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1. 02 MODEL 5 ROSUUA EXHAUST EMISSION DISPLACEMENT TUNE UP SPEGIFIGATIONS IGNITION TIMING 10 BTOC AT 1300 RPM IDLE SPEED 1300 50 RPM IN NEUTRAL MIXTURE SETTING H ENGINE COLD 9 MM 0 035 IN FUEL GASOLINE WITH ANTIKNOCK INDEX 2 87 HIN ENGINE 011 SERVICE RATING API S6 SH SJ SL OR SM WITH JASO WA VISCOSITY SAE 108 40 SEE THE S MANUAL FOR ENGINE OIL INFORMATION THIS VEHICLE CONFORMS TO U S REGULATIONS APPLICABLE 2010 MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO AN HC NOX 4 EMISSION STANDARD OF 0 76 KAWASAKI MOTORS ENTERPRISE THAILAND CO LTD 59464 1802 TEO3223C29 http www motorcycle in th 168 LOCATION OF LABELS 6 Only on California model VEHICLE EMISSION CONTROL INFORMATION ENGINE FAMILY CODE ARAXG 4 PERMEATION FAMILY AKAXPHETALO FAMILY AKAXUT7 0407 WODEL S ERS50CA EXHAUST EMISSION CONTROL SYSTEM SFI PAIR 0C DISPLACEMENT TUNE UP SPECIFICATIONS IGNITION TIMING 10 BTDC AT 1300 RPM IOLE SPEED 1300 50 RPM IN NEUTRAL MIXTURE SETTI ENGINE COLD SPARK PLUG ENGINE OIL SERVICE RATING API SG SH SJ SL OR SM WITH JASO WA VISCOSITY SAE 109 40 SEE THE ONNER S MANUAL FOR ENGINE OIL INFORMATION THIS VEHICLE CONFORMS 0 5 AND CALIFORNIA REGULATIONS APPLICABLE TO 2010 MODEL YEAR NEW MOTORCYCLES AND 15 CERTIFIED TO 0 7G KM HO NOX E
2. 32 Starter Button sees esteem 33 Left Handlebar Switches 33 Dimmer Switch 33 Turn Signal Switch 34 Horm BUOM adelanto 34 Hazard Switch 34 Brake Clutch Lever Adjusters 35 Fuel Tank 36 Fuel Tank cc 37 Fuel Requirement 38 ej gro NORTE 42 el s NONE NR RR RET 43 Helmet Holding Cable 45 Tool Kit U Shaped Lock Compartment 46 Rear View Mirror 47 jbieass cy 48 49 HOW RIDE THE MOTORCYCLE 51 Starting the Engine 51 Jump Starting accede 53 PVG NN 56 Shifting Gears 2 57 Brak seansen 59 Stopping the Engine 60 http www motorcycle in th Stopping Motorcycle in Emergency 61 pro Meer C 62 Catalytic Converter 64 SAFE OPERATION 66 Safe Riding Technique 66 Daily Safety Checks 69 Additional Considerations for High Speed Operation 72 MAINTENANCE AND ADJUSTMENT 74 Periodic Maintenance Chart 79 Engine Oil MEM 90 Cooling System
3. Install the U shaped part and lock separately and secure them with its strap A Tool Kit B U Shaped Lock not supplied C Lock Strap NOTE O When storing a U shaped lock store the U shaped part and the lock sep arately http www motorcycle in th OSome U shaped locks cannot stored by the size of them GENERAL INFORMATION 47 Rear View Mirror Rear View Mirror Adjustment e Adjust the rear view mirror by slightly moving only the mirror portion of the assembly e f the rear visibility cannot be assured by moving the mirror adjust the stay position by loosening the lock nut 76340128 A Rear View Mirror B Stay C Rubber Boot D Lock Nut http www motorcycle in th 48 GENERAL INFORMATION Tying Hooks When tying up light loads to the seat use the tying hooks located on the left and right sides of the rear fender A Tying Hooks http www motorcycle in th BREAK IN 49 BREAK IN The first 1 600 km 1 000 mi that the motorcycle is ridden is designated as the break in period If the motorcycle is not used carefully during this period you may very well end up with a broken down instead of a broken in motorcycle after a few thousand kilometers The following rules should be observed during the break in period e he table shows maximum recommended engine speed during the break in pe riod Distance traveled Maximum engine speed 0 800 km 0 500 mi 4 000 r m
4. 96 Spark PIE 102 Evaporative Emission Control System California model only 103 Kawasaki Clean Air System 104 Valve Clearance 105 106 Throttle Control System 107 Engine Vacuum Synchronization 110 Idle 110 ro MET EN EN 112 DAVE CNAIN C 114 ij M 123 Brake Light Switches 127 Front F OM 2 129 Rear Shock Absorbers 130 NIG 132 T 138 Headlight Beam 143 Ei T 145 General Lubrication 147 Cleaning Your Motorcycle 148 Bolt and Nut Tightening 153 155 TROUBLESHOOTING GUIDE 157 OWNER SATISFACTION 158 REPORTING SAFETY DEFECTS 160 ENVIRONMENTAL PROTECTION 161 LOCATION OF LABELS 162 MAINTENANCE RECORD 173 http www motorcycle in th 8 SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass ENGINE Type Displacement Bore x Stroke Compression Ratio Starting System Cylinder Numbering Method Firing Order SPECIFICATIONS 2 100 mm 82 68 in 760 mm 2
5. Due to friction plate wear and clutch ularity have the clutch cable checked cable stretch over a long period of use by an authorized Kawasaki dealer the clutch operation should be checked e Check the clutch lever play as shown each day before riding the motorcycle in the figure a and carry out the maintenance and ad Clutch Lever Play justments in accordance with the Peri odic Maintenance Chart 2 3mm 0 08 0 12 in A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch a hot engine or an exhaust pipe during clutch adjustment Inspection TK150578 6 e Check that the clutch lever operates A properly and that the inner cable B Clutch Lever Play C Adjuster http www motorcycle in th If the play is incorrect adjust the lever play as follows Adjustment Loosen the locknut and turn the adjuster so that the clutch lever will have the proper play A WARNING Too much cable play can pre vent clutch disengagement and cause an accident resulting in serious injury or death When adjusting the clutch or replac ing the cable be sure the up per end of the clutch outer cable is fully seated in its fitting or it could slip into place later creat ing enough cable play to prevent clutch disengagement e f it cannot be done use the adjuster at the lower end of the clutch cable MAINTENANCE AND ADJUSTMENT 113 A Adj
6. the high beam indicator light is lit High beam Low beam 22 http www motorcycle in th 34 GENERAL INFORMATION NOTE O When the headlight is on high beam both head lights go on When the headlight is on low beam only one headlight goes on A Dimmer Switch B Turn Signal Switch C Horn Button D Hazard Turn Signal Switch When the turn signal switch is turned to the left 4 or right the corresponding turn signal flashes on and off To stop flashing push the switch in Horn Button When the horn button is pushed the horn sounds Hazard Switch If an emergency requires you to park on the highway shoulder turn on the hazard lights to warn other drivers of your location Push in the hazard switch with the ignition switch in the ON or P Park position All the turn signals and turn signal indicator lights will flash on and off http www motorcycle in th If you leave switch on for a long time the battery may be come totally discharged So be careful not to use the hazard lights for more than 30 minutes GENERAL INFORMATION 35 Brake Clutch Lever Adjusters There is an adjuster on both the brake and clutch levers Each adjuster has 5 positions so that the released lever position can be adjusted to suit the operator s hands Push the lever forward and turn the adjuster to align the number with the mark on the lever holder http
7. 4 Kawasaki Includes Important Safety Information Operating Instructions Maintenance and Storage ER 6n Motorcycle ORT A http www motorcycle in th WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm NOTICE THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY http www motorcycle in th GENERAL INFORMATION Quick Reference Guide HOW TO RIDE THE MOTORCYCLE This Quick Reference Guide will SAFE OPERATION assist you in finding the information youre looking for MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE A Table of Contents is included after the Foreword http www motorcycle in th http www motorcycle in th Whenever you see the symbols A CAUTION shown below heed their instructions E Always follow safe operating and main PAU TION Indicates hazardous situation which if not avoided tenance practices could result in minor or moder A DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious in jury NOTICE NOTICE is used to address prac tices not related to personal in jury A WARNING WARNING indicates a hazardous NOTE situation which if not avoided O This note
8. mum specified by Kawasaki Never use gasohol with more than 10 ethanol or more than 5 methanol Gasoline con taining methanol must also be blended with solvents and cor rosion inhibitors Certain ingredients of gasoline may cause paint fading or dam age Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling When not operating your Kawasaki for 30 to 60 days mix a fuel stabilizer such as STA BIL with the gasoline in the fuel tank Fuel stabilizer additives inhibit oxidation of the fuel which mini mizes gummy deposits GENERAL INFORMATION 41 NOTICE Never store this product with gasohol in the fuel system Before storage it is recom mended that you drain all fuel from the fuel system See the Storage section in this manual http www motorcycle in th 42 GENERAL INFORMATION Stand The motorcycle is equipped with a side stand 6140348 G A Side Stand NOTE When using the side stand turn the handlebar to the left Whenever the side stand is used make it a practice to kick the stand fully up before sitting on the motorcycle NOTE O The motorcycle is equipped with a side stand switch This switch is de signed so that the engine does not start if the transmission is in gear and the side stand is down http www motorcycle in th Seat Seat Removal e Insert the ignition key into the seat lock located under the rear cowling
9. 140 MAINTENANCE AND ADJUSTMENT Battery Sulfation A common cause of battery failure is sulfation Sulfation occurs when the battery is left in a discharged condition for an ex tended time Sulfate is a normal by product of the chemical reactions within a battery But when continuous dis charge allows the sulfate to crystallize in the cells the battery plates become permanently damaged and will not hold a charge Battery failure due to sulfa tion is not warrantable Battery Maintenance Itis 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 a voltmeter f it drops below 12 8 volts the battery should be charged using an appropriate charger check with a Kawasaki dealer If you will not be using the motorcy cle for longer than two weeks the battery should be charged using an appropriate charger Do not use an au tomotive type quick charger that may overcharge the battery and damage it Kawasaki recommended chargers are OptiMate III Yuasa 1 5 Amp Automatic charger Battery Mate 150 9 If the above chargers are not avail able use equivalent one For more details ask your Kawasaki dealer http www motorcycle in th MAINTENANCE AND ADJUSTMENT 141 Battery Charging NOTE e Remove the battery from the motor Olf you charge the sealed battery
10. 3 m 7 5 11 Air cleaner element clean Valve clearance inspect Throttle control system play smooth year return no drag inspect http www motorcycle in th 80 MAINTENANCE AND ADJUSTMENT Frequency Whichever Odometer Reading km x 1 000 mile x 1 000 See Page Operation Engine Items Engine vacuum synchronization inspect Idle speed inspect Fuel leak fuel hose and pipe inspect Fuel hoses K installation condition inspect http www motorcycle in th MAINTENANCE AND ADJUSTMENT 81 Frequency Whichever Odometer Reading km x 1 000 mile x 1 000 See Page Operation 12 24 36 Engine Items 0 0 6 3 m 7 5 T 25 15 s 22 Te Radiator hoses year damage inspect Radiator hoses installation condition year inspect Evaporative emission control system 103 function California model only Air suction system 104 damage inspect http www motorcycle in th 82 MAINTENANCE AND ADJUSTMENT 2 Periodic Inspection Chassis Related Items Frequency Whichever Odometer Reading km x 1000 mile x 1000 See Page Operation 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 engagement disengagement inspect Drive chain lubrication condition every 600 km 400 mile inspect Drive chain slack every 1 000 km 600 mile
11. as often as possible not while the motorcycle is in motion and adjust as necessary Do not carry heavy or bulky items on a luggage rack They are designed for light items and overloading can affect handling due to changes in weight distribution and aerodynamic forces http www motorcycle in th 18 LOADING AND ACCESSORIES INFORMATION 6 Do not install accessories or carry baggage that impairs the perfor mance of the motorcycle Make sure that you have not adversely affected any lighting components road clearance banking capability i e lean angle control operation wheel travel front fork movement or any other aspect of the motorcy cle s operation Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can re sult in an unsafe riding condition Fairings windshields backrests and other large items have the ca pability of adversely affecting stabil ity and handling of the motorcycle designed or installed items can re sult in an unsafe riding condition This motorcycle is not intended to be equipped with a sidecar or to be used to tow any trailer or other ve hicle Kawasaki does not manu facture sidecars or trailers for mo torcycles and cannot predict the ef fects of such accessories on han dling or stability but can only warn that the effects can be adverse and that Kawasaki cannot assume re sponsibility for the results of such unintend
