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ENGLISH

MotorcycleOwner's Manual

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

WARNING

This warning symbol identifiesspecial instructions or proce-dures which, if not correctly fol-lowed, could result in personalinjury, or loss of life.

CAUTION

This caution symbol identifiesspecial instructions or proce-dures which, if not strictly ob-served, could result in damage toor destruction of equipment.

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

NOTICE

THIS PRODUCT HAS BEEN MAN-UFACTURED FOR USE IN A REA-SONABLE AND PRUDENTMANNER BY A QUALIFIED OP-ERATOR AND AS AVEHICLE ON-LY.

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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 ve-hicle 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 pur-chase from any authorized Kawasaki motorcycle dealer. The Service Manualcontains detailed disassembly and maintenance information. Those who plan to dotheir own work should, of course, be competent mechanics and possess the spe-cial tools described in the Service Manual.

Keep this Owner's Manual aboard your motorcycle at all times so that you can re-fer to it whenever you need information.

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

All rights reserved. No part of this publication may be reproduced without our pri-or written permission.

This publication includes the latest information available at the time of printing.However, there may be minor differences between the actual product and illustra-tions and text in this manual.All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.Consumer Products & Machinery Company

© 2006 Kawasaki Heavy Industries, Ltd. September 2006. (3). (C, C, K3)

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TABLE OF CONTENTS

SPECIFICATIONS ................................ 8LOCATION OF PARTS ........................ 12LOADING AND ACCESSORIES IN-FORMATION ..................................... 15

GENERAL INFORMATION .................. 18Meter Instruments .............................. 18Tachometer: ................................... 19LCD (Speedometer, Clock, Odom-eter, Trip Meters, Fuel LevelGauge): ...................................... 19

Warning/Indicator Lights: ............... 26Key ..................................................... 29Ignition Switch/Steering Lock ............ 29Right Handlebar Switches ................. 31Engine Stop Switch: ...................... 31Starter Button: ................................ 31

Left Handlebar Switches .................... 32Dimmer Switch: .............................. 32Turn Signal Switch: ........................ 32Horn Button: ................................... 33

Passing Button: .............................. 33Hazard Switch: ............................... 33

Brake/Clutch Lever Adjusters ............ 34Fuel Tank Cap .................................... 35Fuel Tank ........................................... 36Fuel Requirement: ......................... 37

Stand .................................................. 38Seat Lock ........................................... 39Helmet Holding Hooks ....................... 41Tool Kit/U-Shaped lock Compartment

42Rear View Mirror ................................ 43Windshield ......................................... 44

BREAK-IN ............................................ 46HOW TO RIDE THE MOTORCYCLE .. 48Starting the Engine ............................ 48Jump Starting ..................................... 50Moving Off .......................................... 53Shifting Gears .................................... 54Braking ............................................... 55

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Anti-lock Brake System (ABS) formodels equipped with ABS ............ 57ABS Indicator Light: ....................... 58

Stopping the Engine .......................... 59Stopping the Motorcycle in an Emer-gency .............................................. 60

Parking ............................................... 61Catalytic Converter ............................ 62

SAFE OPERATION .............................. 64Safe Riding Technique ....................... 64Daily Safety Checks .......................... 67Additional Considerations for HighSpeed Operation ............................ 69

MAINTENANCE AND ADJUSTMENT 71Periodic Maintenance Chart .............. 72Engine Oil .......................................... 81Cooling System .................................. 87Spark Plugs ....................................... 93Kawasaki Clean Air System .............. 94Valve Clearance ................................. 95Air Cleaner ......................................... 96Throttle Control System ..................... 97Engine Vacuum Synchronization .......100

Idle Speed ..........................................100Clutch .................................................102Drive Chain ........................................104Brakes ................................................113Brake Light Switches .........................117Front Fork ..........................................119Rear Shock Absorbers ......................122Wheels ...............................................125Battery ................................................130Headlight Beam .................................135Fuses .................................................137Cleaning Your Motorcycle ..................140

STORAGE ............................................144ENVIRONMENTAL PROTECTION .....147LOCATION OF LABELS ......................148

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SPECIFICATIONS

PERFORMANCEMaximum Horsepower 47 kW (64 PS) @8 000 r/min (rpm)

Maximum Torque61 N·m (6.2 kgf·m, 45 ft·lb) @6 800 r/min(rpm)

Minimum Turning Radius 2.7 m (106.3 in.)DIMENSIONSOverall Length 2 125 mm (83.66 in.)Overall Width 840 mm (33.07 in.)Overall Height 1 315 mm (51.77 in.)Wheelbase 1 415 mm (55.71 in.)Road Clearance 180 mm (7.09 in.)Dry Weight (A) 181 kg (399 lb)

(B) 184 kg (406 lb)

8 SPECIFICATIONS

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

cooled

Displacement 649 cm3 (39.6 cu in.)Bore × Stroke 83 × 60 mm (3.27 × 2.36 in.)Compression Ratio 10.6 : 1Starting System Electric starterCylinder Numbering Method Left to right, 1-2Firing Order 1-2Carburetion System KEIHIN 38 × 2Ignition System Battery and coil (transistorized ignition)Ignition Timing 10° BTDC @1 300 r/min (rpm) ~(Electronically advanced) 33° BTDC @5 000 r/min (rpm)Spark Plugs NGK CR9EIA-9Lubrication System Forced lubrication (semi-dry sump)Engine Oil Type: API SE, SF or SG

API SH, SJ or SL with JASO MASAE 10W-40

Capacity: 2.4 L (2.5 US qt)Coolant Capacity 1.2 L (1.3 US qt)

SPECIFICATIONS 9

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TRANSMISSIONTransmission Type 6-speed, return shiftClutch Type Wet, multi discDriving System Chain drivePrimary Reduction Ratio 2.095 (88/42)Final Reduction Ratio 3.067 (46/15)Overall Drive Ratio 5.473 (Top gear)Gear Ratio 1st 2.438 (39/16)

2nd 1.714 (36/21)3rd 1.333 (32/24)4th 1.111 (30/27)5th 0.966 (28/29)6th 0.852 (23/27)

FRAMECastor 25°Trail 108 mm (4.3 in.)Tire Size: Front 120/70ZR17 M/C (58 W) Tubeless

Rear 160/60ZR17 M/C (69 W) TubelessRim Size: Front 17 × 3.50

Rear 17 × 4.50Fuel Tank Capacity 19.0 L (5.0 US gal)

10 SPECIFICATIONS

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ELECTRICAL EQUIPMENTBattery 12 V 10 AhHeadlight 12 V 55 W/55 W (Hi/Lo)LED Tail/Brake Light 0.5/3.7 W

(A): KLE650A(B): KLE650B

Even if one of LED (Light Emitting Diode) tail/brake light is not lit, consult with anauthorized Kawasaki dealer.Specifications subject to change without notice, and may not apply to every coun-try.

SPECIFICATIONS 11

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LOCATION OF PARTS

1. Clutch Lever2. Left Handlebar Switches3. Meter Instruments4. Brake Fluid Reservoir (Front)5. Right Handlebar Switches

6. Front Brake Lever7. Throttle Grip8. Ignition Switch/Steering Lock

12 LOCATION OF PARTS

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9. Wheel10. Turn Signal Light11. Headlight/Position12. Spark Plugs13. Air Cleaner14. Main Fuse15. Battery

16. Seat17. Helmet Holding Hook18. Tool Kit/Storage Com-

partments19. Seat Lock20. Front Fork21. Brake Disc

22. Brake Caliper23. Shift Pedal24. Side Stand25. Drive Chain

LOCATION OF PARTS 13

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26. License Plate Light27. Tail/Brake Light28. Brake Fluid Reservoir

(Rear)29. Fuel Tank

30. Fuel Tank Cap31. Muffler32. Rear Brake Light Switch33. Rear Brake Pedal34. Oil Level Gauge

35. Rear Shock Absorber36. Rebound Damping Force

Adjuster37. Idle Adjusting Screw38. Coolant Reserve Tank

14 LOCATION OF PARTS

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LOADING AND ACCESSORIES INFORMATION

WARNING

Incorrect loading, improper in-stallation or use of accessories,or modification of your motor-cycle may result in an unsafe rid-ing condition. Before you ride themotorcycle, make sure that themotorcycle is not overloaded andthat you have followed these in-structions.

