Kawasaki Ninja ZX-10R Motorcycle. Owner's manual (2008-2010 year)

Whenever you see the symbols

CAUTION

shown below, heed their instructions!

This caution symbol identifies

Always follow safe operating and main-

special instructions or proce-

tenance practices.

dures which, if not strictly ob-

served, could result in damage

WARNING

to or destruction of equipment.

This warning symbol identifies

special instructions or proce-

NOTE

dures which, if not correctly fol-

lowed, could result in personal

żThis note symbol indicates points of

injury, or loss of life.

particular interest for more efficient

and convenient operation.

(Australian model only)

TAMPERING WITH NOISE CONTROL SYSTEM

PROHIBITED

Owners are warned that the law may prohibit:

(a) The removal or rendering inoperative by any person other than for purposes

of maintenance, repair or replacement, of any device or element of design

incorporated into any new vehicle for the purpose of noise control prior to

its sale or delivery to the ultimate purchaser or while it is in use; and

(b) the use of the vehicle after such device or element of design has been re-

moved or rendered inoperative by any person.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-

torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,

and continuous striving for superior reliability, safety and performance.

Please read this Owner’s Manual carefully before riding so that you will be

thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-

tures, capabilities, and limitations. This manual offers many safe riding tips, but its

purpose is not to provide instruction in all the techniques and skills required to ride

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

cle enroll in a motorcycle rider training program to attain awareness of the mental

and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and

maintenance described in this manual. For those who would like more detailed in-

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

from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-

tailed disassembly and maintenance information. Those who plan to do their own

work should, of course, be competent mechanics and possess the special tools

described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can

refer to it whenever you need information.

TABLE OF CONTENTS

SPECIFICATIONS

Passing Button:

LOCATION OF PARTS

LAP Button:

LOADING AND ACCESSORIES

Brake Lever Adjuster

INFORMATION

Fuel Tank Cap

GENERAL INFORMATION

Fuel Tank

Meter Instruments

Fuel Requirement:

Tachometer:

Side Stand

Digital Meter:

Seat Lock

Warning/Indicator Lights:

Helmet Hooks

Key

Tool Kit

Ignition Switch/Steering Lock

Air Cleaner Intake

Right Handlebar Switches

BREAK-IN

Engine Stop Switch:

HOW TO RIDE THE MOTORCYCLE .

Starter Button:

Starting the Engine

START/STOP Switch (Stop

Jump Starting

Watch):

Moving Off

Left Handlebar Switches

Shifting Gears

Dimmer Switch:

Braking

Turn Signal Switch:

Stopping the Engine

Horn Button:

Stopping the Motorcycle in an

Throttle Control System

112

Emergency

Engine Vacuum Synchronization

115

Parking

Idle Speed

115

Catalytic Converter

Clutch

117

SAFE OPERATION

Drive Chain

119

Safe Riding Technique

Brakes

129

Daily Safety Checks

Brake Light Switches

133

Additional Considerations for High

Steering Damper

135

Speed Operation

Front Fork

136

MAINTENANCE AND ADJUSTMENT

Rear Shock Absorber

141

Periodic Maintenance Chart

Wheels

145

Engine Oil

Battery

150

Cooling System

Headlight Beam

156

Spark Plugs

104

Fuses

157

Valve Clearance

105

Cleaning Your Motorcycle

159

Kawasaki Clean Air System

105

STORAGE

165

Exhaust Device

106

ENVIRONMENTAL PROTECTION

168

Air Cleaner

107

LOCATION OF LABELS

169

8 SPECIFICATIONS

SPECIFICATIONS

PERFORMANCE

Maximum Horsepower

138.3 kW (188.1 PS) @12 500 r/min (rpm)

(MY)

119.2 kW (162.1 PS) @10 000 r/min (rpm)

Maximum Torque

113 N·m (11.5 kgf·m, 83.3 ft·lb) @8 700 r/min (rpm)

(MY)

113 N·m (11.5 kgf·m, 83.3 ft·lb) @8 700 r/min (rpm)

Minimum Turning Radius

3.4 m (134 in.)

DIMENSIONS

Overall Length

2 110 mm (83.1 in.)

Overall Width

710 mm (28.0 in.)

Overall Height

1 135 mm (44.7 in.)

Wheelbase

1 415 mm (55.7 in.)

Road Clearance

125 mm (4.9 in.)

Curb Mass

208 kg (459 lb)

SPECIFICATIONS 9

ENGINE

Type

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

Displacement

998 cm³ (60.9 cu in.)

Bore × Stroke

76.0 × 55.0 mm (3.0 × 2.2 in.)

Compression Ratio

12.9 : 1

Starting System

Electric starter

Cylinder Numbering Method

Left to right, 1-2-3-4

Firing Order

1-2-4-3

Carburetion System

FI (Fuel Injection)

Ignition System

Battery and coil (transistorized ignition)

Ignition Timing (Electronically

10° BTDC @1 100 r/min (rpm)

advanced)

Spark Plugs

NGK CR9EIA-9

Lubrication System

Forced lubrication (wet sump)

Engine Oil

Type:

API SE, SF or SG

API SH, SJ or SL with JASO MA, MA1 or MA2

SAE 10W-40

10 SPECIFICATIONS

Capacity:

4.0 L (4.2 US qt)

Coolant Capacity

2.9 L (3.1 US qt)

TRANSMISSION

Transmission Type

6-speed, return shift

Clutch Type

Wet, multi disc

Driving System

Chain drive

Primary Reduction Ratio

1.611 (87/54)

Final Reduction Ratio

2.412 (41/17)

Overall Drive Ratio

5.068 (Top gear)

Gear Ratio

1st

2.600 (39/15)

2nd

2.053 (39/19)

3rd

1.737 (33/19)

4th

1.550 (31/20)

5th

1.400 (28/20)

6th

1.304 (30/23)

SPECIFICATIONS 11

FRAME

Castor

25.5°

Trail

110 mm (4.3 in.)

Tire Size:

Front

120/70ZR17 M/C (58 W)

Rear

190/55ZR17 M/C (75 W)

Rim Size:

Front

17 × 3.50

Rear

17 × 6.00

Fuel Tank Capacity

17 L (4.5 US gal)

ELECTRICAL EQUIPMENT

Battery

12 V 10 Ah

Headlight

High beam

12 V 55 W + 65 W

Low beam

12 V 55 W + 55 W

LED Tail/Brake Light

0.5/4.1 W

LOCATION OF PARTS 13

LOCATION OF PARTS

1. Clutch Lever

6. Brake Fluid Reservoir (Front)

2. Left Handlebar Switches

7. Right Handlebar Switches

3. Spring Preload Adjuster

8. Front Brake Lever

4. Rebound Damping Force Adjuster

9. Throttle Grip

(Front Fork)

10. Ignition Switch/Steering Lock

5. Meter Instruments

11. Steering Damper

14 LOCATION OF PARTS

12. Headlight

21. Tail/Brake Light

28. Idle Adjusting Screw

13. Air Cleaner Intake

22. License Plate Light

29. Side Stand

14. Turn Signal Light

23. Brake Disc

30. Shift Pedal

15. Spark Plugs

24. Compression

31. Rebound Damping

16. Fuel Tank

Damping Force

Force Adjuster

17. Air Cleaner

Adjuster

32. Drive Chain

18. Rider’s Seat

25. Front Fork

33. Chain Adjuster

19. Seat Lock

26. Brake Caliper

20. Passenger’s Seat

27. Coolant Reserve Tank

16 LOADING AND ACCESSORIES INFORMATION

LOADING AND ACCESSORIES INFORMATION

WARNING

warranty can negatively affect perfor-

mance, and can even be illegal. In

Incorrect loading, improper in-

selecting and using accessories, and

stallation or use of accessories,

in loading the motorcycle, you are

or modification of your motorcy-

personally responsible for your own

cle may result in an unsafe rid-

safety and the safety of other persons

ing condition. Before you ride

involved.

the motorcycle, make sure that

the motorcycle is not overloaded

NOTE

and that you have followed these

żKawasaki Parts and Accessories

instructions.

have been specially designed for

use on Kawasaki motorcycles. We

With the exception of genuine

strongly recommend that all parts

Kawasaki Parts and Accessories,

and accessories you add to your

Kawasaki has no control over the

motorcycle be genuine Kawasaki

design or application of accessories.

components.

In some cases, improper installation

or use of accessories, or motorcycle

Because a motorcycle is sensitive to

modification, will void the motorcycle

changes in weight and aerodynamic

forces, you must take extreme care

LOADING AND ACCESSORIES INFORMATION 17

in carrying cargo, passengers and/or

All baggage should be carried as

in the fitting of additional accessories.

low as possible to reduce the effect

The following general guidelines have

on the motorcycle center of gravity.

been prepared to assist you in making

Baggage weight should also be dis-

your determinations.

tributed equally on both sides of the

Any passenger should be thor-

motorcycle. Avoid carrying baggage

oughly familiar with motorcycle op-

that extends beyond the rear of the

eration. The passenger can affect

motorcycle.

control of the motorcycle by im-

Baggage should be securely at-

proper positioning during cornering

tached. Make sure that the baggage

and sudden movements. It is impor-

will not move around while you are

tant that the passenger sit still while

riding. Recheck baggage security

the motorcycle is in motion and not

as often as possible (not while the

interfere with the operation of the

motorcycle is in motion) and adjust

motorcycle. Do not carry animals

as necessary.

on your motorcycle.

Do not carry heavy or bulky items on

You should instruct any passenger

a luggage rack. They are designed

before riding to keep his feet on the

for light items, and overloading can

passenger footpegs and hold on to

affect handling due to changes in

the operator, seat strap or grab rail.

weight distribution and aerodynamic

Do not carry a passenger unless he

forces.

or she is tall enough to reach the

footpegs and footpegs are provided.

18 LOADING AND ACCESSORIES INFORMATION

Do not install accessories or carry

designed or installed items can re-

baggage that impairs the perfor-

sult in an unsafe riding condition.

mance of the motorcycle. Make

9. This motorcycle was not intended

sure that you have not adversely

to be equipped with a sidecar or to

affected any lighting components,

be used to tow any trailer or other

road clearance, banking capability

vehicle. Kawasaki does not manu-

(i.e., lean angle), control operation,

facture sidecars or trailers for mo-

wheel travel, front fork movement,

torcycles and cannot predict the ef-

or any other aspect of the motorcy-

fects of such accessories on han-

cle’s operation.

dling or stability, but can only warn

Weight attached to the handlebar or

that the effects can be adverse and

front fork will increase the mass of

that Kawasaki cannot assume re-

the steering assembly and can re-

sponsibility for the results of such

sult in an unsafe riding condition.

unintended use of the motorcycle.

Fairings, windshields, backrests,

Furthermore, any adverse effects on

and other large items have the ca-

motorcycle components caused by

pability of adversely affecting stabil-

the use of such accessories will not

ity and handling of the motorcycle,

be remedied under warranty.

not only because of their weight, but

Maximum Load

also due to the aerodynamic forces

Weight of rider, passenger, baggage,

acting on these surfaces while the

and accessories must not exceed 180 kg

motorcycle is in operation. Poorly

(397 lb).

20 GENERAL INFORMATION

Tachometer:

NOTE

The tachometer shows the engine

żThe illumination in the meter instru-

speed in revolutions per minute (r/min,

ment can be adjusted at four modes

rpm). On the right side of the tachome-

by pushing RESET button when turn-

ter face is a portion called the “red

ing the ignition key to ON.

zone”.

Engine r/min (rpm) in the

red zone is above maximum recom-

CAUTION

mended engine speed and is also

above the range for good performance.

Engine r/min (rpm) should not

When the ignition key is turned to

be allowed to enter the red zone;

“ON”, the tachometer momentarily

operation in the red zone will

goes from the minimum to the maxi-

overstress the engine and may

mum, then goes back from the maxi-

cause serious engine damage.

mum to the minimum reading to check

its operation. If the tachometer does

not operate correctly, have it checked

by an authorized Kawasaki dealer.

GENERAL INFORMATION 21

Digital Meter:

The digital meter displays the fol-

lowing functions: the speedometer,

clock, trip meter, odometer, coolant

temperature meter, stop watch, gear

position, oil pressure warning symbol,

A. Odometer

immobilizer warning symbol and fuel

B. Trip meter

injection warning symbol. Pushing the

C. Clock

D. Stop Watch

MODE button shifts the display in the

E. Push MODE Button

digital meter through the following four

modes: odometer, trip meter, clock,

and stop watch. When the ignition key

is turned to “ON”, all the LCD segments

are displayed for three seconds, then,

depending on the mode selected, the

clock or meters operate normally.

22 GENERAL INFORMATION

Digital Meter

Mile/Km Display -

Mile/Km Display can alternate be-

tween English and metric modes (mile

and km) in the digital meter. Make sure

that km or mile according to local reg-

ulations is correctly displayed before

riding.

NOTE

Do not operate the vehicle with the

digital meter displaying in the wrong

unit (km or mile) of the digital meter.

