K - OWNER`s Manual
Contents
1. 146 spect 86 MAINTENANCE AND ADJUSTMENT 3 Periodic Replacement Frequency Whichever xOdometer Reading comes km x 1 000 first gt mile 1 000 See V Page Every 1 12 24 36 48 Change Replacement Items 0 6 7 5 15 22 5 30 K Air cleaner element replace every 18 000 km 12 000 mile Engine oil change year Oil filter replace year Fuel hoses replace 4 years Coolant change 3 years K Radiator hoses and O rings re 3 years place K Brake hoses replace 4 years K Brake fluid front and rear 2 years change K Rubber parts of master cylinder 4 years and caliper replace MAINTENANCE AND ADJUSTMENT 87 Frequency Whichever xOdometer Reading comes km 1 000 first gt mile x 1 000 See V Page E Change Replacement Items vay K Spark plug replace 102 88 MAINTENANCE AND ADJUSTMENT Engine Oil In order for the engine transmission and clutch to function properly main tain the engine oil at the proper level and change the oil and replace the oil filter in accordance with the Periodic Maintenance Chart Not only do dirt and metal particles collect in the oil but the oil itself loses its lubricative quality if used too long A WARNING Motorcycle operation with insuffi cient deteriorated or contami nated engine oil will cause accelerated wear2. OR changing the spring preload of the OF Sm A rear shock absorber turn the adjust Me er by using the suitable hook 5 O wrenches A Spring Preload Adjuster B Wrench Position 112 3 4 5 6 7 Spring Action gt Strong The standard setting position for an TK200458 6 average build rider of 68 kg 150 Ib ACHSE WARE B Extension Bar Wheels Tubeless tires are installed on the wheels of this motorcycle The indica tions of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless USE 1 210568 6 TUBELESS Mark MAINTENANCE AND ADJUSTMENT 123 A TUBELESS Mark The tire and rim form leakproof unit by making airtight contacts at the tire chamfers and the rim flanges instead of using an inner tube 124 MAINTENANCE AND ADJUSTMENT A WARNING Installing tube inside tube less type tire can create exces sive heat build up that can damage the tube and cause rapid deflation The tires rims and air valves on this motorcycle are de signed only for tubeless type wheels The recommended standard tires rims and air valves must be used for replace ment Do not install tube type tires on tubeless rims The beads may not seat properly on the rim causing tire deflation Do not in stall a tube inside a tubeless tire Excessive heat build up may damage t
3. wx e o TK150318 6 A Locknut B Clutch Cable C Adjuster NOTE OAfter the adjustment is made start the engine and check that the clutch MAINTENANCE AND ADJUSTMENT 113 does not slip and that it releases properly OFor minor corrections use the ad juster at the clutch lever 114 MAINTENANCE AND ADJUSTMENT Brakes Brake Wear Inspection Inspect the brakes for wear For each front and rear disc brake caliper if the thickness of either pad is less than 1 mm 0 04 in replace both pads in the caliper as set Pad replacement should be done by an authorized Ka wasaki dealer TK17057BS1 Lining Thickness B 1 mm 0 04 in Disc Brake Fluid In accordance with the Periodic Maintenance Chart inspect the brake fluid level in both the front and rear brake fluid reservoirs and change the brake fluid The brake fluid should also be changed if it becomes contami nated with dirt or water Fluid Requirement Use heavy duty brake fluid only from container marked DOT4 Do not spill brake fluid onto any painted surface Do not use fluid from container that has been left open or that has been unsealed for long time Check for fluid leakage around the fittings Check brake hose for damage Fluid Level Inspection e The brake fluid level in the front brake fluid reservoir must be kept above the line lower level line next to the gauge a
4. Be sure to correct any of these conditions be fore riding A WARNING Operation with damaged cables could result in an unsafe riding condition Replace damaged con trol cables before operation MAINTENANCE AND ADJUSTMENT 111 Clutch Due to friction plate wear and clutch cable stretch over a long period of use the clutch must be adjusted in accord ance with the Periodic Maintenance Chart A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch hot engine or an exhaust pipe during clutch adjustment 112 MAINTENANCE AND ADJUSTMENT Inspection Adjustment e Check that the clutch lever has 2 3 mm 0 08 0 12 in of play as WARNING shown in the figure Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death When adjusting the clutch or replacing the cable 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 cable play to prevent clutch disengage ment 1 150288 6 A Locknut B Adjuster C 2 3 mm 0 08 0 12 in If the play is incorrect adjust the lev er play as follows Turn the adjuster so that the clutch lever will have 2 3 mm 0 08 0 12 in of play e If it cannot be done use the nuts at the middle of the clutch cable LM
5. optimize overall performance and extend its useful life Covering your motorcycle with high quality breathable motorcycle cover will help protect its finish from harmful UV rays pollutants and reduce the amount of dust reaching its surfaces Be sure the engine and exhaust cool before washing Avoid applying degreaser to seals brake pads and tires Always use non abrasive wax and cleaner polisher Avoid all harsh chemicals solvents detergents and household cleaning products such as ammonia based window cleaners Gasoline brake fluid and coolant will damage the finish of painted and MAINTENANCE AND ADJUSTMENT 141 plastic surfaces wash them off im mediately Avoid wire brushes steel wool and all other abrasive pads or brushes e Use care when washing the head light cover and the plastic parts as they can easily be scratched e Avoid using pressure washers water can penetrate seals and electrical components and damage your mo torcycle e Avoid spraying water in delicate areas such as in air intakes fuel sys tem brake components electrical components muffler outlets and fuel tank openings e After cleaning your motorcycle check the rubber boot covering the shift pedal ball joint for correct instal lation Be sure the sealing lip of the rubber boot fits into the groove of the ball joint 142 MAINTENANCE AND ADJUSTMENT 1 270038 6 O
