kawasaki ninja 300 owners manual eng

8/10/2019 Kawasaki Ninja 300 Owners Manual Eng

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Quick Reference GuideSAFETY INFORMATION j

GENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

MAINTENANCE AND ADJUSTMENT j

APPENDIX j

MAINTENANCE RECORD j

This Quick Reference Guide willassist you in finding the informationyoure looking for.

A Table of Contents is included after the Foreword.



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Whenever you see the symbolsshown below, heed their instructions! Always follow safe operating and main-tenance practices.

DANGERDANGER indicates a hazardoussituation which, if not avoided,will result in death or serious injury.

WARNINGWARNING indicates a hazardoussituation which, if not avoided,could result in death or seriousinjury.

NOTICE NOTICE is used to address prac-tices not related to personal injury.

NOTE This note symbol indicates points of

particular interest for more efficient and convenient operation.



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WARNINGEngine exhaust, some of itsconstituents, and certain vehi-cle components contain or emit

chemicals known to the State of California to cause cancer andbirth defects or other reproduc-tive harm.

NOTICE THIS VEHICLE HAS BEEN MAN-UFACTURED FOR USE IN AREASONABLE AND PRUDENT

MANNER BY A QUALIFIED OP-ERATOR AND AS A VEHICLEONLY.



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Foreword

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-torcycle is the product of Kawasakis advanced engineering, exhaustive testing,and continuous striving for superior reliability, safety and performance.

Please read this Owners Manual carefully before riding so that you will bethoroughly familiar with the proper operation of your motorcycles controls, its fea-tures, capabilities, and limitations. This manual offers many safe riding tips, but itspurpose is not to provide instruction in all the techniques and skills required to ridea motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-

cle enroll in a motorcycle rider training program to attain awareness of the mentaland physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care andmaintenance described in this manual. For those who would like more detailed in-formation on their Kawasaki Motorcycle, a Service Manual is available for purchasefrom any authorized Kawasaki motorcycle dealer. The Service Manual contains de-tailed disassembly and maintenance information. Those who plan to do their ownwork should, of course, be competent mechanics and possess the special toolsdescribed in the Service Manual.

Keep this Owners Manual aboard your motorcycle at all times so that you canrefer to it whenever you need information.



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This manual should be considered a permanent part of the motorcycle and shouldremain 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 & Engine Company

2012 Kawasaki Heavy Industries, Ltd. May 2012. (4)



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3. Evaporative Emission Control SystemThe 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 InformationHigh Altitude adjustment is not required.



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Maintenance and Warranty

Proper maintenance is necessary to ensure that your motorcycle will continue to

have low emission levels. This Owners 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 thatthe recommended maintenance is carried out according to the instructions in thisOwners Manual at your own expense.

The Kawasaki Limited Emission Control System Warranty requires that you re-turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty.Please read the warranty carefully, and keep it valid by complying with the ownersobligations it contains.

You should keep a maintenance record for your motorcycle. To assist you inkeeping this record, we have provided space on pages 152 through 157 of thismanual where an authorized Kawasaki dealer, or someone equally competent, canrecord the maintenance. You should also retain copies of maintenance work orders,bills, etc., as verification of this maintenance.



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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 newvehicle for the purpose of noise control prior to its sale or delivery to the ultimatepurchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:* Replacement of the original exhaust system or muffler with a component not in

compliance with Federal regulations.* Removal of the muffler(s) or any internal portion of the muffler(s).* Removal of the air box or air box cover.* Modifications to the muffler(s) or air intake system by cutting, drilling, or other

means if such modifications result in increased noise levels.



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TABLE OF CONTENTS

SAFETY INFORMATION .................... 12Read Owners Manual ..................... 12Training ............................................ 12Daily Safety Chec ks and Periodic

Maintenance ................................. 12Loading and Acce ssories

Information.................................... 13Passenger .................................... 14

Baggage and Luggage ................. 15 Accessories .................................. 15Other Load .................................... 16

If You are Involved in a Accident ...... 16Safe Operation ................................. 17

Carbon Monoxide Hazard ............. 17Fueling .......................................... 18

Never Ride with Drugs or Alcohol . 18Protective Gear and Clothing ....... 18Safe Riding Techniques ................ 19 Additional Conside rations for High

Speed Operation ....................... 21

GENERAL INFORMATION ................. 23Specifications ................................... 23Serial Number Locations .................. 27Location of Labels ............................ 28Location of Parts .............................. 38Meter Instruments ............................ 41

Tachometer ................................... 42Multifunction Meter ....................... 43

Indicator Lights ............................. 49Warning Indicator Light ................. 50Keys ................................................. 52Ignition Switch/Steering Lock ........... 53Right Handlebar Switches ................ 55Left Handlebar Switches .................. 56Fuel Tank Cap .................................. 57

Fuel Tank ......................................... 57Side Stand ....................................... 62Seats ................................................ 63Helmet Hooks ................................... 66Tying Hooks ..................................... 66



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Tool Kit Compartment. ...................... 67Event Data Recorder ........................ 67

HOW TO RIDE THE MOTORCYCLE . 69Break-In ........................................... 69Starting the Engine .......................... 70Jump Starting ................................... 72Moving Off ........................................ 75Shifting Gears .................................. 76Braking ............................................. 77 Anti-lock Brake System (ABS) ......... 78

Yellow ABS Indicator Light ............ 81Stopping the Engine ......................... 81Stopping the Moto rcycle in an

Emergency ................................... 82Parking ............................................. 83

MAINTENANCE AND ADJUSTMENT 85Daily Safety Checks ......................... 87

Periodic Maintenance. ...................... 90Engine Oil ........................................ 95Coolant ............................................. 98 Air Cleaner ....................................... 101Throttle Control System ................... 105Idle Speed ........................................ 107

Clutch ............................................... 108Drive Chain ...................................... 110Brakes .............................................. 114Brake Light Switches. ....................... 117Suspension System ......................... 119

Rear Shock Absober .................... 119Setting Table ................................. 121

Wheels ............................................. 122Battery .............................................. 125Headlight .......................................... 130

Fuses ............................................... 132General Lubrication .......................... 133Cleaning Your Motorcycle ................ 134

General Precautions ..................... 134Washing Your Motorcycle ............. 136

APPENDIX .......................................... 140Storage ............................................ 140

Troubleshooting Guide ..................... 143Your Warranty/Owner Satisfaction ... 144Reporting Safety Defects ................. 150Environmental Protection ................. 151

MAINTENANCE RECORD ................. 152



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12 SAFETY INFORMATION

SAFETY INFORMATION

Read Owners ManualRead this Owners Manual care-

fully before riding so that you will bethoroughly familiar with the proper op-eration of your motorcycles controls,its features, capabilities, and limita-tions. This manual offers many saferiding tips, but its purpose is not to pro-vide instruction in all of the techniquesand skills required to ride a motorcyclesafely.

TrainingKawasaki strongly recommends that

all operators of this vehicle complete asuitable motorcycle rider training pro-gram to learn the proper skills and tech-niques necessary for safe motorcycleoperation.

Daily Safety Checks and

Periodic MaintenanceIt is important to keep your motor-

cycle properly maintained and in saferiding condition. Inspect your motorcy-cle before every ride and carry out allperiodic maintenance. See the DailySafety Checks section and PeriodicMaintenance section in the MAINTE-NANCE AND ADJUSTMENT chapter for more information.