A. Speedometer

Shift the km/mile display in the digital

B. Gear Position

meter as follows.

C. Lap Counter/Coolant Temperature Meter

D. Clock, Trip Meter, Odometer, Stop Watch

E. Immobilizer Warning Symbol (

)

F. Fuel Injection Warning Symbol (FI)

G. Oil Pressure Warning Symbol

NOTE

żDo not shift the digital meter display

while riding for safe operation.

GENERAL INFORMATION 23

• Display the odometer in the digital

• The km/mile (and °C/°F temperature)

meter.

display shifts as follows.

• The km/mile (or °C/°F temperature)

display shifts by pushing the RE-

SET button while the MODE button

pushed in.

A. Km and °C Display

B. Mile and °F Display

C. Mile and °C Display

D. Km and °F Display

E. Push RESET Button with MODE Button in

NOTE

The data is maintained even if the

battery is disconnected.

A. Km/Mile Display

Speedometer -

B. °C/°F Display

The speedometer shows the speed

of the vehicle in digital values.

24 GENERAL INFORMATION

Gear Position -

The gear position shows the cor-

responding gear position where the

transmission is shifted.

When the transmission is in 1st

gear, the “1” is displayed.

When the transmission is in 2nd

gear, the “2” is displayed.

When the transmission is in 3rd

A. Gear Position

gear, the “3” is displayed.

When the transmission is in 4th

NOTE

gear, the “4” is displayed.

żIf the gear position is in the neutral

When the transmission is in 5th

position, the gear position has no dis-

gear, the “5” is displayed.

play. The neutral indicator light is lit.

When the transmission is in 6th

gear, the “6” is displayed.

GENERAL INFORMATION 25

Clock -

• Push the RESET button. The hour

To adjust hours and minutes:

display stops flashing and the minute

display starts flashing.

Push the

• Turn the ignition key to “ON”.

MODE button to advance the min-

• Push the MODE button to display the

clock.

utes.

• Push the RESET button for more

than two seconds. Both the hour and

minute displays start flashing.

• Push the RESET button. Both the

hour and minute displays start flash-

ing again.

• Push the RESET button. The hour

• Push the MODE button. The dis-

display only flashes.

Push the

plays stop flashing and the clock

MODE button to advance the hours.

starts working.

26 GENERAL INFORMATION

NOTE

Odometer -

The odometer shows the total dis-

żPushing the MODE button momen-

tance in kilometers or miles that the ve-

tarily advances the hour or minute

hicle has been ridden. This meter can-

step by step. Pushing and hold-

not be reset.

ing the button advances the hour or

minute continuously.

żThe clock works normally from the

back-up power while the ignition

switch is turned off.

żWhen the battery is disconnected,

the clock resets to 1:00 and starts

working again when the battery is

connected.

NOTE

żThe data is maintained even if the

battery is disconnected.

żWhen the figures come to 999999,

they are stopped and locked.

GENERAL INFORMATION 27

Trip Meters -

• After two second, the figure display

The trip meter shows the distance in

turns to 0.0, and then starts counting

kilometers or miles traveled since it was

when the vehicle is operated. The

last reset to zero.

meter counts until it is next reset.

To reset the trip meter:

• Push the MODE button to display the

trip meter.

• Push the RESET button and hold it

in.

28 GENERAL INFORMATION

NOTE

Lap Counter/Coolant Temperature

Meter -

żThe data is maintained by the back

The Lap counter/coolant temperature

-up power if the ignition key is turned

meter shows either the lap number or

off.

the coolant temperature. The lap num-

żWhen the trip meter reaches 999.9

ber is displayed when in the stop watch

while riding, the meter resets to 0.0

mode.

and continues counting.

The coolant temperature is displayed

żWhen the battery is disconnected,

as follows.

the meter display resets to 0.0.

• Start the engine. If the coolant tem-

perature is below 40 °C (104 °F), no

temperature is displayed.

GENERAL INFORMATION 29

• When the coolant temperature rises

• If the coolant temperature rises to

to above 40 °C (104 °F), the numer-

above 115 °C (239 °F) and below

ical value of the coolant temperature

120 °C (248 °F), the numerical value

at the present state is displayed.

of the current coolant temperature

starts flashing. This warns the oper-

ator that the coolant temperature is

high.

30 GENERAL INFORMATION

Stop Watch -

• If the coolant temperature rises to

above 120 °C (248 °F), “HI” is dis-

The stop watch can be used in closed

played and starts flashing.

This

course competition.

warns the operator that the coolant

The stop watch is operated as fol-

temperature is too high; stop the

lows;

engine and check the coolant level

• Turn the ignition Key to “ON”.

in the reserve tank after the engine

• Push the MODE button to display the

cools down.

stop watch.

Push the START/STOP switch on the

•

right handlebar switch to the left.

CAUTION

Do not let the engine continue

running when the coolant tem-

perature shows “HI”. Prolonged

engine operation will result in

severe engine damage from

overheating.

A. Start/Stop Switch

32 GENERAL INFORMATION

• The stop watch starts timing the next

• To stop the stop watch, push the

lap and the previous lap time is dis-

START/STOP switch on the right

played for ten seconds.

handlebar switch to the left.

To display each measured lap time,

•

push the RESET button momentarily.

When no lap number is displayed,

the time displayed is the total time of

all timed laps.

A. Lap Time

B. Lap Number

A. Total Lap Time

GENERAL INFORMATION 33

Warning/Indicator Lights:

• To reset the stop watch and erase all

lap numbers and times, push the RE-

N : When the transmission is in neutral,

SET button for more than two sec-

the neutral indicator light is lit.

onds.

: When the headlight is on high

NOTE

beam, the high beam indicator light is

żIf the coolant temperature rises

lit.

above 115 °C (239 °F) with the Lap

number displayed, the Lap number

: When the turn signal switch is

display in the Lap/Coolant Tempera-

pushed to the left or right, the turn sig-

ture Meter automatically shifts to the

nal indicator light flashes.

coolant temperature meter.

żWhen the battery is disconnected, all

Warning Light: This warning light in

lap numbers and times are reset.

the meter instrument has the three

żThe lap time can be stored for a max-

warning light function: oil pressure

imum of 99 times.

warning light and fuel injection system

warning light and immobilizer system

warning light. This warning light flash

on with the each warning symbols:

engine oil pressure warning symbol

(

)/fuel injection warning sym-

bol (FI)/immobilizer warning symbol

34 GENERAL INFORMATION

(

). If the warning light flashs on

FI: The warning light in the meter in-

with the engine running, have its cause

strument and the fuel injection warn-

checked by an authorized Kawasaki

ing symbol (FI) in the digital meter flash

dealer. Refer to the following each

on whenever the ignition key is turned

to “ON” or trouble occurs in the fuel

symbol instructions

(

), (FI) or

injection system. After turning the ig-

(

) for more detailed information.

nition key to “ON”, the fuel injection

warning symbol (FI) goes off soon af-

: The warning light in the meter

ter it has been ensured that its circuit

instrument and the oil pressure warn-

functions properly. If the warning light

ing symbol (

) in the digital meter

and warning symbol flashs on, have the

flash on whenever the oil pressure is

FI system checked by an authorized

dangerously low or the ignition switch

Kawasaki dealer.

is in the ON position with the engine

not running, and go off when the en-

: The warning light in the meter in-

gine oil pressure is high enough. Re-

strument and the immobilizer warning

fer to the Maintenance and Adjustment

symbol (

) in the digital meter flash

chapter for more detailed engine oil in-

on whenever the ignition key is turned

formation.

to “ON” or trouble occurs in the immo-

bilizer system. After turning the igni-

tion key to “ON”, the immobilizer warn-

ing symbol (

) goes off soon after it

GENERAL INFORMATION 35

has been ensured that its circuit func-

(For models equipped with an

tions properly. If the warning light and

immobilizer system)

warning symbol flashes on, have the

When the key is turned to “OFF”, the

immobilizer system checked by an au-

warning light will start flashing indicat-

thorized Kawasaki dealer.

ing that the immobilizer system is en-

abled. After 24 hours have passed, the

warning light will stop flashing, however

the immobilizer system is still enabled.

Warning light flashes if the improp-

erly coded key is used, or any incor-

rect communication between antenna

and key is occurred. However, when

the properly coded key can be used, or

the communication is clear, the warn-

ing light does not flash.

36 GENERAL INFORMATION

NOTE

: The fuel level warning light goes on

żWarning light flashing mode can be

and “FUEL” flashes in the digital me-

set to either on or off. Push and

ter, when only 3.7 L (3.9 US qt) of fuel

hold the MODE and RESET buttons

remains. Refuel at the earliest oppor-

simultaneously for more than two

tunity when the fuel level warning light

seconds, within twenty seconds after

goes on and “FUEL” flash.

turning the ignition key to the “OFF”

position, then the warning light will

not flash.

żWhen the battery is connected, warn-

ing light defaults to flashing mode.

żWhen the battery voltage is low (be-

low 12 V), warning light flashing au-

tomatically goes off to prevent exces-

sive battery discharge.

A. Fuel Level Warning Light

B. “FUEL” Flashes

GENERAL INFORMATION 37

NOTE

Shift Up Indicator Light -

The Shift-up indicator light can be

żWhen pushing the MODE button

used in closed course competition. Do

while “FUEL” is displayed, the dis-

not use the shift-up indicator during ev-

play can be shifted to odometer, trip

eryday riding.

meter, or clock mode.

When the engine speed reaches a

pre-set speed, the shift-up indicator

light comes on to indicate the timing for

shifting up to prevent engine damage.

The shift-up indicator light has four

modes, light off, flash, light on (dim)

and light on (bright). The shift-up indi-

cator light timing can be adjusted be-

tween 9 500 r/min (rpm) and 13 000

r/min (rpm).

To select a shift-up indicator light

mode or adjust the shift-up engine

speed setting in the tachometer, do

the following while the motorcycle is

stopped:

38 GENERAL INFORMATION

• Push the MODE and RESET button

• To adjust the shift-up engine speed,

simultaneously for more than 2 sec-

press the RESET button and the shift

onds. The previous shift-up engine

-up engine speed timing advances

speed setting will be displayed in the

in 50 r/min (rpm) increments up to

tachometer gauge.

13 000 r/min (rpm). Once 13 000

r/min (rpm) is reached while advanc-

• To change the shift-up indicator light

mode, push the MODE button and

ing, the reading returns to 9 500 r/min

the shift-up indicator light will shift be-

(rpm) and begins advancing.

tween light off, flash, light on (bright)

and light on (dim). The shift-up en-

gine speed can only be adjusted

when the light is on.

A. Shift Up Indicator Light

B. Adjustable Range

GENERAL INFORMATION 39

WARNING

• To complete the adjustment, push

the MODE button and RESET but-

Failing to properly observe the

ton simultaneously for more than two

road ahead increases the chance

seconds. The tachometer now oper-

of an accident. Do not concen-

ates normally.

trate on the shift-up indicator

light by taking your eyes off the

road, observe using peripheral

vision.

When shifting down to a lower

gear, do not shift at such a high

speed that the engine r/min

(rpm) jumps excessively. Not

only can this cause engine dam-

age, but the rear wheel may skid

and cause an accident. Down-

shifting should be done below

5 000 r/min (rpm) for each gear.

40 GENERAL INFORMATION

NOTE

Key

This motorcycle has a combination

żPushing and holding the RESET but-

key, which is used for the ignition

ton advances the shift-up engine

switch/steering lock, seat lock, and fuel

speed continuously.

tank cap.

żThe data is maintained even if the

battery is disconnected.

(Except for models equipped with an

immobilizer system)

CAUTION

Blank keys are available at your

Kawasaki dealers. Ask your dealer to

Engine r/min (rpm) should not

make any additional spare keys you

be allowed to enter the red zone;

may need, using your original key as a

operation in the red zone will

master.

overstress the engine and may

cause serious engine damage.

Immobilizer System (For models

equipped with an Immobilizer

system)

This motorcycle is equipped with an

immobilizer system to protect your mo-

torcycle from theft. This motorcycle

has one master key with a red head

and two user-keys with black heads.

Kawasaki strongly recommends you do

not use the master key for daily driving.

GENERAL INFORMATION 41

Store the master key and the key tag in

CAUTION

a safe place. If the master key is lost,

Do not put two keys of any immo-

registering new codes for replacement

bilizer system on the same key

user keys into the electronic control unit

ring.

is impossible. To make additional user

Do not submerge any key in wa-

keys, take the vehicle along with the

ter.

master key and all user keys to an au-

Do not expose any key to exces-

thorized Kawasaki dealer to have them

sively high temperature.

re-registered. Up to five user keys can

Do not place any key close to

be registered with the immobilizer sys-

magnets.

tem at one time.

Do not place heavy item on any

key.

Do not grind any key or alter its

shape.

Do not disassemble the plastic

part of any key.

Do not drop any key and/or apply

shocks to it.

If a user-key is lost, re-registry

at dealer is securely required to

prevent the possibility of theft.