6. 86 40 C 104 TK03023BZ2 Kawasaki Performance Oils and Lu bricants have been specifically engi neered for your vehicle Consistent use of these products meets or ex ceeds warranty and service require ments and can help to extend the life of your Kawasaki MAINTENANCE AND ADJUSTMENT 95 Cooling System Radiator and Cooling Fin Check the radiator fins for obstruc tion by insects or mud Clean off any obstructions with a stream of low pres sure water A WARNING The cooling fan spins at high speed and can cause serious in juries Keep your hands and clothing away from the cooling fan blades at all times 96 MAINTENANCE AND ADJUSTMENT Using high pressure water as from car wash facility could damage the radiator fins and im pair the radiator s effectiveness Do not obstruct or deflect airflow through the radiator by installing unauthorized accessories in front of the radiator or behind the cool ing fan Interference with the radi ator airflow can lead to overheating and consequent en gine damage Radiator Hoses Check the radiator hoses for leak age cracks or deterioration and con nections for leakage or looseness each day before riding the motorcycle and in accordance with the Periodic Maintenance Chart Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level
7. A Reservoir B Cap C Clockwise D 1 6 turn 170238 5 MAINTENANCE AND ADJUSTMENT 117 Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer Front and Rear Brakes Disc and disc pad wear is automati cally compensated for and has no ef fect on the brake lever or pedal action So there are no parts that require ad justment on the front and rear brakes A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in in jury or death If the brake lever or pedal feels mushy when it is ap plied there might be air in the brake lines or the brake may be defective Have the brake checked immediately by an au thorized Kawasaki dealer 118 MAINTENANCE AND ADJUSTMENT Brake Light Switches When either the front or rear brake is applied the brake light goes on The front brake light switch requires no ad 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 e If it does not ask your authorized Kawasaki dealer to inspect the front brake light switch e Check the operation of the rear brake light switch by depressing the brake pedal The brake light should go on after about 10 mm 0 4 in of pedal travel TK180438 6 A Brake Pedal B 10 mm 0 4
8. in e If it does not adjust the rear brake light switch MAINTENANCE AND ADJUSTMENT 119 Adjustment e To adjust the rear brake light switch move the switch up or down by turn ing the adjusting nut xig DE A Rear Brake Light Switch B Adjusting Nut Lights sooner D Lights later 1 180448 6 120 MAINTENANCE AND ADJUSTMENT NOTICE To avoid damaging the electrical connections inside the switch be sure that the switch body does not turn during adjustment Rear Shock Absorber The rear shock absorber can be ad justed by changing the spring preload for various riding and loading condi tions MAINTENANCE AND ADJUSTMENT 121 Spring Preload Adjustment NOTE The rear shock absorber spring pre when removing the reservoir tank load adjuster has 7 positions hook the under part of the reservoir Remove the left side cover and res tank to the holder of the frame as ervoir tank cover see Cooling Sys shown in the figure tem section in this chapter e Remove the reservoir tank TK200448 G A Under Part of Reservoir Tank B Holder TK200438 G A Reservoir Tank B Bolt 122 MAINTENANCE AND ADJUSTMENT e In accordance with the following ta with no passenger and no accessories ble turn the preload adjuster with the is No 4 wrench from the tool kit Ame NOTE O This motorcycle has two hook wrenches in the tool kit When
9. of the engine While the engine is operating the vapors are drawn into the combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model mo torcycle includes a catalytic converter system MAINTENANCE AND ADJUSTMENT 73 3 Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low per meation fuel hoses and a fuel tank 3 Evaporative Emission Control System California Vapors caused by fuel evaporation in the fuel system are not vented into the at mosphere Instead fuel vapors are routed into the running engine to be burned or stored in canister when the engine is stopped Liquid fuel is caught by vapor separator and returned to the fuel tank High Altitude Performance Adjustment Information High altitude adjustment is not required 74 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND WARRANTY Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels This Owner s Manual contains those maintenance rec ommendations for your motorcycle Those item
10. point of water use permanent anti freeze in the coolant to protect the cooling system against engine and ra diator freeze up as well as from rust and corrosion Use permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators in the cooling system On the mixture ra tio of coolant choose the suitable one referring to the relation between 98 MAINTENANCE AND ADJUSTMENT freezing point and strength directed on the container Permanent types of antifreeze on the market have anti corrosion and anti rust properties When it is diluted excessively it loses its anti corrosion property Dilute permanent type of antifreeze in accordance with the instructions of the manufacturer NOTE OA permanent type of antifreeze is stalled in the cooling system when shipped It is colored green and con tains ethylene glycol It is mixed at 50 and has the freezing point of 35 C 31 F Coolant Level Inspection Situate the motorcycle so that it is perpendicular to the ground Check the coolant level through the coolant level gauge The coolant lev el should be between the F Full and L Low marks NOTE O Check the level when the engine is cold room or atmospheric tempera ture 1 040478 6 A F Full Level Line B L Low Level Line Reserve Tank e If the amount of coolant is in