WARNINGFailure to perform these checks

or to correct a problem beforeoperation may result in seriousdamage or an accident. Alwaysperform daily safety checks be-fore operation.



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SAFETY INFORMATION 13

To ensure your motorcycle is ser-viced using the latest servicing infor-mation, it is recommended that anauthorized Kawasaki Dealer performsthe periodic maintenance as directedin the Owners Manual.

If you notice any irregular operat-ing condition, have your motorcyclethoroughly checked at an authorizedKawasaki dealer as soon as possible.

Loading and AccessoriesInformation

WARNINGIncorrect loading, improper in-stallation or use of accessoriesor modification of your motorcy-cle may result in an unsafe ridingcondition. Before you ride themotorcycle, make sure it is notoverloaded and that you havefollowed these instructions.

Maximum Load

Weight of rider, passenger, baggage,and accessories must not exceed 180 kg(397 lb).

With the exception of genuineKawasaki Parts and Accessories,Kawasaki has no control over thedesign or application of accessories.In some cases, improper installation

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or use of accessories, or motorcyclemodification, will void the motorcyclewarranty; can negatively affect perfor-mance, stability and safety; and caneven be illegal.

In selecting and using accessories,and in loading the motorcycle, you arepersonally responsible for your ownsafety and the safety of other personsinvolved.

NOTE Kawasaki Parts and Accessories

have been specially designed for use on Kawasaki motorcycles. Westrongly recommend that all partsand accessories you add to your

motorcycle be genuine Kawasaki components.

Because a motorcycle is sensitive tochanges in weight and aerodynamicforces, you must take extreme care incarrying cargo, passengers an d/or in

fitting additional accessories. The fol-lowing general guidelines have beenprepared 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 affectcontrol of the motorcycle by im-proper positioning during corneringand sudden movements. It is im-

portant that the passenger sits stillwhile the motorcycle is in motionand not interfere with the operationof the motorcycle. Do not carry ani-mals on your motorcycle.



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4. Do not carry passengers unlesspassenger footpegs are installed.Instruct any passenger before ridingto keep his or her feet on the pas-senger footpegs and hold on to theoperator or seat strap. Do not carrya passenger unless he or she is tallenough to reach the footpegs withtheir feet.

Baggage and Luggage

1. All baggage should be carried aslow as possible to reduce the effecton the motorcycles center of grav-ity. Baggage weight should also be

distributed equally on both sides of the motorcycle. Avoid carrying bag-gage that extends beyond the rear of the motorcycle.

2. Baggage should be securely at-tached. Make sure that the baggage

will not move around while you areriding. Recheck baggage securityas often as possible (not while themotorcycle is in motion) and adjustas necessary.

3. Do not carry heavy or bulky itemson a luggage rack. It is designedfor light items, and overloading canaffect handling due to changes inweight distribution and aerodynamic

forces.

Accessories

1. Do not install accessories or carrybaggage that impairs the perfor-

mance of the motorcycle. Makesure that you have not adverselyaffected any lighting components,road clearance, banking capability(i.e., lean angle), control operation,wheel travel, front fork movement,



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or any other aspects of the motor-cycles operation.

2. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can re-sult in an unsafe riding condition.

3. Fairings, windshields, backrests,and other large items have the ca-pability of adversely affecting stabil-ity and handling of the motorcycle,

not only due to their weight, butalso due to the aerodynamic forceacting on these surfaces while themotorcycle is in operation. Poorlydesigned or installed items can re-sult in an unsafe riding condition.

Other Load

1. This motorcycle is not intended tobe equipped with a sidecar or to be

used to tow any trailers or other ve-hicles. Kawasaki does not manu-facture sidecars or trailers for mo-torcycles and cannot predict the ef-fects of such accessories on han-dling or stability, but can only warnthat the effects can be adverse andthat Kawasaki cannot assume re-sponsibility for the results of suchunintended use of the motorcycle.

2. Furthermore, any adverse effects onmotorcycle components caused bythe use of such accessories will notbe remedied under warranty.

If You are Involved in aAccident

Make sure of your own safety first.Determine the severity of any injuriesand call for emergency assistance if needed. Always follow applicable laws



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and regulations if any other person, ve-hicle or property is involved.

Do not attempt to continue ridingwithout first evaluating your motorcy-cles condition. Inspect for fluid leaks,check critical nuts and bolts, and checkthe 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 thoroughlychecked at a Kawasaki dealer as soonas possible.

Safe Operation

The following should be carefully ob-served for safe and effective vehicleoperation.

Carbon Monoxide Hazard

DANGERExhaust gas contains carbonmonoxide, a colorless, odorlesspoisonous gas. Inhaling carbonmonoxide can cause seriousbrain injury or death.

Do not run the engine in en-closed areas. Operate only in awell-ventilated area.



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Fueling

WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions. To prevent fireor explosion, turn the ignitionkey off. Do not smoke. Make

sure the area is well ventilatedand free from any source of flame or sparks; this includesany appliance with a pilot light.

Never Ride with Drugs or Alcohol Alcohol and drugs impair your judg-

ment and reaction time. Never con-sume alcohol or drugs before or whileriding motorcycles.

Protective Gear and Clothing

Helmet Kawasaki strongly recommends boththe operator and passenger wear aDOT-approved helmet even if this isnot a legal requirement.

- Make sure that your helmet fits cor-rectly and is properly fastened.

- Choose a motorcycle helmet thatmeets DOT safety standards. Askyour motorcycle dealer to adviseyou if necessary.

Eye Protect ion Always use eye protection. If your

helmet does not have a visor installed,wear goggles.



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Acc elerate and B rake Smo othly In general your actions should be

smooth as sudden acceleration, brak-ing or turning may cause loss of control,especially when riding in wet conditionsor on loose road surfaces, when theability to maneuver will be reduced.

Select Cor rect 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. Applyingonly one brake for sudden braking may

cause the motorcycle to skid and losecontrol.

Use Engine Brake When going down long slopes, help

control vehicle speed by closing the

throttle so that the engine can act as anauxiliary brake. Use the front and rear brakes for primary braking.

Riding in Wet Cond it ions Rely more on the throttle to controlvehicle speed and less on the front andrear brakes. The throttle should also beused judiciously to avoid skidding therear wheel from too rapid accelerationor deceleration.

Braking performance is also reducedin wet conditions. Carefully ride at aslow speed and apply the brakes sev-eral times to help dry and restores themto normal operating performance.

Lubricate the drive chain after wet-weather riding to prevent rust and cor-rosion.

Ride Prudent ly Riding at the proper speed and avoid-

ing unnecessarily fast acceleration areimportant not only for safety and low


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fuel consumption but also for long ve-hicle life and quieter operation.

Riding on Rough Roads

Exercise caution, slow down, andgrip the fuel tank with the knees for better stability.

Acceleration When quick acceleration is neces-

sary to pass another vehicle, shift toa lower gear to obtain the necessarypower.

Downshi f t ing To avoid engine damage and rear

-wheel lock-up do not downshift at highrpm.

Avo id Unnecessary Weaving Unnecessary weaving jeopardizesthe safety of both the rider and other motorists.

Additional Considerations for High Speed Operation

WARNINGHandling characteristics of amotorcycle at high speeds mayvary from those you are familiar with at legal highway speeds.

Do not attempt high speed oper-ation unless you have receivedsufficient training and have therequired skills.Do not operate at high speeds onpublic roads.

