oil that is

Fr
already in the engine.

ee
CAUTION

D
If the engine oil gets extremely

ow
low or if the oil pump does not
function properly or oil pas-

nl
sages are clogged, the warning

oa
light in the tachometer will light.

d
A. Oil Level Gauge
B. Upper Level Line
C. Lower Level Line
D. Oil Filler Cap
72 MAINTENANCE AND ADJUSTMENT

CAUTION Oil and/or Oil Filter Change

If this light stays on when the • To change the engine oil and replace
oil filter, the engine oil drain plug
engine speed is slightly above
and oil filter must be removed. The
the idle speed, stop the engine

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oil change and oil filter replacement
immediately and find the cause.
should be done by an authorized

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Kawasaki dealer.

es
cl
Cy
sic
as
Cl
w.
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A. Oil Pressure Warning Light

A. Drain Plug
 MAINTENANCE AND ADJUSTMENT 73

WARNING
Motor oil is a toxic substance.
Dispose of used oil properly.
Contact your local authorities
for approved disposal methods
or possible recycling.

Fr
ee
D
A. Cartridge

ow
nl
oa
d
74 MAINTENANCE AND ADJUSTMENT

Tightening Torque Engine Oil Capacity

Engine Oil Drain Plug : Capacity : 1.7 L (1.8 US qt)
30 N·m (3.0 kgf·m, 22 ft·lb) [when filter is not removed]
Cartridge : 1.9 L (2.0 US qt)

rg
17.5 N·m (1.75 kgf·m, 13 ft·lb) [when filter is removed]

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2.4 L (2.5 US qt)
Recommended Engine Oil

es
[when engine is completely
Type : API SE, SF or SG

cl
dry]
API SH, SJ or SL with

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JASO MA

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Viscosity : SAE 10W-40

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 MAINTENANCE AND ADJUSTMENT 75

Although 10W-40 engine oil is the Cooling System

recommended oil for most condi-
Radiator and Cooling Fan -
tions, the oil viscosity may need to
Check the radiator fins for obstruc-
be changed to accommodate atmo-
tion by insects or mud. Clean off
spheric conditions in your riding area.
any obstructions with a stream of
low-pressure water.

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WARNING

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The cooling fan turns on auto-

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matically, even with the ignition
switch off. Keep your hands

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and clothing away from the fan
blades at all times.

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oa
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76 MAINTENANCE AND ADJUSTMENT

CAUTION Coolant -
Coolant absorbs excessive heat from
Using high-pressure water, as
the engine and transfers it to the air
from a car wash facility, could
at the radiator. If the coolant level be-
damage the radiator fins and im-

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comes low, the engine overheats and
pair the radiator’s effectiveness.
may suffer severe damage. Check the

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Do not obstruct or deflect air-
coolant level each day before riding the
flow through the radiator by

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motorcycle, and in accordance with the
installing unauthorized acces-

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periodic maintenance chart and replen-
sories in front of the radiator or
ish coolant if the level is low. Change

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behind the cooling fan. Inter-
the coolant in accordance with the Pe-
ference with the radiator airflow

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riodic Maintenance Chart.
can lead to overheating and con-
sequent engine damage.

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Information for Coolant
Radiator Hoses - Cl To protect the cooling system (con-
sisting of the aluminum engine and
w.
Check the radiator hoses for leak-
age, cracks or deterioration, and con- radiator) from rust and corrosion, the
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nections for leakage or looseness each use of corrosion and rust inhibitor
day before riding the motorcycle, and chemicals in the coolant is essential. If
coolant containing corrosion and rust
in accordance with the Periodic Main-
inhibitor chemicals is not used, over a
tenance Chart.
 MAINTENANCE AND ADJUSTMENT 77

period of time, the cooling system ac- CAUTION

cumulates rust and scale in the water
If hard water is used in the sys-
jacket and radiator. This will clog up
tem, it causes scale accumula-
the coolant passages, and consider-
tion in the water passages, and
ably reduce the efficiency of the cooling
considerably reduces the effi-
system.
ciency of the cooling system.

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WARNING
If the lowest ambient temperature en-

ee
Use coolant containing corro- countered falls below the freezing point
sion inhibitors made specifically of water, use permanent antifreeze in

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for aluminum engines and ra- the coolant to protect the cooling sys-

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diators in accordance with the tem against engine and radiator freeze
instructions of the manufacturer. -up, as well as from rust and corrosion.

nl
Chemicals are harmful to the hu- Use a permanent type of antifreeze

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man body. (soft water and ethylene glycol plus cor-
rosion and rust inhibitor chemicals for

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Soft or distilled water must be used aluminum engines and radiators) in the
with the antifreeze (see below for an- cooling system. On the mixture ratio
tifreeze) in the cooling system. of coolant, choose the suitable one re-
ferring to the relation between freezing
point and strength directed on the con-
tainer.
78 MAINTENANCE AND ADJUSTMENT

CAUTION • Check the coolant level if it is be-

tween the F (Full) and L (Low) level
Permanent types of antifreeze on
lines.
the market have anti-corrosion
and anti-rust properties. When it NOTE

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is diluted excessively, it loses its
Check the level when the engine is

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anti-corrosion property. Dilute a
permanent type of antifreeze in cold (room or atmospheric tempera-

es
accordance with the instructions ture).