With the exception of genuine Kawa-saki Parts and Accessories, Kawasakihas no control over the design or appli-cation of accessories. In some cases,improper installation or use of acces-sories, or motorcycle modification, willvoid the motorcycle warranty can neg-atively affect performance, and can

even be illegal. In selecting and usingaccessories, and in loading the motor-cycle, you are personally responsiblefor your own safety and the safety ofother persons involved.

NOTE○Kawasaki Parts and Accessorieshave been specially designed foruse on Kawasaki motorcycles. Westrongly recommend that all partsand accessories you add to your mo-torcycle be genuine Kawasaki com-ponents.

Because a motorcycle is sensitive tochanges in weight and aerodynamicforces, you must take extreme care incarrying cargo, passengers and/or inthe fitting of additional accessories.The following general guidelines have

LOADING AND ACCESSORIES INFORMATION 15

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been 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 improp-er positioning during cornering andsudden movements. It is importantthat the passenger sit still while themotorcycle is in motion and not in-terfere with the operation of the mo-torcycle. Do not carry animals onyour motorcycle.

2. You should instruct any passengerbefore riding to keep his feet on thepassenger footpegs and hold on tothe operator, seat strap or grab rail.Do not carry a passenger unless heor she is tall enough to reach thefootpegs and footpegs are pro-vided.

3. All baggage should be carried aslow as possible to reduce the effect

on 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 bag-gage will not move around whileyou are riding. Recheck baggagesecurity as often as possible (notwhile the motorcycle is in motion)and adjust as necessary.

5. Do not carry heavy or bulky itemson a luggage rack. They are de-signed for light items, and overload-ing can affect handling due tochanges in weight distribution andaerodynamic forces.

6. Do not install accessories or carrybaggage that impairs the perform-ance of the motorcycle. Make surethat you have not adversely

16 LOADING AND ACCESSORIES INFORMATION

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affected any lighting components,road clearance, banking capability(i.e., lean angle), control operation,wheel travel, front fork movement,or any other aspect of the motorcy-cle's operation.

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

8. Fairings, windshields, backrests,and other large items have the ca-pability of adversely affecting stabil-ity and handling of the motorcycle,not only because of their weight,but also due to the aerodynamicforces acting on these surfaceswhile the motorcycle is in operation.Poorly designed or installed itemscan result in an unsafe riding condi-tion.

9. This motorcycle was not intendedto be equipped with a sidecar or to

be used to tow any trailer or othervehicle. Kawasaki does not manu-facture sidecars or trailers for mo-torcycles and cannot predict theeffects 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 effectson motorcycle components causedby the use of such accessories willnot be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage, andaccessories must not exceed 180 kg (397lb).

LOADING AND ACCESSORIES INFORMATION 17

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GENERAL INFORMATION

Meter Instruments

A. Coolant Temperature Warn-ing Light

B. Oil Pressure Warning 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,

Trip Meter A/B, Odometer,Fuel Level Gauge)

L. FI Indicator LightM. ABS Indicator Light (model

with ABS)

18 GENERAL INFORMATION

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Tachometer:The 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 the redzone is above maximum recom-mended engine speed and is alsoabove the range for good perform-ance.When ignition key is turned to “ON”,

the tachometer needle momentarilypoints to the last reading to check itsoperation. If the tachometer needledoes not operate correctly, have it in-spected by an authorized Kawasakidealer.

CAUTION

Engine r/min (rpm) should not beallowed to enter the red zone; op-eration in the red zone will over-stress the engine and may causeserious engine damage.

LCD (Speedometer, Clock, Odome-ter, Trip Meters, Fuel LevelGauge):

The LCD (Liquid Crystal Display) lo-cated in the tachometer face is used todisplay the speedometer, Clock, odom-eter, Trip Meters A/B, and Fuel LevelGauge. Pushing the MODE buttonshifts the display through the followingfour modes: CLOCK, ODO, and TRIPA/B. When the ignition key is turned to“ON”, all the LCD segments are dis-played for three seconds, then the

GENERAL INFORMATION 19

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clock or meters operate normally de-pending on the mode selected.

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

NOTE○For safe operation do not press theMODE button while riding.

Digital Meter

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

NOTE○Do not shift the digital meter displaywhile riding for safe operation.


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Mile/km Display -Mile/km Display can alternate be-

tween English and metric modes (mileand km) in the digital meter. Make surethat km or mile according to local regu-lations is correctly displayed before rid-ing.

NOTE○Do not operate the vehicle with thedigital meter displaying in the wrongunit (km or mile). Shift the km/miledisplay in the digital meter as fol-lows.

• Display the odometer in the digitalmeter.

• The km/mile display shifts by push-ing the RESET button while theMODE button pushed in.

A. km/Mile Display


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• The km/mile display shifts as follows.

A. Mile DisplayB. km DisplayC. Push RESET Button with MODE Button in

NOTE○The 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 displaythe clock.

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


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• Push the “RESET” button. The hourdisplay only flashes. Push the“MODE” button to advance thehours.

• Push the “RESET” button. The hourdisplay stops flashing and the minutedisplay starts flashing. Push the“MODE” button to advance the mi-nutes.

• 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.

NOTE○Pushing the “MODE” button momen-tarily advances the hour or minutestep by step. Pushing and holdingthe button advance the hour or mi-nute 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.


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Odometer -The odometer shows the total dis-

tance the vehicle has been ridden.This meter cannot be reset.

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

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

Trip Meter -The trip meters show the distance in

kilometers traveled since they werelast reset to zero.TRIP A: 0.0 ~ 999.9TRIP B: 0.0 ~ 9999.9To reset the trip meter:

• Push the “MODE” button to displaythe trip 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 next reset.


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

○When the trip meter is reset whilethe vehicle is stopped, it starts count-ing as soon as the vehicle startsmoving.

○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.


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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) to E(empty). When only the most bottomsegment is displayed, 5.0 L (1.3 USgal) of fuel remain. Furthermore, whenthe lowest segment and “FUEL” flashin the digital meter, only 3.5 L (0.9 USgal) of fuel remain.Refuel at the earliest opportunity if

the most bottom segment of the fuelgauge flashes.

A. Flash

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

Warning/Indicator Lights:N:When the transmission is in neutral,the neutral indicator light is lit.


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

: When the turn signal switch ispushed to the left or right, the corre-sponding 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 Adjustmentchapter for more detailed engine oil in-formation.

FI: The fuel injection (FI) indicator lightin the tachometer goes on when theignition key is turned to “ON” and goesoff soon after ensuring that its circuitfunctions properly. The indicator lightalso goes on whenever the troublesoccur in digital fuel injection system(DFI). If the indicator light comes on,have the DFI system checked by anauthorized Kawasaki dealer. When theindicator light flashes, first turn the igni-tion key to “OFF” and then back to“ON”.


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: The coolant temperature warninglight in the speedometer goes onwhenever the coolant temperature ris-es to 115°C (239°F) when the motor-cycle is in operation. This warns theoperator that the coolant temperatureis too high. If the warning light goes on,stop the engine and check the coolantlevel in the reserve tank after the en-gine cools down.

CAUTION

Do not let the engine continuerunning when the warning lightflashes. Prolonged engine opera-tion will result in severe damagefrom overheating.