Brakes The importance of the brakes, es-

pecially during high speed operation,cannot be overemphasized. Check to




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see that they are correctly adjusted andfunctioning properly.

Steering

Looseness in the steering can causeloss of control. Check to see that thehandlebar 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, andcheck the wheel balance.

Fuel Have sufficient fuel for the high fuel

consumption during high speed opera-tion.

Engine Oil To avoid engine seizure and resulting

loss of control, make sure that the oillevel is at the upper level line.

Coolant To avoid overheating, check that the

coolant level is at the upper level line.

Electr ical Equ ipment 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 arein good condition.


GENERAL INFORMATION 23


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GENERAL INFORMATION

SpecificationsPERFORMANCE

Minimum Turning Radius 2.4 m (94 in.)

DIMENSIO NS

Overall L ength 2 015 mm (7 9.33 in.)

Overall Width 715 mm (28.1 in.)

Overall H eight 1 110 mm (4 3.70 in.)

Wheelbase 1 405 mm ( 55.31 in.)

Road Cle arance 140 mm (5 .51 in.)

Curb Mass (EX300A) 172 kg (379 lb)

(EX300B ) 174 kg (3 84 lb)

ENGINE

Type DOHC, 2 -cylinder, 4-stroke, liquid-cooled

Displacement 296 cm (18.1 cu in.)

Bore S troke 62.0 4 9.0 mm (2.44 1.93 in.)http://www.motorcycle.in.th

24 GENERAL INFORMATION


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Compression Ratio 10.6 : 1

Starting System Electric starter

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Fuel System FI (Fuel Injection)

Ignition System Battery and coil (transistorized ignition)

Ignitio n Timing(Electronically advanced)

10 BTDC @1 300 r/min (rpm) 31 BTDC @7 000r/min (rpm)

Spark Plug: Type NGK CR8EGap 0.7 0.8 mm (0.028 0.031 in.)

Lubrication System Forced lubrication (wet sump)

Engine Oil: Type API SG, SH, SJ, SL, or SM with JASO MA, MA1 or MA2

Viscosity SAE 10W-40

Capacity 2.4 L (2.5 US qt)Coolant Capacity 1.5 L (1.6 US qt)

TRANSMISSION

Transmission Type 6-speed, return shift



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Rim Size: Front J17M/C MT2.75

Rear J17M/C MT4.00

Fuel Tank Capacity 17 L (4.5 US gal)

ELECTRICAL EQUIPMENT

Battery 12 V 8 Ah

Headlight: High Beam 12 V 55 W + 55 W

Low Beam 12 V 55 W

Tail/Brake Light 12 V 5/21 W

Specifications are subject to change without notice.




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Serial Number LocationsThe engine and frame serial numbers are used to register the motorcycle. They

are the only means of identifying your particular machine from others of the samemodel type. These serial numbers may be needed by your dealer when orderingparts. In the event of theft, the investigating authorities will require both numbersas well as the model type and any peculiar features of your machine that can helpthem identify it.

Engine No.

A. Engine Number

Frame No.

A. Frame Number




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Location of Labels All warning labels which are on your

vehicle are repeated here. Read labelson your vehicle and understand themthoroughly. They contain informationwhich is important for your safety andthe safety of anyone else who may op-erate your vehicle. Therefore, it is veryimportant that all warning labels be onyour vehicle in the locations shown. If

any label is missing, damaged, or worn,get a replacement from your Kawasakidealer and install it in the correct posi-tion.

NOTE The sample warning labels in this

section have part numbers to help

you and your dealer obtain the cor-rect replacement.

Refer to the actual vehicle label for model specific data grayed out in theillustration.

1. Brake Fluid (Front)




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2. Brake Fluid (Rear)3. Battery Poison/Danger 4. Rear Shock Absorber Warning




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5. Radiator Cap Danger 6. Important Drive Chain Information7. Tire and Load Data8. Weight and Manufacture




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9. Daily Safety Checks10. Vehicle Emission Control Information11. Noise Emission Control Information12. Fuel Level



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1)

2)

3)




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4) 5)

6)



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10) only on California model

11)





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Location of Parts

1. Rear View Mirrors2. Clutch Lever 3. Starter Lockout Switch4. Meter Instruments5. Brake Fluid Reservoir (Front)

6. Front Brake Lever 7. Throttle Grip8. Left Handlebar Switches9. Ignition Switch/Steering Lock

10. Right Handlebar Switches




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1. Headlight2. Turn Signal Light3. Spark Plugs4. Fuel Tank5. Idle Adjusting Screw6. Battery and Fuse Box

7. Tool Kit8. Tying Hooks9. License Plate Light

10. Front Fork11. Radiator 12. Side Stand Switch

13. Shift Pedal14. Side Stand15. Swingarm16. Drive Chain17. Chain Adjuster 18. Seat Lock




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1. Muffler 2. Tail/Brake Light3. Passengers Seat4. Brake Fluid Reservoir (Rear)5. Riders Seat6. Air Cleaner 7. Rear Shock Absorber

8. Fuel Tank Cap9. Coolant Reserve Tank

10. Brake Discs11. Brake Calipers12. Rear Brake Light Switch13. Rear Brake Pedal14. Oil Level Inspection Window




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Meter InstrumentsA. Green Neutral Indicator

LightB. Red Battery Charging

System Warning Indicator Light

C. Red Oil Pressure WarningIndicator Light

D. Red Coolant TemperatureWarning Indicator Light

E. Yellow Engine WarningIndicator Light

F. Yellow ABS Indicator Light(Only on ABS model)

G. Blue High Beam Indicator Light

H. Green Right Turn SignalIndicator Light

I. Green Left Turn SignalIndicator Light

J. Left ButtonK. Right ButtonL. Tachometer M. Red ZoneN. Multifunction Meter




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NOTE 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 calledthe red zone. Engine r/min (rpm) inthe red zone is above maximum rec-ommended engine speed and is alsoabove the range for good performance.

NOTICE Engine r/min (rpm) should notbe allowed to enter the red zone;operation in the red zone willoverstress the engine and maycause serious engine damag e.

A. Tachometer B. Red Zone

When the ignition switch is turnedon, 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 checkits operation. If the tachometer doesnot operate correctly, have it checkedby an authorized Kawasaki dealer.




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Multifunction Meter

A. Economical RidingIndicator

B. Speedometer C. ClockD. Multifunction Display

- Odometer - Trip meter A- Trip meter B

E. Fuel Gauge

When the ignition switch is turnedon, all LCD segments are displayedwith opening display functions for fewseconds, then the multifunction meter turns to operational mode.



d NOTE


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Speedometer The speedometer shows the speed

of the vehicle in digital values.

Unit SettingThe unit setting in the meter instru-

ment can be changed according to lo-cal regulations. Make sure the unit set-ting is correctly displayed before riding.

A. mph or km/h Display

NOTE Do not operate the motorcycle with

wrong unit (mph or km/h) of thespeedometer.

To change the meter display unit inthe meter instrument as follows:

Push the left button to display theodometer.

Push the right button while pushingthe left button to select the display

unit.km/h mph

Mult i funct ion Display The following display modes can be

shifted by pushing the left button.Odometer Trip meter A Trip me-

ter B Odometer...



NOTE NOTE


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NOTE For safety, do not operate the instru-

ment buttons while riding the motor-cycle.

