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Kawasaki-Z800-Owners-Manual-Eng

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1. Note Keep this information and a spare key in a secure location Date Odometer Reading Maintenance Performed Dealer Name Dealer Address Kawasaki Z800 Owner s Manual http www motorcycle in th 158 MAINTENANCE RECORD j Date Odometer Reading Maintenance Performed Dealer Name Dealer Address Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE RECORD 159 j Date Odometer Reading Maintenance Performed Dealer Name Dealer Address Kawasaki Z800 Owner s Manual http www motorcycle in th 160 MAINTENANCE RECORD j Date Odometer Reading Maintenance Performed Dealer Name Dealer Address Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE RECORD 161 j Date Odometer Reading Maintenance Performed Dealer Name Dealer Address Kawasaki Z800 Owner s Manual http www motorcycle in th 162 MAINTENANCE RECORD j Date Odometer Reading Maintenance Performed Dealer Name Dealer Address Kawasaki Z800 Owner s Manual http www motorcycle in th Kawasaki Z800 Owner s Manual http www motorcycle in th
2. 11 Passenger 12 Baggage and Luggage 13 Accessories 13 Other Load 14 If You are Involved in an Accident 14 Safe Operation 15 Carbon Monoxide Hazard 15 Fueling 16 Never Ride with Drugs or Alcohol 16 Protective Gear and Clothing 16 Safe Riding Techniques 17 Additional Considerations for High Speed Operation 19 GENERAL INFORMATION 21 Specifications 21 Serial Number Locations 25 Location of Labels 26 Location of Parts 33 Meter Instruments 36 Tachometer 37 Multifunction Meter Right Side 39 Multifunction Meter Left Side 46 Indicator Lights 52 Warning Indicator Lights 53 Keys 56 Ignition Switch Steering Lock 59 Right Handlebar Switches 60 Left Handlebar Switches 61 Brake Lever Adjuster 62 Fuel Tank Cap 63 Fuel
3. 64 Fuel Requirements 64 Filling the Tank 66 Kawasaki Z800 Owner s Manual http www motorcycle in th Side Stand 68 Seats 69 Tying Hooks 72 Tool Kit 72 Rear View Mirror 73 Event Data Recorder 75 HOW TO RIDE THE MOTORCYCLE 76 Break In 76 Starting the Engine 77 Jump Starting 79 Moving Off 82 Shifting Gears 83 Braking 84 Anti lock Brake System ABS 85 Yellow ABS Indicator Light 87 Stopping the Engine 88 Stopping the Motorcycle in an Emergency 88 Parking 89 MAINTENANCE AND ADJUSTMENT 92 Daily Safety Checks 94 Periodic Maintenance 97 Engine Oil 102 Coolant 106 Air Cleaner 111 Throttle Control System
4. 112 Idle Speed 114 Clutch 115 Drive Chain 117 Brakes 121 Brake Light Switches 124 Suspension System 125 Front Fork 125 Rear Shock Absorber 127 Setting Tables 129 Wheels 132 Battery 135 Headlight 139 Fuses 141 General Lubrication 142 Cleaning Your Motorcycle 144 General Precautions 144 Washing Your Motorcycle 145 APPENDIX 150 Storage 150 Troubleshooting Guide 153 Kawasaki Z800 Owner s Manual http www motorcycle in th Owner Satisfaction 154 Environmental Protection 156 MAINTENANCE RECORD 157 Kawasaki Z800 Owner s Manual http www motorcycle in th 10 SAFETY INFORMATION j SAFETY INFORMATION Read Owner s Manual Read this Owner s Manual care fully before riding so that you will be thoroughl
5. Brake system 1 Brake fluid level 0 5 122 Brake fluid front and rear 2 Brake hose rubber parts of brake master cylinder and caliper 4 every 48 000 km 30 000 mile Brake pad wear C 123 Brake light switch operation 124 Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 101 j Odometer Reading B 1 000 km 1 000 mile Items year A 1 0 6 6 3 8 12 7 6 18 11 4 24 15 2 See Page Suspension system 1 Steering play 1 Steering stem bearings 2 Electrical system 1 Spark plugs Chassis parts 1 Condition of bolts nuts and fasteners Kawasaki Z800 Owner s Manual http www motorcycle in th 102 MAINTENANCE AND ADJUSTMENT j Engine Oil Oil Level Inspection If the engine is cold start the engine and run it for several minutes at idle speed Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches every part can cause en gine seizure Check the engine oil level through the oil level inspection window With the motorcycle held level the oil level should come up between the upper and lower level lines next to the oil level inspection window A Oil Level Inspection Window B Oil Filler Cap C Upper Level Line D Lower Level Line If the oil level is too high remove
6. Terminal Take the battery Clean the battery using a solution of baking soda and water Be sure that the cable connections are clean Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 139 j Battery Installation Run the cables outside the battery case and under the main harness A Cable with Red Cap B Cable C Projection D Battery Case E Main Harness Place the battery on the battery case Connect the cable to the ter minal and then connect the cable to the terminal NOTICE Installing the cable to the terminal of the battery or the cable to the terminal of the battery can seriously damaged the electrical system Put a light coat of grease on the ter minals to prevent corrosion Cover the terminal with the red cap Place the battery in the original place so that the battery fits to the projec tion on the battery case Install the removed parts Headlight Headlight aiming should be done by an authorized Kawasaki dearer Kawasaki Z800 Owner s Manual http www motorcycle in th 140 MAINTENANCE AND ADJUSTMENT j Horizontal Adjustment The headlight beam is adjustable horizontally If not properly adjusted horizontally the beam will point to one side rather than straight ahead Turn the horizontal adjuster in or out until the beam points straight ahead A Horizont
7. HOW TO RIDE THE MOTORCYCLE 81 j A Motorcycle Battery Positive Terminal B From Booster Battery Positive Terminal C Footpeg D From Booster Battery Negative Terminal Connect another jumper cable from the negative terminal of the booster battery to your motorcy cle footpeg or other unpainted metal surface Do not use the negative terminal of the battery DANGER 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 fuel system or battery Take care not to touch the positive and nega tive cables together and do not lean over the battery when mak ing this last connection Do not connect to a frozen battery It could explode Do not reverse polarity by connecting positive to negative or a battery explosion and serious damage to the electrical system may oc cur Follow the standard engine starting procedure Kawasaki Z800 Owner s Manual http www motorcycle in th 82 HOW TO RIDE THE MOTORCYCLE j 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 Wait 15 seconds between each operation of the starter to let it cool and the bat tery power recover After the engine has started discon nect the jumper cables Disconnect the negative cable from the mo torcyc
8. j Customer Relations Technical Service Department KAWASAKI MOTORS Pty Ltd Private Mail Bag 24 RYDALMERER N S W 2116 A C N 002 840 315 Environmental Protection To help preserve the environment properly discard used batteries tires oils and fluids or other vehicle components that you might dispose of in the future Con sult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure This also applies to disposal of the entire vehicle at the end of its life Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE RECORD 157 j MAINTENANCE RECORD Owner Name Address Phone Number Engine Number Vehicle Number Key Code Selling Dealer Name Phone Number Warranty Start Date
9. Ignition Cover C Hole D Bracket Insert the hooks on the ignition cover into the slots Install the ignition cover and install the bolts and plastic washers Kawasaki Z800 Owner s Manual http www motorcycle in th 110 MAINTENANCE AND ADJUSTMENT j A Bolts and Plastic Washers B Hooks Both Sides C Ignition Cover Coolant Change Have the coolant changed by an au thorized Kawasaki dealer Coolant Requirement WARNING Coolant containing corrosion in hibitors for aluminum engines and radiators include harm ful chemicals for human body Drinking coolant can result in serious injury or death Use coolant in accordance with the instructions of the manufacturer 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 On the mixture ratio of coolant choose the suitable one re ferring to the relation between freezing point and strength directed on the con tainer Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 111 j 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 NOTE A permanent type of antifreeze is in stalled in the cooling system when shipped It is mixed at 50 and has the freezing point of 35 C 31
10. Kawasaki dealer as soon as possible 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 riding condition Before you ride the motorcycle make sure it is not overloaded and that you have followed these instructions Maximum Load Weight of rider passenger baggage and accessories must not exceed 180 kg 397 lb 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 Kawasaki Z800 Owner s Manual http www motorcycle in th 12 SAFETY INFORMATION j or use of accessories or motorcycle modification will void the motorcycle warranty can negatively affect perfor mance stability and safety and can even be illegal In selecting and using accessories and in loading the motorcycle you are personally responsible for your own safety and the safety of other persons involved NOTE Kawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles We strongly recommend that all parts 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 fitting additional accessories The fol l
11. Odometer Trip Meter A Trip Meter B When the left button is pushed the display modes can be shifted as fol lows Odometer Trip meter A Trip me ter B Odometer NOTE When the battery is disconnected the multifunction display indicates the odometer Odometer The odometer shows the total dis tance in kilometers or miles that the ve hicle has run If the odometer is dis played the ODO is displayed on the multifunction display This meter can not be reset A Odometer B ODO Kawasaki Z800 Owner s Manual http www motorcycle in th 50 GENERAL INFORMATION j NOTE The data are maintained even if the battery is disconnected When the figures come to 999999 the display is stopped and locked Trip Meter A B The trip meter has two meters which distinguished between the TRIP A and TRIP B The trip meter shows the distance in kilometers or miles trav eled since it was last reset to zero TRIP A 0 0 9999 9 TRIP B 0 0 9999 9 A Trip Meter B TRIP A To reset the trip meter Push the left button to select the trip meter A or B Push the left button for more than 2 seconds The figure display turns to 0 0 and then starts counting when the vehicle is operated The meter counts until it is next reset NOTE The data is maintained even if the battery is disconnected When the trip meter reaches 9999 9 while riding the meter
12. The red warning indicator light and the immobilizer warning symbol blinks whenever the ignition switch is turned on or trouble occurs in the immobilizer system After turning the ignition switch on the immobilizer warning symbol goes off soon after it is ensured that its circuit is func tioning properly If the red warning indicator light and warning symbol blinks have the immo bilizer system checked by an autho rized Kawasaki dealer When the ignition switch is turned off the red warning indicator light will start blinking which indicates that the immo bilizer system is functioning After 24 hours have passed the red warning in dicator light will stop blinking however the immobilizer system is still function ing Red warning indicator light blinks Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 55 j if the improperly coded key is used or any incorrect communication between antenna and key is occurred How ever when the properly coded key can be used or the communication is clear the red warning indicator light does not blink NOTE The red warning indicator light blink ing mode can be set to either on or off Push and hold the left and right meter buttons simultaneously for more than 2 seconds within twenty seconds after turning the ignition switch to the OFF position then the red warning indicator light will not blink When the battery is connec
13. perature or altitude A Tire Pressure Gauge Tire Air Pressure when cold Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Tire Wear Damage As the tire tread wears down the tire becomes more susceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 10 of tread life 90 worn Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 133 j So it is false economy and unsafe to use the tires until they are bald Tire Wear Inspection Measure the depth of the tread with a depth gauge and replace any tire that has worn down to the minimum allowable tread depth A Tire Depth Gauge Minimum Tread Depth Front 1 mm 0 04 in Under 130 km h 80 mph 2 mm 0 08 in Rear Over 130 km h 80 mph 3 mm 0 12 in Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indicate internal damage requiring tire replacement Kawasaki Z800 Owner s Manual http www motorcycle in th 134 MAINTENANCE AND ADJUSTMENT j A Crack or Cur B Nail C Swelling or High spot D Stone Remove any imbedded stones or other foreign particles from the tread NOTE Have the wheel balance inspected whenever a new tire is installed WARNING Tires that have been punctured and repaired do not have the same capabilities as
