Quick Reference Guide This Quick Reference Guide will assist you in finding the information you’re looking for. A Table of Contents is included after the Foreword.
Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE NOTICE is used to address practices not related to personal injury.
NOTICE THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.
Foreword Congratulations on your purchase of a new Kawasaki motorcycle. Your new motorcycle 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 features, capabilities, and limitations.
This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold. All rights reserved. No part of this publication may be reproduced without our prior written permission. This publication includes the latest information available at the time of printing. However, there may be minor differences between the actual product and illustrations and text in this manual. All products are subject to change without prior notice or obligation.
(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 removed or rendere
TABLE OF CONTENTS SAFETY INFORMATION .................... Read Owner’s Manual ..................... Training ............................................ Daily Checks and Periodic Maintenance ................................. Loading and Accessories Information.................................... Passenger .................................... Baggage and Luggage ................. Accessories .................................. Other Load.................................... If You are Involved in an Accident.
Side Stand ....................................... Seat.................................................. Tool Kit ............................................. Rear View Mirrors ............................ Windshield........................................ Tie Hooks ......................................... Helmet Hooks................................... Event Data Recorder........................ Electric Accessory Connectors ........ HOW TO RIDE THE MOTORCYCLE . Break-In ................................
Storage ............................................ 154 Troubleshooting Guide ..................... 157 Owner Satisfaction ........................... 162 Environmental Protection ................. 164 MAINTENANCE RECORD .................
10 SAFETY INFORMATION SAFETY INFORMATION j Read Owner’s Manual 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 features, capabilities, and limitations. This manual offers many safe riding tips, but its purpose is not to provide instruction in all of the techniques and skills required to ride a motorcycle safely.
SAFETY INFORMATION 11 To ensure your motorcycle is serviced using the latest servicing information, it is recommended that an authorized Kawasaki Dealer performs the periodic maintenance as directed in the Owner’s Manual. If you notice any irregular operating condition, have your motorcycle thoroughly checked at an authorized Kawasaki dealer as soon as possible.
12 SAFETY INFORMATION j or use of accessories, or motorcycle modification, will void the motorcycle warranty; can negatively affect performance, stability and safety; and can even be illegal. In selecting and using accessories, and in loading the motorcycle, you are personally responsible for your own safety and the safety of other persons involved. ○Kawasaki NOTE Parts and Accessories have been specially designed for use on Kawasaki motorcycles.
SAFETY INFORMATION 13 4. Do not carry passengers unless passenger footpegs are installed. Instruct any passenger before riding to keep his or her feet on the passenger footpegs and hold on to the operator or grab rail. Do not carry a passenger unless he or she is tall enough to reach the footpegs with their feet. Baggage and Luggage 1. All baggage should be carried as low as possible to reduce the effect on the motorcycle’s center of gravity.
14 SAFETY INFORMATION j or any other aspects of the motorcycle’s operation. 2. Weight attached to the handlebars or front fork will increase the mass of the steering assembly and can result in an unsafe riding condition. 3. Fairings, windshields, backrests, and other large items have the capability of adversely affecting stability and handling of the motorcycle, not only due to their weight, but also due to the aerodynamic force acting on these surfaces while the motorcycle is in operation.
SAFETY INFORMATION 15 and regulations if any other person, vehicle or property is involved. Do not attempt to continue riding without first evaluating your motorcycle’s condition. Inspect for fluid leaks, check critical nuts and bolts, and check the handlebars, control levers, brakes, and wheels for damage and proper function. Ride slowly and cautiously - your motorcycle may have suffered damage that is not immediately apparent.
16 SAFETY INFORMATION j Fueling Never Ride with Drugs or Alcohol WARNING Gasoline is extremely flammable and can be explosive under certain conditions. To avoid a possible fire or explosion, turn the ignition switch 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. Alcohol and drugs impair your judgment and reaction time. Never consume alcohol or drugs before or while riding motorcycles.
SAFETY INFORMATION 17 Eye Protection Always use eye protection. If your helmet does not have a visor installed, wear goggles. Gloves Boots Wear proper protective boots that fit properly and do not interfere with gear shifting or braking. Wear gloves which have suitable protection for your hands, especially against abrasion. Safe Riding Techniques Clothing When riding always keep both hands on the handlebars and both feet on the footpegs.
18 SAFETY INFORMATION j view mirror; you may misjudge a vehicle’s distance and speed, or you may not see it at all. Accelerate and Brake Smoothly In general your actions should be smooth as sudden acceleration, braking or turning may cause loss of control, especially when riding in wet conditions or on loose road surfaces, when the ability to maneuver will be reduced.
SAFETY INFORMATION 19 Ride Prudently Riding at the proper speed and avoiding unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for long vehicle life and quieter operation. Riding on Rough Roads Exercise caution, slow down, and grip the fuel tank with the knees for better stability. Acceleration When quick acceleration is necessary to pass another vehicle, shift to a lower gear to obtain the necessary power.
20 SAFETY INFORMATION j Brakes The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly. Steering Looseness in the steering can cause loss of control. Check to see that the handlebars turns freely but has no play. Tires High speed operation is hard on tires, and good tires are crucial for safe riding.
GENERAL INFORMATION 21 GENERAL INFORMATION j Specifications PERFORMANCE Maximum Horsepower 51 kW (69 PS) @8 500 r/min (rpm) (AU LAMS) 39 kW (53 PS) @7 800 r/min (rpm) Maximum Torque 64 N·m (6.5 kgf·m, 47 ft·lb) @7 000 r/min (rpm) (AU LAMS) 57 N·m (5.8 kgf·m, 42 ft·lb) @3 800 r/min (rpm) Minimum Turning Radius 2.7 m (106 in.) DIMENSIONS Overall Length 2 165 mm (85.24 in.) Overall Width 840 mm (33.1 in.) Overall Height/High Position 1 400 mm (55.12 in.)/1 450 mm (57.09 in.
22 GENERAL INFORMATION Curb Mass j (KLE650E) 214 kg (472 lb) (KLE650F) 216 kg (476 lb) ENGINE Type DOHC, 2-cylinder, 4-stroke, liquid-cooled Displacement 649 cm³ (39.6 cu in.) Bore × Stroke 83.0 × 60.0 mm (3.3 × 2.4 in.) Compression Ratio 10.
GENERAL INFORMATION 23 Engine Oil: Type API SG, SH, SJ, SL, or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.3 L (2.4 US qt) Coolant Capacity 1.2 L (1.3 US qt) TRANSMISSION Transmission Type 6-speed, constant mesh, return shift Clutch Type Wet, multi disc Driving System Chain drive Primary Reduction Ratio 2.095 (88/42) Final Reduction Ratio 3.067 (46/15) Overall Drive Ratio 5.473 (Top gear) Gear Ratio: 1st 2.438 (39/16) 2nd 1.714 (36/21) 3rd 1.333 (32/24) 4th 1.