12. cycle see Battery Removal never fail to observe the instructions e Attach the leads from the charger to shown in the label on the battery the battery and charge the battery at a rate that is 1 10th of the battery capacity For example the charging WARNING rate for a 10 Ah battery would be 1 0 Lead is a toxic substance Bat ampere tery posts terminals and related e The charger will keep the battery fully accessories contain lead and charged until you are ready to re lead compounds Wash hands install the battery in the motorcycle after handling see Battery Installation Battery Removal NOTICE e Remove the seat Never remove the sealing strip e Disconnect the wires from the bat or the battery can be damaged tery first from the terminal and Do not install a conventional then the terminal battery in this motorcycle or the e the battery out of the case electrical system cannot work e Clean the battery using a solution of properly baking soda and water Be sure that the wire connections are clean http www motorcycle in th 142 MAINTENANCE AND ADJUSTMENT A Terminal B Terminal Battery Installation e Place the battery in the battery case e Connect the capped wire to the terminal and then connect the black wire to the terminal NOTE O Install the battery in the reverse order of the Battery Removal NOTICE Installing the cable to the termin
13. inspect Drive chain wear 118 inspect http www motorcycle in th MAINTENANCE AND ADJUSTMENT 83 Frequency Whichever Odometer Reading km x 1000 mile 1000 see Operation 12 24 36 Chassis Items 0 6 3 2 7 5 n 25 15 m Em 22 5 K Drive chain guide wear inspect Wheels and tires inspect Wheels tires damage ol el del fe fe Tire tread wear abnormal wear 135 inspect K Wheel bearings year damage inspect http www motorcycle in th 84 MAINTENANCE AND ADJUSTMENT Frequency Whichever Odometer Reading km x 1000 mile x 1000 See Page Operation 1 6 12 18 24 30 36 Chassis Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Brake system ren fete fete tet fete inspect Brake hoses and pipe damage year inspect inspect Brake hose installation year 123 condition inspect inspect http www motorcycle in th MAINTENANCE AND ADJUSTMENT 85 Frequency Whichever Odometer Reading km 1000 mile x 1000 Operation Chassis Items Brake operation effectiveness play drag inspect Brake light switch operation inspect Suspensions Front forks rear shock absorber operation damping and smooth stroke inspect Front forks rear shock absorber oil leak inspect http www motorcycle in th 86 MAINTENANCE AND ADJUSTMENT Frequency Whichever Odometer Reading km x 1000 mile x 100
14. www motorcycle in th 36 GENERAL INFORMATION The distance from the grip to the re leased lever is minimum at Number 5 and maximum at Number 1 A Adjuster B Mark Fuel Tank Cap To open the fuel tank cap pull up the key hole cover Insert the ignition key into the fuel tank cap and turn the key to the right To close the cap push it down into place with the key inserted The key can be removed by turning it to the left to the original position http www motorcycle in th O The fuel tank cap cannot be closed without the key inserted and the key cannot be removed unless the cap is locked properly O Do not push on the key to close the cap or the cap cannot be locked T 10798 A Key Hole Cover B Ignition Key C Fuel Tank Cap GENERAL INFORMATION 37 Fuel Tank Avoid filing the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated TGi2002B22 A Tank Cap B Fuel Tank C Top Level D Filler Neck http www motorcycle in th 38 GENERAL INFORMATION E AwaNNG Gasoline is extremely flammable and can be explosive under cer tain conditions Turn the igni tion key to OFF Do not smoke Make sure the area is well ven tilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat
15. 122 MAINTENANCE AND ADJUSTMENT Lubrication e Apply oil to the sides of the rollers so Lubrication is also necessary after that it will penetrate to the rollers and riding through rain or on wet roads or bushings Apply oil to the O rings so any time that the chain appears dry A that the O rings will be coated with heavy oil such as SAE 90 is preferred oil Wipe off any excess oil to a lighter oil because it will stay on the chain longer and provide better lubrica tion TKi6011B22 e If the chain is especially dirty clean it using diesel oil or kerosine and then apply oil as mentioned above http www motorcycle in th 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 a set Pad replace ment should be done by an authorized Kawasaki dealer TKi7005BZ2 A Lining Thickness B 1 mm 0 04 in MAINTENANCE AND ADJUSTMENT 123 Disc Brake Fluid In accordance with the Periodic Main tenance 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 contaminated with dirt or water Fluid Requirement Use heavy duty brake fluid only from a container marked 4 NOTICE Do not spill brake fluid onto any painted surface Do not use fluid from
16. 8 0 9 mm Plug 0 032 0 035 in Tightening 15 Nem Torque 1 5 kgf m 11 ft Ib http www motorcycle in th TK06006B722 Evaporative Emission Control System California model only 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 a thorough vi sual inspection must be made at the in tervals specified by the Periodic Main tenance Chart Inspection e Check that the hoses are securely connected e Replace any kinked deteriorated or damaged hoses MAINTENANCE AND ADJUSTMENT 103 VACUUM HOSE ROUTING DIAGRAM TE039607BN7 http www motorcycle in th 104 MAINTENANCE AND ADJUSTMENT 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 ex haust 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 unburned gases as well as chang ing a significant portion of the carbon monoxide 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
17. ADJUSTMENT Engine Vacuum Synchronization Engine vacuum synchronization must be checked and adjusted period ically in accordance with the Periodic Maintenance Chart only by a compe tent mechanic following the instructions in the Service Manual NOTE O Poor engine vacuum synchronization will cause unstable idling sluggish throttle response and reduce engine power and performance Idle Speed The idle speed check should be per formed in accordance with the Peri odic Maintenance Chart or whenever the idle speed is disturbed Adjustment Start the engine and warm it up thor oughly e Adjust the idle speed by turning the idle adjusting screw http www motorcycle in th Idle Speed 1 250 1 350 r min rpm TRIZOZOR G A Idle Adjusting Screw Open and close the throttle a few times to make sure that the idle speed does not change Readjust if necessary MAINTENANCE AND ADJUSTMENT 111 With the engine idling turn the han dlebar to each side If handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or they may be damaged Be sure to correct any of these conditions before riding A WARNING Operation with damaged cables could result in an unsafe riding condition Replace damaged control cables before operation http www motorcycle in th 112 MAINTENANCE AND ADJUSTMENT Clutch slides smoothly If there is any irreg
18. B Center of Brightest Spot C 7 6 m 25 ft D Height of Headlight Center http www motorcycle in th MAINTENANCE AND ADJUSTMENT 145 Fuses e Remove the left side cover by remov Fuses are arranged in the fuse box ing the bolt located under the seat The main fuse is mounted on the starter relay behind the left side cover If a fuse fails during operation inspect the electrical system to determine the cause and then re place it with a new fuse of proper am perage A Left Side Cover B Bolt A Fuse Box http www motorcycle in th 146 MAINTENANCE AND ADJUSTMENT A WARNING Substituting fuses can cause wiring to overheat catch fire and or fail Do not use any sub stitute for the standard fuse Replace the blown fuse with a new one of the correct capacity as specified on the junction box and main fuse A Main Fuse B Spare Fuse 25007 22 A Normal B Failed http www motorcycle in th MAINTENANCE AND ADJUSTMENT 147 General Lubrication Apply motor oil to the following Lubricate the points shown below pivots with either motor oil or regular grease Side Stand in accordance with the Periodic Main OClutch Lever tenance Chart or whenever the vehicle O Front Brake Lever has been operated under wet or rainy O Rear Brake Pedal i conditions Before lubricating each part clean off Lubricate the following cables with a any rusty spots with rust remover and pressure cable
19. GLOSING RPN 80DBA 4852RPM 59464 1803 TEO3225CN9 AIR CLEANER THROTTLE INJECTOR TE039607BN7 http www motorcycle in th LOCATION OF LABELS 171 10 WFO BY KAWASAKI HEAVY INDUSTRIES LTD DATE THIS VEHICLE GONFORWS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOYE GYNR 836 LBS F 277 LBS WITH 120 702R02N C 580 TIRE J178 6XHT3 50 RIM AT 32 PSI COLD GAWR R 558 LBS WITH 160 802R17M C 609 TIRE J128 6XHT4 50 RIM 36 PSI COLD JKAEREGCTXXDAXXXXX NOTOR CYCLE 86506 WADE IN THAILAND 39168 9 http www motorcycle in th 172 LOCATION OF LABELS 11 VAN DANGER POISON UP FLUSH EYES Q cS wenn NO SULFURIG ACID EXPLOSIVE GASES i cpapxs CAUSE GET CAN CAUSE BLINDNESS eF AMES BLINDNESS OR PM MED CAL OR INJURY ie SMOKING SEVERE BURNS HELP FAST KEEP OUT OF THE REACH OF CHILDREN C5 IN U S A DISTR BY KAWASAKI MOTORS CORP USA P O BOX 25252 SANTA ANA CA 92 799 5252 RECYCLE 032186 5 http www motorcycle in th MAINTENANCE RECORD 173 MAINTENANCE RECORD Owner T EE 5 Phone 2 oe soa sa pa Sa Ra ER
20. Push the MODE button to advance the hours TG602421B G http www motorcycle in th e Push the RESET button The hour display stops flashing and the minute display starts flashing Push the MODE button to advance the min utes T602422B 6 e Push the RESET button Both the hour and minute displays start flash ing again e Push the MODE button The dis plays stop flashing and the clock starts working GENERAL INFORMATION 23 NOTE O Pushing the MODE button momen tarily advances the hour or minute step by step Pushing and hold ing the button advance the hour or minute continuously O The clock works normally from the back up power while the ignition switch is turned off OWhen the battery is disconnected the clock resets to 1 00 and starts working again when the battery is connected http www motorcycle in th 24 GENERAL INFORMATION Odometer The odometer shows the total dis tance in kilometers or miles that the ve hicle has been ridden This meter can not be reset T6024238 G NOTE O The data is maintained even if the battery is disconnected O When the figures come to 999999 they are stopped and locked Trip Meter The trip meters show the distance in kilometers miles traveled since they were last reset to zero TRIP A 0 0 999 9 TRIP B 0 0 9999 9 To reset the trip meter e Push the MODE button to display the trip meter A or B e Push the RESET button and hold
21. create a dangerous situation known as throt tle failure Two of the most common causes of throttle failure are 1 An improperly serviced or clogged air cleaner may allow dirt and dust to enter the throttle body and stick the throttle open HOW TO RIDE THE MOTORCYCLE 61 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 en gine 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 http www motorcycle in th 62 HOW TO RIDE THE MOTORCYCLE Parking e Shift the transmission into neutral and turn the ignition key to OFF e Support the motorcycle on a firm level surface with the side stand Do not park on a soft or steeply A WARNING The muffler and exhaust pipe are very hot while the engine is running and just after the engine stops This can ignite a fire re sulting in property damage or severe personal injury Do not idle or park your vehi cle in an area where flammable materials such as grasses or dry leaves may contact with muffler e f parking inside a garage or other or exhaust pipe structure be sure it is well ventilated and the motorcycle is not close to any source of
22. in serious injury or death Re whenever a new tire is installed place damaged tires as soon as possible To ensure safe han dling and stability use only the recommended standard tires for replacement inflated to the stan dard pressure If it is necessary to ride on a repaired tire do not exceed 100 km h 60 mph until the tire is replaced NOTE O When operating on public roadways keep maximum speed under traffic law limits http www motorcycle in th MAINTENANCE AND ADJUSTMENT 137 Standard Tire Tubeless WARNING oe 58W New tires are slippery and may cause loss of control and injury break in period of 160 km 100 Size 160 60ZR17 M C 69W DUNLOP SPORTMAX ROADSMART G miles is necessary to estab lish normal tire traction During break in avoid sudden and max imum braking and acceleration and hard cornering 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 http www motorcycle in th 138 MAINTENANCE AND ADJUSTMENT Battery The battery installed in this motorcy cle is a sealed type so it is not nec essary to check the battery electrolyte level or add distilled water The sealing strip should not be pulled off once the specified electrolyte has been installed in the battery for initial service However
