kawasaki super sherpa kl250g9 owners manual

Quick Reference GuideGENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

This Quick Reference Guide willassist you in finding the informationyou’re looking for.

A Table of Contents is included afterthe Foreword.

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

WARNING

This warning symbol identifiesspecial instructions or proce-dures which, if not correctly fol-lowed, could result in personalinjury, or loss of life.

CAUTION

This caution symbol identifiesspecial instructions or proce-dures which, if not strictly ob-served, could result in damageto or destruction of equipment.

NOTE

This note symbol indicates points ofparticular interest for more efficientand convenient operation.

FOREWORD

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

Please read this Owner’s Manual carefully before riding so that you will bethoroughly familiar with the proper operation of your motorcycle’s 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 Owner’s Manual aboard your motorcycle at all times so that you canrefer to it whenever you need information.

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 ourprior written permission.

This publication includes the latest information available at the time of printing.However, there may be minor differences between the actual product and illustra-tions and text in this manual.All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.Consumer Products & Machinery Company

© 2008 Kawasaki Heavy Industries, Ltd. Nov. 2008. (1). (S, Ke)

TABLE OF CONTENTS

SPECIFICATIONS............................... 8

SERIAL NUMBER LOCATIONS......... 12

LOCATION OF PARTS ....................... 13

LOCATION OF LABELS..................... 16

LOADING INFORMATION .................. 19

GENERAL INFORMATION ................. 22

Meter Instruments ............................ 22

Speedometer, Odometer/Clock,

and Trip Meter: .......................... 23

Speedometer : .............................. 23

Indicator Lights: ............................ 26

Key................................................... 27

Ignition Switch/Steering Lock........... 28

Right Handlebar Switches................ 29

Engine Stop Switch: ..................... 29

Starter Button: .............................. 30

Left Handlebar Switches .................. 31

Dimmer Switch: ............................ 31

Turn Signal Switch:....................... 31

Horn Button: ................................. 31

Fuel Tank Cap.................................. 32

Fuel Tank ......................................... 33

Fuel Requirement: ........................ 34

Fuel Tap ........................................... 37

Stand................................................ 38

Helmet Hook .................................... 39

Tool Kit Case/Tool Kit ....................... 40

Side Cover ....................................... 41

Seat.................................................. 43

BREAK-IN ........................................... 44

HOW TO RIDE THE MOTORCYCLE . 46

Starting the Engine .......................... 46

Jump Starting................................... 50

Moving Off........................................ 52

Shifting Gears .................................. 53

Braking............................................. 55

Stopping the Engine......................... 56

Stopping the Motorcycle in an

Emergency ................................... 57

Parking............................................. 58

SAFE OPERATION............................. 59

Safe Riding Technique ..................... 59

Daily Safety Checks......................... 61

Additional Considerations for Off

Road Operation ............................ 63

MAINTENANCE ANDADJUSTMENT 64

Periodic Maintenance Chart............. 69

Engine Oil ........................................ 80

Spark Plugs...................................... 85

Valve Clearance ............................... 87

Air Cleaner ....................................... 87

Throttle Grip ..................................... 91

Carburetors ...................................... 94

Clutch............................................... 95

Drive Chain ...................................... 98

Brakes.............................................. 103

Brake Light Switches........................ 108

Rear Shock Absorber....................... 110

Wheels ............................................. 112

Battery.............................................. 115

Headlight Beam................................ 117

Fuses ............................................... 119

General Lubrication.......................... 121

Cleaning Your Motorcycle ................ 122

Bolt and Nut Tightening.................... 127

STORAGE ........................................... 129

TROUBLESHOOTING GUIDE............ 133

OWNER SATISFACTION.................... 134

REPORTING SAFETY DEFECTS ...... 136

ENVIRONMENTAL PROTECTION ..... 137

MAINTENANCE RECORD ................. 138

LABEL INFORMATION ...................... 143

8 SPECIFICATIONS

SPECIFICATIONS

DIMENSIONS

Overall Length 2 080 mm (81.89 in.)

Overall Width 780 mm (30.71 in.)

Overall Height 1 190 mm (46.85 in.)

Wheelbase 1 375 mm (54.13 in.)

Road Clearance 270 mm (10.63 in.)

Curb Mass 128 kg (282 lb)

ENGINE

Type DOHC, single-cylinder, 4-stroke, air-cooled

Displacement 249 cm³ (15.2 cu in.)

Bore x Stroke 72.0 × 61.2 mm (2.83 × 2.41 in.)

Compression Ratio 9.3 : 1

Starting System Electric starter

Carburetors MIKUNI BST34

Ignition System CDI

SPECIFICATIONS 9

Ignition Timing(Electronically advanced)

10° BTDC @1 300 r/min (rpm) ∼ 30° BTDC @5 750r/min (rpm)

Spark Plugs NGK CR8E or ND U24ESR-N

Lubrication System Forced lubrication (wet sump)

Engine Oil

Type: API SE, SF or SG

API SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

Capacity: 1.5 L (1.6 US qt)

TRANSMISSION

Transmission Type 6-speed, return shift

Clutch Type Wet, multi disc

Driving System Chain drive

Primary Reduction Ratio 2.800 (84/30)

Final Reduction Ratio 3.071 (43/14)

Overall Drive Ratio 7.326 (Top gear)

10 SPECIFICATIONS

Gear Ratio

1st 3.090 (34/11)

2nd 2.125 (34/16)

3rd 1.500 (27/18)

4th 1.148 (31/27)

5th 0.962 (25/26)

6th 0.852 (23/27)

FRAME

Castor 28°

Trail 107 mm (4.21 in.)

Tire Size:

Front 2.75-21 45P

Rear 4.10-18 59P

Rim Size:

Front 21 × 1.60

Rear 18 × 2.15

Fuel Tank Capacity 9.0 L (2.38 US gal)

SPECIFICATIONS 11

ELECTRICAL EQUIPMENT

Battery 12 V 6 Ah

Headlight 12 V 60/55 W

Tail/Brake Light 12 V 5/21 W

Specifications subject to change without notice.

12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. Theyare 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.

Frame No.

A. Frame Number

Engine No.

A. Engine Number

LOCATION OF PARTS 13

LOCATION OF PARTS

1. Clutch Lever2. Meter Instruments3. Choke Knob4. Brake Fluid Reservoir (Front)5. Front Brake Lever

6. Left Handlebar Switches7. Ignition Switch/Steering Lock8. Right Handlebar Switches9. Throttle Grip

14 LOCATION OF PARTS

10. Front Fork11. Headlight12. Turn Signal Light13. Fuel Tank Cap14. Fuel Tank15. Fuel Tap

16. Rear Shock Absorber17. Battery18. Helmet Hook19. Tool Kit Case/Tool Kit20. Brake Disc21. Brake Caliper

22. Shift Pedal23. Idle Adjusting Screw24. Side Cover25. Side Stand26. Drive Chain

LOCATION OF PARTS 15

27. Tail/Brake Light28. Muffler29. Air Cleaner Element30. Seat31. Front Brake Light

Switch

32. Brake Fluid Reservoir(Rear)

33. Rear Brake LightSwitch

34. Rear Brake Pedal35. Oil Level Gauge

36. Carburetor

16 LOCATION OF LABELS

LOCATION OF LABELS

1. Important Break-In Instructions2. Tire and Load Data3. Important Drive Chain Information4. Vehicle Emission Control Information5. Daily Safety Checks

(For further information of label,refer to the “LABEL INFORMATION”chapter.)

LOCATION OF LABELS 17

6. Battery Poison/Danger7. Engine Oil and Oil Filter8. Brake Fluid (Rear)9. Brake Fluid (Front)


18 LOCATION OF LABELS

10. Noise Emission Control Information11. Weight and Manufacture


LOADING INFORMATION 19

LOADING INFORMATION

WARNING

Incorrect loading, improper in-stallation or use of accessories,or modification of your motorcy-cle may result in an unsafe rid-ing condition. Before you ridethe motorcycle, make sure thatthe motorcycle is not overloadedand that you have followed theseinstructions.

With the exception of genuineKawasaki Parts and Accessories,Kawasaki has no control over thedesign or application of accessories.In some cases, improper installationor use of accessories, or motorcyclemodification, will void the motorcycle

warranty. In selecting and using acces-sories, and in loading the motorcycle,you are personally responsible for yourown safety and the safety of other per-sons involved.

NOTE

Kawasaki Parts and Accessorieshave been specially designed foruse on Kawasaki motorcycles. Westrongly recommend that all partsand accessories you add to yourmotorcycle be genuine Kawasakicomponents.

Because a motorcycle is sensitive tochanges in weight and aerodynamicforces, you must take extreme carein carrying cargo, passengers and/orin the fitting of additional accessories.

20 LOADING INFORMATION

The following general guidelines havebeen prepared to assist you in makingyour determinations.

1. 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 impor-tant that the passenger sit still whilethe motorcycle is in motion and notinterfere with the operation of themotorcycle. Do not carry animalson your motorcycle.

2. You should instruct any passengerbefore riding to keep his feet on thepassenger footpegs and hold on tothe operator grab rail. Do not carrya passenger unless he or she is tallenough to reach the footpegs andfootpegs are provided.

3. All baggage should be carried aslow as possible to reduce the effecton the motorcycle center of gravity.Baggage weight should also be dis-tributed equally on both sides of themotorcycle. Avoid carrying baggagethat extends beyond the rear of themotorcycle.

4. Baggage should be securely at-tached. Make sure that the baggagewill not move around while you areriding. Recheck baggage securityas often as possible (not while themotorcycle is in motion) and adjustas necessary.