14. death When adjusting the clutch cable be sure the upper end of the outer cable is fully seated in its fitting so that it doesn t slip into place later and create excessive cable play Tighten the locknut If it cannot be done adjustment of the clutch free play should be done by an authorized Kawasaki dealer NOTE After the adjustment is made start the engine and check that the clutch does not slip and that it releases properly Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 117 j Drive Chain Drive Chain Lubrication Lubrication is necessary after riding through rain or on wet roads or any time that the chain appears dry Use a lubricant for sealed chains to prevent deterioration of chain seals If the chain is especially dirty clean it using a cleaner for sealed chains fol lowing the instructions supplied by the chain cleaner manufacturer Apply lubricant to the sides of the rollers so that it will penetrate to the rollers and bushings Apply lubricant to the seals so that the seals will be coated with lubricant Wipe off any excess lubricant Wipe off any lubricant that gets on the tire surface Drive Chain Slack Inspection Set the motorcycle up on its side stand Clean the chain if it is dirty and lubri cate it if it appears dry Rotate the rear wheel to find the po sition where the chain is tightest and measure the maximum chain
15. flammable materials can cause a fire and can result in property damage or severe per sonal injury Do not idle or park your vehicle in an area where tall or dry veg etation or other flammable ma terials could come into contact with the muffler or exhaust pipe Kawasaki Z800 Owner s Manual http www motorcycle in th 90 HOW TO RIDE THE MOTORCYCLE j WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch a hot engine ex haust pipe or muffler during op eration or after stopping the en gine Shift the transmission into neutral and turn the ignition key to OFF Support the motorcycle on a firm level surface with the side stand NOTICE Do not park on a soft or steeply inclined surface or the motorcy cle may fall over If parking inside a garage or other structure be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks this includes any appliance with a pilot light WARNING Gasoline is extremely flammable and can be explosive under cer tain conditions creating the po tential for serious burns Turn the ignition switch 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 pi lot light Lock the steering to help prevent theft Kawasaki Z800 Owner s Manual http www motorcycl
16. http www motorcycle in th GENERAL INFORMATION 39 j Multifunction Meter Right Side A Economical Riding Indicator B Speedometer C Multifunction Display Current Mileage Average Mileage Cruising Range D Fuel Gauge Fuel Warning Symbol Kawasaki Z800 Owner s Manual http www motorcycle in th 40 GENERAL INFORMATION j Speedometer The speedometer shows the speed of the vehicle in digital values NOTE When the input value to the speedometer becomes less than 5 km h 4 mph the numerical value shows 0 Unit Setting The unit setting in the multifunction meter can be changed according to lo cal regulations Make sure the unit set ting is correctly displayed before riding A Meter Display Units NOTE Do not operate the motorcycle with wrong unit mph or km h of the speedometer To change the meter display units in the multifunction meter as follows Display the odometer in the multi function display Display current mileage or cruising range and push the left button while Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 41 j pushing the right button to select the meter display units The display units can be shifted in the following order NOTE The meter display units are main tained even if the battery is discon nected Multifunction Display The multifunction display indicates the following modes Current Mil
17. idle speed until the engine stalls If left in for a long time the fuel will break down and could clog the fuel system WARNING An air oil mist may be forcibly ejected from the spark plug holes and could get into your eyes Do not lean over the engine when performing this procedure If you do get oil in your eyes wash them immediately with liberal amounts of clean fresh water and consult a physician as soon as possible Reduce tire pressure by about 20 Set the motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards under the front and rear wheels to keep damp ness away from the tire rubber Kawasaki Z800 Owner s Manual http www motorcycle in th 152 APPENDIX j Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes Lubricate the drive chain and all the cables Remove the battery and store it where it will not be exposed to direct sunlight moisture or freezing temperatures During storage it should be given a slow charge one ampere or less about once a month Keep the battery well charged especially during cold weather Tie plastic bags over the muffler to prevent moisture from entering Put a cover over the motorcycle to keep dust and dirt from collecting on it Preparation after Storage Remove the plastic bags from the muffler Install the battery in the motorcycle and c
18. in the table Start the engine Check the oil level and oil leakage Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 105 j Tightening Torque Engine Oil Drain Plug 29 N m 3 0 kgf m 21 ft lb Cartridge 17 N m 1 7 kgf m 13 ft lb Recommended Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 rating Viscosity SAE10W 40 NOTE Do not add any chemical additive to the oil Oils fulfilling the above re quirements are fully formulated and provide adequate lubrication for both the engine and the clutch Engine Oil Capacity Capacity 3 1 L 3 3 US qt when filter is not removed 3 4 L 3 6 US qt when filter is removed Although 10W 40 engine oil is the recommended oil for most condi tions the oil viscosity may need to be changed to accommodate atmo spheric conditions in your riding area Kawasaki Z800 Owner s Manual http www motorcycle in th 106 MAINTENANCE AND ADJUSTMENT j Coolant Coolant Level Inspection Position the motorcycle so that it is perpendicular to the ground Check the coolant level through the coolant level gauge on the reserve tank located to the left of the engine The coolant level should be between the F Full and L Low level lines A F Full Level Line B L Low Level Line C Reserve Tank NOTE Check the level when the engine is cold room or atmospheric tempera tu
19. ken down instead of a broken in mo torcycle after a few thousand kilome ters The following rules should be ob served during the break in period The table shows maximum recom mended engine speed during the break in period Distance traveled Maximum engine speed 0 800 km 0 500 mi 4 000 r min rpm 800 1 600 km 500 1 000 mi 6 000 r min rpm NOTE When operating on public roadways keep maximum speed under traffic law limits Do not start moving or race the en gine immediately after starting it even if the engine is already warm Run the engine for two or three min utes at idle speed to give the oil a chance to work up into all the engine parts Kawasaki Z800 Owner s Manual http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 77 j Do not race the engine while the transmission is in neutral 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 estab lish normal tire traction During break in avoid sudden and max imum braking and acceleration and hard cornering In addition to the above at 1 000 km 600 mi it is extremely important that the owner has the initial mainte nance service performed by an autho rized Kawasaki dealer Starting the Engine Check that the engine stop switch is in the position A Engine Stop Switch B Starter Button Turn the ignition
20. key to ON position Make sure the transmission is in neu tral Kawasaki Z800 Owner s Manual http www motorcycle in th 78 HOW TO RIDE THE MOTORCYCLE j A Green Neutral Indicator Light B Ignition Switch C ON position NOTE The motorcycle is equipped with a vehicle down sensor which causes the engine to stop automatically if the motorcycle falls down The engine warning indicator light blinks when the starter button is pressed if the engine cannot be started After righting the motorcycle first turn the ignition key to OFF and then back to ON before starting the engine Without holding the throttle grip push the starter button to start 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 Wait 15 seconds between each operation of the starter to let it cool and the bat tery power recover NOTE 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 Kawasaki Z800 Owner s Manual http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 79 j the side stand is down However the engine can be started if the clutch lever is pulled and the side stand is fully up A Clutch Lever B Starter Lockout Switch NOTICE Do not let the engine idle longer than five minut
21. lens and other nonpainted plastic parts with an approved plastic cleaner polisher product Kawasaki Z800 Owner s Manual http www motorcycle in th 148 MAINTENANCE AND ADJUSTMENT j NOTICE Plastic parts may deteriorate and break if they come in con tact with chemical substances or household cleaning products such as gasoline brake 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 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 The sidewalls of tires and other rub ber components should be tr
22. light goes on have the DFI system checked by an au thorized Kawasaki dealer Red Warning Indicator Light This warning indicator light has the four warning functions coolant tem perature warning oil pressure warning immobilizer warning and battery charg ing system warning For more detailed information see appropriate sections in this chapter Coolant Temperature Warning Symbol The red warning indicator light and the coolant temperature warning symbol go on whenever the coolant temperature rises to about 115 C 239 F when the motorcycle is in op eration If they go on stop the engine and check the coolant level in the re serve tank after the engine cools down Have the cooling system checked by an authorized Kawasaki dealer Kawasaki Z800 Owner s Manual http www motorcycle in th 54 GENERAL INFORMATION j NOTICE Do not let the engine continue running when the coolant tem perature warning symbol goes on Prolonged engine operation will result in severe damage from overheating Oil Pressure Warning Symbol The red warning indicator light and the oil pressure warning symbol goes on whenever the oil pres sure is dangerously low or the ignition switch is in the ON position with the engine not running and go off when the engine oil pressure is high enough Refer to the MAINTENANCE AND AD JUSTMENT chapter for more detailed engine oil information Immobilizer Warning Symbol
23. maximum rec ommended 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 A Tachometer B Red Zone When the ignition switch is turned on the tachometer bar s momentar ily go from the minimum to the maxi mum then go back from the maximum to the minimum reading to check its op eration If the tachometer does not op erate correctly have it checked by an authorized Kawasaki dealer Kawasaki Z800 Owner s Manual http www motorcycle in th 38 GENERAL INFORMATION j Display Pattern Setting The tachometer display can be changed as follows Push the left and right buttons for more than 2 seconds The tachome ter will sweep in the current display pattern Pushing the left button changes the display pattern as follows A Zone Display Black B Bar Display C Zone Display White Hold the left and right buttons for more than 2 seconds to set the dis play NOTE The tachometer display pattern can not be changed while the input value to the speedometer is more than 5 km h 4 mph When the input value to the speedometer becomes more than 5 km h 4 mph while changing the tachometer display pattern the pat tern at the time is set and the meter returns to the normal operation Kawasaki Z800 Owner s Manual
24. pletely to the top If the tank is filled completely to the top heat may cause the fuel to expand and overflow through the vents in the tank cap After refueling make sure the tank cap is closed securely If gasoline is spilled on the fuel tank wipe it off immedi ately Kawasaki Z800 Owner s Manual http www motorcycle in th 68 GENERAL INFORMATION j NOTICE Certain ingredients of gasoline may cause paint fading or dam age Be extra careful not to spill gasoline or gasoline oxygenates blends during refueling Side Stand The motorcycle is equipped with the side stand A Side Stand NOTE When using the side stand turn the handlebar to the left Do not sit on the motorcycle while it is on its side stand Always kick the stand fully up before sitting on the motorcycle Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 69 j NOTE 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 Seats Passenger s Seat Removal Insert the ignition key into the seat lock Pull up the front of passenger s seat while turning the key clockwise Remove the passenger s seat for ward A Ignition Key B Seat Lock C Passenger s Seat Rider s Seat Removal Remove the passenger s seat see the Passenger s Seat Removal in this secti
