kawasaki kle650 versys 650 owners maintenance manual

Quick Reference GuideGENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

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

A Table of Contents is included afterthe Foreword.

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

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

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

CAUTIONCAUTION indicates a hazardoussituation which, if not avoided,could result in minor or moder-ate injury.

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

NOTEThis note symbol indicates points ofparticular interest for more efficientand convenient operation.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,and continuous striving for superior reliability, safety and performance.

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

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

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

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

All rights reserved. No part of this publication may be reproduced without ourprior written permission.

This publication includes the latest information available at the time of printing.However, there may be minor differences between the actual product and illustra-tions and text in this manual.

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

TABLE OF CONTENTS

SPECIFICATIONS............................... 8SERIAL NUMBER LOCATIONS......... 12LOCATION OF PARTS ....................... 13LOADING AND ACCESSORIESINFORMATION ................................ 16

GENERAL INFORMATION ................. 19Meter Instruments ............................ 19Tachometer ................................... 20LCD (Speedometer, Clock,Odometer, Trip Meter A/B, FuelGauge) ...................................... 20

Warning/Indicator Lights ............... 27Key................................................... 29Ignition Switch/Steering Lock........... 30Left Handlebar Switches .................. 32Dimmer Switch ............................. 32Turn Signal Switch........................ 32Horn Button .................................. 33Passing Button ............................. 33Hazard Switch .............................. 33

Right Handlebar Switches................ 34Engine Stop Switch ...................... 34Starter Button ............................... 34

Brake/Clutch Lever Adjusters........... 35Fuel Tank Cap.................................. 36Fuel Tank ......................................... 37Fuel Requirement ......................... 38

Stand................................................ 41Seat.................................................. 42Helmet Hooks................................... 44Tool Kit/U-Shaped LockCompartment ................................ 45

Rear View Mirror .............................. 46Windshield........................................ 48

BREAK-IN ........................................... 51HOW TO RIDE THE MOTORCYCLE . 53Starting the Engine .......................... 53Jump Starting................................... 55Moving Off........................................ 58Shifting Gears .................................. 59

Braking............................................. 61Stopping the Engine......................... 62Stopping the Motorcycle in anEmergency ................................... 63

Parking............................................. 64Catalytic Converter........................... 66

SAFE OPERATION............................. 68Safe Riding Technique ..................... 68Daily Safety Checks......................... 71Additional Considerations for HighSpeed Operation .......................... 74

MAINTENANCE ANDADJUSTMENT 76Periodic Maintenance Chart............. 81Engine Oil ........................................ 92Cooling System................................ 98Spark Plugs...................................... 105Evaporative Emission ControlSystem (California model only) .... 106

Valve Clearance ............................... 107Kawasaki Clean Air System............. 108Air Cleaner ....................................... 109Throttle Control System ................... 110

Engine Vacuum Synchronization ..... 113Idle Speed........................................ 113Clutch............................................... 115Drive Chain ...................................... 118Brakes.............................................. 126Brake Light Switches........................ 130Front Fork......................................... 132Rear Shock Absorber....................... 135Wheels ............................................. 138Battery.............................................. 144Headlight Beam................................ 149Fuses ............................................... 151General Lubrication.......................... 154Cleaning Your Motorcycle ................ 155Bolt and Nut Tightening.................... 161

STORAGE ........................................... 164TROUBLESHOOTING GUIDE............ 167OWNER SATISFACTION.................... 168REPORTING SAFETY DEFECTS ...... 170ENVIRONMENTAL PROTECTION ..... 171MAINTENANCE RECORD ................. 172LOCATION OF LABELS..................... 177

8 SPECIFICATIONS

SPECIFICATIONS

PERFORMANCEMinimum Turning Radius 2.7 m (8.9 ft)

DIMENSIONSOverall Length 2 125 mm (83.7 in.)

Overall Width 840 mm (33.1 in.)

Overall Height 1 330 mm (52.4 in.)

Wheelbase 1 415 mm (55.7 in.)

Road Clearance 180 mm (7.1 in.)

Curb Mass 206 kg (454 lb)

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

Displacement 649 cm3 (39.6 cu in.)

Bore × Stroke 83.0 × 60.0 mm (3.3 × 2.4 in.)

Compression Ratio 10.6:1

Starting System Electric starter

SPECIFICATIONS 9

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Fuel System FI (Fuel Injection)

Ignition System Battery and coil (transistorized ignition)

Ignition Timing (Electronicallyadvanced)

10° BTDC @1 300 r/min (rpm) ∼ 33° BTDC @5 000r/min (rpm)

Spark Plugs NGK CR9EIA-9

Lubrication System Forced lubrication (semi-dry sump)

Engine Oil:

Type API SG, SH, SJ, SL or SM with JASO MA, MA1 orMA2

Viscosity SAE 10W-40

Capacity 2.4 L (2.5 US qt)

Coolant Capacity 1.2 L (1.3 US qt)

TRANSMISSIONTransmission Type 6-speed, return shift

Clutch Type Wet, multi disc

10 SPECIFICATIONS

Driving System Chain drive

Primary Reduction Ratio 2.095 (88/42)

Final Reduction Ratio 3.067 (46/15)

Overall Drive Ratio 5.473 @Top gear

Gear Ratio:

1st 2.438 (39/16)

2nd 1.714 (36/21)

3rd 1.333 (32/24)

4th 1.111 (30/27)

5th 0.966 (28/29)

6th 0.852 (23/27)

FRAMECaster 25°

Trail 108 mm (4.3 in.)

Tire Size:

Front 120/70 ZR17 M/C (58W)

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

SPECIFICATIONS 11

Rim Size:

Front 17 × 3.50

Rear 17 × 4.50

Fuel Tank Capacity 19 L (5.0 US gal)

ELECTRICAL EQUIPMENTBattery 12 V 10 Ah

Headlight:

High Beam 12 V 55 W

Low Beam 12 V 55 W

Tail/Brake Light LED

Even if one of LED (Light Emitting Diode) tail/brake light is not lit, consult with anauthorized Kawasaki dealer.Specifications are subject to change without notice.

12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. Theyare the only means of identifying your particular machine from others of the samemodel type. These serial numbers may be needed by your dealer. when orderingparts. In the event of theft, the investigating authorities will require both numbersas well as the model type and any peculiar features of your machine that can helpthem identify it.

Frame No.

A. Frame Number

Engine No.

A. Engine Number

LOCATION OF PARTS 13LOCATION OF PARTS

1. Clutch Lever2. Left Handlebar Switches3. Meter Instruments4. Ignition Switch/Steering Lock5. Brake Fluid Reservoir (Front)6. Front Brake Lever

7. Spring Preload Adjuster (Front Fork)8. Rebound Damping Force Adjuster(Front Fork)

9. Right Handlebar Switches10. Throttle Grip

14 LOCATION OF PARTS

1. Headlight/City Light2. Turn Signal Light3. Spark Plugs4. Air Cleaner5. Main Fuse6. Battery

7. Seat8. Helmet Holding Hook9. Tool Kit/StorageCompartments

10. Seat Lock11. Wheel

12. Brake Disc13. Brake Caliper14. Front Fork15. Shift Pedal16. Side Stand17. Drive Chain

LOCATION OF PARTS 15

1. License Plate Light2. Tail/Brake Light3. Rebound DampingForce Adjuster (RearShock Absorber)

4. Brake Fluid Reservoir(Rear)

5. Rear Shock Absorber6. Spring PreloadAdjuster (Rear ShockAbsorber)

7. Fuel Tank8. Fuel Tank Cap9. Coolant Reserve Tank

10. Muffler11. Rear Brake Light

Switch12. Rear Brake Pedal13. Oil Level Gauge14. Idle Adjusting Screw

16 LOADING AND ACCESSORIES INFORMATION

LOADING AND ACCESSORIES INFORMATION

WARNINGIncorrect loading, improper in-stallation or use of accessories,or modification of your motorcy-cle may result in an unsafe rid-ing condition. Before you ridethe motorcycle, make sure thatthemotorcycle is not overloadedand that you have followed theseinstructions.

With the exception of genuineKawasaki Parts and Accessories,Kawasaki has no control over thedesign or application of accessories.In some cases, improper installationor use of accessories, or motorcyclemodification, will void the motorcycle

warranty, can negatively affect per-formance, and can even be illegal.In selecting and using accessories,and in loading the motorcycle, you arepersonally responsible for your ownsafety and the safety of other personsinvolved.