5. Do not carry heavy or bulky items ona luggage rack. They are designedfor light items, and overloading canaffect handling due to changes inweight distribution and aerodynamicforces.

LOADING INFORMATION 21

6. 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,or any other aspect of the motorcy-cle’s operation.

7. Weight attached to the handlebar orfront fork will increase the mass ofthe steering assembly and can re-sult in an unsafe riding condition.

8. Fairings, windshields, backrests,and other large items have the ca-pability of adversely affecting stabil-ity and handling of the motorcycle,not only because of their weight, butalso due to the aerodynamic forcesacting on these surfaces while themotorcycle is in operation. Poorly

designed or installed items can re-sult in an unsafe riding condition.

9. This motorcycle was not intendedto be equipped with a sidecar or tobe used to tow any trailer or othervehicle. 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.Furthermore, any adverse effects onmotorcycle components caused bythe use of such accessories will notbe remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage,and accessories must not exceed 165 kg(364 lb).

22 GENERAL INFORMATION

GENERAL INFORMATION

Meter Instruments

A. SpeedometerB. Odometer/ClockC. Twin Trip MeterD. Odometer/Clock Mode

ButtonE. Trip A/B Mode ButtonF. Neutral Indicator LightG. Turn Signal Indicator LightH. High Beam Indicator Light

GENERAL INFORMATION 23

Speedometer, Odometer/Clock, andTrip Meter:

In the meter instruments face arethe LCD (Liquid Crystal Display)speedometer, odometer/clock and tripmeter. Pushing the odometer/clock(ODO/CLOCK) mode button shifts thedisplay in the odometer/clock throughthe two modes; odometer and clock.Pushing the trip meter A/B (TRIP A/B)mode button shifts the display in thetrip meter through the two modes; tripA and B. When the ignition switch isturned on, all the LCD segments aredisplayed for three seconds, then theclock or meters operate normally de-pending on the mode selected.

Speedometer :The speedometer shows the speed

of the vehicle.

Odometer -The odometer shows the total dis-

tance in kilometers that the vehicle hasbeen ridden. The meter cannot be re-set.

NOTE

The data is maintained even if thebattery is disconnected.When the figures come to 99999,they are stopped and locked.

Clock:To adjust hours and minutes:

• Turn the ignition key to “ON”.• Push the ODO/CLOCK button, anddisplay the clock.


• Push the TRIP A/B button with theODO/CLOCK button pushed in. Boththe hour and minute displays startflashing.

• Again push the ODO/CLOCK button,then the hour display only flashes.And push the TRIP A/B button to ad-vance the hours.

• Push the ODO/CLOCK button. Thehour display stops flashing and theminute display starts flashing. Andpush the TRIP A/B button to advancethe minutes.

• Push the ODO/CLOCK button. Boththe hour and minute displays startflashing again.

• Push the TRIP A/B button. The dis-play stop flashing and the clock startsworking.


NOTE

Pushing the TRIP A/B button mo-mentarily advances the hour orminute step by step. Pushing andholding the button advance the houror minute continuously.The clock works normally from theback-up power while the ignitionswitch is turned off.When the battery is disconnected,the clock resets to 1:00 and startsworking again when the battery isconnected.

Trip Meters A/B -The trip meter shows the distance in

kilometers traveled since it was last re-set to zero.TRIP A: 0.0 ∼ 999.9TRIP B: 0 ∼ 9999To reset the trip meter:

• Push the TRIP A/B button and hold itin.

• After two second, the figure displayturns to 0.0 (TRIP A) or 0 (TRIP B),and then starts counting when the ve-hicle is operated. The meter countsuntil it is next reset.

NOTE

The data is maintained by the back-up power if the ignition key is turnedto “OFF”When the trip meter is reset while thevehicle is stopped, it starts countingas soon as the vehicle starts moving.When the figures come to 999.9(TRIP A) or 9999 (TRIP B) when thevehicle is running, they turn back to0.0 and start counting again.When the battery is disconnected,the meter display resets to 0.0 or 0.


Indicator Lights:N : When the transmission is in neutral,the neutral indicator light is lit.

: When the turn signal switch isturned to left or right, the turn signalindicator light flashes on and off.

: When the headlight is on highbeam, the high beam indicator light islit.


KeyThis motorcycle has a combination

key, which is used for the ignitionswitch/steering lock, helmet hook, andfuel tank cap.Blank keys are available at your

Kawasaki dealers. Ask your dealer tomake any additional spare keys youmay need, using your original key asa master, or using the key code on thetag with your keys.Record the code on the tag with your

keys here. Participating Kawasakidealers can use the code to make anew key in the event that your originalkeys are lost.

Write your key number here.


Ignition Switch/Steering LockThis is a four-position, key-operated

switch. The key can be removed fromthe switch when it is in the OFF, LOCK,or P (Park) position.

A. Ignition Switch/Steering LockB. ON positionC. OFF positionD. LOCK positionE. P (Park) position

ONEngine on. All electricalequipment can be used.

OFFEngine off. All electricalcircuits off.

LOCKSteering locked. Engine off.All electrical circuits off.

P (Park)Steering locked. Engine off.Taillight on. All other electricalcircuits cut off.

NOTE

The headlight and taillight are onwhenever the ignition key is in theON position. To avoid battery dis-charge, always start the engine im-mediately after turning the ignitionkey to "ON".If you leave the P (Park) position onfor a long time (one hour), the batterymay become totally discharged.


To lock the steering:1. Turn the handlebar fully to the left.2. With the ignition key in the OFF posi-tion, push down and release the key.

3. Turn the key to LOCK or P (Park)position.

4. Pull the key out.

NOTE

If the steering is hard to lock, turn thehandlebar slightly to the left or theright.

Right Handlebar SwitchesEngine Stop Switch:In addition to the ignition switch, the

engine stop switch must be in the RUNposition (RUN switch pushed in) for themotorcycle to operate.The engine stop switch is for emer-

gency use. If some emergency re-quires stopping the engine, push theengine stop switch to the OFF position(OFF switch pushed in).

NOTE

Although the engine stop switchstops the engine, it does not turn offall the electrical circuits. Ordinarily,the ignition switch should be used tostop the engine.


A. Engine Stop SwitchB. RUN SwitchC. OFF SwitchD. Starter Button

Starter Button:The starter button operates the elec-

tric starter when pushed with the clutchlever pulled in or the transmission is inneutral.

Refer to the Starting the Engine sec-tion of the "How to Ride the Motorcycle"chapter for starting instructions.


Left Handlebar SwitchesDimmer Switch:High or low beam can be selected

with the dimmer switch. When theheadlight is on high beam (HI), thehigh beam indicator light is lit.

A. Dimmer SwitchB. Turn Signal SwitchC. Horn Button

Turn Signal Switch:When the turn signal switch is turned

to L (left) or R (right), the correspondingturn signals flash on and off.To stop flashing, push the switch in.

Horn Button:When the horn button is pushed, the

horn sounds.


Fuel Tank CapTo open the fuel tank cap, insert the

ignition key into the fuel tank cap, turnthe key to the right.To close the cap, push it down into

place with the key inserted. The keycan be removed by turning it to the leftto the original position.

A. Ignition KeyB. Fuel Tank Cap

NOTE

The fuel tank cap cannot be closedwithout the key inserted, and the keycannot be removed unless the cap islocked properly.Do not push on the key to close thecap, or the cap cannot be locked.


Fuel TankThe following octane rating gasoline

is recommended in the fuel tank. Avoidfilling the tank in the rain or whereheavy dust is blowing so that the fueldoes not get contaminated.

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

WARNING

Gasoline is extremely flammableand can be explosive under cer-tain conditions. Turn the igni-tion key to "OFF". Do not smoke.Make sure the area is well ven-tilated and free from any sourceof flame or sparks; this includesany appliance with a pilot light.Never fill the tank so the fuellevel rises into the filler neck. Ifthe tank is overfilled, heat maycause the fuel to expand andoverflow through the vents inthe tank cap.After refueling, make sure thefuel tank cap is closed securely.If gasoline is spilled on the fueltank, wipe it off immediately.


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." TheAntiknock Index is an average of theResearch Octane Number (RON) andthe Motor Octane Number (MON) asshown in the table.

MinimumOctane Rating Method

Rating

(RON + MON)AntiknockIndex 2

87

CAUTION

If engine "knocking" or "ping-ing" occurs, use a differentbrand of gasoline of a higheroctane 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.

Fuels Containing OxygenatesGasoline 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 toreduce exhaust emissions.The types and volume of fuel oxy-

genates approved for use in unleadedgasoline by the U.S. EnvironmentalProtection Agency include a broadrange of alcohols and ethers, but onlytwo components have seen any signif-icant level of commercial use.Gasoline/Alcohol Blends - Gasoline

containing up to 10% ethanol (alco-hol produced from agricultural productssuch as corn), also known as "gasohol"is approved for use.

CAUTION

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


CAUTION

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 yourKawasaki for 30 to 60 days, mix afuel stabilizer (such as STA-BIL)with the gasoline in the fuel tank.Fuel stabilizer additives inhibitoxidation of the fuel which mini-mizes gummy deposits.

CAUTION

Never store this product with"gasohol" in the fuel system.Before storage it is recom-mended that you drain all fuelfrom the fuel tank and carbure-tor. See the Storage section inthis manual.


Fuel TapThe fuel tap is an automatic type

which shuts off the fuel supply whenthe engine is stopped in the ON or RESposition.