(For models equipped with ABS): The ABS (Anti-lock Brake Sys-

tem) indicator light in the tachometercomes on when the ignition switch isturned on and goes off shortly after themotorcycle starts moving. If the ABS isnormal, it stays off. If something iswrong with the ABS, the indicatorcomes on and remains lit. When the in-dicator light is on, the ABS does notfunction but if the ABS fails, the con-ventional brake system will still worknormally.For more detailed information about

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


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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 Ka-

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

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


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OFFEngine off. All electrical cir-cuits off.

ONEngine on. All electricalequipment can be used.

LOCKSteering locked. Engine off.All electrical circuits off.

P(Park)

Steering locked. Engine off.License plate, tail, and citylights on and turn signalscan be used. All other elec-trical circuits cut off.

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


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Right Handlebar SwitchesEngine Stop Switch:In addition to the ignition switch, the

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

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

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

Starter Button:The starter button operates the elec-

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

tion of the “How to Ride the Motor-cycle” chapter for starting instructions.

A. Engine Stop SwitchB. Starter Button


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

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

NOTE○When the headlight is on high beam,both head lights are lit. When theheadlight is on low beam, only oneheadlight is lit.

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

Turn Signal Switch:When the turn signal switch is turned

to the left ( ) or right ( ), thecorresponding turn signal flashes onand off.To stop flashing, push the switch in.


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Horn Button:When the horn button is pushed, the

horn sounds.

Passing Button:When the passing button is pushed,

the headlight high beam (passingbeam) comes on to signal the driver ofthe vehicle ahead that you are about topass him. The passing light shuts offas soon as the button is released.

Hazard Switch:If an emergency requires you to park

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

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

CAUTION

If 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.


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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 arrow mark on thelever holder.The distance from the grip to the re-

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

B. Mark


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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.

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

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

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


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Fuel TankAvoid filling the tank in the rain or

where heavy dust is blowing so thatthe fuel does not get contaminated.

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

WARNING

Gasoline is extremely flammableand can be explosive under cer-tain conditions. Turn the ignitionkey to “OFF”. Do not smoke.Make sure the area is well venti-lated and free from any source offlame or sparks; this includesany appliance with a pilot light.Never fill the tank so the fuel levelrises into the filler neck. If thetank is overfilled, heat may causethe fuel to expand and overflowthrough the vents in the tank cap.After refueling, make sure thefuel tank cap is closed securely.If gasoline is spilled on the fueltank, wipe it off immediately.


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Fuel Requirement:Your Kawasaki engine is designed to

use only unleaded gasoline.

CAUTION

Do not use leaded gasoline, asthis will destroy the catalytic con-verter. (For further information,refer to the “Catalytic Converter”section in the “How to Ride theMotorcycle” chapter.)

Octane RatingThe octane rating of a gasoline is a

measure of its resistance to detonationor “knocking.” The term commonlyused to describe a gasoline's octanerating is the Research Octane Number(RON). Always use a gasoline with anoctane rating equal to, or higher than,RON 91.

NOTE○If “knocking” or “pinging” occurs, usea different brand of gasoline or high-er octane rating.


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StandThe motorcycle is equipped with a

side stand.

A. Side Stand

NOTE○When 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.

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


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Seat LockSeat RemovalInsert the ignition key into the seat

lock, located on the rear cowling.Turn the key clockwise while pulling

on the rear end of the seat.

NOTE○If 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


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Seat InstallationInstall seats in the reverse order of

removal.

• Place the tabs into the matching slotand receptacles.

A. SeatB. SlotC. TabD. ReceptacleE. HookF. Lock

• Insert the hook at the rear of the seatinto the lock on the frame.

• 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.

NOTE○If there is difficulty removing the igni-tion key from the seat lock, turn itlightly counterclockwise while pullingit out.


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Helmet Holding HooksHelmets can be secured to the mo-

torcycle using the helmet holdinghooks located under the seat.

A. Helmet Holding Hook

WARNING

Do not ride the motorcycle withhelmets attached to the hooks.The helmets could cause an acci-dent by distracting the operatoror interfering with normal vehicleoperation.


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Tool Kit/U-Shaped lock Compart-ment

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 maintenanceprocedures explained in this manual.Also under the seat, there is a lock

strap which holds a U-Shaped lock.Install the U-shaped part and lock

separately and secure them each withits strap. A. Tool Kit

B. StrapC. U-Shaped Lock


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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

CAUTION

Do not force to tighten and/orloosen the upper hexagonal areawith a pair of spanners orwrench. Forcible loosening an-d/or tightening may damage theupper hexagonal area and/or theturning mechanism of the stay.


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

WindshieldThe windshield can be adjusted with-

in 3 positions in height to suit the rider'spreference. Loosen the upper and low-er bolts on the windshield and move itup or down. After adjusting, make sureto tighten all four bolts securely.

A. WindshieldB. Bolts


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Tightening Torque

Windshield Bolt

0.35 ~ 0.5 N·m (0.035 ~ 0.05 kgf·m,0.25 ~ 0.36 ft·lb)

NOTE○Make sure that there is a damperwhen tightening the bolts.


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BREAK-IN

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

• The table shows maximum recommended engine speed during the break-in peri-od.

Distance traveled Maximum engine speed

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

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

• 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.

46 BREAK-IN

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WARNING

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

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

BREAK-IN 47

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HOW TO RIDE THE MOTORCYCLE

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


• Make sure the transmission is inneutral.

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

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

48 HOW TO RIDE THE MOTORCYCLE

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the Fi indicator light to flash whenthe motorcycle falls down. After right-ing the motorcycle, first turn the igni-tion key to “OFF” and then back to“ON” before starting the engine.

CAUTION

Do not operate the starter contin-uously for more than 5 seconds,or the starter will overheat andthe battery power will drop tem-porarily. Wait 15 seconds be-tween each operation of thestarter to let it cool and the bat-tery power recover.

NOTE○The motorcycle is equipped with astarter lockout switch. This switch isdesigned so that the engine does notstart if the transmission is in gearand the side stand is down. How-ever, the engine can be started if theclutch lever is pulled and the sidestand is fully up.

A. Clutch LeverB. Starter Lockout Switch

HOW TO RIDE THE MOTORCYCLE 49

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CAUTION

Do not let the engine idle longerthan five minutes, or engine over-heating and damage may occur.

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.

WARNING

Battery acid generates hydrogengas which is flammable and ex-plosive under certain conditions.It is present within a battery at alltimes, even in a discharged con-dition. Keep all flames and sparks(cigarettes) away from the bat-tery. Wear eye protection whenworking with a battery. In theevent of battery acid contact withskin, eyes, or clothing, wash theaffected areas immediately withwater for at least 5 minutes. Seekmedical attention.


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Connecting Jumper Cables

• Remove the seat.

• Make sure the ignition key is turnedto OFF.

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

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

nal

• Connect another jumper cable fromthe negative (–) terminal of the boos-ter battery to your motorcycle foot-peg or other unpainted metalsurface. Do not use the negative (–)terminal of the battery.


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WARNING

Do not make this last connectionat the fuel system or battery. Takecare that you do not touch thepositive and negative cables to-gether, and do not lean over thebattery when making this lastconnection. Do not jump start afrozen battery. It could explode.Do not reverse polarity by con-necting positive (+) to negative(–) or a battery explosion andserious damage to the electricalsystem may occur.

• Follow the standard engine startingprocedure.

CAUTION

Do not operate the starter contin-uously for more than 5 secondsor the starter will overheat andthe battery power will drop tem-porarily. Wait 15 seconds be-tween 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 parts removed.


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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 theengine just enough fuel to keep itfrom stalling.

A. Shift Pedal

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

○When the headlight is on high beam,two headlight beams are lit, and onlow beam, one headlight is lit.


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Shifting Gears• Close the throttle while pulling in theclutch lever.

• Shift into the next higher or lowergear.

WARNING

When shifting down to a lowergear, do not shift at such a highspeed that the engine r/min (rpm)jumps excessively. Not only canthis cause engine damage, butthe rear wheel may skid andcause an accident. Downshiftingshould be done below 5,000 r/min(rpm) for each gear.

