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GENERAL INFORMATION
Quick Reference Guide
HOW TO RIDE THE MOTORCYCLE
This Quick Reference Guide will SAFE OPERATION
assist you in finding the information
you're looking for. MAINTENANCE AND ADJUSTMENT

STORAGE

TROUBLESHOOTING GUIDE

A Table of Contents is included after


the Foreword.

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Whenever you see the symbols
shown below, heed their instructions! CAUTION
Always follow safe operating and main- CAUTION indicates a hazardous
tenance practices. situation which, if not avoided,
could result in minor or moderate
DANGER injury.
DANGER indicates a hazardous
situation which, if not avoided,
will result in death or serious in- NOTICE
jury. NOTICE is used to address prac-
tices not related to personal in-
jury.
WARNING
WARNING indicates a hazardous
situation which, if not avoided, NOTE
could result in death or serious ○ This note symbol indicates points of
injury. particular interest for more efficient
and convenient operation.

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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 be
thoroughly familiar with the proper operation of your motorcycle's controls, its fea-
tures, capabilities, and limitations. This manual offers many safe riding tips, but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this ve-
hicle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-
formation on their Kawasaki Motorcycle, a Service Manual is available for pur-
chase from any authorized Kawasaki motorcycle dealer. The Service Manual
contains detailed disassembly and maintenance information. Those who plan to do
their own work should, of course, be competent mechanics and possess the spe-
cial tools described in the Service Manual.

Keep this Owner's Manual aboard your motorcycle at all times so that you can re-
fer to it whenever you need information.

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This manual should be considered a permanent part of the motorcycle and
should remain with the motorcycle when it is sold.

All rights reserved. No part of this publication may be reproduced without our pri-
or 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

© 2009 Kawasaki Heavy Industries, Ltd. March 2009. (1). (CR, K3)

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TABLE OF CONTENTS

SPECIFICATIONS ................................ 8 Fuel Tank Cap .................................... 30


SERIAL NUMBER LOCATIONS ......... 12 Fuel Tank ........................................... 31
LOCATION OF PARTS ........................ 13 Fuel Tap ............................................. 35
LOCATION OF LABELS ...................... 16 Stand .................................................. 37
LOADING INFORMATION ................... 19 Helmet Hook ...................................... 38
GENERAL INFORMATION .................. 22 Rear Carrier ....................................... 39
Meter Instruments .............................. 22 Tool Kit Container/Tool Kit ................. 40
Speedometer and Tachometer: ..... 23 Tying Hooks ....................................... 40
Coolant Temperature Gauge: ........ 23 BREAK-IN ............................................ 41
Warning/Indicator Lights: ............... 24 HOW TO RIDE THE MOTORCYCLE .. 43
Key ..................................................... 24 Starting the Engine ............................ 43
Ignition Switch/Steering Lock ............ 25 Jump Starting ..................................... 46
To lock the steering: ....................... 26 Moving Off .......................................... 50
Right Handlebar Switches ................. 27 Shifting Gears .................................... 51
Engine Stop Switch: ...................... 27 Braking ............................................... 53
Starter Button: ................................ 28 Stopping the Engine .......................... 54
Left Handlebar Switches .................... 28 Stopping the Motorcycle in an Emer-
Dimmer Switch: .............................. 28 gency .............................................. 55
Turn Signal Switch: ........................ 29 Parking ............................................... 56
Horn Button: ................................... 29 Catalytic Converter ............................ 57

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SAFE OPERATION .............................. 59 Front Fork ..........................................127
Safe Riding Technique ....................... 59 Rear Shock Absorbers ......................128
Daily Safety Checks .......................... 62 Wheels ...............................................131
Additional Considerations for OFF Tires - ............................................. 131
Road Operation .............................. 65 Battery ................................................134
MAINTENANCE AND ADJUSTMENT 67 Headlight Beam .................................140
Periodic Maintenance Chart .............. 72 Rear Turn Signal Light .......................142
Engine Oil .......................................... 85 Fuses .................................................142
Cooling System .................................. 91 General Lubrication ...........................144
Spark Plugs ....................................... 97 Cleaning Your Motorcycle ..................146
Evaporative Emission Control Sys- Bolt and Nut Tightening .....................150
tem (California model only) ............ 98 STORAGE ............................................ 152
Kawasaki Clean Air System .............. 99 TROUBLESHOOTING GUIDE ............ 155
Valve Clearance .................................100 Owner Satisfaction ............................. 156
Air Cleaner .........................................100 Reporting Safety Defects ................... 158
Throttle Control System .....................104 ENVIRONMENTAL PROTECTION ..... 159
Choke Lever ......................................108 LABEL INFORMATION ....................... 160
Idle Speed ..........................................109 MAINTENANCE RECORD .................. 171
Clutch .................................................110
Spark Arrester ....................................112
Drive Chain ........................................114
Brakes ................................................122
Brake Light Switches .........................125

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8 SPECIFICATIONS
SPECIFICATIONS

DIMENSIONS
Overall Length 2 295 mm (90.4 in.)
Overall Width 960 mm (37.8 in.)
Overall Height 1 350 mm (53.1 in.)
Wheelbase 1 480 mm (58.3 in.)
Road Clearance 210 mm (8.3 in.)
Curb Mass 196 kg (432 lb)
ENGINE
Type DOHC, 4-valve, 1-cylinder, 4-stroke, liquid-cooled
Displacement 651 cm³ (39.7 cu in.)
Bore × Stroke 100.0 × 83.0 mm (3.94 × 3.27 in.)
Compression Ratio 9.8 : 1

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SPECIFICATIONS 9

Starting System Electric starter


Carburetion System KEIHIN CVK 40 × 1
Ignition System Battery and coil (transistorized ignition)
Ignition Timing 10° BTDC @1 300 r/min (rpm) ~
(Electronically advanced) 30° BTDC @4 000 r/min (rpm)
Spark Plugs NGK DPR8EA-9, ND X24EPR-U9
Lubrication System Forced lubrication
API SG, SH, SJ, SL or SM with JASO MA, MA1 or
Engine Oil: Type
MA2
SAE 10W-40
Capacity 2.5 L (2.6 US qt)
Coolant Capacity 1.5 L (1.6 US qt)

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10 SPECIFICATIONS
TRANSMISSION
Transmission Type 5-speed, return shift
Clutch Type Wet, multi disc
Driving System Chain drive
Primary Reduction Ratio 2.273 (75/33)
Final Reduction Ratio 2.867 (43/15)
Overall Drive Ratio 5.158 (Top gear)
Gear Ratio: 1st 2.267 (34/15)
2nd 1.444 (26/18)
3rd 1.136 (25/22)
4th 0.955 (21/22)
5th 0.792 (19/24)

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SPECIFICATIONS 11

FRAME
Castor 28°
Trail 112 mm (4.4 in.)
Tire Size: Front 90/90-21 M/C 54S
Rear 130/80-17 M/C 65S
Rim Size: Front 21 × 1.60
Rear 17M/C × MT2.50
Fuel Tank Capacity 22 L (5.8 US gal)
ELECTRICAL EQUIPMENT
Battery 12 V 14 Ah
Headlight 12 V 55 W × 2/55 W (Hi/Lo)
Tail/Brake Light 12 V 5/21 W
Specifications subject to change without notice.

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12 SERIAL NUMBER LOCATIONS
SERIAL NUMBER LOCATIONS

The 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 same
model type. These serial numbers may be needed by your dealer when ordering
parts. In the event of theft, the investigating authorities will require both numbers
as well as the model type and any peculiar features of your machine that can help
them identify it.

Frame No. Engine No.

A. Frame Number A. Engine Number

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LOCATION OF PARTS 13

LOCATION OF PARTS

1. Clutch Lever 6. Front Brake Lever


2. Left Handlebar Switches 7. Throttle Grip
3. Meter Instruments 8. Ignition Switch/Steering Lock
4. Brake Fluid Reservoir (Front)
5. Right Handlebar Switches

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14 LOCATION OF PARTS

9. Turn Signal Light 15. Tool Kit/Storage Com- 20. Brake Caliper
10. Headlight partments 21. Shift Pedal
11. Spark Plugs 16. Helmet Hook 22. Side Stand
12. Main Fuse 17. Tying Hooks 23. Rear Shock Absorber
13. Battery 18. Front Fork 24. Drive Chain
14. Seat 19. Brake Disc

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LOCATION OF PARTS 15

25. Tail/Brake Light 29. Fuel Tank 34. Oil Level Gauge
26. Rear Carrier 30. Fuel Tank Cap 35. Idle Adjusting Screw
27. Brake Fluid Reservoir 31. Muffler 36. Coolant Reserve Tank
(Rear) 32. Rear Brake Light Switch
28. Air Cleaner 33. Rear Brake Pedal

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16 LOCATION OF LABELS
LOCATION OF LABELS

1. Brake Fluid (Front)


2. Brake Fluid (Rear)
3. Tire and Load Data
4. Important Drive Chain Information

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LOCATION OF LABELS 17
5. Daily Safety Checks
6. Vehicle Emission Control Informa-
tion
7. Noise Emission Control Information
*8. Vacuum Hose Routing Diagram
9. Battery Vent Hose
10. Weight and Manufacture

*: only on California model

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18 LOCATION OF LABELS

11. Carrier Caution


12. Battery Poison/Danger
*13. Fuel Level

*: only on California model

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LOADING INFORMATION 19

LOADING INFORMATION

loading the motorcycle, you are per-


WARNING sonally responsible for your own safety
Incorrect loading, improper in- and the safety of other persons in-
stallation or use of accessories, volved.
or modification of your motor- NOTE
cycle may result in an unsafe rid-
ing condition. Before you ride the
○ Kawasaki Parts and Accessories
have been specially designed for
motorcycle, make sure that the
use on Kawasaki motorcycles. We
motorcycle is not overloaded and
strongly recommend that all parts
that you have followed these in-
and accessories you add to your mo-
structions.
torcycle be genuine Kawasaki com-
ponents.
With the exception of genuine Kawa-
saki Parts and Accessories, Kawasaki Because a motorcycle is sensitive to
has no control over the design or appli- changes in weight and aerodynamic
cation of accessories. In some cases, forces, you must take extreme care in
improper installation or use of acces- carrying cargo, passengers and/or in
sories, or motorcycle modification, will the fitting of additional accessories.
void the motorcycle warranty. In select- The following general guidelines have
ing and using accessories, and in

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20 LOADING INFORMATION
been prepared to assist you in making Baggage weight should also be dis-
your determinations. tributed equally on both sides of the
1. Any passenger should be thor- motorcycle. Avoid carrying baggage
oughly familiar with motorcycle op- that extends beyond the rear of the
eration. The passenger can affect motorcycle.
control of the motorcycle by improp- 4. Baggage should be securely at-
er positioning during cornering and tached. Make sure that the bag-
sudden movements. It is important gage will not move around while
that the passenger sit still while the you are riding. Recheck baggage
motorcycle is in motion and not in- security as often as possible (not
terfere with the operation of the mo- while the motorcycle is in motion)
torcycle. Do not carry animals on and adjust as necessary.
your motorcycle. 5. Do not carry heavy or bulky items
2. You should instruct any passenger on a luggage rack. They are de-
before riding to keep his feet on the signed for light items, and overload-
passenger footpegs and hold on to ing can affect handling due to
the operator or grab rail. Do not changes in weight distribution and
carry a passenger unless he or she aerodynamic forces.
is tall enough to reach the footpegs 6. Do not install accessories or carry
and footpegs are provided. baggage that impairs the perform-
3. All baggage should be carried as ance of the motorcycle. Make sure
low as possible to reduce the effect that you have not adversely af-
on the motorcycle center of gravity. fected any lighting components,