11. 8 24 30 36 gine Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Fuel leak fuel K hose and pipe year e e e inspect Fuel hoses dam age inspect Fuel hoses in K stallation condi tion inspect Coolant level in d 99 spect Coolant leak in _ spect Radiator hose 4 96 damage inspect 78 MAINTENANCE AND ADJUSTMENT Frequency Whichever xOdometer Reading comes km 1 000 mile x 1 000 first See V Page Operation En Every 1 6 12 18 24 30 36 gine Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Radiator hoses installation condi year 96 tion inspect Air suction sys tem damage in spect Evaporative emission control system function California model only MAINTENANCE AND ADJUSTMENT 79 2 Periodic Inspection Chassis Related Items Frequency Whichever Odometer Reading comes km x 1 000 mile x 1 000 first V Page Operation Every 1 6 12 18 24 30 36 Chassis Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Clutch and drive train Clutch operation play engage ment disen e e 111 gagement inspect K Drive belt deflec e e 102 tion inspect K Drive belt wear e e e 102 inspect Wheels and tires Tire air pressure inspect 124 80 MAIN
12. Ah battery would be 1 0 ampere MAINTENANCE AND ADJUSTMENT 131 e The charger will keep the battery fully charged until you are ready to reinstall the battery in the motorcycle see Battery Installation Never remove the sealing stirp or the battery can be damaged Do not install a conventional bat tery is this vehicle or the electri cal system cannot work properly NOTE Olf you charge the sealed battery never fail to observe the instructions shown on the label on the battery 132 MAINTENANCE AND ADJUSTMENT Battery Removal WARNING Remove the seat and tool kit case Lead is a toxic substance Battery see Jump Starting section in the posts terminals and related ac How to Ride the Motorcycle chap cessories contain lead and lead ter compounds Wash hands after e Disconnect the cables from the bat handling tery first from the terminal and then the terminal A Terminal B Terminal e Pull the battery out of the motor cycle Clean the battery using solution of baking soda and water Be sure that the cable connections are clean Battery Installation Connect the capped red cable to the terminal and then connect the black cable to the terminal NOTE Olnstall the battery in the reverse or der of the Battery Removal NOTICE Installing the cable to the terminal of the battery or the cable to the terminal of
13. ENANCE AND ADJUSTMENT 93 e Fill the engine up to the upper level line with a good quality engine oil specified in the table Start the engine Check the oil level and for oil leak age e Be sure to install the parts removed Tightening Torque Engine Drain Plug 20 N m 2 0 14 5 ft lb Cartridge 18 N m 1 8 13 ft lb Regulator Rectifier Bolt 7 N m 0 7 5 2 16 94 MAINTENANCE AND ADJUSTMENT Recommended Engine Oil Engine Oil Capacity Type Kawasaki Performance 4 Stroke Motorcycle Kawasaki Performance 4 Stroke Semi Synthetic Oil Kawasaki Performance 4 Stroke Full Synthetic or other 4 stroke oils with API SG SH SJ SL SM and JASO MA2 rating Viscosity SAE 10W 40 NOTE O Do not add any chemical additive to the oil Oils fulfilling the above re quirements are fully formulated and provide adequate lubrication for both the engine and the clutch Capacity 3 0 L 3 2 US qt when filter is not removed 3 2 L 3 4 US qt when filter is removed 3 7 L 3 9 US qt when engine is completely dry Although 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area 1 1 1 1 SAE 20W 50 gt SAE 20W 40 SAE 10W 50 gt SAE 10W 40 SAE 10W 30 20 10 0 10 20 30 4 14 32 50 68
14. MAINTENANCE AND ADJUSTMENT 71 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition The initial maintenance is vitally impor tant and must not be neglected With 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 re pair work should be completed by qualified technician Please note that Kawasaki cannot assume any responsibility for damage result ing from incorrect or improper adjustment done by the owner 72 MAINTENANCE AND ADJUSTMENT EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Additionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the United States Environmental Protection Agency 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the intake side
15. TENANCE AND ADJUSTMENT Tire tread wear abnormal wear inspect Frequency Whichever xOdometer Reading comes km 1 000 mile 1 000 first See V Page Operation Every 1 6 12 18 24 30 36 Chassis Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Wheels tires damage in e e e 126 spect Wheel bearings damage in spect Brake system Brake fluid leak inspect Brake hoses K damage in spect MAINTENANCE AND ADJUSTMENT 81 Frequency Whichever xOdometer Reading comes km x 1 000 mile x 1 000 first See V Page Operation Every 1 6 12 18 24 30 36 Chassis Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Brake pad wear inspect 2 e 114 K stallation condi year 114 tion inspect Brake fluid level inspect 6 month 115 Brake operation effectiveness e e e e 117 play drag in spect Brake light switch operation e 118 inspect 82 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first M Operation Every Chassis Items xOdometer Reading km 1 000 mile x 1 000 1 6 12 0 6 3 75 7 5 18 11 25 24 15 30 36 18 75 22 5 Suspensions Front forks rear shock absorber operation damp ing and smooth stroke inspect Front f