24 GENERAL INFORMATION FRAME j Caster 25° Trail 108 mm (4.25 in.) Tire Size: Rim Size: Front 120/70ZR17 M/C (58W) Rear 160/60ZR17 M/C (69W) Front J17M/C × MT3.50 Rear J17M/C × MT4.50 Fuel Tank Capacity 21 L (5.
GENERAL INFORMATION 25 Even if one of LED (Light Emitting Diode) brake/tail light does not go on, consult with an authorized Kawasaki dealer. Specifications are subject to change without notice, and may not apply to every country.
26 GENERAL INFORMATION Serial Number Locations j The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it. Engine No. A. Engine Number Frame No.
GENERAL INFORMATION 27 Location of Labels All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your vehicle. Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct position.
28 GENERAL INFORMATION j 2. Brake Fluid (Rear) 3. Battery Poison/Danger 4.
GENERAL INFORMATION 29 j 5. *1 6. 1 * 7. *2 8. *3 9. *4 10. *1 11. *4 12.
30 GENERAL INFORMATION j 13. Tire and Load Data 14. Important Drive Chain Information Noise Test Information Stationary Noise Test Information * 17. Vehicle Emission Control Information *5 15. *6 16.
GENERAL INFORMATION 31 1) 3) j 2)
32 GENERAL INFORMATION 4) 5) j 6) only on Indonesia model
GENERAL INFORMATION 33 7) only on Indonesia model 9) only on Philippines model j 8) only on Thailand model 10) only on Thailand model
34 GENERAL INFORMATION 10) only on Southeast Asia B1 model 12) only on Thailand model 11) only on Indonesia model 12) only on Southeast Asia B1 model j
GENERAL INFORMATION 35 13) Except Indonesia and Thailand models 13) only on Indonesia model 13) only on Thailand model j 14) Except Indonesia and Thailand models
36 GENERAL INFORMATION 14) only on Indonesia model j 14) only on Thailand model 15) only on Malaysia and Southeast Asia B2 models 16) only on Australia model
GENERAL INFORMATION 37 17) only on Thailand model j
38 GENERAL INFORMATION Location of Parts j 1. 2. 3. 4. 5. 6. 7. Rear View Mirrors Starter Lockout Switch Windshield Adjusting Knobs Meter Instrument Brake Fluid Reservoir (Front) Clutch Lever Left Handlebar Switches 8. 9. 10. 11. 12. 13.
GENERAL INFORMATION 39 j 1. 2. 3. 4. 5. 6. Headlight Spark Plugs Air Cleaner Fuel Tank Seat Helmet Hook 7. 8. 9. 10. 11. 12. Tie Hooks Turn Signal Lights License Plate Light Seat Lock Chain Adjuster Drive Chain 13. 14. 15. 16. 17.
40 GENERAL INFORMATION j 1. 2. 3. 4. 5. 6. 7. 8. Tail/Brake Light Brake Fluid Reservoir (Rear) Fuse Boxes Battery Fuel Tank Cap Coolant Reserve Tank Brake Discs Brake Calipers 9. 10. 11. 12. 13. 14. 15.
GENERAL INFORMATION 41 Meter Instruments 1. Tachometer 2. Left Meter Button 3. Right Meter Button 4. Multifunction Meter 5. Fuel Gauge 6. Economical Riding Indicator 7. Speedometer 8. Multifunction Display - Odometer - Trip Meter A/B - Current Mileage/Average Mileage/Cruising Range 9. Clock When the ignition switch is turned on, all LCD functions are shown for a few seconds, then the multifunction meter turns to operational mode.
42 GENERAL INFORMATION j Indicators 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
GENERAL INFORMATION 43 Indicator Initial Operation When the ignition switch is turned on, all indicators go on/off as shown in the table. If any indicator does not operate as shown, have it checked by an authorized Kawasaki dealer. Indicators ON □ □ □ □ □ ■ □ ■ ■ ■ ■ ■ ON: : : □: ■: *: When ignition switch is turned on. After a few seconds When engine starts. Goes on. Goes off. goes off shorty after the motorcycle starts moving.
44 GENERAL INFORMATION j When Warning Indicators Go On or Blink When warning indicators appear, there could be a problem with vehicle function. Follow actions in the table after stopping the vehicle in a safe place. *: The numbers in this column corresponds to reference numbers on page 42. *No. 2 Indicators Status ON*1 The ABS has malfunctioned. ABS will not work but conventional brakes function. Have the ABS checked by an authorized Kawasaki dealer. ON The DFI system has malfunctioned.
GENERAL INFORMATION 45 *No. 8 7 8 9 Indicators Status Actions ON These indicators go on whenever the oil pressure is dangerously low or the ignition switch is in the position with the engine not running. If these indicators go on when the engine speed is above idle, stop the engine immediately and check the engine oil level. If the amount of engine oil is insufficient, add engine oil. If the oil level is good, have the engine checked by an authorized Kawasaki dealer.
46 GENERAL INFORMATION j *No. Indicators Status Blink 10 Actions The lowest segment and fuel level warning indicator blink in the multifunction display when approximately 5.6 L (1.5 US gal) of usable fuel remains. Refuel at the earliest opportunity. If the vehicle is on the side stand, the warning indicator cannot estimate the amount of fuel in the tank. Stand the vehicle upright to check the fuel level. The fuel level warning system has malfunctioned.
GENERAL INFORMATION 47 *1: ABS indicator may go on: ○After continuous riding on a rough road. ○When the engine is started with the stand raised and the transmission engaged, and the rear wheel turns. ○When accelerating so abruptly that the front wheel leaves the ground. ○When the ABS has been subjected to strong electrical interference. ○When tire pressure is abnormal. Adjust tire pressure. ○When a tire different in size from the standard size is being used. Replace with standard size.
48 GENERAL INFORMATION Other Indicators j *No. Indicators Status 1 When the turn signal switch is pushed to the left, this indicator blinks. 4 When the turn signal switch is pushed to the right, this indicator blinks. 5 When the headlight is on high beam, this indicator goes on. 11 When the transmission is in neutral, this indicator goes on.
GENERAL INFORMATION 49 Speedometer/Tachometer the unit setting (km/h or mph) is correctly displayed before riding. Refer to the Unit Setting in the Display Setting section. Tachometer The tachometer shows the engine speed in revolutions per minute (r/min, rpm). NOTICE A. Speedometer B. Tachometer C. Red Zone Speedometer The speedometer is digital and can be set for km/h or mph. The unit setting can be changed according to local regulations.
50 GENERAL INFORMATION j the tachometer does not operate correctly, have it checked by an authorized Kawasaki dealer. the left meter button to se• Push lect the display modes. The display modes can be shifted in the following order. Display Setting Multifunction Display WARNING For safety, do not operate the meter buttons while riding the motorcycle. ○The NOTE multifunction display is displayed in the unit depending on the unit mode setting.