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LOADING INFORMATION 21

road clearance, banking capability vehicle. Kawasaki does not manu-


(i.e., lean angle), control operation, facture sidecars or trailers for mo-
wheel travel, front fork movement, torcycles and cannot predict the
or any other aspect of the motorcy- effects of such accessories on han-
cle's operation. dling or stability, but can only warn
7. Weight attached to the handlebar that the effects can be adverse and
or front fork will increase the mass that Kawasaki cannot assume re-
of the steering assembly and can sponsibility for the results of such
result in an unsafe riding condition. unintended use of the motorcycle.
8. Fairings, windshields, backrests, Furthermore, any adverse effects
and other large items have the ca- on motorcycle components caused
pability of adversely affecting stabil- by the use of such accessories will
ity and handling of the motorcycle, not be remedied under warranty.
not only because of their weight, Maximum Load
but also due to the aerodynamic
Weight of rider, passenger, baggage, and
forces acting on these surfaces
accessories must not exceed 182 kg (401
while the motorcycle is in operation. lb).
Poorly designed or installed items
can result in an unsafe riding condi-
tion.
9. This motorcycle was not intended
to be equipped with a sidecar or to
be used to tow any trailer or other

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22 GENERAL INFORMATION
GENERAL INFORMATION

Meter Instruments
A. Tachometer
B. Red Zone
C. Speedometer
D. Odometer
E. Coolant Temperature
Gauge
F. Neutral Indicator Light
G. Trip RESET Button
H. Trip Meter
I. High Beam Indicator Light
J. Turn Signal Indicator Light

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GENERAL INFORMATION 23

Speedometer and Tachometer:


The speedometer shows the speed NOTICE
of the vehicle. In the speedometer face Engine r/min (rpm) should not be
are the odometer and trip meter. The allowed to enter the red zone; op-
odometer shows the total distance that eration in the red zone will over-
the vehicle has been ridden. The trip stress the engine and may cause
meter shows the distance traveled serious engine damage.
since it was last reset to zero. The trip
meter can be reset to zero by pushing
the trip reset button. Coolant Temperature Gauge:
The tachometer shows the engine This gauge shows the temperature
speed in the revolutions per minute of coolant. Ordinarily, the needle
(r/min, rpm). On the right side of the should stay within the white zone. If
tachometer face is a portion called the the needle reaches the “H” line, stop
“red zone”. Engine r/min (rpm) in the the engine and check the coolant level
red zone is above maximum recom- in the reserve tank after the engine
mended engine speed and is also cools down.
above the range for good perform-
ance.

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24 GENERAL INFORMATION

NOTICE Key
This motorcycle has a combination
Do not let the engine continue key, which is used for the ignition
running when the gauge needle switch/steering lock, seat lock, helmet
reaches the “H” line. Prolonged hook and fuel tank cap.
engine operation will result in se- Blank keys are available at your Ka-
vere damage from overheating. wasaki dealers. Ask your dealer to
make any additional spare keys you
may need, using your original key as a
Warning/Indicator Lights: master, or using the key code on the
: When the headlight is on high tag with your keys.
beam, the high beam indicator light is Record the code from the tag with
lit. your keys here. Participating Kawasaki
dealers can use the code to make a
N: When the transmission is in neutral, new key in the event that your original
the neutral indicator light is lit. keys are lost.
: When the turn signal switch is
turned to left or right, the turn signal in-
dicator light flashes on and off.
Write your key number here.

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GENERAL INFORMATION 25

Ignition Switch/Steering Lock


This is a three-position, key-operated
switch. The key can be removed from
the switch when it is in the OFF or
LOCK position.

A. Ignition Switch/Steering Lock


B. ON position
C. OFF position
D. LOCK position

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26 GENERAL INFORMATION

Engine off. All electrical circuits 4. Pull the key out.


OFF
off.
Engine on. All electrical equip-
ON
ment can be used.
Steering locked. Engine off. All
LOCK
electrical circuits off.

NOTE
○ The head, and tail lights are on
whenever the ignition key is in the
ON position. One headlight goes on
when the ignition key is in the ON
position. To avoid battery discharge,
always start the engine immediately
after turning the ignition key to “ON”.

To lock the steering:


1. Turn the handlebar fully to the left.
2. With the ignition key in the OFF po-
sition, push down and release the
key.
3. Turn the key to LOCK position.

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GENERAL INFORMATION 27

Right Handlebar Switches NOTE


Engine Stop Switch:
In addition to the ignition switch, the
○ Although the engine stop switch
stops the engine, it does not turn off
engine stop switch must be in all the electrical circuits. Ordinarily,
the position for the motorcycle to the ignition switch should be used to
operate. stop the engine.
The engine stop switch is for emer-
gency use. If some emergency re-
quires stopping the engine, move the
engine stop switch to the position.

A. Engine Stop Switch


B. Starter Button

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28 GENERAL INFORMATION
Starter Button: Left Handlebar Switches
The starter button operates the elec- Dimmer Switch:
tric starter when the transmission is in High or low beam can be selected
neutral. with the dimmer switch. When the
Refer to the Starting the Engine sec- headlight is on high beam ( ), the
tion of the "How to Ride the Motor- high beam indicator light is lit.
cycle" chapter for starting instructions. High beam.......( )
Low beam.......( )

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GENERAL INFORMATION 29

NOTE corresponding turn signal flashes on


○ When the headlight is on high beam, and off.
To stop flashing, push the switch in.
both head lights are lit. When the
headlight is on low beam, only one Horn Button:
headlight is lit. When the horn button is pushed, the
horn sounds.

A. Dimmer Switch
B. Turn Signal Switch
C. Horn Button

Turn Signal Switch:


When the turn signal switch is turned
to the left ( ) or right ( ), the

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30 GENERAL INFORMATION
Fuel Tank Cap NOTE
To open the fuel tank cap, insert the
ignition key into the fuel tank cap and
○ Do not push on the key to close the
cap, or the cap cannot be locked.
turn the key to the right.
To close the cap, push it down into
place with the key inserted. The key
can be removed by turning it to the left
to the original position.
NOTE
○ The fuel tank cap cannot be closed
without the key inserted, and the key
cannot be removed unless the cap is
locked properly.

A. Ignition Key
B. Fuel Tank Cap

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GENERAL INFORMATION 31

Fuel Tank
Avoid filling the tank in the rain or WARNING
where heavy dust is blowing so that Gasoline is extremely flammable
the fuel does not get contaminated. and can be explosive under cer-
tain conditions. Turn the ignition
key to “OFF”. Do not smoke.
Make sure the area is well venti-
lated and free from any source of
flame or sparks; this includes
any appliance with a pilot light.
Never fill the tank so the fuel level
rises into the filler neck. If the
tank is overfilled, heat may cause
the fuel to expand and overflow
through the vents in the tank cap.
A. Tank Cap After refueling, make sure the
B. Fuel Tank fuel tank cap is closed securely.
C. Top Level If gasoline is spilled on the fuel
D. Filler Neck
tank, wipe it off immediately.

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32 GENERAL INFORMATION
the Motor Octane Number (MON) as
NOTICE shown in the table.
California models only: Never fill
the tank so the fuel level rises in- Minimum
Octane Rating Method
to the filler neck. If the tank is Rating
overfilled, heat may cause the Antiknock (RON + MON)
fuel to expand and flow into the 87
Index 2
Evaporative Emission Control
System resulting in hard starting
and engine hesitation.

Fuel Requirement:
Fuel Type
Use clean, fresh unleaded gasoline
with a minimum Antiknock Index of 87.
The Antiknock Index is posted on serv-
ice station pumps. The octane rating of
a gasoline is a measure of its resist-
ance to detonation or “knocking”. The
Antiknock Index is an average of the
Research Octane Number (RON) and

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GENERAL INFORMATION 33

which are required to sell such refor-


NOTICE mulated fuels as part of a strategy to
If engine “knocking” or “pinging” reduce exhaust emissions.
occurs, use a different brand of The types and volume of fuel oxy-
gasoline of a higher octane rat- genates approved for use in unleaded
ing. If this condition is allowed to gasoline by the U.S. Environmental
continue it can lead to severe en- Protection Agency include a broad
gine damage. range of alcohols and ethers, but only
Gasoline quality is important. two components have seen any signifi-
Fuels of low quality or not meet- cant level of commercial use.
ing standard industry specifica- Gasoline/Alcohol Blends - Gasoline
tions may result in unsatisfactory containing up to 10% ethanol (alcohol
performance. Operating prob- produced from agricultural products
lems that result from the use of such as corn), also known as “gasohol”
poor quality or nonrecommended is approved for use.
fuel may not be covered under
your warranty.

Fuels Containing Oxygenates


Gasoline frequently contains oxy-
genates (alcohols and ethers) espe-
cially in areas of the U.S. and Canada

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34 GENERAL INFORMATION

NOTICE NOTICE
Avoid using blends of unleaded Never use gasoline with an oc-
gasoline and methanol (wood al- tane rating lower than the mini-
cohol) whenever possible, and mum specified by Kawasaki.
never use “gasohol” containing Never use “gasohol” with more
more than 5% methanol. Fuel than 10% ethanol, or more than
system damage and performance 5% methanol. Gasoline contain-
problems may result. ing methanol must also be
blended with solvents and corro-
Gasoline/Ether Blends - The most sion inhibitors.
common ether is methyl tertiary butyl Certain ingredients of gasoline
ether (MTBE). You may use gasoline may cause paint fading or dam-
containing up to 15% MTBE. age. Be extra careful not to spill
gasoline or gasoline oxygenate
NOTE blends during refueling.
○ Other oxygenates approved for use When not operating your Kawa-
saki for 30 to 60 days, mix a fuel
in unleaded gasoline include TAME
(up to 16. %) and ETBE (up to stabilizer (such as STA-BIL) with
17.2%). Fuel containing these oxy- the gasoline in the fuel tank. Fuel
genates can also be used in your stabilizer additives inhibit oxida-
Kawasaki. tion of the fuel which minimizes
gummy deposits.

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GENERAL INFORMATION 35

NOTICE Fuel Tap


The fuel tap has three positions: ON,
Never store this product with “ga- RES (reserve), and OFF. For normal
sohol” in the fuel system. Before operation, turn the tap lever to the ON
storage it is recommended that position. If the fuel runs out with the tap
you drain all fuel from the fuel in the ON position, the last 1.9 L (0.5
system. See the Storage section US gal) of fuel can be used by turning
in this manual. the tap lever to RES.

A. Tap Lever
B. ON position
C. OFF position
D. RES position

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36 GENERAL INFORMATION
Turn the fuel tap lever to the OFF po-
sition when the fuel tank is removed for WARNING
maintenance and adjustments or the Practice operating the fuel tap
motorcycle is stored for long time. with the motorcycle stopped. To
NOTE prevent an accident you should
be able to operate the fuel tap
○ Since riding distance is limited when while riding without taking your
on RES, refuel at the earliest oppor- eyes off the road.
tunity. Be careful not to touch the hot
○ Make certain that the fuel tap lever is engine while operating the fuel
turned to ON (Not RES) after filling tap.
up the fuel tank.

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GENERAL INFORMATION 37

Stand NOTE
The motorcycle is equipped with a
side stand.
○ The motorcycle is equipped with a
side stand switch. This switch is de-
signed so that the engine does not
start if the transmission is in gear
and the side stand is down.

A. Side Stand

NOTE
○ When using the side stand, turn the
handlebar to the left.
Whenever the side stand is used,
make it a practice to kick the stand fully
up before sitting on the motorcycle.

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38 GENERAL INFORMATION
Helmet Hook
Helmet can be secured to the motor-
cycle using the helmet hook.
The helmet hook can be unlocked by
inserting the ignition switch key into the
lock, and turning the key to the right.