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of the manufacturer.

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NOTE

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A permanent type of antifreeze is in-

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stalled in the cooling system when
Cl
shipped. It is colored green and con-
tains ethylene glycol. It is mixed at
w.
50% and has the freezing point of
ww

–35°C (–31°F).

Coolant Level Inspection

•
A. F (Full) Level Line
Situate the motorcycle so that it is B. L (Low) Level Line
perpendicular to the ground. C. Right Side Cover
 MAINTENANCE AND ADJUSTMENT 79

• Ifcient,
the amount of coolant is insuffi-
remove the right side cover
• Remove the cap from the reserve
tank and add coolant through the
and add coolant into the reserve filler opening to the F(Full) level line.
tank.

Coolant Filling
•Remove the upper right inner cowl by

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removing the bolt.

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A. Cap
B. Reserve Tank

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• Install the cap.
• tighten theupper
Install the
bolt.
right inner cowl and
A. Upper Right Inner Cowl
B. Bolt
80 MAINTENANCE AND ADJUSTMENT

NOTE Spark Plugs

In an emergency you can add wa- The standard spark plug is shown in
ter alone to the coolant reserve tank, the table. The spark plugs should be
however it must be returned to the replaced in accordance with the Peri-

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correct mixture ratio by the addition odic Maintenance Chart.
of antifreeze concentrate as soon as Spark plug removal should be done

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possible. by an authorized Kawasaki dealer.

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CAUTION

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If coolant must be added of-

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ten, or the reserve tank com-
pletely runs dry, there is proba-

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bly leakage in the system. Have
the cooling system inspected
by your authorized Kawasaki
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dealer.
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Coolant Change
Have the coolant changed by an au-
thorized Kawasaki dealer.
 MAINTENANCE AND ADJUSTMENT 81

Spark Plug
Standard Plug NGK CR9EIA-9
0.8 0.9 mm
Plug Gap
(0.032 0.035 in.)
Tightening 15 N·m
Torque (1.5 kgf·m, 11 ft·lb)

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A. Plug Gap

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82 MAINTENANCE AND ADJUSTMENT

Kawasaki Clean Air System the air suction valve is prevented from
The Kawasaki Clean Air System returning. Inspect the air suction valves
(KCA) is a secondary air suction sys- in accordance with the Periodic Main-
tem that helps the exhaust gases to tenance Chart. Also, inspect the air

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burn more completely. When the spent suction valves whenever stable idling
fuel charge is released into the ex- cannot be obtained, engine power is

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haust system, it is still hot enough to greatly reduced, or there are abnormal

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burn. The KCA System allows extra engine noises.

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air into the exhaust system so that the Air suction valve removal and inspec-
spent fuel charge can continue to burn. tion should be done by an authorized

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This continued burning action tends to Kawasaki dealer.

sic
burn up a great deal of the normally
unburned gases, as well as chang-

as
ing a significant portion of the carbon
monoxide into carbon dioxide.
Air Suction Valves -
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The air suction valve is essentially a
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check valve which allows fresh air to

flow only from the air cleaner into the
exhaust port. Any air that has passed
 MAINTENANCE AND ADJUSTMENT 83

Valve Clearance Air Cleaner

Valve and valve seat wear decreases A clogged air cleaner restricts the en-
valve clearance, upsetting valve timing. gine’s air intake, increasing fuel con-
sumption, reducing engine power, and
CAUTION causing spark plug fouling.
If valve clearance is left un- The air cleaner element and oil drain
adjusted, wear will eventually must be cleaned in accordance with

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cause the valves to remain the Periodic Maintenance Chart by
an authorized Kawasaki dealer. In

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partly open, which lowers per-
formance, burns the valves and dusty, rainy, or muddy conditions, the

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valve seats, and may cause seri- air cleaner element should be ser-
viced more frequently than the recom-

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ous engine damage.
mended interval.

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Valve clearance for each valve

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should be checked and adjusted in
accordance with the Periodic Mainte-

d
nance Chart.
Inspection and adjustment should
be done by an authorized Kawasaki
dealer.
84 MAINTENANCE AND ADJUSTMENT

Throttle Control System Inspection

Check the throttle grip play in accor-
dance with the Periodic Maintenance
• Check that the throttle grip play is
correct by lightly turning the throttle
Chart, and adjust it if necessary. grip back and forth.

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Throttle Grip -
The throttle grip controls the butterfly

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valves in the throttle body. If the throt-

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tle grip has excessive play due to either

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cable stretch or maladjustment, it will
cause a delay in throttle response, es-

sic
pecially at low engine speed. Also, the
throttle valve may not open fully at full

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throttle. On the other hand, if the throt-
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tle grip has not play, the throttle will be
hard to control, and the idle speed will A. Throttle Grip
w.
B. Throttle Grip Play
be erratic.
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Throttle Grip Play

2 3 mm (0.08 0.12 in.)

• If there is improper play, adjust it.

 MAINTENANCE AND ADJUSTMENT 85

Adjustment • Ifhavethereit inspected

is still not enough play,
•Loosen the locknut at the upper end
of the throttle cable and turn the throt- Kawasaki dealer.
by an authorized

tle cable adjusting nut in completely

so as to give the throttle grip plenty WARNING
of play.
Operation with an improperly

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adjusted, incorrectly routed, or
damaged cables could result in

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an unsafe riding condition.