42 GENERAL INFORMATION

CAUTION

• Master key:

The master key can never be dupli-

If the master key is lost, an au-

cated.

thorized Kawasaki dealer will

have to replace the ECU, order a

• User-keys:

You can register maximum 5 user

new master key, and register the

-keys at one time.

user keys.

If an improperly coded key is used or

any incorrect communication between

ECU and key is occurred, the engine

does not start and warning light flashes.

A properly coded key must be used

or the communication should be clear

for the engine to start.

When the key is turned to “OFF, ” the

warning light will start flashing indicat-

ing that the immobilizer system is en-

abled. After 24 hours have passed, the

warning light will stop flashing, however

A. Master key (red)

the immobilizer system is still enabled.

B. User-keys (black)

GENERAL INFORMATION 43

If the master key is lost, registering

EC Directive Compliance

new user key codes is impossible. If

This immobilizer system complies

all keys are lost, the ECU must be re-

with the R & TTE (Radio equipment and

placed.

telecommunications terminal equip-

ment and the mutual recognition of

NOTE

their conformity) Directive.

żWarning light flashing mode can be

set to either on or off. Push and

hold the MODE and RESET buttons

simultaneously for more than two

seconds, within twenty seconds after

turning the ignition key to the “OFF”

position, then the warning light will

not flash.

żWhen the battery is connected, warn-

ing light defaults to flashing mode.

żWhen the battery voltage is low (be-

low 12 V), warning light flashing au-

tomatically goes off to prevent exces-

sive battery discharge.

44 GENERAL INFORMATION

Ignition Switch/Steering Lock

Engine off. All electrical

OFF

This is a four-position, key-operated

circuits off.

switch. The key can be removed from

Engine on. All electrical

the switch when it is in the OFF, LOCK,

equipment can be used.

or P (Park) position.

Steering locked. Engine off.

LOCK

All electrical circuits off.

Steering locked. Engine off.

Tail and license plate lights on.

P (Park)

All other electrical circuits cut

off.

NOTE

The tail, city and license plate lights

are on whenever the ignition key is

in the ON position. One headlight

A. Ignition Switch/Steering Lock

goes on when the starter button is

B. ON position

released after starting the engine. To

C. OFF position

D. LOCK position

avoid battery discharge, always start

E. P (Park) position

GENERAL INFORMATION 45

the engine immediately after turning

Right Handlebar Switches

the ignition key to “ON”.

Engine Stop Switch:

żIf you leave the P (Park) position on

In addition to the ignition switch,

for a long time (one hour), the battery

the engine stop switch must be in

may become totally discharged.

the

position for the motorcycle to

operate.

The engine stop switch is for emer-

gency use. If some emergency re-

quires stopping the engine, move the

engine stop switch to the

position.

NOTE

żAlthough the engine stop switch

stops the engine, it does not turn off

all the electrical circuits. Ordinarily,

the ignition switch should be used to

stop the engine.

46 GENERAL INFORMATION

Starter Button:

The starter button operates the elec-

tric starter when the transmission is in

neutral.

Refer to the Starting the Engine sec-

tion of the “How to Ride the Motorcycle”

chapter for starting instructions.

START/STOP Switch (Stop Watch):

Refer to the Digital Meter section of

this chapter for stop watch instructions.

A. Engine Stop Switch

B. Start/Stop Switch (Stop Watch)

C. Starter Button

GENERAL INFORMATION 47

Left Handlebar Switches

Dimmer Switch:

High or low beam can be selected

with the dimmer switch. When the

headlight is on high beam (

), the

high beam indicator light is lit.

High beam

(

)

Low beam

(

)

NOTE

A. Dimmer Switch

żWhen the headlight is on high beam,

B. Turn Signal Switch

both headlights are lit. When the

C. Horn Button

headlight is on low beam, only one

D. Lap Button

headlight is lit.

E. Passing Button

48 GENERAL INFORMATION

Turn Signal Switch:

Brake Lever Adjuster

When the turn signal switch is turned

There is an adjuster on the brake

lever. The adjuster has 6 positions so

to the left (

) or right (

), the

that the released lever position can be

corresponding turn signals flash on and

adjusted to suit the operator’s hands.

off.

Push the lever forward and turn the ad-

To stop flashing, push the switch in.

juster to align the number with the mark

Horn Button:

on the lever holder. The distance from

When the horn button is pushed, the

the grip to the released lever is min-

horn sounds.

imum at Number 6 and maximum at

Number 1.

Passing Button:

When the passing button is pushed,

the headlight high beam (passing

beam) comes on to signal the driver of

the vehicle ahead that you are about to

pass him. The passing light shuts off

as soon as the button is released.

LAP Button:

Refer to the Digital Meter section of

the this chapter for stop watch instruc-

tions.

GENERAL INFORMATION 49

Fuel Tank Cap

To open the fuel tank cap, pull up the

key hole cover. Insert the ignition key

into the fuel tank cap and turn the key

to the right.

To close the cap, push it down into

place with the key inserted. The key

can be removed by turning it to the left

to the original position.

NOTE

A. Adjuster

żThe fuel tank cap cannot be closed

B. Mark

without the key inserted, and the key

cannot be removed unless the cap is

locked properly.

żDo not push on the key to close the

cap, or the cap cannot be locked.

50 GENERAL INFORMATION

Fuel Tank

The following octane rating gasoline

is recommended in the fuel tank. Avoid

filling the tank in the rain or where

heavy dust is blowing so that the fuel

does not get contaminated.

A. Key Hole Cover

B. Ignition Key

C. Fuel Tank Cap

A. Tank Cap

B. Fuel Tank

C. Top Level

D. Filler Neck

GENERAL INFORMATION 51

WARNING

Fuel Requirement:

Your Kawasaki engine is designed to

Gasoline is extremely flammable

use only unleaded gasoline with a min-

and can be explosive under cer-

imum octane rating of RON 95.

tain conditions. Turn the igni-

tion key to “OFF”. Do not smoke.

CAUTION

Make sure the area is well ven-

Do not use leaded gasoline, as

tilated and free from any source

this will destroy the catalytic

of flame or sparks; this includes

converter.

(For further infor-

any appliance with a pilot light.

mation, refer to the “Catalytic

Never fill the tank so the fuel

Converter” section in the “How

level rises into the filler neck. If

to Ride the Motorcycle” chap-

the tank is overfilled, heat may

ter.)

cause the fuel to expand and

overflow through the vents in

the tank cap.

After refueling, make sure the

fuel tank cap is closed securely.

If gasoline is spilled on the fuel

tank, wipe it off immediately.

52 GENERAL INFORMATION

Octane Rating

Side Stand

The octane rating of a gasoline is a

The motorcycle is equipped with a

measure of its resistance to detona-

side stand.

tion or “knocking”. The term commonly

used to describe a gasoline’s octane

rating is the Research Octane Number

(RON). Always use a gasoline with an

octane rating equal to, or higher than,

RON 95.

NOTE

żIf “knocking” or “pinging” occurs, use

a different brand of gasoline or higher

octane rating.

A. Side Stand

CAUTION

NOTE

Use minimum of 95 octane gaso-

żWhen using the side stand, turn the

line only to prevent severe en-

handlebar to the left.

gine damage.

Whenever the side stand is used,

make it a practice to kick the stand fully

up before sitting on the motorcycle.

GENERAL INFORMATION 53

NOTE

Seat Lock

żThe motorcycle is equipped with a

Passenger’s Seat Removal

side stand switch. This switch is de-

Remove the passenger’s seat by in-

signed so that the engine does not

serting the ignition key into the seat

start if the transmission is in gear and

lock, and turning it clockwise.

the side stand is down.

A. Seat Lock

B. Ignition Key

54 GENERAL INFORMATION

NOTE

Rider’s Seat Removal

żWhen removing the passenger’s

• Remove the bolt.

seat, pull it up while turning the key.

• Remove the side cover by pulling out

it to detach the projection, and hook

-and-loop fastener.

A. Passenger’s Seat

B. Pull up

C. Turn the Key

A. Screw

B. Side Cover

C. Projection

D. Hook-and-Loop Fastener

GENERAL INFORMATION 55

Rider’s Seat -

• Remove the bolt and pull off the seat

to the up and front.

• Place the tab on the rear of the rider’s

seat into the slot in the frame and

tighten the bolt.

A. Bolt

B. Rider’s Seat

C. Pull Up and Front

A. Rider’s Seat

B. Tab

Seat Installation

C. Slot

Install the rider’s and passenger’s

seats in the reverse order of removal.

56 GENERAL INFORMATION

• Install the side cover and tighten the

bolt.

NOTE

żWhen installing the side cover, insert

the up of the cover into the under

of the rider’s seat as shown in the

figure.

żInsert the projection into the hole,

and attach the hook-and-loop fas-

tener of the side cover to one of the

A. Cover

fuel tank.

B. Projection

C. Hole

D. Hook-and-Loop Fastener

E. Up of Cover

F. Under of Rider’s Seat

GENERAL INFORMATION 57

Passenger’s Seat -

• Pull up the front and rear ends of

the passenger’s and rider’s seats to

• Insert the tab on the rear of the pas-

senger’s seat into the slot in the

make sure they are securely locked.

frame.

• Insert the left and right projections at

the front of the passenger’s seat into

the left and right slots on the frame.

• Push down the front part of the pas-

senger’s seat until the lock clicks.

A. Projections

B. Slots

C. Tab

58 GENERAL INFORMATION

Helmet Hooks

WARNING

Helmets can be secured to the mo-

Do not ride the motorcycle with

torcycle using the helmet hooks located

helmets attached to the hooks.

under the passenger’s seat.

The helmets could cause an ac-

cident by distracting the opera-

tor or interfering with normal ve-

hicle operation.

A. Helmet Hooks

GENERAL INFORMATION 59

Tool Kit

Air Cleaner Intake

The tool kit is located under the pas-

The air cleaner intake allows air to

senger’s seat.

enter the fuel system. Never allow any-

The kit contains tools that can be

thing to restrict the flow of air into the

helpful in making roadside repairs,

air cleaner. A restricted air cleaner will

adjustments, and some maintenance

reduce performance and increase ex-

procedures explained in this manual.

haust emissions.

Keep the tool kit in the original place.

A. Air Cleaner Intake

A. Tool Kit

B. Band

60 BREAK-IN

BREAK-IN

The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the

break-in period. If the motorcycle is not used carefully during this period, you may

very well end up with a “broken down” instead of a “broken in” motorcycle after a

few thousand kilometers.

The following rules should be observed during the break-in period.

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

riod.

Distance traveled

Maximum engine speed

0 ∼ 800 km (0 ∼ 500 mi)

4 000 r/min (rpm)

800 ∼ 1 600 km (500 ∼ 1 000 mi)

6 000 r/min (rpm)

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

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

give the oil a chance to work up into all the engine parts.

• Do not race the engine while the transmission is in neutral.

BREAK-IN 61

WARNING

New tires are slippery and may cause loss of control and injury.

A break-in period of 160 km (100 miles) is necessary to establish normal

tire traction. During break-in, avoid sudden and maximum braking and

acceleration, and hard cornering.

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

owner have the initial maintenance service performed by an authorized Kawasaki

dealer.

62 HOW TO RIDE THE MOTORCYCLE

HOW TO RIDE THE MOTORCYCLE

Starting the Engine

• Turn the ignition key to “ON”.

• Check that the engine stop switch is

• Make sure the transmission is in neu-

in the

position.

tral.

A. Neutral Indicator Light

A. Engine Stop Switch

B. Ignition Switch

B. Starter Button

C. ON position

HOW TO RIDE THE MOTORCYCLE 63

NOTE

CAUTION

żThe motorcycle is equipped with a

Do not operate the starter con-

vehicle-down sensor, which causes

tinuously for more than 5 sec-

the engine to stop automatically and

onds, or the starter will overheat

the fuel injection warning symbol to

and the battery power will drop

flash when the motorcycle falls down

temporarily. Wait 15 seconds

and the starter button pushed in. Af-

between each operation of the

ter righting the motorcycle, first turn

starter to let it cool and the bat-

the ignition key to “OFF” and then

tery power recover.

back to “ON” for a few seconds be-

fore starting the engine.

• After the meter operation check,

leaving the throttle completely

closed, push the starter button.

64 HOW TO RIDE THE MOTORCYCLE

NOTE

CAUTION

żThe motorcycle is equipped with a

Do not let the engine idle longer

starter lockout switch. This switch is

than five minutes, or engine

designed so that the engine does not

overheating and damage may

start if the transmission is in gear and

occur.

the side stand is down. However, the

engine can be started if the clutch

lever is pulled and the side stand is

fully up.

A. Clutch Lever

B. Starter Lockout Switch

HOW TO RIDE THE MOTORCYCLE 65

Jump Starting

WARNING

If your motorcycle battery is “run

Battery acid generates hydro-

down”, it should be removed and

gen gas which is flammable and

charged. If this is not practical, a 12

explosive under certain con-

volt booster battery and jumper cables

ditions. It is present within a

may be used to start the engine.

battery at all times, even in a

discharged condition. Keep all

flames and sparks (cigarettes)

away from the battery. Wear eye

protection when working with a

battery. In the event of battery

acid contact with skin, eyes, or

clothing, wash the affected ar-

eas immediately with water for at

least five minutes. Seek medical

attention.