GENERAL INFORMATION 51 Odometer The odometer shows the total distance. This meter cannot be reset. ○When NOTE the figures come to 999999, the display is stopped and locked. Trip Meter A. Left Meter Button B. Flow when pushing left meter button To reset the trip meter: Push the left meter button to select the trip meter A or B.
52 GENERAL INFORMATION j the right meter button and hold • Push it in until the display turns to 0.0. ○When the ignition switch is turned off, NOTE Average Mileage This display mode shows the average fuel consumption from the reset. The average mileage display is renewed every 4 ∼ 6 seconds. ○When the trip meter reaches 9999.9 while riding, the meter resets to 0.0 and continues counting. the current mileage resets to “0.0.” Current Mileage The current mileage display is renewed every 4 seconds.
GENERAL INFORMATION 53 ○After resetting the average mileage, the numerical value is not displayed until the vehicle has travelled 100 m (328 ft). Cruising Range This display shows the cruising range by numerical value, and indicates the cruising range from the remaining fuel in the fuel tank. This cruising range display is renewed every 20 seconds. NOTE ○The cruising range value is no longer shown if the fuel level gets too low after the fuel level warning indicator starts blinking.
54 GENERAL INFORMATION Unit Setting j A. Odometer B. Units Clock the odometer in the multi• Display function display. the right meter button while • Push pushing the left meter button to se- To adjust the clock: Push the left meter button to select the odometer. Push the right meter button and hold it until both the hour and minute displays blink. lect the meter display units. The display units can be shifted in the following order.
GENERAL INFORMATION 55 Features Economical Riding Indicator the right meter button to select • Push the hour or minute digits. the left meter button to adjust • Push the hour or minute digits. finish the adjustment, push the left • To meter button when both the hour and minute digits blink. ○When When riding the motorcycle efficiently, the economical riding indicator appears on the multifunction meter to indicate favorable fuel consumption.
56 GENERAL INFORMATION WARNING j Failing to properly observe the road ahead increases the chance of an accident resulting in severe injury or death. Do not concentrate on the economical riding indicator by taking your eyes off the road; observe using peripheral vision. Fuel Gauge The fuel in the fuel tank is shown by the number of segments displayed. A. Segments B. F (Full) C. E (Empty) NOTE ○When the fuel tank is full, all the seg- ments are displayed.
GENERAL INFORMATION 57 the “When Warning Indicators Go On or Blink” of Indicators in this chapter. Keys You will need the key number or spare key to have a duplicate made. If all the keys are lost you will need to replace the ignition switch and all other locks operated by that key. Contact your Kawasaki dealer to purchase additional spare keys. Ignition Switch/Steering Lock This is a four-position, key-operated switch. The key can be removed when it is in , or position.
58 GENERAL INFORMATION j ON OFF LOCK LOCK can be started. • Engine All electrical • be used. equipment can • Key cannot be removed. off. • Engine Electrical is off. • Key can beequipment removed. • locked. • Steering off. • Engine equipment is off. • Electrical Key can be removed. • locked. • Steering Engine off. • Hazard lights can be used. • Key can be removed. • For Locking: 1. Turn the handlebars fully to the left. po2. Push the key down in the or .
GENERAL INFORMATION 59 NOTE ○The tail, city and license plate lights are on whenever the ignition key is position. The headlight in the goes on when the starter button is released after starting the engine. ○Do not leave the ignition switch at the position for an extended time with the engine stopped, or the battery may become totally discharged. ○Do not leave the hazard lights switched on for a long time without the engine running or the battery will become discharged. Right Handlebar Switches j A.
60 GENERAL INFORMATION j Ordinarily, the engine stop switch position for the must be in the motorcycle to operate. Left Handlebar Switches NOTE ○Ordinarily, the ignition switch should be used to stop the engine. ○Although the engine stop switch stops the engine, it does not turn off all the electrical circuits and eventually the battery will be discharged. A. Dimmer Switch B. Turn Signal Switch C. Horn Button D. Passing Button E.
GENERAL INFORMATION 61 Low beam... ○Do (Single light goes on) NOTE not allow anything to cover the headlight lens when the headlight is on. If covered, heat can build up in the headlight lens causing lens discoloration or melting, as well as damage to the item covering the lens. Passing Button The high beam turns on only while the passing button is pushed. Hazard Switch Push in the hazard switch with the igposition or the nition switch in the position.
62 GENERAL INFORMATION [Brake Lever Adjustment] j Adjuster Position Lever Position 1 5 2 3 4 Far ← — → Near suitable lever position from the five positions. [Clutch Lever Adjustment] Adjuster Position Lever Position A. Adjuster B. Mark Clutch Lever Adjuster While pushing the clutch lever forward, rotate the adjuster and choose a A. Adjuster B.
GENERAL INFORMATION 63 Fuel WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch 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. Fuel Requirements Your Kawasaki engine is designed to use only unleaded gasoline with a minimum octane rating shown below.
64 GENERAL INFORMATION NOTICE j If engine “knocking” or “pinging” occurs, use a different brand of gasoline of a higher octane rating. If this condition is allowed to continue, it can lead to severe engine damage. Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or no recommended fuel may not be covered under your warranty.
GENERAL INFORMATION 65 (For Australia, Philippines and Thailand Specifications) Use clean, fresh unleaded gasoline with an ethanol volume content not more than 10% and an octane rating equal to or higher than that shown in the table. Fuel Type Unleaded Gasoline Ethanol Content E10 or less Minimum Octane Rating Research Octane Number (RON) 91 NOTICE Do not use any fuel that contains more ethanol or other oxygenates than specified for E10 fuel* in this vehicle.
66 GENERAL INFORMATION WARNING j Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch 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. Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow through the vents in the tank cap.
GENERAL INFORMATION 67 key can be removed by turning • The counterclockwise to the original po- • sition. Close the key hole cover. NOTICE A. B. C. D. Tank Cap Fuel Tank Top Level Bottom of Filler Neck (Maximum Fuel Level) ○Do NOTE not exceed the maximum fuel level as shown. the fuel tank cap down into • Push place with the key inserted. Never fill the tank completely to the top.
68 GENERAL INFORMATION j cannot be removed unless the cap is locked properly. ○Do not push on the key to close the cap, or the cap cannot be locked. Side Stand Always kick the stand fully up before moving the motorcycle. The engine will stop automatically if the motorcycle is in gear and the clutch is released with the side stand down. Seat The seat can be removed using the ignition key. Seat Removal the ignition key into the seat • Insert lock.