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

NOTE○The transmission is equipped with apositive neutral finder. When the mo-torcycle is standing still, the trans-mission cannot be shifted pastneutral from 1st gear. To use thepositive neutral finder, shift down to1st gear, then lift up on the shift ped-al while standing still. The transmis-sion will shift only into neutral.


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Braking• Close the throttle completely, leavingthe 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 alittle more than the rear. Shift downor fully disengage the clutch as nec-essary to keep the engine from stall-ing.

• Never lock the brakes, or it will causethe tires to skid. When turning a cor-ner, it is better not to brake at all. Re-duce your speed before you get intothe corner.

• For emergency braking, disregarddownshifting, and concentrate on

applying the brakes as hard as pos-sible without skidding.


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• Even in motorcycles equipped withABS, braking during cornering maycause wheel slip. When turning acorner, it is better to limit braking tothe light application of both brakes ornot to brake at all. Reduce yourspeed before you get into the corner.

A. Front Brake Lever

A. Rear Brake Pedal


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

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

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

while stopping by preventing wheellock-up, remember the following char-acteristics:

• ABS cannot compensate for adverseroad conditions, misjudgement or im-proper application of brakes. You

must take the same care as with mo-torcycles not equipped with ABS.

• ABS is not designed to shorten thebraking distance. On loose, unevenor downhill surfaces, the stoppingdistance of a motorcycle with ABSmay be longer than that of an equiv-alent motorcycle without ABS. Usespecial caution in such areas.

• ABS will help prevent wheel lock-upduring straight-up braking, but it can-not control wheel slip which may becaused by braking during cornering.When turning a corner, it is better tolimit braking to the light application ofboth brakes or not to brake at all. Re-duce your speed before you get intothe corner.

• The computers integrated in the ABScompare vehicle speed with wheelspeed. Since non-recommendedtires can affect wheel speed, they


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may confuse the computers, whichcan extend braking distance.

WARNING

Use of non-recommended tiresmay cause malfunctioning ofABS and can lead to extendedbraking distance. The rider couldhave an accident as a result. Al-ways use recommended stand-ard tires for this motorcycle.

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

○ABS indicator light may come onunder motorcycle riding condition.(ex. The front or rear wheel races.)In this case, first turn the ignition key

to “OFF”, and then back to “ON”.ABS indicator light goes off by thisoperation, but if ABS indicator lightremains lit after the motorcycle runsat the speed of approx. 6 km/h or be-low, you should have the ABSchecked by an authorized Kawasakidealer.

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

○ABS does not function if the batteryis discharged.

ABS Indicator Light:Normally the ABS indicator light

comes on when the ignition switch isturned on and goes off shortly after themotorcycle starts moving.If the indicator light shows any of the

following, a fault or faults may havetaken place in the ABS. You shouldhave the ABS checked by an author-ized Kawasaki dealer.


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• The light does not come on when theignition switch is turned on.

• The light remains lit after the motor-cycle starts moving.

• The light comes on and remains litafter the motorcycle starts moving.

Remember that the ABS does notfunction when the indicator light is on,but if the ABS fails, the conventionalbrake system still works normally.

Stopping the Engine• Close the throttle completely.

• Shift the transmission into neutral.

• Turn the ignition key to “OFF”.

• Support the motorcycle on a firm,level surface with the side stand.

• Lock the steering.

NOTE○The motorcycle is equipped with avehicle-down sensor, which causesthe engine to stop automatically andthe fuel injection indicator light toflash when the motorcycle fallsdown. After righting the motorcycle,first turn the ignition key to “OFF”and then back to “ON” before startingthe engine.


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Stopping the Motorcycle in anEmergency

Your Kawasaki Motorcycle has beendesigned and manufactured to provideyou optimum safety and convenience.However, in order to fully benefit fromKawasaki's safety engineering andcraftsmanship, it is essential that you,the owner and operator, properly main-tain your motorcycle and become thor-oughly familiar with its operation.Improper maintenance can create adangerous situation known as throttlefailure. Two of the most commoncauses of throttle failure are:1. An improperly serviced or clogged

air 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 asthrottle failure, your vehicle may bestopped by applying the brakes anddisengaging the clutch. Once this stop-ping procedure is initiated, the enginestop switch may be used to stop theengine. If the engine stop switch isused, turn off the ignition switch afterstopping the motorcycle.


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Parking• Shift the transmission into neutraland turn the ignition key to “OFF”.

• Support the motorcycle on a firm,level surface with the side stand.

CAUTION

Do not park on a soft or steeplyinclined surface, or the motor-cycle 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.

WARNING

The muffler and exhaust pipe arevery hot while the engine is run-ning and just after the enginestop. This can ignite a fire, result-ing in property damage or severepersonal injury.Do not idle or park your vehicle inan area where flammable materi-als such as grasses or dry leavesmay contact with muffler or ex-haust pipe.

WARNING

Gasoline is extremely flammableand can be explosive under cer-tain conditions.

• Lock the steering to help preventtheft.


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

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

Catalytic ConverterThis motorcycle is equipped with a

catalytic converter in the exhaust sys-tem. Platinum and rhodium in the con-verter react with carbon monoxide andhydrocarbons to convert them into car-bon dioxide and water resulting inmuch cleaner exhaust gases to be dis-charged into the atmosphere.For proper operation of the catalytic

converter, the following cautions mustbe observed.


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WARNING

The muffler and exhaust pipe arevery hot while the engine is run-ning and just after the enginestop. This can ignite a fire, result-ing in property damage or severepersonal injury.Do not idle or park your vehicle inan area where flammable materi-als such as grasses or dry leavesmay contact with muffler or ex-haust pipe.

• Use only unleaded gasoline. Neveruse leaded gasoline. Leaded gaso-line significantly reduces the capabil-ity of the catalytic converter.

• Do not coast the vehicle with theignition switch and/or engine stopswitch off. Do not attempt to start theengine by rolling the vehicle if thebattery is discharged. Do not operate

the vehicle with the engine or anyone cylinder misfiring. Under theseconditions unburned air/fuel mixtureflowing out of engine excessively ac-celerates reaction in the converter al-lowing the converter to overheat andbecome damaged when the engineis hot, or reduces converter perform-ance when the engine is cold.


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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 motor-cycle. Gloves and suitable footwearshould also be used for added pro-tection.

A motorcycle does not provide theimpact protection of an automobile,so defensive riding in addition towearing protective apparel is ex-tremely important. Do not let protec-tive apparel give you a false senseof security.

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.

When going up steep slopes, shiftto a lower gear so that there isplenty of power to spare rather thanoverloading the engine.

64 SAFE OPERATION

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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 closing thethrottle. 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.

When riding in wet conditions oron loose roadway surfaces, the abil-ity to maneuver will be reduced. Allof your actions should be smoothunder these conditions. Sudden ac-celeration, braking or turning maycause loss of control.

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

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

SAFE OPERATION 65

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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.

66 SAFE OPERATION

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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.

WARNING

Failure to perform these checks every day before you ride may result inserious damage or a severe accident.

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

Front Up to 180 kg (397 lb) Load 225 kPa (2.25 kg/cm², 32 psi)

Rear Up to 180 kg (397 lb) Load 250 kPa (2.50 kg/cm², 36 psi)

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

Lubricate the dive chain if dry.Nuts, bolts, fasteners .. Check that steering and suspension components, axles,

and all controls are properly tightened or fastened.

SAFE OPERATION 67

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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 (0.04in.) left.No brake fluid leakage.

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

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

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

Warning/Indicator Lights) and horn work.Engine stop switch ...... Stops engine.Side stand ................... Returns to its fully up position by spring tension.

Returns spring not weak or not damaged.

Refer to the “Daily Safety Checks” caution label attached to the Tool kit/U-shapedlock compartment.