WARNING
Riding with helmet attached to
the hook could cause an accident
by distracting the operator or in- A. Helmet Hook
terfering with normal vehicle op- B. Ignition Switch Key
eration. Do not ride the
motorcycle with helmet attached
to the hook.

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GENERAL INFORMATION 39

Rear Carrier
The motorcycle is equipped with a WARNING
carrier on the rear. Overloading the motorcycle and
failure to adjust speed for addi-
Vehicle Total Payload tional cargo could result in loss
182 kg (401 lb)
(must not exceed).
of control and an accident result-
ing in injury or death. Never ex-
Rear Carrier Maximum
10 kg (22 lb) ceed the rear carrier load limit of
Load Capacity
10 kg (22 lb); it is designed for
light items and overloading can
affect handling due to changes in
weight distribution and aerody-
namic forces. Speed must also
be adjusted to suit various load,
road and weather conditions.

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40 GENERAL INFORMATION
Tool Kit Container/Tool Kit Tying Hooks
The tool kit container is located on When tying up light loads to the rear
the rear carrier, use the container to carrier, use the tying hooks located
keep the tool kit that should be kept under the rear carrier.
with the motorcycle. The kit contains
tools that can be helpful in making
roadside repairs, adjustments, and
some maintenance procedures ex-
plained in this manual.

A. Rear Carrier
B. Tool Kit Container
C. Tool Kit
D. Tying Hook

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BREAK-IN 41

BREAK-IN

The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the
break-in period. If the motorcycle is not used carefully during this period, you may
very well end up with a “broken down” instead of a “broken in” motorcycle after a
few thousand kilometers.
The following rules should be observed during the break-in period.
• The table shows maximum recommended engine speed during the break-in peri-
od.
Distance traveled Maximum engine speed
0 ~ 800 km (0 ~ 500 mi) 4 000 r/min (rpm)
800 ~ 1 600 km (500 ~ 1 000 mi) 6 000 r/min (rpm)

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

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42 BREAK-IN

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 normal
tire traction. During break-in, avoid sudden and maximum braking and ac-
celeration, and hard cornering.

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

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HOW TO RIDE THE MOTORCYCLE 43

HOW TO RIDE THE MOTORCYCLE

Starting the Engine


• Turn the fuel tap lever to the ON po-
sition.
• Check
in the
that the engine stop switch is
position.
• Turn the ignition key to “ON”.
• Make
neutral.
sure the transmission is in

A. Engine Stop Switch


B. Starter Button
C. Neutral Indicator Light
D. Ignition Switch
E. ON position

• Iflever
the engine is cold, pull the choke
all the way.

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44 HOW TO RIDE THE MOTORCYCLE
NOTE NOTICE
○ When the engine is already warm or Do not operate the starter contin-
on hot days (35°C, 95°F or more),
open the throttle part way instead of uously for more than 5 seconds
using the choke, and then start the or the starter will overheat and
engine. the battery power will drop tem-
porarily. Wait 15 seconds be-
tween each operation of the
starter to let it cool and the bat-
tery power recover.

A. Choke Lever

• Leaving the throttle completely


closed, push the starter button with
the clutch lever pulled in until the en-
gine starts.

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HOW TO RIDE THE MOTORCYCLE 45

NOTE
○ If the engine is flooded, crank the en-
gine over with the throttle fully open
until the engine starts.
○ The motorcycle is equipped with a
starter lockout switch. This switch
prevents the electric starter from op-
erating when the clutch is engaged
and the transmission is not in neu-
tral.
A. Clutch Lever
B. Starter Lockout Switch

• Gradually return the choke lever to-


ward the off position a little at a time
as necessary to keep the engine
speed below 2 000 r/min (rpm) dur-
ing warm-up.
• When the engine is warmed up
enough to idle without using the
choke, return the choke lever all the
way back.

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46 HOW TO RIDE THE MOTORCYCLE
NOTE Jump Starting
○ If you drive the motorcycle before If your motorcycle battery is “run
down”, it should be removed and
the engine is warmed up, return the
choke to the off position as soon as charged. If this is not practical, a 12
your start moving. volt booster battery and jumper cables
may be used to start the engine.
NOTICE DANGER
Do not let the engine idle longer Battery acid generates hydrogen
than five minutes, or engine over- gas which is flammable and ex-
heating and damage may occur. plosive under certain conditions.
It is present within a battery at all
Ambient tempera- choke off after run- times, even in a discharged con-
ture ning for dition. Keep all flames and sparks
20°C (68°F) ~ 35°C (cigarettes) away from the bat-
15 seconds tery. Wear eye protection when
(95°F)
working with a battery. In the
Below 20°C (68°F) 1.5 minutes event of battery acid contact with
Below 5°C (40°F) 2 minutes skin, eyes, or clothing, wash the
affected areas immediately with
water for at least five minutes.
Seek medical attention.

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HOW TO RIDE THE MOTORCYCLE 47

Connecting Jumper Cables • remove


Unscrew the bolt on both side and
•Remove the left and right side cover
by unscrew the bolts.
the seat.

A. Seat
A. Bolts B. Bolt
B. Left Side Cover
• Make sure the ignition key is turned
to OFF.

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48 HOW TO RIDE THE MOTORCYCLE

• Connect a jumper cable from the


positive (+) terminal of the booster
footpeg or other unpainted metal sur-
face. Do not use the negative (–) ter-
battery to the positive (+) terminal of minal of the battery.
the motorcycle battery.
WARNING
Batteries contain sulfuric acid
that can cause burns and pro-
duce hydrogen gas which is
highly explosive. Do not make
this last connection at the carbu-
retor or battery. Take care not to
touch the positive and negative
cables together, and do not lean
over the battery when making
this last connection. Do not con-
A. Motorcycle Battery Positive (+) Terminal
B. From Booster Battery Positive (+) Terminal
nect to a frozen battery. It could
C. Footpeg explode. Do not reverse polarity
D. From Booster Battery Negative (–) Termi- by connecting positive (+) to neg-
nal ative (–), or a battery explosion
• Connect another jumper cable from
the negative (–) terminal of the boos-
and serious damage to the elec-
trical system may occur.
ter battery to your motorcycle

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HOW TO RIDE THE MOTORCYCLE 49

• Follow the standard engine starting NOTE


procedure. ○ To fix the seat, place the slot into the
tab.
NOTICE
Do not operate the starter contin-
uously for more than 5 seconds
or the starter will overheat and
the battery power will drop tem-
porarily. Wait 15 seconds be-
tween each operation of the
starter to let it cool and the bat-
tery power recover.

• After the engine has started, discon-


nect the jumper cables. Disconnect A. Seat
the negative (–) cable from the mo- B. Slot
torcycle first. C. Tab

• Reinstall the parts removed.

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50 HOW TO RIDE THE MOTORCYCLE
Moving Off NOTE
• Check that the side stand is up. ○ The motorcycle is equipped with a
• Pull in the clutch lever. side stand switch. This switch is de-
• Shift into 1st gear. signed so that the engine does not
• Open the throttle a little, and start to
let out the clutch lever very slowly.
start if the transmission is in gear
and the side stand is down.
• As the clutch starts to engage, open
the throttle a little more, giving the
○ When the headlight is on high beam,
two headlight beams are lit, and on
engine just enough fuel to keep it low beam, one headlight is lit.
from stalling.

A. Shift Pedal

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HOW TO RIDE THE MOTORCYCLE 51

Shifting Gears
• Close the throttle while pulling in the
clutch lever.
• Shift
gear.
into the next higher or lower

• For smooth riding, each gear posi-


tion should cover the proper rate of
speed shown in the table.
• Open the throttle part way, while re-
leasing the clutch lever.

WARNING
Downshifting to a lower gear at
high speed causes engine r/min
(rpm) to increase excessively, po-
tentially damaging the engine
and it may also cause the rear
wheel to skid and cause an acci-
dent. Downshifting should be
done below 5,000 r/min (rpm) for
each gear.

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52 HOW TO RIDE THE MOTORCYCLE
Vehicle speed when shifting
Shifting up km/h (mph) Shifting down km/h (mph)
1st → 2nd 15 ( 9) 5th → 4th 25 (15)
2nd → 3rd 25 (15) 4th → 3rd 20 (12)
3rd → 4th 35 (21) 3rd → 2nd 15 (9)
4th → 5th 45 (27) 2nd → 1st 15 (9)

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HOW TO RIDE THE MOTORCYCLE 53

Braking applying the brakes as hard as pos-


• Close the throttle completely, leaving
the clutch engaged (except when
sible without skidding.

shifting gears) so that the engine will


help slow down the motorcycle.
• Shift down one gear at a time so that
you are in 1st gear when you come
to a complete stop.
• When stopping, always apply both
brakes at the same time. Normally
the front brake should be applied a
little more than the rear. Shift down
or fully disengage the clutch as nec-
essary to keep the engine from stall- A. Front Brake Lever
ing.
• Never lock the brakes, or it will cause
the tires to skid. When turning a cor-
ner, it is better not be brake at all.
Reduce your speed before you get
into the corner.
• For emergency braking, disregard
downshifting, and concentrate on

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54 HOW TO RIDE THE MOTORCYCLE
Stopping the Engine
• Close the throttle completely.
• Shift the transmission into neutral.
• Turn the ignition key to “OFF”.
• Support the motorcycle on a firm,
level surface with the side stand.
• Lock the steering.

A. Rear Brake Pedal

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HOW TO RIDE THE MOTORCYCLE 55

Stopping the Motorcycle in an In an emergency situation such as


Emergency throttle failure, your vehicle may be
Your Kawasaki Motorcycle has been stopped by applying the brakes and
designed and manufactured to provide disengaging the clutch. Once this stop-
you optimum safety and convenience. ping procedure is initiated, the engine
However, in order to fully benefit from stop switch may be used to stop the
Kawasaki's safety engineering and engine. If the engine stop switch is
craftsmanship, it is essential that you, used, turn off the ignition switch after
the owner and operator, properly main- stopping the motorcycle.
tain your motorcycle and become thor-
oughly familiar with its operation.
Improper maintenance can create a
dangerous situation known as throttle
failure. Two of the most common
causes of throttle failure are:
1. An improperly serviced or clogged
air cleaner may allow dirt and dust
to enter the throttle body and stick
the throttle open.
2. During removal of the air cleaner,
dirt is allowed to enter and jam the
fuel injection system.

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56 HOW TO RIDE THE MOTORCYCLE
Parking
• Shift the transmission into neutral
and turn the ignition key to “OFF”.
WARNING
The muffler and exhaust pipe are
• Support the motorcycle on a firm,
level surface with the side stand.
very hot while the engine is run-
ning and just after the engine
stop. This can ignite a fire, result-
NOTICE ing in property damage or severe
personal injury.
Do not park on a soft or steeply Do not idle or park your vehicle in
inclined surface, or the motor- an area where flammable materi-
cycle may fall over. als such as grasses or dry leaves
may contact with muffler or ex-
• Ifstructure,
parking inside a garage or other
be sure it is well ventilated
haust pipe.
and the motorcycle is not close to
any source of flame or sparks; this
includes any appliance with a pilot
light.

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HOW TO RIDE THE MOTORCYCLE 57

Catalytic Converter
WARNING This motorcycle is equipped with a
Gasoline is extremely flammable catalytic converter in the exhaust sys-
and can be explosive under cer- tem. Platinum and rhodium in the con-
tain conditions, creating the po- verter react with carbon monoxide and
tential for serious burns. Turn the hydrocarbons to convert them into car-
ignition switch “OFF”. Do not bon dioxide and water resulting in
smoke. Make sure the area is well much cleaner exhaust gases to be dis-
ventilated and free from any charged into the atmosphere.
source of flame or sparks; this in- For proper operation of the catalytic
cludes any appliance with a pilot converter, the following cautions must
light. be observed.