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A. Locknut
B. Adjuster
C. Throttle Cable (Accelerator Cable)
86 MAINTENANCE AND ADJUSTMENT

Engine Vacuum Synchronization Idle Speed

Engine vacuum synchronization The idle speed check should be per-
must be checked and adjusted period- formed in accordance with the Peri-
ically in accordance with the Periodic odic Maintenance Chart or whenever

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Maintenance Chart by an authorized the idle speed is disturbed.
Kawasaki dealer.

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NOTE

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Poor engine vacuum synchronization

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will cause unstable idling, sluggish

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throttle response, and reduce engine
power and performance.

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 MAINTENANCE AND ADJUSTMENT 87

Adjustment • Open and close the throttle a few

•Start the engine, and warm it up thor-
oughly.
times to make sure that the idle
speed does not change. Readjust if
•Adjust the idle speed by turning the necessary.
idle adjusting screw. • With the engine idling, turn the han-
dlebar to each side. If handlebar
Idle Speed
movement changes the idle speed,

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1 250 1 350 r/min (rpm)
the throttle cables may be improperly
adjusted or incorrectly routed, or they

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may be damaged. Be sure to correct

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any of these conditions before riding.

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WARNING

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Operation with damaged cables

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could result in an unsafe riding
condition.

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A. Idle Adjusting Screw
88 MAINTENANCE AND ADJUSTMENT

Clutch Clutch Lever Play

Due to friction plate wear and clutch 2 3 mm (0.08 0.12 in.)
cable stretch over a long period of use,
the clutch operation should be checked

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each day before riding the motorcycle,
and in accordance with the Periodic

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Maintenance Chart.

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WARNING

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To avoid a serious burn, never
touch a hot engine or an exhaust

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pipe during clutch adjustment.

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Inspection A. Locknut
• Cl
Check that the clutch lever operates B. Clutch Lever Play
w.
properly and that the inner cable C. Adjuster
slides smoothly. If there is any irreg- If the play is incorrect, adjust the lever
ww

ularity, have the clutch cable checked play as follows.

by an authorized Kawasaki dealer.
• Check the clutch lever play as shown
in the figure.
 MAINTENANCE AND ADJUSTMENT 89

Adjustment • Ifhavethereit inspected

is still not enough play,
•Loosen the locknut, and turn the
adjuster so that the clutch lever will Kawasaki dealer.
by an authorized

have the proper play.

NOTE
WARNING After the adjustment is made, start
the engine and check that the clutch

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Be sure the upper end of the does not slip and that it releases
clutch outer cable is fully seated

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properly.
in its fitting, or it could slip into For minor corrections, use the ad-
place later, creating enough ca-

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juster at the clutch lever.
ble play to prevent clutch dis-

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engagement, resulting in a haz-
ardous riding condition.

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90 MAINTENANCE AND ADJUSTMENT

Drive Chain Chain Slack Inspection

The drive chain slack and lubrica-
tion must be checked each day be-
•Set the motorcycle up on its side
stand.
fore riding the motorcycle, and in accor- •Rotate the rear wheel to find the po-

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dance with the Periodic Maintenance sition where the chain is tightest, and
Chart for safety and to prevent exces- measure the maximum chain slack

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sive wear. If the chain becomes badly by pulling up and pushing down the

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worn or maladjusted - either too loose chain midway between the engine

cl
or too tight - the chain could jump off sprocket and rear wheel sprocket.
the sprockets or break.

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WARNING
A chain that breaks or jumps off

as
the sprockets could snag on the
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engine sprocket or lock the rear
wheel, severely damaging the
w.
motorcycle and causing it to go
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out of control.

A. Chain Slack
 MAINTENANCE AND ADJUSTMENT 91

• Ifloose,
the drive chain is too tight or too Adjustment
adjust it so that the chain slack
will be within the standard value.
•Loosen the left and right chain ad-
juster locknuts.
Drive Chain Slack •Remove the cotter pin, and loosen
the rear axle nut.
30 40 mm
Standard
(1.2 1.6 in.)

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A. Axle Nut
B. Cotter Pin
C. Adjusting Nut
D. Locknut

• Ifandtheright
chain is too loose, turn in the left
chain adjusting nuts evenly.
92 MAINTENANCE AND ADJUSTMENT

• Iflefttheandchainrightis too tight, turn out the

chain adjusting nuts
• To keep the chain and wheel properly
aligned, the value on the left wheel
evenly. alignment indicator should align with
• Turn both chain adjusting nuts evenly the same (left or right) edge of in-

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until the drive chain has the correct spection window on the swingarm
that the right indicator value aligns

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amount of slack.
with.

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A. Value
B. Inspection Window
C. Adjuster
D. Locknut
 MAINTENANCE AND ADJUSTMENT 93

NOTE NOTE
Wheel alignment can also be If a torque wrench is not available,
checked using the straightedge or this item should be serviced by a
string method. Kawasaki dealer.

WARNING
• Rotate the wheel, measure the chain
slack again at the tightest position,

Fr
Misalignment of the wheel will and readjust if necessary.
• Install a new cotter pin through the

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result in abnormal wear, and may
result in an unsafe riding condi- rear axle nut and axle, and spread its
ends.