Connecting Jumper Cables

• Remove the rider’s and passenger’s

seats.

• Make sure the ignition key is turned

to “OFF”.

66 HOW TO RIDE THE MOTORCYCLE

• Connect a jumper cable from the

• Connect another jumper cable from

positive (+) terminal of the booster

the negative

(-) terminal of the

battery to the positive (+) terminal of

booster battery to your motorcy-

the motorcycle battery.

cle footpeg or other unpained metal

surface. Do not use the negative (-)

terminal of the battery.

WARNING

Do not make this last connec-

tion at the fuel system or battery.

Take care that you do not touch

the positive and negative cables

together, and do not lean over

the battery when making this last

connection. Do not jump start a

A. Motorcycle Battery Positive (+) Terminal

frozen battery. It could explode.

B. From Booster Battery Positive (+) Terminal

C. Footpeg

Do not reverse polarity by con-

D. From Booster Battery Negative (-)

necting positive (+) to negative

Terminal

(-), or a battery explosion and

serious damage to the electrical

system may occur.

HOW TO RIDE THE MOTORCYCLE 67

Moving Off

• Follow the standard engine starting

procedure.

• Check that the side stand is up.

• Pull in the clutch lever.

CAUTION

• Shift into 1st gear.

• Open the throttle a little, and start to

Do not operate the starter con-

let out the clutch lever very slowly.

tinuously for more than 5 sec-

• As the clutch starts to engage, open

onds or the starter will overheat

the throttle a little more, giving the en-

and the battery power will drop

gine just enough fuel to keep it from

temporarily. Wait 15 seconds

stalling.

between each operation of the

starter to let it cool and the bat-

tery power recover.

• After the engine has started, discon-

nect the jumper cables. Disconnect

the negative (-) cable from the mo-

torcycle first.

• Reinstall the parts removed.

A. Shift Pedal

68 HOW TO RIDE THE MOTORCYCLE

NOTE

Shifting Gears

żThe motorcycle is equipped with a

• Close the throttle while pulling in the

side stand switch. This switch is de-

clutch lever.

signed so that the engine does not

• Shift into the next higher or lower

gear.

start if the transmission is in gear and

the side stand is down.

żWhen the headlight is on high beam,

WARNING

two headlight beams are lit, and on

When shifting down to a lower

low beam, the one side of the head-

gear, do not shift at such a high

light is lit.

speed that the engine r/min

(rpm) jumps excessively. Not

only can this cause engine dam-

age, but the rear wheel may skid

and cause an accident. Down-

shifting should be done below

5 000 r/min (rpm) for each gear.

• Open the throttle part way, while re-

leasing the clutch lever.

HOW TO RIDE THE MOTORCYCLE 69

NOTE

Braking

żThe transmission is equipped with a

• Close the throttle completely, leav-

positive neutral finder. When the mo-

ing the clutch engaged (except when

torcycle is standing still, the transmis-

shifting gears) so that the engine will

help slow down the motorcycle.

sion cannot be shifted past neutral

from 1st gear. To use the positive

• Shift down one gear at a time so that

you are in 1st gear when you come

neutral finder, shift down to 1st gear,

to a complete stop.

then lift up on the shift pedal while

standing still. The transmission will

• When stopping, always apply both

brakes at the same time. Normally

shift only into neutral.

the front brake should be applied a lit-

tle more than the rear. Shift down or

fully disengage the clutch as neces-

sary to keep the engine from stalling.

• Never lock the brakes, or it will cause

the tires to skid. When turning a cor-

ner, it is better not to brake at all. Re-

duce your speed before you get into

the corner.

HOW TO RIDE THE MOTORCYCLE 71

Stopping the Engine

Stopping the Motorcycle in an

Emergency

• Close the throttle completely.

Your Kawasaki Motorcycle has been

• Shift the transmission into neutral.

designed and manufactured to pro-

• Turn the ignition key to “OFF”.

vide you optimum safety and conve-

• Support the motorcycle on a firm,

level surface with the side stand.

nience. However, in order to fully ben-

efit from Kawasaki’s safety engineering

• Lock the steering.

and craftsmanship, it is essential that

NOTE

you, the owner and operator, properly

maintain your motorcycle and become

żThe motorcycle is equipped with a

vehicle-down sensor, which causes

thoroughly familiar with its operation.

the engine to stop automatically and

Improper maintenance can create a

the fuel injection warning symbol to

dangerous situation known as throt-

flash when the motorcycle falls down

tle failure. Two of the most common

and the starter button pushed in. Af-

causes of throttle failure are:

ter righting the motorcycle, first turn

1. An improperly serviced or clogged

the ignition key to “OFF” and then

air cleaner may allow dirt and dust

back to “ON” for a few seconds be-

to enter the throttle body and stick

fore starting the engine.

the throttle open.

72 HOW TO RIDE THE MOTORCYCLE

2. During removal of the air cleaner,

Parking

dirt is allowed to enter and jam the

• Shift the transmission into neutral

fuel injection system.

and turn the ignition key to “OFF”.

In an emergency situation such as

• Support the motorcycle on a firm,

level surface with the side stand.

throttle failure, your vehicle may be

stopped by applying the brakes and

disengaging the clutch.

Once this

CAUTION

stopping procedure is initiated, the en-

Do not park on a soft or steeply

gine stop switch may be used to stop

inclined surface, or the motorcy-

the engine. If the engine stop switch is

cle may fall over.

used, turn off the ignition switch after

stopping the motorcycle.

• If parking inside a garage or other

structure, be sure it is well ventilated

and the motorcycle is not close to

any source of flame or sparks; this

includes any appliance with a pilot

light.

HOW TO RIDE THE MOTORCYCLE 73

WARNING

NOTE

The muffler and exhaust pipe

żWhen stopping near traffic at night,

you can leave the taillight on for

are very hot while the engine is

greater visibility by turning the igni-

running and just after the engine

tion key to the P (park) position.

stops. This can ignite a fire, re-

sulting in property damage or

żDo not leave the ignition switch at P

position too long, or the battery will

severe personal injury.

discharge.

Do not idle or park your vehi-

cle in an area where flammable

materials such as grasses or dry

leaves may contact with muffler

or exhaust pipe.

WARNING

Gasoline is extremely flammable

and can be explosive under cer-

tain conditions.

• Lock the steering to help prevent

theft.

74 HOW TO RIDE THE MOTORCYCLE

Catalytic Converter

WARNING

This motorcycle is equipped with a

The muffler and exhaust pipe

catalytic converter in the exhaust sys-

are very hot while the engine is

tem. Palladium, platinum and rhodium

running and just after the engine

in the converter react with carbon

stops. This can ignite a fire, re-

monoxide and hydrocarbons to convert

sulting in property damage or

them into carbon dioxide and water re-

severe personal injury.

sulting in much cleaner exhaust gases

Do not idle or park your vehi-

to be discharged into the atmosphere.

cle in an area where flammable

For proper operation of the catalytic

materials such as grasses or dry

converter, the following cautions must

leaves may contact with muffler

be observed.

or exhaust pipe.

HOW TO RIDE THE MOTORCYCLE 75

• Use only unleaded gasoline. Never

use leaded gasoline. Leaded gaso-

line significantly reduces the capabil-

ity of the catalytic converter.

• Do not coast the vehicle with the igni-

tion switch and/or engine stop switch

off. Do not attempt to start the en-

gine by rolling the vehicle if the bat-

tery is discharged. Do not operate

the vehicle with the engine or any

one cylinder misfiring. Under these

conditions unburned air/fuel mixture

flowing out of engine excessively ac-

celerates reaction in the converter al-

lowing the converter to overheat and

become damaged when the engine

is hot, or reduces converter perfor-

mance when the engine is cold.

76 SAFE OPERATION

SAFE OPERATION

Safe Riding Technique

The points given below are applicable for everyday motorcycle use and should

be carefully observed for safe and effective vehicle operation.

For safety, eye protection and a

Before changing lanes, look over

helmet are strongly recommended.

your shoulder to make sure the way

You should be aware of and verify

is clear. Do not rely solely on the

the applicable safety regulations in

rear view mirror; you may misjudge

force prior to riding your motorcy-

a vehicle’s distance and speed, or

cle. Gloves and suitable footwear

you may not see it at all.

should also be used for added pro-

tection.

When going up steep slopes, shift

to a lower gear so that there is plenty

A motorcycle does not provide

of power to spare rather than over-

the impact protection of an auto-

loading the engine.

mobile, so defensive riding in addi-

tion to wearing protective apparel

When applying the brakes, use

is extremely important. Do not let

both the front and rear brakes. Ap-

protective apparel give you a false

plying only one brake for sudden

sense of security.

SAFE OPERATION 77

braking may cause the motorcycle

When riding in wet conditions or

to skid and lose control.

on loose roadway surfaces, the abil-

ity to maneuver will be reduced. All

When going down long slopes,

of your actions should be smooth

control vehicle speed by closing

under these conditions. Sudden ac-

the throttle. Use the front and rear

celeration, braking or turning may

brakes for auxiliary braking.

cause loss of control.

In wet conditions, rely more on the

On rough roads, exercise caution,

throttle to control vehicle speed and

slow down, and grip the fuel tank

less on the front and rear brakes.

with the knees for better stability.

The throttle should also be used ju-

diciously to avoid skidding the rear

When quick acceleration is neces-

wheel from too rapid acceleration or

sary as in passing, shift to a lower

deceleration.

gear to obtain the necessary power.

Riding at the proper rate of speed

Do not downshift at too high an

and avoiding unnecessarily fast ac-

r/min (rpm) to avoid damage to the

celeration are important not only for

engine from overrevving.

safety and low fuel consumption but

also for long vehicle life and quieter

Avoiding unnecessary weaving is

operation.

important to the safety of both the

rider and other motorists.

78 SAFE OPERATION

Daily Safety Checks

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

and habitual performance of these checks will help ensure you a safe, reliable ride.

If any irregularities are found during these checks, refer to the Maintenance and

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

cycle to a safe operating condition.

WARNING

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

serious 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

250 kPa (2.50 kgf/cm², 36 psi)

Rear

290 kPa (2.90 kgf/cm², 42 psi)

Install the air valve cap.

Drive chain

Slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.).

Lubricate when chain is dry.

Nuts, bolts, fasteners .. Check that steering and suspension components, axles,

and all controls are properly tightened or fastened.

SAFE OPERATION 79

Steering

Action smooth but not loose from lock to lock.

No binding of control cables.

Steering Damper Unit: No oil leakage.

Brakes

Brake pad wear: Lining thickness more than 1 mm (0.04

in.) left.

No brake fluid leakage.

Throttle

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

Clutch

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

Clutch lever operates smoothly.

Coolant

No coolant leakage.

Coolant level between level lines (when engine is cold).

Electrical equipment ...

All lights (Headlight, Tail/Brake Lights, Turn Signal Lights,

Warning/Indicator Lights) and horn work.

Engine stop switch

Stops engine.

Side stand

Return to its fully up position by spring tension.

Return spring not weak or not damaged.

Refer to the “Daily Safety Checks” caution label attached to the back of left side

cover.

80 SAFE OPERATION

Additional Considerations for High Speed Operation

Brakes: The importance of the brakes, especially during high speed operation,

cannot be overemphasized. Check to see that they are correctly adjusted and func-

tioning properly.

Steering: Looseness in the steering can cause loss of control. Check to see that

the handlebar turns freely but has no play.

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

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

check the wheel balance.

Fuel: Have sufficient fuel for the high fuel consumption during high speed oper-

ation.

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

the oil level is at the upper level line.

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

line.

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

horn, etc., all work properly.

Miscellaneous: Make sure that all nuts and bolts are tight and that all safety

related parts are in good condition.

82 MAINTENANCE AND ADJUSTMENT

MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out in

accordance with the Periodic Maintenance Chart to keep the motorcycle in good

running condition. The initial maintenance is vitally important and must not be

neglected.

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

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

lack proper experience or doubt your ability, all adjustments, maintenance, and

repair work should be completed by a qualified technician.

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

ing from incorrect or improper adjustment done by the owner.