16. TK270048 6 Rubber Boot e If the boot is damaged replace it with a new one If the boot is not positioned in the groove correctly re place it in the correct position A Not position B Correct position Washing Your Motorcycle e Rinse your bike with cold water from a garden hose to remove any loose dirt e Mix a mild neutral detergent de signed for motorcycles or automo biles and water in bucket Use a soft cloth or sponge to wash your motor cycle If needed use mild degreaser to remove any oil or grease build up After washing rinse your motorcycle thoroughly with clean water to re move any residue residue from the detergent can damage parts of your motorcycle e Use soft cloth to dry your motor cycle As you dry inspect your mo torcycle for chips and scratches Do not let the water air dry as this can damage the painted surfaces Start the engine and let it idle for sev eral minutes The heat from the en gine will help dry moist areas e 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 MAINTENANCE AND ADJUSTMENT 143 NOTE OAfter riding in an area where the roads are salted or near the ocean immediately wash your motorcycle with cold water Do not use warm water as it accelerates the chemical reaction of the salt After drying ap ply a corrosion protection
17. and may result in engine or transmission seiz ure accident and injury Check the oil level before each ride and change the oil according to the periodic maintenance chart in the Owner s Manual Oil Level Inspection e If the oil has just been changed start the engine and run it for several mi nutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil set tles Racing the engine before the oil reaches every part can cause en gine seizure e If the motorcycle has just been used wait several minutes for all the oil to drain down Check the engine oil level through the oil level gauge With the motor cycle held level the oil level should come up between the upper and low er level lines next to the gauge TK032028 6 Oil Gauge Filler C Upper Level Line D Low Level Line MAINTENANCE AND ADJUSTMENT 89 e If the oil level is too high remove the excess oil through the oil filler open ing using syringe or some other suitable device e 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 al ready in the engine If the engine oil gets extremely low or if the oil pump does not function properly or oil passages are clogged the warning light in the speedometer will light If this light stays on when the engine speed is a
18. be comes low the engine overheats and may suffer severe damage Check the coolant level each day before riding the motorcycle also in accordance with the periodic maintenance chart and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart Information for Coolant To protect the cooling system con sisting of the aluminum engine and ra diator from rust and corrosion the use of corrosion and rust inhibitor chemi cals in the coolant is essential If cool ant containing corrosion and rust inhibitor chemicals are not used over a period of time the cooling system ac cumulates rust and scale in the water jacket and radiator This will clog up the coolant passages and consider ably reduce the efficiency of the cool ing system A WARNING Coolant containing corrosion in hitors for alminum engines and radiators include harmful chemi cals for human body Drinking coolant can result in serious in jury or death Use coolant in ac cordance with the instractions of the manufacturer Soft or distilled water must be used with the antifreeze see below for anti freeze in the cooling system MAINTENANCE AND ADJUSTMENT 97 If hard water is used in the sys tem it causes scale accumula tion in the water passages and considerably reduces the effi ciency of the cooling system If the lowest ambient temperature encountered falls below the freezing
19. bove the idle speed stop the engine immediately and find the cause 90 MAINTENANCE AND ADJUSTMENT A Oil Pressure Warning Light Oil and or Oil Filter Change Warm up the engine thoroughly and then stop it e Place an oil pan beneath the engine e Remove the engine oil drain plug TK03084B 6 A Engine Oil Drain Plug e Let the oil completely drain with the motorcycle perpendicular to the ground MAINTENANCE AND ADJUSTMENT 91 WARNING Remove the regulator rectifier Motor oil is a toxic substance Dispose of used oil properly Contact your local authorities for approved disposal methods or possible recycling Remove the cover TK030958 6 A Regulator Rectifier B Bolt A Cover B Bolt 92 MAINTENANCE AND ADJUSTMENT Remove the bracket Remove the oil filter cartridge and place it with a new one 1 030968 6 Bracket 4 11030978 B Bolt A Cartridge NOTE Olf a torque wrench or required Kawa saki special tool is not available this item should be serviced by an au thorized Kawasaki dealer e Apply a thin film of oil to the packing and tighten the cartridge to the speci fied torque TK030288 6 A Packing Install the engine oil drain plug with new gasket and tighten it to the specified torque NOTE O Replace any gasket with a new one MAINT
20. ccelerator cable adjusting nut until 2 3 mm 0 08 0 12 in of throttle grip play is obtained Tighten the locknut e If the throttle cables cannot be ad justed by using the cable adjusting nuts at the upper ends of the throttle cables further adjustment of the throttle cables should be done by a competent mechanic following the instructions in the Service Manual A WARNING Operation with improperly ad justed incorrectly routed or damaged cables could result in an unsafe riding condition Be sure the control cables are ad justed and routed correctly and are free from damage 110 MAINTENANCE AND ADJUSTMENT Idle Speed Adjustment The idle adjustment should be per Start the engine and warm it up thor formed in accordance with the Periodic oughly Maintenance Chart or whenever the e Wait until the idle speed drops before idle speed is disturbed making the following adjustment e Adjust the idle speed to 950 1 050 r min rpm by turning the idle adjust ing screw located at the right front cylinder 8 Ss lt lt Mh 1 130178 6 A Idle Speed Adjusting Screw Open and close the throttle few times to make sure that the idle speed does not change Readjust if necessary e 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