68 SAFE OPERATION

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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 opera-

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

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

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

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

lated parts are in good condition.

SAFE OPERATION 69

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WARNING

Handling 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.

70 SAFE OPERATION

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MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried outand must be done in accordance with the Periodic Maintenance Chart to keep themotorcycle in good running condition. The initial maintenance is vitally impor-tant and must not be neglected.With a basic knowledge of mechanics and the proper use of tools, you should be

able to carry out many of the maintenance items described in this chapter. If youlack proper experience or doubt your ability, all adjustments, maintenance, and re-pair 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 71

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Periodic Maintenance Chart

K: Should be serviced by an authorized Kawasaki dealer.*: For higher odometer readings, repeat at the frequency interval established here.#: Service more frequently when operating in severe conditions: dusty, wet, muddy, high

speed, or frequent starting/stopping.

1. Periodic Inspection (Engine Related Items)

Frequency Whichevercomesfirst

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

SeePage

Operation (Engine Items)Every

1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

KAir cleaner element -clean • • • 96

K Valve clearance - inspect Every 42 000 km (26 000 mile) 95

Throttle control system(play, smooth return, nodrag) - inspect

year • • • • 98

KEngine vacuum synchro-nization - inspect • • • 100

72 MAINTENANCE AND ADJUSTMENT

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SeePage


1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Idle speed - inspect • • • • 101

KFuel leak (fuel hose andpipe) - inspect

year • • • • –

KFuel hoses damage - in-spect

year • • • • –

KFuel hoses installationcondition - inspect

year • • • • –

Coolant level - inspect • • • • 90

Coolant leak - inspect year • • • • 87

Radiator hose damage -inspect year • • • • 87

Radiator hoses installationcondition - inspect

year • • • • 87


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SeePage


1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

KAir suction system dam-age - inspect • • • 94


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2. Periodic Inspection (Chassis Related Items)



SeePage

Operation (Chassis Items)Every

1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Clutch and drive train:

Clutch operation (play, en-gagement, disengage-ment) - inspect

• • • • 102

Drive chain lubricationcondition - inspect #

every 600 km (400 mile) 112

Drive chain slack - inspect#

every 1 000 km (600 mile) 105

Drive chain wear - inspect# • • • 109

KDrive chain guide wear -inspect • • • –


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SeePage


1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Wheels and tires:

Tire air pressure - inspect year • • • 126

Wheels/tires damage - in-spect • • • 127

Tire tread wear, abnormalwear - inspect • • • 127

KWheel bearings damage -inspect

year • • • –

Brake system:

Brake fluid leak - inspect year • • • • • • • 113

Brake hoses and pipedamage - inspect year • • • • • • • 113

Brake pad wear - inspect# • • • • • • 113


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SeePage


1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Brake hose installationcondition - inspect

year • • • • • • • 113

Brake fluid level - inspect 6 months • • • • • • • 114

Brake operation (effective-ness, play, drag) - inspect

year • • • • • • • 116

Brake light switch opera-tion - inspect • • • • • • • 117

Suspensions:

Front forks/rear shock ab-sorber operation (dampingand smooth stroke) - in-spect

• • • 119,122

Front forks/rear shock ab-sorber oil leak - inspect

year • • • 119,122


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SeePage


1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Steering System:

K Steering play - inspect year • • • • –

KSteering stem bearings -lubricate

2 years • –

Electrical System:

Lights and switches oper-ation - inspect

year • • • –

Headlight aiming - inspect year • • • 135

Side stand switch opera-tion - inspect

year • • • –

Engine stop switch opera-tion - inspect year • • • –


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SeePage


1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Chassis:

K Chassis parts - lubricate year • • • –

KBolts and nuts tightness -inspect • • • • –


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3. Periodic Replacement


*Odometer Readingkm × 1 000

(mile × 1 000) SeePage

Change/Replacement ItemsEvery

1(0.6)

12(7.5)

24(15)

36(24)

48(30)

K Air cleaner element # 2 year 96

Engine oil # year • • • • • 83

Oil filter year • • • • • 83

K Fuel hoses 4 year • –

K Coolant 3 years • 93

K Radiator hoses and O-rings 3 years • –

K Brake hoses and pipe 4 years • –

K Brake fluid (front and rear) 2 years • • 116

KRubber parts of master cylinderand caliper

4 years • –

K Spark plug • • • • 93


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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,but the oil itself loses its lubricativequality if used too long.

WARNING

Motorcycle operation with insuffi-cient, deteriorated, or contami-nated engine oil will causeaccelerated wear and may resultin engine or transmission seiz-ure, accident, and injury.

Oil Level Inspection

• If the oil has just been changed, startthe engine and run it for several

minutes at idle speed. This fills theoil filter with oil. Stop the engine,then wait several minutes until the oilsettles.

CAUTION

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


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• 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 and low-er 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 oil toreach the correct level. Use thesame type and brand of oil that is al-ready in the engine.

CAUTION

If the engine oil gets extremelylow or if the oil pump does notfunction properly or oil passagesare clogged, the oil pressurewarning light will come on. If theystays on while the engine runningabove the idle speed, stop the en-gine immediately and find thecause.


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A. Oil Pressure Warning Light

Oil and/or Oil Filter Change

• Warm up the engine thoroughly, andthen stop it.

• Place an oil pan beneath the engine.

• Remove the engine oil drain plug.

A. Drain Plug

• Let the oil completely drain with themotorcycle perpendicular to theground.


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WARNING

Motor oil is a toxic substance.Dispose of used oil properly.Contact your local authorities forapproved disposal methods orpossible recycling.

• Remove the oil filter cartridge and re-place it with a new one.

NOTE○If a torque wrench or required Kawa-saki special tool is not available, thisitem should be serviced by a Kawa-saki dealer.

A. Cartridge


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• Apply a thin film of oil to the packingand tighten the cartridge to the speci-fied torque.

A. Packing

• Install the drain plug with its newgasket. Tighten it to the specified tor-que.

NOTE○Replace any gaskets with new ones.

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

• Start the engine.

• Check the oil level and oil leakage.

Tightening Torque

Engine Oil Drain Plug :

30 N·m (3.0 kgf·m, 22 ft·lb)

Cartridge :

17.5 N·m (1.75 kgf·m, 13 ft·lb)

Recommended Engine Oil

Type:

API SE, SF or SG

API SH, SJ or SL with JASO MA

Viscosity:

SAE 10W-40


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Engine Oil Capacity

Capacity:

1.7 L (1.8 US qt)

[when filter is not removed]

1.9 L (2.0 US qt)

[when filter is removed]

2.4 L (2.5 US qt)

[when engine is completely dry]

Although 10W-40 engine oil is therecommended oil for most conditions,the oil viscosity may need to bechanged to accommodate atmosphericconditions in your riding area.


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

tion by insects or mud. Clean off anyobstructions with a stream of low-pres-sure water.

WARNING

The cooling fan turns on auto-matically, even with the ignitionswitch off. Keep your hands andclothing away from the fan bladesat all times.

CAUTION

Using high-pressure water, asfrom a car wash facility, coulddamage the radiator fins and im-pair the radiator's effectiveness.Do not obstruct or deflect airflowthrough the radiator by installingunauthorized accessories in frontof the radiator or behind the cool-ing fan. Interference with the radi-ator airflow can lead tooverheating and consequent en-gine damage.

Radiator Hoses -Check the radiator hoses for leak-

age, cracks or deterioration, and con-nections for leakage or loosenesseach day before riding the motorcycle,and in accordance with the PeriodicMaintenance Chart.


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Coolant -Coolant absorbs excessive heat from

the engine and transfers it to the air atthe radiator. If the coolant level be-comes low, the engine overheats andmay suffer severe damage. Check thecoolant level each day before ridingthe motorcycle, and in accordance withthe periodic maintenance chart and re-plenish coolant if the level is low.Change the coolant in accordance withthe Periodic Maintenance Chart.

