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The motorcycle is equipped with a

1. A WARNING Downshifting to a lower gear at high speed causes engine rpm to increase excessively poten tially damaging the engine and it may also cause the rear wheel to skid and cause an accident Downshifting should be done below the vehicle speeds for each gear shown in the table Shifting down km h mph 6th 5th 30 19 5th 4th 25 15 4th 3rd 20 12 3rd 2nd 15 9 2nd 1st 15 9 Vehicle speed when shifting Shifting up km h mph 1st 2nd 15 9 2nd 3rd 25 15 4th 35 21 4th 5th 45 27 5th 6th 55 34 NOTE O 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 Braking e Close the throttle completely leav ing the clutch engaged except when shifting gears so that the engine will help slow down the motorcycle e Shift down one gear at a time so that you are in 1st gear when you come to a complete stop e When stopping always apply both brakes at the same time Normally the front brake should be applied a lit tle more than the rear Shift down or fully disengage the clutch as neces
2. 033040 5 11 WFD BY KAWASAKI HEAVY INDUSTRIES LTD DATE 55555555554 xv THIS VEHICLE CONFORKS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE DF MANUFACTURE SHOWN ABOVE GVAR ERA LOS CAR F LBS SEER TIRE GANR R LBS El MOTOR CYCLE TEO3303D 5 59465 0918 035650 5 GENERAL INFORMATION 37 12 13 WPORTANT NRT CNT CRMATICN RE AND LOAD LAT oreve a7 acc dent and ar an the woloncy e 1e ave chain MESU Tes 1 stag izy and handling characteristics 27 ths note eyee cts martaree I SOOO De cated terr 02 and agivgted as 21700 ag nesessa y Lem atio 7855 p srwarn Les unsuitat e eblacenn tires 2 over 040 Wen Lite trea 46215 lo kees Slack at 2 measured icway bolwee 82024615 o he lower dow o l 2 amil rez ace the irg wth arly Ie slasgerd lie Vaintain te fla on pressure specil sz mn elt the maiarayele om the s de cham is PUMA Ar Press eta Sire i vee Tuberess ei Vrumum Mead Jeol wen cslimatez sevvine Gf b pao dh i de severity of m 250 He XT the 2 lub 0 and For reslace 178 chaia wit ly eite asd e Tn Coni lie sta
3. A Meter Display Unit NOTE ODo 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 e Display the odometer in the multi function display e Push the RESET button while push ing the MODE button to select the 46 GENERAL INFORMATION meter display units The display units can be shifted in the following order km L k Y MPG US MPG UK L 100km k T6027848 6 Multifunction Display The multifunction display indicates the following modes e Odometer e Trip Meter A e Trip Meter B e Current Mileage e Average Mileage e Clock When the MODE button is pushed the display modes can be shifted as follows Odometer ODO Trip meter TRIP Trip meter TRIP B Curret Mileage km L Average Mileage AV km L Glock GLOCK 7002011622 6 NOTE O For safety do not operate the instru ment buttons while riding the motor cycle OThe multifunction display is dis played in the unit depending on the unit mode setting refer to the Unit Setting item in this section 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 is displayed on the multifunction display This meter can not be reset G 3 1802014 6 Odometer ODO
4. O The data are maintained even if the battery is disconnected O When the figures come to 999999 the display is stopped and locked GENERAL INFORMATION 47 Trip Meter The trip meter has two meters which distinguished between the TRIP A and TRIP 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 e Push the MODE button to select the trip meter A or B e Push the RESET button and hold it in e After two seconds the figure display turns to 0 0 and then starts counting 48 GENERAL INFORMATION when the vehicle is operated The meter counts until it is next reset NOTE OThe data is maintained even if the battery is disconnect O When the trip meter reaches 9999 9 while riding the meter resets to 0 0 and continues counting Current Mileage This display mode shows the current mileage by numerical value The cur rent mileage display is renewed every 4 seconds 16020166 6 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 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
5. The engine warning indicator light goes on when the ignition switch is turned on and goes off soon after ensuring that its circuit functions prop erly This light also goes on or blinking whenever the troubles occur in digital fuel injection DFI system The blinking of this light indicates the condition that the engine cannot be started Refer to the Stopping the Engine sec tion in the HOW TO RIDE THE MO TORCYCLE chapter for more informa tion If this light goes on have the DFI system checked by an authorized Kawasaki dealer GENERAL INFORMATION 61 Yellow KTRC Warning Indicator Light amp The KTRC warning indicator light goes on and the KTRC mode indicator and Power mode indicator blink whenever the trouble occurs in the KTRC system At this time the KTRC system does not function If the KTRC warning indicator light goes on have the KTRC system checked by an authorized Kawasaki dealer Yellow Warning Indicator Light For models equipped with KIBS This warning indicator light func tions as the KTRC warning indicator light and KIBS warning indicator light The yellow warning indicator light and the KTRC warning symbol go on and the KTRC mode indicator and Power mode indicator blink whenever the trou ble occurs in the KTRC system 62 GENERAL INFORMATION The yellow warning indicator light and the KIBS warning symbol go on when ever the trouble occurs in the KIBS sys tem For more detail
6. WARNING Failing to properly observe the road ahead increases the chance of an accident Do not concen trate on the shift up indicator light by taking your eyes off the road observe using peripheral vision When shifting down to a lower gear do not shift at such a high speed that the engine r min rpm jumps excessively Not only can this cause engine dam age but the rear wheel may skid and cause an accident Down shifting should be done below 5 000 r min rpm for each gear NOTE O Pushing and holding the RESET but ton advances the shift up engine speed continuously OThe data is maintained even if the battery is disconnected GENERAL INFORMATION 57 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 58 GENERAL INFORMATION Yellow ABS Indicator Light For models equipped with KIBS amp Normally the ABS indicator light goes 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 the ABS indicator light shows any of the following a fault or faults may have taken place in the ABS You should have the ABS checked by an authorized Kawasaki dealer The light does not go on when the ignition switch is turned on e The light remains lit after the motorcycle starts moving e The light goes on whi
7. o AV 7 m L 221 76020 i 6 Average Mileage B e While the average mileage is dis played push the RESET button and hold it in until the average mileage values resets to NOTE OThe data is maintained by backup power if the ignition switch is turned off OWhen the battery is disconnected the average mileage resets to OAfter resetting the average mileage the numerical value is not displayed until 5 mL 0 2 US oz of fuel has been used and 100 m 328 ft has been traveled Clock To adjust hours and minutes do the followings while the motorcycle is at a stop e Turn the ignition switch on e Push the MODE button to select the clock GENERAL INFORMATION 49 e Push the RESET button for more than 2 seconds Both the hour and minute displays start blinking ele ele 123 7 4 16802034821 e Push the RESET button The hour display only blinks Push the MODE button to advance the hours vig te oye TGO2035BZ1 e Push the RESET button The hour display stops blinking and the minute display starts blinking Push the MODE button to advance the min utes 50 GENERAL INFORMATION 1 te oa 76802036821 e Push the RESET button Both the hour and minute displays start blink ing again e Push the MODE button The dis plays stop blinking and the clock starts working NOTE
8. With the exception of genuine Kawasaki Parts and Accessories Kawasaki has no control over the design or application of accessories In some cases improper installation or use of accessories or motorcycle modification will void the motorcycle 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 OKawasaki 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 SAFETY INFORMATION 15 fitting additional accessories The fol lowing 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 t is im portant that the passenger sits still while the motorcycle is in motion and not interfere with the operation
9. 145 Stopping the Motorcycle in an Wheels eee eet en 148 Emergency 97 Battery ete ete 151 Parking cete ete te 98 155 Kawasaki TRaction Control KTRC 99 157 Power 103 General Lubrication 158 KTRC and Power Mode Cleaning Your Motorcycle 160 Combination 104 General Precautions 160 MAINTENANCE AND ADJUSTMENT 106 Washing Your Motorcycle 161 Daily 108 APPENDIX eee enne 166 Storage ise ea mu 166 Troubleshooting Guide 169 Your Warranty Owner Satisfaction 170 Reporting Safety Defects Environmental Protection MAINTENANCE RECORD SAFETY INFORMATION 13 SAFETY INFORMATION Read Owner s Manual Read this Owner s Manual care fully before riding so that you will be thoroughly 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 ri
10. 4 Kawasaki Includes Important Safety Information Operating Instructions Maintenance and Storage Ninja ZX 6R Ninja ZX 6R ABS Motorcycle OWNER MANUAL Quick Reference Guide This Quick Reference Guide will assist you in finding the information you re looking for A Table of Contents is included after the Foreword SAFETY INFORMATION GENERAL INFORMATION HOW TO RIDE THE MOTORCYCLE MAINTENANCE AND ADJUSTMENT APPENDIX MAINTENANCE RECORD Whenever you see the symbols shown below heed their instructions Always follow safe operating and main tenance practices A DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious in jury A 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 O NOTE indicates information that may help or guide you in the operation or service of the vehicle A WARNING NOTICE Engine exhaust some of its constituents and certain vehi cle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproduc tive harm THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OP ERATOR AND AS A VEHICLE ONLY Foreword Congratulations
11. to negative or a battery explosion and serious damage to the electrical system may oc cur e Follow the standard engine starting procedure 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 e After the engine has started discon nect the jumper cables Disconnect the negative cable from the mo torcycle first e Reinstall the parts removed Moving Off e Check that the side stand is up e Pull in the clutch lever e Shift into 1st gear e Open the throttle a little and start to let out the clutch lever very slowly e As the clutch starts to engage open the throttle a little more giving the en gine just enough fuel to keep it from stalling 040618 G Shift Pedal HOW TO RIDE THE MOTORCYCLE 91 NOTE OThe motorcycle is equipped with a side stand switch This switch is de signed so that the engine does not 5 start if the transmission is in gear and the side stand is down Shifting Gears e Close the throttle while pulling in the clutch lever e Shift into the next higher or lower gear e Open the throttle part way while re leasing the clutch lever e For smooth riding each gear position should cover the proper rate of speed shown in the table 92
12. OFF po sition or the battery is discharged or removed Oln the KTRC OFF the mode is au tomatically switched to 1 whenever the ignition switch is turned to OFF position Also the mode is automati cally switched to 1 when the ignition switch is turned to ON position after the battery is discharged or removed Power Mode The Power mode determines the en gine power output characteristics and has two settings The Power mode and the KTRC can be set separately By combining each setting the rider can get various riding feelings For further details on the com bined use of the Power mode and the KTRC refer to KTRC and Power Mode Combination section Mode F Full Power The highest engine power output is achieved The rider can feel the full throttle response of the engine HOW TO RIDE THE MOTORCYCLE 103 Mode L Low Power About 80 of the highest engine power output is achieved The throttle re sponse is milder than F mode Power mode setting e Close the throttle grip completely e Hold down 0 3 0 4 seconds the Power button on the left handlebar Switch to change the mode E nons 6 A Power Button 104 HOW RIDE THE MOTORCYCLE Mode F Full 2 Mode L Low Power 100728 6 OWhen changing the mode stop the motorcycle O The mode can be changed only when the throttle grip is closed completely e Check the indicator to make sure that the m