21. cordance with the Periodic Maintenance Chart 8 Belt check and adjustment should be done by an authorized Kawasaki deal er Improper drive belt deflection can result in belt damage 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 a competent mechanic following the instructions in the Service Manual Spark Plug Standard NGK CPR7EA 9 Plug 0 8 0 9 mm PlugGap 0 032 0 036 in Tightening ae 18 N m 1 8 13 46 NOTE OFit the plug cap securely onto the Spark plug and pull the cap lightly to make sure that it is properly in Stalled Evaporative Emission Control System California model on ly This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped Although no ad justments are required thorough vis ual inspection must be made at the intervals specified by the Periodic Maintenance Chart Inspection Check that the hoses are securely connected Replace any kinked deteriorated or damaged hoses MAINTENANCE AND ADJUSTMENT 103 VACUUM HOSE ROUTING DIAGRAM gt FUEL TANK 2 PUNP amp FILTER A CLEANER WHITE VACUUM CANISTER TE03469BN7 C 104 MAINTENANCE AND ADJUSTMENT Valve Cl
22. e idling cannot be obtained engine power is greatly reduced or there are abnormal engine noise Air suction valve removal and in spection should be done by compe tent mechanic following the instructions in the Service Manual MAINTENANCE AND ADJUSTMENT 105 Air Cleaner clogged air cleaner restricts the engine s air intake increasing fuel con sumption reducing engine power and causing spark plug fouling The air cleaner element must be re placed in accordance with the Periodic Maintenance Chart This motorcycle s air cleaner element consists of wet paper filter which can not be cleaned In dusty rainy or on muddy conditions the air cleaner element should be serv iced more frequently than the recom mended interval 106 MAINTENANCE AND ADJUSTMENT Element Removal Remove the bolts of the air cleaner cover located on the right side of the engine Remove the air cleaner screw the air cleaner If any part of the ele ment is damaged the element must be replaced 100518 6 Air Cleaner Cover B Bolt A Air Cleaner Element B Air Cleaner C Screw MAINTENANCE AND ADJUSTMENT 107 Throttle Control System WARNING Check the throttle grip play in ac If dirt or dust is allowed to pass cordance with the Periodic Mainte through into the fuel injection nance Chart and adjust the throttle system the throttle may stick or grip play become inoperab
23. eadlight rim in or out to adjust the headlight vertically NOTE OOn high beam the brightest point should be slightly below horizontal The proper angle is 0 4 degrees be low horizontal This is a 50 mm 2 0 in drop at 7 6 m 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 136 MAINTENANCE AND ADJUSTMENT TK23129BZ2 C A 50 mm 2 0 in B Center of Brightest Spot C 7 6 m 25 ft D Height of Headlight Center Fuses The fuses are arranged in the fuse box located behind left side cover The main fuse is mounted on the starter relay behind right side cover If a fuse fails during operation inspect the electrical system to determine the cause and then replace it with new fuse of proper amperage Remove the seat Remove the left side cover see Cooling System section in this chapter 1 250558 6 Fuse Box B Spare Fuse MAINTENANCE AND ADJUSTMENT 137 Remove the screw Screw B Right Side Cover 138 MAINTENANCE AND ADJUSTMENT e Pull out the right side cover and then e When installing the right side cover inspect the main fuse be sure to insert the projections of the right side cover 1 250578 6 TK250588 6 A Projections B Right Side Cover A WARNING Substituting fuses can cause wir ing to overheat catch fire and or
24. earance Valve and valve seat wear de creases valve clearance upsetting valve timing NOTICE If valve clearance is left unad justed wear will eventually cause the valves to remain partly open which lowers performance burns the valves and valve seats and may cause serious engine dam age Valve clearance for each valve should be checked and adjusted in ac cordance with the Periodic Mainte nance Chart Inspection and adjustment should be done by a competent mechanic follow ing the instructions in the Service Man ual Kawasaki Clean Air System The Kawasaki Clean Air System KCA is a secondary air suction sys tem that helps the exhaust gases to burn more completely When the spent fuel charge is released into the exhaust system it is still hot enough to burn The KCA System allows extra air into the exhaust system so that the spent fuel charge can continue to burn This continued burning action tends to burn up a great deal of the normally un burned gases as well as changing a significant portion of the carbon mon oxide into carbon dioxide Air Suction Valves The air suction valve is essentially a check valve which allows fresh air to flow only from the air cleaner into the exhaust port Any air that has passed the air suction valve is prevented from returning Inspect the air suction valves in accordance with the Periodic Main tenance Chart Also inspect the air suction valves whenever stabl
25. ed under traffic law limits 128 MAINTENANCE AND ADJUSTMENT O Most counters may have their own regulations requiring a minimum tire thread depth be sure to follow them Standard Tire Tubeless 80 90 21 M C48H DUNLOP D404FJ Front 180 70 15 M C 76H DUNLOP D404 Rear A WARNING Mixing tire brands and types can adversely affect handling and cause an accident resulting in in jury or death Always use the same manufacturer s tires on both front and rear wheels A 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 traction During break in avoid sudden and maxi mum braking and acceleration and hard cornering Battery The battery installed in this vehicle is a sealed type and the sealing strip should not be removed at any time after the specified electrolyte has been installed in the battery for initial serv ice It is not necessary to check the battery electrolyte level or add distilled water 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 the motorcycle is only used occasion ally or for short periods of time the bat tery is more likel