25. position A Ignition Switch Steering Lock B ON position C OFF position D LOCK position E position OFF Engine off Electrical circuits off ON Engine on All electrical equipment can be used LOCK Steering locked Engine off Electrical circuits off Steering locked Engine off Turn signals can be used Other electrical circuits off NOTE The tail and license plate lights are on whenever the ignition key is in the ON position Headlights go on when the starter button is released after starting the engine To avoid battery discharge always start the engine immediately after turning the ignition key to ON If you leave the ON position on for a long time the battery may become totally discharged Kawasaki Z800 Owner s Manual http www motorcycle in th 60 GENERAL INFORMATION j Right Handlebar Switches A Engine Stop Switch B Starter Button Engine Stop Switch In addition to the ignition switch the engine stop switch must be in the position for the motorcycle to operate The engine stop switch is for emer gency use If required move the switch to the position Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 61 j NOTE Although the engine stop switch stops the engine it does not turn off all the electrical circuits Ordinarily the ignition switch should be used to stop the engine Starter Button The starter button ope
26. rpm A Idle Adjusting Screw Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 115 j Open and close the throttle a few times to make sure that the idle speed does not change Readjust if necessary With the engine idling turn the han dlebar to each side If handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or they may be damaged Be sure to correct any of these conditions before riding WARNING Operation with damaged cables could result in an unsafe riding condition Replace damaged control cables before operation Clutch Clutch Operation Inspection Check that the clutch lever operates properly and that the inner cable slides smoothly If there is any irreg ularity have the clutch cable checked by an authorized Kawasaki dealer Check the clutch lever play Clutch Lever Play 2 3 mm 0 08 0 12 in Kawasaki Z800 Owner s Manual http www motorcycle in th 116 MAINTENANCE AND ADJUSTMENT j A Adjuster B Stopper C Clutch Lever Play If the play is incorrect adjust the lever play as follows Clutch Cable Free Play Adjustment Loosen the locknut at the clutch lever Turn the adjuster so that the clutch lever will have the specified free play WARNING Excess clutch cable play could prevent clutch disengagement and cause a crash resulting in serious injury or
27. s Manual http www motorcycle in th 16 SAFETY INFORMATION j Fueling WARNING Gasoline is extremely flammable and can be explosive under cer tain conditions To avoid a possible fire or explo sion turn the ignition switch to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appli ance with a pilot light Never Ride with Drugs or Alcohol Alcohol and drugs impair your judg ment and reaction time Never con sume alcohol or drugs before or while riding motorcycles Protective Gear and Clothing Helmet Kawasaki strongly recommends both the operator and passenger wear a hel met even if this is not a legal require ment Make sure that your helmet fits cor rectly and is properly fastened Choose a motorcycle helmet that meets the safety standards appli cable to your country Ask your motorcycle dealer to advise you if necessary Kawasaki Z800 Owner s Manual http www motorcycle in th SAFETY INFORMATION 17 j Eye Protection Always use eye protection If your helmet does not have a visor installed wear goggles Gloves Wear gloves which have suitable protection for your hands especially against abrasion Clothing Wear protective clothing Wear bright highly visible clothing that allows freedom of movement to suit your riding style Always wear a long sleeved jacket and long trousers which are abra sion resis
28. safety of both the rider and other motorists Additional Considerations for High Speed Operation WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds Do not attempt high speed oper ation unless you have received sufficient training and have the required skills Do not operate at high speeds on public roads Kawasaki Z800 Owner s Manual http www motorcycle in th 20 SAFETY INFORMATION j Brakes The importance of the brakes es pecially during high speed operation cannot be overemphasized Check to see that they are correctly adjusted and functioning properly Steering Looseness in the steering can cause loss of control Check to see that the handlebar turns freely but has no play Tires High speed operation is hard on tires and good tires are crucial for safe rid ing Examine their overall condition in flate them to the proper pressure and check the wheel balance Fuel Have sufficient fuel for the high fuel consumption during high speed opera tion Engine Oil To avoid engine seizure and resulting loss of control make sure that the oil level is at the upper level line Coolant To avoid overheating check that the coolant level is at the upper level line Electrical Equipment Make sure that the headlight tail brake light turn signals horn etc all work properly Miscellaneous Make sure that all nuts an
29. that you are about to pass The passing light is shut off as soon as the button is released Brake Lever Adjuster There is an adjuster on the brake lever The adjuster has 5 positions so that the released lever position can be adjusted to suit the operator s hands Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 63 j Push the lever forward and turn the ad juster to align the number with the mark on the lever holder The distance from the grip to the released lever is min imum 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 clockwise To close the cap push it down into place with the key inserted The key can be removed by turning coun terclockwise to the original position Close the key hole cover NOTE The fuel tank cap cannot be closed without the key inserted and the key cannot be removed unless the cap is locked properly Do not push on the key to close the cap or the cap cannot be locked Kawasaki Z800 Owner s Manual http www motorcycle in th 64 GENERAL INFORMATION j A Key Hole Cover B Ignition Key C Fuel Tank Cap Fuel Fuel Requirements Your Kawasaki engine is designed to use only unleaded gasoline with a minimum octane rating shown below Never use gasoline with an octane rat ing lower than th
30. 00 Owner s Manual http www motorcycle in th 66 GENERAL INFORMATION j For Brazil Specification Use clean fresh unleaded gasoline with an Antiknock Index equal to or higher than that shown in the table The Antiknock Index is posted on ser vice station pumps The Antiknock In dex is an average of the Research Oc tane Number RON and the Motor Oc tane Number MON as shown in the table Fuel Type Unleaded Gasoline Ethanol Content E25 RON MON Antiknock Index 2 Minimum Octane Rating 90 NOTICE Do not use any fuel that con tains more ethanol or other oxy genates than specified for E25 fuel in this vehicle Damage to the engine and fuel system or engine starting and or per formance problems may result from the use of improper fuel E25 means fuel containing up to 25 ethanol Filling the Tank Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 67 j A Tank Cap B Fuel Tank C Top Level D Filler Neck WARNING Gasoline is extremely flammable and can be explosive under cer tain conditions creating the po tential for serious burns Turn the ignition switch off Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pi lot light Never fill the tank com
31. ABS automatically regu lates brake force Intermittently gaining gripping force and braking force helps prevent wheel lock up and allows sta ble steering control while stopping Brake control function is identical to that of a conventional motorcycle The brake lever is used for the front brake and the brake pedal for the rear brake Although the ABS provides stability while stopping by preventing wheel lock up remember the following char acteristics To apply the brake effectively use the front brake lever and rear brake pedal simultaneously in the same manner as conventional motorcycle brake system ABS cannot compensate for adverse road conditions misjudgment or im proper application of brakes You must take the same care as with mo torcycles not equipped with ABS ABS is not designed to shorten the braking distance On loose uneven or downhill surfaces the stopping Kawasaki Z800 Owner s Manual http www motorcycle in th 86 HOW TO RIDE THE MOTORCYCLE j distance of a motorcycle with ABS may be longer than that of an equiv alent motorcycle without ABS Use special caution in such areas ABS will help prevent wheel lock up when braking in a straight line but it cannot control wheel slip which may be caused by braking during corner ing When turning a corner it is bet ter to limit braking to the light appli cation of both brakes or not to brake at all Reduce your speed before you get into
32. 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 fuse boxes and main fuse A Normal B Failed General Lubrication Lubricate the points shown below with either engine oil or regular grease in accordance with the Periodic Main tenance Chart or whenever the vehicle has been operated under wet or rainy conditions Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 143 j Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime Apply engine oil to the following pivots Side Stand Clutch Lever Front Brake Lever Rear Brake Pedal Lubricate the following cables with a pressure cable luber K Clutch Inner Cable K Throttle Inner Cables Apply grease to the following points K Clutch Inner Cable Upper End K Throttle Inner Cable Upper Ends K Should be serviced by an authorized Kawasaki dealer NOTE After connecting the cables adjust them Kawasaki Z800 Owner s Manual http www motorcycle in th 144 MAINTENANCE AND ADJUSTMENT j 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 motorc
33. E 10W 40 Capacity 3 8 L 4 0 US qt Coolant Capacity 2 8 L 3 0 US qt Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 23 j TRANSMISSION Transmission Type 6 speed return shift Clutch Type Wet multi disc Driving System Chain drive Primary Reduction Ratio 1 714 84 49 Final Reduction Ratio 3 000 45 15 Overall Drive Ratio 5 633 Top gear Gear Ratio 1st 2 571 36 14 2nd 1 941 33 17 3rd 1 556 28 18 4th 1 333 28 21 5th 1 200 24 20 6th 1 095 23 21 FRAME Castor 24 Trail 98 mm 3 9 in Kawasaki Z800 Owner s Manual http www motorcycle in th 24 GENERAL INFORMATION j Tire Size Front 120 70ZR17 M C 58W Rear 180 55ZR17 M C 73W Rim Size Front J17M C MT3 50 Rear J17M C MT5 50 Fuel Tank Capacity 17 L 4 5 US gal Brake Fluid DOT4 ELECTRICAL EQUIPMENT Battery 12 V 8 Ah Headlight High Beam 12 V 55 W 2 Low Beam 12 V 55 W Tail Brake Light LED Even if one of LED Light Emitting Diode tail brake light does not go on consult with an authorized Kawasaki dealer Specifications are subject to change without notice and may not apply to every country Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 25 j Serial Number Locations The engine and frame serial numbers are used to register the motorcycle They are the only means of identifying yo
34. F Air Cleaner This motorcycle s air cleaner element consists of a dry paper filter Cleaning and replacement of the air cleaner ele ment should be done by an authorized Kawasaki dealer Oil Draining Inspect the transparent drain hose lo cated under the left side of the engine to see if any oil has run down A Drain Hose B Plug If there is any oil in the hose remove the plug from the lower end of the drain hose and drain the oil Kawasaki Z800 Owner s Manual http www motorcycle in th 112 MAINTENANCE AND ADJUSTMENT j WARNING Oil 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 Throttle Control System Throttle Grip Throttle Grip Free Play Inspection Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely by the return spring in all steering positions If the throttle grip does not return properly have the throttle control system checked by an authorized Kawasaki dealer Check the throttle grip free play by turning back and forth A Throttle Grip B Throttle Grip Play Throttle Grip Play 2 3 mm 0 08 0 12 in If there is improper play adjust it Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 113 j Throttle Grip Free Play Adjustment Loosen the locknuts at
35. Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area WARNING The cooling fan spins at high speed and can cause serious injuries Keep your hands and clothing away from the cooling fan blades at all times NOTE If a torque wrench is not available the maintenance items which require a specific torque value should be serviced by an authorized Kawasaki dealer Kawasaki Z800 Owner s Manual http www motorcycle in th 94 MAINTENANCE AND ADJUSTMENT j 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 motorcycle to a safe operating condition Operation See Page Fuel Adequate supply in tank no leaks Engine Oil Oil level between level lines 102 Tires Air pressure when cold install the air valve cap 132 Tire Wear 133 Drive Chain Slack 117 Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 95 j Operation See Page Lubricate if dry 117 Bolt nuts and fasteners Check for loose and or missing bolts nuts and fasteners Steering Action smooth but not loose f