13. Pushing the MODE button momen tarily advances the hour or minute step by step Pushing and hold ing the button advances the hour or minute continuously O The clock works normally by the back up power while the ignition switch is turned off O When the battery is disconnected the clock is reset to 1 00 and starts working again when the battery is connected Gear Position Indicator The gear position indicator shows the corresponding gear positions where the transmission is shifted For example when the transmission is in 6th gear 6 is displayed A Gear Position Indicator Olf the gear position is in the neutral position the gear position is disap pears and the neutral indicator light goes on Coolant Temperature Meter The coolant temperature meter in dicates temperature of the engine coolant GENERAL INFORMATION 51 16020206 6 When the coolant temperature rises to above 40 104 F the numerical value of the coolant temperature at the present state is displayed 16020196 G Coolant Temperature Meter e the coolant temperature is below 40 C 104 F is displayed e f 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 warning indicator light and coolant temperature warn ing symbol also go on This warns 52 GENERAL INFO
14. contribute to a stable ride not only for sports riding but also when riding on a rough or slippery road surface KTRC is designed for use on public roads KTRC cannot respond to ev ery condition Acceleration may be de layed under certain conditions 100 HOW RIDE THE MOTORCYCLE A WARNING WARNING KTRC cannot protect the rider from all possible hazards and is not a substitute for safe rid ing practices All riders must be aware of how the KTRC system operates and its limitations It is still your responsibility to ride at appropriate speeds and throttle control for weather road surface and traffic conditions If a wheelie occurs due to excessive acceleration KTRC will control the en gine output to make the front wheel contact the road surface In this case slightly release the throttle grip so that the front wheel stays in contact with the road surface Use of nonrecommended tires could cause a malfunction or improper operation of KTRC Always use recommended stan dard tires for this motorcycle KTRC determines the traction control characteristics with three mode selec tions KTRC can also be set to OFF KTRC and the Power mode can be set separately By combining each set ting the rider can get various riding feelings For further details on the com bined use of the KTRC and the Power mode refer to KTRC and Power Mode Combination section Mode 1 KTRC least intervenes amo
15. 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 HOW TO RIDE THE MOTORCYCLE 97 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 98 Parking WARNING The engine and exhaust system A WARNING get extremely hot during normal Operating or parking the vehi operation and can cause serious cle
16. sary to keep the engine from stalling e Never lock the brakes or it will cause the tires to skid When turning a cor ner itis better not to brake at all Re duce your speed before you get into the corner e Even in motorcycles equipped with ABS braking during cornering may HOW TO RIDE THE MOTORCYCLE 93 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 e For emergency braking disregard downshifting and concentrate on applying the brakes as hard as pos sible without skidding A Front Brake Lever 94 HOW RIDE THE MOTORCYCLE 11061178 6 Rear Brake Pedal Kawasaki Intelligent anti lock Brake System KIBS For models equipped with KIBS KIBS regulates anti lock braking per formance with more precision during sports riding compared to a conven tional ABS system KIBS is designed to help prevent the wheels from locking up when the brakes are applied hard while riding straight KIBS automatically regulates brake force using engine data in ad dition to front and rear wheel speed to help prevent wheel lock up and al lows more stable steering control while stopping KIBS helps provide stability while stopping by preventing wheel lock up but you should be aware of the follow ing e To apply the brakes effectively use the front brake lever an
17. Adjustment To increase damping force The adjuster is located at the upper C To decrease damping force end of the rear shock absorber Standard 1 5 turns out Out from the fully seated position turned fully clockwise 144 MAINTENANCE AND ADJUSTMENT e Turn the adjuster clockwise to in crease compression damping force e Turn the adjuster counterclockwise to decrease compression damping force NOTICE A Compression Damping Force Adjuster B To increase damping force C To decrease damping force Standard adjusting damaged 2 5 turns out Out from the fully seated position turned fully clockwise Do not turn the adjuster beyond the fully seated position or the mechanism may be MAINTENANCE AND ADJUSTMENT 145 Setting Tables Front Fork Spring Preload Setting Softest setting limit Standard E i Adjuster Position 5 turns in 20 turns in Spring Action Strong Setting Load Speed gt High This position is the fully seated position turned fully counterclockwise In from the fully seated position turned fully counterclockwise This adjustment range may not exactly match the number shown in the table due to small tolerance of production 146 MAINTENANCE AND ADJUSTMENT Front Fork Damping Force Settings Softest d cud Standard Hardest Poe setting limit Rebo
18. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motor cycle includes a catalytic converter system 3 Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low perme ation fuel hoses and fuel tank 3 Evaporative Emission Control System California Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere Instead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped High Altitude Performance Adjustment Information High Altitude adjustment is not required Maintenance and Warranty Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels This Owner s Manual contains those maintenance rec ommendations for your motorcycle Those items identified by the Periodic Mainte nance Chart are necessary to ensure compliance with the applicable standards As the owner of this motorcycle you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner s Manual at your own expense The Kawasaki Limi
19. Torque Axle Nut 127 N m 13 0 kgf m 94 ft lb NOTE A Cotter Pin Olf a torque wrench is not available NOTE this item should be serviced by an authorized Kawasaki dealer 16069822 6 O When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise to the next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole TK16030B22 6 A Turn Clockwise MAINTENANCE AND ADJUSTMENT 135 A WARNING A loose axle nut can lead to an accident resulting in serious in jury or death Tighten the axle nut to the proper torque and in stall a new cotter pin e Check the rear brake see the Brakes section Brakes If you feel there is something wrong when applying the brakes have the brake system checked by an autho rized Kawasaki dealer immediately 136 MAINTENANCE AND ADJUSTMENT WARNING be kept between the upper and lower Air in the brake lines diminish enes 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 A Front Brake Fluid Reservoir e With the brake fluid re
20. 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 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 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
21. 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 A 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 Fueling SAFETY INFORMATION 19 Never Ride with Drugs or Alcohol A 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 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 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 DOT approved helmet even if th
22. ful chemicals for human body Drinking coolant can result in serious injury or death Use coolant in accordance with the instructions of the manufacturer If coolant must be added of ten or the reserve tank com pletely runs dry there is proba bly leakage in the system Have the cooling system inspected by your authorized Kawasaki dealer Use a permanent type of antifreeze soft water and ethylene glycol plus cor rosion and rust inhibitor chemicals for aluminum engines and radiators in the cooling system the mixture ratio of coolant choose the suitable one re ferring to the relation between freezing point and strength directed on the con tainer e Install the reserve tank cap Coolant Change Have the coolant changed by an au thorized Kawasaki dealer 122 MAINTENANCE AND ADJUSTMENT NOTICE If hard water is used in the sys tem it causes scale accumula tion in the water passages and considerably reduces the effi ciency of the cooling system NOTE OA permanent type of antifreeze is in stalled in the cooling system when shipped It is mixed at 5096 and has the freezing point of 35 C 31 Air Cleaner This motorcycle s air cleaner element consists of a wet paper filter which can not be cleaned Element Replacement e Remove the side covers and rider s Seat e Remove the fuel tank bracket bolts A Fuel Tank Bracket Bolts e Raise the f
23. mm 0 4 in To avoid damaging the electrical connections inside the switch Brake Light Switch Adjustment be sure that the switch body e To adjust the rear brake light switch does notturn during adjustment move the switch up or down by turn ing the adjusting nut Suspension System Front Fork NOTICE Do not force to turn the rebound and compression damping force adjuster from the fully seated po mise D sition at the adjusting mecha nism may be damaged A Rear Brake Light Switch B Adjusting Nut C Lights sooner D Lights later 140 MAINTENANCE AND ADJUSTMENT Spring Preload Adjustment The adjuster is located at the top of the left front fork leg Standard 5 turns in In from the fully seated position turned fully counterclockwise e Turn the adjuster clockwise to in crease spring preload and stiffen the suspension e Turn the adjuster counterclockwise to decrease preload and soften the suspension NOTE OThe spring preload adjuster can be turned with the allen wrench or suit able tool A Spring Preload Adjuster B Allen Wrench Rebound Damping Force Adjustment The adjuster is located at the top of the right front fork leg Standard 4 5 turns out Out from the fully seated position turned fully clockwise e Turn the adjuster clockwise with a Screwdriver to increase damping force e Turn the adjuster counterclockwise
24. most condi tions the oil viscosity may need to be changed to accommodate atmo spheric conditions in your riding area MAINTENANCE AND ADJUSTMENT 119 L L 1 SAE 204 50 SAE 20W 40 SAE 101 50 SAE 10W 40 20 10 0 10 20 20 40 0 L J 4 14 32 50 68 86 104 F 03023 22 6 Coolant Level Inspection e Position the motorcycle so that it is perpendicular to the ground e Check the coolant level through the coolant level gauge on the reserve tank located to the right ofthe engine The coolant level should be between the F Full and L Low level lines 120 MAINTENANCE AND ADJUSTMENT Coolant Filling e Remove the cap from the reserve 1x042118 6 A F Full Level Line B L Low Level Line C Reserve Tank NOTE O Check the level when the engine is cold room or atmospheric tempera ture e lf the amount of coolant is insuffi cient add coolant into the reserve tank tank and add coolant through the filler opening to the F Full level line A Reserve Tank Cap NOTE an emergency you can add wa ter alone to the coolant reserve tank however it must be returned to the correct mixture ratio by the addition MAINTENANCE AND ADJUSTMENT 121 of antifreeze concentrate as soon as Coolant Requirement possible A WARNING NOTICE Coolant containing corrosion in hibitors for aluminum engines and radiators include harm
25. neret dina 65 Ignition Switch Steering Lock 66 Right Handlebar Switches 68 Left Handlebar Switches 69 Brake Lever Adjuster 70 Fuel Tank 70 Fuel Tank 22222 71 Side Stand 76 EE 77 Helmet 81 Tool Kit eines 81 Periodic Maintenance 111 Air Cleaner Intake 82 are EAO cnt 116 Event Data Recorder 82 Coolant e i ded ces 119 HOW TO RIDE THE MOTORCYCLE 84 Cleaner 222 122 Break Iti 84 Throttle Control System 126 Starting the Engine 85 Idle 128 Jump 88 CIUtChi nere pend 129 Moving Off sse 90 Drive Chain eene 131 Shifting Gears 91 Biak65 eiie utendi rd 135 Braking emi 93 Brake Light Switches 138 Kawasaki Intelligent anti lock Suspension System 139 Brake System KIBS For models Front Fork ete 139 equipped with KIBS 94 Rear Shock Absorber 142 Stopping the Engine 96 Setting