26. fail Do not use any substitute for the standard fuse Replace the blown fuse with new one of the correct capacity as specified on the junction box and main fuse TK25007BZ2 Normal MAINTENANCE AND ADJUSTMENT 139 General Lubrication Lubricate the points shown below with either motor oil or regular grease in accordance with the Periodic Main tenance Chart or whenever the vehicle has been operated under wet or rainy conditions Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime NOTE OA few drops of oil are effective to keep bolts and nuts from rusting and sticking This makes removal easier Badly rusted nuts bolts etc should be replaced with new ones Apply motor oil to the following piv ots Side Stand Clutch Lever 140 MAINTENANCE AND ADJUSTMENT O Front Brake Lever K Should be serviced by an author O Rear Brake Pedal ized Kawasaki dealer Lubricate the following cables with NOTE a pressure cable lubber Clutch Inner Cables O K Throttle Inner Cables O After connecting the cables adjust them TK26001BZ2 Apply grease to the following points O K Clutch Inner Cable Upper Ends O K Throttle Inner Cable Upper Ends Cleaning Your Motorcycle General Precautions Frequent and proper care of your Ka wasaki motorcycle will enhance its ap pearance
27. he tube causing tire de flation Tires Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires may adversely affect han dling and performance of your motor cycle and can result in loss of control The maximum recommended load in addition to vehicle weight is 180 kg 397 lb including rider passenger baggage and accessories Remove the air valve cap Check the tire pressure often using an accurate gauge Make sure that the air valve cap is securely installed wR GUY ADAE A Tire Pressure Gauge NOTE O Measure the tire pressure when the tires are cold that is when the MAINTENANCE AND ADJUSTMENT 125 motorcycle has not been ridden more than a mile during the past 3 hours O Tire pressure is affected by changes in ambient temperature and altitude and so the tire pressure should be checked and adjusted when your rid ing involves wide variations in tem perature or altitude Tire Air Pressure when cold Upto 180kg 280 kPa Front 397 Ib Load 2 80 kgf cm 40 psi Up to 97 5 kg 200 kPa 215 Ib Load 2 00 kgf cm 28 psi ear 97 5 180 kg 225 kPa 215 397 Ib 2 25 kgf cm 32 Load psi 126 MAINTENANCE AND ADJUSTMENT Tire Wear Damage In accordance with the Periodic As the tire tread wears down the tire Maintenance Chart measure the becomes more susceptible to pu
28. le resulting in Throttle Grip hazardous operating condition The throttle grip controls the butterfly valves in the throttle body If the throttle grip has excessive play due to either cable stretch or maladjustment it will If dirt gets through into the en cause delay in throttle response es gine excessive engine wear and pecially at low engine speed Also the possibly engine damage will oc throttle valve may not open fully at full Cur throttle On the other hand if the throt tle grip has no play the throttle will be hard to control and idle speed will be NOTE erratic O Element installation is performed in the reverse order of removal 108 MAINTENANCE AND ADJUSTMENT Inspection Check that there is 2 3 mm 0 08 0 12 in throttle grip play when lightly turning the throttle grip back and forth TKI10518 6 A Throttle Grip B 2 3 mm 0 08 0 12 in f there is improper play adjust it Adjustment e Loosen the locknuts at the upper ends of the throttle cables and screw both throttle cable adjusting nuts in completely so as to give the throttle grip plenty of play e Turn out the decelerator cable ad justing nut until there is no play when the throttle grip is completely closed Tighten the locknut 1 110508 6 Accelerator Cable B Decelerator Cable Adjusting Nuts D Locknuts MAINTENANCE AND ADJUSTMENT 109 Turn the a
29. n occurs when the battery is left in a discharged condition for an ex tended time Sulfate is normal by product of the chemical reactions with in battery But when continuous dis charge allows the sulfate to crystallize in the cells the battery plates become permanently damaged and will not hold charge Battery failure due to sulfation is not warrantable Battery Maintenance It is the owner s responsibility to keep the battery fully charged Failure to do so can lead to battery failure and leave you stranded If you are riding your vehicle infre quently inspect the battery voltage weekly using voltmeter If it drops be low 12 6 volts the battery should be charged using an appropriate charger check with your Kawasaki dealer If you will not be using the motorcycle for longer than two weeks the battery should be charged using an appropri ate charger Do not use an automotive type quick charger that may over charge the battery and damage it Kawasaki recommended are Battery Mate 150 9 OptiMate PRO 4 S PRO S PRO 2 Yuasa MB 2040 2060 Christie C10122S If the above chargers are not avail able use equivalent one For more details ask your Kawasaki dealer chargers Battery Charging e Remove the battery from the motor cycle see Battery Removal e Attach the leads from the charger and charge the battery at a rate that is 1 10th of the battery capacity For example the charging rate for a 10