36. Kawasaki Z800 Owner s Manual http www motorcycle in th Quick Reference Guide SAFETY INFORMATION j GENERAL INFORMATION j HOW TO RIDE THE MOTORCYCLE j MAINTENANCE AND ADJUSTMENT j APPENDIX j MAINTENANCE RECORD j This Quick Reference Guide will assist you in finding the information you re looking for A Table of Contents is included after the Foreword Kawasaki Z800 Owner s Manual http www motorcycle in th Whenever you see the symbols shown below heed their instructions Always follow safe operating and main tenance practices DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious in jury WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE NOTICE is used to address prac tices not related to personal in jury NOTE This note symbol indicates points of particular interest for more efficient and convenient operation Kawasaki Z800 Owner s Manual http www motorcycle in th NOTICE THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OP ERATOR AND AS A VEHICLE ONLY Kawasaki Z800 Owner s Manual 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 s
37. NFORMATION j 5 Unleaded Gasoline 6 Tire and Load Data 7 Important Drive Chain Information 8 Radiator Cap Danger Only on Australian model Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 29 j 9 Daily Safety Checks 10 Stationary Noise Test Information Only on Australian model Kawasaki Z800 Owner s Manual http www motorcycle in th 30 GENERAL INFORMATION j 1 2 3 4 Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 31 j 5 6 7 8 Kawasaki Z800 Owner s Manual http www motorcycle in th 32 GENERAL INFORMATION j 9 10 only on Australia model Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 33 j Location of Parts 1 Rear View Mirrors 2 Clutch Lever 3 Left Handlebar Switches 4 Meter Instruments 5 Brake Fluid Reservoir Front 6 Right Handlebar Switches 7 Front Brake Lever 8 Spring Preload Adjusters 9 Ignition Switch Steering Lock 10 Rebound Damping Force Adjuster Front Fork 11 Throttle Grip Kawasaki Z800 Owner s Manual http www motorcycle in th 34 GENERAL INFORMATION j 1 Headlight 2 Turn Signal Lights 3 Spark Plugs 4 Air Cleaner 5 Fuel Tank 6 Fuse Box 7 Rider s Seat 8 Passenger s Seat 9 Tail Brake Light 10 License Plate Light 11 Seat Lock 12 Brake Disc 13 Front Fork 14 Brake Caliper 15 Idle Adju
38. Spring Preload Adjustment The adjuster is located at the top of each front fork leg Standard 9 mm 0 4 in From the top of the adjuster Turn the spring preload adjuster into the nut to increase spring force and out to decrease spring force The adjusting range stretches 4 19 mm 0 2 0 7 in from the top of the adjuster A Spring Preload Adjuster B Adjuster Position Rebound Damping Force Adjustment The adjuster is located at the top of right front fork leg Standard 12 clicks Out from the fully seated position turned fully clockwise Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 127 j Turn the adjuster clockwise with a screwdriver to increase damping force Turn the adjuster counterclockwise to decrease damping force NOTICE Do not turn the adjuster beyond the fully seated position or the adjusting mechanism may be damaged A Rebound Damping Force Adjuster B Screwdriver Rear Shock Absorber Spring Preload Adjustment The spring adjusting nut on the rear shock absorber can be adjusted If the spring action feels too soft or too stiff have it adjusted by an authorized Kawasaki dealer Kawasaki Z800 Owner s Manual http www motorcycle in th 128 MAINTENANCE AND ADJUSTMENT j Rebound Damping Force Adjustment The adjuster is located at the lower end of the rear shock absorber A Rebound Damping Force Adjuster B To inc
39. a ter can penetrate seals and electrical components and damage your mo torcycle Avoid spraying water in delicate areas such as in air intakes fuel system brake components electri cal components muffler outlets and fuel tank openings Washing Your Motorcycle Rinse your bike with cold water from a garden hose to remove any loose dirt 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 build up After washing rinse your motorcy cle thoroughly with clean water to re move any residue residue from the detergent can damage parts of your motorcycle Kawasaki Z800 Owner s Manual http www motorcycle in th 146 MAINTENANCE AND ADJUSTMENT j 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 Start the engine and let it idle for sev eral minutes The heat from the en gine will help dry moist areas Carefully ride your motorcycle at a slow speed and apply the brakes several times This helps dry the brakes and restores them to normal operating performance Lubricate the drive chain to prevent rusting NOTE After riding in an area where the roads are salted or near the ocean immediately
40. al Adjuster B Vertical Adjuster 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 Turn the vertical adjuster in or out to adjust the headlight vertically NOTE On high beam the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper angle according to local regulations Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 141 j Fuses Fuses are arranged in the fuse boxes located under the rider s seat The main fuse is located at the battery com partment If a fuse fails during opera tion inspect the electrical system to de termine the cause and then replace it with a new fuse of proper amperage If the fuse fails repeatedly there is something wrong with the electrical system Have the motorcycle checked by an authorized Kawasaki dealer The main fuse removal should be done by an authorized Kawasaki dealer A Fuse Box B Fuses C Spare Fuses Kawasaki Z800 Owner s Manual http www motorcycle in th 142 MAINTENANCE AND ADJUSTMENT j A Main Fuse WARNING Substituting fuses can cause wiring to overheat catch fire and or fail
41. and adjust as necessary 3 Do not carry heavy or bulky items on a luggage rack It is designed for light items and overloading can affect handling due to changes in weight distribution and aerodynamic forces Accessories 1 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 Kawasaki Z800 Owner s Manual http www motorcycle in th 14 SAFETY INFORMATION j or any other aspects of the motor cycle s operation 2 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 3 Fairings windshields backrests and other large items have the ca pability of adversely affecting stabil ity and handling of the motorcycle not only due to their weight but also due to the aerodynamic force acting on these surfaces while the motorcycle is in operation Poorly designed or installed items can re sult in an unsafe riding condition Other Load 1 This motorcycle is not intended to be equipped with a sidecar or to be used to tow any trailers or other ve hicles 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
42. awasaki Z800 Owner s Manual http www motorcycle in th 84 HOW TO RIDE THE MOTORCYCLE j Braking Close the throttle completely leav ing the clutch engaged except when shifting gears so that the engine will help slow down the motorcycle Shift down one gear at a time so that you are in 1st gear when you come to a complete stop 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 engine from stalling Never lock the brakes or it will cause the tires to skid When turning a cor ner it is better not to brake at all Re duce your speed before you get into the corner For emergency braking disregard downshifting and concentrate on applying the brakes as hard as pos sible without skidding Even in motorcycles equipped with ABS braking during cornering may cause wheel slip When turning a corner it is better to limit braking to the light application of both brakes or not to brake at all Reduce your speed before you get into the corner A Front Brake Lever Kawasaki Z800 Owner s Manual http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 85 j A Rear Brake Pedal Anti lock Brake System ABS Only on ABS model ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight The
43. cause the motorcycle to skid and lose control Use Engine Brake When going down long slopes help control vehicle speed by closing the throttle so that the engine can act as an auxiliary brake Use the front and rear brakes for primary braking Riding 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 judiciously to avoid skidding the rear wheel from too rapid acceleration or deceleration Braking performance is also reduced in wet conditions Carefully ride at a slow speed and apply the brakes sev eral times to help dry and restores them to normal operating performance Lubricate the drive chain after wet weather riding to prevent rust and cor rosion Kawasaki Z800 Owner s Manual http www motorcycle in th SAFETY INFORMATION 19 j Ride Prudently Riding at the proper speed and avoid ing unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for long ve hicle life and quieter operation Riding on Rough Roads Exercise caution slow down and grip the fuel tank with the knees for better stability Acceleration When quick acceleration is neces sary to pass another vehicle shift to a lower gear to obtain the necessary power Downshifting To avoid engine damage and rear wheel lock up do not downshift at high rpm Avoid Unnecessary Weaving Unnecessary weaving jeopardizes the
44. d at the fac tory with an event data recorder EDR The main purpose of this device is to record data that assists with under standing of how a vehicle s systems performed during a short period of time Among other things this data can help provide a better understanding of the circumstances in which crashes oc cur This device does not collect or store personal data or information e g name gender age The EDR in this vehicle is designed to record such data as vehicle speed engine crankshaft rotational speed throttle opening To read the data recorded by the EDR special equipment is required and access to the vehicle or EDR is necessary In addition to Kawasaki other parties such as law enforcement that have special equipment can read the information if they have access to the EDR Kawasaki does not access the EDR information without obtaining consent unless pursuant to court order or where required by law enforcement other government authorities or other third parties acting with lawful author ity Other parties may seek to access the recorded data independently of Kawasaki Kawasaki Z800 Owner s Manual http www motorcycle in th 76 HOW TO RIDE THE MOTORCYCLE j HOW TO RIDE THE MOTORCYCLE 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 bro
45. d bolts are tight and that all safety related parts are in good condition Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 21 j GENERAL INFORMATION Specifications PERFORMANCE Maximum Horsepower 83 0 kW 113 PS 10 200 r min rpm Maximum Torque 83 0 N m 8 5 kgf m 61 ft lb 8 000 r min rpm Minimum Turning Radius 3 m 118 in DIMENSIONS Overall Length 2 100 mm 82 7 in Overall Width 800 mm 31 5 in Overall Height 1 050 mm 41 3 in Wheelbase 1 445 mm 56 9 in Road Clearance 150 mm 5 91 in Curb Mass ZR800A 229 kg 505 lb ZR800B 231 kg 509 lb ENGINE Type DOHC 4 cylinder 4 stroke liquid cooled Kawasaki Z800 Owner s Manual http www motorcycle in th 22 GENERAL INFORMATION j Displacement 806 cm 49 2 cu in Bore Stroke 71 0 50 9 mm 2 8 2 0 in Compression Ratio 11 9 1 Starting System Electric starter Cylinder Numbering Method Left to right 1 2 3 4 Firing Order 1 2 4 3 Fuel System FI Fuel Injection Ignition System Battery and coil transistorized ignition Ignition Timing Electronically advanced 10 BTDC 1 100 r min rpm 37 BTDC 5 000 r min rpm Spark Plugs Type NGK CR9EK ND U27ETR Gap 0 7 0 8 mm 0 028 0 031 in Lubrication System Forced lubrication wet sump Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SA
46. displayed When the fuel tank is full all the seg ments are displayed As the fuel level in the tank goes down the segments disappear one by one from F full to E empty The lowest segment and fuel level warning symbol blink in the multi function meter when approximately 4 0 L 1 1 US gal of usable fuel remains Refuel at the earliest opportunity if the most bottom segment of the fuel gauge blinks 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 A Segment E B Fuel Warning Symbol Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 45 j All of the segments and fuel warning symbol will blink in case of the open or short of the wiring Have the wiring inspected by an authorized Kawasaki dealer immediately Kawasaki Z800 Owner s Manual http www motorcycle in th 46 GENERAL INFORMATION j Multifunction Meter Left Side A Coolant Temperature Meter B Multifunction Display Odometer Trip Meter A Trip Meter B C Clock D Warning Symbols Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 47 j Coolant Temperature Meter The coolant temperature meter in dicates temperature of the engine coolant A Coolant Temperature Meter If the coolant temperature is below 40 C 104 F is displayed When