26. on your purchase of a new Kawasaki motorcycle Your new mo torcycle is the product of Kawasaki s advanced engineering exhaustive testing and continuous striving for superior reliability safety and performance Please read this Owner s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle s controls its fea tures capabilities and limitations This manual offers many safe riding tips but its purpose is not to provide instruction in all the techniques and skills required to ride a motorcycle safely Kawasaki strongly recommends that all operators of this vehi cle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle operation To ensure a long trouble free life for your motorcycle give it the proper care and maintenance described in this manual For those who would like more detailed in formation on their Kawasaki Motorcycle a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer The Service Manual contains de tailed disassembly and maintenance information Those who plan to do their own work should of course be competent mechanics and possess the special tools 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 This manual should be considered a permanent par
27. to decrease damping force NOTICE Do not turn the adjuster beyond the fully seated position or the adjusting mechanism may be damaged MAINTENANCE AND ADJUSTMENT 141 A Rebound Damping Force Adjuster Compression Damping Force Adjuster The adjuster is located at the top of the right front fork leg Standard 6 turns out Out from the fully seated position turned fully clockwise 142 MAINTENANCE AND ADJUSTMENT e Turn the adjuster clockwise with a Screwdriver to increase damping force e Turn the adjuster counterclockwise to decrease damping force noe Do not turn the adjuster beyond the fully seated position or the adjusting mechanism may be damaged A Compression Damping Force Adjuster 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 MAINTENANCE AND ADJUSTMENT 143 Rebound Damping Force Adjustment e Turn the adjuster clockwise to in The adjuster is located at the lower crease rebound damping force end of the rear shock absorber e 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 Compression Damping Force A Rebound Damping Force Adjuster
28. vehicle speed with wheel speed Since non recommended tires can affect wheel speed they may cause the 96 computers to make incorrect cal OKIBS does not function if the battery culations that can extend braking is discharged When riding with an distance insufficiently charged battery KIBS may not function Keep the battery in WARNING good condition according to the 5 tery Maintenance section Use of non recommended tires y can cause the KIBS to malfunc tion and lead to extended brak Stopping the Engine ing distance resulting in a crash causing serious injury or death e Close the throttle completely Always use the recommended e Shift the transmission into neutral standard tires for this motorcy Turn the ignition key to OFF cle e Support the motorcycle on a firm level surface with the side stand e Lock the steering NOTE OWhen the KIBS is functioning you NOTE may feel a pulsing in the brake lever motorcycle is equipped with a and or pedal This is normal Main vehicle down sensor which causes tain pressure on the lever and or the engine to stop automatically if the pedal for most effective braking motorcycle falls down The engine OKIBS does not function below speeds of approx 5 km h 3 1 mph warning indicator light blinks when the starter button is pressed if the engine cannot be started After
29. 30 40 mm 1 2 1 6 in Drive Chain Slack Adjustment e Loosen the left and right chain ad juster locknuts e Remove the cotter pin and loosen the axle nut A Axle Nut B Cotter Pin C Adjuster D Locknut e If the chain is too loose turn out the left and right chain adjusters evenly MAINTENANCE AND ADJUSTMENT 133 e If the chain is too tight turn in the left and right chain adjusters evenly e 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 Adjuster E Locknut NOTE OWheel alignment can also be checked using the straightedge or string method 134 MAINTENANCE AND ADJUSTMENT WARNING e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Install a new cotter pin through the axle nut and axle and spread its ends Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding con dition Align the rear wheel us ing the marks on the swingarm or measuring the distance be tween the center of the axle and swingarm pivot e Tighten both chain adjuster locknuts e Tighten the axle nut to the specified torque Tightening
30. ADJUSTMENT 125 Oil Draining e Inspect the transparent reservoir lo cated under the left side of the engine to see if any oil has run down TK102058 6 A Reservoir e If there is any oil in the reservoir re move the reservoir from the lower end of the drain hose and drain the oil 126 MAINTENANCE AND ADJUSTMENT A WARNING Oil on tires will make them slip pery and can cause an accident and injury Be sure to install the reservoir in the drain hose after draining Throttle Control System Throttle Grip Throttle Grip free play Inspection e 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 e If the throttle grip does not return properly have the throttle control system checked by an authorized Kawasaki dealer e Check the throttle grip free play by turning back and forth 1111508 6 A Throttle Grip B Throttle Grip Play Throttle Grip Play 2 3 mm 0 08 0 12 in e f there is improper play adjust it Throttle Grip free play Adjustment e Loosen the locknuts at the lower ends of the throttle cables and screw both throttle cable adjusters in com pletely 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 MAINTENA
31. ENANCE AND ADJUSTMENT NOTICE Never remove the sealing strip or the battery can be damaged Do not install a conventional battery in this motorcycle or the electrical system cannot work properly Make Yuasa Battery Type YTX9 BS Battery Maintenance It is the owner s responsibility to keep the battery fully charged Failure to do so can lead to battery failure and leave you stranded If you are riding your vehicle infre quently inspect the battery voltage weekly using a voltmeter If it drops below 12 8 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 OLeaving 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 101225 If the above chargers are not avail able use equivalent one For more details ask your Kawasaki dealer Battery Charging e Charge the battery
32. FORMATION beam goes on to signal the driver of the vehicle ahead that you are about to pass The passing light is shut off as Soon as the button is released Power KTRC Button Refer to the KTRC or Power mode system instructions of the How to Ride the Motorcycle chapter for operations Brake Lever Adjuster There is an adjuster on the brake lever The adjuster has 6 positions so that the released lever position can be adjusted to suit the operator s hands 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 6 and maximum at Number 1 A Adjuster B Mark Fuel Tank Cap To open the fuel tank cap pull up the key hole cover Insert the ignition key into the fuel tank cap and turn the key to the right To close the cap push it down into place with the key inserted The key can be removed by turning it to the left to the original position Close the key hole cover NOTE O The fuel tank cap cannot be closed without the key inserted and the key cannot be removed unless the cap is locked properly O Do not push on the key to close the cap or the cap cannot be locked GENERAL INFORMATION 71 A Key Hole Cover B Ignition Key C Fuel Tank Cap Fuel Tank The following octane rating gaso line is recommended for the fuel tank Avoid filling the tank in the rain or whe
33. NCE AND ADJUSTMENT 127 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 e f 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 128 MAINTENANCE AND ADJUSTMENT be done by an authorized Kawasaki dealer e With the engine idling turn the han dlebar to each side If handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or they may be damaged Be sure to correct any of these conditions before idling A WARNING Operation with improperly ad justed incorrectly routed or damaged cables could result in an unsafe riding condition Be sure the control cables are ad justed and routed correctly and are free from damage Idle Speed Idle Speed Adjustment e Start the engine and warm it up thor oughly e Adjust the idle speed by turning the idle adjusting screw NOTE O While the engine is cold the fast idle system automatically raises the en gine idling speed Idle Speed 1 250 1 350 r min rpm 18130468 6 A Idle Adjusting Screw e Open and close the throttle a few times to make sure that the idle speed does not change Readjust if necessary e With the engine idl
34. Power Mode Indicator This indicator shows the selected Power mode For more detailed in formation about the Power mode see 54 GENERAL INFORMATION Power mode section in the HOW TO RIDE THE MOTORCYCLE chapter 234 160020256 6 A Power Mode Indicator KTRC Mode Indicator This indicator shows the selected KTRC mode For more detailed in formation about the KTRC mode see Kawasaki TRaction Control KTRC section in the HOW TO RIDE THE MOTORCYCLE chapter A KTRC Mode Indicator KTRC Level Indicator The instantaneous strength and weakness of the KTRC operation can be checked with the KTRC level indica tor in the multifunction meter while the motorcycle is running The stronger the traction control works the more the segments go on A KTRC Level Indicator 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 is 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 Shift Up Indicator Light The Shift up indicator light can be used in closed course competition Do not use the shift up indicator during ev eryday riding When the engine speed reaches a pre set speed the shift up indicator ligh
35. RMATION the operator that the coolant temper ature is high A Coolant Temperature Warning Symbol B Red Warning Indicator Light If the coolant temperature rises to above 120 C 248 F is displayed and starts blinking the warning indica tor light and coolant temperature warn ing symbol also go on This warns the operator that the coolant temperature is too high Stop the engine and check the coolant level in the reserve tank af ter the engine cools down Have the cooling system checked by an autho rized Kawasaki dealer A Coolant Temperature Warning Symbol B Red Warning Indicator Light Do not let the engine continue running when the coolant tem perature shows Prolonged engine operation will result in severe engine damage from overheating 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 GENERAL INFORMATION 53 A Economical Riding Indicator A 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
36. ake sure they e Pull out the side cover out slowly to are securely locked clear the projections and the hook and loop fasteners Rider s Seat Removal e Clear the hook and remove the side e Remove the bolts and washers on cover the inner cover GENERAL INFORMATION 79 A Wellnut B Projections C Hook and Loop Fasteners D Hook E Side Cover e Remove the other side of the inner cover and side cover in the same Way e Remove the bolts and pull off the seat upward A Bolt Both Sides B Rider s Seat Rider s Seat Installation e Insert the tab on the rear of the rider s seat into the slot in the frame and tighten the bolts 80 GENERAL INFORMATION A Rider s Seat A Hook B Tab B Slot C Slot C Projections D Holes e When install the side cover insert the E Hook and Loop Fasteners hook into the slot and then insert the projections into the holes and attach the hook and loop fasteners e Install the wellnut e Install the inner cover e Install the bolts and washers e Install the other side of the inner cover and side cover in the same Helmet Hooks Helmets can be secured to the motor cycle using the helmet hooks The hel met hooks are located under the pas senger s seat A WARNING Riding with helmets attached to the hooks could cause an ac cident by distracting the oper ator or interfering with normal vehicle operation Do not ride the
37. al 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 e Be sure the engine and exhaust cool before washing e Avoid applying degreaser to seals brake pads and tires e Avoid all harsh chemicals solvents detergents and household cleaning products such as ammonia based window cleaners e Gasoline brake fluid and coolant will damage the finish of painted and plastic surfaces wash them off im mediately e Avoid wire brushes steel wool and all other abrasive pads or brushes e Use care when washing the wind shield headlight lens and other plastic parts as they can easily be scratched e Avoid using pressure washers wa ter can penetrate seals and electrical components and damage your mo torcycle MAINTENANCE AND ADJUSTMENT 161 e Avoid spraying water in delicate ar eas such air intake fuel system brake component electrical compo nents muffler outlet and fuel tank openings Washing Your Motorcycle e Rinse your bike with cold water from a garden hose to remove any loose dirt e Mix a mild neutral detergent de signed for motorcycles or automo