Information for CoolantTo protect the cooling system (con-

sisting of the aluminum engine and ra-diator) from rust and corrosion, the useof corrosion and rust inhibitor chemi-cals in the coolant is essential. If cool-ant containing corrosion and rustinhibitor chemicals is not used, over aperiod of time, the cooling system ac-cumulates rust and scale in the waterjacket and radiator. This will clog up

the coolant passages, and consider-ably reduce the efficiency of the cool-ing system.

WARNING

Use coolant containing corrosioninhibitors made specifically foraluminum engines and radiatorsin accordance with the instruc-tions of the manufacturer. Chemi-cals are harmful to the humanbody.

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


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CAUTION

If 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 temperatureencountered falls below the freezingpoint of water, use permanent anti-freeze in the coolant to protect thecooling system against engine and ra-diator freeze-up, as well as from rustand corrosion.Use a permanent type of antifreeze

(soft water and ethylene glycol pluscorrosion and rust inhibitor chemicalsfor aluminum engines and radiators) inthe cooling system. On the mixture ra-tio of coolant, choose the suitable onereferring to the relation between

freezing point and strength directed onthe container.

CAUTION

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

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


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Coolant Level Inspection

• Situate the motorcycle so that it isperpendicular to the ground.

• Check the coolant level if it is be-tween the F (Full) and L (Low) levellines.

A. F (Full) Level LineB. L (Low) Level LineC. Right Side Cover

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

• If the amount of coolant is insuffi-cient, remove the right cowl and addcoolant into the reserve tank.


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Coolant Filling

• Remove the windshield.

• Remove the right cowl by removingthe bolt.

A. Right CowlB. Bolt

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

A. CapB. Reserve TankC. F (Full) Level LineD. L (Low) Level Line

• Install the cap.


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• To install the right cowl, fit the projec-tion into the hole.

A. Right CowlB. ProjectionC. Hole

• Tighten the bolts in the order di-rected.

A. Right Cowl

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


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CAUTION

If coolant must be added often, orthe reserve tank completely runsdry, there is probably leakage inthe system. Have the cooling sys-tem inspected by your authorizedKawasaki dealer.

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 Gap0.8 ~ 0.9 mm(0.031 ~ 0.035 in.)

Tightening Torque15 N·m(1.5 kgf·m, 11 ft·lb)


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A. Plug Gap

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 exhaustsystem, it is still hot enough to burn.The KCA System allows extra air intothe exhaust system so that the spentfuel charge can continue to burn. Thiscontinued burning action tends to burnup a great deal of the normally un-burned gases, as well as changing asignificant portion of the carbon mon-oxide into carbon dioxide.

Air Suction Valves -The air suction valve is essentially a

check valve which allows fresh air toflow only from the air cleaner into theexhaust port. Any air that has passedthe air suction valve is prevented fromreturning. Inspect the air suction valves


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

spection should be done by an author-ized Kawasaki dealer.

Valve ClearanceValve and valve seat wear de-

creases valve clearance, upsettingvalve timing.

CAUTION

If valve clearance is left unad-justed, wear will eventually causethe valves to remain partly open,which lowers performance, burnsthe valves and valve seats, andmay cause serious engine dam-age.

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

done by an authorized Kawasaki deal-er.


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Air CleanerA clogged air cleaner restricts the

engine'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 Peri-odic Maintenance Chart. In dusty,rainy, or muddy conditions, the aircleaner element should be servicedmore frequently than the recom-mended interval by an authorized Ka-wasaki 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 are any oil in the reservoir,remove the plug from the lower endof the drain hose and drain the oil.


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WARNING

Be sure to install the plug in thedrain hose after draining. Oil ontires will make them slippery andcan cause an accident and injury.

Throttle Control SystemCheck the throttle grip play in ac-

cordance with the Periodic Mainte-nance Chart, and adjust it if necessary.

Throttle Grip -The throttle grip controls the butterfly

valves in the throttle body. If the throttlegrip 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.


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Inspection

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

A. Throttle GripB. Throttle Grip Play

Throttle Grip Play

2 ~ 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 adjusting nut in com-pletely so as to give the throttle gripplenty of play.

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


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• Turn out the decelerator cable ad-justing nut until there is no play whenthe throttle grip is completely closed.

• Tighten the locknut.

A. AdjusterB. LocknutC. Decelerator Cable

• Turn out the accelerator cable ad-justing nut until a play of 2 ~ 3 mm(0.08 ~ 0.12 in.) is obtained at thethrottle grip.

• Tighten the locknut.

WARNING

Operation with an improperly ad-justed, incorrectly routed, ordamaged cables could result inan unsafe riding condition.


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Engine Vacuum SynchronizationEngine vacuum synchronization

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

NOTE○Poor engine vacuum synchroniza-tion will cause unstable idling, slug-gish throttle response, and reduceengine power and performance.

Idle SpeedThe idle speed check should be per-

formed in accordance with the PeriodicMaintenance Chart or whenever theidle speed is disturbed.


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Adjustment

• Start the engine, and warm it up thor-oughly.

• Adjust the idle speed by turning theidle adjusting screw.

A. Idle Adjusting Screw

Idle Speed

1 250 ~ 1 350 r/min (rpm)

• Open and close the throttle a fewtimes to make sure that the idle

speed 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, orthey may be damaged. Be sure tocorrect any of these conditions be-fore riding.

WARNING

Operation with damaged cablescould result in an unsafe ridingcondition.


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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.

WARNING

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

Inspection

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

• Check the clutch lever play as shownin the figure.

A. LocknutB. Clutch Lever PlayC. Adjuster


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Clutch Lever Play

2 ~ 3 mm (0.08 ~ 0.12 in.)

If the play is incorrect, adjust the lev-er play as follows.

Adjustment

WARNING

Be sure the upper end of theclutch outer cable is fully seatedin its fitting, or it could slip intoplace later, creating enough cableplay to prevent clutch disengage-ment, resulting in a hazardousriding condition.

• Loosen the locknut, and turn the ad-juster 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

NOTE○After the adjustment is made, startthe engine and check that the clutch


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does not slip and that it releasesproperly.

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

Drive ChainThe drive chain slack and lubrication

must be checked each day before rid-ing the motorcycle, and in accordancewith the Periodic Maintenance Chartfor safety and to prevent excessivewear. If the chain becomes badly wornor maladjusted - either too loose or tootight - the chain could jump off thesprockets or break.

WARNING

A 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.


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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 chainslack will be within the standard val-ue.

Drive Chain Slack

Standard 25 ~ 35 mm (1.0 ~ 1.4 in.)


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Chain Slack Adjustment

• Loosen the left and right chain ad-juster locknuts.

• Remove the cotter pin, and loosenthe axle nut.

A. Axle NutB. Cotter PinC. AdjusterD. Locknut

• If the chain is too loose, turn out theleft and right chain adjusters evenly.

• If the chain is too tight, turn in the leftand right chain adjusters evenly.

• Turn out both chain adjusters evenlyuntil the drive chain has the correctamount of slack. To keep the chainand wheel properly aligned, thenotch on the left wheel alignment in-dicator should align with the sameswingarm mark that the right indica-tor notch aligns with.


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A. MarksB. NotchC. IndicatorD. AdjusterE. Locknut

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

WARNING

Misalignment of the wheel will re-sult in abnormal wear, and mayresult in an unsafe riding condi-tion.

• Tighten both chain adjuster locknuts.

• Tighten the rear axle nut to the speci-fied torque.

Tightening Torque

Axle Nut:

108 N·m (11 kgf·m, 80 ft·lb)

NOTE○If a torque wrench is not available,this item should be serviced by a Ka-wasaki dealer.

• Rotate the wheel, measure the chainslack again at the tightest position,and readjust if necessary.


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• Install a new cotter pin through therear axle nut and axle, and spread itsends.