A. Fuel TapB. ON positionC. PRI positionD. RES position

The fuel tap has three positions: ON,RES (reserve), and PRI (prime). Fornomal operation, turn the tap lever to

the ON position. If the fuel runs out withthe tap in the ON position, turn the taplever to PRI, leave it for a few seconds,and then turn it to RES. The last 3.0 L(0.80 US gal) of fuel can be used byturning the fuel tap lever to RES.The PRI position bypasses the auto-

matic control and is useful for primingthe engine after running out of gas, orfor completely draining the fuel tank.

NOTE

Since riding distance is limited whenon RES, refuel at the earliest oppor-tunity.Make certain that the fuel tap lever isturned to ON (Not RES) after fillingup the fuel tank.To start a cold engine after the motor-cycle has been stored for a long time,first turn the tap lever to PRI, leave itfor a moment, and return it to “ON”.


WARNING

Practice operating the fuel tapwith the motorcycle stopped. Toprevent an accident you shouldbe able to operate the fuel tapwhile riding without taking youreyes off the road.Be careful not to touch the hotengine while operating the fueltap.Do not leave the fuel tap in thePRI (prime) position while ridingor parking the motorcycle. Theengine may become flooded orfuel may spill onto the groundand create a fire hazard, if thevehicle falls over.

StandThe motorcycle is equipped with a

side stand.

A. Side Stand

NOTE

When using the side stand, turn thehandlebar to the left.

Whenever the side stand is used,make it a practice to kick the stand fullyup before sitting on the motorcycle.


NOTE

The motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine dose notstart if the transmission is in gear andthe side stand is left down.

Helmet HookHelmet can be secured to the motor-

cycle using the helmet hook located atthe front of the tool kit case.The helmet hook can be unlocked by

inserting the ignition key into the lock,and turning the key to the right.

A. Helmet Hook


WARNING

Do not ride themotorcycle with ahelmet attached to the hook. Thehelmet could cause an accidentby distracting the operator or in-terfering with normal vehicle op-eration.

Tool Kit Case/Tool KitThe tool kit is stored in the tool kit

case.The kit contains tools that can be

helpful in making roadside repairs, ad-justments, and some maintenance pro-cedures explained in this manual.

A. Tool Kit CaseB. Screw


A. Tool Kit

Side CoverThe left and right side covers are re-

moved for battery removal or installa-tion and air cleaner element cleaning.

Right and Left Side Cover Removal• To remove the right and left sidecover, remove a screw of the leftside cover (two screws of the rightside cover), and pull out the left andright side cover.


A. Left Side CoverB. Screw

A. Right Side CoverB. Screws


Seat

Seat RemovalTo remove the seat, follow this step.

1. Remove the left and right side cov-ers.

2. Remove the seat mounting bolts.3. Pull the seat up and to the rear.

A. SeatB. Mounting Bolt

44 BREAK-IN

BREAK-IN

The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as thebreak-in period. If the motorcycle is not used carefully during this period, you mayvery well end up with a "broken down" instead of a "broken in" motorcycle after afew thousand kilometers.The following rules should be observed during the break-in period.

• The table shows maximum recommended engine speed during the break-in pe-riod.

Gear Position

Distance traveled

1st 2nd 3rd 4th 5th 6th

0 ∼ 800 km (0 ∼ 500 mi) 20(12)

30(18)

40(25)

50(31)

60(38)

70(44)

800 ∼ 1,600 km (500 ∼ 1,000 mi) 30(18)

40(25)

50(31)

60(38)

70(44)

85(53)

NOTE

When operating on public roadways, keep maximum speed under traffic law lim-its.

BREAK-IN 45

• Do not start moving or race the engine immediately after starting it, even if theengine is already warm. Run the engine for two or three minutes at idle speed togive the oil a chance to work up into all the engine parts.

• Do not race the engine while the transmission is in neutral.

WARNING

New tires are slippery and may cause loss of control and injury.A break-in period of 160 km (100 miles) is necessary to establish normaltire traction. During break-in, avoid sudden and maximum braking andacceleration, and hard cornering.

In addition to the above, at 1 000 km (600 mi) it is extremely important that theowner have the initial maintenance service performed by a compartment mechanicfollowing the procedures in the Service Manual.

46 HOW TO RIDE THE MOTORCYCLE

HOW TO RIDE THE MOTORCYCLE

Starting the Engine

• Turn the fuel tap lever to "ON" posi-tion.

A. Fuel Tap LeverB. ON position

NOTE

To start a cold engine after the motor-cycle has been stored for a long time,

first turn the tap lever to PRI, leave itfor a moment, and return it to ON.

• Check that the engine stop switchis in the RUN position (RUN switchpushed in).

A. Engine Stop SwitchB. RUN SwitchC. Starter Button

HOW TO RIDE THE MOTORCYCLE 47

• Turn the ignition key to "ON".• Make certain the transmission is inneutral.

A. Neutral Indicator LightB. Ignition SwitchC. ON position

• If the engine is cold, pull up the chokeknob all the way.

A. Choke Knob

NOTE

When the engine is already warm oron hot days (35°C, 95°F or more),close the throttle completely withoutusing the choke knob, and then startthe engine.


• Leaving the throttle completelyclosed, push the starter button.

CAUTION

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.

NOTE

If the engine is flooded, crank the en-gine over with the throttle fully openuntil the engine starts.The motorcycle is equipped with astarter lockout switch. This switch

prevents the electric starter from op-erating when the clutch is engagedand the transmission is not in neutral.

A. Clutch LeverB. Starter Lockout Switch

• Gradually push the choke knob backa little at a time as necessary to keepthe engine running properly duringwarm-up.

• When the engine is warmed upenough to idle without using the


choke, and push the choke knob allthe way back.

NOTE

If you drive the motorcycle beforethe engine is warmed up, return thechoke knob all the way after you havedriven the motorcycle for the lengthof time shown in the table.

CAUTION

Do not let the engine idle longerthan five minutes, or engineoverheating and damage mayoccur.

Ambienttemperature

Choke off afterrunning for

20°C (68°F) ∼ 35°C(95°F)

15 seconds

Below 20°C (68°F) 1.5 minutes

Below 5°C (40°F) 2 minutes


Jump StartingIf your motorcycle battery is "run

down", it should be removed andcharged. If this is not practical, a 12volt booster battery and jumper cablesmay be used to start the engine.

WARNING

Battery acid generates hydro-gen gas which is flammable andexplosive under certain con-ditions. It is present within abattery at all times, even in adischarged condition. Keep allflames and sparks (cigarettes)away from the battery. Wear eyeprotection when working with abattery. In the event of batteryacid contact with skin, eyes, orclothing, wash the affected ar-eas immediately with water for atleast five minutes. Seek medicalattention.

Connecting Jumper Cables• Remove the left side cover.• Make sure the ignition key is turned"OFF".


• Connect a jumper cable from thepositive (+) terminal of the boosterbattery to the positive (+) battery ter-minal at the starter relay.

A. Battery-connected Starter Relay TerminalB. From Booster Battery Positive (+) TerminalC. Unpainted Metal SurfaceD. From Booster Battery Negative (–)

Terminal

• Connect another jumper cable fromthe negative (–) terminal of thebooster battery to your motorcycle

shift pedal or other unpainted metalsurface. Do not use the negative (–)terminal of the battery.

WARNING

Do not make this last connec-tion at the carburetor or battery.Take care that you do not touchthe positive and negative cablestogether, and do not lean overthe battery whenmaking this lastconnection. Do not jump start afrozen battery. It could explode.Do not reverse polarity by con-necting positive (+) to negative( ), or a battery explosion andserious damage to the electricalsystem may occur.

• Follow the standard engine startingprocedure.


CAUTION

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.

• After the engine has started, discon-nect the jumper cables. Disconnectthe negative ( ) cable from the mo-torcycle first.

• Reinstall the parts removed.

Moving Off

• Check that the side stand is up.• Pull in the clutch lever.• Shift into 1st gear.• Open the throttle a little, and start tolet out the clutch lever very slowly.

• As the clutch starts to engage, openthe throttle a little more, giving the en-gine just enough fuel to keep it fromstalling.

A. Shift Pedal


NOTE

The motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine stops if theclutch is engaged with the transmis-sion in gear when the side stand isleft down.

Shifting Gears

• Close the throttle while pulling in theclutch lever.

• Shift into the next higher or lowergear. For smooth riding, shift up ordown when the motorcycle is oper-ated the speeds shown in the table.

• Open the throttle part way, while re-leasing the clutch lever.

WARNING

When shifting down to a lowergear, do not shift at such a highspeed that the engine r/min(rpm) jumps excessively. Notonly can this cause engine dam-age, but the rear wheel may skidand cause an accident. Down-shifting should be done the ve-hicle speeds shown in the tablein this section.


Vehicle speed when shifting

Shifting up km/h (mph) Shifting down km/h (mph)

1st 2nd 15 ( 9) 6th 5th 30 (19)

2nd 3rd 25 (15) 5th 4th 25 (15)

3rd 4th 35 (21) 4th 3rd 20 (12)

4th 5th 45 (27) 3rd 2nd 15 ( 9)

5th 6th 55 (34) 2nd 1st 15 ( 9)


Braking

• Close the throttle completely, leav-ing the clutch engaged (except whenshifting gears) so that the engine willhelp 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 orfully 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.

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

A. Front Brake Lever


A. Rear Brake Pedal

Stopping the Engine

• Close the throttle completely.• Shift the transmission into neutral.• Turn the ignition key to "OFF".• Support the motorcycle on a firmlevel surface with the side stand.

• Lock the steering.