38. and check the wheel balance Fuel Have sufficient fuel for the high fuel consumption during high speed opera tion SAFETY INFORMATION 23 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 and bolts are tight and that all safety related parts are in good condition 24 GENERAL INFORMATION GENERAL INFORMATION Specifications PERFORMANCE Minimum Turning Radius DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass ZX636E ZX636F ENGINE Type Displacement Bore x Stroke 3 4 m 134 in 2 085 mm 82 09 in 705 mm 27 8 in 1 115 mm 43 90 in 1 395 mm 54 92 in 130 mm 5 12 in 192 kg 423 Ib 194 kg 428 Ib DOHC 4 cylinder 4 stroke liquid cooled 636 38 8 cu in 67 0 x 45 1 mm 2 64 x 1 78 in Compression Ratio Starting System Cylinder Numbering Method Firing Order Fuel System Ignition System Ignition Timing Electronically advanced Spark Plug Type Gap Lubrication System Engine Oil Type Viscosity Capacity Coolant Capacity TRANSMISSION Transmission Type GENERAL INFORMATION 25 12 9 1 Electric
39. ash the affected ar eas immediately with water for at least five minutes Seek medical attention Connecting Jumper Cables e Make sure the ignition switch is turned off e Remove the side cover and rider s seat e Slide the red cap from the positive terminal e 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 HOW TO RIDE THE MOTORCYCLE 89 A Motorcycle Battery Positive Terminal B From Booster Battery Positive Terminal C Shift Pedal Bracket D From Booster Battery Negative Terminal e Connect another jumper cable from the negative terminal of the booster battery to your motorcycle shift pedal bracket or other unpainted metal surface Do not use the nega tive terminal of the battery 90 HOW RIDE THE MOTORCYCLE 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
40. aster cylinder and caliper Brake pad wear C Brake light switch operation 138 MAINTENANCE AND ADJUSTMENT 115 Odometer Reading B year 1 000 km x 1 000 mile see CA 6 12 18 24 Items 0 6 3 8 7 6 11 4 15 2 Suspension system 2 4 3 Steering play Electrical system Spark plugs Chassis parts B Condition of bolts nuts and fasteners DL mL m I 116 MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection e If the engine is cold start the engine and run it for several minutes at idle speed e Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil A Level Inspection Window B Oil Filler Cap reaches every part can cause en C Upper Level Line gine seizure D Lower Level Line e If the oil level is too high remove the excess oil through the oil filler open ing using a syringe or some other suitable device e f the oil level is too low add oil to reach the correct level Use the same type and brand of oil that is already in the engine e 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 MAINTENANCE AND ADJUSTMENT 117 Oil and or Oil Filter Change e The oil
41. ature and altitude and so the tire pressure should be checked and adjusted when your rid ing involves wide variations in tem perature or altitude 11478 6 Tire Pressure Gauge Tire Air Pressure when cold Front 250 kPa 2 50 kgf cm 36 psi 290 kPa 2 90 kgf cm 42 psi Rear 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 1096 of tread life 9096 worn So it is false economy and unsafe to use the tires until they are bald Tire Wear Inspection e 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 MAINTENANCE AND ADJUSTMENT 149 Minimum Tread Depth 1 mm 0 04 in Under 130 km h 80 mph 2 mm 0 08 in Over 130 km h 3 mm 0 12 in 80 mph 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 150 MAINTENANCE AND ADJUSTMENT TK21146822 6 A Crack or Cut B Nail C Swelling or High spot D Stone e Remove any imbedded stones or other foreign particles from the tread NOTE OHave the wheel balance inspected whenever a new tire is installed WARNING Tires that have
42. been punctured and repaired do not have the same capabilities as 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 O When operating on public roadways keep maximum speed under traffic law limits Standard Tire Tubeless Make Type Front HYPERSPORT S20F J Size 120 70ZR17M C 58W BRIDGESTONE BATTLAX Make Type Rear HYPERSPORT S20R J Size 180 55ZR17M C 73W BRIDGESTONE BATTLAX A WARNING Mixing tire brands and types can adversely affect handling and cause an accident resulting in injury or death Always use the same manufacturer s tires on both front and rear wheels MAINTENANCE AND ADJUSTMENT 151 A WARNING New tires are slippery and may cause loss of control and injury A break in period of 160 km 100 miles is necessary to 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 electrolyte level or add distilled water 152 MAINT
43. 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 e After washing rinse your motorcy cle thoroughly with clean water to re move any residue residue from the 162 MAINTENANCE AND ADJUSTMENT detergent can damage parts of your motorcycle e Use a soft cloth to dry your motorcy cle As you dry inspect your motor cycle for chips and scratches Do not let the water air dry as this can dam age the painted surfaces e Start the engine and let it idle for sev eral minutes The heat from the en gine will help dry moist areas e Carefully ride your motorcycle at a slow speed and apply the brakes several times This helps dry the brakes and restores them to normal operating performance e Lubricate the drive chain to prevent rusting NOTE OAfter riding an area where the roads are salted or near the ocean immediately wash your motorcycle with cold water Do not use warm water as it accelerates the chemical reaction of the salt After drying apply a corrosion protection spray on all metal and chrome surfaces to prevent corrosion O Condensation may form on the inside of the headlight lens after riding in the rain 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 Cl
44. ble connections are clean Battery Installation e Place the battery in the battery case e Install the band e Connect the capped cable to the terminal and then connect the black cable to the terminal NOTE O Install the battery in the reverse order of the Battery Removal NOTICE Installing the cable to the terminal of the battery or the cable to the terminal of the battery can seriously damage the electrical system e Put a light coat of grease on the ter minals to prevent corrosion MAINTENANCE AND ADJUSTMENT 155 e Cover the terminal with its protec tive cap e Reinstall the parts removed Headlight Headlight aiming should be done by an authorized Kawasaki dearer Horizontal Adjustment The headlight beam is adjustable horizontally If not properly adjusted horizontally the beam will point to one side rather than straight ahead e Turn the horizontal adjuster in or out until the beam points straight ahead 156 MAINTENANCE AND ADJUSTMENT TK23214822 A Horizontal 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 e Turn the vertical adjuster in or out to adjust the headlight
45. change and oil filter replace ment should be done by an autho rized Kawasaki dealer A WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local authorities for approved disposal methods or possible recycling TK002458 6 A Engine Oil Drain Bolt Tightening Torque Engine Oil Drain Bolt 29 N m 3 0 kgf m 21 ft lb 118 MAINTENANCE AND ADJUSTMENT 18022468 6 Oil Filter Tightening Torque Oil Filter 17 N m 1 7 kgf m 13 ft lb Recommended Engine Oil Type Kawasaki Performance 4 Stroke Motorcycle Oil Kawasaki Performance 4 Stroke Semi Synthetic Oil Kawasaki Performance 4 Stroke Full Synthetic Oil or other 4 stroke oils with API SG SH SJ SL or SM with JASO MA MA1 or MA2 rating Viscosity SAE10W 40 Kawasaki Performance Oils and Lu bricants have been specifically engi neered for your vehicle Consistent use of these products meets or ex ceeds warranty and service require ments and can help to extend the life of your Kawasaki 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 2 8 L 3 0 US qt when filter is not removed 3 1 L 3 3 US qt when filter is removed Although 10W 40 engine oil is the recommended oil for
46. d either be able to answer any other questions you might have immediately or be able to find the answer for you Please send your correspondence to Consumer Services Kawasaki Motors Corp U S A P O Box 25252 Santa Ana CA 92799 5252 949 460 5688 176 APPENDIX Reporting Safety Defects For Products Sold in the United States of America District of Columbia and U S Territories Only If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Kawasaki Motors Corpora tion U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems be tween you your dealer or Kawasaki Motors Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S De partment of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline APPENDIX 177 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
47. d rear brake pedal simultaneously in the same manner as a conventional motorcy cle brake system e KIBS cannot compensate for ad verse road conditions misjudgment or improper application of brakes You must use the same discretion as you would with motorcycles not equipped with KIBS KIBS is not designed to shorten the braking distance On loose uneven or downhill surfaces the stopping distance of a motorcycle with KIBS may be longer than that of an equiv alent motorcycle without KIBS Use special caution in such areas KIBS 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 a light applica tion of both brakes or not to brake at all Reduce your speed before you get into the corner Same as conventional brake system an excessive sudden braking may cause wheel lock up that makes it harder to control a motorcycle HOW TO RIDE THE MOTORCYCLE 95 e KIBS will not prevent the rear wheel lifting A WARNING KIBS cannot protect the rider from all possible hazards and is not a substitute for safe rid ing practices Be aware of how the KIBS 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 eThe computers integrated the KIBS compares
48. der training pro gram to learn the proper skills and tech niques necessary for safe motorcycle operation Daily 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 Checks section and the Periodic Main tenance section in the MAINTENANCE AND ADJUSTMENT chapter for more information A WARNING Failure to perform these checks or to correct a problem before operation may result in serious damage or an accident Always perform daily checks before op eration 14 SAFETY INFORMATION 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 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 Ib
49. e Clutch does not properly disengage While Riding e No fuel in tank e Fuel tank air vent is obstructed e Overheating e Battery discharged Your Warranty Owner Satisfaction Welcome to the Kawasaki family Congratulations on buying your Kawasaki vehicle You ve chosen a great high quality product with state of the art features and built to Kawasaki s high standards Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Corp U S A Here is some important information regarding your vehicle s limited warranty Frequently Asked Questions APPENDIX 171 What is a Limited Warranty The most important thing to know about your warranty is that it protects you from manufacturing defects in material or workmanship during the warranty pe riod You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale The warranty does not cover the cost of regularly scheduled maintenance The warranty also does not ap ply to the normal wear of items such as tires brake pads transmission drive belts chains sprockets etc What is the Good Times Protection Plan Much of the warranty coverage offered by the limited warranty can be extended by purchasing Kawasaki s Good Time Protection Plan GTPP See your Kawasaki dealer or go to Kawasaki com for more information if you don t already have the GTPP What Am Responsible For You are r
50. ean off any obstructions with a stream of low pressure water 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 MAINTENANCE AND ADJUSTMENT 163 e When washing the motorcycle al ways use a mild neutral detergent and water e The semi gloss finish effect may be lost when the finish is excessively rubbed e If any doubt consult an authorized Kawasaki dealer Windshield and Other Plastic Parts After washing use a soft cloth to gently dry plastic parts When dry treat the windshield headlight lens and other nonpainted plastic parts with an approved plastic cleaner polisher product 164 MAINTENANCE AND ADJUSTMENT 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 ab