GENERAL INFORMATION 69 Seat Installation • • • Insert the tab at the front part of the seat under the fuel tank bracket. Insert the hook at the rear part of the seat into the latch hole on the frame. Push down the rear part of the seat until the lock clicks. A. Seat B. Tab C. Fuel Tank Bracket D. Hook E. Latch Hole the front and rear ends of the • Lift seat to make sure they are securely locked. Tool Kit The tool kit is located under the seat. Keep the tool kit in the original place.
70 GENERAL INFORMATION Rear View Mirrors j Rear View Mirror Adjustment the rear view mirror by slightly • Adjust moving only the mirror portion of the assembly. rear visibility cannot be assured • Ifbythemoving the mirror, loosen the upper hexagonal area and turn the stay by hand. NOTE ○The upper hexagonal area (locknut) has left hand threads. A. Rear View Mirror B. Stay C. Rubber Boot D. Upper Hexagonal Area E. Lower Hexagonal Area Windshield The windshield can be adjusted up to about 60 mm (2.
GENERAL INFORMATION 71 Windshield Height Adjustment • Loosen the adjusting knobs on the windshield. sure the windshield is fixed se• Be curely. Tie Hooks When securing light loads to the seat, use the tie hooks located at the left and right grab rails. A. Windshield B. Windshield Adjusting Knobs moving the windshield up or • When down. the adjusting knobs on the • Tighten windshield. A.
72 GENERAL INFORMATION Helmet Hooks j Helmets can be secured to the motorcycle using the helmet hooks located under the seat. WARNING Riding with helmets attached to the hooks could cause an accident by distracting the operator or interfering with normal vehicle operation. Do not ride the motorcycle with helmets attached to the hooks. Event Data Recorder A. Helmet Hooks In common with many other vehicle manufacturers, Kawasaki has equipped this motorcycle with an event data recorder (EDR).
GENERAL INFORMATION 73 NOTE ○During normal riding data is recorded but is constantly overwritten and then erased when the ignition is switched off. ○At no time other than in the event of an accident is EDR data stored for retrieval. ○This device does not collect or store personal data or information (e.g. name, gender, age).
74 GENERAL INFORMATION Accessory Connectors j Location Purpose Polarity Wire Color Back of Headlight Gear Position Indicator (+) White/Blue (–) Black/Yellow Back of Headlight Accessory Socket (+) White/Red (–) Black/White Back of Left Middle Fairing Grip Heater (+) White/Blue (–) Black/Yellow Back of Left Middle Fairing (+) White/Blue Fog Light (–) Black/Yellow Maximum Current: 3.3 A A. For Gear Position Indicator B.
GENERAL INFORMATION 75 NOTICE A. For Grip Heater B. For Fog Light The vehicle has electrical accessory circuit (5 A fuse) for the socket and connectors. Always install a fuse 5 A or less for the circuit. Do not connect more than 40 W of total load to the vehicle’s electrical system or the battery may become discharge, even with the engine running.
76 HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE j Break-In The first 1 600 km (1 000 mile) 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 period.
HOW TO RIDE THE MOTORCYCLE 77 not race the engine while • Do transmission is in neutral. the WARNING Starting the Engine • Check that the engine stop switch is in the position. 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.
78 HOW TO RIDE THE MOTORCYCLE j A. Neutral Indicator (Green) B. Ignition Switch C. Position NOTE ○While the engine is cold, the fast idle system automatically raises the engine idling speed. At this time, the ) may engine warning indicator ( go on if you operate the throttle grip unnecessarily. ○The motorcycle is equipped with a vehicle-down sensor which causes the engine to stop automatically if the motorcycle falls down.
HOW TO RIDE THE MOTORCYCLE 79 NOTICE Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. ○The NOTE motorcycle is equipped with a starter lockout switch. This switch is designed so that the engine does not start if the transmission is in gear and the side stand is down.
80 HOW TO RIDE THE MOTORCYCLE Jump Starting j If your motorcycle battery is “run down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. • • DANGER Battery acid generates hydrogen gas which is flammable and explosive under certain conditions. It is present within a battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away from the battery.
HOW TO RIDE THE MOTORCYCLE 81 the seat (see Seat section • Remove in the GENERAL INFORMATION chapter). the red cap from the positive • Slide (+) terminal (see Battery section in • the MAINTENANCE AND ADJUSTMENT chapter). Connect a jumper cable from the positive (+) terminal of the booster battery to the positive (+) terminal of the motorcycle battery. NOTICE Be careful not to contact the jumper cable slip on the positive battery terminal to the frame, or it will cause a short circuit. j A.
82 HOW TO RIDE THE MOTORCYCLE DANGER j Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. Do not make this last connection at the fuel system or battery. Take care not to touch the positive and negative cables together, and do not lean over the battery when making this last connection. Do not connect to a frozen battery. It could explode.
HOW TO RIDE THE MOTORCYCLE 83 in the clutch lever. • Pull Shift 1st gear. • Openinto the a little, and start to • let out the throttle clutch lever very slowly. the clutch starts to engage, open • As the throttle a little more, giving the engine just enough fuel to keep it from stalling. ○The NOTE motorcycle is equipped with a side stand switch. This switch is designed so that the engine does not start if the transmission is in gear and the side stand is down.
84 HOW TO RIDE THE MOTORCYCLE WARNING j Downshifting to a lower gear at high speed causes engine rpm to increase excessively, potentially damaging the engine and it may also cause the rear wheel to skid and cause an accident. Downshifting should be done below 5 000 rpm for each gear. Braking the throttle completely, leav• Close ing the clutch engaged (except when • • NOTE ○The transmission is equipped with a positive neutral finder.
HOW TO RIDE THE MOTORCYCLE 85 • applying the brakes as hard as possible without skidding. Even in motorcycles equipped with ABS, braking during cornering may cause wheel slip. When turning a corner, it is better to limit braking to the light application of both brakes or not to brake at all. Reduce your speed before you get into the corner. j A. Rear Brake Pedal Anti-lock Brake System (ABS) A.
86 HOW TO RIDE THE MOTORCYCLE j prevent wheel lock-up and allows stable steering control while stopping. Brake control function is identical to that of a conventional motorcycle. The brake lever is used for the front brake and the brake pedal for the rear brake.
HOW TO RIDE THE MOTORCYCLE 87 WARNING WARNING ABS cannot protect the rider from all possible hazards and is not a substitute for safe riding practices. Be aware of how the ABS system operates and its limitations. It is the rider’s responsibility to ride at appropriate speeds and manner for weather, road surface and traffic conditions. Use of non-recommended tires may cause malfunctioning of ABS and can lead to extended braking distance. The rider could have an accident as a result.
88 HOW TO RIDE THE MOTORCYCLE in good condition according to the “Battery Maintenance” section. j Stopping the Engine the throttle completely. • Close the transmission into neutral. • Shift the ignition key to . • Turn Support the motorcycle on a firm, • level surface with the side stand. • Lock the steering. ○The NOTE motorcycle is equipped with a vehicle-down sensor which causes the engine to stop automatically if the motorcycle falls down.