A. Cotter Pin

NOTE○When inserting the cotter pin, if theslots in the nut do not align with thecotter pin hole in the axle shaft, tight-en the nut clockwise up to the nextalignment.

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

A. Turning Clockwise


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WARNING

If the axle nut is not securelytightened or the cotter pin is notinstalled, an unsafe riding condi-tion may result.

• Check the rear brake (see theBrakes section).

Wear Inspection

• Remove the bolts to take off thechain guide.

A. Chain GuideB. Bolts


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• 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 pincenter of the 1st pin to pin center ofthe 21st pin. Since the chain maywear unevenly, take measurementsat several places.

• If the length exceeds the service lim-it, the chain should be replaced.

A. MeasureB. Weight

Drive Chain 20-Link Length

Service Limit

323 mm (12.7 in.)


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WARNING

For safety, use only the standardchain. It is an endless type andshould not be cut for installation;have it installed by an authorizedKawasaki 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.

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

A. Good TeethB. Worn TeethC. Damaged Teeth

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


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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 onthe chain longer and provide better lu-brication.

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

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


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BrakesBrake Wear InspectionInspect the brakes for wear. For each

front and rear disc brake caliper, if thethickness of either pad is less than 1mm (0.04 in.), replace both pads in thecaliper as a set. Pad replacementshould be done by an authorized Ka-wasaki dealer.

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

Disc Brake Fluid -In accordance with the Periodic

Maintenance Chart, inspect the brakefluid level in both the front and rearbrake fluid reservoirs and change thebrake fluid. The brake fluid should alsobe changed if it becomes contami-nated with dirt or water.

Fluid RequirementUse heavy-duty brake fluid only from

a container marked DOT4.

CAUTION

Do 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.


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Fluid Level Inspection

• The brake fluid level in the frontbrake fluid reservoir must be keptabove the line (lower level line) nextto the gauge and that in the rearbrake fluid reservoir (located underthe seat) must be kept between theupper and lower level lines (reser-voirs held horizontal).

A. Front Brake Fluid ReservoirB. Lower Level Line

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


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• 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 theupper level line.

A. Front Brake Fluid ReservoirB. Upper Level Line

WARNING

Do not mix two brands of brakefluid. Change the brake fluid inthe brake line completely if thebrake fluid must be refilled butthe type and brand of the brakefluid that is already in the reser-voir are unidentified.


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NOTE○First, 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 automati-

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

WARNING

If the brake lever or pedal feelsmushy when it is applied, theremight be air in the brake lines orthe brake may be defective. Sinceit is dangerous to operate the mo-torcycle under such conditions,have the brake checked immedi-ately by an authorized Kawasakidealer.


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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


• The brake light should go on whenthe front brake is applied.

• If it does not, ask your authorizedKawasaki dealer to inspect the frontbrake light switch.


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• Check the operation of the rearbrake light switch by depressing thebrake pedal. The brake light shouldgo on after the proper pedal travel.

A. Brake PedalB. Pedal Travel

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

Brake Pedal Travel

10 mm (0.4 in.)

Adjustment

• Disconnect the connector.

A. Connector


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• 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 for inspection of smoothstroke.

• Visually inspect the front fork for oilleakage, scoring or scratches on theouter surface of the inner tube.


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• If any doubt about the front fork, itshould be done by an authorized Ka-wasaki dealer.

A. Inner Tube

On top of each front fork leg is aspring 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 adjusted fordifferent riding and loading conditions.Weaker spring force and dampingforce are for comfortable riding, butthey should be increased for highspeed riding or riding on rough roads.


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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. The ad-justing range is as follows.

Spring Preload AdjusterAdjusting Range 15 turns out*

*: out from the fully seated position

Rebound Damping Force Adjustment

• Turn the rebound damping force ad-juster all the way into the spring pre-load adjuster with a screwdriver. Thismakes the damping force greatest.

• Turn out the adjuster to decreasedamping force.

A. ScrewdriverB. Rebound Damping Force Adjuster

The standard setting positions of thespring preload adjuster and rebound


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damping force adjuster for an average-build rider of 68 kg (150 lb) with nopassenger and no accessories are asfollows:

Spring Preload Ad-juster

7 turns out*

Rebound DampingForce Adjuster 1 3/4 turns out*


CAUTION

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

Rear Shock AbsorbersThe rear shock absorber operation

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


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Rear Shock Absorber Inspection

• Press down on the seat severaltimes to check if the rear shock ab-sorber stroke is smooth.

• Visually inspect the rear shock ab-sorber for oil leakage.

• If any doubt about the rear shock ab-sorber, it should be done by an au-thorized 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


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• 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.

WARNING

This unit contains high pressurenitrogen gas. Mishandling cancause explosion.Read Service Manual for instruc-tions.Do not incinerate, puncture oropen.

CAUTION

Be careful not to damage the mo-torcycle parts when adjusting thespring preload.

Rebound Damping Force AdjustmentThe rebound damping force adjuster

is located at the lower end of the rearshock absorber.

A. Rebound Damping Force Adjuster


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• 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 positions of therebound damping force adjuster andcompression damping force adjusterfor an average-build rider of 68 kg (150lb) with no passenger and no accesso-ries are as follows:

Rebound DampingForce Adjuster

5 clicks*


WheelsTubeless tires are installed on the

wheels of this motorcycle. The indica-tions of TUBELESS on the tire sidewall and the rim show that the tire andrim are specially designed for tubelessuse.

A. TUBELESS Mark


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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.

WARNING

The tires, rims, and air valves onthis motorcycle are designed on-ly for tubeless type wheels. Therecommended standard tires,rims, and air valves must be usedfor replacement.Do not install tube-type tires ontubeless rims. The beads may notseat properly on the rim causingtire deflation.Do not install a tube inside atubeless tire. Excessive heatbuild-up may damage the tubecausing tire deflation.

Tires -Payload and Tire PressureFailure to maintain proper inflation

pressures or observe payload limits foryour tires may adversely affect


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handling and performance of your mo-torcycle and can result in loss of con-trol. The maximum recommended loadin addition 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.

A. Tire Pressure Gauge

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

○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.

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).


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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 that hasworn down to the minimum allowabletread depth.

A. Tire Depth Gauge

Minimum Tread Depth

Front —1 mm(0.04 in.)

Rear

Under 130 km/h(80 mph)

2 mm(0.08 in.)

Over 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.

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

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


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WARNING

To ensure safe handling andstability, use only the recom-mended standard tires for re-placement, inflated to thestandard pressure.Tires that have been puncturedand repaired do not have thesame capabilities as undamagedtires. Do not exceed 100 km/h (60mph) within 24 hours after repair,and 180 km/h (110 mph) at anytime after that.

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

Standard Tire (Tubeless)

FrontSize: 120/70ZR17 M/C (58W)DUNLOP“D221FA G”

RearSize: 160/60ZR17 M/C (69W)DUNLOP“D221 G”

WARNING

Use the same manufacturer'stires on both front and rearwheels.


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WARNING

New tires are slippery and maycause loss of control and injury.A break-in period of 160 km (100miles) is necessary to establishnormal tire traction. Duringbreak-in, avoid sudden and maxi-mum braking and acceleration,and hard cornering.

BatteryThe battery installed in this motor-

cycle 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 electrolytehas been installed in the battery for ini-tial service.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


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temperature. As temperatures rise, sodoes the 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. Combinesuch “key-off” draws with hot tempera-ture, and a battery can go from fullycharged to completely discharged in amatter of days.

Self-discharge

Temperature

Approx. Number of DaysFrom 100% Charged to100% discharged

Lead-Anti-mony

Lead-Calci-um

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


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Current Drain

DischargingAmpere

Days form100%charged to50% Dis-charged

Days form100%charged to100% Dis-charged

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-freezingtemperatures with no damage.

Battery SulfationA common cause of battery failure is

sulfation.