51. ed Item Inspection 2 Dealer Inspection Change or Replace Dealer Change or Replace Lubrication Dealer Lubrication 112 MAINTENANCE AND ADJUSTMENT Odometer Reading B year x 1 000 km x 1 000 mile see CA 6 12 18 24 Items 0 6 3 8 7 6 11 4 15 2 O Air cleaner element C Q 122 128 Throttle control system play smooth 126 return no drag Engine vacuum synchronization Fuel system Fuerhose hose Coolant level 119 Cooling system MAINTENANCE AND ADJUSTMENT 113 Odometer Reading B x 1 000 km x 1 000 mile year See CA 1 6 12 18 24 Items 0 6 3 8 7 6 11 4 15 2 Coolant water hoses and O rings 3 every 36 000 km Valve clearance 22 500 mile Air suction system Clutch operation play engagement disengagement 129 Tire air pressure 148 Wheels and tires 148 Wheel bearing damage Drive chain lubrication condition C 131 every 600 km 400 mile 114 MAINTENANCE AND ADJUSTMENT Odometer Reading B x 1 000 km x 1 000 mile see s 12 18 24 Page Items 0 6 3 8 7 6 11 4 15 2 Q every 1 000 434 Drive chain slack C 600 mile mile Drive chain wear C Brake system Brake fluid level Brake fluid front and rear Brake hose rubber parts of brake m
52. es on if you operate the throttle grip un the engine to stop automatically if the necessarily HOW RIDE THE MOTORCYCLE 87 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 A Clutch Lever NOTE B Starter Lockout Switch The motorcycle is equipped with a starter lockout switch This switch is NOTICE designed so that the engine does not start if the transmission is in gear and the side stand is down However the engine can be started if the clutch lever is pulled and the side stand is fully up Do not let the engine idle longer than five minutes or engine overheating and damage may occur 88 HOW RIDE THE MOTORCYCLE Jump Starting DANGER If your motorcycle battery is run Battery acid generates hydro down it should be removed and gen gas which is flammable and uH charged If this is not practical 12 explosive under certain con volt booster battery and jumper cables ditions is present within may be used to start the engine 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 w
53. esponsible for maintaining your vehicle according to the maintenance schedule shown in this owner s manual 172 APPENDIX You are responsible for notifying your dealer immediately if there is a problem and you as the owner will need to authorize the dealer to inspect the unit You will be responsible for paying for routine maintenance including the first scheduled service You can have the required servicing done by your Kawasaki dealer recommended or an equally qualified service facility You can also do your own maintenance work if you have the proper tools service references and me chanical skills However if a failure is found to be caused by improper servicing it would not be covered by the limited warranty You may purchase a Kawasaki Service Manual and any necessary special tools directly from your Kawasaki dealer You will be responsible for paying for repairs needed because of an accident to replace worn parts such as tires chains brakes and for repairs needed because of a lack of maintenance misuse or racing Whether you do it yourself or take your vehicle to a Kawasaki dealer be sure to record your service in the Maintenance Record section of this Owner s Manual Keep all receipts for the service and or items necessary to perform the maintenance so that in the event of a failure you can document the service history APPENDIX 173 What Are Dealership s Responsibilities Your Kawasaki dealer offers a w
54. f the Research Octane Number RON and the Motor Octane Number MON as shown in the table Octane Rating Method Minimum Rating Antiknock RON MON Index 2 NOTICE Use only unleaded gasoline Never use leaded gasoline Leaded gasoline significantly reduces the capability of the cat alytic converter in the exhaust system 74 GENERAL INFORMATION NOTICE Use minimum of 90 octane gaso line only to prevent severe en gine damage 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 Gasoline quality is important Fuels of low quality or not meet ing standard industry specifi cations may result in unsatis factory performance Operating problems that result from the use of poor quality or nonrecom mended fuel may not be covered under your warranty Fuels Containing Oxygenates Gasoline frequently contains oxy genates alcohols and ethers espe cially in areas of the U S and Canada which are required to sell such refor mulated fuels as part of a strategy to reduce exhaust emissions The types and volume of fuel oxy genates approved for use in unleaded gasoline by the U S Environmental Protection Agency include a broad range of alcohols and ethers but only two components have seen any signif icant level of commercial use Ga
55. following the in structions of your battery charger e The charger will keep the battery fully charged until you are ready to re install the battery in the motorcycle see Battery Installation MAINTENANCE AND ADJUSTMENT 153 A DANGER Battery acid generates hydro gen gas which is flammable and explosive under certain con ditions t 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 154 MAINTENANCE AND ADJUSTMENT A WARNING Battery posts terminals and re lated accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproduc tive harm handling Wash hands after Battery Removal e Make sure the ignition switch is turned off e Remove the side covers and the riders seat Refer to the Seats section in the GENERAL INFORMA TION chapter e Disconnect the cables from the bat tery first from the terminal and then the terminal e Remove the band n2 6 A Terminal B Terminal C Band e Take the battery out of the case e Clean the battery using a solution of baking soda and water Be sure that the ca
56. fuel level rises i filler seck If tank is overtilled hea say cause fuel to expand and flow inte Evaseralive Emission Control System resulting in hard starting and eagine hesitati 56071 0158 1031426 CONTRO IAF ORNK TON TAIL pisi anta SYSTEN SE Sue m HaT AMT Joc gu mecs Set iae ro ur id SE HE ESIC S PEQUATIBIS APPLICABLE TO 9 4 d ELT 8 LID E033000 5 GENERAL INFORMATION 35 8 only on California model CORTE Mo SODE FAMILY 53127 N AD US MENT TERRY repe gus SERVICE CT 2 SL ST ESAE SAL at OL OTN T FE KE Rus Mess 033010 5 36 GENERAL INFORMATION 9 only on California model 10 IE VACUUM 5067 ROT 0 2 AGRAM MOTORCYCLE NOISE EMISSION CONTROL THIS MOTORCYCIF MFFTS FPA NOISF FM SSION REQUIREMENTS BY FEDERAL TEST PROCTDUR MOD II ICALIONS WHICH CAUSE THIS MOTORCYCLE 10 EXCEED FEDERAL NOISE STANDARDS ARE PROH D TED BY FEDERAL LAW SEE OWNER S MANUAL MODET SPECIFIC CODE SEE VEHICLE IDENTIFICAT ION NUMBER ON STEERING TIL AD NOISE LIMIT CLOSING FUEL
57. grease in accordance with the Periodic Main tenance Chart or whenever the vehicle has been operated under wet or rainy conditions Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime Apply engine oil to the following pivots e Side Stand e Clutch Lever e Front Brake Lever e Rear Brake Pedal Lubricate the following cables with a pressure cable luber e K Clutch Inner Cables e K Throttle Inner Cables MAINTENANCE AND ADJUSTMENT 159 TK26001B22 6 Apply grease to the following points e K Clutch Inner Cable Upper Ends e K Throttle Inner Cable Upper Ends K Should be serviced by an authorized Kawasaki dealer NOTE OAfter connecting the cables adjust them 160 MAINTENANCE AND ADJUSTMENT Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance optimize overall per formance and extend its useful life Covering your motorcycle with a high quality breathable motorcycle cover will help protect its finish from harmful UV rays pollutants and reduce the amount of dust reaching its surfaces 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 materi
58. he 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 maintenance service performed by a competent me chanic following the procedures in the Service Manual HOW TO RIDE THE MOTORCYCLE 85 Starting the Engine e Check that the engine stop switch is inthe position Engine Stop Switch B Starter Button e Turn the ignition key to ON position e Make sure the transmission is in neu tral 86 HOW RIDE THE MOTORCYCLE 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 e Without holding the throttle grip push the starter button to start the engine A Green Neutral Indicator Light NOTE B Ignition Switch C ON position O While the engine is cold the fast idle system automatically raises the en NOTE gine idling speed At this time the O The motorcycle is equipped with a engine warning indicator light may go vehicle down sensor which caus
59. ide range of services parts accessories and information on your product and on Kawasaki Each dealer is independently owned and operated and is responsible for the deal ership s operations its repair warranty and service work and its personnel Your dealer is responsible for completing the set up and pre delivery service of your new Kawasaki vehicle The dealership should also explain its operation main tenance and warranty provisions so you understand them at the time of purchase or at any other time you have questions The dealership is responsible for inspecting your Kawasaki vehicle if there is a failure investigating the cause of the problem and getting any needed authoriza tion from Kawasaki if the repair is one that will be covered by the limited warranty The dealership will also file all necessary paperwork The dealership is responsi ble for correctly completing any necessary repairs whether they are covered by the limited warranty or not 174 APPENDIX How Do Get Warranty Service If there is a problem with your vehicle within the limited warranty period you will need to schedule a service appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diagnosis You can go to any Kawasaki dealer for warranty repairs Your Kawasaki dealer will inspect your vehi cle and give you the results of the inspection The dealer will perform the repairs at no cost to you if it is dete
60. ifornia model 32 GENERAL INFORMATION 9 Vacuum Hose Routing Diagram 10 Noise Emission Control Information 11 Weight and Manufacture 12 Important Drive Chain Information 13 Tire and Load Data only on California model 1 2 TE03527D 5 TE03528D 5 3 GENERAL INFORMATION 33 DANGER POISON EU Ex FLUSH EYES es ES IMMEDIATELY 7 SHIELD SULFURIC WITH WATER ACID GET EXPLOSIVE SPARKS CAN CAUSE GASES CAUSE FLAMES BLINDNESS OR BLINDNESS OR INJURY SMOKING SEVERE BURNS KEEP OUT OF REACH OF CHILDREN EYES NO SERVICED BY READING PA 19605 IN U S A YUASA BATTERY INC lt 9 DOSADA X 034590 5 34 GENERAL INFORMATION 4 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Do not incinerate puncture or open A AVERTISSEMENT Cette unite contient de I azote haute pression Une mauvaise manipulation peut entralner d explosion 9 Ne pas bruler ni perforer ni ouvrir axa eu BIESSJIAAUC 316083 XPAORA ROU 2090 ETN 03460087 6 5 033530 5 6 IMPORTANT USE 90 0GTANE 25 GASOLINE ONLY NOTICE USE MINIMUM OF 90 0CTANE GASOLINE ONLY TO PREVENT SEVERE ENGINE DAMAGE 56030 0357 TEO31720N9 C 7 only on California model 8 1 Never fill tank se
61. ine 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 Frame No 10011208 6 10911218 6 A Engine Number A Frame Number GENERAL INFORMATION 29 Location of Labels All warning labels which are on your you and your dealer obtain the cor s vehicle are repeated here Read labels rect replacement on your vehicle and understand them Refer to the actual vehicle label for thoroughly They contain information model specific data grayed out in the which is important for your safety and illustration 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 OThe sample warning labels in this section have part numbers to help 1 Brake Fluid Front 30 GENERAL INFORMATION 2 Brake Fluid Rear 3 Battery Poison Danger 4 Rear Shock Absorber Warning TEO2035C72 GENERAL INFORMATION 31 5 Radiator Cap Danger 6 Fuel Notice 7 Fuel Level 8 Vehicle Emission Control Information only on Cal
62. ines 116 Tires Air pressure when cold install the air valve cap 148 Tire wear 149 Drive Chain Slack 132 Lubricate if dry 131 MAINTENANCE AND ADJUSTMENT 109 See Operation Page Bolt nuts and fasteners Check for loose and or missing bolts nuts and fasteners Steering Action smooth but not loose from lock to lock No binding of control cables Brakes Brake pad wear 137 Brake fluid level 136 No brake fluid leakage Throttle Throttle grip play 126 Clutch Clutch lever play 129 Clutch lever operates smoothly E Coolant No coolant leakage 110 MAINTENANCE AND ADJUSTMENT 5 See Operation Page Coolant level between level lines when engine is cold 119 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 MAINTENANCE AND ADJUSTMENT 111 Periodic Maintenance Service at number of years shown or indicated odometer reading intervals whichever comes first For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping California model only Emission Relat