The multifunction display is displayed in the unit depending on theunit 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 been ridden. This meter can-not be reset.

A. Odometer

NOTE The data is maintained even if the

battery is disconnected. When the figures come to 999999,

they are stopped and locked.

Trip Meter The trip meters show the distance in

kilometers or miles traveled since theywere last reset to zero.

TRIP A: 0.0 9999.9TRIP B: 0.0 9999.9

A. Trip Meter A

To reset the trip meter, do the follow-ings while the motorcycle is at the stop.

Push the left button to display the tripmeter A or B.



P h th i ht b tt d h ld it i P h th i ht b tt f th


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Push the right button and hold it in. After two seconds, the figure displayturns to 0.0, and then starts countingwhen the vehicle is operated. The

meter counts until it is reset.NOTE

The data is maintained by theback-up power if the ignition switchis turned off.

When the trip meter reaches 9999.9while running, the meters reset to 0.0 and continues counting.

When the battery is disconnected,the meter display resets to 0.0.

Clock

To adjust hours and minutes, do thefollowings while the motorcycle is at astop.

Turn the ignition switch on. Push the left button to display theodometer.

Push the right button for more thantwo seconds. Both the hour andminute displays start blinking.

Push the right button. The hour dis-play only blinks. Push the left buttonto advance the hours.

Push the right button. The hour dis-play stops blinking and the minutedisplay starts blinking. Push the leftbutton to advance the minutes.



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WARNING the fuel gauge checked by an autho


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WARNINGFailing to properly observe theroad ahead increases the chanceof an accident resulting in se-vere injury or death. Do not con-centrate on the economical rid-ing indicator by taking your eyesoff the road; observe using pe-ripheral vision.

Fuel Gauge The fuel in the fuel tank is shown by

the number of segments displayed.When the fuel tank is full, all the

segments are displayed. If the fuelgauge is not correctly displayed, have

the fuel gauge checked by an autho-rized Kawasaki dealer.

As the fuel level in the tank goesdown, the segments disappear one by

one from F (full) to E (empty).The bottom segment and fuel symbolblink in the digital meter when approxi-mately 3.5 L (0.9 US gal) of usable fuelremains. Refuel at the earliest opportu-nity if the most bottom segment of thefuel gauge and fuel symbol blink.

When vehicle stands with the sidestand, the fuel gauge cannot show theamount of fuel in the fuel tank exactly.Stand upright the vehicle to check thefuel level.



multifunction display modes can be


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A. Fuel Symbol ( )B. Segment (E)

All of the segments and fuel symbolwill blink in case of the open or short of the wiring. Have the wiring inspectedby an authorized Kawasaki dealer im-mediately.

NOTE When pushing the left button while

low fuel warning is displayed, the

multifunction display modes can beshifted.

Indicator Lights

Green Neutral Indicator Light N: When the transmission is in neutral,the neutral indicator light goes on.

Yellow ABS Indicator Light (Only on A B S mod el )

: The ABS (Anti-lock Brake Sys-tem) indicator light goes on when theignition switch is turned on and goes off shortly after the motorcycle starts mov-ing. If the ABS is normal, it stays off. If

something is wrong with the ABS, thislight goes on and stays on. When thislight is on, the ABS does not functionbut if the ABS fails, the conventionalbrake system will still work normally.



For more detailed information about


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For more detailed information about ABS, see the Anti-lock Brake System(ABS) section in the HOW TO RIDETHE MOTORCYCLE chapter.

Blue High Beam Indicator Light : When the headlight is on high

beam, the high beam indicator lightgoes on.

Green Turn Signal Ind icator Lig ht : When the turn signal switch is

pushed to the left or right, the cor-responding turn signal indicator lightblinks.

Warning Indicator Light

Red B at ter y C harg in g Sy s tem Warning Indicator Ligh t

: The battery charging systemwarning indicator light goes on when-ever the battery voltage is less than 11V or higher than 16 V.

If this light goes on, have the battery

checked by an authorized Kawasakidealer.

Red Oil Pres su re Warn ing Indicator Light

: The oil pressure warning indica-tor light should go on whenever the ig-

nition switch is turned on and go off af-ter starting the engine.This light goes on whenever the oil

pressure is dangerously low while the



engine running Refer to the MAIN- NOTICE


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engine running. Refer to the MAINTENANCE AND ADJUSTMENT chap-ter for more detailed engine oil informa-tion. If this light goes on, have the en-

gine lubrication system checked by anauthorized Kawasaki dealer.

Red Coo lan t Tem peratu re Warning Indicator Ligh t : The coolant temperature warning

indicator light goes on whenever the

coolant temperature rises to 118C(245F) when the motorcycle is in op-eration. If this light goes on, stop theengine and check the coolant level inthe reserve tank after the engine coolsdown, then have the cooling systemchecked by an authorized Kawasaki

dealer.

NOTICE Do not let the engine continuerunning when the warning indi-cator light goes on. Prolongedengine operation will result insevere damage from overheat-ing.

Yellow Engine Warning Indicator L igh t

: The engine warning indicator light goes on when the ignition switchis turned on and goes off soon after ensuring that its circuit functions prop-erly. This light also goes on or blinkingwhenever the troubles occur in digital

fuel injection (DFI) system.The blinking of this light indicates thecondition that the engine cannot bestarted.



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you purchased your Kawasaki motor-


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y p ycycle. Its possible the dealer may havethe number in its records. If the keynumber is lost completely, you will need

to replace the ignition switch and allother locks operated by that key.Contact your Kawasaki 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/SteeringLock

This is a three-position, key-operated

switch. The key can be removed fromthe switch when it is in the OFF or LOCK position.

A. Ignition Switch/Steering LockB. ON positionC. OFF positionD. LOCK position

OFF Engine off. Electrical circuitsoff.

ON Engine on. All electrical

equipment can be used.LOCK Steering locked. Engine off.Electrical circuits off.



NOTE


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The tail, city and license plate lightsare on whenever the ignition key is inthe ON position. Headlights go on

when the starter button is released after starting the engine. To avoid battery discharge, always start theengine immediately after turning theignition key to ON.

If you leave the key in the ON po-sition on for a long time, the battery may become totally discharged.



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Fuel Tank Cap


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To open the fuel tank cap, pull up thekey hole cover. Insert the ignition keyinto the fuel tank cap and turn the keyto the right.

To close the cap, push it down intoplace with the key inserted. The keycan be removed by turning it to the leftto the original position. Close the keyhole cover.

NOTE The fuel tank cap cannot be closed

without the key inserted, and the key cannot be removed unless the cap islocked properly.

Do not push on the key to close the

cap, or the cap cannot be locked.

A. Key Hole Cover B. Ignition KeyC. Fuel Tank Cap

Fuel TankThe following octane rating gaso-

line is recommended for the fuel tank. Avoid filling the tank in the rain or whereheavy dust is blowing so that the fueldoes not get contaminated.



WARNING


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A. Tank CapB. Fuel TankC. Top LevelD. Filler Neck

Gasoline is extremely flammableand can be explosive under cer-tain conditions, creating the po-tential for serious burns. Turnthe ignition switch off. Do notsmoke. Make sure the area iswell ventilated and free from anysource of flame or sparks; thisincludes any appliance with a pi-lot light. Never fill the tank com-pletely to the top. If the tank isfilled completely to the top, heatmay cause the fuel to expandand overflow through the ventsin the tank cap. After refueling,make sure the tank cap is closed

securely. If gasoline is spilled onthe fuel tank, wipe it off immedi-ately.



