90 & 100 Riders Handbook.indd
Contents
1. 70 9in 1 800mm 171mi gal 25mph 75km 1 40kph 4 speed constant mesh return shift return shift Wet multi plate 3 52 74 21 2 79 39 14 GA2 A 69mph 110kph 27 176mi gal 25mph 75km 1 40kph 5 speed constant mesh 2 54 36 14 Transmission Oil Frame cen d Brakes Front Diameter X Width Rear Diameter X Width Braking Distance Electrical Equipment Battery see Head Lamp nm Tail Brake Lamp Dimensions Overall Length Overall Width E Overall Height Wheelbase Ground Clearance Dry Weight Fuel Tank Capacity Oil Tank Capacity GA 1A SAE 20 30 motor oil 0 74qt GA2 A Tubular double cradle Telescopic fork Swinging arm 2 50 18 4PR 2 50 18 4PR 4 3X1 2in 110X30mm 4 3X1 2in 110X30mm 21 3ft 22mph 6 5m 35kph 6V 4AH 6V 25 25W 6V 5 3 17W 71 3in 1 810mm 29 1in 740mm 402in 1 020mm 45 5in 1 150mm 5 9in 150mm 174165 79kg 2 3 US gal 8 6liters 1 4 U S qt 1 2liters Specifications subject to change without notice 3 Stopping Distance and Passing time Information VEHICLE MINIMUM STOPPING DISTANCE ON DRY PAVEMENT This figure indicates braking performance that can be met or exceeded by the vehicles to which it applies without locking the wheels under different conditions of loading The inf2. Ground Clearance Dry Weight Width Rear Diameter X Width Braking Distance Electrical Equipment Battery eoi NOR Fuel Tank Capacity Oil Tank Capacity G3SS GA5 A SAE 20 30 motor oil 0 74qt Tubular double cradle Telescopic fork Swinging arm 2 75 18 4PR 2 50 18 4PR 2 75 18 4PR 2 75 18 4PR 4 3X1 2in 110X30mm 4 3X1 2in 110X30mm 21ft 22mph 6 5m 35kph 6V 4AH 6V 25 25W 6V 17 5 3W 72 0in 1 830mm 33 lin 840mm 40 5in 1 035mm 45 3in 1 150mm 6 5in 160mm 178lbs 81kg 174lbs 79kg 2 3 US gal 8 6liters 1 4 U S qt 1 2liters Specifications subject to change without notice Engine Type itcr Displacement Bore X Stroke Compression Ra tio PUG ocn Ignition Ignition Timing Starting Lubrication Engine Oil Carburetor Spark Plug Performance Max Torque Max Speed Climbing Ability Minimurn Turning Radius Fuel Consumption Transmission Primary Reduction Ratio Final Reduction Ratio GA 1A 2 stroke rotary valve single cylinder air cooled 5 43cu in 89cc 1 85X2 04in 47X51 8mm 7 0 1 Gasoline Fly wheel magneto 20 Before TDC Primary Kick Superlube Oil injection 2 stroke engine oil Mikuni VM19SC NGK B 7HZ 7 08ft Ib 0 98kg m 7 000rpm 62 5mph 100kph 29
3. Kawasaki 100 GAS A RIDER S HANDBOOK Col 22 Foreword We wish to thank you for your choosing this fine Kawasaki Motorcycle With the proper care and maintenance you will find your dynamic partner will go any time and anywhere Please read this handbook carcfully to obtain instuctions for proper use of your motorcycle so that you can always enjoy its best performance This handbook has been painstakingly reconstructed by D A S ENgineering of Sweden to exactly resemble the original The variations of fonts kerning and strange spacing are all fully intentional and follow the original design KAWASAKI HEAVY INDUSTRIES LTD Motorcycle Division Contents Foreword ectetuer este E iR ea 1 Illustration nicas 4 2 SpecifiCatloris eet eee sey een eee 6 3 Stopping Distance and Passing Time 10 Consumer Information 4 Breaking i eee ene denn 13 De GODLEOIS cinta eere tete fud ete tete etin 15 Fuel tania e ete edle 15 Starter Lever 15 Clutch Lever 16 Gear Change Pedal 16 Brakes pU es 17 6 Starting th Engine ee nete epp 18 eB ATKIN ciclo eir Arta 19 8 Maintenance and Adjustments 20 Electrical System eases ee 20 Carburetors naked isete 24 Control Cable ise ete eter 24 Brake moni reet e epe tn 26 PIPES ecce POI oe 27 Clutch age eee neret 28 Drive Chain 29 Air Cleaner 30 Muttler