23. it in e After two seconds the figure display turns to 0 0 and then starts counting when the vehicle is operated The meter counts until it is reset http www motorcycle in th G The data is maintained by back up power if the ignition key is turned off When the trip meter is without the engine operation it starts counting as soon as the vehicle starts moving O When the trip meter reaches 999 9 TRIP A or 9999 9 TRIP B while running the meters reset to 0 0 and continues counting GENERAL INFORMATION 25 OWhen the battery is disconnected the meter display resets to 0 0 Km Mile Display Km Mile Display can alternate be tween metric and English modes km and mile in the digital meter Make sure that km or mile is correctly dis played according to local regulations before riding c T602425B G A Km Mile Display NOTE O Do not operate the vehicle with the digital meter displaying in the wrong unit km or mile Shift the km mile display in the digital meter as follows http www motorcycle in th 26 GENERAL INFORMATION e Display the odometer in the digital meter e The km mile display shifts by pushing the RESET button while the MODE button pushed in e The km mile display shifts as follows 9m T602102871 A Km Display B MileDisplay C Push RESET Button with MODE Button in NOTE O The data is maintained ev
24. lubber wipe off any grease oil dirt or grime O K Clutch Inner Cable NOTE Throttle Inner Cables 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 TK26001B72 http www motorcycle in th 148 MAINTENANCE AND ADJUSTMENT Apply grease to the following points O K Clutch Inner Cable Upper End O K Throttle Inner Cable Upper Ends K Should be serviced by an authorized Kawasaki dealer NOTE O After connecting the cables adjust them Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance optimize overall per formance and extend its useful life Covering your motorcycle with a high quality breathable motorcycle cover will help protect its finish from harmful UV rays pollutants and reduce the amount of dust reaching its surfaces e Be sure the engine and exhaust are cool before washing e Avoid applying degreaser to seals brake pads and tires e Always use non abrasive wax and cleaner polisher e Avoid all harsh chemicals solvents detergents and household cleaning products such as ammonia based window cleaners http www motorcycle in th e Gasoline brake fluid and coolant will damage the finish of painted and plastic surfaces wash them off im mediately e Avoid wire br
25. or a battery explosion and serious damage to the electrical system may occur NOTICE Do not operate the starter con tinuously for more than 5 sec onds or the starter will overheat and the battery power will drop temporarily 15 seconds between each operation of the starter to let it cool and the bat tery power recover e After the engine has started discon nect the jumper cables Disconnect the negative cable from the mo torcycle first e Reinstall the removed parts http www motorcycle in th 56 HOW TO RIDE THE MOTORCYCLE Moving Off RI e Check that the side stand is up e Pull in the clutch lever e Shift into 1st gear e Open the throttle a little and start to let out the clutch lever very slowly e As the clutch starts to engage open the throttle a little more giving the en gine just enough fuel to keep it from stalling TIDADG4B A Shift Pedal NOTE O The motorcycle is equipped with a side stand switch This switch is de signed so that the engine does not start if the transmission is in gear and the side stand is down O When the headlight is on high beam two headlight beams go on and on low beam one headlight goes on http www motorcycle in th Shifting Gears e Close the throttle while pulling in the clutch lever e Shift into the next higher or lower gear e Open the throttle half way while re leasing the clutch lever e For smooth riding each ge
26. replacement tires or overloading When tire tread wears down to the limit replace the tire with only the standard tire Maintain the inflation pressure specified Air Pressureltold Size amp Make Tubeless Tire Minimum Tread Depth te Load 225 kPa B osal tan 0 04 in 2 mid 0tim Up to 18 kg Load 250 kPa 60 8OZR17H C 89 Up to 30 ear ROA shat E 190 knh 80KPH 3 1210 IMPORTANT DRIVE CHAIN INFORMATION To prevent an accident and or damage to the motorcycle the drive chain must be properly maintained It should be lubricated every 808km 400mi and adjusted as often as necessary to keep chain slack at about 25 35mm 1 8 1 4in measured midway between sprockets on the lower chain run with the motorcycle on the side stand The standard chain is DIDBO20YP2 with estimated service life of 15600 45000km 9400 28000mi depending on the severity of use and the frequency of lubrication and adjustment For safety replace the chain with only the standard chain any time it wears to over 32amm i2 7in measured over 20 link portion pulled straight with 10 201 bf of tension See the Owner s Manual for chain information http www motorcycle in th TEO3839BN8 TEO38460BN8 6 LOCATION OF LABELS 167 VEHICLE EMISSION CONTROL INFORMATION ENGINE FAMILY CODE AKAXG 649 PERMEATION FAMILY
27. should be serviced more frequently than the recom mended interval only by a competent mechanic following the instructions in the Service Manual Oil Draining e Inspect the drain hose located on the rear side of the engine to see if any oil or water has run down from the air cleaner housing TkiDMM6B 6 A Drain Hose B Plug e f there is any oil in the hose remove the plug and drain the oil http www motorcycle in th A WARNING on tires will make them slip pery and can cause an accident and injury Be sure to install the plug in the drain hose after drain ing MAINTENANCE AND ADJUSTMENT 107 Throttle Control System Check the throttle grip play in accor dance with the Periodic Maintenance Chart and adjust it if necessary Throttle Grip The throttle grip controls the butterfly valves in the throttle body If the throt tle grip has excessive play due to either cable stretch or maladjustment it will cause a delay in throttle response es pecially at low engine speed Also the throttle valve may not open fully at full throttle On the other hand if the throt tle grip has not play the throttle will be hard to control and the idle speed will be erratic http www motorcycle in th 108 MAINTENANCE AND ADJUSTMENT Inspection e Check that the throttle grip play is correct by lightly turning the throttle grip back and forth TK1l gBB G A Throttle Grip B Throttle Grip Pla
28. symbol indicates points of could result in death or serious particular interest for more efficient injury and convenient operation http www motorcycle in th FOREWORD Congratulations on your purchase of a new Kawasaki motorcycle Your new mo torcycle is the product of Kawasaki s advanced engineering exhaustive testing and continuous striving for superior reliability safety and performance Please read this Owner s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle s controls its fea tures capabilities and limitations This manual offers many safe riding tips but its purpose is not to provide instruction in all the techniques and skills required to ride a motorcycle safely Kawasaki strongly recommends that all operators of this vehi cle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle operation To ensure a long trouble free life for your motorcycle give it the proper care and maintenance described in this manual For those who would like more detailed in formation on their Kawasaki Motorcycle a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer The Service Manual contains de tailed disassembly and maintenance information Those who plan to do their own work should of course be competent mechanics and possess the special tools describe
29. www motorcycle in th 20 21 22 23 24 25 TDOT2108 6 Front Fork Brake Disc Brake Caliper Side Stand Shift Pedal Drive Chain LOCATION OF PARTS 15 TDO1211B G 26 License Plate Light 31 Fuel Tank 37 Oil Level Gauge 27 Tail Brake Light 32 Fuel Tank Cap 38 Idle Adjusting Screw 28 Brake Fluid Reservoir 33 Coolant Reserve Tank Rear 34 Muffler 29 Rear Shock Absorber 35 Rear Brake Light 30 Spring Preload Switch Adjuster 36 Rear Brake Pedal http www motorcycle in th 16 LOADING AND ACCESSORIES INFORMATION WARNING Incorrect loading improper in stallation or use of accessories or modification of your motorcy cle may result in an unsafe rid ing condition Before you ride the motorcycle make sure that the motorcycle is not overloaded and that you have followed these instructions With the exception of genuine Kawasaki Parts and Accessories Kawasaki has no control over the design or application of accessories In some cases improper installation or use of accessories or motorcycle modification will void the motorcycle LOADING AND ACCESSORIES INFORMATION warranty In selecting and using acces sories and in loading the motorcycle you are personally responsible for your own safety and the safety of other per sons involved NOTE OKawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles We strongly recommend that all pa
30. 0 See Page Operation 1 6 12 18 24 30 36 Chassis Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Steering System mesmo ww Je je fe fe inspect Steering stem bearings lubricate Bes je Electrical System Lights and switches year pe inspect Side stand switch year operation inspect Engine stop switch year operation inspect http www motorcycle in th MAINTENANCE AND ADJUSTMENT 87 Frequency Whichever Odometer Reading km x 1000 mile 1000 see Page Operation 1 6 12 18 24 30 36 Chassis Items 0 6 3 75 7 5 11 25 15 18 75 22 5 Chassis Chassis parts Bolts and nuts 453 tightness inspect http www motorcycle in th 88 MAINTENANCE AND ADJUSTMENT 3 Periodic Replacement Frequency Whichever comes Odometer Reading first BP km 1 000 mile x 1 000 See V 12 Change Replacement Items 7 5 Air cleaner element replace 2 year ad amp A X bd Engine oil change year Radiator hoses and O rings K 3 years replace K Brake hoses and pipe replace 4 years I K Brake fluid front and rear fes change http www motorcycle in th MEN N O Pm NE MAINTENANCE AND ADJUSTMENT 89 Frequency Whichever comes Odometer Reading first P km x 1000 mile x 1 000 See V Page Eve 24 36 48 Change Replac
31. 9 92 in 1 100 mm 43 31 in 1 405 mm 55 31 in 140 mm 5 51 in 200 kg 441 Ib 4 valve 2 cylinder 4 stroke liquid cooled 649 cm 39 6 cu in 83 x 60 mm 3 27 x 2 36 in 11 3 1 Electric starter Left to right 1 2 1 2 http www motorcycle in th Carburetion System Ignition System Ignition Timing Electronically advanced Spark Plugs Lubrication System Engine Oil Type Capacity Coolant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio SPECIFICATIONS 9 FI Fuel Injection Battery and coil transistorized ignition 10 BTDC 91 300 r min rpm 34 BTDC 95 000 r min rpm NGK CR9EIA 9 Forced lubrication semi dry sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 241 2 5 US qt 1 2 L 1 3 US qt 6 speed return shift Wet multi disc Chain drive 2 095 88 42 3 067 46 15 http www motorcycle in th 10 SPECIFICATIONS Overall Drive Ratio Gear Ratio FRAME Castor Trail Tire Size Rim Size Fuel Tank Capacity 1st 2nd 3rd 4th oth 6th Front Rear Front Rear 5 473 Top gear 2 438 39 16 1 714 36 21 1 333 32 24 1 111 30 27 0 966 28 29 0 852 23 27 24 5 102 mm 4 0 in 120 70 ZR 17 M C 58 W 160 60 ZR 17 M C 69 W J17M C x MT3 50 J17M C x MT4 50 15 5 L 4 1 US gal http www motorcycle in th SPECIFICATIONS 11 ELEC
32. A Seat Lock B Ignition Key GENERAL INFORMATION 43 e Pull the rear end of the seat up while turning the key clockwise and then remove the seat backward A Turn the Key B Seat C Pull upward D Pull backward Seat Installation Install seats in the reverse order of removal http www motorcycle in th 44 GENERAL INFORMATION e Place the tabs into the matching e Push down the rear part of the seat slots until the lock clicks e Pull up the rear end of the seat to make sure it is securely locked A Seat B Tab C Slots D Hook E Lock e Insert the hook at the rear of the seat into the lock on the frame http www motorcycle in th Helmet Holding Cable Helmets can be secured to the mo torcycle by the helmet holding cables located under the seat 7621036 6 A Helmet Holding Cables GENERAL INFORMATION 45 A WARNING Riding with helmet attached to the cable could cause an acci dent by distracting the operator or interfering with normal vehi cle operation Do not ride the motorcycle with helmet attached to the cable http www motorcycle in th 46 GENERAL INFORMATION Tool Kit U Shaped Lock Compartment The tool kit is stored under the seat The kit contains tools that are helpful in making roadside repairs adjustments and some maintenance procedures ex plained in this manual Also under the seat there is a lock strap which can hold a U Shaped lock not supplied
33. Make sure that all nuts and bolts are tight and that all safety related parts are in good condition http www motorcycle in th 73 A WARNING Handling characteristics of motorcycle at high speeds may vary from those you are familiar with at legal highway speeds Do not attempt high speed operation unless you have received sufficient training and have the required skills http www motorcycle in th 74 MAINTENANCE AND ADJUSTMENT 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 a basic knowledge of mechanics and the proper use of tools you should be able to carry out many of the maintenance items described in this chapter If you lack proper experience or doubt your ability all adjustments maintenance and repair work should be completed by a qualified technician Please note that Kawasaki cannot assume any responsibility for damage result ing from incorrect or improper adjustment done by the owner http www motorcycle in th MAINTENANCE AND ADJUSTMENT 75 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 appli