NOTICE Antiknock Index is an average of theh b ( ) d


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California model only: Never fillthe tank so the fuel level risesinto the filler neck. If the tank isoverfilled, heat may cause thefuel to expand and flow into theEvaporative Emission ControlSystem resulting in hard start-ing and engine hesitation andin compliance with the emissionregulation.

Fuel Requirement

Fuel TypeUse clean, fresh unleaded gasoline

with a minimum Antiknock Index of 87.

The Antiknock Index is posted on ser-vice station pumps. The octane ratingof a gasoline is a measure of its resis-tance to detonation or knocking. The

Research Octane Number (RON) andthe Motor Octane Number (MON) asshown in the table.

MinimumOctane Rating Method

Rating

(RON + MON) AntiknockIndex 2

87

NOTICE Use only unleaded gasoline.Never use leaded gasoline.Leaded gasoline significantlyreduces the capability of the cat-alytic converter in the exhaustsystem.



NOTICE Fuels Containing OxygenatesG li f l i


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Use minimum of 87 octane gaso-line only to prevent severe en-gine damage.

NOTICE If engine knocking or ping-ing occurs, use a differentbrand of gasoline of a higher

octane rating. If this condition isallowed to continue it can leadto 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. Operatingproblems that result from theuse of poor quality or nonrecom-mended fuel may not be coveredunder your warranty.

Gasoline frequently contains oxy-genates (alcohols and ethers) espe-cially in areas of the U.S. and Canadawhich are required to sell such refor-mulated fuels as part of a strategy toreduce exhaust emissions.

The types and volume of fuel oxy-genates approved for use in unleadedgasoline by the U.S. EnvironmentalProtection Agency include a broad

range of alcohols and ethers, but onlytwo components have seen any signif-icant level of commercial use.

Gasoline/Alcohol Blends - Gasolinecontaining up to 10% ethanol (alco-hol produced from agricultural productssuch as corn), also known as gasoholis approved for use.



NOTICE NOTICE


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Avoid using blends of unleadedgasoline and methanol (woodalcohol) whenever possible, andnever use gasohol contain-ing more than 5% methanol.Fuel system damage and perfor-mance problems may result.

Gasoline/Ether Blends - The mostcommon ether is methyl tertiary butylether (MTBE). You may use gasolinecontaining up to 15% MTBE.

NOTE Other oxygenates approved for use

in unleaded gasoline include TAME (up to 16.7%) and ETBE (up to17.2%). Fuel containing these oxy-genates can also be used in your Kawasaki.

Never use gasoline with an oc-tane rating lower than the mini-mum specified by Kawasaki.Never use gasohol with morethan 10% ethanol, or more than5% methanol. Gasoline con-taining methanol must also beblended with cosolvents andcorrosion inhibitors.Certain ingredients of gasolinemay cause paint fading or dam-age. Be extra careful not to spillgasoline or gasoline oxygenateblends 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 inhibitoxidation of the fuel which mini-mizes gummy deposits.



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NOTEh l d h


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The motorcycle is equipped with aside 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.

SeatsPassengers Seat Removal

Remove the passengers seat by in-serting the ignition key into the seatlock, and turning it clockwise.

Pull up the front of seat, and removethe passengers seat by pushing it tothe front.

A. Ignition Key

B. Seat LockC. Passengers Seat

Passengers Seat InstallationInstall the passangers seat in the re-

verse order of removal.

Insert the tabs in rear of the pas-sengers seat into the slots of thebracket.

Insert the projection in front of thepassengers seat into the hole on theframe.



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A. Bolt and Collar (Left Side)

B. Riders SeatC. Pull Up and Rear

Riders Seat InstallationInstall the riders seat in the reverse

order of removal.

Insert the tabs on the rear of theriders seat into the slots on theframe.

A. Riders Seat

B. TabsC. SlotsD. Insert

Install the collars and tighten thebolts.

Install the left and right side covers,collars and tighten the bolts.



Helmet HooksH l b d h


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Helmets can be secured to the motor-cycle using the helmet hooks. The hel-met hooks are located under the pas-

sengers seat.

WARNINGRiding with helmets attached tothe hooks could cause an ac-cident by distracting the oper-ator or interfering with normalvehicle operation. Do not ridethe motorcycle with helmets at-tached to the hooks.

A. Helmet Hooks

Tying HooksWhen tying up light loads to the seat,

use the tying hooks located in front of the rear turn signal lights and rear of therear footpegs.




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A. Tying Hooks

Tool Kit CompartmentThe tool kit compartment is located

under the passengers seat.The kit contains tools that can be

helpful in making roadside repairs,adjustments, and some maintenanceprocedures explained in this manual.Keep the tool kit in the compartment.

A. Tool Kit Compartment

B. Tool Kit

Event Data Recorder This vehicle is equipped at the fac-

tory with an event data recorder (EDR).The main purpose of this device is torecord data that assists with under-standing of how a vehicles systemsperformed during a short period of time. Among other things, this data can helpprovide a better understanding of the



circumstances in which crashes oc-cur. This device does not collect or

that have special equipment, can readthe information if they have access to


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store personal data or information (e.g.name, gender, age). The EDR in thisvehicle is designed to record such dataas: vehicle speed, engine crankshaftrotational speed, throttle opening.

To read the data recorded by theEDR, special equipment is required,and access to the vehicle or EDR isnecessary. In addition to Kawasaki,

other parties, such as law enforcement

ythe EDR. Kawasaki does not accessthe EDR information without obtainingconsent, 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 accessthe recorded data independently of Kawasaki.


HOW TO RIDE THE MOTORCYCLE 69

HOW TO RIDE THE MOTORCYCLE


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Break-InThe first 1 600 km (1 000 mi) that the

motorcycle is ridden is designated asthe break-in period. If the motorcycleis 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.

The table shows maximum recom-mended engine speed during thebreak-in period.

Distancetraveled

Maximum enginespeed

0 800 km(0 500 mi) 4 000 r/min (rpm)

800 1 600 km(500 1 000 mi) 6 000 r/min (rpm)

NOTE When operating on public roadways,

keep maximum speed under traffic law limits.

Do not start moving or race the en-gine immediately after starting it,even if the engine is already warm.

Run the engine for two or three min-utes at idle speed to give the oil achance to work up into all the engineparts.


70 HOW TO RIDE THE MOTORCYCLE

Do not race the engine while thetransmission is in neutral.

Starting the EngineCh k th t th i t it h i


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WARNINGNew tires are slippery and maycause loss of control and injury.A break-in period of 160 km (100miles) is necessary to estab-lish normal tire traction. Duringbreak-in, avoid sudden and max-imum braking and acceleration,and hard cornering.

In addition to the above, at 1 000km (600 mi) it is extremely importantthat the owner has the initial mainte-nance service performed by an autho-rized Kawasaki dealer.

Check that the engine stop switch isin the position.

A. Engine Stop SwitchB. Starter Button

Turn the ignition key to ON position.

Make sure the transmission is in neu-tral.



if the engine cannot be started. Af-ter righting the motorcycle, first turn


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A. Green Neutral Indicator Light

B. Ignition SwitchC. ON position

NOTE The motorcycle is equipped with a

vehicle-down sensor which causesthe engine to stop automatically if themotorcycle falls down. The enginewarning indicator light ( ) blinkswhen the starter button is pressed

the ignition key to OFF position and then back to ON position beforestarting the engine.