• Lock
theft.
the steering to help prevent

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58 HOW TO RIDE THE MOTORCYCLE
the vehicle with the engine or any
WARNING one cylinder misfiring. Under these
The muffler and exhaust pipe are conditions unburned air/fuel mixture
very hot while the engine is run- flowing out of engine excessively ac-
ning and just after the engine celerates reaction in the converter al-
stop. This can ignite a fire, result- lowing the converter to overheat and
ing in property damage or severe become damaged when the engine
personal injury. is hot, or reduces converter perform-
Do not idle or park your vehicle in ance when the engine is cold.
an area where flammable materi-
als such as grasses or dry leaves NOTICE
may contact with muffler or ex-
In order to protect the emission
haust pipe.
control parts, do not turn off the
ignition switch when the motor-
• Use only unleaded gasoline. Never
use leaded gasoline. Leaded gaso-
cycle is in motion.
line significantly reduces the capabil-
ity of the catalytic converter.
• Do not coast the vehicle with the
ignition switch and/or engine stop
switch off. Do not attempt to start the
engine by rolling the vehicle if the
battery is discharged. Do not operate

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SAFE OPERATION 59

SAFE OPERATION

Safe Riding Technique


The 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 a When riding always keep both
helmet are strongly recommended. hands on the handlebars and both
Gloves and suitable footwear feet on the footpegs. Removing your
should also be used for added pro- hands from the handlebars or feet
tection in case of a mishap. from the footpegs while riding can
be hazardous. If you remove even
A motorcycle does not provide the one hand or foot, you can reduce
impact protection of an automobile, your ability to control the motor-
so defensive riding in addition to cycle.
wearing protective apparel is ex-
tremely important. Do not let protec- Before changing lanes, look over
tive apparel give you a false sense your shoulder to make sure the way
of security. is clear. Do not rely solely on the
rear view mirror; you may misjudge
a vehicle's distance and speed, or
you may not see it at all.

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60 SAFE OPERATION
In general your actions should be In wet conditions, rely more on the
smooth as sudden acceleration, throttle to control vehicle speed and
braking or turning may cause loss less on the front and rear brakes.
of control, especially when riding in The throttle should also be used ju-
wet conditions or on loose roadway diciously to avoid skidding the rear
surfaces, when the ability to maneu- wheel from too rapid acceleration or
ver will be reduced. deceleration.

When going up steep slopes, shift Riding at the proper rate of speed
to a lower gear so that there is and avoiding unnecessarily fast ac-
plenty of power to spare rather than celeration are important not only for
overloading the engine. safety and low fuel consumption but
also for long vehicle life and quieter
When applying the brakes, use operation.
both the front and rear brakes. Ap-
plying only one brake for sudden On rough roads, exercise caution,
braking may cause the motorcycle slow down, and grip the fuel tank
to skid and lose control. with the knees for better stability.

When going down long slopes, When quick acceleration is neces-


control vehicle speed by closing the sary as in passing, shift to a lower
throttle. Use the front and rear gear to obtain the necessary power.
brakes for auxiliary braking.

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SAFE OPERATION 61

Do not downshift at too high an


r/min (rpm) to avoid damage to the
engine from overrevving.

Avoiding unnecessary weaving is


important to the safety of both the
rider and other motorists.

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62 SAFE OPERATION
Daily Safety Checks
Check the following items each day before you ride. The time required is minimal,
and habitual performance of these checks will help ensure you a safe, reliable ride.
If any irregularities are found during these checks, refer to the Maintenance and
Adjustment chapter or see your dealer for the action required to return the motor-
cycle to a safe operating condition.

WARNING
Failure to perform these checks before operation may result in serious
damage or an accident. Always perform daily safety checks before opera-
tion.

DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous
gas.
Inhaling carbon monoxide can cause serious brain injury or death.
Do not run the engine in enclosed areas. Operate only in a well-ventilated
area.

Fuel ............................. Adequate supply in tank, no leaks.


Engine oil .................... Oil level between level lines.

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SAFE OPERATION 63

Tires ............................ Air pressure (when cold):


Front 150 kPa (1.5 kg/cm², 21 psi)
Up to 97.5 kg (215 lbs) 150 kPa (1.5 kg/cm², 21
Load psi)
Rear
97.5 ~ 182 kg (215 ~ 200 kPa (2.0 kg/cm², 28
401 lbs) Load psi)

Install the air valve cap.


Drive chain .................. Slack 35 ~ 45 mm (1.4 ~ 1.8 in.)
Lubricate the dive chain 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 binding of control cables.
Brakes ......................... Brake pad wear: Lining thickness more than 1 mm (0.04
in.) left.
No brake fluid leakage.
Throttle ........................ Throttle grip play 2 ~ 3 mm (0.08 ~ 0.12 in.).
Clutch .......................... Clutch lever play 8 ~ 12 mm (0.31 ~ 0.47 in.).
Clutch lever operates smoothly.
Coolant ....................... No coolant leakage.
Coolant level between level lines (when engine is cold).

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64 SAFE OPERATION
Electrical equipment ... All lights (Headlight, Tail/Brake Lights, Turn Signal Lights,
Warning/Indicator Lights) and horn work.
Engine stop switch ...... Stops engine.
Side stand ................... Returns to its fully up position by spring tension.
Returns spring not weak or not damaged.

Refer to the “Daily Safety Checks” caution label attached to the Left Side Cover.

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SAFE OPERATION 65

Additional Considerations for OFF Road Operation


Brakes: The importance of the brakes, especially during high speed operation,
cannot be overemphasized. Check to see that they are correctly adjusted and func-
tioning properly.
Steering: Looseness in the steering can cause loss of control. Check to see that
the handlebar turns freely but has no play.
Tires: High speed operation is hard on tires, and good tires are crucial for riding
safety. Examine their overall condition, inflate them to the proper pressure, and
check the wheel balance.
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 the
chain slack and alignment, and lubricate if necessary.
Fuel: Have sufficient fuel for the high fuel consumption during high speed opera-
tion.
Engine Oil: To avoid engine seizure and resulting loss of control, make sure that
the oil level is at the upper level line.
Coolant: To avoid overheating, check that the coolant level is at the upper level
line.
Miscellaneous: Make sure that all nuts and bolts are tight and that all safety re-
lated parts are in good condition.

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66 SAFE OPERATION

WARNING
Handling characteristics of a motorcycle at high speeds may vary from
those you are familiar with at legal highway speeds. Do not attempt high
speed operation unless you have received sufficient training and have the
required skills.

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MAINTENANCE AND ADJUSTMENT 67

MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out
and must be done in accordance with the Periodic Maintenance Chart to keep the
motorcycle in good running condition. The initial maintenance is vitally impor-
tant and must not be neglected.
With a basic knowledge of mechanics and the proper use of tools, you should be
able to carry out many of the maintenance items described in this chapter. If you
lack proper experience or doubt your ability, all adjustments, maintenance, and re-
pair 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 done by the owner.

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68 MAINTENANCE AND ADJUSTMENT
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated
crankcase emission (1) and exhaust emission (2) control systems in compliance
with applicable regulations of the United States Environmental Protection Agency
and California Air Resources Board. Additionally, Kawasaki has incorporated an
evaporative emission control system (3) in compliance with applicable regulations
of the United States Environmental Protection Agency and California Air Resour-
ces Board.

1. Crankcase Emission Control System


This system eliminates the release of crankcase vapors into the atmosphere. In-
stead, the vapors are routed through an oil separator to the intake side of the en-
gine. While the engine is operating, the vapors are drawn into the combustion
chamber, where they are burned along with the fuel and air supplied by the fuel in-
jection system.

2. Exhaust Emission Control System


This system reduces the amount of pollutants discharged into the atmosphere by
the exhaust of this motorcycle. The fuel, ignition and exhaust systems of this mo-
torcycle have been carefully designed and constructed to ensure an efficient en-
gine with low exhaust pollutant levels. The exhaust system of this model
motorcycle includes a catalytic converter system.

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MAINTENANCE AND ADJUSTMENT 69

3. Evaporative Emission Control System


The evaporative emission control system for this vehicle consists of low permea-
tion fuel hoses and a fuel tank.

3. Evaporative Emission Control System (California)


Vapors caused by fuel evaporation in the fuel system are not vented into the at-
mosphere. Instead, fuel vapors are routed into the running engine to be burned, or
stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor
separator and returned to the fuel tank.

High Altitude Performance Adjustment Information


To improve the EMISSION CONTROL PERFORMANCE of the vehicles oper-
ated above 4 000 feet, Kawasaki recommends the following Environmental Protec-
tion Agency (EPA) approved modification.
NOTE
○ When properly performed, these specified modifications only are not considered
to 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 Kawasaki

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70 MAINTENANCE AND ADJUSTMENT
dealer, 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 to
have low emission levels. This Owner's Manual contains those maintenance rec-
ommendations for your motorcycle. Those items identified by the Periodic Mainte-
nance Chart are necessary to ensure compliance with the applicable standards.
As the owner of this motorcycle, you have the responsibility to make sure that
the recommended maintenance is carried out according to the instructions in this
Owner's Manual at your own expense.
The Kawasaki 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's
obligations it contains.
You should keep a maintenance record for your motorcycle. To assist you in
keeping this record, we have provided space on pages 171 through 177 of this
manual where an authorized Kawasaki dealer, or someone equally competent, can
record the maintenance. You should also retain copies of maintenance work or-
ders, bills, etc., as verification of this maintenance.

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MAINTENANCE AND ADJUSTMENT 71

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:


Federal law prohibits the following acts or the causing thereof: (1) the removal or
rendering inoperative by any person other than for purposes of maintenance, re-
pair, or replacement, of any device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the vehicle after such device or ele-
ment 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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72 MAINTENANCE AND ADJUSTMENT

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.
(e): Emission Related Item
1. Periodic Inspection (Engine Related Items)
Frequency Whichev- *Odometer Reading
er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation (En- 1 6 12 18 24 30 36
Every
gine Item) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Air cleaner ele-
ment - clean (e) • • • 100

Valve clearance -
inspect (e) • 100

Throttle control
system (play,
smooth return, no
year • • • • 104
drag) - inspect (e)

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MAINTENANCE AND ADJUSTMENT 73

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation (En- 1 6 12 18 24 30 36
Every
gine Item) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Choke operation -
inspect (e)
year • • • • 108

Idle speed - in-


spect (e) • • • • 109

Fuel leak (fuel


hose and pipe) -
inspect
year • • • • –

Fuel hoses dam-


age - inspect
year • • • • –

Fuel hoses instal-


lation condition -
inspect
year • • • • –

Coolant level - in-


spect • • • • 94

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74 MAINTENANCE AND ADJUSTMENT

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation (En- 1 6 12 18 24 30 36
Every
gine Item) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Coolant leak - in-
spect
year • • • • 91

Radiator hose
damage - inspect
year • • • • 91

Radiator hoses in-


stallation condition
- inspect
year • • • • 91

Evaporative emis-
sion control sys-
tem - function
(California model
• • • • • • • 98

only) (e)
Air suction system
damage - inspect
(e)
• • • 99

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MAINTENANCE AND ADJUSTMENT 75

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation (En- 1 6 12 18 24 30 36
Every
gine Item) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Balancer chain
tension- adjust • • • –

Spark arrester-
every 5 000 km (3 000 mile) –
clean

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76 MAINTENANCE AND ADJUSTMENT
2. Periodic Inspection (Chassis Related Items)
Frequency Whichev- *Odometer Reading
er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Clutch and drive train:
Clutch operation
(play, engage-
ment, disengage- • • • • 110
ment) - inspect
Drive chain lubri-
cation condition - every 600 km (400 mile) 121
inspect #
Drive chain slack -
every 1 000 km (600 mile) 115
inspect #
Drive chain wear -
inspect # • • • 119