34. NGINE FAMILY EXHAUST B 4 EMISSION STANDARD IN CALIFORNIA KAWASAKI MOTORS ENTERPRISE THAILAND CO LTD 59464 1805 TE03224C29 http www motorcycle in th LOCATION OF LABELS 169 7 DAILY SAFETY CHECKS Handlebar not loose Clutch lever play correct releases properly no slippage Headlight works Steering turns freely but has no play Turn signals work No coolant leakage coolant level betwee level lines Horn orks No abnormal engine noise Engine oil level correct Tires in good condition wear within service limit air pressure correct http www motorcycle in th Rear view mirror adjustment Brake lever play correct fluid up to upper level line no leakage Fuel in tank Throttle grip play correct Setail Brake light works Turn signals work Chain in good condition with proper slack oil if necessary Brake pedal play correct fluid up to upper level line no leakage abnormal exhaust noise TEO3838B29 170 LOCATION OF LABELS 8 9 Only on California model MOTGRCYCLE NOISE EMISSION CONTROL INF THIS 2010 MOTORCYCLE MEETS EPA NOISE EMISSION REQUIREMENTS BY THE FEDERAL TEST PROCEDURE MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE VACUUM HOSE ROUTING DIAGRAM EXCEED FEDERAL NOISE STANDARDS ARE PROHIBITED BY FEDERAL LAW SEE OWNER S MANUAL ER6506 MODEL SPECIFIC CODE KAWS980650 SEE VEHICLE IDENTIFICATION NUNEER ON STEERING HEAD NOISE LIMIT
35. OR ADAC Engine NUMDET aio nuu Vehicle TT TT Selling Dealer xiirej 3IU nol lge etr Warranty Start Note Keep this information and a spare key in a secure location http www motorcycle in th 174 MAINTENANCE RECORD Odometer Maintenance Performed Dealer Name Dealer Address Reading http www motorcycle in th MAINTENANCE RECORD 175 Odometer Maintenance Performed Dealer Name Dealer Address Reading http www motorcycle in th 176 MAINTENANCE RECORD Odometer Maintenance Performed Dealer Name Dealer Address Reading http www motorcycle in th MAINTENANCE RECORD 177 Odometer Maintenance Performed Dealer Name Dealer Address Reading http www motorcycle in th 650 CA OYAN N 4 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99987 1619 Printed in Thailand http www motorcycle in th
36. TRICAL EQUIPMENT Battery 12 V 10 Ah Headlight 12 V 55 W 55 W Hi Lo Tail Brake Light LED Even if one of LED Light Emitting Diode tail brake lights does not go on consult with an authorized Kawasaki dealer Specifications subject to change without notice http www motorcycle in th 12 SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATIONS 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 A Frame Number A Engine Number http www motorcycle in th LOCATION OF PARTS 13 LOCATION OF PARTS 0011538 6 1 Clutch Lever 5 Right Handlebar Switches 2 Left Handlebar Switches 6 Front Brake Lever 3 Meter Instruments 7T Throttle Grip 4 Brake Fluid Reservoir Front 8 Ignition Switch Steering Lock http www motorcycle in th 14 LOCATION OF PARTS 9 Headlight 10 Turn Signal Light 11 Spark Plugs 12 Air Cleaner 13 Main Fuse 14 Battery i i i Pes ee i i i i i i 1 i i Ar A 15 Seat 16 Tool Kit Storage Compartments 17 Helmet Holding Cable 18 Tying Hooks 19 Seat Lock http
37. a container that has been left open or that has been unsealed for a long time Check for fluid leakage around the fittings Check brake hose for damage http www motorcycle in 124 MAINTENANCE AND ADJUSTMENT 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 and that in the rear brake fluid reservoir located under the seat must be kept between the upper and lower level lines reservoirs held hor izontal A Rear Brake Fluid Reservoir B Upper Level Line C Lower Level Line Front Brake Fluid Reservoir B Lower Level Line http www motorcycle in th MAINTENANCE AND ADJUSTMENT 125 If the fluid level in either reservoir is A WARNING lower than the lower level line check Mixing brands and types of for fluid leaks in the brake lines and fill the reservoir to upper level brake fluid can reduce the brake system s effectiveness and line Inside the front brake fluid reser cause an accident resulting in voir is a stepped line showing the up s per level line injury or death Do not mix two brands of brake fluid Change the brake fluid 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 A T7008 6 A Front Brake Fluid Reservoir B Upper Level Line http www moto
38. al of the battery or the cable to the terminal of the battery can seriously damage the electrical system 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 removed parts http www motorcycle in th 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 adjuster clock wise or counterclockwise until the beam points straight ahead TK231078 6 A Horizontal Adjuster MAINTENANCE AND ADJUSTMENT 143 Vertical Adjustment The headlight beam is adjustable ver tically 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 illuminate the road close ahead and the low beam will blind oncoming drivers e Turn the vertical adjuster clockwise or counterclockwise to adjust its ver tical angle A Vertical Adjuster http www motorcycle in th 144 MAINTENANCE AND ADJUSTMENT 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 TK23142B G A 50 mm 2 0 in
39. and restores its normal operating performance e Lubricate the drive chain to prevent rusting 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 apply a corrosion protection spray on all metal and chrome surfaces to prevent corrosion O Condensation may form on the inside of the headlight lens after riding in the rain or washing the motorcycle To remove the moisture start the engine and turn on the headlight Gradually the condensation 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 mo torcycle automotive wax Wax should be applied once every three months or as conditions require Avoid surfaces with satin or flat finishes Always use non abrasive products and apply them according to the instructions on the container Windshield and Other Plastic Parts After washing use a soft cloth to gen tly dry plastic parts When dry treat the windshield headlight lens and other non painted plastic parts with http www motorcycle in th an approved plastic cleaner polisher product NOTICE Plastic parts may deteriorate and break if they come in con tact with chemical substances or household cleaning products such as gasoline brake
40. ank keys are available at your Kawasaki dealers Ask your dealer to make any additional spare keys you may need using your original key as a master or using the key code on the tag with your keys Record the code from the tag with your keys here Participating Kawasaki dealers can use the code to make a new key in the event that your original keys are lost Oo Write your key number here http www motorcycle in th 30 GENERAL INFORMATION Key Number Ignition Key T6G03002B74 0 Ignition Switch Steering Lock This is a four position key operated switch The key can be removed from the switch when it is in OFF LOCK or P Park position 004007 22 A Ignition Switch Steering Lock B ON position C OFF position D LOCK position E P Park position http www motorcycle in th Engine off All electrical circuits off Engine on All electrical equipment can be used Steering locked Engine off FOGR All electrical circuits off Steering locked Engine off License plate tail and city P Park lights on and turn signals can be used All other electrical circuits cut off NOTE O The city tail and license plate lights are on whenever the ignition key 15 in the ON position One headlight goes on when the starter button is released after starting the engine To avoid battery discharge always start GENERAL INFORMATION 31 the engine immediately after turning the igni
41. ant to any tread area http www motorcycle in th MAINTENANCE AND ADJUSTMENT 153 Bolt and Nut Tightening 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 1 Front Fender Mounting Bolts 2 Front Fork Clamp Bolts 3 Handlebar Clamp Bolts 4 Clutch Lever Holder Bolts 5 Steering Stem Head Bolt 6 Steering Stem Nut 7 Pivot Shaft Bolt 8 Step Stay Mounting Bolt 9 Grab Rail Mounting Bolt 10 Brake Disk Mounting Bolts 11 Caliper Mounting Bolts 12 Engine Mounting Bolts and Nuts 13 Side Stand Bolt 14 Rear Axle Nut 15 Rear Sprocket Mounting TMOBOTTB Bolts http www motorcycle in th 154 MAINTENANCE AND ADJUSTMENT 16 Front Brake Master Cylinder Clamp Bolt 17 Rear Shock Absorber Mounting Bolts 18 Front Axle Clamp Bolt 19 Front Axle Shaft 20 Brake Pedal Mounting Bolt 21 Rear Master Cylinder Mounting Bolts TK B07BB http www motorcycle in th STORAGE 155 5 Preparation for Storage e Clean the entire vehicle thoroughly e Run the engine for about five minutes to warm the oil shut it off and drain the engine oil A WARNING Motor oil is a toxic substance Dispose of used oil properly Contact your local authorities for approved disposal me
42. ar position should cover the proper rate of speed shown in the table HOW TO RIDE THE MOTORCYCLE 57 A WARNING Downshifting to a lower gear at high speed causes engine rpm to increase excessively poten tially 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 http www motorcycle in th 58 HOW TO RIDE THE MOTORCYCLE Vehicle speed when shifting Shf ngup kmh mph Shifting down kmn mph 3rd 4th 35 21 4th gt 3rd 20 12 4th 5th 45 27 3rd 2nd 15 9 5th 6th 55 34 2nd 4st 15 9 NOTE O The transmission is equipped with a positive neutral finder When the motorcycle is standing still the transmission cannot be shifted past neutral from 1st gear To use the positive neutral finder shift down to 1st gear then lift up on the shift pedal while standing still The transmission will shift only into neutral http www motorcycle in th Braking e Close the throttle completely leav ing the clutch engaged except when shifting gears so that the engine will help slow down the motorcycle e Shift down one gear at a time so that you are in 1st gear when you come to a complete stop e When stopping always apply both brakes at the same time Normally the front brake should be applied a lit tle more than the rear Shift down or fully disengage the clutch as neces sary to keep the eng
43. asaki Motors Corp U S A If you have a problem concerning warranty or service please take the following action Contact the owner and or service manager of your authorized Kawasaki dealer Fully explain your problem and ask for assistance in resolving the situation The OWNER of the dealership is concerned with your satisfaction and your future busi ness For this reason the owner is in the best position to assist you Also all warranty and service matters are handled and resolved through the authorized Kawasaki dealer network If you are unsatisfied after working with your Kawasaki dealer and feel you still re quire 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 To assist us in resolving http www motorcycle in th OWNER SATISFACTION 159 your inquiry please include copies of related receipts and any other pertinent infor mation including the names of the dealership personnel with whom you have been working in the resolution of your problem Upon receipt of your correspondence we will contact the dealership and work with them in resolving your problem In order to provide a permanent record all warranty and service resolutions take place only through written correspondence Please send yo
44. asaki dealer or possible recycling Remove the oil filter cartridge and re place it with a new one TK03 147H G A Cartridge http www motorcycle in th 94 MAINTENANCE AND ADJUSTMENT e Apply a thin film of oil to the packing and tighten the cartridge to the spec ified torque TK03071B G A Packing e Install the drain plug with its new gas ket Tighten it to the specified torque NOTE O Replace any gaskets with new ones e Fill the engine up to the upper level line with a good quality engine oil specified in the table e Start the engine e Check the oil level and oil leakage Tightening Torque Engine Oil Drain Plug 30 N m 3 0 22 ft lb Cartridge 17 5 1 75 kgf m 13 ft lb Recommended Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 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 http www motorcycle in th provide adequate lubrication for both the engine and the clutch Engine Oil Capacity Capacity 1 71 1 8 US qt when filter is not removed 1 9 L 2 0 US qt when filter is removed 2 4 L 2 5 US qt when engine is completely dry MAINTENANCE AND ADJUSTMENT 95 Although 10W 40 engine oil is the recommended oil for most condi tions the oil viscosity may need to be changed to accommodate atmo spheric conditions in you
45. ases to be discharged into the atmosphere For proper operation of the catalytic converter the following cautions must be observed A WARNING The muffler and exhaust pipe are very hot while the engine is running and just after the engine stop This can ignite a fire re sulting in property damage or severe personal injury Do not idle or park your vehi cle in an area where flammable materials such as grasses or dry leaves may contact with muffler or exhaust pipe http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 65 e Use only unleaded gasoline Never use leaded gasoline Leaded gaso line significantly reduces the capabil ity of the catalytic converter e Do not operate the vehicle with the engine or any one cylinder misfiring Under these conditions unburned air fuel mixture flowing out of engine excessively accelerates reaction in the converter allowing the converter to overheat and become damaged when the engine is hot or reduces converter performance when the en gine is cold http www motorcycle in th 66 SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation For safety eye protection and a helmet are strongly recommended You should be aware of and verify the applicable safety regulations in force prior to riding your motorcy cle Glove