Without holding the throttle grip, pushthe starter button to start the engine.

NOTICE Do not operate the starter con-

tinuously for more than 5 sec-onds, or the starter will overheatand the battery power will droptemporarily. Wait 15 secondsbetween each operation of thestarter to let it cool and the bat-tery power recover.


starter lockout switch. This switch ishttp://www.motorcycle.in.th


designed so that the engine does not start if the transmission is in gear and

NOTICE Do not let the engine idle longer


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the side stand is down. However, theengine can be started if the clutchlever is pulled and the side stand isfully up.

A. Clutch Lever B. Starter Lockout Switch

Do not let the engine idle longer than five minutes, or engineoverheating and damage may

occur.

Jump StartingIf your motorcycle battery is run

down, it should be removed and

charged. If this is not practical, a 12volt booster battery and jumper cablesmay be used to start the engine.



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DANGERBatteries contain sulfuric acid


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A. Motorcycle Battery Positive (+) Terminal

B. From Booster Battery Positive (+) TerminalC. Rear FootpegD. From Booster Battery Negative ()

Terminal

Connect another jumper cable fromthe negative () terminal of thebooster battery to your motorcy-

cle rear footpeg or other unpaintedmetal surface. Do not use the nega-tive () terminal of the battery.

Batteries contain sulfuric acidthat can cause burns and pro-duce hydrogen gas which is

highly explosive. Do not makethis last connection at the fuelsystem or battery. Take care notto touch the positive and nega-tive cables together, and do notlean over the battery when mak-ing this last connection. Do notconnect to a frozen battery. Itcould explode. Do not reversepolarity by connecting positive(+) to negative (), or a batteryexplosion and serious damageto the electrical system may oc-cur.

Follow the standard engine startingprocedure.



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WARNINGDownshifting to a lower gear at


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side stand switch. This switch is de-signed so that the engine does not start if the transmission is in gear and the side stand is down.

Shifting Gears

Close the throttle while pulling in theclutch lever.

Shift into the next higher or lower gear. Open the throttle part way, while re-

leasing the clutch lever.

For smooth riding, each gear positionshould cover the proper rate of speedshown in the table.

g ghigh speed causes engine rpmto increase excessively, poten-

tially damaging the engine andit may also cause the rear wheelto skid and cause an accident.Downshifting should be donebelow the vehicle speeds for each gear shown in the table.

Vehicle speed when shiftingShifting up km/h (mph)

1st 2nd 15 ( 9)

2nd 3rd 25 (15)

3rd 4th 35 (21)

4th 5th 45 (27)5th 6th 55 (34)



Shifting down km/h (mph)

6th 5th 30 (19)

Braking

Close the throttle completely, leav-


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5th 4th 25 (15)

4th 3rd 20 (12)

3rd 2nd 15 ( 9)

2nd 1st 15 ( 9)

NOTE The transmission is equipped with a

positive neutral finder. When the mo-torcycle is standing still, the transmis-sion cannot be shifted past neutral from 1st gear. To use the positiveneutral finder, shift down to 1st gear,then lift up on the shift pedal whilestanding still. The transmission will shift only into neutral.

p y,ing the clutch engaged (except whenshifting gears) so that the engine will

help slow down the motorcycle. Shift down one gear at a time so thatyou are in 1st gear when you cometo a complete stop.

When stopping, always apply bothbrakes at the same time. Normallythe front brake should be applied a lit-tle more than the rear. Shift down or fully disengage the clutch as neces-sary to keep the engine from stalling.

Never lock the brakes, or it will causethe tires to skid. When turning a cor-ner, it is better not to brake at all. Re-duce your speed before you get intothe corner.

Even in motorcycles equipped with ABS, braking during cornering maycause wheel slip. When turning a



corner, it is better to limit braking tothe light application of both brakesor not to brake at all Reduce your


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or not to brake at all. Reduce your speed before you get into the corner.

For emergency braking, disregarddownshifting, and concentrate onapplying the brakes as hard as pos-sible without skidding.

A. Front Brake Lever

A. Rear Brake Pedal

Anti-lock Brake System(ABS)(only on ABS model)

ABS is designed to help preventthe wheels from locking up when thebrakes are applied hard while runningstraight. The ABS automatically regu-lates brake force. Intermittently gaininggripping force and braking force helps



prevent wheel lock-up and allows sta-ble steering control while stopping.

Brake control function is identical to

or downhill surfaces, the stoppingdistance of a motorcycle with ABSmay be longer than that of an equiv-


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Brake control function is identical tothat of a conventional motorcycle. Thebrake lever is used for the front brakeand the brake pedal for the rear brake.

Although the ABS provides stabilitywhile stopping by preventing wheellock-up, remember the following char-acteristics:

To apply the brake effectively, usethe front brake lever and rear brakepedal simultaneously in the samemanner as conventional motorcyclebrake system.

ABS cannot compensate for adverseroad conditions, misjudgment or im-proper application of brakes. You

must take the same care as with mo-torcycles not equipped with ABS.

ABS is not designed to shorten thebraking distance. On loose, uneven

may be longer than that of an equiv-alent motorcycle without ABS. Usespecial caution in such areas.

ABS will help prevent wheel lock-upwhen braking in a straight line, but itcannot control wheel slip which maybe caused by braking during corner-ing. When turning a corner, it is bet-ter to limit braking to the light appli-cation of both brakes or not to brakeat all. Reduce your speed before youget into the corner.

Same as conventional brake system,an excessive sudden braking maycause wheel lock up that makes itharder to control a motorcycle.

During braking, ABS will not preventthe rear wheel lifting.



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When the ABS is functioning, youmay feel a pulsing in the brake lever or pedal. This is normal. You need

The light remains lit after the motor-cycle starts moving.

The light comes on and remains lit


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or pedal. This is normal. You need not suspend applying brakes.

ABS does not function at speeds of approx. 10 km/h (6 mph) or below.

ABS does not function if the battery is discharged.

Yellow ABS Indicator Light

Normally the ABS indicator light goeson when the ignition switch is turned onand goes off shortly after the motorcy-cle starts moving.

If this light shows any of the follow-ing, a fault or faults may have occurredin the ABS. You should have the ABSchecked by an authorized Kawasakidealer.

The light does not come on when theignition switch is turned on.

The light comes on and remains litafter the motorcycle starts moving.

Remember that the ABS does notfunction when this light is on, but if the ABS fails, the conventional brake sys-tem still works normally.

Stopping the Engine

Close the throttle completely. Shift the transmission into neutral. Turn the ignition key to OFF posi-tion.

Support the motorcycle on a firm,level surface with the side stand.

Lock the steering.


vehicle-down sensor which causeshttp://www.motorcycle.in.th


the engine to stop automatically if themotorcycle falls down. The enginewarning indicator light ( ) blinks

thoroughly familiar with its operation.Improper maintenance can create adangerous situation known as throt-


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warning indicator light ( ) blinkswhen the starter button is pressed if the engine cannot be started. Af-ter righting the motorcycle, first turnthe ignition key to OFF position and then back to ON position beforestarting the engine.