4. and at every 2 000 miles 3 000 km after that Drain the oil when the engine is warm and refill with good quality SAE 200130 motor oil To fill the transmission remove the oil filler cap and fill until the oil level is between the two lines marked on the level gauge when the gauge is screwed in Do Not Race Engine Do not race the engine or run at high revs immediately after starting Over revving the engine in neutral can cause severe engine damage Do Not Overspeed Ride the motorcycle at 35 mph 55 kph or slower the first 300 mi 500 km Even after that do not strain the engine by running it at high speeds In particular be careful not to run the engine at high speeds with the gears in neutral as this overloads turning parts and can cause defective engine operation Do not brake the motorcycle suddenly do not strain the engine and do not slip the clutch half clutch Note Allow engine to warm up thoroughly at idling speed for 2 3 minutes before riding to let the oil reach the engine Starter Lever V Fig 5 Stop 5 Controls Fuel Tap Fuel tap lever position 0 is closed 1 is open and 2 opens a reserve supply of about I 8 US gal 0 5 liter Every 2 000 miles 3 000 km reove the bowl from the bottom of the fuel tap clean the fuel tap filter and flush the gas tank Starter Lever Use the starter lever when the engine is cold Push the lever all the way to the left to supply an extra
5. deposits are too heavy to remove in this manner burn the carbon off with a torch or by placing the baffle tube in a fire 31 32 9 Tool Kit D Tool Bag 17 X 19 mm Open End Wrench 10 X 14 mm Open End Wrench 5C N amp 10 X 13 mm Open End Wrench Screwdriver Grip p Combination Screwdriver 2 Phillips Screwsirver i O 3 Phillips Screwdriver Spark Plug Wrench QV QV y 3 1 5 4 1 2 10 Daily Checks Fig 35 Front Brake id With brake fully applied 2 2 inches 55 65 mm space left between brake lever and throttle grip Rear Brake avsa Sandsa Brake pedal play 1 1 2 inch 25 35 mm Buell Capacity 2 3 US gal 8 6 liters Oil Tank ss SALG Guns Capacity 1 3 US qt 1 2 liters Transmission Oil Capacity 0 74 qt 0 7 liters Front Tire Air pressure 22 Psi 1 55 kg cm2 Rear TITS ue eR Air pressure 28 Psi 1 97 kg cm2 Electrical Equipment Check to see that head lamp tail lamp brake lamp and horn work Chromium Plated Parts Wash clean and wipe with oily cloth to prevent rusting Clutchi soe mirare eren DIOS Clutch lever play 1 16 1 8 inch 2 3 mm 11 Periodical Inspection Chart 1 000 2 000 Every 2 000 1 600 3 3 000 Change Transmission Oil Clean Air Cleaner Tighten Cylinder Head Bolts Clean Spark Plug
6. Caution Improper adjustment can cause erratic gear shifting clutch slippage or incomplete disengagement cycle creeps forward while stopped Loosen the clutch release lever lock nut and back out the adjusting screw one or two turns to where the clutch lever turns freely Turn the clutch cable adjuster and set the release lever at an 80 angle with the cable Screw the clutch release lever adjusting screw back in until you feel pressure and lock it there Adjust the clutch hand lever with the cable adjuster for 1 16 to 1 8 inch 2 3 mm play before you start to feel clutch spring tension Use the small hand adjuster for minor corrections while riding Tighten all lock nuts Just under 1 inch zem n orque Yin er AF Fig 29 Drive Chain If the drive chain is not properly lubricated the links become stiff resulting in rapid wear of sprockets and drive chain or power loss as well as straining the engine Inspect and lubricate the chain periodically There should be about 20 mm play just under 1 inch measured midway between the sprockets when the rear wheel is turned arouned to where the chain is tightest To adjust chain tension first loosen axle axle sleeve and torque link nuts and then turn the chain adjusters Be sure the chain adjusters on each side are moved the same amount After chain adjustment check the rear brake and brake lamp adjust ments which are ch