46. cable 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 Envitonmental Protection Agency and California Air Resources Board 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 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 http www motorcycle in th 76 MAINTENANCE AND ADJUSTMENT 3 Evaporative Emission Control System California Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere Instead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and re
47. cal equipment lights Headlight Tail Brake Lights Turn Signal Lights Warning Indicator Lights and horn work http www motorcycle in th SAFE OPERATION 71 Engine stop switch Stops engine Side SLANG zoe Returns to its fully up position by spring tension Returns spring not weak or not damaged Refer to the Daily Safety Checks caution label attached to the Tool Kit U Shaped i Lock compartment http www motorcycle in th 72 Additional Considerations for Speed Operation Brakes The importance of the brakes especially during high speed operation cannot be overemphasized Check to see that they are correctly adjusted and func tioning properly Steering Looseness in the steering can cause loss of control Check to see that the handlebar turns freely but has no play Tires High speed operation is hard on tires and good tires are crucial for riding safety Examine their overall condition inflate them to the proper pressure and check the wheel balance Fuel Have sufficient fuel for the high fuel consumption during high speed oper ation Engine Oil To avoid engine seizure and resulting loss of control make sure that the oil level is at the upper level line Coolant To avoid overheating check that the coolant level is at the upper level line Electrical Equipment Make sure that the headlight tail brake light turn signals horn etc all work properly Miscellaneous
48. ck again at the tightest position and readjust if necessary e Install a new cotter pin through the rear axle nut and axle and spread its ends TK16069B22 A Cotter Pin MAINTENANCE AND ADJUSTMENT 117 NOTE O When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise up to the next alignment should be within 30 degree Loosen once and tighten again when the slot goes past the nearest hole 16030 22 A Turning Clockwise http www motorcycle in th 118 MAINTENANCE AND ADJUSTMENT A WARNING A loose axle nut can lead to an accident resulting in serious in jury or death Tighten the axle nut to the proper torque and in stall a new cotter pin e Check the rear brake see the Brakes section Wear Inspection e Remove the bolts and quick rivet to take off the chain cover 1612138 A Bolts B Quick Rivet C Chain Cover NOTE O The chain cover uses the quick rivet The quick rivet can be removed by pushing the central pin into the quick rivets and when installing it pull the central pin fully up first and then push into the central pin after insert ing it http www motorcycle in th MAINTENANCE AND ADJUSTMENT 119 Quick Rivet Removal Quick Rivet Installation TK230578 0 TK230568 6 A Quick Rivet A Quick Rivet B Center Pin B Center Pin C Push in C Pull u
49. d adjusted when your rid ing involves wide variations in tem perature or altitude TK21085B G A Tire Pressure Gauge Tire Air Pressure when cold 225 kPa 2 25 kgficm 32 psi 250 kPa 2 50 kgf cm 36 psi http www motorcycle in th MAINTENANCE AND ADJUSTMENT 135 Tire Wear Damage Minimum Tread Depth As the tire tread wears down the tire mm becomes more susceptible to puncture Front 0 04 in and failure An accepted estimate is Under 130 km h Rear 80 mph 0 08 in 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 In accordance with the Periodic Maintenance Chart measure the depth of the tread with a depth gauge and replace any tire that has worn down to the minimum al lowable tread depth Over 130 km h 3mm 80 mph 0 12 in P 210858 6 A Tire Depth Gauge e Visually inspect the tire for cracks and cuts replacing the tire in case of http www motorcycle in th 136 MAINTENANCE AND ADJUSTMENT bad damage Swelling or high spots A WARNING indicate internal damage requiring Tires that have been punctured Ire repacement and repaired do not have the Remove any imbedded stones or same capabilities other foreign particles from tread aged tires and can suddenly fail NOTE causing an accident resulting Have the wheel balance inspected
50. d in the Service Manual Keep this Owner s Manual aboard your motorcycle at all times so that you can refer to it whenever you need information http www motorcycle in th This manual should be considered permanent 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 illustra tions and text in this manual All products are subject to change without prior notice or obligation KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company 2009 Kawasaki Heavy Industries Ltd May 2009 1 CR Ke http www motorcycle in th TABLE OF CONTENTS SPECIFICATIONS 8 SERIAL NUMBER LOCATIONS 12 LOCATION OF PARTS 13 LOADING AND ACCESSORIES INFORMATION 16 GENERAL INFORMATION 19 Meter Instruments 19 Speedometer 20 Digital Meter 20 Warning Indicator Light 28 Hil M 29 Ignition Switch Steering Lock 30 Right Handlebar Switches 32 Engine Stop Switch
51. damage or an accident Always perform daily safety checks before oper ation 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 Fuel Adequate supply in tank no leaks Engine oil Oil level between level lines http www motorcycle in th 70 SAFE OPERATION TOS tsina Air pressure when cold Up to 180 kg 397 Ib Front cad 225 kPa 2 25 kgf cm 32 psi Lp fo 180 kg 397 250 kPa 2 50 kgf cm 36 psi Install the air valve cap Drive chain Slack 25 35 mm 1 0 1 4 in Lubricate the dive chain if dry Nuts bolts fasteners Check that steering and suspension components axles and all controls are properly tightened or fastened Steering Action smooth but not loose from lock to lock No binding of control cables Brakes Brake pad wear Lining thickness more than 1 mm 0 04 in left No brake fluid leakage Throttle Throttle grip play 2 3 mm 0 08 0 12 in Clutch Clutch lever play 2 3 mm 0 08 0 12 in Clutch lever operates smoothly Coolant No coolant leakage Coolant level between level lines when engine is cold Electri
52. ed use of the motorcycle Furthermore any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty not only because of their weight but Maximum Load also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation Poorly Weight of rider passenger baggage and accessories must not exceed 180 kg 397 Ib http www motorcycle in th GENERAL INFORMATION 19 GENERAL INFORMATION Meter Instruments A Left Turn Signal Indicator Light B Neutral Indicator Light C MODE Button D Speedometer E RESET Button F Right Turn Signal Indicator Light G Coolant Temperature Warning Light H Digital Meter I High Beam Indicator Light J Fl Indicator Light K Oil Pressure Warning Light http www motorcycle in th 1024398 O 20 GENERAL INFORMATION Speedometer The speedometer shows the speed of the vehicle When the ignition key is turned to the speedometer momentarily goes from the minimum to the maxi mum then goes back from the maxi mum to the minimum reading to check its operation If the speedometer does not operate correctly have it checked by an authorized Kawasaki dealer Digital Meter The digital meter displays the follow ing functions the tachometer gauge clock odometer trip meters A B fuel gauge Pushing the MODE button shifts the display in the digital me ter through the follo
53. ement Items ry 0 6 ir 15 22 5 30 K Rubber parts of master cylinder 4 years and caliper replace wee http www motorcycle in th 90 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 WARNING Motorcycle operation with insuf ficient deteriorated or contam inated engine oil will cause ac celerated wear and may result in engine or transmission seizure 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 min utes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil set tles NOTICE Racing the engine before the oil reaches every part can cause en gine seizure e f the motorcycle has just been used wait several minutes for all the oil to drain down http www motorcycle in th e Check the engine oil level through the oil level gauge With the motor cycle held level the oil level sho
54. en if the battery is disconnected Fuel Gauge The fuel in the fuel tank is shown by the number of segments displayed When the fuel tank is full all 6 seg ments are displayed If the fuel gauge is not correctly dis played have the fuel gauge checked by an authorized Kawasaki dealer A Fuel Gauge As the fuel level in the tank goes down the segments disappear one by one from F full to E empty When http www motorcycle in th only last 1 segment is displayed in the fuel gauge the fuel warning mes sage FUEL is displayed in the digi tal meter and FUEL and segment E flash This indicates that the remaining fuel in the tank is 3 7 L 3 9 US qt Refuelat the earliest opportunity if the fuel warn ing message FUEL is displayed in the digital meter When vehicle stands with Side Stand Fuel Gauge cannot show the amount of fuel in the fuel tank exactly Stand upright the vehicle to check the fuel level GENERAL INFORMATION 27 A FUEL Display B Segment E NOTE OWhen pushing the MODE button while FUEL is displayed the dis play can be shifted to odometer trip meter A B or clock mode http www motorcycle in th 28 GENERAL INFORMATION Warning Indicator Light N When the transmission is in neutral the neutral indicator light goes on so When the headlight is on high beam the high beam indicator light goes on 4 When the turn signal switch is p
55. en the left and right chain ad juster locknuts Remove the cotter pin and loosen the rear axle nut MAINTENANCE AND ADJUSTMENT 115 A Axle Nut B Cotter Pin C Adjusting Nut D Locknut e chain is too loose turn in the left and right chain adjusting nuts evenly e f the chain is too tight turn out the left and right chain adjusting nuts evenly e Turn both chain adjusting nuts evenly until the drive chain has the correct amount of slack http www motorcycle in th 116 MAINTENANCE AND ADJUSTMENT e o keep the chain and wheel prop erly aligned the left wheel alignment indicator should align with the same swingarm mark that the right indica tor aligns with TK16122B 6 A Marks B Indicator C Adjusting Nut D Locknut NOTE Wheel alignment can also be checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding con dition Align the rear wheel us ing the marks on the swingarm or measuring the distance be tween the center of the axle and swingarm pivot e Tighten both chain adjuster locknuts e Tighten the rear axle nut to the spec ified torque Tightening Torque Axle Nut 108 N m 11 kgf m 80 ft Ib http www motorcycle in Olf a torque wrench is not available this item should be serviced by a Kawasaki dealer e Rotate the wheel measure the chain sla
56. flame or sparks this includes any appliance with a pilot light inclined surface or the motorcy cle may fall over http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 63 A WARNING e Lock the steering to prevent theft Gasoline is extremely flammable NOTE and can be explosive under cer tain conditions creating the po O When stopping near traffic at night tential for serious burns Turn you can leave the taillight on for the ignition switch OFF Do greater visibility by turning the igni not smoke Make sure the area tion key to the P park position is well ventilated and free from O Do not leave the ignition switch at P any source of flame or sparks position too long or the battery will this includes any appliance with discharge 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 ex pand and overflow through the vents in the tank cap After re fueling make sure the tank cap is closed securely If gasoline is spilled on the fuel tank wipe it off immediately http www motorcycle in th 64 HOW TO RIDE THE MOTORCYCLE Catalytic Converter This motorcycle is equipped with a catalytic converter in the exhaust system Platinum and rhodium in the converter react with carbon monox ide hydrocarbons and nitrogen oxides to convert them into carbon dioxide water nitrogen and oxygen resulting in much cleaner exhaust g
57. fluid window cleaners thread locking agents or other harsh chemi cals If a plastic part comes in contact with any harsh chemical substance wash it off immedi ately with water and a mild neu tral detergent and then inspect for damage Avoid using abra sive pads or brushes to clean plastic parts as they will dam age the part s finish MAINTENANCE AND ADJUSTMENT 151 Chrome and Aluminum Chrome and uncoated aluminum parts can be treated with a chrome alu minum polish Coated aluminum should be washed with a mild neu tral detergent and finished with a 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 ac cessories 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 http www motorcycle in th 152 MAINTENANCE AND ADJUSTMENT The sidewalls of tires and other rub ber components should be treated with a rubber protectant to help prolong their useful life WARNING Rubber protectants can be slip pery and if used on the tread area cause loss of traction re sulting in accident causing in jury or death Do not apply rub ber protect