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tion.

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• Tighten both chain adjuster locknuts.
• ified torque.

nl
Tighten the rear axle nut to the spec-

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Tightening Torque

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Axle Nut:
108 N·m (11 kgf·m, 80ft·lb)

A. Cotter Pin
94 MAINTENANCE AND ADJUSTMENT

NOTE WARNING
When inserting the cotter pin, if the If the axle nut is not securely
slots in the nut do not align with tightened or the cotter pin is not
the cotter pin hole in the axle shaft, installed, an unsafe riding condi-

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tighten the nut clockwise up to the tion may result.
next alignment.

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It should be within 30 degree.
• Check the rear brake (see the Brakes

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Loosen once and tighten again when section).

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the slot goes past the nearest hole.

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A. Turning Clockwise
 MAINTENANCE AND ADJUSTMENT 95

Wear Inspection the 21st pin. Since the chain may

•Remove the bolts to take off the chain
guide.
wear unevenly, take measurements
at several places.
• If the length exceeds the service limit,
the chain should be replaced.

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ee
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A. Chain Guide
B. Bolts

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• Stretch the chain taut either by using
the chain adjusters, or by hanging a
A. Measure
B. Weight

10 kg (20 lb) weight on the chain.

• Measure the length of 20 links on
the straight part of the chain from pin
Drive Chain 20–Link Length
Service Limit
center of the 1st pin to pin center of 323 mm (12.7 in.)
96 MAINTENANCE AND ADJUSTMENT

WARNING NOTE
For safety, use only the standard Sprocket wear is exaggerated for il-
chain. It is an endless type and lustration. See Service Manual for
should not be cut for installa- wear limits.

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tion; have it installed by an au-

.o
thorized Kawasaki dealer.

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• Rotate the rear wheel to inspect the

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drive chain for damaged rollers, and

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loose pins and links.
• Also inspect the sprockets for un-

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evenly or excessively worn teeth,
and damaged teeth.

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A. Good Teeth
B. Worn Teeth
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C. Damaged Teeth

• Ifdrive
there is any irregularity, have the
chain and/or the sprockets re-
placed by an authorized Kawasaki
dealer.
 MAINTENANCE AND ADJUSTMENT 97

Lubrication
Lubrication is also necessary after
• Apply oil to the sides of the rollers so
that it will penetrate to the rollers and
riding through rain or on wet roads, or bushings. Apply oil to the O-rings so
any time that the chain appears dry. A that the O-rings will be coated with
heavy oil such as SAE 90 is preferred oil. Wipe off any excess oil.
to a lighter oil because it will stay on the
chain longer and provide better lubrica-

Fr
tion.

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• Ifusing
the chain is especially dirty, clean it
diesel oil or kerosine and then
apply oil as mentioned above.
98 MAINTENANCE AND ADJUSTMENT

Brakes Disc Brake Fluid -

In accordance with the Periodic Main-
Brake Wear Inspection
tenance Chart, inspect the brake fluid
Inspect the brakes for wear. For each
level in both the front and rear brake
front and rear disc brake caliper, if the

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fluid reservoirs and change the brake
thickness of either pad is less than
fluid. The brake fluid should also be

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1 mm (0.04 in.), replace both pads
changed if it becomes contaminated
in the caliper as a set. Pad replace-

es
with dirt or water.
ment should be done by an authorized

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Kawasaki dealer. Fluid Requirement

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Use heavy-duty brake fluid only from
a container marked DOT4.

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CAUTION

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Do not spill brake fluid onto any
Cl painted surface.
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Do not use fluid from a container
that has been left open or that
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has been unsealed for a long

time.
A. Lining Thickness
Check for fluid leakage around
B. 1 mm (0.04 in.) the fittings.
Check brake hose for damage.
 MAINTENANCE AND ADJUSTMENT 99

Fluid Level Inspection

• The brake fluid level in the front brake
fluid reservoir must be kept above
the line (lower level line) next to the
gauge and that in the rear brake
fluid reservoir (located near the rear
fender) must be kept between the

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upper and lower level lines (reser-
voirs held horizontal).

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A. Rear Brake Fluid Reservoir

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B. Upper Level Line
C. Lower Level Line

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A. Front Brake Fluid Reservoir
B. Lower Level Line
100 MAINTENANCE AND ADJUSTMENT

• Iflower
the fluid level in either reservoir is
than the lower level line, check
WARNING
Do not mix two brands of brake
for fluid leaks in the brake lines, and
fluid. Change the brake fluid in
fill the reservoir to the upper level
the brake line completely if the

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line. Inside the front brake fluid reser-
brake fluid must be refilled but
voir is a stepped line showing the up-

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the type and brand of the brake
per level line.
fluid that is already in the reser-

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voir are unidentified.

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A. Front Brake Fluid Reservoir

B. Upper Level Line
 MAINTENANCE AND ADJUSTMENT 101

NOTE Fluid Change

First, tighten until slight resistance is Have the brake fluid changed by an
felt indicating that the cap is seated authorized Kawasaki dealer.
on the reservoir body; then, tighten
the cap an additional 1/6 turn while Front and Rear Brakes -
holding the brake fluid reservoir Disc and disc pad wear is automat-
body.

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ically compensated for and has no ef-
fect on the brake lever or pedal action.