7. Check Gap Check Ignition timing Inspect Drive Chain Check Adjust Brakes Tighten Nuts and Bolts Grease Motorcycle Clean Fuel Tap Strainer Check Battery Voltage OO00000 Replenish Battery Solution Remove Wheels Clean Brakes Clean Exhaust Pipe and Muffler Wash Lubricate Drive Chain Check Adiust Contact Points gt O O O e O O O O O Check Tighten Spokes 33 12 Wiring Diagram 90 G3SS Sprer BY TLL gt D oti iir LLLI Ferg Maition Switch Consecticns les far ba nooo owe wv m CAC o ow Note M battery overcharge when hend light it off du connect the LB 10 the magnet 9 and secsesect as thown by domed le to Ge Yellow Green wire en 34 90 GA1 A GA2 A mg rit Te 8 S Right Beas Turn Signal Lamp 6v sw AT wise gz Lamp ev SIW Lett Froen Turn Saat lang 6v 3w 35 European Model Ei ji i 36 ES KAWA SAK Part 99997 ex HEAVY INDUSTRIES LTD Printed in Japan MOTORCYCLE DIVISION July 1972 10 ITP
8. PASSING DISTANCE FEET TOTALPASSING TIME SECONDS TOTALPASSING TIME SECONDS N 100 md La CONSTANT 20 MPH m CONSTANT 50 MPH p 12 TRUCK TRUCK 4 Breaking In This Kawasaki motorcycle is precision manufactured but it must be broken in properly for the first 1 000 miles 1 600 km to ensure long and troublefree service life Superlube Oil Injection System Your Kawasaki is equipped with Superlube oil injection which elirninates the need to mix oil with the gas Check the level in the oil tank regularly Add one quart of oil when the level falls to the line on the tank guage Never let the tank run dry Do not disconnect the oil pipe to the engine as this may cause an air lock leading to engine damage Use any good quality two 2 cycle oil designated for use in motorcycles or air cooled engines Racing type oils are not required tor normal riding conditions Your dealer can recommennd oils most suitable and available in your area Avoid use of oils which do not flow readily at low tem peratures as these will not flow to the oil pump in the proper quantity in cold weather Do not attempt to adjust the oil pump yourselt When adjustment is required consult your Kawasaki dealer Fig 1 G3SS 13 14 Oil Level Li Fig 3 Adding and Changing Transmission Oil Check the oil level daily and never let it drop below the mark on oil level gauge dip stick Change the transmission oil at 500 miles 800 km
9. anged by chain adjustment Caution After adjustment be sure to tighten the axle nut axle sleeve nut torque link nut 29 30 Fig 31 e 1 5 1 2 Model Fig 32 Air Cleaner A clogged air cleaner restricts the engine s air intake decreasing gas mileage and engine power and causing the spark plug to foul The filter element must be cleaned at least every 2 000 miles 3 000 km In dusty areas the element should be cleaned every 500 miles 800 km or less After riding through rain or on muddy roads the element should be cleaned immediately To remove the G3SS GA5 A element for cleaning loosen the hose clamp and then unhook the body and pull out the element To remove the GA1 A GA2 A element for cleaning take out the four bolts and remove the cover then pull out the element Wash the element housing and felt pieces with gasoline or solvent and blow them dry After cleaning dampen it with a small amount of gasoline oil mixture about a 20 1 mixture of gasoline and SAE 30 motor oil Replace the element after 6 000 miles 10 000 km after cleaning it 5 times or if it is damaged Note When replacing the element make sure the sponge fits onto the frame well and there is no place for unfilted air to enter and wear down the engine Muffler Remove screw A and pull out the baffle tube B Clean it with a wire brush and by striking it gently and wash it with gasoline If the carbon