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

Because a motorcycle is sensitive tochanges in weight and aerodynamicforces, you must take extreme care

LOADING AND ACCESSORIES INFORMATION 17

in carrying cargo, passengers and/orin the fitting of additional accessories.The following general guidelines havebeen prepared to assist you in makingyour determinations.1. Any passenger should be thor-oughly familiar with motorcycle op-eration. The passenger can affectcontrol of the motorcycle by im-proper positioning during corneringand sudden movements. It is im-portant that the passenger sits stillwhile the motorcycle is in motionand not interfere with the operationof the motorcycle. Do not carry ani-mals on your motorcycle.

2. You should instruct any passengerbefore riding to keep his or her feeton the passenger footpegs and holdon to the operator or seat strap. Donot carry a passenger unless he orshe is tall enough to reach the foot-pegs and footpegs are provided.

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

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

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

18 LOADING AND ACCESSORIES INFORMATION

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

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

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

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

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

Maximum LoadWeight of rider, passenger, baggage,and accessories must not exceed 180 kg(397 lb).

GENERAL INFORMATION 19GENERAL INFORMATION

Meter InstrumentsA. Water Temperature

Warning Indicator LightB. Oil Pressure Warning

Indicator LightC. RESET ButtonD. Neutral Indicator LightE. MODE ButtonF. High Beam Indicator LightG. Left Turn Signal Indicator

LightH. TachometerI. Red ZoneJ. Right Turn Signal Indicator

LightK. LCD (Speedometer, Clock,

Odometer, Trip Meter A/B,Fuel Gauge)

L. FI Indicator Light

20 GENERAL INFORMATION

TachometerThe tachometer shows the engine

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

“ON”, the tachometer needle momen-tarily points to the last reading to checkits operation. If the tachometer nee-dle does not operate correctly, have itinspected by an authorized Kawasakidealer.

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

LCD (Speedometer, Clock,Odometer, Trip Meter A/B,Fuel Gauge)

The LCD (Liquid Crystal Display) lo-cated in the tachometer face is usedto display the Speedometer, Clock,Odometer, Trip Meter A/B, and FuelGauge. Pushing the MODE buttonshifts the display through the follow-ing four modes: CLOCK, ODO, andTRIP A/B. When the ignition key isturned to “ON”, all the LCD segmentsare displayed for three seconds, thenthe clock or meters operate normallydepending on the mode selected.

GENERAL INFORMATION 21

A. ClockB. OdometerC. Trip Meter AD. Trip Meter BE. Push MODE Button

NOTEFor safe operation do not press theMODE button while riding.

Digital Meter

A. Fuel GaugeB. SpeedometerC. Clock, Trip Meter A/B, Odometer

NOTEDo not shift the digital meter displaywhile riding for safe operation.


mph·km/h Display -mph·km/h Display can alternate be-

tween English and metric modes (mphand km/h) in the digital meter. Makesure that mph or km/h is correctly dis-played according to local regulationsbefore riding.

NOTEDo not operate the vehicle withthe digital meter displaying in thewrong unit (mph or km/h). Shift themph·km/h display in the digital meteras follows.

• Display the odometer in the digitalmeter.• The mph·km/h display shifts by push-ing the RESET button while theMODE button pushed in.

A. mph·km/h Display


• The mph·km/h display shifts as fol-lows.

A. mph DisplayB. km/h DisplayC. Push RESET Button with MODE Button in

NOTEThe data is maintained even if thebattery is disconnected.

Speedometer -The speedometer shows the speed

of the vehicle in digital value.

Clock -To adjust the hours and minutes:• Turn the ignition key to “ON”.• Push the MODE button to display theclock.

• Push the RESET button for morethan two seconds. Both the hour andminute displays start flashing.


• Push the RESET button. The hourdisplay only flashes. Push theMODE button to advance the hours.

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

• Push the RESET button. Both thehour and minute displays start flash-ing again.• Push the MODE button. The dis-plays stop flashing and the clockstarts working.

NOTEPushing the MODE button momen-tarily advances the hour or minutestep by step. Pushing and hold-ing the button advance the hour orminute continuously.The clock works normally from theback-up power while the ignitionswitch is turned off.When the battery is disconnected,the clock resets to 1:00 and startsworking again when the battery isconnected.


Odometer -The odometer shows the total dis-

tance the vehicle has been ridden. Thismeter cannot be reset.

NOTEThe data is maintained even if thebattery is disconnected.When the figures come to 999999,they are stopped and locked.

Trip Meter -The trip meters show the distance in

kilometers traveled since they were lastreset to zero.TRIP A: 0.0 ∼ 999.9TRIP B: 0.0 ∼ 9999.9To reset the trip meter:• Push the MODE button to display thetrip meter A or B.• Push the RESET button and hold itin.• After two seconds, the figure displayturns to 0.0, and then starts countingwhen the vehicle is operated. Themeter counts until it is reset.


NOTEThe data is maintained by the back-up power if the ignition key is turnedoff.When the trip meter is reset while thevehicle is stopped, it starts countingas soon as the vehicle starts moving.When the trip meter reaches 999.9(TRIP A) or 9999.9 (TRIP B) whilerunning, the meters reset to 0.0 andcontinues counting.When the battery is disconnected,the meter display resets to 0.0.


Fuel Gauge -The fuel in the fuel tank is shown

by the number of segments displayed.When the fuel tank is full, all the seg-ments are displayed. As the fuel levelin the tank goes down, the segmentsdisappear one by one from F (full) toE (empty). When only the most bot-tom segment is displayed, 5.0 L (1.3US gal) of fuel remain. Furthermore,when the lowest segment and “FUEL”flash in the digital meter, only 3.5 L (0.9US gal) of fuel remain.Refuel at the earliest opportunity if

the most bottom segment of the fuelgauge flashes.When vehicle stands with Side

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

A. Flash

NOTEWhen pushing the MODE buttonwhile “FUEL” is displayed, the dis-play can be shifted to odometer, tripmeter, or clock mode.

Warning/Indicator Lights: When the transmission is in neu-

tral, the neutral indicator light goes on.


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

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

: The oil pressure warning lightgoes on whenever the oil pressure isdangerously low or the ignition key isin the ON position with the engine notrunning, and goes off when the engineoil pressure is high enough. Refer tothe Maintenance and Adjustment chap-ter for more detailed engine oil informa-tion.

: The fuel injection (FI) indicatorlight goes on when the ignition switch

is turned to “ON” and goes off soonafter ensuring that its circuit functionsproperly. The indicator light also goeson whenever the troubles occur indigital fuel injection system (DFI). Ifthe indicator light goes on, have theDFI system checked by an authorizedKawasaki dealer. When the indicatorlight flashes, first turn the ignition keyto “OFF” and then back to “ON”.

: The water temperature warning in-dicator light goes on whenever the wa-ter temperature rises to about 119°C(246°F) when the motorcycle is in op-eration. This warns the operator thatthe water temperature is too high. If thewarning indicator light goes on, stopthe engine and check the coolant levelin the reserve tank after the enginecools down.


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

KeyThis motorcycle has a combination

key, which is used for the ignitionswitch/steering lock, seat lock, and fueltank cap.Blank keys are available at your

Kawasaki dealers. Ask your dealer tomake any additional spare keys youmay need, using your original key asa master, or using the key code on thetag with your keys.Record the code from the tag with

your keys here. Participating Kawasakidealers can use the code to make anew key in the event that your originalkeys are lost.

Write your key number here.


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

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

A. Ignition Switch/Steering LockB. ON PositionC. OFF PositionD. LOCK PositionE. P (Park) Position


OFF Engine off. All electricalcircuits off.

ON Engine on. All electricalequipment can be used.

LOCK Steering locked. Engineoff. All electrical circuits off.

P (Park)

Steering locked. Engineoff. License plate, tail,and city lights on and turnsignals can be used. Allother electrical circuits cutoff.

NOTEThe city, tail and license plate lightsare on whenever the ignition key isin the ON position. One headlightgoes on when the starter button isreleased after starting the engine. To

avoid battery discharge, always startthe engine immediately after turningthe ignition key to “ON”.If you leave the P (Park) position onfor a long time (one hour), the batterymay become totally discharged.


Left Handlebar Switches

A. Dimmer SwitchB. Turn Signal SwitchC. Horn ButtonD. Passing ButtonE. Hazard Switch

Dimmer SwitchHigh or low beam can be selected

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

NOTEWhen the headlight is on high beam,both headlights go on. When theheadlight is on low beam, only oneheadlight goes on.