MAINTENANCE AND ADJUSTMENT 83

Periodic Maintenance Chart

1. Periodic Inspection (Engine Related Items)

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Operation (Engine

Ev-

Items)

ery

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Valve clearance -

105

inspect

•

Throttle control system

(play, smooth return,

year

112

•

no drag) - inspect

Engine vacuum

Ksynchronization -

115

•

inspect

Idle speed - inspect

115

•

Fuel leak (fuel hose

year

and pipe) - inspect

•

84 MAINTENANCE AND ADJUSTMENT

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Operation (Engine

Ev-

Items)

ery

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Fuel hoses damage -

year

inspect

•

Fuel hoses installation

year

condition - inspect

•

Coolant level - inspect

100

•

Coolant leak - inspect

year

•

Radiator hose damage

year

- inspect

•

Radiator hoses

installation condition -

year

•

inspect

Air suction system

105

damage - inspect

•

MAINTENANCE AND ADJUSTMENT 85

2. Periodic Inspection (Chassis Related Items)

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Operation (Chassis

Ev-

Items)

ery

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Clutch and drive

train:

Clutch operation

(play, engagement,

117

disengagement) -

•

inspect

Drive chain

lubrication condition -

every 600 km (400 mile)

128

inspect #

Drive chain slack -

every 1 000 km (600 mile)

119

inspect #

Drive chain wear -

123

inspect #

•

86 MAINTENANCE AND ADJUSTMENT

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Operation (Chassis

Ev-

Items)

ery

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Drive chain guide

wear - inspect

•

Wheels and tires:

Tire air pressure -

year

146

inspect

•

Wheels/tires damage

147

- inspect

•

Tire tread wear,

abnormal wear -

147

•

inspect

Wheel bearings

year

damage - inspect

•

Brake system:

MAINTENANCE AND ADJUSTMENT 87

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Operation (Chassis

Ev-

Items)

ery

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Brake fluid leak -

year

130

inspect

•

Brake hoses damage

year

130

- inspect

•

Brake pad wear -

129

inspect #

•

Brake hose

installation condition

year

130

•

- inspect

Brake fluid level -

130

inspect

month

•

Brake operation

(effectiveness, play,

year

132

•

drag) - inspect

88 MAINTENANCE AND ADJUSTMENT

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Operation (Chassis

Ev-

Items)

ery

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Brake light switch

132

operation - inspect

•

Suspensions:

Front forks/rear

shock absorber

136/

operation (damping

•

141

and smooth stroke) -

inspect

Front forks/rear

136/

shock absorber oil

year

•

141

leak - inspect

Uni-trak rocker arm

operation - inspect

•

Uni-trak tie rods

operation - inspect

•

MAINTENANCE AND ADJUSTMENT 89

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Operation (Chassis

Ev-

Items)

ery

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Steering system:

Steering play -

year

inspect

•

Steering stem

bearings - lubricate

years

•

Steering damper oil

135

leak - inspect

•

90 MAINTENANCE AND ADJUSTMENT

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Operation

Every

(Chassis Items)

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Electrical system:

Lights and switches

year

operation - inspect

•

Headlight aiming -

year

156

inspect

•

Side stand switch

year

operation - inspect

•

Engine stop switch

year

operation - inspect

•

Chassis:

Chassis parts -

year

lubricate

•

Bolts and nuts

tightness - inspect

•

MAINTENANCE AND ADJUSTMENT 91

3. Periodic Replacement

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Change/Replace-

Every

ment Items

(0.6)

(7.5)

(15)

(22.5)

(30)

Air cleaner element #

every 18 000 km (11 250 mile)

107

K Engine oil #

year

•

KOil filter

year

•

K Fuel hoses

4 years

•

KCoolant

3 years

103

•

Radiator hoses and

3 years

O-rings

•

KBrake hoses

4 years

•

Brake fluid (front and

2 years

132

rear)

•

92 MAINTENANCE AND ADJUSTMENT

Frequency

Whichever

comes

*Odometer Reading

first

km × 1 000 (mile × 1 000)

See

Page

Change/Replace-

Every

ment Items

(0.6)

(7.5)

(15)

(22.5)

(30)

Rubber parts of

Kmaster cylinder and

4 years

•

caliper

KSpark plug

104

•

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.

MAINTENANCE AND ADJUSTMENT 93

Engine Oil

Oil Level Inspection

In order for the engine, transmission,

• If the oil has just been changed, start

and clutch to function properly, main-

the engine and run it for several min-

tain the engine oil at the proper level,

utes at idle speed. This fills the oil

and change the oil and replace the oil

filter with oil. Stop the engine, then

filter in accordance with the Periodic

wait several minutes until the oil set-

Maintenance Chart. Not only do dirt

tles.

and metal particles collect in the oil, but

the oil itself loses its lubricative quality

CAUTION

if used too long.

Racing the engine before the oil

reaches every part can cause en-

WARNING

gine seizure.

Motorcycle operation with insuf-

ficient, deteriorated, or contami-

• If the motorcycle has just been used,

nated engine oil will cause accel-

wait several minutes for all the oil to

erated wear and may result in en-

drain down.

gine or transmission seizure, ac-

cident, and injury.

94 MAINTENANCE AND ADJUSTMENT

• Check the engine oil level through

• If the oil level is too high, remove the

the oil level gauge. With the motor-

excess oil through the oil filler open-

cycle held level, the oil level should

ing using a syringe or some other

come up between the upper and

suitable device.

lower level lines next to the gauge.

• If the oil level is too low, add the oil

to reach the correct level. Use the

same type and brand of oil that is

already in the engine.

CAUTION

If the engine oil gets extremely

low or if the oil pump does not

function properly or oil pas-

sages are clogged, the warning

light in the meter instrument and

oil pressure warning symbol in

A. Oil Level Inspection Window

the digital meter will flash. If

B. Oil Filler Cap

C. Lower Level Line

they flash on while the engine

D. Upper Level Line

running above the idle speed,

stop the engine immediately and

find the cause.

96 MAINTENANCE AND ADJUSTMENT

Tightening Torque

Engine Oil Drain Plug:

30 N·m (3.1 kgf·m, 22 ft·lb)

Cartridge:

17 N·m (1.7 kgf·m, 13 ft·lb)

Recommended Engine Oil

Type:

API SE, SF or SG

API SH, SJ or SL with JASO MA, MA1

or MA2

A. Oil Filter Cartridge

Viscosity:

SAE10W-40

WARNING

NOTE

Motor oil is a toxic substance.

Dispose of used oil properly.

żDo not add any chemical additive to

Contact your local authorities

the oil. Oils fulfilling the above re-

for approved disposal methods

quirements are fully formulated and

or possible recycling.

provide adequate lubrication for both

the engine and the clutch.

MAINTENANCE AND ADJUSTMENT 97

Engine Oil Capacity

Capacity:

3.2 L (3.4 US qt)

[when filter is not removed]

3.7 L (3.9 US qt)

[when filter is removed]

4.0 L (4.2 US qt)

[when engine is completely dry]

Although 10W-40 engine oil is the

recommended oil for most condi-

tions, the oil viscosity may need to

be changed to accommodate atmo-

spheric conditions in your riding area.

98 MAINTENANCE AND ADJUSTMENT

Cooling System

CAUTION

Radiator and Cooling Fan -

Using high-pressure water, as

Check the radiator fins for obstruc-

from a car wash facility, could

tion by insects or mud.

Clean off

damage the radiator fins and im-

any obstructions with a stream of

pair the radiator’s effectiveness.

low-pressure water.

Do not obstruct or deflect air-

flow through the radiator by

WARNING

installing unauthorized acces-

sories in front of the radiator or

Keep your hands and clothing

behind the cooling fan. Inter-

away from the cooling fan blades

ference with the radiator airflow

at all times.

can lead to overheating and con-

sequent engine damage.

Radiator Hoses -

Check the radiator hoses for leakage,

cracks or deterioration, and connec-

tions for leakage, or looseness each

day before riding the motorcycle, and

in accordance with the Periodic Main-

tenance Chart.

MAINTENANCE AND ADJUSTMENT 99

Coolant -

a period of time, the cooling system

Coolant absorbs excessive heat from

accumulates rust and scale in the wa-

the engine and transfers it to the air

ter jacket and radiator. This will clog

at the radiator. If the coolant level be-

up the coolant passages, and con-

comes low, the engine overheats and

siderably reduce the efficiency of the

may suffer severe damage. Check the

cooling system.

coolant level each day before riding the

motorcycle, also in accordance with the

WARNING

periodic maintenance chart and replen-

Use coolant containing corro-

ish coolant if the level is low. Change

sion inhibitors made specifically

the coolant in accordance with the Pe-

for aluminum engines and ra-

riodic Maintenance Chart.

diators in accordance with the

Information for Coolant

instructions of the manufacturer.

To protect the cooling system (con-

Chemicals are harmful to the hu-

sisting of the aluminum engine and

man body.

radiator) from rust and corrosion, the

use of corrosion and rust inhibitor

Soft or distilled water must be used

chemicals in the coolant is essential. If

with the antifreeze (see below for an-

coolant containing corrosion and rust

tifreeze) in the cooling system.

inhibitor chemicals are not used, over

100 MAINTENANCE AND ADJUSTMENT

CAUTION

If hard water is used in the sys-

Permanent types of antifreeze on

tem, it causes scale accumula-

the market have anti-corrosion

tion in the water passages, and

and anti-rust properties. When it

considerably reduces the effi-

is diluted excessively, it loses its

ciency of the cooling system.

anti-corrosion property. Dilute a

permanent type of antifreeze in

If the lowest ambient temperature en-

accordance with the instructions

countered falls below the freezing point

of the manufacturer.

of water, use permanent antifreeze in

the coolant to protect the cooling sys-

NOTE

tem against engine and radiator freeze

żA permanent type of antifreeze is in-

-up, as well as from rust and corrosion.

stalled in the cooling system when

Use a permanent type of antifreeze

shipped. It is colored green and con-

(soft water and ethylene glycol plus cor-

tains ethylene glycol. It is mixed at

rosion and rust inhibitor chemicals for

50% and has the freezing point of

aluminum engines and radiators) in the

-35 °C (-31 °F).

cooling system. On the mixture ratio

of coolant, choose the suitable one re-

Coolant Level Inspection

ferring to the relation between freezing

point and strength directed on the con-

• Situate the motorcycle so that it is

perpendicular to the ground.

tainer.

MAINTENANCE AND ADJUSTMENT 101

NOTE

• Check the coolant level through the

coolant level gauge on the reserve

żCheck the level when the engine is

tank located to the left of the engine.

cold (room or atmospheric tempera-

The coolant level should be between

ture).

the F (Full) and L (Low) level lines.

If the amount of coolant is insuffi-

•

cient, add coolant into the reserve

tank.

•Removethedcapofrom theureserve

filler opening to the F (Full) level line.

A. Reserve Tank

B. F (Full) Level Line

C. L (Low) Level Line

MAINTENANCE AND ADJUSTMENT 103

NOTE

• When installing the front left side

cover, insert the tab of the top and

żIn an emergency you can add wa-

under on the cover into the each hole

ter alone to the coolant reserve tank,

of the fairing.

however it must be returned to the

correct mixture ratio by the addition

of antifreeze concentrate as soon as

possible.

CAUTION

If coolant must be added of-

ten, or the reserve tank com-

pletely runs dry, there is proba-

bly leakage in the system. Have

the cooling system inspected

A. Tab

by your authorized Kawasaki

B. Front Left Side Cover

dealer.

Coolant Change

Have the coolant changed by an au-

thorized Kawasaki dealer.

104 MAINTENANCE AND ADJUSTMENT

Spark Plugs

The standard spark plug is shown in

the table. The spark plugs should be

replaced in accordance with the Peri-

odic Maintenance Chart.

Spark plug removal should be done

by an authorized Kawasaki dealer.

Spark Plug

Standard

NGK CR9EIA-9

Plug:

A. 0.8 ∼ 0.9 mm (0.032 ∼ 0.035 in.)

0.8 ∼ 0.9 mm

Plug Gap:

(0.032 ∼ 0.036 in.)

Tightening

13 N·m (1.3 kgf·m, 10 ft·lb)

Torque:

MAINTENANCE AND ADJUSTMENT 105

Valve Clearance

Kawasaki Clean Air System

Valve and valve seat wear decreases

The Kawasaki Clean Air System

valve clearance, upsetting valve timing.

(KCA) is a secondary air suction sys-

tem that helps the exhaust gases to

CAUTION

burn more completely. When the spent

fuel charge is released into the ex-

If valve clearance is left un-

haust system, it is still hot enough to

adjusted, wear will eventually

burn. The KCA System allows extra

cause the valves to remain

air into the exhaust system so that the

partly open; which lowers per-

spent fuel charge can continue to burn.

formance, burns the valves and

This continued burning action tends to

valve seats, and may cause seri-

burn up a great deal of the normally

ous engine damage.

unburned gases, as well as chang-

Valve clearance for each valve

ing a significant portion of the carbon

should be checked and adjusted in

monoxide into carbon dioxide.

accordance with the Periodic Mainte-

nance Chart.

Inspection and adjustment should

be done by an authorized Kawasaki

dealer.

106 MAINTENANCE AND ADJUSTMENT

Air Suction Valves -

Exhaust Device

The air suction valve is essentially a

This motorcycle is equipped with a

check valve which allows fresh air to

exhaust device system. This system

flow only from the air cleaner into the

controls the valve in the exhaust pipe

exhaust port. Any air that has passed

and produces stable engine power at

the air suction valve is prevented from

low and middle engine speed. This ex-

returning. Inspect the air suction valves

haust device is controlled by the ECU,

in accordance with the Periodic Main-

and adjustment or maintenance should

tenance Chart. Also, inspect the air

be done by an authorized Kawasaki

suction valves whenever stable idling

dealer.

cannot be obtained, engine power is

greatly reduced, or there are abnormal

engine noises.