10. ear wheel and the green neutral lamp in the speedometer lights Gear sequence is as follows Neutral green lamp on first second third fourth fifth Brakes The motorcycle will stop smoothly and safely when both front and rear brakes are applied at the same time The rear brake operates when the brake pedal is pushed by the right foot The front brake operates when the brake lever on the handlebar is pulled in with the right hand 17 6 Starting the Engine Starting is by thc primary kick system so the engine can be started by pulling up the clutch lever and kicking the pedal regardless of gear position Cold Engine This Kawasaki motorcycle has carburetor starter system for easy starting even when cold 1 d O tao Open fuel cock If fuel does not flow to carburetor turn fuel cock lever to open reserve supply Push carburetor starter lever all the way to the Close throttle completely If the throttle is open even a little the carburetor starter systern will not work effectively and the engine will be hard to start Insert key in ignition switch and turn it on Squeeze the clutch lever Kick the starter pedal down smartly After the engine starts twist the throttle grip open just a little When engine speed increases indicating the engine has warmed up return the starter lever to its normal position If the starter lever is not returned to its normal position too rich a mix
11. haft The contact points should just begin to open when mark B on the outside of the flywheel coincides with mark on the crankcase 20 before top dead center Fig 14 0 024 in Spark Plug Use only a NGK B 7HZ spark plug or a plug of equivalent heat range and reach as the spark plug and its condition directly affect engine performance It is important that the spark plug be kept in good condition The spark plug electrodes are subjected to extremcly high temperatures and wear down necessitating periodic adjustment Check the plug gap frequently and set it to 0 024 0 6mm A spark plug with a gap too large or too small will cause hard start ing misfiring etc Clean the spark plug with a wire or brush and wash with gasoline if carbon accumulates on the spark plug electrodes Dry it completely and insert the spark plug by screwing it down hand tight then tightening it with a plug wrench Be sure to insert a spark plug gasket 21 22 Battery The battery is important as the electrical source for starting and electrical equipment If the battery is not given proper care it will not give satisfactory performance and its life will be short Be sure to give the battery frequent inspections and proper care at all times Keep the solution level above the lower line printed on the battery If the solution level is low add distilled water only up to the upper line Do not add diluted sulphuric acid Make sure the a
12. ir vent is kept open Do not spill the acid Keep the battery clean Completely charge the battery before installing it If the motorcycle is not ridden for more than one month charge the battery once a month Be sure the positive and negative terminals are connected to the correct wires Tighten terminal nuts and bolts firmly n for up down adjustment Leftr ight adjustment Fig 16 Head Lamp The 6V 25 25W head lamp is turned on when the ignition switch key is turned to position 2 for night riding The head lamp is dimmed with the dimmer switch mounted on the left handlebar Left or right adjustment is performed by turning the adjuster screw in the front of the headlight Adjust the beam lower or higher by first loosening the mount ing bolts on the sides of the headlight and moving the light by hand After adjustment is complete be sure to retighten the bolts 23 24 Fig 18 Carburetor The carburetor atomizes the gasoline mixes it with the proper amount of air and supplies it to the engine To achieve correct carburetor settings adjust it only when the engine is completely warmed up The standard setting of the pilot air screw is 1 turns backed out from full in Standard idle speed is 1 300 1 500 rpm To adjust idling speed turn the throttle stop screw out to increase speed and turn in it to decrease rpm As incorrect adjustment can cause serious problems it is best to have you