Turn Signal SwitchWhen the turn signal switch is

pushed to the left ( ) or right( ), the corresponding turn sig-nals flash on and off.To stop flashing, push the switch in.


Horn ButtonWhen the horn button is pushed, the

horn sounds.

Passing ButtonWhen the passing button is pushed,

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

Hazard SwitchIf an emergency requires you to park

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

ignition switch in the ON or P (Park)position. All the turn signals and turn

signal indicator lights will flash on andoff.

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


Right Handlebar Switches

A. Engine Stop SwitchB. Starter Button

Engine Stop SwitchIn addition to the ignition switch,

the engine stop switch must be inthe position for the motorcycle tooperate.

The engine stop switch is for emer-gency use. If some emergency re-quires stopping the engine, move theengine stop switch to the position.

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

Starter ButtonThe starter button operates the elec-

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

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


Brake/Clutch Lever AdjustersThere is an adjuster on both the

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

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

A. AdjusterB. MarkC. Brake Lever


A. AdjusterB. MarkC. Clutch Lever

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

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

place with the key inserted. The keycan be removed by turning it to the leftto the original position.

NOTEThe fuel tank cap cannot be closedwithout the key inserted, and the keycannot be removed unless the cap islocked properly.Do not push on the key to close thecap, or the cap cannot be locked.


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

Fuel TankThe following octane rating gaso-

line is recommended for the fuel tank.Avoid filling the tank in the rain or whereheavy dust is blowing so that the fueldoes not get contaminated.

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


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

Fuel RequirementFuel TypeUse clean, fresh unleaded gasoline

with a minimum Antiknock Index of 87.The Antiknock Index is posted on ser-vice station pumps. The octane ratingof a gasoline is a measure of its resis-tance to detonation or “knocking”. TheAntiknock Index is an average of theResearch Octane Number (RON) andthe Motor Octane Number (MON) asshown in the table.

Octane Rating Method MinimumRating

(RON +MON)AntiknockIndex 2

87


NOTICEUse minimum of 87 octane gaso-line only to prevent severe en-gine damage.

NOTICEIf engine “knocking” or “ping-ing” occurs, use a differentbrand of gasoline of a higheroctane rating. If this condition isallowed to continue it can leadto severe engine damage.Gasoline quality is important.Fuels of low quality or not meet-ing standard industry specifi-cations may result in unsatis-factory performance. Operatingproblems that result from theuse of poor quality or nonrecom-mended fuel may not be coveredunder your warranty.

Fuels Containing OxygenatesGasoline frequently contains oxy-

genates (alcohols and ethers) espe-cially in areas of the U.S. and Canadawhich are required to sell such refor-mulated fuels as part of a strategy toreduce exhaust emissions.The types and volume of fuel oxy-

genates approved for use in unleadedgasoline by the U.S. EnvironmentalProtection Agency include a broadrange of alcohols and ethers, but onlytwo components have seen any signif-icant level of commercial use.Gasoline/Alcohol Blends - Gasoline

containing up to 10% ethanol (alco-hol produced from agricultural productssuch as corn), also known as “gasohol”is approved for use.


NOTICEAvoid using blends of unleadedgasoline and methanol (woodalcohol) whenever possible, andnever use “gasohol” contain-ing more than 5% methanol.Fuel system damage and perfor-mance problems may result.

Gasoline/Ether Blends - The mostcommon ether is methyl tertiary butylether (MTBE). You may use gasolinecontaining up to 15% MTBE.

NOTEOther oxygenates approved for usein unleaded gasoline include TAME(up to 16.7%) and ETBE (up to17.2%). Fuel containing these oxy-genates can also be used in yourKawasaki.

NOTICENever use gasoline with an oc-tane rating lower than the mini-mum specified by Kawasaki.Never use “gasohol” with morethan 10% ethanol, or more than5% methanol. Gasoline con-taining methanol must also beblended with cosolvents andcorrosion inhibitors.Certain ingredients of gasolinemay cause paint fading or dam-age. Be extra careful not to spillgasoline or gasoline oxygenateblends during refueling.When not operating yourKawasaki for 30 to 60 days, mix afuel stabilizer (such as STA-BIL)with the gasoline in the fuel tank.Fuel stabilizer additives inhibitoxidation of the fuel which mini-mizes gummy deposits.


NOTICENever store this product with“gasohol” in the fuel system.Before storage it is recom-mended that you drain all fuelfrom the fuel system. See theStorage section in this manual.

StandThe motorcycle is equipped with a

side stand.

A. Side Stand

NOTEWhen using the side stand, turn thehandlebar to the left.

Whenever the side stand is used,make it a practice to kick the stand fullyup before sitting on the motorcycle.


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

SeatSeat RemovalInsert the ignition key into the seat

lock, located on the seat cover.Turn the key clockwise while pulling

on the rear end of the seat.

NOTEIf there is difficulty removing the seat,be sure to insert the key all the wayand to push down strongly on therear end of the seat while turning thekey clockwise.


A. SeatB. Seat LockC. Ignition KeyD. Insert

Seat InstallationInstall the seat in the reverse order of

removal.• Place the tabs into the matching slotand receptacles.• Insert the hook at the rear of the seatinto the lock on the frame.

A. SeatB. SlotC. TabsD. ReceptaclesE. HookF. Lock


• Push down the rear part of the seatuntil the lock clicks.• Pull up the rear end of the seat tomake sure it is securely locked.

NOTEIf there is difficulty removing the ig-nition key from the seat lock, turn itlightly counterclockwise while pullingit out.

Helmet HooksHelmets can be secured to the mo-

torcycle using the helmet hooks locatedunder the seat.

A. Helmet Hooks


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

Tool Kit/U-Shaped LockCompartment

The tool kit is stored under the seat.The kit contains tools that can be help-ful in making roadside repairs, adjust-ments, and some maintenance proce-dures explained in this manual.Also, under the seat, there is a lock

strap which can hold a U-shaped lock(not supplied).Install the U-shaped part and lock

separately and secure them each withits strap.


A. Tool KitB. StrapC. U-Shaped Lock (not supplied)

Rear View MirrorRear View Mirror Adjustment• Adjust the rear view mirror by slightlymoving only the mirror portion of theassembly.• If the rear visibility can not be as-sured by moving the mirror, turn thestay by hand.

A. StayB. Rear View Mirror


NOTICEDo not force to tighten and/orloosen the upper hexagonalarea with a pair of spannersor wrench. Forcible looseningand/or tightening may damagethe upper hexagonal area and/orthe turning mechanism of thestay.

A. Lower Hexagonal Area for TighteningB. Upper Hexagonal AreaC. Rear View Mirror


WindshieldThe windshield can be adjusted

within 3 positions in height to suit therider’s preference. Remove the boltson the windshield.

A. WindshieldB. Bolts

• Remove the wellnuts and rivets, andinstall them in the positions to suitthe rider’s preference. After adjust-ing, make sure to tighten all four boltssecurely.

A. WellnutsB. Rivets


Windshield Position 1

A. WindshieldB. BoltsC. WellnutsD. Rivets


A. WindshieldB. BoltsC. WellnutsD. Rivets



A. WindshieldB. BoltsC. Wellnuts

NOTEKeep the uninstalled rivets in a safeplace.

BREAK-IN 51BREAK-IN

The first 1 600 km (1 000 miles) that the motorcycle is ridden is designated as thebreak-in period. If the motorcycle is not used carefully during this period, you mayvery well end up with a “broken down” instead of a “broken in” motorcycle after afew thousand kilometers.The following rules should be observed during the break-in period.• The table shows maximum recommended engine speed during the break-in pe-riod.

Distance traveled Maximum engine speed

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

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

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

52 BREAK-IN

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

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

HOW TO RIDE THE MOTORCYCLE 53HOW TO RIDE THE MOTORCYCLE

Starting the Engine• Check that the engine stop switch isin the position.

A. Engine Stop SwitchB. Starter Button

• Turn the ignition key to “ON”.• Make sure the transmission is in neu-tral.

A. Neutral Indicator LightB. Ignition SwitchC. ON Position

NOTEThe motorcycle is equipped with avehicle-down sensor, which causesthe engine to stop automatically andthe FI indicator light to flash when themotorcycle falls down. After righting

54 HOW TO RIDE THE MOTORCYCLE

the motorcycle, first turn the ignitionkey to “OFF” and then back to “ON”before starting the engine.

• After the meter operation check,leaving the throttle completelyclosed, push the starter button.