HOW TO RIDE THE MOTORCYCLE 89 to enter the throttle body and stick the throttle open. 2. During removal of the air cleaner, dirt is allowed to enter and jam the fuel injection system. In an emergency situation such as throttle failure, your vehicle may be stopped by applying the brakes and disengaging the clutch. Once this stopping procedure is initiated, the engine stop switch may be used to stop the engine. If the engine stop switch is used, turn off the ignition switch after stopping the motorcycle.
90 HOW TO RIDE THE MOTORCYCLE WARNING j The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch a hot engine, exhaust pipe, or muffler during operation or after stopping the engine. the transmission into neutral • Shift . and turn the ignition key to Support the motorcycle on a firm, • level surface with the side stand. NOTICE Do not park on a soft or steeply inclined surface, or the motorcycle may fall over.
HOW TO RIDE THE MOTORCYCLE 91 NOTE ○When stopping near traffic at night, you can leave the turn signal lights blinking for greater visibility by turning the ignition key to the position and push in the hazard switch.
92 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT j The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Daily Checks and Periodic Maintenance to keep the motorcycle in good running condition and to reduce air pollution. The initial maintenance is vitally important and must not be neglected. WARNING Failure to perform these checks or to correct a problem before operation may result in serious damage or an accident.
MAINTENANCE AND ADJUSTMENT 93 DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area. WARNING The cooling fan spins at high speed and can cause serious injuries. Keep your hands and clothing away from the cooling fan blades at all times.
94 MAINTENANCE AND ADJUSTMENT Daily Checks j 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 motorcycle to a safe operating condition.
MAINTENANCE AND ADJUSTMENT 95 Operation See Page Bolts, nuts and fasteners Check for loose and/or missing bolts, nuts and fasteners – Steering Action smooth but not loose from lock to lock – No binding of control cables – Brakes Brake pad wear 126 Brake fluid level 125 – No brake fluid leakage Throttle Throttle grip free play 115 Clutch Clutch lever free play Clutch lever operates smoothly 118 – Coolant No coolant leakage – j
96 MAINTENANCE AND ADJUSTMENT Operation Coolant level between level lines (when engine is cold) See Page 106 Electrical equipment j All lights (head, city, tail/brake, turn signal, license plate, warning/indicator) 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 – Rear view mirrors Rear view sight –
MAINTENANCE AND ADJUSTMENT 97 Periodic Maintenance *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first. *B: For higher odometer readings, repeat at the frequency interval established here. *C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
98 MAINTENANCE AND ADJUSTMENT year (*A) Items j Odometer Reading (*B) × 1 000 km (× 1 000 mile) See 1 6 12 18 24 Page (0.6) (3.8) (7.6) (11.4) (15.
MAINTENANCE AND ADJUSTMENT 99 year (*A) Items Coolant, water hoses and O-rings :3 Valve clearance Odometer Reading (*B) × 1 000 km (× 1 000 mile) See 1 6 12 18 24 Page (0.6) (3.8) (7.6) (11.4) (15.
100 MAINTENANCE AND ADJUSTMENT year (*A) Items j Odometer Reading (*B) × 1 000 km (× 1 000 mile) See 1 6 12 18 24 Page (0.6) (3.8) (7.6) (11.4) (15.2) : every 1 000 km (600 mile) Drive chain slack (*C) 120 Drive chain wear (*C) – Drive chain guide wear – Brake system :1 – Brake operation (effectiveness, play, no drag) :1 – :0.
MAINTENANCE AND ADJUSTMENT 101 year (*A) Items Odometer Reading (*B) × 1 000 km (× 1 000 mile) See 1 6 12 18 24 Page (0.6) (3.8) (7.6) (11.4) (15.
102 MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection is cold, start the engine • Ifandtherunengine it for several minutes at idle j • speed. Stop the engine, then wait several minutes until the oil settles. NOTICE Racing the engine before the oil reaches every part can cause engine seizure. the engine oil level through • Check the oil level inspection window.
MAINTENANCE AND ADJUSTMENT 103 WARNING Oil and/or Oil Filter Change the bolts and left lower fair• Remove ing. Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. A. Bolts B. Left Lower Fairing up the engine thoroughly, and • Warm then stop it. an oil pan beneath the engine. • Place Remove the engine oil drain bolt. • A.
104 MAINTENANCE AND ADJUSTMENT the oil filter is to be replaced, re• Ifmove the oil filter cartridge and replace it with a new one. a thin film of oil to the packing • Apply and tighten the cartridge to the specified torque. NOTE j ○If a torque wrench or required Kawasaki special tool is not available, this item should be serviced by an authorized Kawasaki dealer. A. Packing the drain bolt with a new gas• Install ket. Tighten it to the specified torque. NOTE A.
MAINTENANCE AND ADJUSTMENT 105 Tightening Torque Engine Oil Capacity Oil Filter: 17.5 N·m (1.78 kgf·m, 12.9 ft·lb) Engine Oil Drain Bolt: 30 N·m (3.1 kgf·m, 22 ft·lb) • Fill the engine up to the upper level line with a good quality engine oil specified in the table. Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 rating Viscosity: SAE 10W-40 NOTE ○Do not add any chemical additive to the oil.
106 MAINTENANCE AND ADJUSTMENT the left lower fairing and • Install tighten the bolts. the engine. • Start • Check the oil level and oil leakage. j Coolant Coolant Level Inspection the motorcycle so that it is • Position perpendicular to the ground. the coolant level through the • Check coolant level gauge on the reserve tank located in back of the middle fairing. The coolant level should be between the F (Full) and L (Low) level lines. A. F (Full) Level Line B. L (Low) Level Line C.
MAINTENANCE AND ADJUSTMENT 107 Coolant Filling Quick Rivet Removal Quick Rivet Installation j A. Quick Rivet B. Center Pin C. Push in. A. B. C. D. Quick Rivet Center Pin Pull up fully. Push in. the quick rivet. • Remove Remove the and washers. • Remove the bolts bolt and collar.
108 MAINTENANCE AND ADJUSTMENT j A. Quick Rivet B. Bolts and Washers C. Bolt and Collar the rear part of right middle fair• Pull ing outward to clear the projections. NOTE ○To protect the hook and tab, hold the middle part of middle fairing. A. Projections the hook and tab of the middle • Clear fairing from the inner cover.
MAINTENANCE AND ADJUSTMENT 109 j A. Hook B. Tab C. Inner Cover the front part of middle fairing • Pull outward to clear the projections. A. Projections the right turn signal light • Disconnect lead connector, and remove the right middle fairing.
110 MAINTENANCE AND ADJUSTMENT j A. Right Turn Signal Light Lead Connector the cap from the reserve • Remove tank and add coolant through the filler opening to the F (Full) level line. A. Reserve Tank Cap ○In NOTE an emergency you can add water alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible.