Stopping the Motorcycle in anEmergency

Your Kawasaki Motorcycle has beendesigned and manufactured to pro-vide you optimum safety and conve-nience. However, in order to fully ben-efit from Kawasaki’s safety engineeringand craftsmanship, it is essential thatyou, the owner and operator, properlymaintain your motorcycle and becomethoroughly familiar with its operation.Improper maintenance can create adangerous situation known as throt-tle failure. Two of the most commoncauses of throttle failure are:1. An improperly serviced or cloggedair cleaner may allow dirt and dustto enter the carburetor and stack thethrottle open.

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

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 afterstopping the motorcycle.


Parking

• Shift the transmission into neutraland turn the ignition key to "OFF".

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

CAUTION

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

• If parking inside a garage or otherstructure, be sure it is well ventilatedand the motorcycle is not close toany source of flame or sparks; thisincludes any appliance with a pilotlight.

WARNING

Gasoline is extremely flammableand can be explosive under cer-tain conditions.

• Lock the steering to help preventtheft.

NOTE

When stopping near traffic at night,you can leave taillight on for greatervisibility by turning the ignition key tothe P (Park) position.Do not leave the ignition switch at Pposition too long, or the battery willdischarge.

SAFE OPERATION 59

SAFE OPERATION

Safe Riding TechniqueThe points given below are applicable for everyday motorcycle use and should

be carefully observed for safe and effective vehicle operation.

For safety, eye protection and ahelmet are strongly recommended.Gloves and suitable footwearshould also be used for added pro-tection in case of a mishap.

A motorcycle does not providethe impact protection of an auto-mobile, so defensive riding in addi-tion to wearing protective apparelis extremely important. Do not letprotective apparel give you a falsesense of security.

Before changing lanes, look overyour shoulder to make sure the wayis clear. Do not rely solely on therear view mirror; you may misjudgea vehicle’s distance and speed, oryou may not see it at all.

When going up steep slopes, shiftto a lower gear so that there is plentyof power to spare rather than over-loading the engine.

When applying the brakes, useboth the front and rear brakes. Ap-plying only one brake for sudden

60 SAFE OPERATION

braking may cause the motorcycleto skid and lose control.

When going down long slopes,control vehicle speed by closingthe throttle. Use the front and rearbrakes for auxiliary braking.

In wet conditions, rely more on thethrottle to control vehicle speed andless on the front and rear brakes.The throttle should also be used ju-diciously to avoid skidding the rearwheel from too rapid acceleration ordeceleration.

Riding at the proper rate of speedand avoiding unnecessarily fast ac-celeration are important not only forsafety and low fuel consumption butalso for long vehicle life and quieteroperation.

When riding in wet conditions oron loose roadway surfaces, the abil-ity to maneuver will be reduced. Allof your actions should be smoothunder these conditions. Sudden ac-celeration, braking or turning maycause loss of control.

On rough roads, exercise caution,slow down, and grip the fuel tankwith the knees for better stability.

When quick acceleration is neces-sary as in passing, shift to a lowergear to obtain the necessary power.

Do not downshift at too high anr/min (rpm) to avoid damage to theengine from overrevving.

Avoiding unnecessary weaving isimportant to the safety of both therider and other motorists.

SAFE OPERATION 61

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.If any irregularities are found during these checks, refer to the Maintenance and

Adjustment chapter or see your dealer for the action required to return the motor-cycle to a safe operating condition.

WARNING

Failure to perform these checks every day before you ride may result inserious damage or a severe accident.

Fuel ............................. Adequate supply in tank, no leaks.Engine oil .................... Oil level between level lines.Tires ............................ Air pressure (when cold):

FrontUp to 165 kg (364 lb)Load

150 kPa (1.50 kgf/cm², 21 psi)

RearUp to 97.5 kg (215 lb)Load

150 kPa (1.50 kgf/cm², 21 psi)

97.5 ∼ 165 kg (215 ∼364 lb) Load

175 kPa (1.75 kgf/cm², 25 psi)

62 SAFE OPERATION

Drive chain .................. Slack 35 ∼ 55 mm (1.4 ∼ 2.2 in.).Lubricate if dry

Nuts, bolts, fasteners .. Check that steering and suspension components, axles,and all controls are properly tightened or fastened.

Steering ...................... Action smooth but not loose from lock to lock. No bindingof control cables.

Brakes ........................ Brake pad wear: Lining thickness more than 1 mm (0.04in.) left.No brake fluid leakage.Brake lever play 2 ∼ 5 mm (0.08 ∼ 0.20 in.)

Throttle ....................... Throttle grip play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).Clutch ......................... Clutch lever play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).

Clutch lever operates smoothly.Electrical equipment ... All lights 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.

Refer to the "Daily Safety Checks" caution label attached to the back of the rightside cover.

SAFE OPERATION 63

Additional Considerations for Off Road OperationBrakes: The importance of reliable brakes is obvious. 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: Due to the extra stress to the tires on rough roads, be sure to examine

their overall condition, and inflate them to the proper pressure.Drive Chain: When not adjusted properly, the severe stress on rough roads can

cause damage to the sprockets and cause the chain to be thrown. Examine thechain slack and alignment, and lubricate if necessary.Fuel: Have sufficient fuel for the high fuel consumption on rough roads.Engine Oil: To avoid engine seizure and resulting loss of control, make certain

the oil level is at the upper level line.Miscellaneous: Check to see that the electrical equipment is functioning prop-

erly, all nuts and bolts are tight, and all safety related parts are in good condition.

64 MAINTENANCE AND ADJUSTMENT

MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter are easily carried outand must be done in accordance with the Periodic Maintenance Chart to keep themotorcycle in good running condition. The initial maintenance is vitally impor-tant and must not be neglected.If you are in doubt as to any adjustment or vehicle operation, please ask your

authorized Kawasaki dealer to check the motorcycle.Please note that Kawasaki cannot assume any responsibility for damage result-

ing from incorrect maintenance or improper adjustment done by the owner.

MAINTENANCE AND ADJUSTMENT 65

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporatedcrankcase emission (1) and exhaust emission (2) control systems in compliancewith applicable regulations of the United States Environmental Protection Agency.

1. Crankcase Emission Control SystemThis system eliminates the release of crankcase vapors into the atmosphere.

Instead, the vapors are routed through an oil separator to the intake side of theengine. While the engine is operating, the vapors are drawn into the combustionchamber, where they are burned along with the fuel and air supplied by the car-buretor.

2. Exhaust Emission Control SystemThis system reduces the amount of pollutants discharged into the atmosphere

by the exhaust of this motorcycle. The fuel and ignition systems of this motorcyclehave been carefully designed and constructed to ensure an efficient engine withlow exhaust pollutant levels.

High Altitude Performance Adjustment InformationTo improve the EMISSION CONTROL PERFORMANCE of vehicles operated

above 4 000 feet, Kawasaki recommends the following Environmental ProtectionAgency (EPA) approved modification.


NOTE

When properly performed, these specified modifications only are not consideredto be emissions system “tampering” and vehicle performance is generally un-changed as a result.

Installation Instructions:High altitude adjustment requires replacement of certain carburetor components.

Installation of these optional parts may be performed by an authorized Kawasakidealer, or the consumer, following repair recommendations specified in the appro-priate Kawasaki Service Manual.


MAINTENANCE AND WARRANTY

Proper maintenance is necessary to ensure that your motorcycle will continue tohave 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 thisOwner’s Manual at your own expense.The Kawasaki Limited Emission Control System Warranty requires that you re-

turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty.Please read the warranty carefully, and keep it valid by complying with the owner’sobligations it contains.You should keep a maintenance record for your motorcycle. To assist you in

keeping this record, we have provided space on pages 138 through 142 of thismanual where an authorized Kawasaki dealer, or someone equally competent, canrecord themaintenance. 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 orrendering 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 orelement 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 incompliance 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 othermeans if such modifications result in increased noise levels.


Periodic Maintenance Chart

K: Should be serviced by an authorized Kawasaki dealer.

*: For higher odometer readings, repeat at the frequency interval established here.

#: Service more frequently when operating in severe conditions: dusty, wet, muddy,

high speed, or frequent starting/stopping.

1. Periodic Inspection (Engine Related Items)

Frequency Whichevercomesfirst

*Odometer Readingkm × 1000 ( mile × 1000)

SeePage

Operation (EngineItems)

Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

Air cleaner element -clean • • • 88

Valve clearance - inspect • • • 87




SeePage


Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

Throttle controlsystem (play, smoothreturn, no drag) -inspect

year • • • • 92

Choke operation -inspect

year • • • • –

Idle speed - inspect • • • • 94

KFuel leak (fuel hoseand pipe) - inspect

year • • • • –

KFuel hoses damage- inspect

year • • • • –




SeePage


Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

KFuel hosesinstallation condition- inspect

year • • • • –

Air suction systemdamage - inspect • • • –


2. Periodic Inspection (Chassis Related Items)



SeePage

Operation (ChassisItems)

Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

Clutch and drive train:

Clutch operation(play, engagement,disengagement) -inspect

• • • • 95

Drive chainlubrication condition- inspect #

every 600 km (400 mile) 102

Drive chain slack -inspect #

every 1 000 km (600 mile) 98

Drive chain wear -inspect # • • • 100




SeePage


Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

KDrive chain guidewear - inspect • • • –

Wheels and tires:

Tire air pressure -inspect

year • • • 112

Wheels/tires damage- inspect • • • 113

Tire tread wear,abnormal wear -inspect

• • • 113

KWheel bearingsdamage - inspect

year • • • –

KSpoke tightness andrim runout - inspect • • • • • • • –




SeePage


Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

Brake system:

Brake fluid leak -inspect

year • • • • • • • 107

Brake hoses damage- inspect

year • • • • • • • –

Brake pad wear -inspect # • • • • • • 105

Brake hoseinstallation condition- inspect

year • • • • • • • –

Brake fluid level -inspect

6months • • • • • • • 106




SeePage


Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

Brake operation(effectiveness, play,drag) - inspect

year • • • • • • • 103

Brake light switchoperation - inspect • • • • • • • 108

Suspensions:

Rear shock absorberoperation (dampingand smooth stroke) -inspect

• • • 110

Front forks/rearshock absorber oilleak - inspect

year • • • –

KUni-trak rocker armbearings - lubricate • –




SeePage


Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

KUni-trak rocker armoperation - inspect • • • –

KUni-trak tie rodsoperation - inspect • • • –

KUni-trak tie rodsbearings - lubricate • –

KSwing arm pivot -lubricate • –

Steering system:

KSteering play -inspect

year • • • • –




SeePage


Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

KSteering stembearings - lubricate

2years • –

Electrical system:

Lights and switchesoperation - inspect

year • • • –

Headlight aiming -inspect

year • • • 117

Side stand switchoperation - inspect

year • • • –

Engine stop switchoperation - inspect

year • • • –

Chassis:




SeePage


Every1

(0.6)6

(3.75)12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

Chassis parts -lubricate

year • • • 121

Bolts and nutstightness - inspect • • • • 127


3. Periodic Replacement



SeePage

Change/Replacement Item Every1

(0.6)12(7.5)

24(15)

36(22.5)

48(30)

Air cleaner element # - replace 2 years 88

Engine oil # - change year • • • • • 81

Oil filter - replace year • • • • • 81

K Fuel hoses - replace 4 years • –

K Brake hoses - replace 4 years • –

KBrake fluid (front and rear) -change

2 years • • 108

KRubber parts of master cylinderand caliper - replace

4 years • –

Spark plug - replace • • • • 85


Engine OilIn order for the engine, transmission,

and clutch to function properly, main-tain the engine oil at the proper level,and change the oil and oil filter in accor-dance with the Periodic MaintenanceChart. Not only do dirt and metal par-ticles collect in the oil, but the oil itselfloses its lubricative quality if used toolong.

WARNING

Motorcycle operation with insuf-ficient, deteriorated, or contami-nated engine oil will cause accel-erated wear andmay result in en-gine or transmission seizure, ac-cident, and injury.

Oil Level Inspection• Situate the motorcycle so that it isperpendicular to the ground.

• If the oil has just been changed, startthe engine and run it for several min-utes at idle speed. This fills the oilfilter with oil. Stop the engine, thenwait several minutes until the oil set-tles.

CAUTION

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

• If the motorcycle has just been used,wait several minutes for all the oil todrain down.

• Check the engine oil level throughthe oil level gauge. With the motor-cycle held level, the oil level shouldcome up between the upper andlower level lines next to the gauge.


A. Oil Filler CapB. Oil Level GaugeC. 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 same othersuitable device.

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

Oil and/or Oil Filter Change• Warm up the engine thoroughly, andthen stop it.

• Set the motorcycle up on its sidestand.

• Remove the bolt of the engine guard,and take off the engine guard.

A. Engine GuardB. Bolt

• Place an oil pan beneath the engine.• Remove the engine oil drain plug.


A. Drain Plug

• Let the oil completely drain withthe motorcycle perpendicular to theground.

WARNING

Motor oil is a toxic substance.Dispose of used oil properly.Contact your local authoritiesfor approved disposal methodsor possible recycling.

• If the oil filter is to be changed, re-move the oil filter cover bolts andtake off the cover with O-ring.

A. BoltsB. Oil Filter Cover


• Replace the element with a new one.• Put the spring and element into theright engine cover.

A. ElementB. GrommetC. Spring

• Apply a little engine oil to the grom-met and O-ring, and install the oil fil-ter cover and tighten its bolts.

• After the oil has completely drainedout, install the engine oil drain plug

with its gasket. Proper torque for it isshown in the table.

NOTE

Replace the any gasket with a newone.

• Fill the engine up to the upper levelline with a good quality motor oilspecified in the table.

• Start the engine.• Check the oil level and for oil leak-age.

• Install the engine guard.Tightening Torque

Engine Oil Drain Plug:

15 N·m (1.5 kgf·m, 11 ft·lb)

NOTE

If a torque wrench is not available,this item should be serviced by aKawasaki dealer.


Recommended Engine Oil

Type: API SE, SF or SG

API SH, SJ, SL or SM withJASO MA, MA1 or MA2

Viscosity: SAE 10W-40

NOTE

Do not add any chemical additive tothe oil. Oils fufilling the above re-quirements are fully formulated andprovide adequate lubrication for boththe engine and the clutch.

Engine Oil Capacity

Capacity: 1.3 L (1.4 US qt)[when filter is not removed]

1.4 L (1.5 US qt)[when filter is removed]

1.5 L (1.6 US qt)[when engine is completelydry]

Although 10W-40 engine oil is therecommended oil for most condi-tions, the oil viscosity may need to bechanged to accumulate atmosphericconditions in your riding area.


Spark PlugsThe standard spark plug is shown in

the table. The spark plug should betaken out in accordance with the Pe-riodic Maintenance Chart for cleaning,inspection, and resetting of the pluggap.

MaintenanceIf the plug is oily or has carbon built

up on it, have it cleaned, preferably ina sand-blasting device, and then cleanoff any abrasive particles. The plugmay also be cleaned using a high-flashpoint solvent and a wire brush or othersuitable tool. Measure the gap with awire-type thickness gauge, and adjustthe gap if incorrect by bending the outerelectrode. If the spark plug electrodesare corroded or damaged, or if the insu-lator is cracked, replace the plug. Usethe standard plug.

Spark Plug

Standard PlugNGK CR8E,ND U24ESR-N

Plug Gap0.7 ∼ 0.8 mm(0.028 ∼ 0.031 in.)

TighteningTorque

13 N·m(1.3 kgf·m, 115 in·lb)

A. Plug Gap


NOTE

If a torque wrench is not available,this item should be serviced by aKawasaki dealer.

CAUTION

For cold weather and/or lowspeed riding, a hotter spark plugshown in the table may be usedfor quicker warm-ups and moreefficient engine operation. How-ever, for normal temperaturesand/or high speed use, the stan-dard spark plug must be used toprevent engine damage.

Hotter Spark Plug

NGK CR7E

NOTE

When installing the spark plug caponto the spark plug, fit the plug capsecurely onto the spark plug, and pullthe cap lightly to make sure that it isproperly installed.


Valve ClearanceValve and valve seat wear decreases

valve clearance, upsetting valve timing.

CAUTION

If valve clearance is left un-adjusted, wear will eventuallycause the valves to remainpartly open, which lowers per-formance, burns the valves andvalve seats, and may cause seri-ous engine damage.

Valve clearance for each valveshould be checked and adjusted inaccordance with the Periodic Mainte-nance Chart.Inspection and adjustment should be

done only by a competent following theService Manual.

Air CleanerA clogged air cleaner restricts the en-

gine’s air intake, increasing fuel con-sumption, reducing engine power, andcausing spark plug fouling.The air cleaner element must be

cleaned in accordance with the Peri-odic Maintenance Chart. In dusty ar-eas, the element should be cleanedmore frequently than the recom-mended interval. After riding throughrain or on muddy roads, the elementshould be cleaned immediately. Theelement should be replaced if it is dam-aged.


Element Removal• Remove the right side cover.• Unscrew the air cleaner element capscrews and bolt, then remove the aircleaner element cap.

A. Air Cleaner Element CapB. ScrewsC. Bolt

• Pull out the air cleaner element fromthe air cleaner housing.

A. Element


• Remove the element from the frame.

A. ElementB. Frame

• Push a clean, lint-free towel into theair cleaner housing to keep dirt orother foreign material from entering.

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

WARNING

If dirt or dust is allowed to passthrough into the carburetor, thethrottle may become stuck, pos-sibly causing accident.

CAUTION

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

NOTE

Element installation is performed inthe reverse order of removal.

Element Cleaning• Clean the element in a bath of a high-flash point solvent.


• Dry the element with compressed airor by squeezing it.

• After cleaning, saturate the elementwith SE, SF or SG class SAE 10W40motor oil, squeeze out the excessoil, then wrap it in a clean rag andsqueeze it as dry as possible. Becareful not to tear the element.

WARNING

Clean the element in a well ven-tilated area, and take care thatthere are no sparks or flame any-where near the working area;this includes any appliance witha pilot light. Do not use gaso-line or a low flash-point solventto clean the element. A fire orexplosion could result.

Oil Draining• Inspect the transparent drain hoseslocated at the lower end of the aircleaner housing to see if any oil hasrun down from the air cleaner hous-ing.

A. Drain HosesB. Plugs

• If there are any oil in the drain hoses,remove the plugs from the lower endof the drain hoses and drain the oil.


WARNING

Be sure to install each plug inthe drain hose after draining. Oilon tires will make them slipperyand can cause an accident andinjury.

Throttle GripThe throttle grip controls the throttle

valves. If the throttle grip has exces-sive play due to either cable stretch ormaladjustment, it will cause a delay inthrottle response, especially at low en-gine speed. Also, the throttle valvesmay not open fully at full throttle. Onthe other hand, if the throttle grip hasno play, the throttle will be hard to con-trol, and the idle speed will be erratic.Check the throttle grip play in accor-dance with the Periodic MaintenanceChart, and adjust the play if necessary.


Inspection• Check that there is 2 ∼ 3 mm (0.08

∼ 0.12 in.) throttle grip play whenlightly turning the throttle grip backand forth.

• If there is improper play, adjust it.

A. Throttle GripB. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Adjustment• Loosen the locknut at the upper endof the throttle cable, and turn theadjuster until the proper amount ofthrottle grip play is obtained.