Air suction valve removal and inspec-

tion should be done by an authorized

Kawasaki dealer.

A. Exhaust Device Cables

MAINTENANCE AND ADJUSTMENT 107

CAUTION

Air Cleaner

A clogged air cleaner restricts the en-

Do not adjust the exhaust device

gine’s air intake, increasing fuel con-

system by yourself. The mal-

sumption, reducing engine power, and

adjustment will cause the poor

causing spark plug fouling.

engine performance and engine

This motorcycle’s air cleaner element

damage.

consists of a wet paper filter, which can-

not be cleaned.

The air cleaner element must be re-

placed in accordance with the Periodic

Maintenance Chart. In dusty, rainy, or

muddy conditions, the air cleaner el-

ement should be serviced more fre-

quently than the recommended inter-

val.

108 MAINTENANCE AND ADJUSTMENT

CAUTION

• Remove the left and right side cov-

ers.

Use only the recommended air

cleaner element (Kawasaki part

number 11013-0026 or equiva-

lent type). Using the another

air cleaner element will wear the

engine prematurely or lower the

engine performance.

A. Left Side Cover

110 MAINTENANCE AND ADJUSTMENT

• Pull up the air cleaner element.

• Put a clean, lint-free towel over the

air cleaner element duct to keep dirt

or other foreign material from enter-

ing.

WARNING

If dirt or dust is allowed to pass

through into the fuel injection

system, the throttle may become

stuck, possibly causing an acci-

dent.

A. Element

B. Pull Up

CAUTION

If dirt gets through into the en-

gine, excessive engine wear and

possibly engine damage will oc-

cur.

MAINTENANCE AND ADJUSTMENT 111

NOTE

Oil Draining

żElement and fuel tank installation is

• Inspect the transparent hose located

on the left lower side of the engine to

performed in the reverse order of re-

see if any oil or water has run down

moval.

from the air cleaner housing.

A. Transparent Hose

B. Plug

112 MAINTENANCE AND ADJUSTMENT

Throttle Control System

• If there is any oil in the hose, remove

the plug and drain the oil.

Check the throttle grip play each day

before riding the motorcycle, and in

accordance with the Periodic Mainte-

WARNING

nance Chart, and adjust it if necessary.

Be sure to install the plug in the

Throttle Grip -

drain hose after draining. Oil on

The throttle grip controls the butterfly

tires will make them slippery and

valves in the throttle body. If the throt-

can cause an accident and in-

tle grip has excessive play due to either

jury.

cable stretch or maladjustment, it will

cause a delay in throttle response, es-

pecially at low engine speed. Also, the

throttle valve may not open fully at full

throttle. On the other hand, if the throt-

tle grip has not play, the throttle will be

hard to control, and the idle speed will

be erratic.

MAINTENANCE AND ADJUSTMENT 113

Inspection

Throttle Grip Play

• Check that the throttle grip play is

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

correct by lightly turning the throttle

grip back and forth.

• If there is improper play, adjust it.

Adjustment

•Loosenthelocknutsaattherupperof

throttle cable adjusters in completely

so as to give the throttle grip plenty

of play.

•Turnroutilthedeceleratorncablead-

tle grip is completely closed. Tighten

the locknut.

A. Throttle Grip

• Turn out the accelerator cable ad-

B. Throttle Grip Play

juster until the throttle grip has the

proper play. Tighten the locknut.

114 MAINTENANCE AND ADJUSTMENT

• If the throttle cables cannot be ad-

justed with the adjuster at the up-

per of the throttle cable, further ad-

justment of the throttle cables should

be done by an authorized Kawasaki

dealer.

•Withtheengineidling,turnthelhan-

movement changes the idle speed,

the throttle cables may be improp-

erly adjusted or in correctly routed,

A. Decelerator Cable

B. Accelerator Cable

or they may be damaged. Be sure

C. Adjuster

to correct any of these conditions be-

D. Locknuts

fore idling.

WARNING

Operation with improperly ad-

justed, incorrectly routed, or

damaged cables could result in

an unsafe riding condition.

MAINTENANCE AND ADJUSTMENT 115

Engine Vacuum Synchronization

Idle Speed

Engine vacuum synchronization

The idle speed adjustment should be

must be checked and adjusted period-

performed in accordance with the Pe-

ically in accordance with the Periodic

riodic Maintenance Chart or whenever

Maintenance Chart by an authorized

the idle speed is disturbed.

Kawasaki dealer.

Adjustment

NOTE

• Start the engine, and warm it up thor-

oughly.

żPoor engine vacuum synchronization

will cause unstable idling, sluggish

• Adjust the idle speed by turning the

idle adjusting screw.

throttle response, and reduce engine

power and performance.

116 MAINTENANCE AND ADJUSTMENT

Idle Speed

• Open and close the throttle a few

times to make sure that the idle

1 050 ∼ 1 150 r/min (rpm)

speed does not change. Readjust if

necessary.

• With the engine idling, turn the han-

dlebar to each side. If handlebar

movement changes the idle speed,

the throttle cables may be improperly

adjusted or incorrectly routed, or they

may be damaged. Be sure to correct

any of these conditions before riding.

WARNING

A. Idle Adjusting Screw

Operation with damaged cables

could result in an unsafe riding

condition.

MAINTENANCE AND ADJUSTMENT 117

Clutch

• Check the clutch lever play as shown

Due to friction plate wear and clutch

in the figure.

cable stretch over a long period of use,

Clutch Lever Play

the clutch operation should be checked

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

each day before riding the motorcycle,

and must be adjusted in accordance

with the Periodic Maintenance Chart.

WARNING

To avoid a serious burn, never

touch a hot engine or an exhaust

pipe during clutch adjustment.

Inspection

• Check that the clutch lever operates

properly and that the inner cable

A. Adjuster

slides smoothly. If there is any irreg-

B. Clutch Lever Play

ularity, have the clutch cable checked

If the play is incorrect, adjust the lever

by an authorized Kawasaki dealer.

play as follows.

118 MAINTENANCE AND ADJUSTMENT

Adjustment

• If it cannot be done, use the nuts at

the lower end of the clutch cable.

• Turn the adjuster so that the clutch

lever will have the proper play.

WARNING

Be sure the upper end of the

clutch outer cable is fully seated

in its fitting, or it could slip into

place later, creating enough ca-

ble play to prevent clutch dis-

engagement, resulting in a haz-

ardous riding condition.

A. Nuts

B. Clutch Cable

NOTE

żAfter the adjustment is made, start

the engine and check that the clutch

does not slip and that it releases

properly.

żFor minor corrections, use the ad-

juster at the clutch lever.

MAINTENANCE AND ADJUSTMENT 119

Drive Chain

• Rotate the rear wheel to find the po-

The drive chain slack and lubrica-

sition where the chain is tightest, and

tion must be checked each day be-

measure the maximum chain slack

fore riding the motorcycle, and in accor-

by pulling up and pushing down the

dance with the Periodic Maintenance

chain midway between the engine

Chart for safety and to prevent exces-

sprocket and rear wheel sprocket.

sive wear. If the chain becomes badly

worn or maladjusted - either too loose

or too tight - the chain could jump off

the sprockets or break.

WARNING

A chain that breaks or jumps off

the sprockets could snag on the

engine sprocket or lock the rear

wheel, severely damaging the

motorcycle and causing it to go

out of control.

A. Chain Slack

If the drive chain is too tight or too

•

Chain Slack Inspection

loose, adjust it so that the chain slack

will be within the standard value.

• Set the motorcycle up on its side

stand.

120 MAINTENANCE AND ADJUSTMENT

Drive Chain Slack

• If the chain is too loose, turn out the

left and right chain adjusters evenly.

Standard: 30 ∼ 40 mm (1.2 ∼ 1.6 in.)

If the chain is too tight, turn in the left

•

and right chain adjusters evenly.

Chain Slack Adjustment

• Turn out both chain adjusters evenly

• Loosen the left and right chain ad-

until the drive chain has the cor-

juster locknuts.

rect amount of slack. To keep the

• Remove the cotter pin, and loosen

chain and wheel properly aligned,

the axle nut.

the notch on the left wheel alignment

indicator should align with the same

swingarm mark that the right indica-

tor notch aligns with.

A. Axle Nut

B. Cotter Pin

C. Adjuster

D. Locknut

MAINTENANCE AND ADJUSTMENT 121

NOTE

Wheel alignment can also be

checked using the straightedge or

string method.

WARNING

Misalignment of the wheel will

result in abnormal wear, and may

result in an unsafe riding condi-

A. Marks

tion.

B. Notch

C. Indicator

• Tighten both chain adjuster locknuts.

D. Adjuster

• Tighten the axle nut to the specified

E. Locknut

torque.

Tightening Torque

Axle Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb)

NOTE

żIf a torque wrench is not available,

this item should be serviced by a

Kawasaki dealer.

122 MAINTENANCE AND ADJUSTMENT

NOTE

• Rotate the wheel, measure the chain

slack again at the tightest position,

żWhen inserting the cotter pin, if the

and readjust if necessary.

slots in the nut do not align with

the cotter pin hole in the axle shaft,

• Install a new cotter pin through the

axle nut and axle, and spread its

tighten the nut clockwise up to the

ends.

next alignment.

żIt should be within 30 degree.

żLoosen once and tighten again when

the slot goes past the nearest hole.

A. Cotter Pin

A. Turn Clockwise

124 MAINTENANCE AND ADJUSTMENT

NOTE

• Remove the chain cover bolts and

quick rivet.

żThe chain cover uses the quick rivet.

The quick rivet can be removed by

pushing the central pin into the quick

rivets, and when installing it, pull the

central pin fully up first, and then

push into the central pin after insert-

ing them.

A. Bolts

B. Quick Rivet

C. Chain Cover

126 MAINTENANCE AND ADJUSTMENT

• Stretch the chain taut either by using

• If the length exceeds the service limit,

the chain adjusters, or by hanging a

the chain should be replaced.

10 kg (20 lb) weight on the chain.

• Measure the length of 20 links on

the straight part of the chain from pin

center of the 1st pin to pin center of

the 21st pin. Since the chain may

wear unevenly, take measurements

at several places.

A. Measure

B. Weight

MAINTENANCE AND ADJUSTMENT 127

Drive Chain 20-Link Length

WARNING

For safety, use only the standard

Service Limit: 323 mm (12.7 in.)

chain. It is an endless type and

should not be cut for installa-

NOTE

tion; have it installed by an au-

żInstall the chain cover and front foot-

thorized Kawasaki dealer.

peg bracket in the reverse order of

removal.

• Rotate the rear wheel to inspect the

drive chain for damaged rollers, and

żApply the nonpermanent locking

loose pins and links.

agent to the chain cover font side

bolt.

• Also inspect the sprockets for un-

evenly or excessively worn teeth,

Tightening Torque

and damaged teeth.

Front Footpeg Bracket Bolt: 25 N·m (2.5

kgf·m, 18 ft·lb)

128 MAINTENANCE AND ADJUSTMENT

NOTE

Lubrication

Lubrication is also necessary after

żSprocket wear is exaggerated for il-

riding through rain or on wet roads, or

lustration. See Service Manual for

any time that the chain appears dry. A

wear limits.

heavy oil such as SAE 90 is preferred

to a lighter oil because it will stay on the

chain longer and provide better lubrica-

tion.

A. Good Teeth

B. Worn Teeth

C. Damaged Teeth

• If there is any irregularity, have the

drive chain and/or the sprockets re-

placed by an authorized Kawasaki

dealer.

MAINTENANCE AND ADJUSTMENT 129

Brakes

• Apply oil to the sides of the rollers so

that it will penetrate to the rollers and

Brake Wear Inspection

bushings. Apply oil to the O-rings so

Inspect the brakes for wear. For each

that the O-rings will be coated with

front and rear disc brake caliper, if the

oil. Wipe off any excess oil.

thickness of either pad is less than

1 mm (0.04 in.), replace both pads

in the caliper as a set. Pad replace-

ment should be done by an authorized

Kawasaki dealer.

• If the chain is especially dirty, clean it

using diesel oil or kerosine and then

apply oil as described above.

A. Lining Thickness

B. 1 mm (0.04 in.)

130 MAINTENANCE AND ADJUSTMENT

Disc Brake Fluid -

Fluid Level Inspection

In accordance with the Periodic Main-

• With the brake fluid reservoirs held

tenance Chart, inspect the brake fluid

horizontal, the brake fluid level must

level in both the front and rear brake

be kept between the upper and lower

fluid reservoirs and change the brake

level lines.

fluid. The brake fluid should also be

changed if it becomes contaminated

with dirt or water.

Fluid Requirement

Use heavy-duty brake fluid only from

a container marked DOT4.

CAUTION

Do not spill brake fluid onto any

painted surface.

Do not use fluid from a container

A. Front Brake Fluid Reservoir

that has been left open or that

B. Upper Level Line

has been unsealed for a long

C. Lower Level Line

time.

Check for fluid leakage around

the fittings.