Stopping the Motorcycle inan Emergency

Your Kawasaki Motorcycle has beendesigned and manufactured to pro-vide you optimum safety and conve-nience. However, in order to fully ben-efit from Kawasakis safety engineeringand craftsmanship, it is essential thatyou, the owner and operator, properlymaintain your motorcycle and become

da ge ous s tuat o ow as t ottle failure. Two of the most commoncauses of throttle failure are:1. An improperly serviced or clogged

air cleaner may allow dirt and dustto enter the throttle body and stickthe throttle open.

2. During removal of the air cleaner,dirt is allowed to enter and jam thefuel injection system.

In an emergency situation such asthrottle failure, your vehicle may bestopped by applying the brakes anddisengaging the clutch. Once thisstopping procedure is initiated, the en-gine stop switch may be used to stopthe engine. If the engine stop switch isused, turn off the ignition switch after stopping the motorcycle.



Parking

WARNING

WARNINGThe engine and exhaust system

t t l h t d i l


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WARNINGOperating or parking the vehi-

cle near flammable materials cancause a fire, and can result inproperty damage or severe per-sonal injury.Do not idle or park your vehiclein an area where tall or dry veg-etation, or other flammable ma-terials could come into contactwith the muffler or exhaust pipe.

get extremely hot during normaloperation and can cause serious

burns.Never touch a hot engine, ex-haust pipe, or muffler during op-eration or after stopping the en-gine.

Shift the transmission into neutraland turn the ignition key to OFFposition.

Support the motorcycle on a firm,level surface with the side stand.

NOTICE

Do not park on a soft or steeplyinclined surface, or the motorcy-cle may fall over.



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MAINTENANCE AND ADJUSTMENT 85MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out


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in accordance with the Daily Safety Checks and Periodic Maintenance to keep themotorcycle in good running condition and to reduce air pollution. The initial main-tenance is vitally important and must not be neglected.

WARNINGFailure to perform these checks or to correct a problem before operationmay result in serious damage or an accident. Always perform daily safetychecks before operation.

With a basic knowledge of mechanics and the proper use of tools, you should beable to carry out many of the maintenance items described in this chapter. If youlack proper experience or doubt your ability, all adjustments, maintenance, andrepair 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.


86 MAINTENANCE AND ADJUSTMENT

DANGERExhaust gas contains carbon monoxide, a colorless, odorless poisonousgas Inhaling carbon monoxide can cause serious brain injury or


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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.

WARNINGThe cooling fan spins at high speed and can cause serious injuries. Keepyour hands and clothing away from the cooling fan blades at all times.

NOTE If a torque wrench is not available, the maintenance items which require a specific

torque value should be serviced by an authorized Kawasaki dealer.


MAINTENANCE AND ADJUSTMENT 87

Daily Safety ChecksCheck 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


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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 themotorcycle to a safe operating condition.

Operation SeePage

Fuel

Adequate supply in tank, no leaks Engine Oil

Oil level between level lines 95

Tires

Air pressure (when cold), install the air valve cap 122

Tire wear 123Drive Chain

Slack 110



Operation SeePage

L b i t if d 110


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Lubricate if dry 110

Bolts, nuts and fasteners

Check for loose and/or missing bolts, nuts and fasteners

Steering

Action smooth but not loose from lock to lock

No binding of control cables

Brakes

Brake pad wear 116

Brake fluid level 115

No brake fluid leakage

Throttle

Throttle grip play 105

Clutch

Clutch lever play 108

Clutch lever operates smoothly http://www.motorcycle.in.th


Operation SeePage

Coolant


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Coolant

No coolant leakage

Coolant level between level lines (when engine is cold) 98

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



Periodic Maintenance

*A: Service at number of years shown or indicated odometer reading intervals,hi h fi t


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whichever comes first.*B: For higher odometer readings, repeat at the frequency interval established here.

*C: Service more frequently when operating in severe conditions: dusty, wet, muddy,high speed, or frequent starting/stopping.

*D: California Model only : Emission Related Item

: Inspection : Dealer Inspection

: Change or Replace : Dealer Change or Replace

: Lubrication : Dealer Lubrication



Odometer Reading (*B) 1 000 km ( 1 000 mile)year

(*A) 1 6 12 18 24SeePage


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Items (0.6) (3.8) (7.6) (11.4) (15.2)

Air cleaner element (*C) : 2 101 Idle speed 107

Throttle control system (play, smoothreturn, no drag) :1 105

Engine vacuum synchronization

Fuel system :1

Fuel hose :5

Evaporative emission control system(*D)

Coolant level 98

Cooling system :1



Odometer Reading (*B) 1 000 km ( 1 000 mile)year

(*A) 1( )

6( )

12( )

18( )

24( )

SeePage


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Items (0.6) (3.8) (7.6) (11.4) (15.2)

Coolant, water hoses and O-rings :3 : every 36 000 km(22 500 mile)

Valve clearance

Air suction system

Clutch operation (play, engagement,disengagement) 108

Engine oil and Oil filter (*C) :1

Tire air pressure :1 122

Wheels and tires :1 123

Wheel bearing damage :1

Drive chain l ubrication condition (*C) : every 600 km (400 mile) 110



Odometer Reading (*B) 1 000 km ( 1 000 mile)

I

year (*A) 1

(0 6)6

(3 8)12

(7 6)18

(11 4)24

(15 2)

SeePage


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Items (0.6) (3.8) (7.6) (11.4) (15.2)

Drive chain slack (*C) : every 1 000 km(600 mile)

110

Drive chain wear (*C)

Drive chain guide wear

Brake system :1

Brake fluid level :0.5 115

Brake fluid (front and rear) :2

Brake hose/rubber parts of brake master cylinder and caliper :4

: every 48 000 km(30 000 mile)

Brake pad wear (*C) 116

Brake light switch operation 117



Odometer Reading (*B) 1 000 km ( 1 000 mile)

It

year (*A) 1

(0 6)6

(3 8)12

(7 6)18

(11 4)24

(15 2)

SeePage


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Items (0.6) (3.8) (7.6) (11.4) (15.2)

Suspension system : 1 Lubrication of rear suspension

Steering play :1

Steering stem bearings :2

Electrical system :1

Spark plugs

Chassis parts :1

Condition of bolts, nuts and fasteners



Engine Oil

Oil Level Inspect ion

If the engine is cold start the engine


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If the engine is cold, start the engineand run it for several minutes at idlespeed.

Stop the engine, then wait severalminutes until the oil settles.

NOTICE Racing the engine before the oilreaches every part can cause en-gine seizure.

Check the engine oil level throughthe oil level inspection window. Withthe motorcycle held level, the oil levelshould come up between the upper and lower level lines next to the oillevel inspection window.

A. Oil Level Inspection WindowB. Oil Filler CapC. Upper Level LineD. Lower Level Line

If the oil level is too high, remove theexcess oil through the oil filler open-ing using a syringe or some other suitable device.

If the oil level is too low, add oil toreach the correct level. Use thesame type and brand of oil that isalready in the engine.



Oil and/or Oi l F i l ter Change

The oil change and oil filter replace-ment should be done by an autho-rized Kawasaki dealer.


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rized Kawasaki dealer.