MAINTENANCE AND ADJUSTMENT 111 NOTICE If coolant must be added often, or the reserve tank completely runs dry, there is probably leakage in the system. Have the cooling system inspected by your authorized Kawasaki dealer. the reserve tank cap. • Install the right turn signal light • Connect lead connector. the projections at the front part • Insert of middle fairing into the grommets on the upper fairing. j A. Projections B.
112 MAINTENANCE AND ADJUSTMENT j A. Hook B. Tab C. Slots the projections at the rear part • Insert of middle fairing into the grommets on the fuel tank and frame. A. Projections B. Grommets the washers and collar. • Install Tighten bolts. • Install thethequick rivet.
MAINTENANCE AND ADJUSTMENT 113 Coolant Requirement WARNING A. Washer and M5 Bolt, L = 12 mm (0.47 in.) B. Washer and M5 Bolt, L = 16 mm (0.63 in.) C. Collar and M6 Bolt, L = 14 mm (0.55 in.) D. Quick Rivet Coolant Change Have the coolant changed by an authorized Kawasaki dealer. Coolant containing corrosion inhibitors for aluminum engines and radiators include harmful chemicals for human body. Drinking coolant can result in serious injury or death.
114 MAINTENANCE AND ADJUSTMENT NOTICE j If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Oil Draining the transparent drain hose lo• Inspect cated to the left of the engine to see if any oil has run down. NOTE ○A permanent type of antifreeze is installed in the cooling system when shipped. It is mixed at 50% and has the freezing point of –35°C (–31°F).
MAINTENANCE AND ADJUSTMENT 115 WARNING Oil on tires will make them slippery and can cause an accident and injury. Be sure to install the plug in the drain hose after draining. the throttle grip free play by • Check turning back and forth. j Throttle Control System Throttle Grip Throttle Grip Free Play Inspection that the throttle grip moves • Check smoothly from full open to close, • and the throttle closes quickly and completely by the return spring in all steering positions.
116 MAINTENANCE AND ADJUSTMENT Throttle Grip Free Play Adjustment • Loosen the locknut at the upper end of the accelerator cable, and turn the adjuster until the proper amount of throttle grip free play is obtained. j • • decelerator cable adjuster located under the fuel tank. Remove the right middle fairing (see Coolant section). Turn out the decelerator cable adjuster until there is no play when the throttle grip is completely closed. Tighten the locknut. A. Accelerator Cable B. Adjuster C.
MAINTENANCE AND ADJUSTMENT 117 out the accelerator cable ad• Turn juster until 2 ∼ 3 mm (0.08 ∼ 0.12 • in.) of throttle grip play is obtained. Tighten the locknut. With the engine idling, turn the handlebars to each side. If handlebars 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.
118 MAINTENANCE AND ADJUSTMENT WARNING Operation with damaged cables could result in an unsafe riding condition. Replace damaged control cables before operation. j Clutch Clutch Operation Inspection A. Idle Adjusting Screw and close the throttle a few • Open times to make sure that the idle • speed does not change. Readjust if necessary. With the engine idling, turn the handlebars to each side.
MAINTENANCE AND ADJUSTMENT 119 WARNING A. Adjuster B. Locknut C. Clutch Lever Free Play • If the free play is incorrect, adjust the clutch lever free play as follows. Clutch Lever Free Play Adjustment the locknut, and turn the • Loosen adjuster so that the clutch lever will have the specified free play. Excess clutch lever free play could prevent clutch disengagement and cause a crash resulting in serious injury or death.
120 MAINTENANCE AND ADJUSTMENT j Use a lubricant for sealed chains to prevent deterioration of chain seals. If the chain is especially dirty, clean it using a cleaner for sealed chains following the instructions supplied by the chain cleaner manufacturer. Apply lubricant to the sides of the rollers so that it will penetrate to the rollers and bushings. Apply lubricant to the seals so that the seals will be coated with lubricant. Wipe off any excess lubricant.
MAINTENANCE AND ADJUSTMENT 121 the cotter pin, and loosen • Remove the axle nut. j A. Chain Slack the drive chain is too tight or too • Ifloose, adjust it so that the chain slack is within the standard value. Drive Chain Slack Standard: 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack Adjustment the left and right chain ad• Loosen juster locknuts. A. B. C. D. Axle Nut Cotter Pin Adjuster Locknut is too loose, turn out the • Iflefttheandchain right chain adjusters evenly.
122 MAINTENANCE AND ADJUSTMENT both chain adjusters evenly • Turn until the drive chain has the cor- j rect amount of slack. To keep the chain and wheel properly aligned, the notch on the left wheel alignment indicator should align with the same swingarm mark that the right indicator notch aligns with. A. Marks B. Notch C. Indicator D. Adjuster E. Locknut ○Wheel NOTE alignment can also be checked using the straightedge or string method.
MAINTENANCE AND ADJUSTMENT 123 WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Align the rear wheel using the marks on the swingarm or measuring the distance between the center of the axle and swingarm pivot. the wheel, measure the chain • Rotate slack again at the tightest position, and readjust if necessary. a new cotter pin through the • Install axle nut and axle, and spread its ends. j both chain adjuster locknuts.
124 MAINTENANCE AND ADJUSTMENT tighten the nut clockwise up to the next alignment. ○It should be within 30 degrees. ○Loosen once and tighten again when the slot goes past the nearest hole. j WARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. the rear brake (see Brakes • Check section).
MAINTENANCE AND ADJUSTMENT 125 WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. 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. Have the brake checked immediately by an authorized Kawasaki dealer. Brake Fluid Level Inspection • With the front brake fluid reservoir held horizontal, the brake fluid level must be above the lower level line. j A.
126 MAINTENANCE AND ADJUSTMENT thickness of either pad lining is less than 1 mm (0.04 in.), replace both pads in the caliper as a set. Pad replacement should be done by an authorized Kawasaki dealer. j A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line the fluid level is lower than the • Iflower level line it may indicate that the fluid is leaking. In this case, have the brake system inspected by an authorized Kawasaki dealer. Brake Pad Wear Inspection Inspect the brakes for wear.
MAINTENANCE AND ADJUSTMENT 127 it does not, ask your authorized • IfKawasaki dealer to inspect the front brake light switch. the operation of the rear brake • Check light switch by depressing the brake pedal. The brake light should go on after the proper pedal travel. A. Rear Brake Pads B. Lining Thickness C. 1 mm (0.04 in.) Brake Light Switches Brake Light Switch Inspection the ignition switch on. • Turn brake light should go on when • The the front brake is applied. A. Brake Pedal B. 12 mm (0.47 in.
128 MAINTENANCE AND ADJUSTMENT NOTICE Brake Pedal Travel 12 mm (0.47 in.) Brake Light Switch Adjustment j adjust the rear brake light switch, • To move the switch up or down by turning the adjusting nut. To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Suspension System Front Fork Spring Preload Adjustment The adjuster is located at the top of left front fork leg. Standard 6 1/2 turns in A. B. C. D.