58. ght Side Cover http www motorcycle in th 100 MAINTENANCE AND ADJUSTMENT e Disconnect the turn signal light con e Install the cap nector e Connect the turn signal light connec e Remove the cap from the reserve tor tank and add coolant through the e Fitin the projections of the cover into filler opening to the F Full level line the holes of the frame side e Tighten the bolts A Reserve Tank B F Full Level Line A Right Side Cover C L Low Level Line B Projections D Cap C Holes http www motorcycle in th MAINTENANCE AND ADJUSTMENT 101 NOTE Coolant Change Oln an emergency you can wa Have the coolant changed by an au ter alone to the coolant reserve tank thorized Kawasaki dealer however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible NOTICE If coolant must be added of ten or the reserve tank com pletely runs dry there is proba bly leakage in the system Have the cooling system inspected by your authorized Kawasaki dealer http www motorcycle in th 102 MAINTENANCE AND ADJUSTMENT Spark Plugs The standard spark plug is shown in the table The spark plugs should be replaced in accordance with the Peri odic Maintenance Chart Spark plug removal should be done only by a competent mechanic follow ing the instructions in the Service Man ual Spark Plug Standard Plug NGK CR9EIA 9 A Plug Gap 0
59. in rpm 800 1 600 km 500 1 000 mi 6 000 r min rpm e Do not start moving or race the engine immediately after starting it even if the engine is already warm Run the engine for two or three minutes at idle speed to give the oil a chance to work up into all the engine parts e Do not race the engine while the transmission is in neutral http www motorcycle in th 50 BREAK IN 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 tire traction During break in avoid sudden and maximum braking and acceleration and hard cornering In addition to the above at 1 000 km 600 mi it is extremely important that the owner have the initial maintenance service performed by a competent mechanic following the instructions in the Service Manual http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 51 HOW TO RIDE THE MOTORCYCLE Starting the Engine e Check that the engine stop switch is inthe position e Turn the ignition key to ON e Make sure the transmission is in neu tral e After the meter operation check leaving throttle completely closed push the starter button TIQZTIOIR G Engine Stop Switch Starter Button Neutral Indicator Light Ignition Switch ON position moou http www motorcycle in th 52 HOW TO RIDE THE MOTORCYCLE NOTE O The motorcycle is equipped with a vehic
60. in order to maximize bat tery life and ensure that it will provide the power needed to start the motor cycle you must properly maintain the battery s charge When used regularly the charging system in the motorcycle helps keep the battery fully charged If your motorcycle is only used occasion ally or for short periods of time the bat tery is more likely to discharge Due to their internal composition batteries continually self discharge The discharge rate depends on the type of battery and ambient temper ature As temperature rises 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 Due to a combination of such key off draws and hot temperature a battery can go from fully charged to completely dis charged in a matter of days http www motorcycle in th MAINTENANCE AND ADJUSTMENT 139 Approx Number of Days Days from Days from From 10096 Charged to 100 100 100 discharged charged to charged to mpere E Temperature 50 100 pa Discharged Discharged Antimony Calcium 9 9 104 In extremely cold weather the fluid in an inadequately charged battery can easily freeze which can crack the case and buckle the plates A fully charged battery can withstand sub freezing temperature with no damage http www motorcycle in th
61. ine from stalling e Never lock the brakes or it will cause the tires to skid When turning a cor it is better not to brake at all Re duce your speed before you get into the corner HOW TO RIDE THE MOTORCYCLE 59 e For emergency braking disregard downshifting and concentrate on applying the brakes as hard as pos sible without skidding TiD6DB3B A Front Brake Lever http www motorcycle in th 60 HOW TO RIDE THE MOTORCYCLE Stopping the Engine e Close the throttle completely e Shift the transmission into neutral e Turn the ignition key to OFF e Support the motorcycle on a firm level surface with the side stand e Lock the steering NOTE O The motorcycle is equipped with a A Rear Brake Pedal vehicle down sensor which causes the engine to stop automatically and the fuel injection indicator light to flash when the motorcycle falls down After righting the motorcycle first turn the ignition key to OFF and then back to ON before starting the engine http www motorcycle in th Stopping Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to pro vide you optimum safety and conve nience However in order to fully ben efit from Kawasaki s safety engineering and craftsmanship it is essential that you the owner and operator properly maintain your motorcycle and become thoroughly familiar with its operation Improper maintenance can
62. ish 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 radiator from rust and corrosion the use of corrosion and rust inhibitor chemicals in the coolant is essential If coolant containing corrosion and rust inhibitor chemicals is not used over a MAINTENANCE AND ADJUSTMENT 97 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 cooling system WARNING Coolant containing corrosion in hitors for alminum engines and radiators include harmful chem icals 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 an tifreeze in the cooling system http www motorcycle in th 98 MAINTENANCE AND ADJUSTMENT NOTICE 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 en countered falls below the freezing point of water use permanent antifreeze in the coolant to protect the cooling sys tem against engine and radiator freeze Up as we
63. king SAFE OPERATION 67 In wet conditions rely more on the throttle to control vehicle speed and less on the front and rear brakes The throttle should also be used ju diciously to avoid skidding the rear wheel from too rapid acceleration or deceleration Riding at the proper rate of speed and avoiding unnecessarily fast ac celeration are important not only for safety and low fuel consumption but also for long vehicle life and quieter operation On rough roads exercise caution slow down and grip the fuel tank with the knees for better stability When quick acceleration is neces sary as in passing shift to a lower gear to obtain the necessary power http www motorcycle in th 68 Do not downshift at too high an Avoiding unnecessary weaving is r min rpm to avoid damage from important to the safety of both the overrevving to the engine rider and other motorists http www motorcycle in th 69 Daily Safety Checks Check the following items each day before you ride The time required is minimal and habitual performance of these checks will help ensure you a safe reliable ride If any irregularities are found during these checks refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor cycle to a safe operating condition WARNING Failure to perform these checks before operation may result in serious
64. l 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 element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not 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 http www motorcycle in th MAINTENANCE AND ADJUSTMENT 79 Periodic Maintenance Chart K Should be serviced by an authorized Kawasaki dealer For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping 1 Periodic Inspection Engine Related Items Frequency Whichever Odometer Reading km x 1 000 mile x 1 000 Operation 12 Engine Items 0 6
65. le down sensor which causes the engine to stop automatically and the Fi indicator light to flash when the motorcycle falls down After righting the motorcycle first turn the ignition key to OFF and then back to ON before starting the engine NOTICE Do not operate the starter con tinuously for more than 5 sec onds or the starter will overheat and the battery power will drop temporarily 15 seconds between each operation of the starter to let it cool and the bat tery power recover NOTE O The 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 However the engine can be started if the clutch lever is pulled and the side stand is fully up 1 TiDnz1D3B G A Clutch Lever B Starter Lockout Switch http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 53 NOTICE Jump Starting If your motorcycle battery is run E 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 Do not let the engine idle longer than five minutes or engine overheating and damage may occur http www motorcycle in th 54 HOW TO RIDE THE MOTORCYCLE DANGER Battery acid generates hydro gen gas which is flammable and explosive under certain con ditions It is present within a battery at all times e
66. lity or nonrecom mended fuel may not be covered under your warranty Fuels Containing Oxygenates Gasoline frequently contains oxy genates alcohols and ethers espe cially in areas of the U S and Canada http www motorcycle in th 40 GENERAL INFORMATION which are required to sell such refor mulated fuels as part of a strategy to reduce exhaust emissions The types and volume of fuel oxy genates approved for use in unleaded gasoline by the U S Environmental Protection Agency include a broad range of alcohols and ethers but only two components have seen any signif icant level of commercial use Gasoline Alcohol Blends Gasoline containing up to 10 ethanol alco hol produced from agricultural products such as corn also known as gasohol is approved for use NOTICE Avoid using blends of unleaded gasoline and methanol wood alcohol whenever possible and never use gasohol contain ing more than 5 methanol Fuel system damage and perfor mance problems may result Gasoline Ether Blends The most common ether is methyl tertiary butyl ether MTBE You may use gasoline containing up to 15 MTBE NOTE O Other oxygenates approved for use in unleaded gasoline include TAME up to 16 7 and ETBE up to 17 2 96 Fuel containing these oxy genates can also be used in your Kawasaki http www motorcycle in th Never use gasoline with an tane rating lower than the mini
67. ll as from rust and corrosion Use a permanent type of antifreeze soft water and ethylene glycol plus cor rosion and rust inhibitor chemicals for aluminum engines and radiators in the cooling system the mixture ratio of coolant choose the suitable one re ferring to the relation between freezing point and strength directed on the con tainer Permanent types of antifreeze the market have anti corrosion and anti rust properties When it is diluted excessively it loses its anti corrosion property Dilute a permanent type of antifreeze in accordance with the instructions of the manufacturer NOTE OA permanent type of antifreeze is in 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 31 F Coolant Level Inspection e Situate the motorcycle so that it is perpendicular to the ground http www motorcycle in th MAINTENANCE AND ADJUSTMENT 99 e Check the coolant level if it is be e f the amount of coolant is insuffi tween the F Full and L Low level cient remove the right side cover lines and add coolant into the reserve tank NOTE Check the level when the engine is Coolant Filling E cold room or atmospheric tempera Remove the right side cover by re ture moving the bolts A Right Side Cover B Bolts A F Full Level Line B L Low Level Line C Ri
68. may cause the fuel to expand and overflow through the vents in the tank cap After refueling make sure the fuel tank cap is closed securely If gasoline is spilled on the fuel tank wipe it off immediately NOTICE California models only Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand and flow into the Evaporative Emission Control System resulting in hard start ing and engine hesitation and in compliance with the emission regulation Fuel Requirement Fuel Type Use clean fresh unleaded gasoline with a minimum Antiknock Index of 87 The Antiknock Index is posted on ser vice station pumps The octane rating of a gasoline is a measure of its resis tance to detonation or knocking The Antiknock Index is an average of the Research Octane Number RON and http www motorcycle in th GENERAL INFORMATION 39 the Motor Octane Number MON as NOTICE shown in the table Minimum Octane Rating Method Rating If engine knocking or ping ing 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 Antiknock RON MON Index 2 Fuels of low quality or not meet ing standard industry specifi cations may result in unsatis factory performance Operating problems that result from the use of poor qua