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

NOTEThe motorcycle is equipped with astarter lockout switch. This switch isdesigned so that the engine does notstart if the transmission is in gear andthe side stand is down. However, theengine can be started if the clutchlever is pulled and the side stand isfully up.

A. Clutch LeverB. Starter Lockout Switch

HOW TO RIDE THE MOTORCYCLE 55

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

Jump StartingIf your motorcycle battery is “run

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


DANGERBattery acid generates hydro-gen gas which is flammable andexplosive under certain con-ditions. It is present within abattery at all times, even in adischarged condition. Keep allflames and sparks (cigarettes)away from the battery. Wear eyeprotection when working with abattery. In the event of batteryacid contact with skin, eyes, orclothing, wash the affected ar-eas immediately with water forat least 5 minutes. Seek medicalattention.

Connecting Jumper Cables• Remove the seat (see Seat sectionin the GENERAL INFORMATIONchapter).• Make sure the ignition key is turnedto “OFF”.• Connect a jumper cable from thepositive (+) terminal of the boosterbattery to the positive (+) terminal ofthe motorcycle battery.• Connect another jumper cable fromthe negative (–) terminal of thebooster battery to your motorcy-cle footpeg or other unpainted metalsurface. Do not use the negative (–)terminal of the battery.


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

Terminal

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

• Follow the standard engine startingprocedure.


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

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

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

A. Shift Pedal


NOTEThe motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine does notstart if the transmission is in gear andthe side stand is down.When the headlight is on high beam,two headlight beams go on, and onlow beam, one headlight goes on.

Shifting Gears• Close the throttle while pulling in theclutch lever.• Shift into the next higher or lowergear.• Open the throttle halfway, while re-leasing the clutch lever.• For smooth riding, each gear positionshould cover the proper rate of speedshown in the table.

WARNINGDownshifting to a lower gear athigh speed causes engine rpmto increase excessively, poten-tially damaging the engine andit may also cause the rear wheelto skid and cause an accident.Downshifting should be donebelow the vehicle speeds foreach gear shown in the table.


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

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

standing still. The transmission willshift only into neutral.


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

• For emergency braking, disregarddownshifting, and concentrate onapplying the brakes as hard as pos-sible without skidding.

A. Front Brake Lever


A. Rear Brake Pedal

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

NOTEThe motorcycle is equipped with avehicle-down sensor, which causesthe engine to stop automatically andthe FI indicator light to flash when themotorcycle falls down. After rightingthe motorcycle, first turn the ignitionkey to “OFF” and then back to “ON”before starting the engine.


Stopping the Motorcycle in anEmergency

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

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

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


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

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

• If parking inside a garage or otherstructure, be sure it is well ventilatedand the motorcycle is not close toany source of flame or sparks; thisincludes any appliance with a pilotlight.

WARNINGThe muffler and exhaust pipeare very hot while the engine isrunning and just after the enginestops. This can ignite a fire, re-sulting in property damage orsevere personal injury.Do not idle or park your vehi-cle in an area where flammablematerials such as grasses or dryleaves may contact with muffleror exhaust pipe.


WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions, creating the po-tential for serious burns. Turnthe ignition switch “OFF”. Donot smoke. Make sure the area iswell-ventilated and free from anysource of flame or sparks; thisincludes any appliance with a pi-lot light.Never fill the tank completelyto the top. If the tank is filledcompletely to the top, heat maycause the fuel to expand andoverflow through the vents inthe tank cap. After refueling,make sure the tank cap is closedsecurely.If gasoline is spilled on the fueltank, wipe it off immediately.

• Lock the steering to prevent theft.NOTE

When stopping near traffic at night,you can leave the taillight on forgreater visibility by turning the igni-tion key to the P (Park) position.Do not leave the ignition switch at P(Park) position too long, or the bat-tery will discharge.


Catalytic ConverterThis motorcycle is equipped with

a catalytic converter in the exhaustsystem. Platinum and rhodium in theconverter react with carbon monox-ide, hydrocarbons and nitrogen oxidesto convert them into carbon dioxide,water, nitrogen and oxygen resultingin much cleaner exhaust gases to bedischarged into the atmosphere.For proper operation of the catalytic

converter, the following cautions mustbe observed.

WARNINGThe muffler and exhaust pipeare very hot while the engine isrunning and just after the enginestops. This can ignite a fire, re-sulting in property damage orsevere personal injury.Do not idle or park your vehi-cle in an area where flammablematerials such as grasses or dryleaves may contact with muffleror exhaust pipe.

• Use only unleaded gasoline. Neveruse leaded gasoline. Leaded gaso-line significantly reduces the capabil-ity of the catalytic converter.• Do not operate the vehicle with theengine or any one cylinder misfiring.Under these conditions unburnedair/fuel mixture flowing out of engineexcessively accelerates reaction in


the converter allowing the converterto overheat and become damagedwhen the engine is hot, or reduces

converter performance when the en-gine is cold.

68 SAFE OPERATION

SAFE OPERATION

Safe Riding TechniqueThe points given below are applicable for everyday motorcycle use and should

be carefully observed for safe and effective vehicle operation.

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

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

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

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

SAFE OPERATION 69

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

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

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

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

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

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

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

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

70 SAFE OPERATION

Do not downshift at too high anr/min (rpm) to avoid damage to theengine from overrevving.

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

SAFE OPERATION 71

Daily Safety ChecksCheck the following items each day before you ride. The time required is minimal,

and habitual performance of these checks will help ensure you a safe, reliable ride.If any irregularities are found during these checks, refer to the Maintenance and

Adjustment chapter or see your dealer for the action required to return the motor-cycle to a safe operating condition.

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

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

Fuel ............................. Adequate supply in tank, no leaks.Engine Oil ................... Oil level between level lines.

72 SAFE OPERATION

Tires ............................ Air pressure (when cold):Front 225 kPa (2.25 kgf/cm², 32 psi)

Rear 250 kPa (2.50 kgf/cm², 36 psi)

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

Lubricate the drive chain if dry.Nuts, Bolts, Fasteners Check that steering and suspension components, axles,

and all controls are properly tightened or fastened.Steering ...................... Action smooth but not loose from lock to lock.

No binding of control cables.Brakes ........................ Brake pad wear: Lining thickness more than 1 mm (0.04

in.) left.No brake fluid leakage.

Throttle ....................... Throttle grip play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).Clutch ......................... Clutch lever play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).

Clutch lever operates smoothly.Coolant ....................... No coolant leakage.

Coolant level between level lines (when engine is cold).Electrical Equipment ... All lights (Headlight, City Light, Tail/Brake Lights, Turn Sig-

nal Lights, License Plate Light, Warning/Indicator Lights)and horn work.

Engine Stop Switch .... Stops engine.

SAFE OPERATION 73

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

Refer to the “Daily Safety Checks” caution label attached on the rear fender rear.

74 SAFE OPERATION

Additional Considerations for High Speed OperationBrakes: The importance of the brakes, especially during high speed operation,

cannot be overemphasized. Check to see that they are correctly adjusted and func-tioning properly.Steering: Looseness in the steering can cause loss of control. Check to see that

the handlebar turns freely but has no play.Tires: High speed operation is hard on tires, and good tires are crucial for riding

safety. Examine their overall condition, inflate them to the proper pressure, andcheck the wheel balance.Fuel: Have sufficient fuel for the high fuel consumption during high speed oper-

ation.Engine Oil: To avoid engine seizure and resulting loss of control, make sure that

the oil level is at the upper level line.Coolant: To avoid overheating, check that the coolant level is at the upper level

line.Electrical Equipment: Make sure that the headlight, tail/brake light, turn signal

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

related parts are in good condition.

SAFE OPERATION 75

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

76 MAINTENANCE AND ADJUSTMENT

MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out inaccordance with the Periodic Maintenance Chart to keep the motorcycle in goodrunning condition. The initial maintenance is vitally important and must not beneglected.With a basic knowledge of mechanics and the proper use of tools, you should be

able to carry out many of the maintenance items described in this chapter. If youlack proper experience or doubt your ability, all adjustments, maintenance, andrepair work should be completed by a qualified technician.Please note that Kawasaki cannot assume any responsibility for damage result-

ing from incorrect or improper adjustment done by the owner.