MAINTENANCE AND ADJUSTMENT 129 the adjuster clockwise to in• Turn crease spring preload and stiffen the suspension. the adjuster counterclockwise • Turn to decrease spring preload and soften the suspension. j NOTICE Do not turn the adjuster beyond the fully seated position or the adjusting mechanism may be damaged. NOTE ○The spring preload adjuster can be turned with the allen wrench or suitable tool. A.
130 MAINTENANCE AND ADJUSTMENT the adjuster clockwise with a flat • Turn tip screwdriver to increase damping force. the adjuster counterclockwise • Turn to decrease damping force. j NOTICE Do not turn the adjuster beyond the fully seated position or the adjusting mechanism may be damaged. A. Rebound Damping Force Adjuster Rear Shock Absorber Spring Preload Adjustment The adjuster is located above the rear shock absorber.
MAINTENANCE AND ADJUSTMENT 131 Standard 1 click In from the fully seated position (turned fully counterclockwise). the adjuster clockwise to in• Turn crease spring preload. the adjuster counterclockwise • Turn to decrease spring preload. NOTICE Do not turn the adjuster beyond the fully seated position or the adjusting mechanism may be damaged. j A.
132 MAINTENANCE AND ADJUSTMENT Setting Tables Front Fork Spring Preload Setting j Softest setting limit Standard Hardest setting limit 0* 6 1/2 turns in** 20 turns in** Weak ←→ Strong Setting Soft ←→ Hard Load Light ←→ Heavy Road Good ←→ Bad Speed Low ←→ High Adjuster Position Spring Action *: This position is the fully seated position (turned fully counterclockwise). **: In from the fully seated position (turned fully counterclockwise).
MAINTENANCE AND ADJUSTMENT 133 Front Fork Damping Force Settings Softest setting limit Standard 3 turns out** 2 1/2 turns out** 0* Weak ←→ Strong Setting Soft ←→ Hard Load Light ←→ Heavy Road Good ←→ Bad Speed Low ←→ High Adjuster Position: Damping Force Rebound Hardest setting limit *: This position is the fully seated position (turned fully clockwise). **: Out from the fully seated position (turned fully clockwise).
134 MAINTENANCE AND ADJUSTMENT Rear Shock Absorber Spring Preload Setting Softest setting limit Standard Hardest setting limit 0* 1 click** 24 clicks** Weak ←→ Strong Setting Soft ←→ Hard Load Light ←→ Heavy Road Good ←→ Bad Speed Low ←→ High Adjuster Position Spring Action j *: This position is the fully seated position (turned fully counterclockwise). **: In from the fully seated position (turned fully counterclockwise).
MAINTENANCE AND ADJUSTMENT 135 Wheels Tire Pressure Inspection the air valve cap. • Remove Check the pressure often, using • an accuratetiregauge. sure to install the air valve cap • Make securely. j NOTE ○Measure the tire pressure when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
136 MAINTENANCE AND ADJUSTMENT j 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. Tire Wear Inspection the depth of the tread with • Measure a depth gauge, and replace any tire that has worn down to the minimum allowable tread depth. A.
MAINTENANCE AND ADJUSTMENT 137 indicate internal damage, requiring tire replacement. A. B. C. D. Crack or Cut Nail Swelling or High Spot Stone any imbedded stones or • Remove other foreign particles from the tread. ○Have NOTE the wheel balance inspected whenever a new tire is installed. WARNING Tires that have been punctured and repaired do not have the same capabilities as undamaged tires and can suddenly fail, causing an accident resulting in serious injury or death.
138 MAINTENANCE AND ADJUSTMENT ○When operating on public roadways, keep maximum speed under traffic law limits. Standard Tire (Tubeless) j Make, Type: DUNLOP, D222F J Front Size: 120/70ZR17 M/C (58W) Rear Make, Type: DUNLOP, D222 J Size: 160/60ZR17 M/C (69W) WARNING Mixing tire brands and types can adversely affect handling and cause an accident resulting in injury or death. Always use the same manufacturer’s tires on both front and rear wheels.
MAINTENANCE AND ADJUSTMENT 139 NOTICE Never remove the sealing strip, or the battery can be damaged. Do not install a conventional battery in this motorcycle, or the electrical system cannot work properly. Make Siam Furukawa Type FTX12-BS 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 infrequently, inspect the battery voltage weekly using a voltmeter.
140 MAINTENANCE AND ADJUSTMENT If the above chargers are not available, use equivalent one. For more details, ask your Kawasaki dealer. j • Battery Charging the battery following the in• Charge structions of your battery charger. charger will keep the battery fully • The charged until you are ready to reinstall the battery in the motorcycle (see Battery Installation). • DANGER Battery acid generates hydrogen gas which is flammable and explosive under certain conditions.
MAINTENANCE AND ADJUSTMENT 141 the seat. Refer to the Seat • Remove section in the GENERAL INFORMATION chapter. the negative (–) cable • Disconnect from the (–) terminal. the red cap from the positive (+) • Slide terminal. the positive (+) cable • Disconnect from the (+) terminal. the battery out of the battery • Take case. the battery using a solution of • Clean baking soda and water. Be sure that the cable connections are clean. Battery Installation the battery on the battery case.
142 MAINTENANCE AND ADJUSTMENT the (+) terminal with the red • Cover cap. • Install the removed parts. j Headlight Headlight aiming should be done by an authorized Kawasaki dealer. Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. Turn the horizontal adjuster in or out until the beam points straight ahead. • A. Horizontal Adjusters B.
MAINTENANCE AND ADJUSTMENT 143 ○On NOTE 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. Fuses Fuses are arranged in the fuse boxes located under the seat. The main fuse is located behind the starter relay cover. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
144 MAINTENANCE AND ADJUSTMENT j A. Fuse Boxes B. Fuse Box (Only on ABS model) C. Main Fuse A. Bolt, Collar and Washer B. Projections C. Left Frame Cover access the main fuse, remove • To the left frame cover and starter relay the bolt. • Remove Pull the starter relay cover outward to • clear the tab from the rear fender. cover. the bolts, collar and washer. • Remove Pull the left frame cover outward to • clear the projections from the frame.
MAINTENANCE AND ADJUSTMENT 145 j A. Bolt B. Tab C. Starter Relay Cover A. Starter Relay Connector B. Main Fuse 30 A C. Spare Fuse 30 A the starter relay connec• Disconnect tor. the starter relay cover and left • Install frame cover as follows. the starter relay connector. • Connect the tab on the starter relay • Insert cover into the gap between the rear • • fender and connector. Take care not to pinch the fuel pump lead. Tighten the bolt.