K
Drive chain guide
wear - inspect • • • –

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MAINTENANCE AND ADJUSTMENT 77

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Wheels and tires:
Tire air pressure -
inspect
year • • • 131

Wheels/tires dam-
age - inspect • • • 132

Tire tread wear,


abnormal wear -
inspect
• • • 132

K
Wheel bearings
damage - inspect
year • • • –

Spoke tightness
K and rim runout - in-
spect
• • • • • • • –

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78 MAINTENANCE AND ADJUSTMENT

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Brake system:
Brake fluid leak -
inspect
year • • • • • • • 122

Brake hoses dam-


age - inspect
year • • • • • • • 122

Brake pad wear -


inspect # • • • • • • 122

Brake hose instal-


lation condition -
inspect
year • • • • • • • –

Brake fluid level -


inspect
6 month • • • • • • • 123

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MAINTENANCE AND ADJUSTMENT 79

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Brake operation
(effectiveness,
play, drag) - in-
year • • • • • • • 124
spect
Brake light switch
operation - inspect • • • • • • • 125

Suspensions:
Front forks/rear
shock absorber
K operation (damp-
ing and smooth
• • • 127,
128
stroke) - inspect
Front forks/rear
K shock absorber oil
leak - inspect
year • • • 127,
128

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80 MAINTENANCE AND ADJUSTMENT

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Uni-trak rocker
K arm bearings - lu-
bricate
• –

Uni-trak rocker
K arm operation - in-
spect
• • • –

K
Uni-trak tie rods
operation - inspect • • • –

Uni-trak tie rods


K bearings - lubri-
cate
• –

K
Swing arm pivot -
lubricate • –

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MAINTENANCE AND ADJUSTMENT 81

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Steering system:

K
Steering play - in-
spect
year • • • • –

Steering stem
K bearings - lubri-
cate
2 years • –

Electrical system:
Lights and
switches operation
- inspect
year • • • –

Headlight aiming -
inspect
year • • • 140

Side stand switch


operation - inspect
year • • • –

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82 MAINTENANCE AND ADJUSTMENT

Frequency Whichev- *Odometer Reading


er comes km × 1 000 (mile × 1 000)
first
See
Page
Operation 1 6 12 18 24 30 36
Every
(Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Engine stop switch
operation - inspect
year • • • –

Battery electrolyte
level - inspect
6 months • • • • • • 134

Chassis:
Chassis parts - lu-
bricate
year • • • 144

Bolts and nuts


tightness - inspect • • • • 150

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MAINTENANCE AND ADJUSTMENT 83
3. Periodic Replacement
Frequency Whichever
comes *Odometer Reading
first km × 1 000
(mile × 1 000) See
Page
1 12 24 36 48
Every
Change/Replacement Items (0.6) (7.5) (15) (22.5) (30)
Air cleaner element # (e) - re-
2 year 100
place
Engine oil # - change year • • • • • 86
Oil filter - replace year • • • • • 86
K Fuel hoses - replace 4 years • –
K Coolant - change 3 years • 96

K
Radiator hoses and O-rings - re-
place
3 years • –

K Brake hoses - replace 4 years • –

K
Brake fluid (front and rear) -
change
2 years • • 124

K
Rubber parts of master cylinder
and caliper - replace
4 years • –

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84 MAINTENANCE AND ADJUSTMENT

Frequency Whichever
comes *Odometer Reading
first km × 1 000
(mile × 1 000) See
Page
1 12 24 36 48
Every
Change/Replacement Items (0.6) (7.5) (15) (22.5) (30)
Spark plug (e) - replace • • • • 97

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MAINTENANCE AND ADJUSTMENT 85

Oil Level Inspection



Engine Oil
In order for the engine, transmission, If the oil has just been changed, start
and clutch to function properly, main- the engine and run it for several mi-
tain the engine oil at the proper level, nutes at idle speed. This fills the oil
and change the oil and replace the oil filter with oil. Stop the engine, then
filter in accordance with the Periodic wait several minutes until the oil set-
Maintenance Chart. Not only do dirt tles.
and metal particles collect in the oil,
but the oil itself loses its lubricative NOTICE
quality if used too long. Racing the engine before the oil
reaches every part can cause en-
WARNING gine seizure.
Motorcycle operation with insuffi-
cient, deteriorated, or contami-
nated transmission oil will cause
• Ifwaittheseveral
motorcycle has just been used,
minutes for all the oil to
accelerated wear and may result drain down.
in transmission seizure, accident,
and injury. Check the oil level be-
fore each ride and change the oil
according to the periodic mainte-
nance chart in the owner’s man-
ual.

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86 MAINTENANCE AND ADJUSTMENT

• Check the engine oil level through


the oil level gauge. With the motor-
opening using a syringe or some oth-
er suitable device.
cycle held level, the oil level should
come up between the upper and low-
• If the oil level is too low, add the oil to
reach the correct level. Use the
er level lines next to the gauge. same type and brand of oil that is al-
ready in the engine.
Oil and/or Oil Filter Change
• Warm up the engine thoroughly, and
then stop it.
• Set the motorcycle up on its side
stand.
• Place an oil pan beneath the engine.

A. Oil Level Gauge


B. Upper Level Line
C. Lower Level Line
D. Oil Filler Cap

• Ifexcess
the oil level is too high, remove the
oil through the oil filler

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MAINTENANCE AND ADJUSTMENT 87

• Remove the engine oil drain plug. WARNING


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

A. Drain Plug

• Let the oil completely drain with the


motorcycle perpendicular to the
ground.

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88 MAINTENANCE AND ADJUSTMENT

• Ifmove
the oil filter is to be changed, re-
the oil filter cover bolts and
• Pull off the element with the element
mounting pin.
take off the cover with O-ring. • Pull
ment.
the mounting pin off the ele-

• Replace the element with a new one.


• Apply a little engine oil to the grom-
mets on both side of the element,
and push the mounting pin into the
element. Be careful that the grom-
mets do not slip out of place.
• Install them with the smaller end of
the pin inside.

A. Bolts
B. Oil Filter Cover

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MAINTENANCE AND ADJUSTMENT 89

NOTE
○ If a torque wrench is not available,
this item should be serviced by a Ka-
wasaki dealer.

NOTE
○ Replace the any gasket with a new
one.

• Fill the engine up to the upper level


line with a good quality motor oil
A. Element
specified in the table.

B. Grommet
C. Mounting Pin Start the engine.

• Apply a little engine oil to the grom- • Check the oil level and for oil leak-
age.
met, and install the oil filter cover
and tighten its bolts. Tightening Torque
• After the oil has completely drained
out, install the engine oil drain plug
Engine Oil Drain Plug :
29 N·m (3.0 kgf·m, 21 ft·lb)
with its gasket. Proper torque for it is
shown in the table.

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90 MAINTENANCE AND ADJUSTMENT
Recommended Engine Oil Although 10W-40 engine oil is the
API SG, SH, SJ, SL or SM recommended oil for most conditions,
Type : the oil viscosity may need to be
with JASO MA, MA1 or MA2
Viscosity : SAE 10W-40 changed to accommodate atmospheric
conditions in your riding area.
NOTE
○ Do not add any chemical additive to
the oil. Oils fulfilling the above re-
quirements are fully formulated and
provide adequate lubrication for both
the engine and the clutch.
Engine Oil Capacity
Capacity : 2.2 L (2.3 US qt)
[when filter is not removed]
2.5 L (2.6 US qt)
[when filter is removed]
2.5 L (2.6 US qt)
[when engine is completely
dry]

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MAINTENANCE AND ADJUSTMENT 91

Cooling System NOTICE


Radiator and Cooling Fan -
Check the radiator fins for obstruc- Using high-pressure water, as
tion by insects or mud. Clean off any from a car wash facility, could
obstructions with a stream of low-pres- damage the radiator fins and im-
sure water. pair the radiator's effectiveness.
Do not obstruct or deflect airflow
WARNING through the radiator by installing
unauthorized accessories in front
Keep your hands and clothing
of the radiator or behind the cool-
away from the fan blades at all
ing fan. Interference with the radi-
times.
ator airflow can lead to
overheating and consequent en-
gine damage.

Radiator Hoses -
Check the radiator hoses for leak-
age, cracks or deterioration, and con-
nections for leakage or looseness
each day before riding the motorcycle,
and in accordance with the Periodic
Maintenance Chart.

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92 MAINTENANCE AND ADJUSTMENT
Coolant - the coolant passages, and consider-
Coolant absorbs excessive heat from ably reduce the efficiency of the cool-
the engine and transfers it to the air at ing system.
the radiator. If the coolant level be-
comes low, the engine overheats and WARNING
may suffer severe damage. Check the Coolant containing corrosion in-
coolant level each day before riding hibitors for aluminum engines
the motorcycle, and in accordance with and radiators include harmful
the periodic maintenance chart and re- chemicals for human body.
plenish coolant if the level is low. Drinking coolant can result in
Change the coolant in accordance with serious injury or death. Use cool-
the Periodic Maintenance Chart. ant in accordance with the in-
Information for Coolant structions of the manufacturer.
To protect the cooling system (con-
sisting of the aluminum engine and ra- Soft or distilled water must be used
diator) from rust and corrosion, the use with the antifreeze (see below for anti-
of corrosion and rust inhibitor chemi- freeze) in the cooling system.
cals in the coolant is essential. If cool-
ant containing corrosion and rust
inhibitor chemicals is not used, over a
period of time, the cooling system ac-
cumulates rust and scale in the water
jacket and radiator. This will clog up

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MAINTENANCE AND ADJUSTMENT 93

freezing point and strength directed on


NOTICE the container.
If hard water is used in the sys-
tem, it causes scale accumula- NOTICE
tion in the water passages, and Permanent types of antifreeze on
considerably reduces the effi- the market have anti-corrosion
ciency of the cooling system. and anti-rust properties. When it
is diluted excessively, it loses its
If the lowest ambient temperature anti-corrosion property. Dilute a
encountered falls below the freezing permanent type of antifreeze in
point of water, use permanent anti- accordance with the instructions
freeze in the coolant to protect the of the manufacturer.
cooling system against engine and ra-
diator freeze-up, as well as from rust
and corrosion. NOTE
Use a permanent type of antifreeze ○ A permanent type of antifreeze is in-
(soft water and ethylene glycol plus stalled in the cooling system when
corrosion and rust inhibitor chemicals shipped. It is colored green and con-
for aluminum engines and radiators) in tains ethylene glycol. It is mixed at
the cooling system. On the mixture ra- 50% and has the freezing point of –
tio of coolant, choose the suitable one 35°C (–31°F).
referring to the relation between

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94 MAINTENANCE AND ADJUSTMENT
Coolant Level Inspection NOTE
•Situate the motorcycle so that it is
perpendicular to the ground.
○ Check the level when the engine is

cold (room or atmospheric tempera-
Check the coolant level if it is be- ture).
tween the F (Full) and L (Low) level
lines.

A. F (Full) Level Line


B. L (Low) Level Line
C. Reserve Tank Cover

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MAINTENANCE AND ADJUSTMENT 95

Coolant Filling removing the shroud, push the top of


•If the amount of coolant is insuffi- shroud to the front.
cient, remove the right shroud by un-
screwing the bolts and add coolant • Remove the reserve tank cover by
removing the screws.
into the reserve tank.

A. Reserve Tank Cover


A. Right Shroud B. Screws
B. Bolt
C. Projection

NOTE
○ The right shroud has a projection at
the top of the right shroud. When

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96 MAINTENANCE AND ADJUSTMENT

• Remove the cap from the reserve NOTE


tank and add coolant through the fill-
er opening to the F (Full) level line.
○ In an emergency you can add water
alone to the coolant reserve tank,
however it must be returned to the
correct mixture ratio by the addition
of antifreeze concentrate as soon as
possible.