47. e level or add distilled water Kawasaki Z800 Owner s Manual http www motorcycle in th 136 MAINTENANCE AND ADJUSTMENT j NOTICE Never remove the sealing strip or the battery can be damaged Do not install a conventional battery in this motorcycle or the electrical system cannot work properly Battery Maintenance It is the owner s responsibility to keep the battery fully charged Failure to do so can lead to battery failure and leave you stranded If you are riding your vehicle infre quently inspect the battery voltage weekly using a voltmeter If it drops below 12 6 volts the battery should be charged using an appropriate charger check with your 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 NOTE Leaving the battery connected causes the electrical components clock etc to make the battery dis charged resulting the over discharge of the battery In this case the repair or replacement of the battery is not included in the warranty If you do not drive for four weeks or more dis connect the battery from the vehicle Kawasaki recommended chargers are Battery Mate 150 9 OptiMate 4 Yuasa MB 2040 2060 Christie C10122S If the above chargers are not avail able use equivalent one Kawasaki Z800 Owner
48. e in th HOW TO RIDE THE MOTORCYCLE 91 j NOTE When stopping near traffic at night you can leave the turn signals blink ing for greater visibility by turning the ignition key to the position and push in the hazard switch Kawasaki Z800 Owner s Manual http www motorcycle in th 92 MAINTENANCE AND ADJUSTMENT j MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Daily Safety Checks and Periodic Maintenance to keep the motorcycle in good running condition and to reduce air pollution The initial main tenance is vitally important and must not be neglected WARNING Failure to perform these checks or to correct a problem before operation may result in serious damage or an accident Always perform daily safety checks before operation 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 made by the owner Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 93 j DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas
49. e minimum specified by Kawasaki to prevent severe engine damage The octane rating of a gasoline is a measure of its resistance to detona tion or knocking The term commonly used to describe a gasoline s octane rating is the Research Octane Number RON NOTICE Do not use leaded gasoline as this will destroy the catalytic converter Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 65 j NOTICE 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 Gaso line quality is important Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory per formance Operating problems that result from the use of poor quality or no recommended fuel may not be covered under your warranty Fuel Type and Octane Rating Except for Brazil Specification Use clean fresh unleaded gasoline with an octane rating equal to or higher than that shown in the table Fuel Type Unleaded Gasoline Minimum Octane Rating Research Octane Number RON 95 NOTICE Do not use any fuel with an ethanol in this vehicle It has not been tested and certified for use with such fuels Damage to the engine and fuel system or engine starting and or per formance problems may result from the use of improper fuel Kawasaki Z8
50. eage Average Mileage Cruising Range When the right button is pushed the display modes can be shifted as fol lows Current mileage Average mileage Cruising range Current mileage NOTE When the battery is disconnected the multifunction display indicates the current mileage Current Mileage This display mode shows the current mileage by numerical value The cur rent mileage display is renewed every 4 seconds Kawasaki Z800 Owner s Manual http www motorcycle in th 42 GENERAL INFORMATION j A Current Mileage NOTE The numerical value shows until 4 seconds have passed and the speedometer is rises to above 0 km h 0 mph When the ignition switch is turned off the current mileage resets to 0 0 Average Mileage This display mode shows the av erage mileage by numerical value counted from the start of measuring to present time The average mileage display is renewed every 5 seconds A Average Mileage B AV While the average mileage is dis played push the right button for more than 2 seconds The average mileage values resets to NOTE The data is maintained by backup power if the ignition switch is turned off When the battery is disconnected the average mileage resets to After resetting the average mileage the numerical value is not displayed until 5 mL 0 2 US oz of fuel has Kawasak
51. eat use the tying hooks located in rear of the rear footpegs below the passen ger s seat A Tying Hooks B Tying Hooks Other than Australian model Tool Kit The tool kit is located under the pas senger s seat Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 73 j The kit contains tools that can be helpful in making roadside repairs adjustments and some maintenance procedures explained in this manual Keep the tool kit in the original place A Tool Kit Rear View Mirror Rear View Mirror Adjustment Adjust the rear view mirror by slightly moving only the mirror portion of the assembly If the rear visibility can not be as sured by moving the mirror loosen the upper hexagonal area and turn the stay by hand NOTE The upper hexagonal area locknut has left hand threads Kawasaki Z800 Owner s Manual http www motorcycle in th 74 GENERAL INFORMATION j A Stay B Rear View Mirror Tightening Torque Lower Hexagonal Area 30 N m 3 1 kgf m 22 ft lb Upper Hexagonal Area 18 N m 1 8 kgf m 13 ft lb A Lower Hexagonal Area for Tightening B Upper Hexagonal Area C Rear View Mirror D Rubber Boots NOTE If a torque wrench is not available this item should be serviced by a Kawasaki dealer Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 75 j Event Data Recorder This vehicle is equippe
52. eated with a rubber protectant to help prolong their useful life Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 149 j 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 protectant to any tread area Kawasaki Z800 Owner s Manual http www motorcycle in th 150 APPENDIX j APPENDIX Storage Preparation for Storage Clean the entire vehicle thoroughly Run the engine for about five minutes to warm the oil shut it off and drain the engine oil WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local authorities for approved disposal methods or possible recy cling Put in fresh engine oil Empty the fuel from the fuel tank by the pump or siphon Kawasaki Z800 Owner s Manual http www motorcycle in th APPENDIX 151 j WARNING Gasoline is extremely flammable and can be explosive under certain con ditions creating the potential for serious burns 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 Con tact your local authorities for approved disposal methods Empty the fuel system by running the engine at
53. es or engine overheating and damage may occur Jump Starting If your motorcycle battery is run down it should be removed and charged If this is not practical a 12 volt booster battery and jumper cables may be used to start the engine Kawasaki Z800 Owner s Manual http www motorcycle in th 80 HOW TO RIDE THE MOTORCYCLE j 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 even in a discharged condition Keep all flames and sparks cigarettes away from the battery Wear eye protection when working with a battery In the event of battery acid contact with skin eyes or clothing wash the affected ar eas immediately with water for at least five minutes Seek medical attention Connecting Jumper Cables Make sure the ignition switch is turned off Remove the rider s seat see Rider s Seat Removal in the GENERAL IN FORMATION chapter Slide the red cap from the positive terminal see Battery Removal in the MAINTENANCE AND ADJUST MENT chapter Connect a jumper cable from the positive terminal of the booster battery to the positive terminal of the motorcycle battery NOTICE Be careful not to contact the jumper cable slip on the positive battery terminal to the frame or it will cause a short circuit Kawasaki Z800 Owner s Manual http www motorcycle in th
54. from the fully seated position turned fully clockwise This adjustment range may not exactly match the number shown in the table due to small tolerance of production Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 131 j Rear Shock Absorber Damping Force Settings Softest setting limit Standard Hardest setting limit Adjuster Position Rebound 2 2 4 turns out 1 1 4 turns out 0 Damping Force Weak Strong Setting Soft Hard Load Light Heavy Road Good Bad Speed Low High This position is the fully seated position turned fully clockwise Out from the fully seated position turned fully clockwise This adjustment range may not exactly match the number shown in the table due to small tolerance of production Kawasaki Z800 Owner s Manual http www motorcycle in th 132 MAINTENANCE AND ADJUSTMENT j Wheels Tire Pressure Inspection Remove the air valve cap Check the tire pressure often using an accurate gauge Make sure to install the air valve cap securely NOTE 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 Tire pressure is affected by changes in ambient temperature and altitude and so the tire pressure should be checked and adjusted when your rid ing involves wide variations in tem
55. g B 1 000 km 1 000 mile Items year A 1 0 6 6 3 8 12 7 6 18 11 4 24 15 2 See Page Air cleaner element C every 36 000 km 22 500 mile Idle speed 114 Throttle control system play smooth return no drag 1 112 Engine vacuum synchronization Fuel system 1 Fuel hoses 5 Coolant level 106 Cooling system 1 Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 99 j Odometer Reading B 1 000 km 1 000 mile Items year A 1 0 6 6 3 8 12 7 6 18 11 4 24 15 2 See Page Coolant water hose and O ring 3 every 36 000 km 22 500 mile Valve clearance every 42 000 km 26 250 mile Air suction system Clutch operation play engagement disengagement 115 Engine Oil and Oil filter C 1 103 Tire air pressure 1 132 Wheels and tires 1 133 Wheel bearing damage 1 Drive chain lubrication condition C every 600 km 400 mile 117 Kawasaki Z800 Owner s Manual http www motorcycle in th 100 MAINTENANCE AND ADJUSTMENT j Odometer Reading B 1 000 km 1 000 mile Items year A 1 0 6 6 3 8 12 7 6 18 11 4 24 15 2 See Page Drive chain slack C every 1 000 km 600 mile 117 Drive chain wear C Drive chain guide wear
56. harge the battery if necessary Fill the fuel tank with fuel Check all the points listed in the Daily Safety Checks section Lubricate the pivots bolts and nuts Kawasaki Z800 Owner s Manual http www motorcycle in th APPENDIX 153 j Troubleshooting Guide Engine Does Not Start Starter Motor Won t Turn Engine stop switch off Transmission not in neutral Fuse blown Battery leads do not make good electrical contact with battery terminals Battery discharged Engine Cranks But Won t Start No fuel in tank Fuel line clogged Fuel broken down Engine flooded Spark plugs not in good contact Spark plugs fouled or wet Incorrect spark plug gap Incorrect valve clearance No first turning the ignition switch to OFF when the motorcycle falls down Kawasaki Z800 Owner s Manual http www motorcycle in th 154 APPENDIX j Engine Stalls Just When Shifting Into 1st Gear Side stand has been left down Clutch does not properly disengage While Riding No fuel in tank Fuel tank air vent is obstructed Overheating Battery discharged Owner Satisfaction For Products Sold in Australia Only Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Pty Ltd If you have a problem concerning warranty or service please take the following action Contact the owner and or service manager of your aut
57. horized Kawasaki dealer Fully explain your problem and ask for assistance in resolving the situation The OWNER of the dealership is an independent business person and is concerned Kawasaki Z800 Owner s Manual http www motorcycle in th APPENDIX 155 j with your satisfaction and your future business 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 require further assistance WRITE to the address below Please be certain to pro vide 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 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 WRITTEN 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 your correspondence to Kawasaki Z800 Owner s Manual http www motorcycle in th 156 APPENDIX
58. i Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 43 j been used and 100 m 328 ft has been traveled Cruising Range This display mode shows the cruising range by numerical value and indicates the cruising range from the remaining fuel in the fuel tank This cruising range display is renewed every 20 seconds A Cruising Range B RANGE The cruising range value displays when the fuel warning symbol blinks in the multifunction meter A display NOTE The display range for cruising range is 0 999 The cruising range value may not indicate the actual value Use this value for your reference only Economical Riding Indicator When the operator is driving the mo torcycle for optimum fuel efficiency the economical riding indicator appears on the multifunction meter to indicate fa vorable fuel consumption Monitoring the economical riding indicator can help the rider maximize fuel efficiency Kawasaki Z800 Owner s Manual http www motorcycle in th 44 GENERAL INFORMATION j A Economical Riding Indicator WARNING Failing to properly observe the road ahead increases the chance of an accident resulting in se vere injury or death Do not con centrate on the economical rid ing indicator by taking your eyes off the road observe using pe ripheral vision Fuel Gauge The fuel in the fuel tank is shown by the number of segments