MAINTENANCE AND ADJUSTMENT 77

EMISSION CONTROL INFORMATIONTo protect the environment in which we all live, Kawasaki has incorporated

crankcase emission (1) and exhaust emission (2) control systems in compliancewith applicable regulations of the United States Environmental Protection Agencyand California Air Resources Board. Additionally, Kawasaki has incorporatedan evaporative emission control system (3) in compliance with applicable regu-lations of the United States Environmental Protection Agency and California AirResources Board.

1. Crankcase Emission Control SystemThis system eliminates the release of crankcase vapors into the atmosphere.

Instead, the vapors are routed through an oil separator to the intake side of theengine. While the engine is operating, the vapors are drawn into the combustionchamber, where they are burned along with the fuel and air supplied by the fuelinjection system.

2. Exhaust Emission Control SystemThis system reduces the amount of pollutants discharged into the atmosphere

by the exhaust of this motorcycle. The fuel, ignition and exhaust systems of thismotorcycle have been carefully designed and constructed to ensure an efficientengine with low exhaust pollutant levels. The exhaust system of this model mo-torcycle includes a catalytic converter system.


3. Evaporative Emission Control SystemThe evaporative emission control system for this vehicle consists of low per-

meation fuel hoses and a fuel tank.

3. Evaporative Emission Control System (California)Vapors caused by fuel evaporation in the fuel system are not vented into the

atmosphere. Instead, fuel vapors are routed into the running engine to be burned,or stored in a canister when the engine is stopped. Liquid fuel is caught by a vaporseparator and returned to the fuel tank.

High Altitude Performance Adjustment InformationHigh Altitude adjustment is not required.


MAINTENANCE AND WARRANTYProper maintenance is necessary to ensure that your motorcycle will continue to

have low emission levels. This Owner’s Manual contains those maintenance rec-ommendations for your motorcycle. Those items identified by the Periodic Mainte-nance Chart are necessary to ensure compliance with the applicable standards.As the owner of this motorcycle, you have the responsibility to make sure that

the recommended maintenance is carried out according to the instructions in thisOwner’s Manual at your own expense.The Kawasaki Limited Emission Control System Warranty requires that you re-

turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty.Please read the warranty carefully, and keep it valid by complying with the owner’sobligations it contains.You should keep a maintenance record for your motorcycle. To assist you in

keeping this record, we have provided space on pages 172 through 176 of thismanual where an authorized Kawasaki dealer, or someone equally competent, canrecord themaintenance. You should also retain copies of maintenance work orders,bills, etc., as verification of this maintenance.


TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or the causing thereof: (1) the removal or

rendering inoperative by any person other than for purposes of maintenance, re-pair, or replacement, of any device or element of design incorporated into any newvehicle for the purpose of noise control prior to its sale or delivery to the ultimatepurchaser or while it is in use, or (2) the use of the vehicle after such device orelement of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:* Replacement of the original exhaust system or muffler with a component not incompliance with Federal regulations.

* Removal of the muffler(s) or any internal portion of the muffler(s).* Removal of the air box or air box cover.* Modifications to the muffler(s) or air intake system by cutting, drilling, or othermeans if such modifications result in increased noise levels.


Periodic Maintenance Chart1. Periodic Inspection (Engine Related Items)

Frequency Whichevercomes first *Odometer Reading

km × 1 000 (mile × 1 000)

Operation(Engine Items) Every 1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

K Air cleanerelement - clean • • • 109

K Valve clearance- inspect every 42 000 km (26 250 mile) 107

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

year • • • • 110

KEngine vacuumsynchronization- inspect

• • • 113

Idle speed -inspect • • • • 113



km × 1 000 (mile × 1 000)


(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

KFuel leak (fuelhose and pipe) -inspect

year • • • • –

KFuel hosesdamage -inspect

year • • • • –

KFuel hosesinstallationcondition -inspect

year • • • • –

Coolant level -inspect • • • • 101

Coolant leak -inspect year • • • • 98



km × 1 000 (mile × 1 000)


(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Radiator hosedamage -inspect

year • • • • 98

Radiator hosesinstallationcondition -inspect

year • • • • 98

Evaporativeemissioncontrol system- function(Californiamodel only)

• • • • • • • 106

KAir suctionsystem damage- inspect

• • • 108


2. Periodic Inspection (Chassis Related Items)Frequency Whichever

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

Operation(ChassisItems)

Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

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

• • • • 115

Drive chainlubricationcondition -inspect #

every 600 km (400 mile) 125

Drive chainslack - inspect # every 1 000 km (600 mile) 118

Drive chainwear - inspect # • • • 123



km × 1 000 (mile × 1 000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

KDrive chainguide wear -inspect

• • • –

Wheels and tires:Tire air pressure- inspect year • • • 139

Wheels/tiresdamage -inspect

• • • 140

Tire tread wear,abnormal wear -inspect

• • • 140

KWheel bearingsdamage -inspect

year • • • –



km × 1 000 (mile × 1 000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Brake system:Brake fluid leak- inspect year • • • • • • • 126

Brake hosesdamage -inspect

year • • • • • • • 126

Brake pad wear- inspect # • • • • • • 126

Brake hoseinstallationcondition -inspect

year • • • • • • • 126

Brake fluid level- inspect 6 months • • • • • • • 127



km × 1 000 (mile × 1 000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Brake operation(effectiveness,play, drag) -inspect

year • • • • • • • 129

Brake lightswitch operation- inspect

• • • • • • • 130

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

• • • 132,135



km × 1 000 (mile × 1 000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Front forks/rearshock absorberoil leak - inspect

year • • • 132,135

Steering system:

K Steering play -inspect year • • • • –

KSteering stembearings -lubricate

2 years • –

Electrical system:Lights andswitchesoperation -inspect

year • • • –



km × 1 000 (mile × 1 000)


Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Headlightaiming - inspect year • • • 149

Side standswitch operation- inspect

year • • • –

Engine stopswitch operation- inspect

year • • • –

Chassis:

K Chassis parts -lubricate year • • • 154

KBolts and nutstightness -inspect

• • • • 161


3. Periodic ReplacementFrequency Whichever

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

Change/Replacement Items Every 1(0.6)

12(7.5)

24(15)

36(22.5)

48(30)

SeePage

K Air cleaner element # - replace 2 years 109

Engine oil # - change year • • • • • 94

Oil filter - replace year • • • • • 94

K Fuel hoses - replace 4 years • –

K Coolant - change 3 years • 105

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

K Brake hoses - replace 4 years • –

K Brake fluid (front and rear) -change 2 years • • 129

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



km × 1 000 (mile × 1 000)

Change/Replacement Items Every 1(0.6)

12(7.5)

24(15)

36(22.5)

48(30)

SeePage

K Spark plug - replace • • • • 105

K Vehicle-down sensor mountingdampers - replace 4 years • –

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.


Engine OilIn order for the engine, transmission,

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

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

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

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


• If the motorcycle has just been used,wait several minutes for all the oil todrain down.• Check the engine oil level throughthe oil level gauge. With the motor-cycle held level, the oil level shouldcome up between the upper andlower level lines next to the gauge.

A. Oil Level GaugeB. Upper Level LineC. Lower Level LineD. Oil Filler Cap

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

NOTICEIf the engine oil gets extremelylow or if the oil pump does notfunction properly or oil pas-sages are clogged, the oil pres-sure warning indicator lightwill go on. If it stays on whenthe engine speed is above idle,stop the engine immediately andhave it serviced. Failure to doso could cause serious enginedamage.


A. Oil Pressure Warning Indicator Light

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

A. Drain Bolt

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


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

• Remove the oil filter and replace itwith a new one.

NOTEIf a torque wrench or requiredKawasaki special tool is not avail-able, this item should be serviced bya Kawasaki dealer.

A. Oil Filter


• Apply a thin film of engine oil to thepacking and tighten the oil filter to thespecified torque.

Tightening TorqueOil Filter:17.5 N·m (1.8 kgf·m, 13 ft·lb)

A. Packing

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

NOTEReplace the gasket with a new one.

Tightening TorqueEngine Oil Drain Bolt:30 N·m (3.1 kgf·m, 22 ft·lb)

• Fill the engine up to the upper levelline with a good quality engine oilspecified in the table.

Recommended Engine OilType:API SG, SH, SJ, SL or SM with JASOMA, MA1 or MA2

Viscosity:SAE 10W-40

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


provide adequate lubrication for boththe engine and the clutch.

Engine Oil CapacityCapacity:1.7 L (1.8 US qt) (when filter is notremoved)1.9 L (2.0 US qt) (when filter isremoved)2.4 L (2.5 US qt) (when engine iscompletely dry)

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

• Start the engine.• Check the oil level and oil leakage.