146 MAINTENANCE AND ADJUSTMENT j A. Starter Relay Connector B. Tab C. Starter Relay Cover D. Gap E. Fuel Pump Lead • • Fit the tab on the frame cover to the slot on the frame. Insert the projections on the frame cover to the grommets on the frame. A. B. C. D. Slot and Tab Projections Left Frame Cover Grommets the washer and collar. • Install Tighten the bolt securely.
MAINTENANCE AND ADJUSTMENT 147 WARNING Substituting fuses can cause wiring to overheat, catch fire and/or fail. Do not use any substitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse boxes and main fuse. General Lubrication Lubricate the points shown below, with either engine oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions.
148 MAINTENANCE AND ADJUSTMENT ○After them. NOTE connecting the cables, adjust Cleaning Your Motorcycle j General Precautions Apply grease to the following points Clutch Inner Cable Upper End • (K) • (K) Throttle Inner Cable Upper Ends (K): Should be serviced by an authorized Kawasaki dealer. Frequent and proper care of your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its useful life.
MAINTENANCE AND ADJUSTMENT 149 WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. If debris or flammable materials have collected, park the vehicle outside and stop the engine.
150 MAINTENANCE AND ADJUSTMENT system, brake components, electrical components, muffler outlets, and fuel tank openings. j Washing Your Motorcycle your motorcycle with cold wa• Rinse ter from a garden hose to remove any • • loose dirt. Mix a mild neutral detergent (designed for motorcycles or automobiles) and water in a bucket. Use a soft cloth or sponge to wash your motorcycle. If needed, use a mild degreaser to remove any oil or grease build up.
MAINTENANCE AND ADJUSTMENT 151 NOTICE apply a corrosion protection spray on all metal and chrome surfaces to prevent corrosion. ○Condensation may form on the inside 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 condensation on the inside of the lens will clear off.
152 MAINTENANCE AND ADJUSTMENT any doubt, consult an authorized • IfKawasaki dealer. Windshield and Other Plastic Parts j After washing use a soft cloth to gently dry plastic parts. When dry, treat the windshield, headlight lens and other nonpainted plastic parts with an approved plastic cleaner/polisher product.
MAINTENANCE AND ADJUSTMENT 153 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 accessories, 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, shortening their life.
154 APPENDIX APPENDIX Storage j Whenever your motorcycle will not be in use for a long period, proper storage is essential. It consists of checking and replacing missing or worn parts; lubricating parts to ensure that they do not corrode and, in general, preparing the motorcycle so that when the time comes to use it again, it will be in top condition. See your authorized Kawasaki dealer for this service or do the following.
APPENDIX 155 WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. the ignition key off. • Turn Do not smoke. • Make sure area is well ventilated and free from any source of flame or sparks; • this includestheany appliance with a pilot light. WARNING Gasoline is a toxic substance. Dispose of gasoline properly. Contact your local authorities for approved disposal methods. the entire vehicle thoroughly.
156 APPENDIX WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. j in fresh engine oil. • Put Empty from the fuel tank using a pump or syphon. • Removethethefuelspark and add fogging oil into the combustion chambers. If the • spark plugs cannotplugs be removed, take the motorcycle to an authorized Kawasaki • • • • • • dealer. Set the motorcycle on a stand so that both wheels are raised off the ground.
APPENDIX 157 Preparation after Storage the plastic bag from the muffler. • Remove Charge the battery if necessary and install the battery in the motorcycle. • Fill the fuel tank with fresh fuel. • Check all the points in the Daily Checks section. • Lubricate the pivots, listed bolts, and nuts. • Troubleshooting Guide If a Problem Occurs Performing daily checks and periodic maintenance prevents unexpected troubles from occurring.
158 APPENDIX • • • • j • • • WARNING When carrying out an inspection, follow the precautions below. Secure a place where you can work in safety without obstructing traffic around you. Do not carry out any inspection unless it is safe. Support the motorcycle on a firm, level surface with the stand. The engine and muffler will become hot during operation. To avoid burns etc., do not touch the hot engine or muffler just after the engine has stopped.
APPENDIX 159 the fuel level in the fuel tank. If only a small quantity of fuel remains in • Check the bottom, replenish the fuel tank. (Fuel in the tank cannot be completely consumed.) the motorcycle unused for a long time may cause fuel in the tank to • Leaving deteriorate. In that case, ask an authorized Kawasaki dealer for inspection. the engine warning indicator on the meter goes on and stays on, there may • When be a problem with the fuel injection system.
160 APPENDIX the fuse condition. If any fuse has blown, replace it with a new one of the • Inspect same amperage. WARNING Substituting fuses can cause wiring to overheat, catch fire and/or fail. Use only standard fuses of the correct capacity and specifications. j the battery cable connections etc. (see page 141). If necessary, tighten • Check the connecting bolts to securely connect them.
APPENDIX 161 If the Engine Stalls or Runs Poorly the fuel level in the fuel tank. If only a small quantity of fuel remains, • Check replenish the fuel tank. (Fuel in the tank cannot be completely consumed.) the side stand fully up before starting the engine. (If you try to move off • Raise with the side stand is still down, the engine will stop.) sure that correct fuel is used. If not, replace the fuel the correct type (see • Make page 63).
162 APPENDIX the engine warning indicator on the meter goes on and stays on, there • When is something wrong with the fuel injection system. Ask an authorized Kawasaki dealer for inspection and maintenance. If the engine stalls after completing the above inspection and maintenance, there may be something wrong with other system. Ask an authorized Kawasaki dealer for inspection and maintenance.
APPENDIX 163 If you are unsatisfied after working with your Kawasaki dealer and feel you still require further assistance, WRITE to the address below. Please be certain to provide the model, product identification number, mileage or hours of use, accessories, dates that events occurred and what action has been taken by both you and your dealer. Include the name and address of the dealership.
164 APPENDIX Please send your correspondence to: j Customer Relations: Technical Services Department KAWASAKI MOTORS Pty., Ltd. LOCKED BAG 802, ERMINGTON. NSW. 1700. A.C.N. 002 840 315. E-mail: info@Kawasaki.com.au Environmental Protection To help preserve the environment, properly discard used batteries, tires, oils and fluids, or other vehicle components that you might dispose of in the future.
MAINTENANCE RECORD 165 MAINTENANCE RECORD Owner Name....................................................................................... Address .............................................................................................. Phone Number ................................................................................... Engine Number .................................................................................. Vehicle Number............................................................
166 MAINTENANCE RECORD Date j Odometer Reading Maintenance Performed Dealer Name Dealer Address
MAINTENANCE RECORD 167 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address j
168 MAINTENANCE RECORD Date j Odometer Reading Maintenance Performed Dealer Name Dealer Address
MAINTENANCE RECORD 169 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address j
170 MAINTENANCE RECORD Date j Odometer Reading Maintenance Performed Dealer Name Dealer Address