59. i dealer When the ABS is functioning you may feel a pulsing in the brake lever or pedal This is normal You need not suspend applying brakes ABS does not function at speeds of approx 10 km h 6 mph or below ABS does not function if the battery is discharged Yellow ABS Indicator Light Normally the ABS indicator light goes on when the ignition switch is turned on and goes off shortly after the motorcy cle starts moving If this light shows any of the follow ing a fault or faults may have occurred in the ABS You should have the ABS checked by an authorized Kawasaki dealer The light does not come on when the ignition switch is turned on Kawasaki Z800 Owner s Manual http www motorcycle in th 88 HOW TO RIDE THE MOTORCYCLE j The light remains lit after the motor cycle starts moving The light comes on and remains lit after the motorcycle starts moving Remember that the ABS does not function when this light is on but if the ABS fails the conventional brake sys tem still works normally Stopping the Engine Close the throttle completely Shift the transmission into neutral Turn the ignition key to OFF Support the motorcycle on a firm level surface with the side stand Lock the steering NOTE The motorcycle is equipped with a vehicle down sensor which causes the engine to stop automatically if the motorcycle falls down The engine warning indica
60. ki dealer Lining Thickness Service Limit Front 1 0 mm 0 04 in Rear 1 5 mm 0 06 in A Front Brake Pads B Lining Thickness C Service Limit Kawasaki Z800 Owner s Manual http www motorcycle in th 124 MAINTENANCE AND ADJUSTMENT j A Rear Brake Pads B Lining Thickness C Service Limit Brake Light Switches Brake Light Switch Inspection Turn the ignition switch on The brake light should go on when the front brake is applied If it does not ask your authorized Kawasaki dealer to inspect the front brake light switch Check the operation of the rear brake light switch by depressing the brake pedal The brake light should go on after the proper pedal travel A Brake Pedal B 10 mm 0 4 in Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 125 j If the light does not come on the rear brake light switch should be adjusted by an authorized Kawasaki dealer Brake Pedal Travel 10 mm 0 4 in A Rear Brake Light Switch NOTICE To avoid damaging the electrical connections inside the switch be sure that the switch body does not turn during adjustment Suspension System Front Fork NOTICE Do not force to turn the rebound damping force adjuster from the fully seated position at the ad justing mechanism may be dam aged Kawasaki Z800 Owner s Manual http www motorcycle in th 126 MAINTENANCE AND ADJUSTMENT j
61. l 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 Tighten both chain adjuster locknuts and the axle nut to the specified torque Tightening Torque Chain Adjuster Locknuts 16 5 N m 1 68 kgf m 12 ft lb Axle Nut 108 N m 11 0 kgf m 80 ft lb NOTE If a torque wrench is not available this item should be serviced by an authorized Kawasaki dealer Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary Install a new cotter pin through the axle nut and axle and spread its ends A Cotter Pin Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 121 j NOTE 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 It should be within 30 degrees Loosen once and tighten again when the slot goes past the nearest hole A Turn Clockwise 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 Check the rear brake see the Brakes section Install the cap Brakes If you feel there is something wrong when applying the brake
62. le first Reinstall the removed parts Moving Off Check that the side stand is up Pull in the clutch lever Shift into 1st gear Open the throttle a little and start to let out the clutch lever very slowly As the clutch starts to engage open the throttle a little more giving the en gine just enough fuel to keep it from stalling A Shift Pedal Kawasaki Z800 Owner s Manual http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 83 j NOTE 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 Shifting Gears Close the throttle while pulling in the clutch lever Shift into the next higher or lower gear Open the throttle part way while re leasing the clutch lever 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 NOTE The transmission is equipped with a positive neutral finder When the mo torcycle is standing still the transmis sion 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 K
63. oded key must be used and the communication should be clear for the engine to start When the key is turned to OFF the warning indicator light will start blink ing which indicates that the immobi lizer system is functioning After 24 hours have passed the warning indica tor light will stop blinking however the immobilizer system is still functioning If all ignition keys are lost registering new ignition key codes is impossible and the ECU must be replaced NOTE Warning indicator light blinking mode can be set to either on or off Push and hold the left and right buttons simultaneously for more than two seconds within twenty seconds after turning the ignition key to the OFF position then the warning indicator light will not blink When the battery is connected warn ing indicator light is set to blinking mode by default When the battery voltage is low be low 12 V warning indicator light au tomatically stops blinking to prevent excessive battery discharge EC Directive Compliance This immobilizer system complies with the R amp TTE Radio equipment and telecommunications terminal equip ment and the mutual recognition of their conformity Directive Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 59 j Ignition Switch Steering Lock This is a four position key operated switch The key can be removed from the switch when it is in the OFF LOCK or
64. on Remove the bolt and bracket Kawasaki Z800 Owner s Manual http www motorcycle in th 70 GENERAL INFORMATION j A Bolt B Bracket C Rider s Seat Pull the rider s seat backward to clear the tabs Remove the rider s seat A Tabs B Slots C Rider s Seat Rider s Seat Installation Insert the tabs at the front of the rider s seat into the slots on the frame Be sure that the hooks fit into the holes of the rider s seat Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 71 j A Tabs B Slots C Hooks D Holes E Rider s Seat Insert the bracket into the hole at the rear of rider s seat while pushing down the rear part of the rider s seat Tighten the bolt while pushing for ward the rear part of the rider s seat A Bracket B Hole C Rider s Seat D To Forward Passenger s Seat Installation Insert the tab at the rear of the pas senger s seat into the slot on the frame Insert the hook at the front of the pas senger s seat into the hole on the frame Kawasaki Z800 Owner s Manual http www motorcycle in th 72 GENERAL INFORMATION j Push down the front part of the pas senger s seat until the lock clicks A Tab B Slot C Hook D Hole Pull up the front and rear ends of the passenger s seat to make sure they are securely locked Tying Hooks When tying up light loads to the s
65. only warn that the effects can be adverse and that Kawasaki cannot assume re sponsibility for the results of such unintended use of the motorcycle 2 Furthermore any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty If You are Involved in an Accident Make sure of your own safety first Determine the severity of any injuries and call for emergency assistance if needed Always follow applicable laws Kawasaki Z800 Owner s Manual http www motorcycle in th SAFETY INFORMATION 15 j and regulations if any other person ve hicle or property is involved Do not attempt to continue riding without first evaluating your motorcy cle s condition Inspect for fluid leaks check critical nuts and bolts and check the handlebars control levers brakes and wheels for damage and proper function Ride slowly and cautiously your motorcycle may have suffered damage that is not immediately appar ent Have your motorcycle thoroughly checked at a Kawasaki dealer as soon as possible Safe Operation The following should be carefully ob served for safe and effective vehicle operation Carbon Monoxide Hazard 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 en closed areas Operate only in a well ventilated area Kawasaki Z800 Owner
66. owing general guidelines have been prepared to assist you in making your determinations Passenger 1 Never carry more than one passen ger 2 The passenger should only sit on the pillion 3 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 im portant that the passenger sits still while the motorcycle is in motion and not interfere with the operation of the motorcycle Do not carry ani mals on your motorcycle Kawasaki Z800 Owner s Manual http www motorcycle in th SAFETY INFORMATION 13 j 4 Do not carry passengers unless passenger footpegs are installed Instruct any passenger before riding to keep his or her feet on the pas senger footpegs and hold on to the operator or seat strap Do not carry a passenger unless he or she is tall enough to reach the footpegs with their feet Baggage and Luggage 1 All baggage should be carried as low as possible to reduce the effect on the motorcycle s center of grav ity Baggage weight should also be distributed equally on both sides of the motorcycle Avoid carrying bag gage that extends beyond the rear of the motorcycle 2 Baggage should be securely at tached Make sure that the baggage will not move around while you are riding Recheck baggage security as often as possible not while the motorcycle is in motion
67. rates the elec tric starter when the transmission is in neutral Refer to the Starting the Engine section in the HOW TO RIDE THE MOTORCYCLE chapter for starting instructions Left Handlebar Switches A Dimmer Switch B Horn Button C Turn Signal Switch D Hazard Switch E Passing Button Dimmer Switch High or low beam can be selected with the dimmer switch When the headlight is on high beam the high beam indicator light goes on Kawasaki Z800 Owner s Manual http www motorcycle in th 62 GENERAL INFORMATION j High beam Low beam Turn Signal Switch When the turn signal switch is turned to the left or right the corresponding turn signals blink on and off To stop blinking 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 ig nition switch in the ON or posi tion All the turn signals and turn signal indicator lights will blink on and off NOTICE If you leave the 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 Passing Button When the passing button is pushed the headlight high beam passing beam goes on to signal the driver of the vehicle ahead
68. re If the amount of coolant is insuffi cient add coolant into the reserve tank Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 107 j Coolant Filling Remove the bolts and plastic wash ers Clear the hooks on the ignition cover and remove it A Bolts and Plastic Washers B Hooks Both Sides C Ignition Cover Clear the projection and tab on the left tank cover Pull the left tank cover forward to clear the hook A Projection B Tab C Hook D Left Tank Cover Remove the bolts and screws Remove the left inner shroud Kawasaki Z800 Owner s Manual http www motorcycle in th 108 MAINTENANCE AND ADJUSTMENT j A Bolts B Screws C Left Inner Shroud Remove the cap from the reserve tank and add coolant through the filler opening to the F Full level line A Cap B Reserve Tank C F Full Level Line D L Low Level Line Install the left inner shroud Install the left tank cover so that the hook on the fuel tank fits into the slot Insert the tab on the left tank cover into the slot Insert the projection on the left tank cover into the hole Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 109 j A Hook B Fuel Tank C Slot D Tab E Slot F Left Tank Cover G Projection H Hole Insert the pin on the ignition cover into the hole on the bracket A Pin B
69. rease damping force C To decrease damping force Standard 1 1 4 turns out Out from the fully seated position turned fully clockwise Turn the adjuster clockwise to in crease rebound damping force Turn the adjuster counterclockwise to decrease rebound damping force NOTICE Do not turn the adjuster beyond the fully seated position or the adjusting mechanism may be damaged Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 129 j Setting Tables Front Fork Spring Preload Setting Softest setting limit Standard Hardest setting limit Adjuster Position 19 mm 0 7 in 9 mm 0 4 in 4 mm 0 2 in Spring Action Weak Strong Setting Soft Hard Load Light Heavy Road Good Bad Speed Low High From the top of the adjuster This adjustment range may not exactly match the number shown in the table due to small tolerance of production Kawasaki Z800 Owner s Manual http www motorcycle in th 130 MAINTENANCE AND ADJUSTMENT j Front Fork Damping Force Settings Softest setting limit Standard Hardest setting limit Adjuster Position Rebound 26 clicks 12 clicks 0 Damping Force Weak Strong Setting Soft Hard Load Light Heavy Road Good Bad Speed Low High This position is the fully seated position turned fully clockwise Out