63. information about the lighting pattern of the KIBS system see the Yellow ABS Indicator Light in this chapter If the yellow warning indicator light goes on have the KTRC system and or KIBS system checked by an authorized Kawasaki dealer Amber Fuel Level Indicator Light By The fuel level warning indicator light goes on and FUEL blinks in the multifunction display when approxi mately 3 5 L 0 9 US gal of usable fuel remains Refuel at the earliest opportunity when the fuel level warn ing indicator light goes on and FUEL blinks Warning When vehicle stands with Side Stand Fuel Level Warning Indicator Light cannot show the amount of fuel in the fuel tank exactly Stand upright the vehicle to check the fuel level _ A Yellow Fuel Level Warning Indicator Light B FUEL NOTE O When pushing the mode button while FUEL is displayed the display can be shifted to the odometer mode The Fuel level warning indicator light and FUEL will blink in case of the open or short of the wiring Have the wiring inspected by an authorized Kawasaki dealer immediately Red Warning Indicator Light This warning indicator light and the oil pressure warning symbol 357 should go on whenever the ignition Switch is turned on and go off after starting the engine GENERAL INFORMATION 63 160020386 6 A Warning Symbols B Red Warning Indicator Light This warning indicator light has the three wa
64. ing 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 MAINTENANCE AND ADJUSTMENT 129 A 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 e Check the clutch lever play as shown Clutch Lever Play 2 3 mm 0 08 0 12 in 130 MAINTENANCE AND ADJUSTMENT 510 0 A Adjuster B Clutch Lever Play e f the play is incorrect adjust the lever play as follows Clutch Cable Free Play Adjustment e Turn the adjuster so that the clutch lever will have the specified free play WARNING Too much cable play can pre vent clutch disengagement and cause an accident resulting in serious injury or death When adjusting the clutch or replac ing the cable be sure the up per end of the clutch outer cable is fully seated in its fitting or it could slip into place later creat ing enough cable play to prevent clutch disengagement If it cannot be done have the clutch cable adjusted by an auth
65. ion 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 NOTE OAlthough 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 operates the elec tric starter when the transmission is in neutral Refer to the Starting the Engine sec tion in the How to Ride the Motorcycle chapter for starting instructions Left Handlebar Switches 76041468 0 Dimmer Switch B Power KTRC Button C Turn Signal Switch D Horn Button 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 GENERAL INFORMATION 69 High beam Low beam 2 NOTE O When the headlight is on high beam both headlights go on When the headlight is on low beam only one headlight goes on Turn Signal Switch When the turn signal switch is pushed to the left lt or right 9 the corresponding turn sig nals blink on and off To stop blinking push the switch in Horn Button When the horn button is pushed the horn sounds Passing Button When the passing button is pushed the headlight high beam passing 70 GENERAL IN
66. is is not a legal requirement Make sure that your helmet fits cor rectly and is properly fastened Choose a motorcycle helmet that meets DOT safety standards Ask your motorcycle dealer to advise you if necessary 20 SAFETY INFORMATION 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 resistant 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 view mirror may misjudge a vehi cle s dis
67. ki dealer to pur chase additional spare keys either us ing your original key as a master or us ing the key code on the tag or your key Store one key at home and keep an other spare in your wallet or riding gear in case the original is lost Ignition Switch Steering Lock This is a three position key operated Switch The key can be removed from the switch when it is in the OFF or LOCK position A Ignition Switch Steering Lock B ON position C OFF position D LOCK position GENERAL INFORMATION 67 OFF Engine off Electrical circuits Olf you leave the key in the ON po off sition on for a long time the battery Engine on All electrical may become totally discharged equipment can be used LOCK Steering locked Engine off Electrical circuits off To operate the ignition Switch orF gt ON 1 Turn the handlebar fully to the O The tail city and license plate lights 1 left T 2 For locking push down the are on whenever the ignition key is in key in the OFF position and the ON position Headlights go on T turn rete LOCK when the starter button is released after starting the engine To avoid 1004128822 battery discharge always start the engine immediately after turning the ignition key to ON 68 GENERAL INFORMATION Right Handlebar Switches A Engine Stop Switch B Starter Button Engine Stop Switch In addition to the ignit
68. le riding Remember that the ABS does not function when the indicator light is on If the ABS fails the front and rear brakes work normally as a conventional brake system GENERAL INFORMATION 59 Ty Yellow ABS Yellow Warning Multifunction Status Brake Condition Indicator Light Indicator Light Meter Normal KIBS Goes off Goes off None Engine information ABS Goes off Goes on KIBS communication error Battery voltage Low voltage Blinks Goes off None decreases ABS ABS error Normal brake Goes on Goes off None NOTE OABS indicator light may come on under 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 5 km h 3 1 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 Kawasaki dealer O When the ABS indicator light is blinking the ABS has been in the low voltage mode insufficient battery voltage When it is in the low voltage mode the KIBS system does not function but the ABS functions To recover the KIBS system turn the ignition switch OFF and charge the battery If the battery is fully charged 60 GENERAL INFORMATION and the low voltage mode continues you should have the KIBS checked by an authorized Kawasaki dealer Warning Indicator Lights Yellow Engine Warning Indicator Light
69. llowed to enter the red zone operation in the red zone will overstress the engine and may GENERAL INFORMATION 43 cause serious engine damage 16020086 6 Tachometer B Red Zone When the ignition switch is turned on the tachometer needle momentar ily goes from the minimum to the max imum then goes back from the maxi mum to the minimum reading to check its operation If the tachometer does not operate correctly have it checked by an authorized Kawasaki dealer 44 GENERAL INFORMATION Multifunction Meter Coolant Temperature Meter Gear Position Indicator Power Mode Indicator KTRC Mode Indicator Multifunction Display Odometer Trip Meter A B Current Mileage Average Mileage Clock F KTRC Level Indicator G Warning Symbols H Speedometer Economical Riding Indicator J KIBS Warning Symbol for models equipped with KIBS K KTRC Warning Symbol for models equipped with KIBS moou When the ignition switch is turned on all LCD segments are displayed with opening display functions for few seconds then the multifunction meter turns to operational mode Speedometer The speedometer shows the speed of the vehicle in digital values 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 GENERAL INFORMATION 45 8 n
70. mbol E3 The red warning indicator light and the battery warning symbol E3 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 authorized Kawasaki dealer NOTE O When the all indicator lights and dis play of the multifunction meter go off the battery voltage is insufficient Have the machine checked by an authorized Kawasaki dealer promptly because the engine might stop sud denly when keeping running in that condition Keys This motorcycle has a combination key which is used for the ignition Switch steering lock seat lock and fuel tank cap Included with the key is a key num ber which may be stamped on a sep arate plate Record the key number in GENERAL INFORMATION 65 the space provided and store the num ber in a safe place If your keys came with a plate store it in a safe place as well 1603035822 6 A Ignition Key B Tag C Key Number Write your key number here Lo E 66 GENERAL INFORMATION In the event you lose your keys you will need the key number to have a du plicate made If you cannot locate your key number contact the dealer where you purchased your Kawasaki motor cycle It s possible the dealer may have the number in its records If the key number is lost completely you will need to replace the ignition switch and all other locks operated by that key Contact your Kawasa
71. motorcycle with helmets at tached to the hooks GENERAL INFORMATION 81 A Helmet Hooks Tool Kit The tool kit is located under the pas senger s seat 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 82 GENERAL INFORMATION A Tool Kit B Band Air Cleaner Intake The air cleaner intake allows air to enter the fuel system Never allow any thing to restrict the flow of air into the air cleaner A restricted air cleaner will reduce performance and increase ex haust emissions A Air Cleaner Intake Event Data Recorder This vehicle is equipped 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 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 n addition to Kawasaki other parties such as law enf
72. ndars crap Live il wears 12 over Banen megsuree over 2T k 200 om SI 0 ka EEA 1 reter sta taz we a 2 4 straig t w i PBNORS 2000 0 tens on See Une Gamer s Manual fer chai slona on 00 roA 56033 0753 56053 0651 TEO3563D 5 035640 5 38 GENERAL INFORMATION Location of Parts NOoROND Rear View Mirrors Clutch Lever Starter Lockout Switch Meter Instrument Brake Fluid Reservoir Front Front Brake Lever Throttle Grip 6 8 Left Handlebar Switches 9 Spring Preload Adjuster 10 Ignition Switch Steering Lock 11 Rebound Damping Force Adjuster 12 Compression Damping Force Adjuster oNA Headlight Fuse Box Spark Plugs Fuel Tank Compression Damping Force Adjuster Battery Tool Kit Turn Signal Lights License Plate Light Front Fork Radiator Idle Adjust Screw Side Stand Switch Shift Pedal GENERAL INFORMATION 39 10012358 6 15 Rebound Damping Force Adjuster 16 Swingarm 17 Drive Chain 18 Chain Adjuster 19 Seat Lock 40 GENERAL INFORMATION 8 s 10012368 6 1 Tail Brake Light 8 Muffler 2 Passenger s Seat 9 Brake Calipers 3 Rider s Seat 10 Brake Disks 4 Rear Shock Absorber 11 Rear Brake Light Switch 5 Brake Fluid Reservoir Rear 12 Rear Brake Pedal 6 Fuel Ta
73. near flammable materials can burns cause a fire and can result in Never touch a hot engine ex property damage or severe per haust pipe or muffler during op sonal injury eration or after stopping the en Do not idle or park your vehicle gine in an area where tallord eg oper MADE d e Shift the transmission into neutral terials could come into contact and turn the ignition key to OFF with the muffler or exhaust pipe e 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 e f 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 elock the steering to help prevent theft HOW TO RIDE THE MOTORCYCLE 99 Kawasaki TRaction Control KTRC KTRC is an intelligent system that calculates the slip level of the rear wheel wheelspin during acceleration and controls the optimum slip ratio to suit the riding conditions KTRC can
74. ng the three modes This mode gives maxi mum acceleration for sport riding 2 KTRC intervention is at the interme diate level between the mode 1 and mode 3 Mode 3 KTRC intervenes early enough to prevent the rear wheel from spinning whenever possible This mode is used in low grip situations KTRC mode setting e Close the throttle grip completely e Hold down 0 3 0 4 seconds the KTRC button on the left handlebar Switch to change the mode HOW TO RIDE THE MOTORCYCLE 101 T0068 6 A KTRC Button KTRC While Stopping OFF 1 1 1 1 1 Mode 1 Mode 2 Mode 100698 6 102 HOW RIDE THE MOTORCYCLE NOTE OWhen changing the mode stop the motorcycle O The mode can be changed only when the throttle grip is closed completely O Operate the throttle carefully while the KTRC is OFF because wheel spin of the rear wheel cannot be con trolled e Check the indicator to make sure that the mode has been changed When the traction control is activated rear wheel starts to break traction the segment s of the KTRC level indica tor goes on ra 1110078 6 KTRC Mode Indicator B KTRC Level Indicator For information about the KTRC warning indicator light see Warning In dicator Light section in the GENERAL INFORMATION chapter NOTE Oln the KTRC mode 1 3 the selected mode is maintained even when the ignition switch is turned to