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So there are no parts that require ad-
justment on the front brakes and rear

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brakes.

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WARNING

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If the brake lever or pedal feels

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mushy when it is applied, there
might be air in the brake lines

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or the brake may be defective.
Since it is dangerous to operate
A. Reservoir the motorcycle under such con-
B. Cap ditions, have the brake checked
C. Clockwise
D. 1/6 turn immediately by an authorized
Kawasaki dealer.
102 MAINTENANCE AND ADJUSTMENT

Brake Light Switches

When either the front or rear brake is
• Check the operation of the rear brake
light switch by depressing the brake
applied, the brake light goes on. The pedal. The brake light should go on
front brake light switch requires no ad- after the proper pedal travel.

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justment, but the rear brake light switch
should be adjusted in accordance with

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the Periodic Maintenance Chart.

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Inspection

cl
• Turn the ignition key to “ON”.

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• The brake light should go on when
the front brake is applied.

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• If it does not, ask your authorized
Kawasaki dealer to inspect the front

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brake light switch.
Cl A. Brake Pedal
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B. Pedal Travel

• Iflightit does
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not, adjust the rear brake

switch.
Brake Pedal Travel
10 mm (0.4 in.)
 MAINTENANCE AND ADJUSTMENT 103

Adjustment • To adjust the rear brake light switch,

•Disconnect the connector. move the switch up or down by turn-
ing the switch body.

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A. Connector

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A. Rear Brake Light Switch
B. Adjusting Nut

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C. Lights sooner
D. Lights later

• Connect the connector.

104 MAINTENANCE AND ADJUSTMENT

Front Fork
The front fork operation and oil leak-
• Ifshould
any doubt about the front fork, it
be done by an authorized
age should be checked in accordance Kawasaki dealer.
with the Periodic Maintenance Chart.

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Front Fork Inspection
•

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Holding the brake lever, pump the
front fork up and down by several

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times for inspection of smooth stroke.

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• Visually inspect the front fork for oil

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leakage, scoring or scratches on the
outer surface of the inner tube.

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Cl A. Inner Tube
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 MAINTENANCE AND ADJUSTMENT 105

Rear Shock Absorbers

The rear shock absorber operation
• Ifsorber,
any doubt about the rear shock ab-
it should be done by an au-
and oil leakage should be checked in thorized Kawasaki dealer.
accordance with the Periodic Mainte-
nance Chart.

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Rear Shock Absorber Inspection
•Press down on the seat several times

ee
to check if the rear shock absorber
stroke is smooth.

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•Visually inspect the rear shock ab-

ow
sorber for oil leakage.

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A. Rear Shock Absorber

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The rear shock absorber can be ad-

d
justed by changing the spring preload
and rebound damping force for various
riding and loading conditions.
106 MAINTENANCE AND ADJUSTMENT

Spring Preload Adjustment Position 1 2 3 4 5 6 7

The spring preload adjuster on the Spring Action Stronger ——
rear shock absorber has 7 positions.
The standard setting position for an

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average-build rider of 75 kg (165 lb)

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with no passenger and no accessories
is No. 3.

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WARNING

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This unit contains high pressure
nitrogen gas. Mishandling can

sic
cause explosion.
Read Service Manual for instruc-

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A. Spring Preload Adjuster tions.
B. Wrench Cl Do not incinerate, puncture or
w.
open.
• Inble,accordance with the following ta-
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turn the preload adjuster with the

wrench from the tool kit.
 MAINTENANCE AND ADJUSTMENT 107

Wheels
Tubeless tires are installed on the
wheels of this motorcycle. The indica-
tions of TUBELESS on the tire side wall
and the rim show that the tire and rim
are specially designed for tubeless use.

Fr
ee
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A. TUBELESS Mark

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The tire and rim form a leakproof unit
by making airtight contacts at the tire

nl
chamfers and the rim flanges instead

oa
of using an inner tube.

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A. TUBELESS Mark
108 MAINTENANCE AND ADJUSTMENT

WARNING Tires -
The tires, rims, and air valves Payload and Tire Pressure
on this motorcycle are designed Failure to maintain proper inflation
only for tubeless type wheels. pressures or observe payload limits for

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The recommended standard your tires may adversely affect han-

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tires, rims, and air valves must dling and performance of your motorcy-
be used for replacement. cle and can result in loss of control. The

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Do not install tube-type tires on maximum recommended load in addi-

cl
tubeless rims. The beads may tion to vehicle weight is 180 kg (397 lb),

Cy
not seat properly on the rim including rider, passenger, baggage,
causing tire deflation. and accessories.

sic
Do not install a tube inside a • Remove the air valve cap.
tubeless tire. Excessive heat • Check the tire pressure often, using

as
build-up may damage the tube an accurate gauge.
causing tire deflation. Cl • Make sure to install the air valve cap
securely.
w.
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NOTE
Measure the tire pressure when the
tires are cold (that is, when the mo-
torcycle has not been ridden more
than a mile during the past 3 hours).
 MAINTENANCE AND ADJUSTMENT 109

Tire pressure is affected by changes Tire Wear, Damage

in ambient temperature and altitude, As the tire tread wears down, the tire
and so the tire pressure should be becomes more susceptible to puncture
checked and adjusted when your rid- and failure. An accepted estimate is
ing involves wide variations in tem- that 90% of all tire failures occur during
perature or altitude. the last 10% of tread life (90 % worn).
So it is false economy and unsafe to

Fr
use the tires until they are bald.
• In accordance with the Periodic

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Maintenance Chart, measure the

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depth of the tread with a depth
gauge, and replace any tire that

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has worn down to the minimum al-

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lowable tread depth.