NOTICE
If coolant must be added often, or
the reserve tank completely runs
dry, there is probably leakage in
the system. Have the cooling sys-
A. Cap tem inspected by your authorized
B. Reserve Tank Kawasaki dealer.

• Install the cap.


• Install the upper right inner cowl and
tighten the bolt.
Coolant Change
Have the coolant changed by an au-
thorized Kawasaki dealer.

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MAINTENANCE AND ADJUSTMENT 97

Spark Plugs
The standard spark plug is shown in
the table. The spark plugs should be
replaced in accordance with the Peri-
odic Maintenance Chart.
Spark plug removal should be done
only by a competent mechanic follow-
ing the instructions in the service man-
ual.
Spark Plug
NGK DPR8EA-9 or
Standard Plug A. Plug Gap
ND X24EPR-U9
0.8 ~ 0.9 mm
Plug Gap
(0.032 ~ 0.036 in.)
14 N·m
Tightening Torque
(1.4 kgf·m, 10.0 ft·lb)

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98 MAINTENANCE AND ADJUSTMENT
Evaporative Emission Control
System (California model on-
ly)
This system routes fuel vapors from
the fuel system into the running engine
or stores the vapors in a canister when
the engine is stopped. Although no ad-
justments are required, a thorough vis-
ual inspection must be made at the
intervals specified by the Periodic
Maintenance Chart.
Inspection
• Check that the hoses are securely
connected.
• Replace any kinked, deteriorated, or
damaged hoses.

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MAINTENANCE AND ADJUSTMENT 99

Kawasaki Clean Air System in accordance with the Periodic Main-


The Kawasaki Clean Air System tenance Chart. Also, inspect the air
(KCA) is a secondary air suction sys- suction valves whenever stable idling
tem that helps the exhaust gases to cannot be obtained, engine power is
burn more completely. When the spent greatly reduced, or there are abnormal
fuel charge is released into the exhaust engine noises.
system, it is still hot enough to burn. Air suction valve removal and in-
The KCA System allows extra air into spection should be done only by a
the exhaust system so that the spent competent mechanic following the in-
fuel charge can continue to burn. This structions in the Service Manual.
continued burning action tends to burn
up a great deal of the normally un-
burned gases, as well as changing a
significant portion of the carbon mon-
oxide into carbon dioxide.
Air Suction Valves -
The air suction valve is essentially a
check valve which allows fresh air to
flow only from the air cleaner into the
exhaust port. Any air that has passed
the air suction valve is prevented from
returning. Inspect the air suction valves

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100 MAINTENANCE AND ADJUSTMENT
Valve Clearance Air Cleaner
Valve and valve seat wear de- A clogged air cleaner restricts the
creases valve clearance, upsetting engine's air intake, increasing fuel con-
valve timing. sumption, reducing engine power, and
causing spark plug fouling.
NOTICE The air cleaner element must be
If valve clearance is left unad- cleaned in accordance with the Peri-
justed, wear will eventually cause odic Maintenance Chart. In dusty
the valves to remain partly open, areas, the element should be cleaned
which lowers performance, burns more frequently than the recom-
the valves and valve seats, and mended interval. After riding through
may cause serious engine dam- rain or on muddy roads, the element
age. should be cleaned immediately. The el-
ement should be replaced if it is dam-
aged.
Valve clearance for each valve
should be checked and adjusted in ac-
cordance with the Periodic Mainte-
nance Chart.
Inspection and adjustment should be
done only by a competent mechanic
following the instructions in the Service
Manual.

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MAINTENANCE AND ADJUSTMENT 101

Element Removal • Remove the wing bolt, and take out


• Remove the right side cover and
seat.
the element.

• Unscrew the air cleaner cover screw


and remove the air cleaner cover.

A. Element
B. Wing Bolt

A. Air Cleaner Cover Screw


B. Air Cleaner Cover

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102 MAINTENANCE AND ADJUSTMENT

• Remove the element from the frame. WARNING


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

NOTICE
If dirt gets through into the en-
gine, excessive engine wear and
possibly engine damage will oc-
A. Element cur.
B. Frame

• Put a clean, lint-free towel over the


air cleaner housing to keep dirt or NOTE
other foreign material from entering. ○ Element installation is performed in
• Inspect the element material for
damage. If any part of the element is
the reverse order of removal.

damaged, the element must be re- Element Cleaning


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

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MAINTENANCE AND ADJUSTMENT 103

• Dry the element with compressed air Oil Draining


or by shaking it. • Inspect the transparent reservoir be-
• After cleaning, saturate the element
with SE, SF or SG class SAE 30W
low the swingarm pivot section on
the right side of the motorcycle to
motor oil. see if any oil has run down from the
• Press the element against a work-
bench to squeeze out the excess oil,
air cleaner housing.

then wrap it in a clean rag and


squeeze it as dry as possible.

WARNING
Gasoline and low-flash point sol-
vents can be flammable and/or
explosive and cause severe
burns. Clean the element in a well
ventilated area, and take care that
there is no spark or flame any-
A. Reservoir
where near the working areas. Do B. Drain Hose
not use gasoline or low-flash C. Plug
point solvents to clean the ele-
ment. • Ifmove
there is any oil in the reservoir, re-
the plug from the lower end of
the drain hose and drain the oil.

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104 MAINTENANCE AND ADJUSTMENT
Throttle Control System
WARNING Check the throttle grip play in ac-
Oil on tires will make them slip- cordance with the Periodic Mainte-
pery and can cause an accident nance Chart, and adjust it if necessary.
and injury. Be sure to install the Throttle Grip -
plug in the drain hose after drain- The throttle grip controls the throttle
ing. valves. If the throttle grip has exces-
sive play due to either cable stretch or
maladjustment, it will cause a delay in
throttle response, especially at low en-
gine speed. Also, the throttle valve
may not open fully at full throttle. On
the other hand, if the throttle grip has
no play, the throttle will be hard to con-
trol, and the idle speed will be erratic.

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MAINTENANCE AND ADJUSTMENT 105

Inspection Adjustment
• Check that the throttle grip play is
correct by lightly turning the throttle
•Turn out the decelerator cable ad-
justing nut until there is no play when
grip back and forth. the throttle grip is completely closed.
Tighten the locknut.

A. Throttle Grip
B. Throttle Grip Play A. Accelerator Cable
B. Decelerator Cable
Throttle Grip Play
C. Adjusting Nuts
2 ~ 3 mm (0.08 ~ 0.12 in.) D. Locknuts

• If there is improper play, adjust it. • Turn the accelerator cable adjusting
nut until 2 ~ 3 mm (0.08 ~ 0.12 in.) of

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106 MAINTENANCE AND ADJUSTMENT
throttle grip play is obtained. Tighten
the locknut.

NOTE
○ If the throttle cables cannot be ad-
justed by using the cable adjusting
nuts at the upper end of the throttle
cables, use the cable adjusters at
the lower end of the throttle cables
(at the carburetor). Do not forget to
securely tighten the adjuster lock-
A. Accelerator Cable
nuts. B. Decelerator Cable
C. Adjusting Nuts
D. Locknuts

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MAINTENANCE AND ADJUSTMENT 107

they may be damaged. Be sure to


WARNING correct any of these conditions be-
Too much cables play can pre- fore riding.
vent throttle operation and cause
an accident resulting in serious WARNING
injury or death. When adjusting
the throttle or replacing the ca- Operation with an improperly ad-
bles, be sure the upper ends of justed, incorrectly routed, or
the outer cables are fully seated damaged cables could result in
in their adjusting nuts, or they an unsafe riding condition. Be
could slip into place later, creat- sure the control cables are ad-
ing enough grip play to prevent justed and routed correctly, and
throttle operation. are free from damage.

• Open and close the throttle a few


times to make sure that the idle
speed does not change. Readjust if
necessary.
• With the engine idling, turn the han-
dlebar to each side. If handlebar
movement changes the idle speed,
the throttle cables may be improperly
adjusted or incorrectly routed, or

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108 MAINTENANCE AND ADJUSTMENT
Choke Lever Inspection
By pulling the choke lever, the carbu-
retor provides a rich starting mixture
• Check that the choke lever returns
properly and that the inner cable
that is necessary to enable easy start- slides smoothly. If there is any irregu-
ing when the engine is cold. larity, in accordance with the Periodic
If starting difficulty or rich fuel mixture Maintenance Chart have the choke
trouble occurs, inspect the choke lever, cable checked by an authorized Ka-
and adjust it if necessary. wasaki dealer.

A. Choke Lever

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MAINTENANCE AND ADJUSTMENT 109

Idle Speed
The idle speed should be performed
in accordance with the Periodic Main-
tenance Chart or whenever the idle
speed is disturbed.
Adjustment
•Start the engine, and warm it up thor-
oughly.
•Adjust the idle speed by turning the
idle adjusting screw.
Idle Speed A. Idle Adjusting Screw

1 200 ~ 1 400 r/min (rpm)


WARNING
Operation with damaged cables
could result in an unsafe riding
condition. Replace damaged con-
trol cables before operation.

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110 MAINTENANCE AND ADJUSTMENT
Clutch
Due to friction plate wear and clutch
• Check the clutch lever play as shown
in the figure.
cable stretch over a long period of use, Clutch Lever Play
the clutch operation should be checked
8 ~ 12 mm (0.31 ~ 0.47 in.)
each day before riding the motorcycle,
and in accordance with the Periodic
Maintenance Chart.

WARNING
The engine and exhaust system
get extremely hot during normal
operation and can cause serious
burns. Never touch a hot engine
or an exhaust pipe during clutch
adjustment.
A. Locknut
B. Clutch Lever Play
Inspection

C. Adjuster
Check that the clutch lever operates
properly and that the inner cable If the play is incorrect, adjust the lev-
slides smoothly. If there is any irregu- er play as follows.
larity, have the clutch cable checked
by an authorized Kawasaki dealer.

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MAINTENANCE AND ADJUSTMENT 111

Adjustment • Tighten the locknut.


•Loosen the locknut, and turn the ad-
juster so that the clutch lever will
• Ifingit nuts
cannot be done, use the mount-
at the lower end of the cable
have the proper play. so that clutch lever has 8 ~ 12 mm
(0.31 ~ 0.47 in.) of play.
WARNING
Too much cable play can prevent
clutch disengagement and cause
an accident resulting in serious
injury or death. When adjusting
the clutch or replacing the cable,
be sure the upper end of the
clutch outer cable is fully seated
in its fitting, or it could slip into
place later, creating enough cable
play to prevent clutch disengage-
A. Nuts
ment. B. Clutch Cable

NOTE
○ After the adjustment is made, start
the engine and check that the clutch

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112 MAINTENANCE AND ADJUSTMENT
does not slip and that it releases Spark Arrester
properly. This motorcycle is equipped with a
spark arrester approved for off-road
use by the U.S. Forest Service. It must
be properly maintained to ensure its ef-
ficiency. In accordance with the Peri-
odic Maintenance Chart, clean the
spark arrester.
NOTICE
The spark arrester must be in-
stalled correctly and functioning
properly to provide adequate fire
protection.

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MAINTENANCE AND ADJUSTMENT 113

Spark Arrester Cleaning • Remove


fler.
the drain plugs on the muf-

WARNING
The muffler can become ex-
tremely hot during normal opera-
tion and cause severe burns.
Since the engine must be running
during this procedure, wear heat-
resistant gloves while cleaning
the spark arrester.

A. Drain Plugs

• Intibleanmaterials,
open area away from combus-
start the engine with
the transmission in neutral.
• Raise and lower engine speed while
tapping on the muffler with a rubber
mallet until carbon particles are
purged from the muffler.