WARNINGEngine oil is a toxic substance.Dispose of used oil properly.Contact your local authoritiesfor approved disposal methodsor possible recycling. A. Engine Oil Drain Bolt

Tightening TorqueEngine O il Drain Bolt:

19.6 Nm (2.00 kgfm, 14.5 ftlb)



Recommended Engine Oil

Type:Kawasaki Performance 4-StrokeMotorcycle Oil*


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A. Oil Filter

Tightening TorqueOil Filter:

17.5 Nm (1.78 kgfm, 12.9 ftlb)

Motorcycle OilKawasaki Performance 4-Stroke

Semi-Synthetic Oil*Kawasaki Performance 4-Stroke FullSynthetic Oil*or other 4-stroke oils with API SG, SH,SJ, SL, SM and JASO MA, MA1, MA2rating

Viscosity:SAE10W-40

*Kawasaki Performance Oils and Lu-bricants have been specifically engi-neered for your vehicle. Consistentuse of these products meets or ex-ceeds warranty and service require-

ments and can help to extend the lifeof your Kawasaki.



NOTE Do not add any chemical additive to

the oil. Oils fufilling the above re-quirements are fully formulated and


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quirements are fully formulated and provide adequate lubrication for boththe engine and the clutch.

Engine Oil Capacity

Capacity: 2.0 L (2.1 US qt)

[when filter is not removed]

2.2 L (2.3 US qt)

[when filter is removed]

Although 10W-40 engine oil is therecommended oil for most condi-tions, the oil viscosity may need tobe changed to accommodate atmo-spheric conditions in your riding area.

CoolantCoolant Level Inspect ion

Position the motorcycle so that it isperpendicular to the ground.

Check the coolant level through thecoolant level gauge on the reserve

tank located to the right of the frontfork. The coolant level should be be-tween the F (Full) and L (Low) levellines.



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of antifreeze concentrate as soon as possible.

NOTICE

Coolant Requirement

WARNINGCoolant containing corrosion in-


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NOTICE

If coolant must be added of-ten, or the reserve tank com-pletely runs dry, there is proba-bly leakage in the system. Havethe cooling system inspectedby your authorized Kawasakidealer.

Install the reserve tank cap.Coolant Change

Have the coolant changed by an au-thorized Kawasaki dealer.

Coolant containing corrosion inhibitors for alminum enginesand radiators include harm-ful chemicals for human body.Drinking coolant can result inserious injury or death. Usecoolant in accordance with theinstructions of the manufacturer.

Use a permanent type of antifreeze(soft water and ethylene glycol plus cor-rosion and rust inhibitor chemicals for aluminum engines and radiators) in thecooling system. On the mixture ratioof coolant, choose the suitable one re-

ferring to the relation between freezingpoint and strength directed on the con-tainer.


MAINTENANCE AND ADJUSTMENT 101NOTICE

If hard water is used in the sys-tem, it causes scale accumula-tion in the water passages and

Unscrew the air cleaner element capmounting screws, then remove theair cleaner element cap.


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tion in the water passages, andconsiderably reduces the effi-ciency of the cooling system.

NOTE A permanent type of antifreeze is in-

stalled in the cooling system whenshipped. It is mixed at 50% and hasthe freezing point of 35C (31F).

Air Cleaner

Element Removal

Remove the right side cover.

A. Air Cleaner Element CapB. Mounting Screws

Pull out the air cleaner element fromthe air cleaner housing.




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A. Element

Remove the element from the frame.A. ElementB. Frame

Put a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering.

Inspect the element material for dam-age. If any part of the element isdamaged, the element must be re-placed.



WARNINGIf dirt or dust is allowed to passthrough into the throttle bodyassembly, the throttle may be-

Element Cleaning

Clean the element in a bath of a highflash-point solvent.

Squeeze it dry in a clean towel. Doi h l bl i d


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assembly, the throttle may become stuck, possibly causingaccident. Be sure to keep thedust from entering during clean-ing.

NOTICE

If dirt gets through into the en-gine, excessive engine wear andpossibly engine damage will oc-cur.

The element and removed part in-stallation is performed in the reverse

order of removal.

not wring the element or blow it dry;

the element can be damaged. Check all the parts of the element for visible damage.

If any of the parts of the element aredamaged, replace them.

After cleaning, saturate the elementwith a high-quality foam-air-filter oil,squeeze out the excess, then wrap itin a clean towel and squeeze it as dryas possible.

Be careful not to tear the sponge fil-ter.



WARNINGGasoline and low flash-point sol-vents are extremely flammableand may explode, causing se-


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and may explode, causing severe burns. Do not use gaso-line or a low flash-point solventto clean the element. Clean theelement in a well-ventilated area.Be sure there are no sparks or flame in the work area, includingany appliance with a pilot light.

Oil Draining

Inspect the transparent drain cap lo-cated at the left lower end of the air cleaner housing to see if any oil hasrun down.

A. Drain Cap

If there is any oil in the drain cap,remove the cap from the lower endof the air cleaner housing and drainthe oil.



WARNINGOil on tires will make them slip-pery and can cause an accidentand injury. Be sure to install the

Check the throttle grip free play byturning back and forth.


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j ydrain cap to the air cleaner hous-ing after draining.

Throttle Control System

Throttle Grip

Thrott le Grip Free Play Inspection

Check that the throttle grip movessmoothly from full open to close,and the throttle closes quickly andcompletely by the return spring in allsteering positions.

If the throttle grip does not returnproperly, have the throttle controlsystem checked by an authorizedKawasaki dealer.

A. Throttle GripB. Throttle Grip Play

Throttle Grip Play

2 3 mm (0.08 0.12 in.)

If there is improper play, adjust it.



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108 MAINTENANCE AND ADJUSTMENTClutch

Clutch Operat ion Inspect ion

Check that the clutch lever operatesproperly and that the inner cable


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properly and that the inner cable

slides smoothly. If there is any irreg-ularity, have the clutch cable checkedby an authorized Kawasaki dealer.

Check the clutch lever play asshown.

Clutch Lever Play

2 3 mm (0.08 0.12 in.)A. Adjuster B. Locknut

C. Clutch Lever Play

If the play is incorrect, adjust thelever play as follows.

Clutch Cable Free Play A djustm ent

Loosen the locknut at the clutchlever. Turn the adjuster so that the clutchlever will have the specified free play.



WARNINGToo much cable play can pre-vent clutch disengagement andcause an accident resulting in


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serious injury or death. Whenadjusting the clutch or replac-ing the cable, be sure the up-per end of the clutch outer cableis fully seated in its fitting, or itcould slip into place later, creat-ing enough cable play to preventclutch disengagement.

Tighten the locknut. If it cannot be done, use the mountingnuts at the lower end of the cable.

A. Nuts

NOTE After the adjustment is made, start

the engine and check that the clutchdoes not slip and that it releases properly.


110 MAINTENANCE AND ADJUSTMENTDrive Chain

Drive Chain Lubr icat ion Lubrication is necessary after riding

through rain or on wet roads, or any


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through rain or on wet roads, or any

time that the chain appears dry.Use a lubricant for sealed chains toprevent deterioration of chain seals. If the chain is especially dirty, clean itusing a cleaner for sealed chains fol-lowing the instructions supplied by thechain cleaner manufacturer.

Apply lubricant to the sides of therollers so that it will penetrate to therollers and bushings. Apply lubricantto the seals so that the seals will becoated with lubricant. Wipe off anyexcess lubricant.

Wipe off any lubricant that gets on thetire surface.

Drive Chain Slack Inspect ion

Set the motorcycle up on its sidestand.

Clean the chain if it is dirty, and lubri-cate it if it appears dry.

Rotate the rear wheel to find the po-sition where the chain is tightest, andmeasure the maximum chain sla

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