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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)
110 MAINTENANCE AND ADJUSTMENT

Minimum Tread Depth • Visually inspect the tire for cracks

and cuts, replacing the tire in case of
1 mm
Front bad damage. Swelling or high spots
(0.04 in.)
indicate internal damage, requiring

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Under 130 km/h 2 mm tire replacement.
(80 mph) (0.08 in.)
• Remove any imbedded stones or

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Rear
Over 130 km/h 3 mm other foreign particles from the tread.

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(80 mph) (0.12 in.)
NOTE

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Most countries may have their own

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regulations requiring a minimum tire
tread depth; be sure to follow them.

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Have the wheel balance inspected

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whenever a new tire is installed.

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A. Tire Depth Gauge

 MAINTENANCE AND ADJUSTMENT 111

WARNING Standard Tire (Tubeless)

To ensure safe handling and Size: 120/70ZR17 M/C (58W)
stability, use only the recom- Front BRIDGESTONE
“BT020F RADIAL GG”
mended standard tires for re-
placement, inflated to the stan- Size: 160/60ZR17 M/C (69W)
dard pressure. Rear BRIDGESTONE
“BT020R RADIAL”

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Tires that have been punctured
and repaired do not have the

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same capabilities as undam- WARNING
aged tires. Do not exceed 100

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km/h (60 mph) within 24 hours Use the same manufacturer’s

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after repair, and 180 km/h (110 tires on both front and rear
mph) at any time after that. wheels.

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NOTE

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When operating on public roadways,
keep maximum speed under traffic
law limits.
112 MAINTENANCE AND ADJUSTMENT

WARNING Battery
The battery installed in this motorcy-
New tires are slippery and may
cle is a sealed type, so it is not nec-
cause loss of control and injury.
essary to check the battery electrolyte
A break-in period of 160 km (100

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level or add distilled water.
miles) is necessary to estab-
The sealing strip should not be pulled

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lish normal tire traction. During
off once the specified electrolyte has
break-in, avoid sudden and max-

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been installed in the battery for initial
imum braking and acceleration,

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service.
and hard cornering.
However, in order to maximize bat-

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tery life and ensure that it will provide

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the power needed to start the motor-
cycle you must properly maintain the

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battery’s charge. When used regularly,
the charging system in the motorcycle
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your motorcycle is only used occasion-
ally or for short periods of time, the bat-
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tery is more likely to discharge.

Due to their internal composition,
batteries continually self discharge.
The discharge rate depends on the
 MAINTENANCE AND ADJUSTMENT 113

type of battery and ambient temper- Self-discharge

ature. As temperatures rise, so does Approx. Number of Days
the discharge rate. Every 15°C (27°F) From 100% Charged to
doubles the rate. 100% discharged
Electrical accessories, such as digi- Temperature
Lead Lead
tal clocks and computer memory, also
-Antimony -Calcium
draw current from the battery even

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when the key is switched off. Combine Battery Battery
such “key-off” draws with hot temper-

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40°C
ature, and a battery can go from fully 100 Days 300 Days
(104°F)

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charged to completely discharged in a
25°C (77°F) 200 Days 600 Days
matter of days.

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0°C (32°F) 550 Days 950 Days

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114 MAINTENANCE AND ADJUSTMENT

Current Drain Sulfation occurs when the battery is

Days form Days form
left in a discharged condition for an ex-
100% 100% tended time. Sulfate is a normal by
Discharging product of the chemical reactions within
charged to charged to
Ampere

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50% 100% a battery. But when continuous dis-
Discharged Discharged charge allows the sulfate to crystallize

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7 mA 60 Days 119 Days in the cells, the battery plates become

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permanently damaged and will not hold
10 mA 42 Days 83 Days

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a charge. Battery failure due to sulfa-
tion is not warrantable.

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15 mA 28 Days 56 Days
20 mA 21 Days 42 Days Battery Maintenance

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30 mA 14 Days 28 Days It is the owner’s responsibility to keep
the battery fully charged. Failure to do

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In extremely cold weather the fluid in so can lead to battery failure and leave
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an inadequately charged battery can you stranded.
If you are riding your vehicle infre-
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easily freeze, which can crack the case
and buckle the plates. A fully charged quently, inspect the battery voltage
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battery can withstand sub-freezing weekly using a voltmeter. If it drops

temperatures with no damage. below 12.8 volts, the battery should be
charged using an appropriate charger
Battery Sulfation (check with your Kawasaki dealer).
A common cause of battery failure is
sulfation.
 MAINTENANCE AND ADJUSTMENT 115

If you will not be using the motorcy- is 1/10th of the battery capacity. For
cle for longer than two weeks, the example, the charging rate for a 10
battery should be charged using an Ah battery would be 1.0 ampere.
appropriate charger. Do not use an au-
tomotive-type quick charger that may
• The charger will keep the battery fully
charged until you are ready to re-
overcharge the battery and damage it. install the battery in the motorcycle
(see Battery Installation).