69. p fully D Push in e Stretch the chain taut either by using the chain adjusters or by hanging a 10 kg 20 Ib weight on the chain e Measure the length of 20 links on the straight part of the chain from pin center of the 1st pin to pin center of the 21st pin Since the chain may http www motorcycle in th 120 MAINTENANCE AND ADJUSTMENT wear unevenly take measurements at several places e length exceeds the service limit the chain should be replaced A Measure B Weight Drive Chain 20 Link Length Service Limit 323 mm 12 7 in e When installing the chain cover in sert the projections of the chain cover into the holes A Projection B Hole C Chain Cover http www motorcycle in th MAINTENANCE AND ADJUSTMENT 121 A WARNING NOTE For safety use only the standard O Sprocket wear is exaggerated for il chain It is an endless type and lustration See Service Manual for should not be cut for installa wear limits tion have it installed by an au thorized Kawasaki dealer e Rotate the rear wheel to inspect the drive chain for damaged rollers and loose pins and links e Also inspect the sprockets for un evenly or excessively worn teeth and damaged teeth TKi16025B72 A Good Teeth B Worn Teeth C Damaged Teeth e f there is any irregularity have the drive chain and or the sprockets re placed by an authorized Kawasaki dealer http www motorcycle in th
70. pect the front brake light switch http www motorcycle in th 128 MAINTENANCE AND ADJUSTMENT e Check the operation of the rear brake Adjustment light switch by depressing the brake e o adjust the rear brake light switch pedal The brake light should go on move the switch up or down by turn after the proper pedal travel ing the switch body A Brake Pedal A Rear Brake Light Switch B Pedal Travel B Adjusting Nut C Lights sooner e f it does not adjust the rear brake D Lights later light switch Brake Pedal Travel 10 mm 0 4 in http www motorcycle in th MAINTENANCE AND ADJUSTMENT 129 NOTICE Front Fork The front fork operation and oil leak age should be checked in accordance with the Periodic Maintenance Chart To avoid damaging the electrical connections inside the switch be sure that the switch body does not turn during adjustment Front Fork Inspection Holding the brake lever pump the front fork up and down by several times for inspection of smooth stroke e Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tube http www motorcycle in th 130 MAINTENANCE AND ADJUSTMENT e f there is any doubt about the front fork it should be checked by an au thorized Kawasaki dealer A Inner Tube Rear Shock Absorbers The rear shock absorber operation and oil leakage should be checked in accordance with the Periodic Main
71. 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 stable idling cannot be obtained engine power is greatly reduced or there are abnormal engine noises Air suction valve removal and inspec tion should be done only by a compe tent mechanic following the instructions in the Service Manual http www motorcycle in th Valve Clearance Valve and valve seat wear decreases valve clearance upsetting valve timing NOTICE If valve clearance is left un adjusted wear will eventually cause the valves to remain partly open which lowers per formance burns the valves and valve seats and may cause seri ous engine damage Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Mainte nance Chart Inspection and adjustment should be done only by a competent mechanic MAINTENANCE AND ADJUSTMENT 105 following the instructions in the Service Manual http www motorcycle in th 106 MAINTENANCE AND ADJUSTMENT Air Cleaner A clogged air cleaner restricts the en gine s air intake increasing fuel con sumption reducing engine power and causing spark plug fouling The air cleaner element must be cleaned in accordance with the Pe riodic Maintenance Chart In dusty rainy or muddy conditions the air cleaner element
72. r proper disposal procedure http www motorcycle in th 162 LOCATION OF LABELS LOCATION OF LABELS 1 Fuel Level 2 Brake Fluid Front 3 Brake Fluid Rear Only on California model TEUQ24 7B fi http www motorcycle in th LOCATION OF LABELS 163 Tire and Load Data Important Drive Chain Information Vehicle Emission Control Information Daily Safety Checks Noise Emission Control Information Vacuum Hose Routing Diagram Only on California model COON OUD E TEO2484B http www motorcycle in th 164 LOCATION OF LABELS TEO2109B72 10 Weight and Manufacture 11 Battery Poison Danger http www motorcycle in th LOCATION OF LABELS 165 1 Only on California model 3 Never Till tank Fuel level rises into filler neck tank is over heal may cause wel to expand and iiad info 1 Emission Control System in hard slarting and engine hesilalion 26071 0158 TEO31420 2 WARNING USE ONLY DOT4 BRAKE FLUID FROM A SEALED CONTAINER CLEAN FILLER CAP BEFORE REM YING N UTILISER QUE DU FLUIDE DE FREIN B T4 TE03841BN9 TE03097B 5 http www motorcycle in th 166 LOCATION OF LABELS 4 5 TIRE AND LOAD DATA The stability and handling characteristics of this motorcycle could become unsafe by the use of improper tire inflation pressures overworn tires unsuitable
73. r riding area y SAE 108 40 30 40 70 86 104 TK03023BZ22 http www motorcycle in th 96 MAINTENANCE AND ADJUSTMENT Cooling System Radiator and Cooling Fan Using high pressure water as Check the radiator fins for obstruc from a car wash facility could tion by insects or mud Clean off damage the radiator fins and im any obstructions with a stream of pair the radiator s effectiveness low pressure water Do not obstruct or deflect air A WARNING Keep your hands and clothing flow through the radiator by installing unauthorized acces sories in front of the radiator or behind the cooling fan Inter ference with the radiator airflow can lead to overheating and con sequent engine damage away from the fan blades at all times 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 carry out the maintenance and adjust ments in accordance with the Periodic Maintenance Chart http www motorcycle in th Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level be comes low the engine overheats and may suffer severe damage Check the coolant level each day before riding the motorcycle and carry out the mainte nance and adjustments in accordance with the periodic maintenance chart Replen
74. rcycle in th 126 MAINTENANCE AND ADJUSTMENT NOTE O First tighten until slight resistance is felt which indicates 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 HI 0238 5 A Reservoir B Cap C Clockwise D 1 6 turn Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer Front and Rear Brakes Disc and disc pad wear is automat ically compensated for and has no ef fect on the brake lever or pedal action So there are no parts that require ad justment on the front brakes and rear brakes http www motorcycle in th A 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 au thorized Kawasaki dealer MAINTENANCE AND ADJUSTMENT 127 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 e Turn the ignition key to e he brake light should go on when the front brake is applied e f it does not ask your authorized Kawasaki dealer to ins
75. rts and accessories you add to your motorcycle be genuine Kawasaki components Because a motorcycle is sensitive to changes in weight and aerodynamic forces you must take extreme care in carrying cargo passengers and or in http www motorcycle in th LOADING AND ACCESSORIES INFORMATION 17 fitting additional accessories The fol lowing general guidelines have been prepared to assist you in making your determinations 1 Any passenger should be thor oughly familiar with motorcycle op eration The passenger can affect control of the motorcycle by im proper positioning during cornering and sudden movements It is impor tant that the passenger sit still while the motorcycle is in motion and not interfere with the operation of the motorcycle Do not carry animals on your motorcycle 2 You should instruct any passenger before riding to keep his 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 and footpegs are provided 3 All baggage should be carried as low as possible to reduce the effect on the motorcycle center of gravity Baggage weight should also be dis tributed equally on both sides of the motorcycle Avoid carrying baggage that extends beyond the rear of the motorcycle Baggage should be securely at tached Make sure that the baggage will not move around while you are riding Recheck baggage security
76. s and suitable footwear should also be used for added pro tection A motorcycle does not provide the impact protection of an auto mobile so defensive riding in addi tion to wearing protective apparel is extremely important Do not let protective apparel give you a false sense of security When riding always keep both hands on the handlebars and both feet on the footpegs Removing your hands from the handlebars or feet from the footpegs while riding can be hazardous If you remove even one hand or foot you can reduce your ability to control the motorcycle Before changing lanes look over your shoulder to make sure the way is clear Do not rely solely on the rear view mirror you may misjudge a vehicle s distance and speed or you may not see it at all http www motorcycle in th 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 roadway surfaces when the ability to maneu ver will be reduced When going up steep slopes shift to a lower gear so that there is plenty of power to spare rather than over loading the engine When applying the brakes use both the front and rear brakes Ap plying only one brake for sudden braking may cause the motorcycle to skid and lose control When going down long slopes control vehicle speed by closing the throttle Use the front and rear brakes for auxiliary bra
77. te nance Chart Rear Shock Absorber Inspection e Press down on the seat several times to check if the rear shock absorber stroke is smooth e Visually inspect the rear shock ab sorber for oil leakage http www motorcycle in th e f any doubt about the rear shock ab sorber it should be done by an au thorized Kawasaki dealer A Rear Shock Absorber The rear shock absorber can be ad justed by changing the spring preload and rebound damping force for various riding and loading conditions MAINTENANCE AND ADJUSTMENT 131 Spring Preload Adjustment The spring preload adjuster on the rear shock absorber has positions A Spring Preload Adjuster B Wrench e n accordance with the following ta ble turn the preload adjuster with the wrench from the tool kit Postion 1 2 5 4 5 7 http www motorcycle in th 132 MAINTENANCE AND ADJUSTMENT The standard setting position for an average build rider of 75 kg 165 Ib with no passenger and no accessories is No 4 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 TK21083B8 G A TUBELESS Mark http www motorcycle in th MAINTENANCE AND ADJUSTMENT 133 A WARNING Installing a tube inside a tube less type tire can create exces sive heat build up that can dam age the tube and ca
78. thods or possible recycling e Put in fresh engine oil e Empty the fuel from the fuel tank by the pump or siphon A WARNING Gasoline is extremely flammable and can be explosive under certain con ditions Turn the ignition key to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Gasoline is a toxic substance Dispose of gasoline properly Contact your local authorities for approved disposal methods http www motorcycle in th 156 STORAGE e Empty the fuel system by running engine at idle speed until the engine stalls If left in for a long time the fuel will break down and could clog the fuel system e Reduce tire pressure by about 2096 e Setthe motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards under the front and rear wheels to keep damp ness away from the tire rubber e Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes e Lubricate the drive chain and all the cables e Remove the battery and store it where it will not be exposed to direct sunlight moisture or freezing temperature During storage it should be given a slow charge one ampere or less about once a month Keep the battery well charged especially during cold weather e Tie plastic bags over the mufflers to prevent moist
79. tion key to ON O If you leave the P Park position for a long time one hour the battery may become totally discharged To operate the ignition Switch din ad N gt Turn the handlebar fully to the left 2 For parking push down the key in the position and turn it to P Park LOCK b For locking push down the key in the OFF position and turn it to LOCK m 7904001822 http www motorcycle in th 32 GENERAL INFORMATION Right Handlebar Switches NOTE Engine Stop Switch OAlthough the engine stop switch In addition to the ignition switch stops the engine it does not turn off the engine stop switch must be in all the electrical circuits Ordinarily the position for the motorcycle to the ignition switch should be used to operate stop the engine The engine stop switch is for emer gency use f some emergency re quires stopping the engine move the engine stop switch to the position TGDJO4 2B G A Engine Stop Switch B Starter Button http www motorcycle in th Starter Button The starter button operates the elec tric starter when the transmission is in neutral Refer to the Starting the Engine sec tion of the How to Ride the Motorcycle chapter for starting instructions GENERAL INFORMATION 33 Left Handlebar Switches Dimmer Switch High or low beam can be selected with the dimmer switch When the headlight is on high beam so