13. orniation presented represents results obtainable by skilled drivers under controlled road and vehicle conditions a nd the information may not be correct under other conditions Description of vehicles to which this table applies 90 Model G3SS Fully Operational Service Brake Load Light Maximum 0 50 100 150 200 250 Stopping Distance in Feet from 60 mph 10 ACCELERATION AND PASSING ABILITY THIS FIGURE INDICATES PASSING TIMES AND DISTANCES THAT CAN BE MET OR EXCEEDED BY THE VEHICLES TO WHICH IT APPLIES IN THE SITUATIONS DIAGRAMMED BELOW THE LOW SPEED PASS ASSUMES AN INITIAL SPEED OF 20 MPH AND A LIMITING SPEED OF 35 MPH THE HIGH SPEED PASS ASSUMES IN INITIAL SPEED OF 50 MPH AND A LIMITING SPEED OF 80 MPH THE INFORMATION PRESENTED REPRESENTS RESULTS OBTAINABLE BY SKILLED DRIVERS NOTICE UNDER CONTROLLED ROAD AND VEHICLE CONDITIONS AND THE INFORMATION MAY NOT BE CORRECT UNDER OTHER CONDITIONS DESCRIPTION OF VEHICLES TO WHICH THIS TABLE APPLIES Model G3SS SUMMARY TABLE G3SS LOW SPEED PASS 440 FEET 10 3 SECONDS HIGH SPEED PASS 1615 FEET 18 6 SECONDS 11 GRAPHIC DETERMINATION OF PASSING TIME AND DISTANCE LOW SPEED PASS HIGH SPEED PASS 1600 600 1200 D feet 400 D feet 800 200 400 0 9 6 12 18 T seconds T seconds LOW SPEED HIGH SPEED LMITINO SPEED LIMITING SPEED 40 INITIAL SPEEO 20 MPH INITIAL SPEED 50 MPH TOTALPASSING DISTANCE FEET TOTAL
14. osi cra 31 Tool Kit 32 I0 Daily Checks oerte EEE E 32 11 Periodical Inspection Chart sss 33 12 Wiring Diagram eiie Re n 34 90 G3SS 100 GA5 A 2 Specifications Engine Type Zoe ee eene Displacement Bore X Stroke Comprcssion Ra tio Buell Ignition Ignition Timing Starting Lubrication Engine Oil Carburetor Spark Plug Performance Max Torque Max Speed Climbing Ability Minimurn Turning Radius Fuel Consumption Transmission Clutch Primary Reduction Ratio Final Reduction Ratio G3SS 2 stroke rotary valve single cylinder air cooled 5 43cu in 89cc 1 85X2 04in 47X51 8mm 7 0 1 Gasoline Fly wheel magneto 20 Before TDC Primary Kick Superlube Oil injection 2 stroke engine oil Mikuni VM19SC NGK B 8HC 7 10ft Ib 0 98kg m 7 000rpm 70mph 113kph 27 71 0in 1 800mm 171mi gal 25mph 75km 1 40kph 5 speed constant mesh return shift Wet multi plate 3 52 74 21 2 64 37 14 GA5 A 6 04cu in 99cc 1 95X2 04in 49 5X51 8mm NGK B 8HC 7 95ft Ib 1 10kg m 7 000rpm 70mph 113kph 29 160mi gal 25mph 70km 1 40kph 2 57 36 14 Transmission Oil Frame Suspension Front A O Tire Size Front Brakes Front Diameter X Head Lamp Tail Brake Lamp Dimensions Overall Length Overall Width Overall Height Wheelbase
15. r Kawasaki Dealer perform any neccssary adjustment Control Cable The throttle cable must be synchronized with the oil pump cable so that the throttle valve of the carburetor opens in accordance with oil pump lever opening Do not adjust the throttle cable adjusters on the mixing chamber top alone because since the throttle cable must be synchronized with the oil pump cable whenever one cable is adjusted the other must be adjusted also to maintain the correct oil flow rate for each degree of throttle opening 1 SA AN Ze Note Fig 20 Adjust engine idling speed 1 300 1 500 rpm By turning adjusting bolt a on the control cable give enough play to the cable so that the throttle grip turns loose Take up all oil pump cable play by turning the oil pump cable adjuster f with the mark on the oil pump lever aligned to that on the stopper Eliminate throttle cable play by turning the cable adjuster d on the carburetor Be sure not to change the idling speed when adjusting the cable d c and e are the lock nuts of the adjusters After step 3 and step 4 check the control cable to see that both the throttle and the oil pump cables are pulled up simultaneously Finally adjust the control cable play by turning the adjusting bolt and taking up throttle grip play 25 26 Fig 21 Brakes Correct brake adjustment is most important for safe riding Always be sure to check the brakes befo