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114 MAINTENANCE AND ADJUSTMENT
Drive Chain
DANGER The drive chain slack and lubrication
Exhaust gas contains carbon must be checked each day before rid-
monoxide, a colorless, odorless ing the motorcycle, and in accordance
poisonous gas. Inhaling carbon with the Periodic Maintenance Chart
monoxide can cause serious for safety and to prevent excessive
brain injury or death. DO NOT run wear. If the chain becomes badly worn
the engine in enclosed areas. Op- or maladjusted - either too loose or too
erate only in a well-ventilated tight - the chain could jump off the
area. sprockets or break.

• Stop
WARNING
the engine.
• Install the drain plugs. A chain that breaks or jumps off
the sprockets could snag on the
engine sprocket or lock the rear
wheel, severely damaging the
motorcycle and causing it to go
out of control. Inspect the chain
for damage and proper adjust-
ment before each ride.

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MAINTENANCE AND ADJUSTMENT 115

Chain Slack Inspection • Ifloose,


the drive chain is too tight or too
•Set the motorcycle up on its side
stand.
adjust it so that the chain
slack will be within the standard val-
•Rotate the rear wheel to find the po-
sition where the chain is tightest.
ue.
Drive Chain Slack
Measure the maximum chain slack
Standard 35 ~ 45 mm (1.4 ~ 1.8 in.)
by pulling up and pushing down the
chain midway between the engine
sprocket and rear wheel sprocket. Chain Slack Adjustment
•Loosen the left and right chain ad-
juster locknuts.

A. Chain Slack

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116 MAINTENANCE AND ADJUSTMENT

• Remove the cotter pin, and loosen


the axle nut.
• Turn out both chain adjusters evenly
until the drive chain has the correct
amount of slack. To keep the chain
and wheel properly aligned, the
notch on the left wheel alignment in-
dicator should align with the same
swingarm mark that the right indica-
tor notch aligns with.

A. Axle Nut
B. Cotter Pin
C. Adjuster
D. Locknut

• Iflefttheandchain is too loose, turn out the


right chain adjusters evenly.
• Ifandtheright
chain is too tight, turn in the left
chain adjusters evenly.

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MAINTENANCE AND ADJUSTMENT 117

WARNING
Misalignment of the wheel will re-
sult in abnormal wear, and may
result in an unsafe riding condi-
tion. Align the rear wheel using
the marks on the swingarm or
measuring the distance between
the center of the axle and swing-
arm pivot.

• Tighten
A. Marks
B. Notch both chain adjuster locknuts.
C. Indicator
D. Adjuster
• Tighten the rear axle nut to the speci-
fied torque.
E. Locknut
Tightening Torque
NOTE Axle Nut:
○ Wheel alignment can also be 98 N·m (10 kgf·m, 72 ft·lb)
checked using the straightedge or
string method.

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118 MAINTENANCE AND ADJUSTMENT
NOTE NOTE
○ If a torque wrench is not available, ○ When inserting the cotter pin, if the
this item should be serviced by a Ka- slots in the nut do not align with the
wasaki dealer. cotter pin hole in the axle shaft, tight-

• Rotate the wheel, measure the chain


en the nut clockwise up to the next
alignment.
slack again at the tightest position,
○ It should be within 30 degree.
and readjust if necessary.
○ Loosen once and tighten again when
• Install a new cotter pin through the
rear axle nut and axle, and spread its
the slot goes past the nearest hole.
ends.

A. Turning Clockwise
A. Cotter Pin

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MAINTENANCE AND ADJUSTMENT 119

Wear Inspection
WARNING
•Remove the bolts to take off the
chain cover.
A loose axle nut can lead to an
accident resulting in serious in-
jury or death. Tighten the axle nut
to the proper torque and install a
new cotter pin.

• Check the rear


Brakes section).
brake (see the

A. Chain Guide
B. Bolts

• Stretch the chain taut either by using


the chain adjusters, or by hanging a
10 kg (20 lb) weight on the chain.
• Measure the length of 20 links on the
straight part of the chain from pin
center of the 1st pin to pin center of

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120 MAINTENANCE AND ADJUSTMENT
the 21st pin. Since the chain may
wear unevenly, take measurements WARNING
at several places. For safety, use only the standard
• If the length exceeds the service lim-
it, the chain should be replaced.
chain. It is an endless type and
should not be cut for installation;
have it installed by an authorized
Kawasaki dealer.

• Rotate the rear wheel to inspect the


drive chain for damaged rollers, and
loose pins and links.
• Also inspect the sprockets for un-
evenly or excessively worn teeth,
and damaged teeth.

NOTE
A. Measure
B. Weight
○ Sprocket wear is exaggerated for il-
lustration. See Service Manual for
wear limits.
Drive Chain 20-Link Length
Service Limit
323 mm (12.7 in.)

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MAINTENANCE AND ADJUSTMENT 121

to a lighter oil because it will stay on


the chain longer and provide better lu-
brication.
• Apply oil to the sides of the rollers so
that it will penetrate to the rollers and
bushings. Apply oil to the O-rings so
that the O-rings will be coated with
oil. Wipe off any excess oil.

A. Good Teeth
B. Worn Teeth
C. Damaged Teeth

• Ifdrive
there is any irregularity, have the
chain and/or the sprockets re-
placed by an authorized Kawasaki
dealer.
Lubrication
Lubrication is also necessary after
riding through rain or on wet roads, or • Ifusing
the chain is especially dirty, clean it
diesel oil or kerosine and then
any time that the chain appears dry. A apply oil as mentioned above.
heavy oil such as SAE 90 is preferred

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122 MAINTENANCE AND ADJUSTMENT
Brakes Disc Brake Fluid -
Brake Wear Inspection In accordance with the Periodic
Inspect the brakes for wear. For each Maintenance Chart, inspect the brake
front and rear disc brake caliper, if the fluid level in both the front and rear
thickness of either pad is less than 1 brake fluid reservoirs and change the
mm (0.04 in.), replace both pads in the brake fluid. The brake fluid should also
caliper as a set. Pad replacement be changed if it becomes contami-
should be done by an authorized Ka- nated with dirt or water.
wasaki dealer. Fluid Requirement
Use heavy-duty brake fluid only from
a container marked DOT4.
NOTICE
Do not spill brake fluid onto any
painted surface.
Do not use fluid from a container
that has been left open or that
has been unsealed for a long
time.
A. Lining Thickness
Check for fluid leakage around
B. 1 mm (0.04 in.) the fittings.
Check brake hose for damage.

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MAINTENANCE AND ADJUSTMENT 123

Fluid Level Inspection


• The brake fluid level in the front
brake fluid reservoir must be kept
above the line (lower level line) next
to the gauge and that in the rear
brake fluid reservoir (located under
the right side cover) must be kept be-
tween the upper and lower level lines
(reservoirs held horizontal).

A. Rear Brake Fluid Reservoir


B. Lower Level Line
C. Upper Level Line

A. Front Brake Fluid Reservoir


B. Lower Level Line

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124 MAINTENANCE AND ADJUSTMENT

• Iflower
the fluid level in either reservoir is
than the lower level line, check WARNING
for fluid leaks in the brake lines, and Mixing brands and types of brake
fill the reservoir to the upper level fluid can reduce the brake sys-
line. Inside the front brake fluid reser- tem’s effectiveness and cause an
voir is a stepped line showing the accident resulting in injury or
upper level line. death. Do not mix two brands of
brake fluid. Change the brake flu-
id in the brake line completely if
the brake fluid must be refilled
but the type and brand of the
brake fluid that is already in the
reservoir are unidentified.

Fluid Change
Have the brake fluid changed by an
authorized Kawasaki dealer.
A. Front/Rear Brake Fluid Reservoir Front and Rear Brakes -
B. Upper Level Line Disc and disc pad wear is automati-
cally compensated for and has no ef-
fect on the brake lever or pedal action.
So there are no parts that require

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MAINTENANCE AND ADJUSTMENT 125

adjustment on the front brakes and Brake Light Switches


rear brakes. When either the front or rear brake is
applied, the brake light goes on. The
WARNING front brake light switch requires no ad-
Air in the brake lines diminish justment, but the rear brake light switch
braking performance and can should be adjusted in accordance with
cause an accident resulting in in- the Periodic Maintenance Chart.
jury or death. If the brake lever or Inspection
pedal feels mushy when it is ap-
• Turn the ignition key to “ON”.
plied, there might be air in the
brake lines or the brake may be
• The brake light should go on when
the front brake is applied.
defective. Have the
checked immediately by an au-
brake
• If it does not, ask your authorized
Kawasaki dealer to inspect the front
thorized Kawasaki dealer. brake light switch.

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126 MAINTENANCE AND ADJUSTMENT

• Check the operation of the rear Adjustment


brake light switch by depressing the
brake pedal. The brake light should
•To adjust the rear brake light switch,
move the switch up or down.
go on after the proper pedal travel.

A. Rear Brake Light Switch


A. Brake Pedal B. Adjusting Nut
B. Pedal Travel C. Lights sooner
D. Lights later
• Iflightit does not, adjust the rear brake
switch.
Brake Pedal Travel
10 mm (0.4 in.)

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MAINTENANCE AND ADJUSTMENT 127

NOTICE Front Fork


The front fork operation and oil leak-
To avoid damaging the electrical age should be checked in accordance
connections inside the switch, be with the Periodic Maintenance Chart
sure that the switch body does by an authorized Kawasaki dealer.
not turn during adjustment.

A. Front Fork

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128 MAINTENANCE AND ADJUSTMENT
Rear Shock Absorbers
The rear shock absorber can be ad-
• Remove the bracket bolts and take
out the separator (California model).
justed by changing the spring preload
and rebound damping force for various
riding and loading conditions.
Before marking any adjustments,
however, read the following proce-
dures:
Rear Spring Preload Adjustment
The spring preload adjuster on the
rear shock absorber has 5 positions.
• Remove the left side cover.
A. Separator
B. Bracket
C. Bracket Bolts

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MAINTENANCE AND ADJUSTMENT 129

• Adjust the spring preload by turning


the adjusting bolt as follows.
• Adjust the spring preload adjuster by
turning the adjusting bolt [A] as fol-
lows.
• When changing the adjuster position
from 1st to 5th in numerical order
(1st→2nd→3rd→4th→5th), turn the
adjusting bolt clockwise.
• When changing the adjuster position
from 5th to 1st in numerical order
(5th→4th→3rd→2nd→1st), turn the A. Adjusting Bolt
B. 1st Position
adjusting bolt counterclockwise. C. 5th Position
D. Turn Clockwise
NOTICE E. Turn Counterclockwise
F. Rear Shock Absorber
When the spring preload adjuster
is at the position of the 1st or 5th, Position 1 2 3 4 5
do not turn the adjusting bolt in Spring Action ——→ Stronger
opposite direction of the above
procedures. The spring preload
adjuster will be damaged by the
shock.

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130 MAINTENANCE AND ADJUSTMENT
Rebound Damping Force Adjustment The standard setting positions of the
The rebound damping force adjuster spring preload adjuster and rebound
is located at the lower end of the rear damping force adjuster for an average-
shock absorber. build rider of 68 kg (150 lb) with no
passenger and no accessories are as
follows:
Spring Preload Adjust-
1st position
er
Rebound Damping
1 turn*
Force Adjuster
*: out from the fully clockwise posi-
tion

A. Rebound Damping Force Adjuster

• Turn the rebound damping force ad-


juster all the way clockwise with a
screwdriver to make the damping
force greatest.
• Turn the adjuster counterclockwise
to decrease damping force.