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Kawasaki-recommended chargers
are:
CAUTION

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OptiMate
Yuasa 1.5 Amp Automatic charger Never remove the sealing strip,

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Battery Mate 150-9 or the battery can be damaged.

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If the above chargers are not avail- Do not install a conventional
able, use equivalent one. battery in this motorcycle, or the

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For more details, ask your Kawasaki electrical system cannot work

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dealer. properly.

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Battery Charging
•Remove the battery from the motor-
cycle (see Battery Removal).
NOTE
If you charge the sealed battery,
•Attach the leads from the charger
and charge the battery at a rate that
never fail to observe the instructions
shown in the label on the battery.
116 MAINTENANCE AND ADJUSTMENT

Battery Removal Battery Installation

•Remove the seat. •Place the battery in the battery case.
•Connect the capped wire to the (+)
terminal, and then connect the black

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wire to the (–) terminal.

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NOTE

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Install the battery in the reverse order

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of the Battery Removal.

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CAUTION

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Installing the (–) cable to the (+)

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A. (+) Terminal terminal of the battery or the (+)
B. (–) Terminal cable to the (–) terminal of the
• Disconnect
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the wires from the bat- battery can seriously damage
w.
tery, first from the (–) terminal and the electrical system.
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then the (+) terminal.

• Take the battery out of the case. • Put a light coat of grease on the ter-

• Clean the battery using a solution of

baking soda and water. Be sure that
minals to prevent corrosion.
• Cover the (+) terminal with its protec-
tive cap.
the wire connections are clean.
• Reinstall the parts removed .
 MAINTENANCE AND ADJUSTMENT 117

Headlight Beam Vertical Adjustment

The headlight beam is adjustable ver-
Horizontal Adjustment
tically. If adjusted too low, neither low
The headlight beam is adjustable
nor high beam will illuminate the road
horizontally. If not properly adjusted
far enough ahead. If adjusted too high,
horizontally, the beam will point to one
the high beam will fail to illuminate the
side rather than straight ahead.
road close ahead, and the low beam
•

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Turn the horizontal adjuster clock-
will blind oncoming drivers.
wise or counterclockwise until the
• Remove the upper left inner cowl by

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beam points straight ahead.
removing the bolts

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A. Horizontal Adjuster
B. View From Back Side d
A. Upper left inner cowl
B. Bolts
118 MAINTENANCE AND ADJUSTMENT

• Turn the vertical adjuster clockwise

or counterclockwise to adjust its ver-
NOTE
On high beam, the brightest point
tical angle. should be slightly below horizontal
with the motorcycle on its wheels and

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the rider seated. Adjust the headlight
to the proper angle according to local

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regulations.

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A. Vertical Adjuster
B. View From Back Side
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 MAINTENANCE AND ADJUSTMENT 119

Rear Turn Signal Light Fuses

To replace the bulb of the rear turn Fuses are arranged in the fuse box
signal light, remove the screw and located under the seat. The main fuse
lightly twist the lens counterclockwise. is mounted on the starter relay behind
the right side cover. If a fuse fails dur-
ing operation, inspect the electrical sys-
tem to determine the cause, and then

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replace it with a new fuse of proper am-
perage.

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A. Lens

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B. Counterclockwise
C. Screw

A. Fuse Box C. Spare Parts

B. Fuses
120 MAINTENANCE AND ADJUSTMENT

• Remove the left side cover by remov-

ing the bolt.

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A. Main Fuse

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A. Left Side Cover
B. Bolt
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 MAINTENANCE AND ADJUSTMENT 121

WARNING Cleaning Your Motorcycle

Do not use any substitute for the General Precautions
standard fuse. Frequent and proper care of your
Replace the blown fuse with a Kawasaki motorcycle will enhance
new one of the correct capacity, its appearance, optimize overall per-
as specified on the junction box formance, and extend its useful life.

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and main fuse. Covering your motorcycle with a high
quality, breathable motorcycle cover

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will help protect its finish from harmful
UV rays, pollutants, and reduce the

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amount of dust reaching its surfaces.
•

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Be sure the engine and exhaust are
cool before washing.

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• Avoid applying degreaser to seals,

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brake pads, and tires.
• Always use non-abrasive wax and

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cleaner/polisher.
• Avoid all harsh chemicals, solvents,
detergents, and household cleaning
A. Normal
B. Failed products such as ammonia-based
window cleaners.
122 MAINTENANCE AND ADJUSTMENT

• Gasoline, brake fluid, and coolant Washing Your Motorcycle

will damage the finish of painted and
plastic surfaces: wash them off im-
•Rinse your bike with cold water from
a garden hose to remove any loose
mediately. dirt.
• •

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Avoid wire brushes, steel wool, and Mix a mild neutral detergent (de-
all other abrasive pads or brushes. signed for motorcycles or automo-

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• Use care when washing the wind- biles) and water in bucket. Use

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shield, headlight cover, and other a soft cloth or sponge to wash your

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plastic parts as they can easily be motorcycle. If needed, use a mild de-
scratched. greaser to remove any oil or grease

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• Avoid using pressure washers; wa- build up.
•

sic
ter can penetrate seals and electrical After washing, rinse your motorcy-
components and damage your mo- cle thoroughly with clean water to re-