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

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

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

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

Radiator Hoses -Check the radiator hoses for leakage,

cracks or deterioration, and connec-tions for leakage, or looseness eachday before riding the motorcycle, andin accordance with the Periodic Main-tenance Chart.


Coolant -Coolant absorbs excessive heat from

the engine and transfers it to the airat the radiator. If the coolant level be-comes low, the engine overheats andmay suffer severe damage. Check thecoolant level each day before riding themotorcycle, and in accordance with theperiodic maintenance chart and replen-ish coolant if the level is low. Changethe coolant in accordance with the Pe-riodic Maintenance Chart.

Information for CoolantTo protect the cooling system (con-

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

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

WARNINGCoolant containing corrosioninhibitors for alminum enginesand radiators include harmfulchemicals for human body.Drinking coolant can result inserious injury or death. Usecoolant in accordance with theinstractions of the manufacturer.

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


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

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

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

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

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


Coolant Level Inspection• Situate the motorcycle so that it isperpendicular to the ground.• Check the coolant level through thecoolant level gauge on the reservetank located to the right of the engine.The coolant level should be betweenthe F (Full) and L (Low) level lines.

A. F (Full) Level LineB. L (Low) Level LineC. Right Middle Fairing

NOTECheck the level when the engine iscold (room or atmospheric tempera-ture).

• If the amount of coolant is insuffi-cient, remove the right middle fair-ing and add coolant into the reservetank.


Coolant Filling• Remove the seat (see Seat sectionin the GENERAL INFORMATIONchapter).• Remove the screw.• Clear the projections from the grom-mets, and remove the right sidecover backward.

A. Right Side CoverB. ScrewC. Projections and Grommets

• Remove the bolts.• Clear the projections from the grom-mets, and remove the right middlefairing forward.

A. Right Middle FairingB. BoltsC. Projections and Grommets


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

A. Reserve TankB. CapC. F (Full) Level LineD. L (Low) Level Line

NOTEIn an emergency you can add wa-ter alone to the coolant reserve tank,

however, it must be returned to thecorrect mixture ratio by the additionof antifreeze concentrate as soon aspossible.

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

• Install the cap.


• Install the right middle fairing as fol-lows.• Fit the projections to the slots.• Fit the projections to the grommets.• Tighten the bolts.

A. Right Middle FairingB. ProjectionsC. SlotsD. Grommets

• Install the right side cover as follows.• Fit the projections to the slots.• Fit the projections to the grommets.• Tighten the screw.• Install the seat (see Seat sectionin the GENERAL INFORMATIONchapter).

A. Right Side CoverB. ProjectionsC. SlotsD. Grommets


Coolant ChangeHave the coolant changed by an au-

thorized Kawasaki dealer.

Spark PlugsThe standard spark plug is shown in

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

by an authorized Kawasaki dealer.Spark Plug

Standard Plug NGK CR9EIA-9

Plug Gap 0.8 ∼ 0.9 mm(0.031 ∼ 0.035 in.)

Tightening Torque 15 N·m(1.5 kgf·m, 11 ft·lb)


A. 0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)

Evaporative Emission ControlSystem (California modelonly)

This system routes fuel vapors fromthe fuel system into the running engineor stores the vapors in a canister whenthe engine is stopped. Although no ad-justments are required, a thorough vi-sual inspection must be made at the in-tervals specified by the Periodic Main-tenance Chart.

Inspection• Check that the hoses are securelyconnected.• Replace any kinked, deteriorated, ordamaged hoses.


Valve ClearanceValve and valve seat wear decreases

valve clearance, upsetting valve timing.

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

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

be done by an authorized Kawasakidealer.


Kawasaki Clean Air SystemThe Kawasaki Clean Air System

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

Air Suction Valve -The air suction valve is essentially a

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

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

tion should be done by an authorizedKawasaki dealer.


Air CleanerA clogged air cleaner restricts the en-

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

cleaned in accordance with the Pe-riodic Maintenance Chart. In dusty,rainy, or muddy conditions, the aircleaner element should be servicedmore frequently than the recom-mended interval by an authorizedKawasaki dealer.

Oil Draining• Inspect the drain hose located on therear side of the engine to see if anyoil or water has run down from the aircleaner housing.

A. Drain HoseB. Plug

• If there is any oil in the hose, removethe plug from the lower end of thedrain hose and drain the oil.


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

Throttle Control SystemCheck the throttle grip play in accor-

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

Throttle Grip -The throttle grip controls the butterfly

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


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

A. Throttle GripB. Throttle Grip Play

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

• If there is improper play, adjust it.

Adjustment• Loosen the locknut at the upper endof the throttle cable, and turn thethrottle cable adjuster in completelyso as to give the throttle grip plentyof play.

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


• If the throttle grip play cannot be ad-justed with the accelerator cable ad-juster at the throttle grip, use the de-celerator cable adjuster located un-der the fuel tank.• Turn out the decelerator cable adjust-ing nut until there is no play when thethrottle grip is completely closed.• Tighten the locknut.

A. AdjusterB. LocknutC. Throttle Cable (Decelerator Cable)

• Turn out the accelerator cable ad-juster until a play of 2 ∼ 3 mm (0.08∼ 0.12 in.) is obtained at the throttlegrip.• Tighten the locknut.• With the engine idling, turn the han-dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improperlyadjusted or incorrectly routed, or theymay be damages. Be sure to correctany of these conditions before idling.

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


Engine Vacuum SynchronizationEngine vacuum synchronization

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

NOTEPoor engine vacuum synchronizationwill cause unstable idling, sluggishthrottle response, and reduce enginepower and performance.

Idle SpeedThe idle speed check should be per-

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


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

Idle Speed1 250 ∼ 1 350 r/min (rpm)

A. Idle Adjusting Screw

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

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


ClutchDue to friction plate wear and clutch

cable stretch over a long period of use,the clutch operation should be checkedeach day before riding the motorcycle,and in accordance with the PeriodicMaintenance Chart.

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

• Check the clutch lever play as shownin the figure.

A. LocknutB. Clutch Lever PlayC. Adjuster

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

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


Adjustment

WARNINGExcess clutch cable play couldprevent clutch disengagementand cause a crash resulting inserious injury or death. Whenadjusting the clutch cable, besure the upper end of the outercable is fully seated in its fittingso that it doesn’t slip into placelater and create excessive cableplay.

• Loosen the locknut, and turn theadjuster so that the clutch lever willhave the proper play.• If it cannot be done, use the nuts atthe lower end of the clutch cable.

A. NutsB. Clutch Cable


WARNINGTo avoid a serious burn, nevertouch a hot engine or an exhaustpipe during clutch adjustment.

NOTEAfter the adjustment is made, startthe engine and check that the clutchdoes not slip and releases properly.For minor corrections, use the ad-juster at the clutch lever.

DANGERExhaust gas contains carbonmonoxide, a colorless, odor-less poisonous gas. Inhalingcarbon monoxide can causeserious brain injury or death.DO NOT run the engine in en-closed areas. Operate only in awell-ventilated area.


Drive ChainThe drive chain slack and lubrica-

tion must be checked each day be-fore riding themotorcycle, and in accor-dance with the Periodic MaintenanceChart for safety and to prevent exces-sive wear. If the chain becomes badlyworn or maladjusted - either too looseor too tight - the chain could jump offthe sprockets or break.

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

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

A. Chain Slack


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

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

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

A. Rear Axle NutB. Cotter PinC. AdjusterD. Locknut


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

A. MarksB. NotchC. IndicatorD. AdjusterE. Locknut

NOTEWheel alignment can also bechecked using the straightedge orstring method.


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

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

Tightening TorqueRear Axle Nut:108 N·m (11.0 kgf·m, 80 ft·lb)

NOTEIf a torque wrench is not available,this item should be serviced by aKawasaki dealer.

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

A. Cotter Pin


NOTEWhen inserting the cotter pin, if theslots in the nut do not align withthe cotter pin hole in the axle shaft,tighten the nut clockwise up to thenext alignment.It should be within 30 degree.Loosen once and tighten again whenthe slot goes past the nearest hole.

A. Turning Clockwise

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

• Check the rear brake (see Brakessection).


Wear Inspection• Remove the bolts to take off the chaincover.

A. Chain CoverB. Bolts

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

of the 21st pin. Since the chain maywear unevenly, take measurementsat several places.• If the length exceeds the service limit,the chain should be replaced.