A. LocknutB. AdjusterC. Throttle Cable (Accelerator Cable)

• Tighten the locknut.• If the throttle cable can not be ad-justed by using the cable adjuster atthe upper end of the throttle cable,


use the upper and lower nuts at thelower ends of the throttle cables.

• Loosen the locknut at the upper endof the throttle cable and turn in theadjuster fully.

• Tighten the locknut.• Turn the upper and lower nuts at thelower end of the decelerator cableuntil there is no play when the throttlegrip is completely closed. Tighten thenuts.

• Turn the upper and lower nuts at thelower end of the accelerator cableuntil 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ofthrottle grip play is obtained. Tightenthe nuts.

A. Upper NutsB. Lower NutsC. Accelerator CableD. Decelerator Cable

• If there is excess play, use the ad-juster at the upper end of the throttlecable.


WARNING

Operation with improperly ad-justed, incorrectly routed, ordamaged cables could result inan unsafe riding condition.

CarburetorsThe following procedure covers the

idle speed adjustment, which should beperformed in accordance with the Pe-riodic Maintenance Chart or wheneverthe idle speed is disturbed.

Adjustment• Start the engine, and warm it up thor-oughly.

• Adjust the idle speed to 1 250 ∼ 1350 r/min (rpm) by turning the idleadjusting screw.

• Open and close the throttle a fewtimes to make sure that the idlespeed does not change. Readjust ifnecessary.

• With the engine idling, turn the han-dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improperlyadjusted or incorrectly routed, or they


may be damaged. Be sure to correctany of these conditions before riding.

A. Idle Adjusting Screw

WARNING

Operation with damaged cablescould result in an unsafe ridingcondition.

ClutchDue to friction plate wear and clutch

cable stretch over a long period of use,the clutch must be adjusted in accor-dance with the Periodic MaintenanceChart.

WARNING

To avoid a serious burn, nevertouch a hot engine or an exhaustpipe during clutch adjustment.

Inspection• Check that the clutch lever has 2 ∼ 3mm (0.08 ∼ 0.12 in.) of play as shownin the figure.


A. AdjusterB. LocknutC. Clutch LeverD. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

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

Adjustment• Slide the dust cover at the clutchlever out of place.

• Loosen the locknut at the clutchlever.

• Turn the adjuster at the upper end ofthe cable so that the clutch lever willhave 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ofplay.

WARNING

Be sure the upper end of theclutch outer cable is fully seatedin its fitting, or it could slip intoplace later, creating enough ca-ble play to prevent clutch dis-engagement, resulting in a haz-ardous riding condition.

• Tighten the locknut.• If it cannot be done, use the adjustingnut at the middle of the clutch cable.

• Loosen the locknut at the clutchlever.

• Turn the adjuster in all the way, thentighten the locknut.


• Loosen the locknut at the middle ofthe clutch cable, and turn the adjust-ing nut so that the clutch lever has 2∼ 3 mm (0.08 ∼ 0.12 in.) of play.

A. Adjusting NutB. Locknut

• Tighten the locknut.• Slide the dust cover back into place.

NOTE

After the adjustment is made, startthe engine and check that the clutchdoes not slip and that it releasesproperly.

WARNING

Do not run the engine in aclosed area. Exhaust gasescontain carbon monoxide; a col-orless, odorless, poisonous gas.Breathing exhaust gas leads tocarbon monoxide poisoning, as-phyxiation, and death.


Drive ChainThe drive chain must be checked,

adjusted, and lubricated in accordancewith the Periodic Maintenance Chartfor safety and to prevent excessivewear. If the chain becomes badly wornor maladjusted - either too loose ortoo tight - the chain could jump off thesprockets or break.

WARNING

A chain that breaks or jumps offthe sprockets could snag on theengine sprocket or lock the rearwheel, severely damaging themotorcycle and causing it to goout of control.

Chain Slack Inspection• Set the motorcycle up on its sidestand.

• Rotate the rear wheel to find the po-sition where the chain is tightest andmeasure the maximum chain slackby pulling up and pushing down thechain midway between the enginesprocket and rear wheel sprocket.

A. 35 ∼ 55 mm (1.4 ∼ 2.2 in.)

• If the drive chain is too tight or tooloose, adjust it so that the chain slackwill be within the standard value.


Drive Chain Slack

Standard 35 ∼ 55 mm (1.4 ∼ 2.2 in.)

Chain Slack Adjustment• Remove the cotter pin, and loosenthe axle nut.

• Rotate the chain adjuster at each endof the swingarm to obtain the stan-dard chain slack.

A. Axle NutB. Chain AdjusterC. ProjectionD. NumbersE. Cotter Pin

NOTE

Wheel alignment can also bechecked using the straightedge orstring method.


WARNING

Misalignment of the wheel willresult in abnormal wear, andmayresult in an unsafe riding condi-tion.

• Tighten the axle nut to the specifiedtorque.

Tightening Torque

Axle Nut:88 N·m (9.0 kgf·m, 65 ft·lb)

• Rotate the wheel, measure the chainslack again at the tightest position,and readjust if necessary.

• Insert a new cotter pin through theaxle nut, and spread its ends.

• Check the rear brake (see the Brakessection).

WARNING

If the axle nut is not securelytightened or the cotter pin is notinstalled, an unsafe riding condi-tion may result.

Wear Inspection• Stretch the chain taut either by usingthe chain adjusters, or by hanging a10 kg (20 lb) weight on the chain.


• Measure the length of 20 links onthe straight part of the chain from pincenter of the 1st pin to pin center ofthe 21st pin. Since the chain maywear unevenly, take measurementsat several places.

• If the length exceeds the service limit,the chain should be replaced.

A. MeasureB. Weight

Drive Chain 20-Link Length

Service Limit: 323 mm (12.7 in.)

WARNING

For safety, use only the standardchain. It is an endless type andshould not be cut for installa-tion; have it installed by an au-thorized Kawasaki dealer.

• Rotate the rear wheel to inspect thedrive chain for damaged rollers, andloose pins and links.

• Also inspect the sprockets for un-evenly or excessively worn teeth,and damaged teeth.


NOTE

Sprocket wear is exaggerated for il-lustration. See Service Manual forwear limits.

• If there is any irregularity, have thedrive chain and/or the sprockets re-placed by an authorized Kawasakidealer.

LubricationLubrication is also necessary after

riding through rain or on wet roads, orany time that the chain appears dry. Aheavy oil such as SAE 90 is preferredto a lighter oil because it will stay on thechain longer and provide better lubrica-tion.


• Apply oil to the sides of the rollers sothat it will penetrate to the rollers andbushings. Apply oil to the O-rings sothat the O-rings will be coated withoil. Wipe off any excess oil.

• If the chain is especially dirty, clean itusing diesel oil or kerosine and thenapply oil as described above.

BrakesDisc and disc pad wear is automat-

ically compensated for and has no ef-fect on the brake lever or pedal action.So there are no parts that require ad-justment on the brakes except brakelever play.

Front Brake Lever PlayThe brake lever has 2 ∼ 5 mm (0.08

∼ 0.20 in.) of play when the brake islightly applied.To adjust the brake lever play, loosen

the locknut and turn the adjuster to ei-ther side. After adjustment, tighten thelocknut securely and check the brakingeffectiveness.


A. Brake LeverB. 2 ∼ 5 mm (0.08 ∼ 0.20 in.)

WARNING

If the brake lever or pedal feelsmushy when it is applied, theremight be air in the brake linesor the brake may be defective.Since it is dangerous to operatethe motorcycle under such con-ditions, have the brake checkedimmediately.

A. Brake LeverB. AdjusterC. Locknut


Brake Wear InspectionIn accordance with the Periodic Main-

tenance chart, inspect the brakes forwear. For each front and rear discbrake caliper, if the thickness of eitherpad is less than 1mm (0.04 in.), replaceboth pads in the caliper as a set. Padreplacement should be done by an au-thorized Kawasaki dealer.

A. Lining ThicknessB. 1 mm (0.04 in.)

Disc Brake Fluid -In accordance with the Periodic Main-

tenance Chart, inspect the brake fluidlevel in both the front and rear brakefluid reservoir and change the brakefluid. The brake fluid should also bechanged if it becomes contaminatedwith dirt or water.

Fluid RequirementUse heavy-duty brake fluid only from

a container marked DOT3 or DOT4.

NOTE

Brake fluid of DOT4 is installed in thebrake system when shipped.


CAUTION

Do not spill brake fluid onto anypainted surface.Do not use fluid from a containerthat has been left open or thathas been unsealed for a longtime.Check for fluid leakage aroundthe fittings.Check brake hose for damage.

Fluid Level Inspection• The brake fluid level in the front brakefluid reservoir must be kept abovethe line (lower level line) next to thegauge and that in the rear brake fluidreservoir (located under the right sidecover) must be kept between the up-per and lower level lines (reservoirsheld horizontal).

A. Front Brake Fluid ReservoirB. Lower Level Line


A. Rear Brake Fluid ReservoirB. Upper Level LineC. Lower Level LineD. Cap

• If the fluid level in ether reservoir islower than the lower level line, checkfor fluid leaks in the brake lines, andfill the reservoir to the upper levelline. Inside the front brake fluid reser-voir is a stepped line showing the up-per level line.

A. Front Brake Fluid ReservoirB. Upper Level Line


WARNING

Do not mix two brands of brakefluid. Change the brake fluid inthe brake line completely if thebrake fluid must be refilled butthe type and brand of the brakefluid that is already in the reser-voir are unidentified.

Fluid ChangeHave the brake fluid changed by an

authorized Kawasaki dealer.