16. re riding Brake play increases gradually with wear so adjust it regularly Rear Brake Adjust brake pedal play to 1 1 inches 25 35 mm with the brake rod adjusting nut Check the brake lamp switch adjustment and adjust it if necessary Front Brake Using the adjusting nut on the front brake cable adjust the brake so that when it is fully applied there is 2 2 inches 55 65 mm space left between the throttle grip and the brake lever measured near the end of the lever Use the hand adjuster at the brake lever for minor adjustment later Tires Tire air pressure has a large effect on riding comfort safety handling and the life of the motorcycle and the tires Check the pressure before riding Standard air pressure for the front tire is 22 psi 1 6 kg cm and for the rear tire 28 psi 2 0 kg cm Insufficient tire pressure gives a soft ride but wears the side walls of the tires rapidly and sometimes the tire slips on the rim and tears out the inner tube valve stem Excessive tire pressure makes riding uncomfortable increases vibrations and wears the center of the tread rapidly An over inflated tire also tends to skid easily 27 28 Clutch Lever 1 16 1 8 inch 2 3mml Fig 27 Clutch The clutch friction plates wear and the clutch cable stretches over a long period of riding so it is necessary to adjust the clutch release mechanism and clutch cable every 2 000 milies 3 000km
17. rich fuel air mixture keep the throttle closed and kick the starter pedal through smartly Be sure to pull the starter lever back to the right to its normal positon after the engine warms up 15 16 Fig 6 Clutch Lever The clutch lever operates the clutch When the lever is pulled in engine power is not tramitted to the rear wheel When the lever is released power is supplicd to the rear wheel and the motorcycle moves Pull in the lever quickly and release it slowly Gear Change Pedal Transmission gears are changed by kicking up the gear change pedal GA1 A The 4 speed transmission is of rotary shift type so the gears are changed with eitlier the front or rear of the gear shift pedal Step on the front of the pedal to shift into a higher gear and on the rear of the pedal to shift into a lower gear When the grears are in neutral between low and top gear engine power cannot be transmitted to the rear wheel and the green neutral lamp in the speedometer lights Gear sequence is neutral green lamp on first second third fourth neutral green lamp on etc NN PV GSS Only Fig 8 GA2 A G3SS GA5 A The 5 speed transmission is a stopper type return change Neutral is located at the lowest position so the gears can be shifted up by lifting the pedal up with the toe and shifted down into a lower gear by stepping on the pedal When the gears are in neutral engine power cannot be transmitted to the r
18. ture is supplied to the engine causing fouled spark plug and defective engine operation Warm Engine Do not use the starter lever when the engine is warm or the engine may be flooded or the spark plug fouled 1 Open fuel cock Insert key in ignition switch and turn it on Squeeze the clutch lever Crack the throttle open a little about 0 4 turn nA Kick the starter pedal down smartly and the engine will start Note At night start the engine first and then turn on the head lamp after the engine is running 7 Parking Shift the gears into neutral and stop the engine Rest the i ie motorcycle on either the side stand or the main stand Close the gt eering Loc ey Pat 8 gt fuel cock Remove the key from the ignition switch Lock the steering lock 19 20 8 Maintenance and Adjustments Electrical System Adjusting Ignition Timing Rotate flywheel A until mark B on the outside of the flywheel coincides with mark C on the crankcase Loosen fitting screw D and move the contact breaker assembly to the right or left by turning a screwdriver in the slots on the contact breaker base F and on the contact breaker assembly G until the contact points are just about to open Tighten mounting screw D securely After adjusting turn the engine in the running direction with the ignition switch turned off by using the kick pedal or a wrench on the nut on the end of the cranks
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