80. turned to the fuel tank High Altitude Performance Adjustment Information High Altitude adjustment is not required 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 items identified by the Periodic Mainte nance Chart are necessary to ensure compliance with the applicable standards As the owner of this motorcycle you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in 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 http www motorcycle in th MAINTENANCE AND ADJUSTMENT 77 You should keep a maintenance record for your motorcycle To assist you in keeping this record we have provided space on pages 173 through 177 of this manual where an authorized Kawasaki dealer or someone equally competent can record the maintenance You should also retain copies of maintenance work orders bills etc as verification of this maintenance http www motorcycle in th 78 MAINTENANCE AND ADJUSTMENT TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federa
81. uld come up between the upper and lower level lines next to the gauge Tko31448 6 Level Gauge B Upper Level Line C Lower Level Line D Oil Filler Cap MAINTENANCE AND ADJUSTMENT 91 e f the oil level is too high remove the excess oil through the oil filler open ing using a syringe or some other suitable device e f the oil level is too low add the oil to reach the correct level Use the same type and brand of oil that is already in the engine NOTICE If the engine oil gets extremely low or if the oil pump does not function properly or oil pas sages are clogged the warning light will light If this light stays on when the engine speed is slightly above the idle speed stop the engine immediately and find the cause http www motorcycle in th 92 MAINTENANCE AND ADJUSTMENT Oil and or Oil Filter Change e Warm up the engine thoroughly and then stop it e Place an oil pan beneath the engine e Remove the engine oil drain plug A Oil Pressure Warning Light TROJI JGH Gi A Drain Plug Let the oil completely drain with the motorcycle perpendicular to the ground http www motorcycle in th MAINTENANCE AND ADJUSTMENT 93 A WARNING NOTE Motor oil is a toxic substance Olf a torque wrench or required Dispose of used oil properly Kawasaki special tool is not avail Contact your local authorities able this item should be serviced by for approved disposal methods a Kaw
82. ur correspondence to CONSUMER RELATIONS KAWASAKI MOTORS CORP U S A P O Box 25252 SANTA ANA CA 92799 5252 949 460 5688 http www motorcycle in th 160 REPORTING SAFETY DEFECTS REPORTING SAFETY DEFECTS For Products Sold in the Continental United States of America Only If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Kawasaki Motors Corpora tion U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems be tween you your dealer or Kawasaki Motors Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S De partment of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline http www motorcycle in th ENVIRONMENTAL PROTECTION 161 ENVIRONMENTAL PROTECTION To protect our environment properly discard used batteries tires engine oil or other vehicle components that you might dispose of in the future Consult your authorized Kawasaki dealer or local environmental waste agency for thei
83. ure from entering e Put a cover over the motorcycle to keep dust and dirt from accumulating on it Preparation after Storage e Remove the plastic bags from the mufflers e Install the battery in the motorcycle and charge the battery if necessary e Fill the fuel tank with fuel e Check all the points listed in the Daily Safety Checks section e Lubricate the pivots bolts and nuts http www motorcycle in th TROUBLESHOOTING GUIDE 157 TROUBLESHOOTING GUIDE Engine Does Not Start e Incorrect spark plug gap Starter Motor Won t Turn e Incorrect valve clearance e Engine stop switch off e Battery discharged e Transmission not in neutral e No first turning the ignition key to e Fuse blown OFF when the motorcycle falls e Battery leads do not make good elec down trical contact with battery terminals e Battery discharged Engine Stalls IN Just When Shifting Into 1st Gear e Side stand has been left down Engine Cranks But Won t Start e Clutch does not properly disengage e No fuel in tank e Fuel line clogged While Riding e Fuel broken down e No fuel in tank e Engine flooded e Fuel tank air vent is obstructed e Spark plugs not in good contact e Overheating e Spark plugs fouled or wet e Battery discharged http www motorcycle in th 158 OWNER SATISFACTION OWNER SATISFACTION For Products Sold in the Continental United States of America Only Your satisfaction is important to your authorized Kawasaki dealer and to Kaw
84. use rapid deflation The tires rims and air valves on this motorcycle are designed only for tubeless type wheels The recommended stan SAVER S dard tires rims and air valves A TUBELESS Mark must be used for replacement Do not install tube type tires on tubeless rims The beads may not seat properly on the rim causing tire deflation Do not install a tube inside a tubeless tire Excessive heat build up may damage the tube causing tire deflation The tire and rim form a leakproof unit by making airtight contacts at the tire chamfers and the rim flanges instead of using an inner tube http www motorcycle in th 134 MAINTENANCE AND ADJUSTMENT 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 motorcy cle and can result in loss of control The maximum recommended load in addi tion to vehicle weight is 180 kg 397 Ib including rider passenger baggage and accessories e Remove the air valve cap e Check the tire pressure often using an accurate gauge e Make sure to install the air valve cap securely NOTE O Measure the tire pressure when the tires are cold that is when the mo torcycle 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 an
85. ushed to the left or right the cor responding turn signal indicator light flashes 3 The oil pressure warning light goes on whenever the oil pressure is dangerously low or the ignition key is in the ON position with the engine not running and goes off when the engine oil pressure is high enough Refer to the Maintenance and Adjustment chap ter for more detailed engine oil informa tion FI The fuel injection indicator light goes on when the ignition key is turned to ON and goes off soon after en suring that its circuit functions prop erly The indicator light also goes on whenever the troubles occur in digital fuel injection system DFI If the indica tor light goes on have the DFI system checked by an authorized Kawasaki dealer E The coolant temperature warning light goes on whenever the coolant temperature rises to 115 239 F when the motorcycle is in operation This warns the operator that the coolant temperature is too high If the warn ing light goes on stop the engine and check the coolant level in the reserve tank after the engine cools down http www motorcycle in th NOTICE Do not let the engine continue running when the warning light flashes Prolonged engine oper ation will result in severe dam age from overheating GENERAL INFORMATION 29 Key This motorcycle has a combination key which is used for the ignition switch steering lock seat lock and fuel tank cap Bl
86. ushes steel wool and all other abrasive pads or brushes e Use care when washing the wind shield headlight cover and other plastic parts as they can easily be scratched e Avoid using pressure washers wa ter can penetrate seals and electrical components and damage your mo torcycle e Avoid spraying water in delicate areas such as in air intakes fuel system brake components electri cal components muffler outlets and fuel tank openings MAINTENANCE AND ADJUSTMENT 149 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 a bucket Use a soft cloth or sponge to wash your motorcycle If needed use a mild de greaser to remove any oil or grease which build up e After washing rinse your motorcy cle thoroughly with clean water to re move any residue residue from the detergent can damage parts of your motorcycle e Use a soft cloth to dry your motorcy cle As you dry inspect your motor cycle for chips and scratches Do not let the water air dry as this can dam age the painted surfaces http www motorcycle in th 150 MAINTENANCE AND ADJUSTMENT e Start the engine and letit 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 the brakes dry
87. uster B Locknut C Clutch Cable NOTE O After the adjustment is made start the engine and check that the clutch does not slip and releases properly O For minor corrections use the ad juster at the clutch lever p www motorcycle in th 114 MAINTENANCE AND ADJUSTMENT Drive Chain The drive chain slack and lubrication must be checked each day before rid ing the motorcycle and must be main tained in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear lf the chain becomes badly worn or maladjusted either too loose or too tight the chain could jump off the sprockets or break WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjust ment before each ride Chain Slack Inspection e Set the motorcycle up on its side stand e Rotate the rear wheel to find the po sition where the chain is tightest and measure the maximum chain slack by pulling up and pushing down the chain midway between the engine sprocket and rear wheel sprocket TKi6043BZ22 A Chain Slack http www motorcycle in th e f the drive chain is too tight or too loose adjust it so that the chain slack Will be within the standard value Drive Chain Slack Standard 25 35 mm 1 0 1 4 in Adjustment Loos
88. ven in a discharged condition Keep all flames and sparks cigarettes away from the battery Wear eye protection when working with a battery In the event of battery acid contact with skin eyes or clothing wash the affected ar eas immediately with water for at least five minutes Seek medical attention Connecting Jumper Cables e Remove the seat e Make sure the ignition key is turned to OFF e Connect a jumper cable from the positive terminal of the booster battery to the positive terminal of the motorcycle battery A Motorcycle Battery Positive Terminal B From Booster Battery Positive Terminal C Footpeg D From Booster Battery Negative Terminal e Connect another jumper cable from the negative terminal of the http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 55 booster battery to your motorcy e Follow the standard engine starting cle footpeg or other unpainted metal procedure surface Do not use the negative terminal of the battery WARNING Batteries contain sulfuric acid that can cause burns and pro duce hydrogen gas which is highly explosive Do not make this last connection at the bat tery Take care not to touch the positive and negative cables to gether and do not lean over the battery when making this last connection Do not connect to a frozen battery It could explode Do not reverse polarity by con necting positive to negative
89. wing four modes clock odometer trip meter A trip me ter B When the ignition key is turned to the display action to display all LCD segments is done for three sec onds then depending on the mode selected the clock or meters operate normally http www motorcycle in th GENERAL INFORMATION 21 Digital Meter TGG2049B71 6 A Clock B Odometer C Trip Meter A D Trip Meter B E Push MODE Button A Fuel Gauge B Tachometer Gauge C Red Zone D Clock Trip Meter A B Odometer NOTE O Do not shift the digital meter display while riding for safe operation http www motorcycle in th 22 GENERAL INFORMATION Tachometer Gauge The tachometer shows the engine speed in revolutions per minute r min rpm On the right side of the tachome ter face is a portion called the red Engine r min rpm in the red zone is above maximum recom mended engine speed and is also above the range for good performance NOTICE Engine r min rpm should not be allowed to enter the red zone operation in the red zone will overstress the engine and may cause serious engine damage Clock To adjust the hours and minutes e Turn the ignition key to ON e Push the MODE button to display the clock e Push the RESET button for more than two seconds Both the hour and minute displays start flashing TG02420H G e Push the RESET button The hour display only flashes
90. y Throttle Grip Play 2 3 mm 0 08 0 12 in e f there is improper play adjust it Adjustment Loosen the locknut at the throttle grip and turn the adjuster until the proper amount of throttle grip play is obtained A Locknut B Adjuster C Throttle Cable Accelerator Cable http www motorcycle in th e f the throttle grip play cannot be ad justed with the accelerator cable ad juster at the throttle grip use the de celerator cable adjuster located un der the fuel tank e Turn outthe decelerator cable adjust ing nut until there is no play when the throttle grip is completely closed e Tighten the locknut TK110508 G A Adjuster B Locknut C Throttle Cable Decelerator Cable MAINTENANCE AND ADJUSTMENT 109 e Turn out the accelerator cable adjust ing nut until a play of 2 3 mm 0 08 0 12 in is obtained at the throttle grip e Tighten the locknut e With the engine idling turn the han dlebar to each side f handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or they may be damaged Be sure to correct any of these conditions before idling A WARNING Operation with an improperly adjusted 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 http www motorcycle in th 110 MAINTENANCE AND

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