Brake Light SwitchesWhen either the front or rear brake is

applied, the brake light goes on. Thefront brake light switch requires no ad-justment, but the rear brake light switchshould be adjusted in accordance withthe Periodic Maintenance Chart.

Inspection• Turn the ignition key to "ON".• The brake light should go on whenthe front brake is applied.

• If it does not, ask your authorizedKawasaki dealer to inspect the frontbrake light switch.


• Check the operation of the rear brakelight switch by depressing the brakepedal. The brake light should go onafter about 10 mm (0.4 in.) of pedaltravel.

A. Brake PedalB. 10 mm (0.4 in.)

• If it does not, adjust the rear brakelight switch.

Adjustment• To adjust the rear brake light switch,move the switch up or down by turn-ing the adjusting nut.

CAUTION

To avoid damaging the electricalconnections inside the switch,be sure that the switch bodydoes not turn during adjustment.


A. Rear Brake Light SwitchB. Adjusting NutC. Lights soonerD. Lights later

Rear Shock AbsorberThe rear shock absorber can be ad-

justed by changing the spring preloadand rebound damping force for vari-ous riding and loading conditions. Be-fore making any adjustments, however,read the following procedures.

Spring Preload AdjustmentThe 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 authorizedKawasaki dealer.

Rebound Damping Force AdjustmentThe rebound damping force adjuster

at the lower end of the rear shock ab-sorber has 20 adjustment clicks.

• First turn the rebound damping forceadjuster all the way clockwise witha screwdriver to make the dampingforce greatest.


• Turn the adjuster counterclockwiseto decrease damping force.

A. Rebound Damping AdjusterB. Mark

The standard setting position of therebound damping force adjuster for anaverage-build rider of 68kg (150 lb) withno passenger and no accessories areas follows.

Rebound DampingForce Adjuster

7 turns out*

* out from the fully seated position


Wheels

Tires -

Payload and Tire PressureFailure to maintain proper inflation

pressures or observe payload limits foryour tires may adversely affect han-dling and performance of your motorcy-cle and can result in loss of control. Themaximum recommended load in addi-tion to vehicle weight is 165 kg (364 lb),including rider, passenger, baggage,and accessories.

• Check the tire pressure often, usingan accurate gauge.

NOTE

Measure the tire pressure when thetires are cold (that is, when the mo-torcycle has not been ridden morethan a mile during the past 3 hours).

Tire pressure is affected by changesin ambient temperature and altitude,and so the tire pressure should bechecked and adjusted when your rid-ing involves wide variations in tem-perature or altitude.

A. Tire Pressure Gauge


Tire Air Pressure (when cold)

FrontUp to 165 kg(364 lb) Load

150 kPa (1.50kgf/cm², 21 psi)

RearUp to 97.5 kg(215 lb) Load

150 kPa (1.50kgf/cm², 21 psi)

97.5 ∼ 165 kg(215 ∼ 364 lb)Load

175 kPa (1.75kgf/cm², 25 psi)

Tire Wear, DamageAs the tire tread wears down, the tire

becomes more susceptible to punctureand failure. An accepted estimate isthat 90% of all tire failures occur duringthe last 10% of tread life (90 % worn).So it is false economy and unsafe touse the tires until they are bald.

• In accordance with the PeriodicMaintenance Chart, measure thedepth of the tread with a depthgauge, and replace any tire thathas worn down to the minimum al-lowable tread depth.

A. Tire Depth Gauge

Minimum Tread Depth

Front 2 mm (0.08 in.)

Rear 2 mm (0.08 in.)


• Visually inspect the tire for cracksand cuts, replacing the tire in case ofbad damage. Swelling or high spotsindicate internal damage, requiringtire replacement.

• Remove any imbedded stones orother foreign particles from the tread.

NOTE

Have the wheel balance inspectedwhenever a new tire is installed.

WARNING

To ensure safe handling andstability, use only the recom-mended standard tires for re-placement, inflated to the stan-dard pressure.

Standard Tire

Front Size: 2.75-21 45P

BRIDGESTONE “TRAILWING-301”

Rear Size: 4.10-18 59P

BRIDGESTONE “TRAILWING-302”

WARNING

Use the same manufacture’stires on both front and rearwheels.


WARNING

New 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.

BatteryThe battery installed in this motorcy-

cle is a sealed type, so it is not nec-essary to check the battery electrolytelevel or add distilled water.The sealing strip should not be pulled

off once the specified electrolyte hasbeen installed in the battery for initialservice.Since the electrical system of this

motorcycle is desighned to use only asealed battery, do not replace it with aconventional battery.

CAUTION

Never remove the sealing strip,or the battery can be damaged.Do not install a conventionalbattery in this motorcycle, or theelectrical system cannot workproperly.


NOTE

If you charge the sealed battery,never fail to observe the instructionsshown in the label on the battery.

WARNING

Battery posts, terminals and re-lated accessories contain leadand lead compounds. Washhands after handling.

Battery Removal• Remove the left side cover.• Disconnect the leads from the bat-tery, first from the (–) terminal andthen the (+) terminal.

A. (–) TerminalB. (+) TerminalC. BatteryD. Band

• Remove the battery band, and takethe battery out of the battery case.


• Clean the battery using a solution ofbaking soda and water. Be sure thatthe lead connections are clean.

Battery Installation• Put the battery in the battery case.• Connect the capped lead to the (+)terminal, and then connect the blacklead to the (–) terminal.

• Put a light coat of grease on the ter-minals to prevent corrosion.

• Cover the (+) terminal with its protec-tive cap.

• Reinstall the parts removed.

Headlight Beam

Horizontal AdjustmentThe headlight beam is adjustable

horizontally. If not properly adjustedhorizontally, the beam will point to oneside rather than straight ahead.

• Turn the horizontal adjusting screwon the headlight rim in or out until thebeam points straight ahead.

A. Vertical Adjusting ScrewB. Horizontal Adjusting Screw


Vertical AdjustmentThe headlight beam is adjustable ver-

tically. If adjusted too low, neither lownor high beam will illuminate the roadfar enough ahead. If adjusted too high,the high beam will fail to illuminate theroad close ahead, and the low beamwill blind oncoming driver.

• Turn the vertical adjusting screw onthe headlight rim in or out to adjustthe headlight vertically.

NOTE

On high beam, the brightest pointshould be slightly below horizontal.The proper angle is 0.4 degrees be-low horizontal. This is a 50 mm (2in.) drop at 7.6 m (25 ft) measuredfrom the center of the headlight, withthe motorcycle on its wheels and therider seated.


CAUTION

When handling the quartz-halogen bulbs, never touch theglass portion with bare hands.Always use a clean cloth. Oilcontamination from hands ordirty rags can reduce bulb life orcause the bulb to explode.

FusesThe main fuse is mounted on the

starter relay located to the left side ofthe battery. The fuse case is located tothe left side of the starter relay. If a fusefails during operation, inspect the elec-trical system to determine the cause,and then replace it with a new fuse ofproper amperage.

A. Main Fuse (20 A)B. Fuse CaseC. Spare Fuse


WARNING

Do not use any substitute for thestandard fuse.Replace the blown fuse with anew one of the correct capacity,as specified on the fuse case.

A. NormalB. Failed

A. NormalB. Failed


General LubricationLubricate the points shown below,

with either motor oil or regular grease,in accordance with the Periodic Main-tenance Chart or whenever the vehiclehas been operated under wet or rainyconditions.Before lubricating each part, clean off

any rusty spots with rust remover andwipe off any grease, oil, dirt, or grime.

NOTE

A few drops of oil are effective tokeep bolts and nuts from rusting andsticking. This makes removal easier.Badly rusted nuts, bolts, etc., shouldbe replaced with new ones.

Apply motor oil to the followingpivots -Side StandClutch LeverFront Brake LeverRear Brake Pedal

Lubricate the following cables with apressure cable lubber -Clutch Inner CableThrottle Inner Cables


Apply grease to the followingpoints -Clutch Inner Cable Upper EndThrottle Inner Cable Upper Ends

* Grease the lower part of the inner

cable sparingly.

NOTE

After connecting the cables, adjustthem.

Cleaning Your Motorcycle

General PrecautionsFrequent and proper care of your

Kawasaki motorcycle will enhanceits appearance, optimize overall per-formance, and extend its useful life.Covering your motorcycle with a highquality, breathable motorcycle coverwill help protect its finish from harmfulUV rays, pollutants, and reduce theamount of dust reaching its surfaces.

• Be sure the engine and exhaust arecool before washing.

• Avoid applying degreaser to seals,brake pads, and tires.

• Always use non-abrasive wax andcleaner/polisher.

• Avoid all harsh chemicals, solvents,detergents, and household cleaningproducts such as ammonia-basedwindow cleaners.


• Gasoline, brake fluid, and coolantwill damage the finish of painted andplastic surfaces: wash them off im-mediately.

• Avoid wire brushes, steel wool, andall other abrasive pads or brushes.

• Use care when washing the head-light cover, and other plastic parts asthey can easily be scratched.

• Avoid using pressure washers; wa-ter can penetrate seals and electricalcomponents and damage your mo-torcycle.

• Avoid spraying water in delicate ar-eas such as in air intakes, carbu-retors, brake components, electricalcomponents, muffler outlets, and fueltank openings.

Washing Your Motorcycle• Rinse your bike with cold water froma garden hose to remove any loosedirt.

• Mix a mild neutral detergent (de-signed for motorcycles or automo-biles) and water in bucket. Usea soft cloth or sponge to wash yourmotorcycle. If needed, use a mild de-greaser to remove any oil or greasebuild up.