70. 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 Motorcycle amp Engine Company 2012 Kawasaki Heavy Industries Ltd Jul 2012 2 Kawasaki Z800 Owner s Manual http www motorcycle in th Australian model only TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Kawasaki Z800 Owner s Manual http www motorcycle in th TABLE OF CONTENTS SAFETY INFORMATION 10 Read Owner s Manual 10 Training 10 Daily Safety Checks and Periodic Maintenance 10 Loading and Accessories Information
71. resets to 0 0 and continues counting Clock To adjust hours and minutes do the followings while the motorcycle is at a stop Display the odometer in the multi function display Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 51 j Push the left button for more than 2 seconds Both the hour and minute displays start blinking Push the right button The hour dis play only blinks Push the left button to advance the hours Push the right button The hour dis play stops blinking and the minute display starts blinking Push the left button to advance the minutes Push the right button Both the hour and minute displays start blinking again Push the left button The displays stop blinking and the clock starts working NOTE Pushing the left button momentarily advances the hour or minute step by step Pushing and holding the button advances the hour or minute contin uously The clock works normally by the backup power while the ignition switch is turned off Kawasaki Z800 Owner s Manual http www motorcycle in th 52 GENERAL INFORMATION j When the battery is disconnected the clock is reset to 1 00 and starts working again when the battery is connected Indicator Lights Green Neutral Indicator Light N When the transmission is in neutral the neutral indicator light goes on Blue High Beam Indicator Light When the headlight i
72. rom lock to lock No binding of control cables Brakes Brake pad wear 123 Brake fluid level 122 No brake fluid leakage Throttle Throttle grip play 112 Clutch Clutch lever play 115 Clutch lever operates smoothly Kawasaki Z800 Owner s Manual http www motorcycle in th 96 MAINTENANCE AND ADJUSTMENT j Operation See Page Coolant No coolant leakage Coolant level between level lines when engine is cold 106 Electrical equipment All lights head tail brake turn signal warning indicator and horn work Engine stop switch Stops engine Side stand Return to its fully up position by spring tension Return spring not weak or not damaged Rear view mirrors Rear view sight 73 Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 97 j Periodic Maintenance A Service at number of years shown or indicated odometer reading intervals whichever comes first B For higher odometer readings repeat at the frequency interval established here C Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping Inspection Dealer Inspection Change or Replace Dealer Change or Replace Lubrication Dealer Lubrication Kawasaki Z800 Owner s Manual http www motorcycle in th 98 MAINTENANCE AND ADJUSTMENT j Odometer Readin
73. s have the brake system checked by an autho rized Kawasaki dealer immediately Kawasaki Z800 Owner s Manual http www motorcycle in th 122 MAINTENANCE AND ADJUSTMENT j 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 Brake Fluid Level Inspection With the front brake fluid reservoir held horizontal the brake fluid level must be above the lower level line A Front Brake Fluid Reservoir B Lower Level Line With the rear brake fluid reservoir held horizontal the brake fluid level must be kept between the upper and lower level lines Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 123 j A Rear Brake Fluid Reservoir B Upper Level Line C Lower Level Line If the fluid level is lower than the lower level line it may indicate that the fluid is leaking In this case have the brake system inspected by an au thorized Kawasaki dealer Brake Pad Wear Inspection Inspect the brakes for wear For each front and rear disc brake caliper if the thickness of either pad lining is less than below table replace both pads in the caliper as a set Pad replace ment should be done by an authorized Kawasa
74. s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 137 j For more details ask your Kawasaki dealer Battery Charging Charge the battery following the in structions of your battery charger The charger will keep the battery fully charged until you are ready to re install the battery in the motorcycle see Battery Installation 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 even in a discharged condition Keep all flames and sparks cigarettes away from the battery Wear eye protection when working with a battery In the event of battery acid contact with skin eyes or clothing wash the affected ar eas immediately with water for at least five minutes Seek medical attention Battery Removal Remove the rider s seat see Rider s Seat Removal in the GENERAL IN FORMATION chapter Kawasaki Z800 Owner s Manual http www motorcycle in th 138 MAINTENANCE AND ADJUSTMENT j Clear the hooks on the frame and remove the rubber band Clear the hook of the fuse box and remove it Pull up the battery slightly A Hooks B Rubber Band C Hook D Fuse Box E Battery Slide the red cap from the positive terminal Disconnect the cables from the bat tery first from the terminal and then the terminal A Red Cap B Terminal C
75. s on high beam the high beam indicator light goes on Green Turn Signal Indicator Light When the turn signal switch is pushed to the left or right the turn sig nal indicator light blinks Yellow ABS Indicator Light For models equipped with ABS The ABS Anti lock Brake Sys tem indicator light comes on when the ignition switch is turned on and goes off shortly after the motorcycle starts moving If the ABS is normal it stays off If something is wrong with the ABS the indicator comes on and remains lit When the indicator light is on the ABS does not function but if the ABS fails the conventional brake system will still work normally For more detailed information about ABS see the Anti lock Brake System ABS section in the HOW TO RIDE THE MOTORCYCLE chapter Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 53 j Warning Indicator Lights Yellow Engine Warning Indicator Light The engine warning indicator light goes on when the ignition key is turned on and goes off soon after en suring that its circuit functions properly The warning indicator light also goes on or blinking whenever the troubles occur in digital fuel injection system DFI The blinking of this warning indicator light indicates the condition that the en gine cannot be started See the Stopping the Engine section in the HOW TO RIDE THE MOTOR CYCLE chapter for more information If the warning indicator
76. slack by pulling up and pushing down the Kawasaki Z800 Owner s Manual http www motorcycle in th 118 MAINTENANCE AND ADJUSTMENT j chain midway between the engine sprocket and rear wheel sprocket A Chain Slack If the drive chain is too tight or too loose adjust it so that the chain slack is within the standard value Drive Chain Slack Standard 20 30 mm 0 8 1 2 in Drive Chain Slack Adjustment Loosen the left and right chain ad juster locknuts Remove the cap Remove the cotter pin and loosen the axle nut A Axle Nut B Cotter Pin C Locknut D Adjuster Nut If the chain is too loose turn in the left and right chain adjusters evenly Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 119 j If the chain is too tight turn out the left and right chain adjusters evenly Turn out both chain adjusters evenly until the drive chain has the cor rect amount of slack To keep the chain and wheel properly aligned the notch on the left wheel alignment indicator should align with the same swingarm mark that the right indica tor notch aligns with A Marks B Notch C Indicator D Locknut E Adjuster Nut NOTE Wheel alignment can also be checked using the straightedge or string method Kawasaki Z800 Owner s Manual http www motorcycle in th 120 MAINTENANCE AND ADJUSTMENT j WARNING Misalignment of the whee
77. sting Screw 16 Shift Pedal 17 Side Stand 18 Rebound Damping Force Adjuster Rear Shock Absorber 19 Drive Chain 20 Chain Adjuster Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 35 j 1 Tool Kit 2 Battery 3 Brake Fluid Reservoir Rear 4 Fuel Tank Cap 5 Tying Hooks Both Sides Other than Australian model 6 Tying Hooks Both Sides 7 Swingarm 8 Muffler 9 Rear Shock Absorber 10 Rear Brake Light Switch 11 Rear Brake Pedal 12 Oil Level Inspection Window 13 Oil Filter Kawasaki Z800 Owner s Manual http www motorcycle in th 36 GENERAL INFORMATION j Meter Instruments A Left Button B Right Button C Multifunction Meter Left Side D Tachometer E Multifunction Meter Right Side F Green Left Turn Signal Indicator Light G Yellow Engine Warning Indicator Light H Yellow ABS Indicator Light only on ABS model I Red Warning Indicator Light J Green Neutral Indicator Light K Blue High Beam Indicator Light L Green Right Turn Signal Indicator Light Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 37 j NOTE For safety do not operate the instru ment buttons while riding the motor cycle Tachometer The tachometer shows the engine speed in revolutions per minute r min rpm The upper higher zone of the tachometer is a portion called the red zone Engine r min rpm in the red zone is above
78. tant and keep you warm Avoid wearing clothes which have loose cuffs or other fastenings which could interfere with the con trols of your motorcycle Boots Wear proper protective boots that fit properly and do not interfere with gear shifting or braking Safe Riding Techniques Keep Hands on Handlebars 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 foot pegs while riding can be hazardous If you remove even one hand or foot you reduce your ability to control the motor cycle Look Over Your Shoulder Before changing lanes look over your shoulder to make sure the way is clear Do not rely solely on the rear Kawasaki Z800 Owner s Manual http www motorcycle in th 18 SAFETY INFORMATION j view mirror you may misjudge a vehi cle s distance and speed or you may not see it at all Accelerate and Brake Smoothly In general your actions should be smooth as sudden acceleration brak ing or turning may cause loss of control especially when riding in wet conditions or on loose road surfaces when the ability to maneuver will be reduced Select Correct Gear Speeds When going up steep slopes shift to a lower gear so that there is power to spare rather than overloading the en gine Use Both Front and Rear Brakes When applying the brakes use both the front and rear brakes Applying only one brake for sudden braking may
79. ted red warning indicator light defaults to blinking mode When the battery voltage is low be low 12 V red warning indicator light blinking automatically stop blinking to prevent excessive battery discharge Battery Warning Symbol The red warning indicator light and the battery warning symbol go on whenever the battery voltage is less than 11 0 V or more than 16 0 V If they go on have the battery voltage checked by an authorized Kawasaki dealer NOTE When the all indicator lights and dis play of the meter go off the bat tery voltage is insufficient Have the machine checked by an authorized Kawasaki dealer promptly because the engine might stop suddenly when keeping running in that condition Kawasaki Z800 Owner s Manual http www motorcycle in th 56 GENERAL INFORMATION j Keys This motorcycle has a combination key which is used for the ignition switch steering lock seat lock and fuel tank cap Immobilizer System This motorcycle is equipped with an immobilizer system to protect your mo torcycle from theft This motorcycle has two ignition keys Store the one ignition key and the key tag in a safe place If all ignition keys are lost regis tering new codes for replacement igni tion keys into the electronic control unit is impossible Registering additional ig nition key should be done by an au thorized Kawasaki dealer Blank keys are available at your Kawasaki dealers Ask yo
80. the excess oil through the oil filler open ing using a syringe or some other suitable device If the oil level is too low add the oil to reach the correct level Use the same type and brand of oil that is already in the engine Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 103 j Oil and or Oil Filter Change Warm up the engine thoroughly and then stop it Place an oil pan beneath the engine Remove the engine oil drain plug WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local authorities for approved disposal methods or possible recycling A Engine Oil Drain Plug Let the oil completely drain with the motorcycle perpendicular to the ground If the oil filter is to be replaced re move the oil filter cartridge and re place it with a new one Kawasaki Z800 Owner s Manual http www motorcycle in th 104 MAINTENANCE AND ADJUSTMENT j NOTE If a torque wrench or required Kawasaki special tool is not avail able this item should be serviced by a Kawasaki dealer A Oil Filter Apply a thin film of oil to the packing and tighten the cartridge to the spec ified torque A Packing Install the drain plug with a new gas ket Tighten it to the specified torque NOTE Replace the gasket with a new one Fill the engine up to the upper level line with a good quality engine oil specified