A. MeasureB. Weight

Drive Chain 20-Link Length

Service Limit 319 mm (12.56 in.)


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

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

NOTESprocket wear is exaggerated for il-lustration. See Service Manual forwear limits.

A. Good TeethB. Worn TeethC. Damaged Teeth

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


LubricationLubrication is also necessary after

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

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

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


BrakesBrake Wear InspectionInspect the brakes for wear. For each

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

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

Disc Brake Fluid -In accordancewith the Periodic Main-

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

Fluid RequirementUse heavy-duty brake fluid only from

a container marked DOT4.

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


Fluid Level Inspection• The brake fluid level in the front brakefluid reservoir must be kept abovethe line (lower level line) next to thegauge and that in the rear brake fluidreservoir (located under the seat)must be kept between the upper andlower level lines (reservoirs held hor-izontal).

A. Front Brake Fluid ReservoirB. Lower Level Line

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


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

A. Front Brake Fluid ReservoirB. Upper Level Line

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


NOTEFirst, tighten until slight resistance isfelt indicating that the cap is seatedon the reservoir body, then tightenthe cap an additional 1/6 turn whileholding the brake fluid reservoirbody.

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

Fluid ChangeHave the brake fluid changed by an

authorized Kawasaki dealer.

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

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

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


Brake Light SwitchesWhen either the front or rear brake is

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

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

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

A. Brake PedalB. 10 mm (0.39 in.)

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

Brake Pedal Travel10 mm (0.39 in.)


Adjustment• Disconnect the connector.

A. Connector

• To adjust the rear brake light switch,move the switch up or down by turn-ing the switch body.

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

• Connect the connector.


Front ForkThe front fork operation and oil leak-

age should be checked in accordancewith the Periodic Maintenance Chart.

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

• If there is any doubt about the frontfork, it should be checked by an au-thorized Kawasaki dealer.

A. Inner Tube


On the top of each front fork leg isa spring preload adjuster and on thespring preload adjuster of the rightfront fork leg is a rebound dampingforce adjuster so that the spring forceand damping force can be adjustedfor different riding and loading condi-tions. Weaker spring force and damp-ing force are for comfortable riding,but they should be increased for highspeed riding or riding on rough roads.

A. Spring Preload AdjusterB. Rebound Damping Force Adjuster

Spring Preload Adjustment• Turn the spring preload adjuster intothe nut to increase spring force andout to decrease spring force. Theadjusting range is as follows.

Adjusting Range15 turns out*

*: Counterclockwise from the fullyseated position


Rebound Damping Force Adjustment• Turn the rebound damping forceadjuster all the way into the springpreload adjuster with a screwdriver.This makes the damping force great-est.• Turn out the adjuster to decreasedamping force.

A. ScrewdriverB. Rebound Damping Force Adjuster

The standard setting positions of thespring preload adjuster and rebounddamping force adjuster for an average-build rider of 68 kg (150 lb) with no pas-senger and no accessories are as fol-lows:

Spring PreloadAdjuster 7 turns out*

ReboundDamping ForceAdjuster

1 3/4 turns out*

*: Counterclockwise from the fullyseated position

NOTICEDo not force to turn the rebounddamping force adjuster from thefully seated position, as the ad-justing mechanism may be dam-aged.


Rear Shock AbsorberThe rear shock absorber operation

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

Rear Shock Absorber Inspection• Press down on the seat several timesto inspect the stroke.• Visually inspect the rear shock ab-sorber for oil leakage.• If there is any doubt about the rearshock absorber, it should be checkedby an authorized Kawasaki dealer.

A. Rear Shock Absorber

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


Spring Preload AdjustmentThe spring preload adjuster on the

rear shock absorber has 7 positions.

A. Spring Preload AdjusterB. Wrench

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

Position 1 2 3 4 5 6 7

Spring Action Stronger ——

The standard setting position for anaverage-build rider of 68 kg (150 lb)with no passenger and no accessoriesis No. 5.

NOTICEBe careful not to damage themotorcycle parts when adjust-ing the spring preload.

Rebound Damping Force AdjustmentThe rebound damping force adjuster

is located at the lower end of the rearshock absorber.


A. Rebound Damping Force Adjuster

• Turn the rebound damping force ad-juster towards the H mark to makethe damping force greatest.• Turn the adjuster towards the S markto decrease damping force.The standard setting position of the

rebound damping force adjuster for anaverage-build rider of 68 kg (150 lb)

with no passenger and no accessoriesis as follows:

Rebound DampingForce Adjuster 5 clicks*

*: out from the fully seated position


WheelsTubeless tires are installed on the

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

A. TUBELESS Mark

A. TUBELESS Mark

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


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

Tires -Payload and Tire PressureFailure to maintain proper inflation

pressures or observe payload limits foryour tires may adversely affect han-dling and performance of your motorcy-cle and can result in loss of control. Themaximum recommended load in addi-tion to vehicle weight is 180 kg (397 lb),including rider, passenger, baggage,and accessories.• Remove the air valve cap.• Check the tire pressure often, usingan accurate gauge.• Make sure to install the air valve capsecurely.

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


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

A. Tire Pressure Gauge

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

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

becomes more susceptible to punctureand failure. An accepted estimate isthat 90% of all tire failures occur duringthe last 10% of tread life (90% worn).So it is false economy and unsafe touse the tires until they are bald.


• In accordance with the PeriodicMaintenance Chart, measure thedepth of the tread with a depthgauge, and replace any tire thathas worn down to the minimum al-lowable tread depth.

A. Tire Depth Gauge

Minimum Tread Depth

Front — 1 mm(0.04 in.)

Under 130 km/h(80 mph)

2 mm(0.08 in.)

RearOver 130 km/h(80 mph)

3 mm(0.12 in.)

• Visually inspect the tire for cracksand cuts, replacing the tire in case ofbad damage. Swelling or high spotsindicate internal damage, requiringtire replacement.• Remove any imbedded stones orother foreign particles from the tread.

NOTEHave the wheel balance inspectedwhenever a new tire is installed.


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

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

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

Standard Tire (Tubeless)

Front

Make, Type:DUNLOP, SPORTMAXRADIAL D221FAG

Size:120/70 ZR17 M/C (58W)

Rear

Make, Type:DUNLOP, SPORTMAX D221G

Size:160/60 ZR17 M/C (69W)


Replacement Tire (Tubeless)

Front

Make, Type:PIRELLI, SCORPIONSYNC FRONT

Size:120/70 ZR17 M/C (58W)

Rear

Make, Type:PIRELLI, SCORPIONSYNC RADIAL

Size:160/60 ZR17 M/C (69W)

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

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


BatteryThe battery installed in this motorcy-

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

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

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

Due to their internal composition,batteries continually self discharge.The discharge rate depends on thetype of battery and ambient temper-ature. As temperature rises, so doesthe discharge rate. Every 15°C (27°F)doubles the rate.Electrical accessories, such as digi-

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


Self-discharge

Approx. number of daysfrom 100% charged to100% discharged

Lead-Antimony

Lead-Calcium

Tempera-ture

Battery Battery

40°C(104°F) 100 Days 300 Days

25°C (77°F) 200 Days 600 Days

0°C (32°F) 550 Days 950 Days

Current Drain

DischargingAmpere

Days from100%chargedto 50%discharged

Days from100%chargedto 100%discharged

7 mA 60 Days 119 Days





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

Battery Sulfation -A common cause of battery failure is

sulfation.


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

Battery Maintenance -It is the owner’s responsibility to keep

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

quently, inspect the battery voltageweekly using a voltmeter. If it dropsbelow 12.8 volts, the battery should becharged using an appropriate charger(check with a Kawasaki dealer). If

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

Kawasaki-recommended chargersare:OptiMateYuasa 1.5 Amp Automatic chargerBattery Mate 150-9

If the above chargers are not avail-able, use equivalent one.For more details, ask a Kawasaki

dealer.

Battery Charging -• Remove the battery from the motor-cycle (see Battery Removal).• Attach the leads from the charger tothe battery and charge the battery ata rate that is 1/10th of the battery


capacity. For example, the chargingrate for a 10 Ah battery would be 1.0ampere.• The charger will keep the battery fullycharged until you are ready to re-install the battery in the motorcycle(see Battery Installation).

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

NOTEIf you charge the sealed battery,never fail to observe the instructionsshown in the label on the battery.

WARNINGLead is a toxic substance. Bat-tery posts, terminals and relatedaccessories contain lead andlead compounds. Wash handsafter handling.