75. nk Cap 13 Oil Level Inspection Window 7 Air Cleaner 14 Coolant Reserve Tank Meter Instruments A Tachometer B RESET Button C MODE Button D Yellow Shift Up Indicator Light E Yellow Engine Warning Indicator Light F Amber Fuel Level Warning Indicator Light G Blue High Beam Indicator Light H Green Neutral Indicator Light 1 Green Turn Signal Indicator Light J Red Warning Indicator Light K Multifunction Meter L Yellow KTRC Warning Indicator Light GENERAL INFORMATION 41 16020326 6 42 GENERAL INFORMATION For models equipped KIBS A Tachometer B Reset Button C Mode Button D Yellow Shift Up Indicator Light E Yellow Engine Warning Indicator Light F Amber Fuel Level Warning Indicator Light G Blue High Beam Indicator Light H Green Neutral Indicator Light 1 Green Turn Signal Indicator Light J Red Warning Indicator Light K Multifunction Meter L Yellow Warning Indicator Light M Yellow ABS Indicator Light 16020320 6 O For safety do not operate the instru ment buttons while riding the motor cycle Tachometer The tachometer shows the en gine speed in revolutions per minute r min rpm On the right side of the tachometer face is a portion called the red zone Engine r min rpm in the red zone is above maximum rec ommended engine speed and is also above the range for good performance NOTICE Engine r min rpm should not be a
76. ns to the muffler s or air intake system by cutting drilling or other means if such modifications result in increased noise levels TABLE CONTENTS SAFETY INFORMATION 13 Read Owner s Manual 13 TRAINING iie a BE 13 Daily Checks and Periodic Maintenance 13 Loading and Accessories 2 2 2 1 14 Passenger 15 Baggage and Luggage 16 Accessories 16 Other toad nie 17 If You are Involved an Accident 17 Safe 18 Carbon Monoxide Hazard 18 F leling 2 6 meters 19 Never Ride with Drugs or Alcohol 19 Protective Gear and Clothing 19 Safe Riding Techniques 20 Additional Considerations for High Speed Operation 22 GENERAL INFORMATION 24 24 Serial Number Locations 28 Location of Labels 29 Location 38 Meter Instruments 41 TACHOMETER 43 Multifunction Meter 44 Indicator Lights 54 Warning Indicator Lights 61 Keys ets uere c
77. ntact your local authorities for approved disposal methods or possible recy cling e Put in fresh engine oil e Empty the fuel from the fuel tank by the pump or siphon APPENDIX 167 A WARNING Gasoline is extremely flammable and can be explosive under certain con ditions creating the potential for serious burns Turn the ignition key off Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Gasoline is a toxic substance Dispose of gasoline properly Contact your local authorities for approved disposal methods e Empty the fuel system by running the engine at idle speed until the engine stalls If left in for a long time the fuel will break down and could clog the fuel system A 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 e Reduce tire pressure by about 20 e Setthe motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards under the front and rear wheels to keep damp ness away from the tire rubber 168 APPENDIX e Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on
78. ode has been changed A Power Mode Indicator NOTE OThe Power mode setting is main tained if the ignition switch is turned to OFF position or if the battery is disconnected KTRC and Power Mode Combination By combining the KTRC mode and Power mode the eight pattern settings are available to suit the various condi tions For example on a slippery road surface combining the Power mode L with the KTRC mode 3 can reduce the rear wheelspin The combination of each mode should be decided according to the driving skill and road conditions Set the combination with reference to the following table HOW RIDE THE MOTORCYCLE 105 examples of mode combinations WET SPORT CITY Slippery Road Power Mode F d L HM KTRC PFE Mode 1 2 3 T110043822 6 106 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Daily Checks and Periodic Maintenance to keep the motorcy cle in good running condition and to reduce air pollution The initial maintenance is vitally important and must not be neglected A WARNING Failure to perform these checks or to correct a problem before opera tion may result in serious damage or an accident Always perform daily checks before operation With a basic knowledge of mechanics and the proper use of tools you should be able to carry out man
79. of the motorcycle Do not carry ani mals on your motorcycle 16 SAFETY INFORMATION 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 will not move around while you are riding Recheck baggage security as often as possible not while the motorcycle is in motion and adjust as necessary Do not carry heavy or bulky items on a luggage rack lt is designed for light items and overloading can affect handling due to changes in weight distribution and aerodynamic forces Baggage and Luggage 1 All baggage should be carried as Accessories low as possible to reduce the effect on the motorcycle s center of grav 1 Do not install accessories or carry 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 Baggage should be securely at tached Make sure that the baggage baggage that impairs the perfor mance of the motorcycle 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 any other aspects of the motor cycle s ope
80. orcement GENERAL INFORMATION 83 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 84 HOW RIDE THE MOTORCYCLE 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 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 e The table shows maximum recom mended engine speed during the break in period Maximum engine Distance traveled 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 O When operating on public roadways keep maximum speed under traffic law limits e 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 e Do not race the engine while t
81. orized Kawasaki dealer NOTE After the adjustment is made start the engine and check that the clutch does not slip and that it releases properly 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 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 e Apply lubricant to the sides of the rollers so that it will penetrate to the rollers and bushings Apply lubricant to the seals so that the seals will be coated with lubricant Wipe off any excess lubricant MAINTENANCE AND ADJUSTMENT 131 16211822 6 e Wipe off any lubricant that gets on the tire surface Drive Chain Slack Inspection e Set the motorcycle up on its side stand e Clean the chain if it is dirty and lubri cate it if it appears dry e Rotate the rear wheel to find the po sition where the chain is tightest and measure the maximum chain slack by pulling up and pushing down the 132 MAINTENANCE AND ADJUSTMENT chain midway between the engine sprocket and rear wheel sprocket TKi16043B22 6 Chain Slack e f 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
82. ra 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 treated with a rubber protectant to help prolong their useful life WARNING Rubber protectants can be slip pery and if used on the tread area cause loss of traction re sulting in accident causing in jury or death Do not apply rub ber protectant to any tread area MAINTENANCE AND ADJUSTMENT 165 166 APPENDIX APPENDIX Storage Preparation for Storage e Clean the entire vehicle thoroughly e Run the engine for about five minutes to warm the oil shut it off and drain the engine oil A WARNING Engine oil is a toxic substance Dispose of used oil properly Co
83. ration Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can re sult in an unsafe riding condition Fairings windshields backrests and other large items have the ca pability of adversely affecting stabil ity and handling of the motorcycle 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 SAFETY INFORMATION 17 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 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 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 18 SAFETY INFORMATION and regulations if any other person ve hicle or property is involved Do not attempt to continue riding without
84. re heavy dust is blowing so that the fuel does not get contaminated 72 GENERAL INFORMATION A Tank Cap B Fuel Tank C Top Level D Filler Neck 812002822 6 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 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 California model only Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand and flow into the Evaporative Emission Control System resulting in hard start ing and engine hesitation and in compliance with the emission regulation Fuel Requirement Fuel Type Use clean fresh unleaded gasoline with a minimum Antiknock Index of 90 The Antiknock Index is posted on ser vice station pumps The octane rating of a gasoline is a measure of its resis tance to detonation or knocking The GENERAL INFORMATION 73 Antiknock Index is an average o
85. re this product with gasohol in the fuel system Before storage it is recom mended that you drain all fuel from the fuel system See the Storage section in this manual Side Stand The motorcycle is equipped with the side stand 16140678 6 Side Stand NOTE O When using the side stand turn the handlebar to the left Do notsit on the motorcycle while it is on its side stand Always kick the stand fully up before sitting on the motorcycle The motorcycle is equipped with 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 Seat Passenger s Seat Removal e Insert the ignition key into the seat lock e Remove the passenger s seat up ward while turning the key clockwise GENERAL INFORMATION 77 1616128 G A Ignition Key B Seat Lock C Passenger s Seat Passenger s Seat Installation e Insert the tab on the rear of the pas senger s seat into the slot in the frame e Insert the projections at the front of the passenger s seat into the holes on the frame e Push down the front part of the pas senger s seat until the lock clicks 78 GENERAL INFORMATION e Remove the inner cover A Tab B Slot C Projections A Bolts and Washers D Holes B Inner Cover e Pull up the front and rear ends of the e Remove the wellnut passenger s seat to m
86. rmined that the problem is covered by the warranty Kawasaki will work with your dealer to resolve any warranty issues No autho rization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer What if I am not Satisfied With My Warranty Service If you aren t satisfied with your dealership s repair work or operations it is best to discuss the situation with the appropriate dealership manager If you have already done this then contact the dealership s owner or general manager to request a review of the issue If you are unable to resolve a problem after consulting with the dealership man agement and need further assistance contact Kawasaki Motors Corp U S A at the address below Please be certain to provide the model vehicle identification APPENDIX 175 number VIN 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 information including the name of the dealership personnel with whom you have been working Upon receipt of your correspondence Kawasaki Motors Corp U S A will contact the dealership and work with it in resolving your problem Want to Contact Kawasaki This owner s manual should answer most of your questions about your Kawasaki Your Kawasaki dealer shoul
87. rning functions engine oil pressure warning coolant temper ature warning and battery warning This warning indicator light goes on with each warning symbols engine oil pressure warning symbol coolant temperature warning symbol and battery warning symbol 64 GENERAL INFORMATION If the red warning indicator light goes on with the engine running have its cause checked by an authorized Kawasaki dealer Oil Pressure Warning Symbol E The red warning indicator light and the oil pressure warning symbol 8 amp 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 Coolant Temperature Symbol The red warning indicator light and the coolant temperature warning symbol go on whenever the coolant temperature rises to about 115 C Warning 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 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 Battery Warning Sy