• After washing, rinse your motorcy-cle thoroughly with clean water to re-move any residue (residue from thedetergent can damage parts of yourmotorcycle).

• Use a soft cloth to dry your motorcy-cle. As you dry, inspect your motor-cycle for chips and scratches. Do notlet the water air dry as this can dam-age the painted surfaces.

• Start the engine and let it idle for sev-eral minutes. The heat from the en-gine will help dry moist areas.

• Carefully ride your motorcycle at aslow speed and apply the brakesseveral times. This helps dry the


brakes and restores them to normaloperating performance.

• Lubricate the drive chain to preventrusting.

NOTE

After riding in an area where theroads are salted or near the ocean,immediately wash your motorcyclewith cold water. Do not use warmwater as it accelerates the chemicalreaction of the salt. After drying,apply a corrosion protection sprayon all metal and chrome surfaces toprevent corrosion.

Painted SurfacesAfter washing your motorcycle, coat

painted surfaces, both metal and plas-tic, with a commercially available mo-torcycle/automotive wax. Wax shouldbe applied once every three months oras conditions require. Avoid surfaceswith "satin" or "flat" finishes. Alwaysuse non-abrasive products and applythem according to the instructions onthe container.

Plastic PartsAfter washing use a soft cloth to gen-

tly dry plastic parts. When dry, treat theheadlight lens, and other non-paintedplastic parts with an approved plasticcleaner/polisher product.


CAUTION

Plastic parts may deteriorateand brake if they come in con-tact with chemical substancesor household cleaning productssuch as gasoline, brake fluid,window cleaners, thread-lockingagents, or other harsh chemi-cals. If a plastic part comes incontact with any harsh chemicalsubstance, wash it off immedi-ately with water and a mild neu-tral detergent, and then inspectfor damage. Avoid using abra-sive pads or brushes to cleanplastic parts, as they will dam-age the part’s finish.

Chrome and AluminumChrome 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 spraypolish. Aluminum wheels, both paintedand unpainted can be cleaned withspecial non-acid based wheel spraycleaners.

Leather, Vinyl, and RubberIf your motorcycle has leather ac-

cessories, special care must be taken.Use a leather cleaner/treatment toclean and care for leather accessories.Washing leather parts with detergentand water will damage them, shorten-ing their life.Vinyl parts should be washed with the

rest of the motorcycle, then treated witha vinyl treatment.The sidewalls of tires and other rub-

ber components should be treated witha rubber protectant to help prolong theiruseful life.


WARNING

Special caremust be taken not toget any rubber protectant on thetire’s tread surface when treat-ing tires. This may decrease thetire’s ability to maintain contactwith the road surface causingthe rider to lose control.


Bolt and Nut TighteningIn accordance with the Periodic Maintenance Chart, it is very important to check

the tightness of the bolts and nuts listed here. Also, check to see that each cotterpin is in place and in good condition. Please ask your authorized Kawasaki dealerfor torque values.

1. Front Fender MountingBolts

2. Front Fork Clamp Bolts3. Clutch Lever Holder Bolts4. Handlebar Clamp Bolts5. Steering Stem Head Bolt6. Cylinder Head Bolts7. Rear Shock Absorber

Mounting Bolts and Nuts8. Caliper Mounting Bolts9. Spokes10. Engine Mounting Bolts

and Nuts11. Shift Pedal Bolt12. Swingarm Pivot Shaft Bolt


13. Muffler Mounting Bolts14. Brake Lever Holder Bolt15. Rear Axle Nut16. Exhaust Pipe Holder Nuts17. Front Axle Nut

STORAGE 129

STORAGE

Preparation for Storage:

• Clean the entire vehicle thoroughly.• Run the engine for about five minutes to warm the oil, shut it off and drain theengine oil.

WARNING

Motor oil is a toxic substance. Dispose of used oil properly. Contact yourlocal authorities for approved disposal methods or possible recycling.

• Put in fresh engine oil.• Empty the fuel from the fuel tank, and empty the carburetors by unscrewing thedrain screw at the float bowl. (If left in for a long time, the fuel will break downand could clog the carburetor.)

130 STORAGE

WARNING

Gasoline is extremely flammable and can be explosive under certain con-ditions. Turn the ignition key to "OFF". Do not smoke. Make sure thearea is well ventilated and free from any source of flame or sparks; thisincludes any appliance with a pilot light.Gasoline is a toxic substance. Dispose of gasoline properly. Contact yourlocal authorities for approved disposal methods.

• Remove the empty fuel tank, pour about 250 mL (1/2 pint) of motor oil into thetank, roll the tank around to coat the inner surfaces thoroughly, and pour out theexcess oil.

• Remove the spark plugs and spray fogging oil, such as Kawasaki K-Kare FoggingOil (part number K61030-002), directly into each cylinder. Turn the engine overseveral times with the starter button to coat the cylinder walls. Install the sparkplug.

STORAGE 131

WARNING

Do not lean over the engine when performing this procedure. An air/oilmist may be forcibly ejected from the spark plug hole and could get intoyour eyes. if you do get some in your eyes, wash your eyes immediatelywith liberal amounts of clean, fresh water. Consult a physician as soonas possible.

• Reduce tire pressure by about 20%.• Set themotorcycle 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.)

• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil onrubber parts or in the brakes.

• Lubricate the drive chain and all the cables.• Remove the battery, and store it where it will not be exposed to direct sunlight,moisture, or freezing temperatures. During storage it should be given a slowcharge (one ampere or less) about once a month. Keep the battery well chargedespecially during cold weather.

• Tie plastic bags over the muffler to prevent moisture from entering.

• Put a cover over the motorcycle to keep dust and dirt from collecting on it.

132 STORAGE

Preparation after Storage:

• Remove the plastic bag from the muffler.

• Install the battery in the motorcycle and charge the battery if necessary.• Make sure the spark plug is tight.• Fill the fuel tank with fuel.• Check all the points listed in the Daily Safety Checks section.• Lubricate the points listed in the General Lubrication section.

TROUBLESHOOTING GUIDE 133

TROUBLESHOOTING GUIDE

Engine Does Not Start -Starter Motor Won’t Turn• Engine stop switch off• Clutch lever not pulled in and trans-mission not in neutral

• Fuse blown• Battery leads do not make good elec-trical contact with battery terminals

• Battery discharged

Engine Cranks, But Won’t Start• No fuel in tank• Fuel line clogged• Fuel broken down• Choke is not used when engine iscold

• Engine flooded• Spark plugs not in good contact

• Spark plugs fouled or wet• Incorrect spark plug gap• Battery dischargedEngine Stalls -Just When Shifting Into 1st Gear• Side stand has been left down• Clutch does not properly disengage

While Riding• Choke is used too long after movingoff

• No fuel in tank• Fuel tap is turned off• Fuel tank air vent is obstructed• Overheating• Battery discharged

134 OWNER SATISFACTION

OWNER SATISFACTION

(For Products Sold in the Continental United States of America Only)

Your satisfaction is important to your authorized Kawasaki dealer and to KawasakiMotors Corp., U.S.A. If you have a problem concerning warranty or service, pleasetake the following action:

Contact the owner and/or service manager of your authorized Kawasaki dealer.Fully explain your problem and ask for assistance in resolving the situation. TheOWNER of the dealership is concerned with your satisfaction and your future busi-ness. For this reason the owner is in the best position to assist you. Also, allwarranty and service matters are handled and resolved through the authorizedKawasaki dealer network.If you are unsatisfied after working with your Kawasaki dealer and feel you still re-quire further assistance, write to the address below. Please be certain to providethe model, product identification number, mileage or hours of use, accessories,dates that events occurred and what action has been taken by both you and yourdealer. Include the name and address of the dealership. To assist us in resolvingyour inquiry, please include copies of related receipts and any other pertinent infor-mation including the names of the dealership personnel with whom you have beenworking in the resolution of your problem.

OWNER SATISFACTION 135

Upon receipt of your correspondence we will contact the dealership and work withthem in resolving your problem.

In order to provide a permanent record, all warranty and service resolutions takeplace only through written correspondence.

Please send your correspondence to:CONSUMER RELATIONSKAWASAKI MOTORS CORP., U.S.A.P. O. Box 25252SANTA ANA, CA. 92799-5252(949) 460–5688

136 REPORTING SAFETY DEFECTS

REPORTING SAFETY DEFECTS

(For Products Sold in the Continental United States of America Only)

If you believe that your vehicle has a defect which could cause a crash or couldcause injury or death, you should immediately inform the National Highway TrafficSafety 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 findsthat a safety defect exists in a group of vehicles, it may order a recall and remedycampaign. 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 otherinformation about motor vehicle safety from the Hotline.

ENVIRONMENTAL PROTECTION 137

ENVIRONMENTAL PROTECTION

To protect our environment, properly discard used batteries, tires, engine oil, orother vehicle components that you might dispose of in the future. Consult yourauthorized Kawasaki dealer or local environmental waste agency for their properdisposal procedures.

138 MAINTENANCE RECORD

MAINTENANCE RECORD

Owner Name.......................................................................................

Address ..............................................................................................

Phone Number ...................................................................................

Engine Number ..................................................................................

Vehicle Number..................................................................................

Selling Dealer Name..........................................................................

Phone Number ...................................................................................

Warranty Start Date ...........................................................................Note: Keep this information and a spare key in a secure location.

OdometerReadingDate Maintenance Performed Dealer Name Dealer Address

MAINTENANCE RECORD 139

OdometerDate

ReadingMaintenance Performed Dealer Name Dealer Address


OdometerDate


MAINTENANCE RECORD 141

OdometerDate



OdometerDate


LABEL INFORMATION 143

LABEL INFORMATION

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144 LABEL INFORMATION

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