30. ncture depth of the tread with depth and failure An accepted estimate is gauge and replace any tire that has that 90 of all tire failures occur during worn down to the minimum allowable EI the last 1096 of tread life 9096 worn tread depth So it is false economy and unsafe to use the tires until they are bald U 1 210458 6 Depth Gauge Minimum Tread Depth 1 mm Fronts j 0 04 in Under 130 km h 2 mm 80 mph 0 08 in 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 e Remove any imbedded stones or other foreign particles from the tread NOTE OHave the wheel balance inspected whenever a new tire is installed MAINTENANCE AND ADJUSTMENT 127 A WARNING Tires that have been punctured and repaired do not have the same capabilities as undamaged tires and can suddenly fail caus ing an accident resulting in seri ous injury or death Replace damaged tires as soon as possi ble To ensure safe handling and stability use only the recom mended standard tires for re placement inflated to the standard pressure If it is neces sary to ride on a repaired tire do not exceed 100 km h 60 mph un til the tire is replaced NOTE O When operating on public roadways keep maximum spe
31. nd Aluminum Chrome and uncoated aluminum parts can be treated with a chrome aluminum polish Coated alu minum should be washed with a mild neutral detergent and finished with a spray polish Aluminum wheels both painted and unpainted can be cleaned with special non acid based wheel spray cleaners Leather Vinyl and Rubber If your motorcycle has leather acces sories special care must be taken Use a leather cleaner treatment to clean and care for leather accessories Washing leather parts with detergent 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 The sidewalls of tires and other rub ber components should be treated with a rubber protectant to help prolong their useful life MAINTENANCE AND ADJUSTMENT 145 A WARNING Rubber protectants can be slip pery and if used on the tread area cause loss of traction re sulting in accident causing injury or death Do not apply rubber protectant to any tread area 146 MAINTENANCE AND ADJUSTMENT Bolt and Nut Tightening oO RON OND 9 In accordance with the Periodic Maintenance Chart it is very important to check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition Please ask your authorized Kawasaki dealer for torque values Front Fender Mounting Bolts and Nuts F
32. nd that in the rear brake fluid reservoir located near the brake pedal must be kept be tween the upper and lower level lines reservoirs held horizontal 1 170568 6 Front Brake Fluid Reservoir B Lower Level Line MAINTENANCE AND ADJUSTMENT 115 A Rear Brake Fluid Reservoir B Cover C Upper Level Line D Lower Level Line 116 MAINTENANCE AND ADJUSTMENT e f 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 Inside the front brake fluid reser voir is stepped line showing the upper level line For the rear reser voir take off the bolt and remove the cover from the reservoir TK170588 6 Front Brake Fluid Reservoir B Upper Level Line WARNING Mixing brands and types of brake fluid can reduce the brake sys tem s effectiveness and cause accident resulting in injury or death Do not mix two brands of brake fluid Change the brake flu id in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified NOTE O First tighten until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn while holding the brake fluid reservoir body Oo 2
33. orks rear shock absorber oil leak inspect Swing arm pivot lubricate Uni trak rocker arm operation inspect MAINTENANCE AND ADJUSTMENT 83 Frequency Whichever xOdometer Reading comes km x 1 000 mile x 1 000 first See V Page Operation Every 1 6 12 18 24 30 36 Chassis Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Uni trak tie rods K operation in spect Uni trak rocker arm bearings lubricate Uni trak tie rods bearings lubri m cate Steering system K Steering play inspect Steering stem K bearings lubri e cate 84 MAINTENANCE AND ADJUSTMENT comes first M Operation Every Chassis Items Frequency Whichever xOdometer Reading km 1 000 mile x 1 000 1 6 12 0 6 3 75 7 5 18 24 30 36 11 25 15 18 75 22 5 Electrical system Lights and switches opera tion inspect Headlight aiming inspect Side stand switch operation inspect Engine stop switch operation inspect Chassis Chassis parts lubricate MAINTENANCE AND ADJUSTMENT 85 Frequency Whichever xOdometer Reading comes km x 1 000 mile x 1 000 first See V Page Operation Every 1 6 12 18 24 30 36 Chassis Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Bolts and nuts tightness in
34. oved or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with component not in compliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air box cover Modifications to the muffler s or air intake system by cutting drilling or other means if such modifications result in increased noise levels 76 MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart Should be serviced by an authorized Kawasaki dealer For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping 1 Periodic Inspection Engine Related Items Frequency Whichever comes xOdometer Reading km x 1 000 mile x 1 000 no drag inspect Idle speed in spect first See V Page Operation En Every 1 6 12 18 24 30 36 gine Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Valve clearance 104 inspect Throttle control system play smooth return year 107 MAINTENANCE AND ADJUSTMENT 77 Frequency Whichever xOdometer Reading comes km x 1 000 mile x 1 000 first See V Page Operation En Every 1 6 12 1
35. ront Fork Clamp Bolts Handlebar Mounting Nuts Stem Head Bolt Clutch Lever Holder Clamp Bolts Front Axle Nut Caliper Mounting Bolts Engine Mounting Bolts and Nuts Footpeg Mounting Bracket Bolts 10 Shift Pedal Bolt 11 Side Stand Bolt 12 Rear Pulley Nuts 13 Rear Axle Nut 906000 DE OOO 8 TK28044BZ7 14 Muffler Mounting Bolts 15 Brake Lever Holder Clamp Bolts 16 Pivot Shaft Bolt 17 Brake Pedal Mounting Bolts 18 Rear Shock Absorber Mounting Nuts MAINTENANCE AND ADJUSTMENT 147 TK28043BZ7