88. ront of the fuel tank e Disconnect the connector e Remove the air cleaner housing cover screws and remove the cover Screws C Air Cleaner Housing Cover e Put a clean lint free towel over the air cleaner housing ducts to keep dirt or other foreign material from enter ing MAINTENANCE AND ADJUSTMENT 123 A WARNING If dirt or dust is allowed to pass through into the throttle body assembly the throttle may be come stuck possibly causing accident Be sure to keep the dust from entering during clean ing NOTICE If dirt gets through into the en gine excessive engine wear and possibly engine damage will oc cur e Replace the air cleaner element with a new one 124 MAINTENANCE AND ADJUSTMENT A Air Cleaner Element A Clamp 5 e Install the air cleaner housing cover and tighten the screws e Run the throttle cables and clutch ca ble under the fuel tank bracket and e Connect the connector and hold the harness with the clamp of the air cleaner housing tighten the fuel tank bracket bolts se curely Clutch Cable B Throttle Cables C Fuel Tank Bracket WARNING Do not pinch the cables between the bracket and the frame Op eration with incorrectly routed or damaged cables could result in an unsafe riding condition Be sure the cables are routed cor rectly and not damaged MAINTENANCE AND
89. rubber parts or in the brakes e Lubricate the drive chain and all the cables e Remove the battery and store it where it will not be exposed to direct sunlight moisture or freezing 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 e Tie plastic bags over the muffler to prevent moisture from entering e Put a cover over the motorcycle to keep dust and dirt from collecting on it Preparation after Storage e Remove the plastic bags from the muffler e Install the battery in the motorcycle and charge the battery if necessary e Fill the fuel tank with fuel e Check all the points listed in the Daily Checks section e Lubricate the pivots bolts and nuts APPENDIX 169 Troubleshooting Guide Engine Does Not Start Starter Motor Won t Turn e Engine stop switch off e Transmission not in neutral e Fuse blown e Battery leads do not make good electrical contact with battery terminals e Battery discharged Engine Cranks But Won t Start e No fuel in tank e Fuel line clogged e Fuel broken down e Engine flooded e Spark plugs not in good contact e Spark plugs fouled or wet e Incorrect spark plug gap e Incorrect valve clearance e No first turning the ignition switch to OFF when the motorcycle falls down 170 APPENDIX Engine Stalls Just When Shifting Into 1st Gear e Side stand has been left down
90. servoirs held B Upper Level Line horizontal the brake fluid level must C Lower Level Line As T7208 6 A Rear Brake Fluid Reservoir B Upper Level Line C Lower Level Line e f 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 MAINTENANCE AND ADJUSTMENT 137 thickness of either pad lining is less than 1 mm 0 04 in replace both pads in the caliper as a set Pad replace ment should be done by an authorized Kawasaki dealer 1172058 6 A Front Brake Pads B Lining Thickness C 1 mm 0 04 in 138 MAINTENANCE AND ADJUSTMENT e If it does not ask your authorized Kawasaki dealer to inspect the front brake light switch e Checkthe operation of the rear brake light switch by depressing the brake pedal The brake light should go on after the proper pedal travel A Rear Brake Pads B Lining Thickness C 1 mm 0 04 in Brake Light Switches Brake Light Switch Inspection e Turn the ignition switch on e The brake light should go on when the front brake is applied A Brake Pedal B 10 mm 0 4 in e If the light does not come on adjust the rear brake light switch MAINTENANCE AND ADJUSTMENT 139 Brake Pedal Travel NO TICE 10
91. soline Alcohol Blends Gasoline containing up to 1096 ethanol alco hol produced from agricultural products such as corn also known as gasohol is approved for use Avoid using blends of unleaded gasoline and methanol wood alcohol whenever possible and never use gasohol contain ing more than 5 methanol Fuel system damage and perfor mance problems may result Gasoline Ether Blends The most common ether is methyl tertiary butyl ether MTBE You may use gasoline containing up to 1596 MTBE NOTE O Other oxygenates approved for use in unleaded gasoline include TAME up to 16 7 and ETBE up to 17 296 Fuel containing these oxy genates can also be used in your Kawasaki GENERAL INFORMATION 75 NOTICE Never use gasoline with an oc tane rating lower than the mini mum specified by Kawasaki Never use gasohol with more than 10 ethanol or more than 5 methanol Gasoline con taining methanol must also be blended with cosolvents and corrosion inhibitors Certain ingredients of gasoline may cause paint fading or dam age Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling When not operating your Kawasaki for 30 to 60 days mix a fuel stabilizer such as STA BIL with the gasoline in the fuel tank Fuel stabilizer additives inhibit oxidation of the fuel which mini mizes gummy deposits 76 GENERAL INFORMATION NOTICE Never sto
92. starter Left to right 1 2 3 4 1 2 4 3 FI Fuel Injection Battery and coil transistorized ignition 12 5 BTDC 91 300 r min rpm 36 4 BTDC 4 800 r min rpm NGK CR9E 0 7 0 8 mm 0 028 0 031 in Forced lubrication wet sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 3 6 L 3 8 US qt 2 5 L 2 6 US qt 6 speed return shift 26 GENERAL INFORMATION Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Gear Ratio 1st 2nd 3rd 4th 5th 6th FRAME Castor Trail Tire Size Front Rear Wet multi disc Chain drive 1 900 76 40 2 688 43 16 6 638 Top gear 2 846 37 13 2 200 33 15 1 850 37 20 1 600 32 20 1 421 27 19 1 300 26 20 23 5 101 mm 3 98 in 120 70ZR17MIC 58W 180 55ZR17MIC 73W GENERAL INFORMATION 27 Rim Size Front J17M C x MT3 50 Rear J17M C x MT5 50 E Fuel Tank Capacity 17 L 4 5 US gal Brake Fluid Front DOT4 Rear DOT4 ELECTRICAL EQUIPMENT Battery 12 V 8 Ah Headlight High Beam 12 V 55 W 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 28 GENERAL INFORMATION Serial Number Locations The engine and frame serial numbers are used to register the motorcycle They are the only means of identifying your particular mach
93. 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 178 MAINTENANCE RECORD Owner Name Address Phone Number Engine Number Vehicle Number Selling Dealer Name Phone Number Warranty Start Date MAINTENANCE RECORD Note Keep this information and a spare key in a secure location Date Odometer Reading Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 179 Odometer Reading Date Maintenance Performed Dealer Name Dealer Address 180 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 181 Odometer Reading Date Maintenance Performed Dealer Name Dealer Address 182 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 183 Odometer Reading Date Maintenance Performed Dealer Name Dealer Address ZX636EE ZX636FE HN RI AA Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Printed in Japan Motorcycle amp Engine Company Part No 99987 1804
94. t goes on to indicate the timing for shifting up to prevent engine damage The shift up indicator light has five modes light off blinking fast blink ing slow light on bright and light on dim The shift up indicator light timing GENERAL INFORMATION 55 can be adjusted between 10 000 r min rpm and 16 000 r min rpm To select a shift up indicator light mode or adjust the shift up engine speed setting in the tachometer do the following while the engine is stopped e Push the MODE and RESET button simultaneously for more than 2 sec onds The previous shift up engine speed setting will be displayed in the tachometer To change the shift up indicator light mode push the MODE button and the shift up indicator light will shift be tween light off blinking fast blink ing slow light on bright and light on dim The shift up engine speed can only be adjusted when the light is on To adjust the shift up engine speed press the RESET button and the shift up engine speed timing advances in 250 r min rpm increments up to 16 56 GENERAL INFORMATION 000 r min rpm Once the reading reaches at 16 000 r min rpm while advancing it returns to 10 000 r min rpm and begins advancing A Yellow Shift Up Indicator Light B Adjustable Range e To complete the adjustment push the MODE button and RESET but ton simultaneously for more than two seconds The tachometer now oper ates normally
95. t of the motorcycle and should remain with the motorcycle when it is sold All rights reserved No part of this publication may be reproduced without our prior written permission This publication includes the latest information available at the time of printing However there may be minor differences between the actual product and illustra tions and text in this manual All products are subject to change without prior notice or obligation KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company 2013 Kawasaki Heavy Industries Ltd May 17 2013 1 Emission Control Information To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Additionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regu lations of the United States Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the intake side of the engine While the engine is operating the vapors are drawn into the combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2
96. tance 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 cause the motorcycle to skid and lose control SAFETY INFORMATION 21 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 22 SAFETY INFORMATION Ride Prudently Riding at the proper speed
97. ted Emission Control System Warranty requires that you re turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty Please read the warranty carefully and keep it valid by complying with the owner s obligations it contains You should keep a maintenance record for your motorcycle To assist you in keeping this record we have provided space on pages 180 through 185 of this manual where an authorized Kawasaki dealer or someone equally competent can record the maintenance You should also retain copies of maintenance work orders bills etc as verification of this maintenance Tampering With Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance re pair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air box cover Modificatio
98. und 5 5 turns out 4 5 turns out 0 Adjuster Position Compression 7 turns out 6 turns out 0 Damping Force Weak Strong Setting ecc Hard Load T Good ec Bad Speed 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 MAINTENANCE AND ADJUSTMENT 147 Rear Shock Absorber Damping Force Settings E s Adjuster Rebound 3 turns out Position Compression 5 turns out 2 5 turns out gt Damping Force Weak Strong Setting Soft e Hard Load Light Good gt 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 148 MAINTENANCE AND ADJUSTMENT Wheels Tire Pressure Inspection e Remove the air valve cap e Check the tire pressure often using an accurate gauge e Make sure to install the air valve cap securely NOTE O Measure the tire pressure when the tires are cold that is when the mo torcycle has not been ridden more than a mile during the past 3 hours O Tire pressure is affected by changes in ambient temper
99. vertically NOTE On high beam the brightest points should be slightly below horizontal The proper angle is 0 4 degrees be low horizontal This is a 50 mm 2 0 in drop at 7 6 m 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 18222168 6 50 2 0 B Center of Brightest Spot C 7 6 m 25 ft D Height of Headlight Center Fuses Fuses are arranged in the fuse boxes located under left inner cover The main fuse is located under the fuel tank If a fuse fails during operation inspect the electrical system to determine the MAINTENANCE AND ADJUSTMENT 157 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 1051618 G A Fuse Box 158 MAINTENANCE AND ADJUSTMENT 10251628 6 TK25007B22 6 A WARNING Substituting fuses can cause wiring to overheat catch fire and or fail Do not use any sub stitute for the standard fuse Replace the blown fuse with a new one of the correct capacity as specified on the fuse boxes and main fuse A Normal B Failed General Lubrication Lubricate the points shown below with either engine oil or regular
100. y 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 MAINTENANCE AND ADJUSTMENT 107 A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area A 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 Olfa torque wrench is not available the maintenance items which require a specific torque value should be serviced by an authorized Kawasaki dealer 108 MAINTENANCE AND ADJUSTMENT Daily 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 Fuel Adequate supply in tank no leaks Engine Oil Oil level between level l

The motorcycle is equipped with a

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