Check brake hose for damage.

MAINTENANCE AND ADJUSTMENT 131

• If the fluid level in either reservoir is

lower than the lower level line, check

for fluid leaks in the brake lines, and

fill the reservoir to the upper level

line.

WARNING

Do not mix two brands of brake

fluid. Change the brake fluid in

the brake line completely if the

A. Rear Brake Fluid Reservoir

brake fluid must be refilled but

B. Upper Level Line

the type and brand of the brake

C. Lower Level Line

fluid that is already in the reser-

voir are unidentified.

NOTE

żWhen filling the brake fluid, remove

the cap by loosing the nut.

132 MAINTENANCE AND ADJUSTMENT

NOTE

Fluid Change

Have the brake fluid changed by an

żFirst, tighten until slight resistance is

authorized Kawasaki dealer.

felt indicating that the cap is seated

on the reservoir body; tighten the cap

Front and Rear Brakes -

an additional 1/6 turn while holding

Disc and disc pad wear is automat-

the brake fluid reservoir body.

ically compensated for and has no ef-

fect on the brake lever or pedal action.

So there are no parts that require ad-

justment on the front and rear brakes.

WARNING

If the brake lever or pedal feels

mushy when it is applied, there

might be air in the brake lines

or the brake may be defective.

Since it is dangerous to operate

the motorcycle under such con-

A. Reservoir

ditions, have the brake checked

B. Cap

immediately by an authorized

C. Clockwise

D. 1/6 turn

Kawasaki dealer.

MAINTENANCE AND ADJUSTMENT 133

Brake Light Switches

• Check the operation of the rear brake

When either the front or rear brake is

light switch by depressing the brake

applied, the brake light goes on. The

pedal. The brake light should go on

front brake light switch requires no ad-

after the proper pedal travel.

justment, but the rear brake light switch

should be adjusted in accordance with

the Periodic Maintenance Chart.

Inspection

• Turn the ignition key to ON.

• The brake light should go on when

the front brake is applied.

• If it does not, ask your authorized

Kawasaki dealer to inspect the front

brake light switch.

A. Brake Pedal

B. 10 mm (0.4 in.)

• If it does not, adjust the rear brake

light switch.

Brake Pedal Travel

10 mm (0.4 in.)

134 MAINTENANCE AND ADJUSTMENT

Adjustment

CAUTION

• To adjust the rear brake light switch,

To avoid damaging the electrical

move the switch up or down by turn-

connections inside the switch,

ing the adjusting nut.

be sure that the switch body

does not turn during adjustment.

A. Rear Brake Light Switch

B. Adjusting Nut

C. Lights sooner

D. Lights later

MAINTENANCE AND ADJUSTMENT 135

Steering Damper

Damping Force Adjustment

This motorcycle is equipped with

When adjusting the damping force of

a steering damper unit.

Kawasaki

the steering damper, turn the damp-

recommends that the steering damp-

ing force adjuster clockwise or counter-

ing adjuster is at the standard setting

clockwise as the following figure.

during everyday riding. When adjust-

ing the damping adjuster for use in

a closed course, adjustment should

be done by an authorized Kawasaki

dealer.

The steering operation should be

checked and the steering damper unit

should be inspected for oil leakage

each day before riding, and in accor-

dance with the Periodic Maintenance

Chart.

A. Steering Damper Unit

B. Damping Force Adjuster

C. Softer

D. Harder

136 MAINTENANCE AND ADJUSTMENT

Steering Damping Adjuster Standard

Front Fork

Setting

The front fork operation and oil leak-

18 clicks*

age should be checked in accordance

with the Periodic Maintenance Chart.

* : Fully turned to the softer direction

Front Fork Inspection

• Holding the brake lever, pump the

front fork up and down several times

to inspect smooth stroke.

• Visually inspect the front fork for oil

leakage, scoring or scratches on the

outer surface of the inner tube.

MAINTENANCE AND ADJUSTMENT 137

so that the spring force and damping

• If any doubt about the front fork, it

should be done by an authorized

force can be adjusted for different rid-

Kawasaki dealer.

ing and loading conditions. Weaker

spring force and damping force are

for comfortable riding, but they should

be increased for high speed riding or

riding on rough roads.

A. Inner Tube

On top of each front fork leg are a

spring preload adjuster and a rebound

damping force adjuster, and on the

lower portion of each front fork leg is

A. Spring Preload Adjuster

B. Rebound Damping Force Adjuster

a compression damping force adjuster

138 MAINTENANCE AND ADJUSTMENT

CAUTION

Spring Preload Adjustment

Do not force to turn the rebound

• Turn the spring preload adjusters into

the nut to increase spring force and

and compression damping force

out to decrease spring force using

adjuster from the fully seated po-

the wrench. The adjusting range is

sition, at the adjusting mecha-

measured from the top of each ad-

nism may be damaged.

juster. Be sure to turn both adjusters

to the same position.

A. Compression Damping Force Adjuster

A. Spring Preload Adjuster

B. Wrench

C. Adjustable Range

D. Nut

MAINTENANCE AND ADJUSTMENT 139

Adjusting Range

Rebound Damping Force Adjustment

4 ∼ 19 mm (0.2 ∼ 0.7 in.)

• Turn the rebound damping force

adjuster all the way into the spring

preload adjuster with a screwdriver.

This makes the damping force great-

est.

• Turn out the adjuster to decrease

damping force. Be sure to turn both

adjusters by the same number of

turns.

A. Rebound Damping Force Adjuster

B. Screwdriver

140 MAINTENANCE AND ADJUSTMENT

Compression

Damping

Force

The standard setting positions of

Adjustment

the spring preload adjuster, rebound

damping force adjuster and compres-

• Turn the compression damping force

adjuster all the way clockwise with

sion damping force adjuster for an

a screwdriver to make the damping

average-build rider of 68 kg (150 lb)

force greatest.

with no passenger and no accessories

are as follows:

• Turn the adjuster counterclockwise

to decrease damping force. Be sure

to turn both adjusters by the same

Spring Preload

14 mm (0.6 in.)

number of turns.

Adjuster

from top of adjuster

Rebound Damping

10 clicks*

WARNING

Force Adjuster

If both spring preload adjusters

Compression

Damping Force

10 clicks*

and both rebound and compres-

Adjuster

sion damping force adjusters

are not adjusted equally, han-

*: out from the fully seated position

dling may be impaired and haz-

ardous condition may result.

MAINTENANCE AND ADJUSTMENT 141

Rear Shock Absorber

• If any doubt about the rear shock ab-

The rear shock absorber operation

sorber, it should be done by an au-

and oil leakage should be checked in

thorized Kawasaki dealer.

accordance with the Periodic Mainte-

nance Chart.

Rear Shock Absorber Inspection

• Press down on the seat several times

to inspect the stroke.

• Visually inspect the rear shock ab-

sorber for oil leakage.

A. Rear Shock Absorber

The rear shock absorber can be ad-

justed by changing the spring preload

and rebound and compression damp-

ing force for various riding and loading

conditions.

142 MAINTENANCE AND ADJUSTMENT

Before making any adjustments,

Rebound Damping Force Adjustment

however, read the following proce-

The rebound damping force adjuster

dures:

is located at the lower end of the rear

shock absorber.

CAUTION

Do not force to turn the rebound

and compression damping force

adjuster from the fully seated po-

sition or the adjusting mecha-

nism may be damaged.

Spring Preload Adjustment

The spring adjusting nut on the rear

shock absorber can be adjusted.

If the spring action feels too soft or too

A. Rebound Damping Force Adjuster

stiff, have it adjusted by an authorized

• Turn the rebound damping force ad-

Kawasaki dealer.

juster all the way clockwise with a

screwdriver to make the damping

force greatest.

• Turn the adjuster counterclockwise

to decrease damping force.

MAINTENANCE AND ADJUSTMENT 143

Compression

Damping

Force

to decrease high speed compression

Adjustment

damping.

The compression damping force ad-

juster is located on the gas reservoir

at the upper end of the rear shock ab-

sorber.

• The compression damping adjuster

has both high and low speed com-

pression damping adjusters.

Low Speed Compression Damping

Adjustment

Turn the low speed compression

adjuster screw clockwise to increase

A. High Speed Adjuster

B. Low Speed Adjuster

low speed damping. Turn the adjuster

screw counterclockwise to decrease

low speed compression damping.

High Speed Compression Damping

Adjustment

Turn the outer screw clockwise to in-

crease high speed compression damp-

ing. Turn the screw counterclockwise

144 MAINTENANCE AND ADJUSTMENT

NOTE

2 turns

Rebound Damping Adjuster

out*

żTurning the high speed adjuster has

the low speed adjuster turning. Al-

2 3/4 turns

Compression

High Speed

though the low speed adjuster turns

out*

Damping

with the high speed adjuster when

2 1/4 turns

Adjuster

Low Speed

turning the high speed adjuster, the

out*

low speed adjuster setting position

dose not change.

*: out from the fully seated position

The standard setting positions of the

WARNING

rebound damping force adjuster and

compression damping force adjuster

This unit contains high pressure

for an average-build rider of 68 kg (150

nitrogen gas. Mishandling can

lb) with no passenger and no acces-

cause explosion.

sories are as follows:

Read service Manual for instruc-

tions.

Do not incinerate, puncture or

open.

146 MAINTENANCE AND ADJUSTMENT

The tire and rim form a leakproof unit

Tires -

by making airtight contacts at the tire

Payload and Tire Pressure

chamfers and the rim flanges instead

Failure to maintain proper inflation

of using an inner tube.

pressures or observe payload limits for

your tires may adversely affect han-

WARNING

dling and performance of your motorcy-

The tires, rims, and air valves

cle and can result in loss of control. The

on this motorcycle are designed

maximum recommended load in addi-

only for tubeless type wheels.

tion to vehicle weight is 180 kg (397 lb),

The recommended standard

including rider, passenger, baggage,

tires, rims, and air valves must

and accessories.

be used for replacement.

• Remove the air valve cap.

Do not install tube-type tires on

• Check the tire pressure often, using

tubeless rims. The beads may

an accurate gauge.

not seat properly on the rim

• Make sure to install the air valve cap

causing tire deflation.

securely.

Do not install a tube inside a

tubeless tire. Excessive heat

NOTE

build-up may damage the tube

żMeasure the tire pressure when the

causing tire deflation.

tires are cold (that is, when the mo-

torcycle has not been ridden more

than a mile during the past 3 hours).

MAINTENANCE AND ADJUSTMENT 147

żTire pressure is affected by changes

Tire Air Pressure (when cold)

in ambient temperature and altitude,

Front

250 kPa (2.50 kgf/cm², 36 psi)

and so the tire pressure should be

Rear

290 kPa (2.90 kgf/cm², 42 psi)

checked and adjusted when your rid-

ing involves wide variations in tem-

perature or altitude.

Tire Wear, Damage

As the tire tread wears down, the tire

becomes more susceptible to puncture

and failure. An accepted estimate is

that 90% of all tire failures occur during

the last 10% of tread life (90% worn).

So it is false economy and unsafe to

use the tires until they are bald.

A. Tire Pressure Gauge

148 MAINTENANCE AND ADJUSTMENT

Minimum Tread Depth

• In accordance with the Periodic

Maintenance Chart, measure the

1 mm

Front

depth of the tread with a depth

(0.04 in.)

gauge, and replace any tire that

Under 130 km/h

2 mm

has worn down to the minimum al-

(80 mph)

(0.08 in.)

lowable tread depth.

Rear

Over 130 km/h

3 mm

(80 mph)

(0.12 in.)

• Visually inspect the tire for cracks

and cuts, replacing the tire in case of

bad damage. Swelling or high spots

indicate internal damage, requiring

tire replacement.

•Removeeianyimbeddedstonesaor

NOTE

A. Tire Depth Gauge

żHave the wheel balance inspected

whenever a new tire is installed.

MAINTENANCE AND ADJUSTMENT 149

WARNING

Standard Tire (Tubeless)

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

To ensure safe handling and

stability, use only the recom-

•PIRELLI “DIABLO CORSA III N”

Front

mended standard tires for re-

placement, inflated to the stan-

•BRIDGESTONE

“BATTLAX BT016F J”

dard pressure.

Size: 190/55ZR17 M/C (75 W)

Tires that have been punctured

and repaired do not have the

•PIRELLI “DIABLO CORSA III”

Rear

same capabilities as undam-

aged tires. Do not exceed 100

•BRIDGESTONE

“BATTLAX BT016R J”

km/h (60 mph) within 24 hours

after repair, and 180 km/h (110

mph) at any time after that.

WARNING

Use the same manufacturer’s

NOTE

tires on both front and rear

wheels.

żMost countries may have their own

regulations requiring a minimum tire

tread depth; be sure to follow them.

żWhen operating on public roadways,

keep maximum speed under traffic

law limits.