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torcycle. move any residue (residue from the
• Avoid spraying water in delicate
Cl
areas such as in air intakes, fuel
detergent can damage parts of your
motorcycle).
•
w.
system, brake components, electri- Use a soft cloth to dry your motorcy-
cal components, muffler outlets, and cle. As you dry, inspect your motor-
ww

fuel tank openings. cycle for chips and scratches. Do not

let the water air dry as this can dam-
age the painted surfaces.
 MAINTENANCE AND ADJUSTMENT 123

• Start the engine and let it idle for sev-

eral minutes. The heat from the en-
rain or washing the motorcycle. To
remove the moisture, start the engine
gine will help dry moist areas. and turn on the headlight. Gradually
• Carefully ride your motorcycle at a
slow speed and apply the brakes
the condensation on the inside of the
lens will clear off.
several times. This helps dry the
brakes and restores them to normal Painted Surfaces

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operating performance. After washing your motorcycle, coat
• Lubricate the drive chain to prevent painted surfaces, both metal and plas-

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rusting. tic, with a commercially available mo-

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torcycle/automotive wax. Wax should
NOTE be applied once every three months or

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After riding in an area where the as conditions require. Avoid surfaces

nl
roads are salted or near the ocean, with “satin” or “flat” finishes. Always
immediately wash your motorcycle use non-abrasive products and apply

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with cold water. Do not use warm them according to the instructions on

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water as it accelerates the chemical the container.
reaction of the salt. After drying, Windshield and Other Plastic Parts
apply a corrosion protection spray After washing use a soft cloth to gen-
on all metal and chrome surfaces to tly dry plastic parts. When dry, treat
prevent corrosion. the windshield, headlight lens, and
Condensation may form on the inside other non-painted plastic parts with
of the headlight lens after riding in the
124 MAINTENANCE AND ADJUSTMENT

an approved plastic cleaner/polisher Chrome and Aluminum

product. Chrome and uncoated aluminum
parts can be treated with a chrome/alu-
CAUTION minum polish. Coated aluminum

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Plastic parts may deteriorate should be washed with a mild neu-
and break if they come in con- tral detergent and finished with a spray

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tact with chemical substances polish. Aluminum wheels, both painted

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or household cleaning products and unpainted can be cleaned with

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such as gasoline, brake fluid, special non-acid based wheel spray
cleaners.

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window cleaners, thread-locking
agents, or other harsh chemi- Leather, Vinyl, and Rubber

sic
cals. If a plastic part comes in If your motorcycle has leather ac-
contact with any harsh chemical cessories, special care must be taken.

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substance, wash it off immedi- Use a leather cleaner/treatment to
Cl
ately with water and a mild neu-
tral detergent, and then inspect
clean and care for leather accessories.
Washing leather parts with detergent
w.
for damage. Avoid using abra- and water will damage them, shorten-
ww

sive pads or brushes to clean ing their life.

plastic parts, as they will dam- Vinyl parts should be washed with the
age the part’s finish. rest of the motorcycle, then treated with
a vinyl treatment.
 MAINTENANCE AND ADJUSTMENT 125

The sidewalls of tires and other rub- WARNING

ber components should be treated with
Special care must be taken not to
a rubber protectant to help prolong their
get any rubber protectant on the
useful life.
tire’s tread surface when treat-
ing tires. This may decrease the
tire’s ability to maintain contact

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with the road surface causing
the rider to lose control.

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126 STORAGE
STORAGE

Preparation for Storage:

• Clean the entire vehicle thoroughly.
• engine oil.engine for about five minutes to warm the oil, shut it off, and drain the

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Run the

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WARNING

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Motorcycle oil is a toxic substance. Dispose of used oil properly. Con-

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tact your local authorities for approved disposal methods or possible re-
cycling.

sic
• Put
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in fresh engine oil.
• Empty the fuel from the fuel tank by the pump or siphon.
Cl
w.
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 STORAGE 127

WARNING
Gasoline is extremely flammable and can be explosive under certain con-
ditions. Turn the ignition key to “OFF”. Do not smoke. Make sure the
area is well ventilated and free from any source of flame or sparks; this
includes any appliance with a pilot light.
Gasoline is a toxic substance. Dispose of gasoline properly. Contact your

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local authorities for approved disposal methods.

• Empty

ee
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.)

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• Reduce tire pressure by about 20%.
• (If this cannot be done,

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Set the motorcycle on a box or stand so that both wheels are raised off the ground.
put boards under the front and rear wheels to keep damp-

nl
ness away from the tire rubber.)
•

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Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on
rubber parts or in the brakes.

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• 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 temperatures. During storage it should be given a slow
charge (one ampere or less) about once a month. Keep the battery well charged
especially during cold weather.
• Tie plastic bags over the mufflers to prevent moisture from entering.
128 STORAGE

• Put a cover over the motorcycle to keep dust and dirt from collecting on it.
Preparation after Storage:
• Remove the plastic bags from the mufflers.
• Fill the fuelbattery
Install the in the motorcycle and charge the battery if necessary.

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• Check all thetank with fuel.
• Lubricate the points

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listed in the Daily Safety Checks section.
• pivots, bolts, and nuts.

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 U5FB15E0.book Page 3 Tuesday, May 11, 2004 3:55 AM

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