81. the coolant temperature rises to above 40 C 104 F the numerical value of the coolant temperature at the present state is displayed If the coolant temperature rises to above 115 C 239 F and below 120 C 248 F the numerical value of the current coolant temperature starts blinking the red warning indi cator light and coolant temperature warning symbol also go on This warns the operator that the coolant temperature is high Kawasaki Z800 Owner s Manual http www motorcycle in th 48 GENERAL INFORMATION j A Coolant Temperature Warning Symbol B Red Warning Indicator Light If the coolant temperature rises to above 120 C 248 F HI is displayed and starts blinking the red warning in dicator light and coolant temperature warning symbol also go on This warns the operator that the coolant tempera ture is too high Stop the engine and check the coolant level in the reserve tank after the engine cools down Have the cooling system checked by an au thorized Kawasaki dealer A Coolant Temperature Warning Symbol B Red Warning Indicator Light Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 49 j NOTICE Do not let the engine continue running when the coolant tem perature shows HI Prolonged engine operation will result in severe engine damage from overheating Multifunction Display The multifunction display indicates the following modes
82. the corner Same as conventional brake system an excessive sudden braking may cause wheel lock up that makes it harder to control a motorcycle During braking ABS will not prevent the rear wheel lifting WARNING ABS cannot protect the rider from all possible hazards and is not a substitute for safe rid ing practices Be aware of how the ABS system operates and its limitations It is the rider s responsibility to ride at appro priate speeds and manner for weather road surface and traffic conditions The computers integrated in the ABS compare vehicle speed with wheel speed Since non recommended tires can affect wheel speed they may confuse the computers which can extend braking distance Kawasaki Z800 Owner s Manual http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 87 j WARNING Use of non recommended tires may cause malfunctioning of ABS and can lead to extended braking distance The rider could have an accident as a re sult Always use recommended standard tires for this motorcy cle NOTE ABS indicator light may come on un der motorcycle riding condition ex The front or rear wheel races In this case first turn the ignition switch to OFF and then back to ON and run the motorcycle at the speed of approx 10 km h 6 mph or above ABS indicator light goes off by this operation but if it remains lit you should have the ABS checked by an authorized Kawasak
83. the upper of the throttle cables and screw both throttle cable adjusters completely so as to give the throttle grip plenty of play Turn out the decelerator cable ad juster until there is no play when the throttle grip is completely closed Tighten the locknut A Decelerator Cable B Accelerator Cable C Adjusters D Locknuts Turn out the accelerator cable ad juster until 2 3 mm 0 08 0 12 in of throttle grip play is obtained Tighten the locknut If the throttle cables cannot be ad justed with the adjuster at the upper end of the throttle cable further ad justment of the throttle cables should Kawasaki Z800 Owner s Manual http www motorcycle in th 114 MAINTENANCE AND ADJUSTMENT j be done by an authorized Kawasaki dealer With the engine idling turn the han dlebar to each side If handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or they may be damaged Be sure to correct any of these conditions before riding WARNING Operation with improperly ad justed incorrectly routed or damaged cables could result in an unsafe riding condition Be sure the control cables are ad justed and routed correctly and are free from damage Idle Speed Idle Speed Adjustment Start the engine and warm it up thor oughly Adjust the idle speed by turning the idle adjusting screw Idle Speed 1 050 1 150 r min
84. tor light blinks when the starter button is pressed if the engine cannot be started After righting the motorcycle first turn the ignition key to OFF and then back to ON before starting the engine Stopping the 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 create a Kawasaki Z800 Owner s Manual http www motorcycle in th HOW TO RIDE THE MOTORCYCLE 89 j 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 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 Parking WARNING Operating or parking the vehi cle near
85. triving for superior reliability safety and performance Please read this Owner s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle s controls its fea tures capabilities and limitations This manual offers many safe riding tips but its purpose is not to provide instruction in all the techniques and skills required to ride a motorcycle safely Kawasaki strongly recommends that all operators of this vehi cle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle operation To ensure a long trouble free life for your motorcycle give it the proper care and maintenance described in this manual For those who would like more detailed in formation on their Kawasaki Motorcycle a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer The Service Manual contains de tailed disassembly and maintenance information Those who plan to do their own work should of course be competent mechanics and possess the special tools described in the Service Manual Keep this Owner s Manual aboard your motorcycle at all times so that you can refer to it whenever you need information Kawasaki Z800 Owner s Manual http www motorcycle in th This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold All rights
86. undam aged tires and can suddenly fail causing an accident resulting in serious injury or death Re 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 Most countries may have their own regulations requiring a minimum tire tread depth be sure to follow them Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 135 j When operating on public roadways keep maximum speed under traffic law limits Standard Tire Tubeless Front Make Type DUNLOP SPORTMAX D214 FJ Size 120 70ZR17 M C 58W Rear Make Type DUNLOP SPORTMAX D214 J Size 180 55ZR17 M C 73W 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 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 estab lish normal tire traction During break in avoid sudden and max imum braking and acceleration and hard cornering Battery The battery installed in this motorcy cle is a sealed type so it is not nec essary to check the battery electrolyt
87. ur dealer to make any additional spare keys you may need using your original key as a master To make ad ditional ignition keys take the vehicle along with all ignition keys to an au thorized Kawasaki dealer to have them re registered Up to five ignition keys can be registered with the immobilizer system at one time Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 57 j NOTICE Do not put two keys of any immo bilizer system on the same key ring Do not submerge any key in wa ter Do not expose any key to exces sively high temperature Do not place any key close to magnets Do not place heavy item on any key Do not grind any key or alter its shape Do not disassemble the plastic part of any key Do not drop any key and or apply shocks to it If a ignition key is lost re registry at dealer is securely required to prevent the possibil ity of theft NOTICE If all ignition keys are lost an authorized Kawasaki dealer will have to replace the ECU and or der new ignition keys A Ignition keys Ignition keys You can register maxi mum 5 ignition keys at one time If an improperly coded key is used or any incorrect communication between Kawasaki Z800 Owner s Manual http www motorcycle in th 58 GENERAL INFORMATION j ECU and key is occurred the engine does not start with the immobilizer warning symbol and warning indicator light blinks A properly c
88. ur particular machine from others of the same model type These serial numbers may be needed by your dealer when ordering parts In the event of theft the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it Engine No A Engine Number Frame No A Frame Number Kawasaki Z800 Owner s Manual http www motorcycle in th 26 GENERAL INFORMATION j Location of Labels All warning labels which are on your vehicle are repeated here Read labels on your vehicle and understand them thoroughly They contain information which is important for your safety and the safety of anyone else who may op erate your vehicle Therefore it is very important that all warning labels be on your vehicle in the locations shown If any label is missing damaged or worn get a replacement from your Kawasaki dealer and install it in the correct posi tion NOTE The sample warning labels in this section have part numbers to help you and your dealer obtain the cor rect replacement Refer to the actual vehicle label for model specific data grayed out in the illustration 1 Brake Fluid Front Kawasaki Z800 Owner s Manual http www motorcycle in th GENERAL INFORMATION 27 j 2 Brake Fluid Rear 3 Battery Poison Danger 4 Rear Shock Absorber Warning Kawasaki Z800 Owner s Manual http www motorcycle in th 28 GENERAL I
89. 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 Condensation may form on the inside of the headlight lens after riding in the rain washing the motorcycle or hu mid weather To remove the mois ture start the engine and turn on the headlight Gradually the condensa tion on the inside of the lens will clear off Radiator Clean off any obstructions with a stream of low pressure water Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 147 j NOTICE Using high pressure water as from a car wash facility could damage the radiator fins and im pair the radiator s effectiveness Do not obstruct or deflect air 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 Semi gloss Finish To clean the semi gloss finish When washing the motorcycle al ways use a mild neutral detergent and water The semi gloss finish effect may be lost when the finish is excessively rubbed If any doubt consult an authorized Kawasaki dealer Other Plastic Parts After washing use a soft cloth to gen tly dry plastic parts When dry treat the headlight
90. y familiar with the proper op eration of your motorcycle s controls its features capabilities and limita tions This manual offers many safe riding tips but its purpose is not to pro vide instruction in all of the techniques and skills required to ride a motorcycle safely Training Kawasaki strongly recommends that all operators of this vehicle complete a suitable motorcycle rider training pro gram to learn the proper skills and tech niques necessary for safe motorcycle operation Daily Safety Checks and Periodic Maintenance It is important to keep your motorcy cle properly maintained and in safe rid ing condition Inspect your motorcy cle before every ride and carry out all periodic maintenance See the Daily Safety Checks section and the Periodic Maintenance section in the MAINTE NANCE AND ADJUSTMENT chapter for more information WARNING Failure to perform these checks or to correct a problem before operation may result in serious damage or an accident Always perform daily safety checks be fore operation Kawasaki Z800 Owner s Manual http www motorcycle in th SAFETY INFORMATION 11 j To ensure your motorcycle is ser viced using the latest servicing infor mation it is recommended that an authorized Kawasaki Dealer performs the periodic maintenance as directed in the Owner s Manual If you notice any irregular operat ing condition have your motorcycle thoroughly checked at an authorized
91. ycle cover will help protect its finish from harmful UV rays pollutants and reduce the amount of dust reaching its surfaces WARNING Build up of debris or flammable material in and around the vehi cle chassis engine and exhaust can cause mechanical problems and increase the risk of fire When operating the vehicle in conditions that allow debris or flammable material to collect in and around the vehicle inspect the engine electrical component and exhaust areas frequently If debris or flammable materials have collected park the vehi cle outside and stop the engine Allow the engine to cool then remove any collected debris Do not park or store the vehicle in an enclosed space prior to in specting for build up of debris or flammable materials Kawasaki Z800 Owner s Manual http www motorcycle in th MAINTENANCE AND ADJUSTMENT 145 j Be sure the engine and exhaust are cool before washing Avoid applying degreaser to seals brake pads and tires Avoid all harsh chemicals solvents detergents and household cleaning products such as ammonia based window cleaners Gasoline brake fluid and coolant will damage the finish of painted and plastic surfaces wash them off im mediately Avoid wire brushes steel wool and all other abrasive pads or brushes Use care when washing the head light lens and other plastic parts as they can easily be scratched Avoid using pressure washers w

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