150 MAINTENANCE AND ADJUSTMENT

WARNING

Battery

The battery installed in this motorcy-

New tires are slippery and may

cle is a sealed type, so it is not nec-

cause loss of control and injury.

essary to check the battery electrolyte

A break-in period of 160 km (100

level or add distilled water.

miles) is necessary to estab-

The sealing strip should not be pulled

lish normal tire traction. During

off once the specified electrolyte has

break-in, avoid sudden and max-

been installed in the battery for initial

imum braking and acceleration,

service.

and hard cornering.

However, in order to maximize bat-

tery life and ensure that it will provide

the power needed to start the motor-

cycle you must properly maintain the

battery’s charge. When used regularly,

the charging system in the motorcycle

helps keep the battery fully charged. If

your motorcycle is only used occasion-

ally or for short periods of time, the bat-

tery is more likely to discharge.

Due to their internal composition,

batteries continually self discharge.

The discharge rate depends on the

MAINTENANCE AND ADJUSTMENT 151

type of battery and ambient temper-

Self-discharge

ature. As temperatures rise, so does

Approx. Number of Days

the discharge rate. Every 15 °C (27 °F)

From 100% Charged to

doubles the rate.

100% discharged

Electrical accessories, such as digi-

Temperature

Lead

tal clocks and computer memory, also

-Antimony

-Calcium

draw current from the battery even

when the key is switched off. Combine

Battery

such “key-off” draws with hot temper-

40 °C

100 Days

300 Days

ature, and a battery can go from fully

(104 °F)

charged to completely discharged in a

25 °C

matter of days.

200 Days

600 Days

(77 °F)

0 °C (32 °F)

550 Days

950 Days

152 MAINTENANCE AND ADJUSTMENT

Current Drain

Battery Sulfation

A common cause of battery failure is

Days form

sulfation.

100%

Discharging

Sulfation occurs when the battery is

charged to

Ampere

50%

100%

left in a discharged condition for an ex-

Discharged

tended time. Sulfate is a normal by

product of the chemical reactions within

7 mA

60 Days

119 Days

a battery. But when continuous dis-

10 mA

42 Days

83 Days

charge allows the sulfate to crystallize

15 mA

28 Days

56 Days

in the cells, the battery plates become

permanently damaged and will not hold

20 mA

21 Days

42 Days

a charge. Battery failure due to sulfa-

30 mA

14 Days

28 Days

tion is not warrantable.

In extremely cold weather the fluid in

an inadequately charged battery can

easily freeze, which can crack the case

and buckle the plates. A fully charged

battery can withstand sub-freezing

temperatures with no damage.

MAINTENANCE AND ADJUSTMENT 153

Battery Maintenance

Kawasaki-recommended chargers

It is the owner’s responsibility to keep

are:

the battery fully charged. Failure to do

OptiMate ǿǿǿ

so can lead to battery failure and leave

Yuasa 1.5 Amp Automatic charger

you stranded.

Battery Mate 150-9

If you are riding your vehicle infre-

If the above chargers are not avail-

quently, inspect the battery voltage

able, use equivalent one.

weekly using a voltmeter. If it drops

For more details, ask your Kawasaki

below 12.8 volts, the battery should be

dealer.

charged using an appropriate charger

(check with your Kawasaki dealer).

Battery Charging

If you will not be using the motorcy-

• Remove the battery from the motor-

cle for longer than two weeks, the

cycle (see Battery Removal).

battery should be charged using an

• Attach the leads from the charger

appropriate charger. Do not use an au-

and charge the battery at a rate that

tomotive-type quick charger that may

is 1/10th of the battery capacity. For

overcharge the battery and damage it.

example, the charging rate for a 10

Ah battery would be 1.0 ampere.

• The charger will keep the battery fully

charged until you are ready to re-

install the battery in the motorcycle

(see Battery Installation).

154 MAINTENANCE AND ADJUSTMENT

CAUTION

Battery Removal

Never remove the sealing strip,

• Remove the rider’s seat.

or the battery can be damaged.

• Unhook the rubber band.

Do not install a conventional

• Disconnect the wire from the battery,

first from the (-) terminal and then the

battery in this motorcycle, or the

(+) terminal.

electrical system cannot work

properly.

NOTE

żIf you charge the sealed battery,

never fail to observe the instructions

shown in the label on the battery.

A. (+) Terminal

B. (-) Terminal

C. Rubber Band

MAINTENANCE AND ADJUSTMENT 155

CAUTION

• Take the battery out of the case.

• Clean the battery using a solution of

Installing the (-) wire to the (+)

baking soda and water. Be sure that

terminal of the battery or the (+)

the wire connections are clean.

wire to the (-) terminal of the bat-

tery can seriously damaged the

Battery Installation

electrical system.

• Place the battery in the battery case.

• Connect the red capped wire to the

(+) terminal, and then connect the

• Put a light coat of grease on the ter-

minals to prevent corrosion.

black capped wire to the (-) terminal.

• Cover the terminals with its protec-

tive cap.

NOTE

• Reinstall the parts removed.

żInstall the battery in the reverse order

of the Battery Removal.

156 MAINTENANCE AND ADJUSTMENT

Headlight Beam

Vertical Adjustment

The headlight beam is adjustable ver-

Horizontal Adjustment

tically. If adjusted too low, neither low

The headlight beam is adjustable

nor high beam will illuminate the road

horizontally. If not properly adjusted

far enough ahead. If adjusted too high,

horizontally, the beam will point to one

the high beam will fail to illuminate the

side rather than straight ahead.

road close ahead, and the low beam

• Turn the horizontal adjuster in or out

will blind oncoming drivers.

until the beam points straight ahead.

• Turn the vertical adjuster in or out to

adjust the headlight vertically.

NOTE

On high beam, the brightest point

should be slightly below horizontal

with the motorcycle on its wheels and

the rider seated. Adjust the headlight

to the proper angle according to local

regulations.

A. Horizontal Adjuster

B. Vertical Adjuster

MAINTENANCE AND ADJUSTMENT 157

CAUTION

Fuses

Fuses are arranged in the fuse box

When handling the quartz

located under the seat. The main fuse

-halogen bulbs, never touch the

is located under the fuel tank. If a fuse

glass portion with bare hands.

fails during operation, inspect the elec-

Always use a clean cloth. Oil

trical system to determine the cause,

contamination from hands or

and then replace it with a new fuse of

dirty rags can reduce bulb life or

proper amperage.

cause the bulb to explode.

The main fuse removal should be

done by an authorized Kawasaki

dealer.

A. Fuse Box

MAINTENANCE AND ADJUSTMENT 159

Cleaning Your Motorcycle

• Gasoline, brake fluid, and coolant

will damage the finish of painted and

General Precautions

plastic surfaces: wash them off im-

Frequent and proper care of your

mediately.

Kawasaki motorcycle will enhance

its appearance, optimize overall per-

• Avoid wire brushes, steel wool, and

all other abrasive pads or brushes.

formance, and extend its useful life.

Covering your motorcycle with a high

• Use care when washing the wind-

shield, headlight cover, and other

quality, breathable motorcycle cover

plastic parts as they can easily be

will help protect its finish from harmful

scratched.

UV rays, pollutants, and reduce the

amount of dust reaching its surfaces.

• Avoid using pressure washers; wa-

ter can penetrate seals and electrical

• Be sure the engine and exhaust are

components and damage your mo-

cool before washing.

torcycle.

• Avoid applying degreaser to seals,

brake pads, and tires.

• Avoid spraying water in delicate

areas such as in air intakes, fuel

• Avoid all harsh chemicals, solvents,

system, brake components, electri-

detergents, and household cleaning

cal components, muffler outlets, and

products such as ammonia-based

fuel tank openings.

window cleaners.

160 MAINTENANCE AND ADJUSTMENT

Washing Your Motorcycle

• After cleaning your motorcycle,

check the rubber boot covering the

• Rinse your bike with cold water from

a garden hose to remove any loose

shift pedal ball joint for correct instal-

dirt.

lation. Be sure the sealing lip of the

rubber boot fits into the groove of the

• Mix a mild neutral detergent (de-

signed for motorcycles or automo-

ball joint.

biles) and water in bucket.

Use

a soft cloth or sponge to wash your

motorcycle. If needed, use a mild de-

greaser to remove any oil or grease

build up.

• After washing, rinse your motorcy-

cle thoroughly with clean water to re-

move any residue (residue from the

detergent can damage parts of your

motorcycle).

• Use a soft cloth to dry your motorcy-

cle. As you dry, inspect your motor-

A. Boots

cycle for chips and scratches. Do not

let the water air dry as this can dam-

age the painted surfaces.

MAINTENANCE AND ADJUSTMENT 161

• If the boot is damaged, replace it with

• Start the engine and let it idle for sev-

a new one. If the boot is not po-

eral minutes. The heat from the en-

sitioned in the groove correctly, re-

gine will help dry moist areas.

place it in the correct position.

• Carefully ride your motorcycle at a

slow speed and apply the brakes

several times. This helps dry the

brakes and restores them to normal

operating performance.

te the drive chain to prevent

•Lubrica

A. Wrongly set lip not in the correct position

B. Lip set correctly in the groove

162 MAINTENANCE AND ADJUSTMENT

NOTE

Semi-Gloss Finish

Semi-Gloss Finish is used for this

żAfter riding in an area where the

motorcycle.

roads are salted or near the ocean,

immediately wash your motorcycle

• When washing the motorcycle, al-

ways use a mild neutral detergent

with cold water. Do not use warm

and water.

water as it accelerates the chemical

reaction of the salt. After drying,

• The semi-gloss finish effect may be

lost when it is excessively rubbed.

apply a corrosion protection spray

on all metal and chrome surfaces to

• If any doubt, consult an authorized

Kawasaki dealer.

prevent corrosion.

żCondensation may form on the inside

Windshield and Other Plastic Parts

of the headlight lens after riding in the

After washing use a soft cloth to

rain, washing the motorcycle or hu-

gently dry plastic parts. When dry,

mid weather. To remove the mois-

treat the windshield, headlight lens,

ture, start the engine and turn on the

and other nonpainted plastic parts with

headlight. Gradually the condensa-

an approved plastic cleaner/polisher

tion on the inside of the lens will clear

product.

off.

MAINTENANCE AND ADJUSTMENT 163

CAUTION

Chrome and Aluminum

Chrome and uncoated aluminum

Plastic parts may deteriorate

parts can be treated with a chrome/alu-

and break if they come in con-

minum polish.

Coated aluminum

tact with chemical substances

should be washed with a mild neu-

or household cleaning products

tral detergent and finished with a spray

such as gasoline, brake fluid,

polish. Aluminum wheels, both painted

window cleaners, thread-locking

and unpainted can be cleaned with

agents, or other harsh chemi-

special non-acid based wheel spray

cals. If a plastic part comes in

cleaners.

contact with any harsh chemical

substance, wash it off immedi-

Leather, Vinyl, and Rubber

ately with water and a mild neu-

If your motorcycle has leather ac-

tral detergent, and then inspect

cessories, special care must be taken.

for damage. Avoid using abra-

Use a leather cleaner/treatment to

sive pads or brushes to clean

clean and care for leather accessories.

plastic parts, as they will dam-

Washing leather parts with detergent

age the part’s finish.

and water will damage them, shorten-

ing their life.

Vinyl parts should be washed with the

rest of the motorcycle, then treated with

a vinyl treatment.

164 MAINTENANCE AND ADJUSTMENT

The sidewalls of tires and other rub-

WARNING

ber components should be treated with

Special care must be taken not to

a rubber protectant to help prolong their

get any rubber protectant on the

useful life.

tire’s tread surface when treat-

ing tires. This may decrease the

tire’s ability to maintain contact

with the road surface causing

the rider to lose control.

STORAGE 165

STORAGE

Preparation for Storage -

• Clean the entire vehicle thoroughly.

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

engine oil.

WARNING

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

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

cycling.

• Put in fresh engine oil.

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

166 STORAGE

WARNING

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

ditions. Turn the ignition key to “OFF”. Do not smoke. Make sure the

area is well ventilated and free from any source of flame or sparks; this

includes any appliance with a pilot light.

Gasoline is a toxic substance. Dispose of gasoline properly. Contact your

local authorities for approved disposal methods.

• Empty the fuel system by running the engine at idle speed until the engine stalls

(If left in for a long time, the fuel will break down and could clog the fuel system).

• Reduce tire pressure by about 20%.

• Set the motorcycle on a box or stand so that both wheels are raised off the ground.

(If this cannot be done, put boards under the front and rear wheels to keep damp-

ness away from the tire rubber.)

• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on

rubber parts or in the brakes.

• Lubricate the drive chain and all the cables.

• Remove the battery, and store it where it will not be exposed to direct sunlight,

moisture, or freezing temperatures. During storage it should be given a slow

charge (one ampere or less) about once a month. Keep the battery well charged

especially during cold weather.

• Tie plastic bags over the mufflers to prevent moisture from entering.

STORAGE 167

• 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.

168 ENVIRONMENTAL PROTECTION

ENVIRONMENTAL PROTECTION

To protect our environment, properly discard used batteries, tires, engine oil, or

other vehicle components that you might dispose of in the future. Consult your

authorized Kawasaki dealer or local environmental waste agency for their proper

disposal procedures.