Battery Removal• Remove the seat (see Seat sectionin the GENERAL INFORMATIONchapter).• Slide the red cap.


• Disconnect the cables from the bat-tery, first from the (–) terminal andthen the (+) terminal.

A. Red Cap ((+) Terminal)B. (–) Terminal

• Take the battery out.• Clean the battery using a solution ofbaking soda and water. Be sure thatthe cable connections are clean.

Battery Installation• Place the battery in the rear fenderfront.• Connect the (+) cable to the (+) ter-minal, and then connect the (–) cableto the (–) terminal.

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

• Put a light coat of grease on the ter-minals to prevent corrosion.• Cover the red cap.• Reinstall the removed parts.


Headlight BeamHorizontal AdjustmentThe headlight beam is adjustable

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

A. Horizontal Adjuster

Vertical AdjustmentThe headlight beam is adjustable ver-

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

A. Vertical Adjuster


NOTEOn high beam, the brightest pointshould be slightly below horizontal.The proper angle is 0.4 degrees be-low horizontal. This is a 50 mm (2.0in.) drop at 7.6 m (25 ft) measuredfrom the center of the headlight, withthe motorcycle on its wheels and therider seated.

A. 50 mm (2.0 in.)B. Center of Brightest SpotC. 7.6 m (25 ft)D. Height of Headlight Center


FusesFuses are arranged in the fuse box

located under the seat. The main fuseis mounted on the starter relay behindthe left side cover. If a fuse fails duringoperation, inspect the electrical systemto determine the cause, and then re-place it with a new fuse of proper am-perage.

A. Fuse BoxB. FusesC. Spare Parts

• Remove the bolt.• Clear the projections from the grom-mets, and remove the left framecover upward.

A. Left Frame CoverB. BoltC. Projections and Grommets


• Remove the cover by removing thebolt.

A. CoverB. Bolt

• Disconnect the connector.

A. Main FuseB. Spare FuseC. Connector


• Install the left frame cover as follows.• Fit the projection to the slot.• Fit the projections to the grommets.• Tighten the bolt.

A. Left Frame CoverB. ProjectionsC. SlotD. Grommets

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

A. NormalB. Failed


General LubricationLubricate the points shown below,

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

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

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

Apply motor oil to the followingpivots -Side StandClutch LeverFront Brake LeverRear Brake Pedal

Lubricate the following cableswith a pressure cable lubber -(K) Clutch Inner Cable(K) Throttle Inner Cables


Apply grease to the followingpoints -(K) Clutch Inner Cable Upper End(K) Throttle Inner Cable Upper Ends

(K): Should be serviced by an authorizedKawasaki dealer.

NOTEAfter connecting the cables, adjustthem.

Cleaning Your MotorcycleGeneral PrecautionsFrequent and proper care of your

Kawasaki motorcycle will enhanceits appearance, optimize overall per-formance, and extend its useful life.Covering your motorcycle with a highquality, breathable motorcycle coverwill help protect its finish from harmfulUV rays, pollutants, and reduce theamount of dust reaching its surfaces.• Be sure the engine and exhaust arecool before washing.• Avoid applying degreaser to seals,brake pads, and tires.• Always use non-abrasive wax andcleaner/polisher.• Avoid all harsh chemicals, solvents,detergents, and household cleaningproducts such as ammonia-basedwindow cleaners.


• Gasoline, brake fluid, and coolantwill damage the finish of painted andplastic surfaces: wash them off im-mediately.• Avoid wire brushes, steel wool, andall other abrasive pads or brushes.• Use care when washing the wind-shield, headlight cover, and otherplastic parts as they can easily bescratched.• Avoid using pressure washers; wa-ter can penetrate seals and electricalcomponents and damage your mo-torcycle.• Avoid spraying water in delicateareas such as in air intakes, fuelsystem, brake components, electri-cal components, muffler outlets, andfuel tank openings.

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


• After cleaning your motorcycle,check the rubber boot covering theshift pedal ball joint for correct instal-lation. Be sure the sealing lip of therubber boot fits into the groove of theball joint.

A. Rubber Boot

• If the boot is damaged, replace it witha new one. If the boot is not posi-tioned in the groove correctly, placeit in the correct position.

A. Not correct positionB. Correct position

• Start the engine and let it idle for sev-eral minutes. The heat from the en-gine will help dry moist areas.• Carefully ride your motorcycle at aslow speed and apply the brakes


several times. This helps the brakesdry and restores its normal operatingperformance.• Lubricate the drive chain to preventrusting.

NOTEAfter riding in an area where theroads are salted or near the ocean,immediately wash your motorcyclewith cold water. Do not use warmwater as it accelerates the chemicalreaction of the salt. After drying,apply a corrosion protection sprayon all metal and chrome surfaces toprevent corrosion.Condensation may form on the insideof the headlight lens after riding in therain, washing the motorcycle or hu-mid weather. To remove the mois-ture, start the engine and turn on the

headlight. Gradually the condensa-tion on the inside of the lens will clearoff.

Painted SurfacesAfter washing your motorcycle, coat

painted surfaces, both metal and plas-tic, with a commercially available mo-torcycle/automotive wax. Wax shouldbe applied once every three months oras conditions require. Avoid surfaceswith “satin” or “flat” finishes. Alwaysuse non-abrasive products and applythem according to the instructions onthe container.

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

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


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

Chrome and AluminumChrome and uncoated aluminum

parts can be treated with a chrome/alu-minum polish. Coated aluminum

should be washed with a mild neu-tral detergent and finished with a spraypolish. Aluminum wheels, both paintedand unpainted can be cleaned withspecial non-acid based wheel spraycleaners.

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

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

rest of the motorcycle, then treated witha vinyl treatment.The sidewalls of tires and other rub-

ber components should be treated witha rubber protectant to help prolong theiruseful life.


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


Bolt and Nut TighteningIn accordance with the Periodic Maintenance Chart, it is very important to check

the tightness of the bolts and nuts listed here. Also, check to see that each cotterpin is in place and in good condition. Please ask your authorized Kawasaki dealerfor torque values.

1. Clutch Lever Clamp Bolts2. Handlebar Holder Bolts3. Steering Stem Head Bolt4. Steering Stem Nut5. Front Master Cylinder

Clamp Bolts


1. Front Fork Clamp Bolts2. Footpeg Stay Bolts3. Tandem Grip Mounting

Bolts4. Front Fender Bolts5. Brake Disc Mounting Bolts6. Caliper Mounting Bolts7. Engine Mounting Bolts

and Nuts8. Side Stand Bolt9. Swingarm Pivot Shaft Nut10. Rear Axle Nut11. Rear Sprocket Nuts


1. Rear Shock Absorber Bolts2. Rear Master Cylinder

Mounting Bolts3. Brake Pedal Bolt4. Muffler Body Mounting

Bolts5. Exhaust Pipe Manifold

Holder Nuts6. Front Axle7. Front Axle Clamp Bolt

164 STORAGE

STORAGE

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

WARNINGMotorcycle oil is a toxic substance. Dispose of used oil properly. Con-tact your local authorities for approved disposal methods or possible re-cycling.

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

STORAGE 165

WARNINGGasoline is extremely flammable and can be explosive under certain con-ditions, creating the potential for serious burns. Turn the ignition key to“OFF”. Do not smoke. Make sure the area is well-ventilated and free fromany source of flame or sparks; this includes any appliance with a pilotlight. Gasoline is a toxic substance. Dispose of gasoline properly. Con-tact your local authorities for approved disposal methods.

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

166 STORAGE

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

TROUBLESHOOTING GUIDE 167TROUBLESHOOTING GUIDE

Engine Does Not Start -Starter Motor Won’t Turn• Engine stop switch off• Transmission not in neutral• Fuse blown• Battery cables do not make goodelectrical contact with battery termi-nals• Battery dischargedEngine Cranks, But Won’t Start• No fuel in tank• Fuel line clogged• Fuel broken down• Engine flooded• Spark plugs not in good contact• Spark plugs fouled or wet

• Incorrect spark plug gap• Incorrect valve clearance• Battery discharged• No first turning the ignition key to“OFF” when the motorcycle fallsdown.

Engine Stalls -Just When Shifting Into 1st Gear• Side stand has been left down• Clutch does not properly disengageWhile Riding• No fuel in tank• Fuel tank air vent is obstructed• Overheating• Battery discharged

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

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kawasaki kle650 versys 650 owners maintenance manual

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odorless poisonous gas

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authorized kawasaki dealer

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