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

Battery MaintenanceIt is the owner's responsibility to keep

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

quently, inspect the battery voltageweekly using a voltmeter. If it drops be-low 12.8 volts, the battery should becharged using an appropriate charger(check with your Kawasaki dealer). Ifyou will not be using the motorcycle forlonger than two weeks, the battery


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should be charged using an appropri-ate charger. Do not use an automotive-type quick charger that may over-charge the battery and damage it.

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

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

dealer.

Battery Charging

• Remove the battery from the motor-cycle (see Battery Removal).

• Attach the leads from the chargerand charge the battery at a rate thatis 1/10th of the battery capacity. Forexample, the charging rate for a 10Ah battery would be 1.0 ampere.

• The charger will keep the batteryfully charged until you are ready toreinstall the battery in the motorcycle(see Battery Installation).

CAUTION

Never remove the sealing strip,or the battery can be damaged.Do not install a conventional bat-tery in this motorcycle, or theelectrical system cannot workproperly.

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


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Battery Removal

• Remove the seat.

A. (+) TerminalB. (–) Terminal

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

• Take the battery out of the case.

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

Battery Installation

• Place the battery in the battery case.

• Connect the capped wire to the (+)terminal, and then connect the blackwire to the (–) terminal.

NOTE○Install the battery in the reverse or-der of the Battery Removal.

CAUTION

Installing the (–) cable to the (+)terminal of the battery or the (+)cable to the (–) terminal of thebattery can seriously damage theelectrical system.

• Put a light coat of grease on the ter-minals to prevent corrosion.

• Cover the (+) terminal with its protec-tive cap.

• Reinstall the parts removed .


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Headlight BeamHorizontal AdjustmentThe headlight beam is adjustable

horizontally. If not properly adjustedhorizontally, the beam will point to oneside rather than straight ahead.

• Remove the left cowl in the same or-der as the right side.

• Turn the horizontal adjuster clock-wise or counterclockwise until thebeam points straight ahead.

A. Horizontal AdjusterB. View From Back Side

Vertical AdjustmentThe headlight beam is adjustable

vertically. If adjusted too low, neitherlow nor high beam will illuminate the


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road far enough ahead. If adjusted toohigh, the high beam will fail to illumi-nate the road close ahead, and the lowbeam will blind oncoming drivers.

• Remove the right cowl.

• Turn the vertical adjuster clockwiseor counterclockwise to adjust its ver-tical angle.

A. Vertical AdjusterB. View From Back Side

NOTE○On high beam, the brightest pointshould be slightly below horizontalwith the motorcycle on its wheelsand the rider seated. Adjust theheadlight to the proper angle accord-ing to local regulations.


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FusesFuses are arranged in the fuse box

located under the seat. The main fuseis mounted on the starter relay behindthe right side cover. If a fuse fails dur-ing operation, inspect the electricalsystem to determine the cause, andthen replace it with a new fuse of prop-er amperage.

A. Fuse BoxB. FusesC. Spare Parts

• Remove the left side cover by re-moving the bolt.

A. Left Side CoverB. Bolt


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• Remove the main fuse cover by re-moving the bolt.

A. Main Fuse CoverB. Bolt

A. Main Fuse


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• Install the left side cover by fitting thereceptacles into the holes andscrewing in the bolt.

A. Left Side CoverB. ReceptaclesC. Holes

WARNING

Do not use any substitute for thestandard fuse.Replace the blown fuse with anew one of the correct capacity,as specified on the junction boxand main fuse.

A. NormalB. Failed


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Cleaning Your MotorcycleGeneral PrecautionsFrequent and proper care of your Ka-

wasaki motorcycle will enhance its ap-pearance, optimize overallperformance, 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 and

plastic 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; watercan penetrate seals and electricalcomponents and damage your mo-torcycle.

• Avoid spraying water in delicateareas such as in air intakes, fuel sys-tem, brake components, electricalcomponents, muffler outlets, and fueltank 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


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automobiles) and water in bucket.Use a soft cloth or sponge to washyour motorcycle. If needed, use amild degreaser to remove any oil orgrease build up.

• After washing, rinse your motorcyclethoroughly with clean water to re-move any residue (residue from thedetergent can damage parts of yourmotorcycle).

• Use a soft cloth to dry your motor-cycle. As you dry, inspect your mo-torcycle for chips and scratches. Donot let the water air dry as this candamage the painted surfaces.

• Start the engine and let it idle for sev-eral minutes. The heat from the en-gine will help dry moist areas.

• Carefully ride your motorcycle at aslow speed and apply the brakesseveral times. This helps dry thebrakes and restores them to normaloperating performance.

• Lubricate the drive chain to preventrusting.

NOTE○After riding in an area where theroads are salted or near the ocean,immediately wash your motorcyclewith cold water. Do not use warmwater as it accelerates the chemicalreaction of the salt. After drying, ap-ply a corrosion protection spray onall metal and chrome surfaces to pre-vent corrosion.

○Condensation may form on the in-side of the headlight lens after ridingin the rain or washing the motor-cycle. To remove the moisture, startthe engine and turn on the headlight.Gradually the condensation on theinside of the lens will clear off.


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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, treat thewindshield, headlight lens, and othernon-painted plastic parts with an ap-proved plastic cleaner/polisher prod-uct.

CAUTION

Plastic parts may deteriorate andbreak if they come in contact withchemical substances or house-hold cleaning products such asgasoline, brake fluid, windowcleaners, thread-locking agents,or other harsh chemicals. If aplastic part comes in contact withany harsh chemical substance,wash it off immediately withwater and a mild neutral deter-gent, and then inspect for dam-age. Avoid using abrasive padsor brushes to clean plastic parts,as they will damage the part's fin-ish.

Chrome and AluminumChrome and uncoated aluminum

parts can be treated with a


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chrome/aluminum polish. Coated alu-minum should be washed with a mildneutral detergent and finished with aspray polish. Aluminum wheels, bothpainted and unpainted can be cleanedwith special non-acid based wheelspray cleaners.

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

sories, 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 treatedwith a vinyl treatment.The sidewalls of tires and other rub-

ber components should be treated witha rubber protectant to help prolongtheir useful life.

WARNING

Special care must be taken not toget any rubber protectant on thetire's tread surface when treatingtires. This may decrease the tire'sability to maintain contact withthe road surface causing the riderto lose control.


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STORAGE

Preparation for Storage:

• Clean the entire vehicle thoroughly.

• Run the engine for about five minutes to warm the oil, shut it off, and drain the en-gine oil.

WARNING

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

• Put in fresh engine oil.

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

144 STORAGE

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WARNING

Gasoline is extremely flammable and can be explosive under certain con-ditions. Turn the ignition key to “OFF”. Do not smoke. Make sure the areais well ventilated and free from any source of flame or sparks; this in-cludes any appliance with a pilot light.Gasoline is a toxic substance. Dispose of gasoline properly. Contact yourlocal 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 theground. (If this cannot be done, put boards under the front and rear wheels tokeep dampness 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 mufflers to prevent moisture from entering.

STORAGE 145

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• Put a cover over the motorcycle to keep dust and dirt from collecting on it.

Preparation after Storage:

• Remove the plastic bags from the mufflers.

• 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.

146 STORAGE

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ENVIRONMENTAL PROTECTION

To protect our environment, properly discard used batteries, tires, engine oil, orother vehicle components that you might dispose of in the future. Consult your au-thorized Kawasaki dealer or local environmental waste agency for their proper dis-posal procedure.

ENVIRONMENTAL PROTECTION 147

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LOCATION OF LABELS

1. Unleaded Gasoline2. Brake Fluid (Front)3. Brake Fluid (Rear)

148 LOCATION OF LABELS

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4. Daily Safety Checks5. Tire and Load Data6. Important Drive Chain Information7. Battery Poison/Danger

LOCATION OF LABELS 149

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(1)

(2)

(3)


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(4)


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(5)

(6)


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(7)


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