36. s identified by the Periodic Mainte nance Chart are necessary to ensure compliance with the applicable standards As the owner of this motorcycle you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner s Manual at your own expense The Kawasaki Limited Emission Control System Warranty requires that you re turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty Please read the warranty carefully and keep it valid by complying with the owner s obligations it contains You should keep maintenance record for your motorcycle To assist you in keeping this record we have provided space on pages 160 through 165 of this manual where an authorized Kawasaki dealer or someone equally competent can record the maintenance You should also retain copies of maintenance work or ders bills etc as verification of this maintenance MAINTENANCE AND ADJUSTMENT 75 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance re pair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or ele ment of design has been rem
37. spray on all metal and chrome surfaces to pre vent corrosion OCondensation may form on the in side of the headlight lens after riding in the rain washing the motorcycle or humid weather To remove the moisture start the engine and turn on the headlight Gradually the con densation on the inside of the lens will clear off Painted Surfaces After washing your motorcycle coat painted surfaces both metal and plas tic with a commercially available 144 MAINTENANCE AND ADJUSTMENT motorcycle automotive wax Wax should be applied once every three months or as conditions require Avoid surfaces with satin or flat finishes Always use nonabrasive products and apply them according to the instruc tions on the container Plastic Parts After washing use a soft cloth to gen tly dry plastic parts When dry treat the headlight lens and non painted plastic parts with an approved plastic clea ner polisher product Plastic parts may deteriorate and break if they come in contact with chemical substances or house hold cleaning products such as gasoline brake fluid window cleaners thread locking agents or other harsh chemicals If a plastic part comes in contact with any harsh chemical substance wash it off immediately with water and a mild neutral deter gent and then inspect for dam age Avoid using abrasive pads or brushes to clean plastic parts as they will damage the part s fin ish Chrome a
38. suffi cient add coolant MAINTENANCE AND ADJUSTMENT 99 Coolant Filling Remove the seat Remove the left side cover by re moving the screw T A Screw B Left Side Cover TK041368 G 100 MAINTENANCE AND ADJUSTMENT Remove the reservoir tank cover t8 1 040458 6 Reservoir Tank Cover B Bolt e Open the cap from the reservoir tank and add coolant through the fill er opening to the F Full mark J 9 Fy TK040448 G e Install the cap after filling coolant e Install the parts removed A Reserve Tank B Reserve Tank Cap MAINTENANCE AND ADJUSTMENT 101 NOTE correct mixture ratio by the addition OWhen installing the left side cover of antifreeze concentrate as soon as be sure to insert the projections of possible the left side cover to each holes If coolant must be added often or the reserve tank completely runs dry there is probably leakage in the system Have the cooling sys tem inspected by your authorized Kawasaki dealer Coolant Change Have the coolant changed by an au thorized Kawasaki dealer A Projections B Left Side Cover NOTE Oln an emergency you can add water alone to the coolant reserve tank however it must be returned to the 102 MAINTENANCE AND ADJUSTMENT Drive Belt In order for the belt and belt pulleys to function properly check the drive belt in ac
39. the battery can seriously damage the electrical system MAINTENANCE AND ADJUSTMENT 133 e Put a light coat of grease on the ter minals to prevent corrosion e Cover the terminal with its protec tive cap e Reinstall the parts removed NOTE O When installing the seat or tool kit case be sure not to pinch the hose or wires The hose or wires should be routed as shown in the figure O After installing the tool kit case run the seat lock cable or wire along the guide and put the connectors into the original place 134 MAINTENANCE AND ADJUSTMENT 71030418 6 1030428 6 A Wires Guide B Guide C Connectors gt 8 o Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally If not properly adjusted horizontally the beam will point to one side rather than straight ahead e Turn the horizontal adjusting screw on the headlight rim in or out until the beam points straight ahead 1 230728 6 Vertical Adjusting Screw B Horizontal Adjusting Screw MAINTENANCE AND ADJUSTMENT 135 Vertical Adjustment The headlight beam is adjustable vertically If adjusted too low neither low nor high beam will illuminate the road far enough ahead If adjusted too high the high beam will fail to illumi nate the road close ahead and the low beam will blind oncoming drivers e Turn the vertical adjusting screw on the h
40. y to discharge Due to their internal composition batteries continually self discharge The discharge rate depends on the type of battery and ambient MAINTENANCE AND ADJUSTMENT 129 temperature As temperatures rise so does the discharge rate Every 15 C 27 F doubles the rate Electrical accessories such as digi tal clocks and computer memory also draw current from the battery even when the key is switched off Combine such key off draws with hot tempera ture and a battery can go from fully charged to completely discharged in a matter of days Self discharge Approx Number of Days From 100 Charged to 100 discharged Temperature ooo Anti Lead Calci mony um Battery Battery 40 C 104 F 100 Days 300 Days 25 C 77 F 200 Days 600 Days 0 C 32 F 550 Days 950 Days 130 MAINTENANCE AND ADJUSTMENT Current Drain Days from Discharg Days from 100 100 ing Charged to 50 Charged to pere Discharged 100 Dis charged 7 mA 60 Days 119 Days 10 mA 42 Days 83 Days 15 mA 28 Days 56 Days 20 mA 21 Days 42 Days 30 mA 14 Days 28 Days In extremely cold weather the fluid in an inadequately charged battery can easily freeze which can crack the case and buckle the plates fully charged battery can withstand sub freezing temperatures with no damage Battery Sulfation common cause of battery failure is sulfation Sulfatio
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