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MAINTENANCE AND ADJUSTMENT 131

Wheels ○ Tire pressure is affected by changes


Tires - in ambient temperature and altitude,
Payload and Tire Pressure and so the tire pressure should be
Failure to maintain proper inflation checked and adjusted when your rid-
pressures or observe payload limits for ing involves wide variations in tem-
your tires may adversely affect han- perature or altitude.
dling and performance of your motor-
cycle and can result in loss of control.
The maximum recommended load in
addition to vehicle weight is 182 kg
(401 lb), including rider, passenger,
baggage, and accessories.
• Remove the air valve cap.
• Check the tire pressure often, using
an accurate gauge.
• Make sure to install the air valve cap
securely.
A. Tire Pressure Gauge
NOTE
○ Measure the tire pressure when the
tires are cold (that is, when the mo-
torcycle has not been ridden more
than a mile during the past 3 hours).

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132 MAINTENANCE AND ADJUSTMENT
Tire Air Pressure (when cold) Minimum Tread Depth
Front 150 kPa (1.5 kgf/cm², 21 psi) Front and Rear 2 mm (0.08 in.)
Up to 97.5 kg 150 kPa (1.5
Load (215 lbs) kgf/cm², 21 psi)
Rear 97.5 ~ 182 kg
200 kPa (2.0
Load (215 ~
kgf/cm², 28 psi)
401 lbs)

Tire Wear, Damage


As the tire tread wears down, the tire
becomes more susceptible to puncture
and failure. An accepted estimate is
that 90% of all tire failures occur during
the last 10% of tread life (90 % worn). A. Tire Depth Gauge
So it is false economy and unsafe to
use the tires until they are bald. • Visually inspect the tire for cracks
and cuts, replacing the tire in case of
• In accordance with the Periodic
Maintenance Chart, measure the
bad damage. Swelling or high spots
indicate internal damage, requiring
depth of the tread with a depth tire replacement.
gauge, and replace any tire that has
worn down to the minimum allowable • Remove any imbedded stones or
other foreign particles from the tread.
tread depth.

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MAINTENANCE AND ADJUSTMENT 133

NOTE NOTE
○ Have the wheel balance inspected ○ When operating on public roadways,
whenever a new tire is installed. keep maximum speed under traffic
law limits.
WARNING Standard Tire (Tubeless)
DUNLOP 90/90-21 M/C 54S
Tires that have been punctured Front
K750
and repaired do not have the
same capabilities as undamaged DUNLOP 130/80-17 M/C 65S
Rear
K750
tires and can suddenly fail, caus-
ing an accident resulting in seri-
ous injury or death. Replace WARNING
damaged tires as soon as possi- Mixing tire brands and types can
ble. To ensure safe handling and adversely affect handling and
stability, use only the recom- cause an accident resulting in in-
mended standard tires for re- jury or death. Always use the
placement, inflated to the same manufacturer's tires on
standard pressure. If it is neces- both front and rear wheels.
sary to ride on a repaired tire, do
not exceed 100 km/h (60 mph) un-
til the tire is replaced.

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134 MAINTENANCE AND ADJUSTMENT
Battery
WARNING Battery Electrolyte Level Inspection
New tires are slippery and may The battery electrolyte level must be
cause loss of control and injury. kept between the upper and lower level
A break-in period of 160 km (100 lines. Check the electrolyte level in
miles) is necessary to establish each cell in accordance with the Peri-
normal tire traction. During odic Maintenance Chart.
break-in, avoid sudden and maxi-
mum braking and acceleration,
• Remove the battery from the motor-
cycle (see Battery Removal).
and hard cornering. • Check that the electrolyte level in
each cell is between the upper and
lower level lines.

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MAINTENANCE AND ADJUSTMENT 135

NOTICE
Add only distilled water to the
battery. Ordinary tap water is not
a substitute for distilled water
and will shorten the life of the bat-
tery.

Battery Charging

A. Lower Level Line


•Remove the battery from the motor-
cycle (see Battery Removal).
B. Upper Level Line
C. Battery Filler Caps
NOTICE
• Ifcells,
the electrolyte level is low in any
remove the battery filler caps Always remove the battery from
and fill with distilled water until the the motorcycle for charging. If
electrolyte level in any cells reaches the battery is charged while still
the upper level line. installed, battery electrolyte may
spill and corrode the frame or
other parts of the motorcycle.

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136 MAINTENANCE AND ADJUSTMENT

• Before charging, check the electro-


lyte level in each cell. If the electro- DANGER
lyte level is low in any cell, fill to Batteries produce an explosive
above the lower level line but not up gas mixture of hydrogen and oxy-
to the upper level line since the level gen that can cause serious injury
rises during charging. and burns if ignited. Keep the bat-
• Remove the caps from all the cells,
and connect the battery charger
tery away from sparks and open
flames during charging. When
leads to the battery terminals (red to using a battery charger, connect
+, black to –). the battery to the charger before
turning on the charger. This pro-
cedure prevents sparks at the
battery terminals which could
ignite any battery gases.

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MAINTENANCE AND ADJUSTMENT 137

NOTICE
Do not use a high rate battery
charger, as is typically employed
at automotive service stations,
unless the charging rate can be
reduced to the level required for
motorcycle batteries. Charging
the battery at a rate higher than
specified may ruin the battery.
Charging at a high rate causes
A. Battery Charger excess heat which can wrap the
B. Filler Caps
C. (+) terminal plates and cause internal short-
D. (–) terminal ing. Higher-than-normal charging

• Charge
rates also cause the plate to shed
the battery at a rate that is active material. Deposits will ac-
1/10th of the battery capacity. For ex- cumulate, and can cause internal
ample, the charging rate for a 10 Ah shorting. If the temperature of the
battery would be 1.0 ampere. electrolyte rises above 45°C (115°
F) during charging, reduce the
charging rate to lower the tem-
perature, and increase charging
time proportionately.

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138 MAINTENANCE AND ADJUSTMENT

• After charging, check the electrolyte Battery Removal


level in each cell. If the level has fall- •Remove the side covers.
en, add distilled water to bring it back •Remove the seat.
up to the upper level line. •Disconnect the leads from the bat-
• Install the caps on the cells. tery, first from the (–) terminal and
• Install the battery. then the (+) terminal.
•Take off the battery holder.
WARNING
Battery posts, terminals and re-
lated accessories contain lead
and lead compounds. Wash
hands after handling.

A. Battery Holder
B. (+) terminal
C. (–) terminal
D. Screw

• Take the battery out.

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MAINTENANCE AND ADJUSTMENT 139

• Clean the battery using a solution of


baking soda and water. Be sure that NOTICE
the lead connections are clean. Make sure the battery vent hose
Battery Installation is kept away from the drive sys-
•Put the battery in the battery case
and route the battery vent hose as
tem and exhaust system. Battery
electrolyte can corrode and dan-
shown on the caution level attached gerously weaken the drive sys-
to the tool kit compartment lid. tem. Do not let the vent hose
•Connect the capped lead to the (+)
terminal, and then connect the black
become folded, pinched, or
melted by the exhaust system.
lead to the (–) terminal. An unvented battery will not keep
•Put a light coat of grease on the ter-
minals to prevent corrosion.
a charge and it may crack from
built-up gas pressure.
•Cover the (+) terminal with its protec-
tive cap.
•Route the battery vent hose cor-
rectly.

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140 MAINTENANCE AND ADJUSTMENT
Headlight Beam
Horizontal Adjustment
The headlight beam is adjustable
horizontally. If not properly adjusted
horizontally, the beam will point to one
side rather than straight ahead.
Vertical Adjustment
The headlight beam is adjustable
vertically. If adjusted too low, neither
low nor high beam will illuminate the
• The battery vent hose should be
routed into the holder on the battery
road far enough ahead. If adjusted too
high, the high beam will fail to illumi-
holder. nate the road close ahead, and the low
• Reinstall the parts removed. beam will blind oncoming drivers.
Horizontal adjuster and vertical ad-
juster adjustment should be done by
an authorized Kawasaki dealer.

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MAINTENANCE AND ADJUSTMENT 141

NOTE
○ On high beam, the brightest point
should be slightly below horizontal.
The proper angle is 0.4 degrees be-
low horizontal. This is a 50 mm (2.0
in.) drop at 7.6 m (25 ft) measured
from the center of the headlight, with
the motorcycle on its wheels and the
rider seated.

A. 50 mm (2.0 in.)
B. Center of Brightest Spot
C. 7.6 m (25 ft)
D. Height of Headlight Center

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142 MAINTENANCE AND ADJUSTMENT
Rear Turn Signal Light Fuses
To replace the bulb of the rear turn Fuses are located under the seat.
signal light, remove the screw and The main fuse is mounted on the start-
lightly twist the lens counterclockwise. er relay behind the cover. If a fuse fails
during operation, inspect the electrical
system to determine the cause, and
then replace it with a new fuse of prop-
er amperage.

A. Lens
B. Counterclockwise
C. Screw

A. Fuse Box
B. Fuses
C. Spare Parts

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MAINTENANCE AND ADJUSTMENT 143

• Remove
the screw.
the cover by unscrewing
WARNING
Substituting fuses can cause wir-
ing to overheat, catch fire and/or
fail. Do not use any substitute for
the standard fuse. Replace the
blown fuse with a new one of the
correct capacity, as specified on
the fuse box and main fuse.

A. Cover
B. Screw
C. Main Fuse

A. Normal
B. Failed

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144 MAINTENANCE AND ADJUSTMENT
General Lubrication ○ Rear Brake Pedal
Lubricate the points shown below, ○ Rear Brake Rod Joint
with either motor oil or regular grease, Lubricate the following cables
in accordance with the Periodic Main- with a pressure cable lubber:
tenance Chart or whenever the vehicle ○ (K)Clutch Inner Cable
has been operated under wet or rainy
conditions.
○ (K)Throttle Inner Cables
Before lubricating each part, clean
off any rusty spots with rust remover
and wipe off any grease, oil, dirt, or
grime.
NOTE
○A few drops of oil are effective to
keep bolts and nuts from rusting and
sticking. This makes removal easier.
Badly rusted nuts, bolts, etc., should
be replaced with new ones.
Apply grease to the following
Apply motor oil to the following
points:
pivots:
○ Side Stand ○ (K)Clutch Inner Cable Upper End
○ Clutch Lever ○ (K)Throttle Inner Cable Upper Ends
* ○Speedometer Inner Cable
○ Front Brake Lever

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MAINTENANCE AND ADJUSTMENT 145
(K): Should be serviced by an author-
ized Kawasaki dealer.
* Grease the lower part of the inner
:
cable sparigly.

A. Grease

NOTE
○ After connecting the cables, adjust
A. Speedometer Cable them.
○ Insert the speedometer inner cable
into the speedometer gear housing
while turning the wheel so that the
slot in the end of the cable will seat
in the tongue of the speedometer
pinion.

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146 MAINTENANCE AND ADJUSTMENT
Cleaning Your Motorcycle plastic surfaces: wash them off im-
General Precautions mediately.
Frequent and proper care of your Ka-
wasaki motorcycle will enhance its ap-
• Avoid wire brushes, steel wool, and
all other abrasive pads or brushes.
pearance, optimize overall
performance, and extend its useful life.
• Use care when washing the wind-
shield, headlight cover, and other
Covering your motorcycle with a high plastic parts as they can easily be
quality, breathable motorcycle cover scratched.
will help protect its finish from harmful
UV rays, pollutants, and reduce the
• Avoid using pressure washers; water
can penetrate seals and electrical
amount of dust reaching its surfaces. components and damage your mo-
• Be sure the engine and exhaust are torcycle.
cool before washing. • Avoid spraying water in delicate
• Avoid applying degreaser to seals,
brake pads, and tires.
areas such as in air intakes, fuel sys-
tem, brake components, electrical
• Always use non-abrasive wax and
cleaner/polisher.
components, muffler outlets, and fuel
tank openings.
• Avoid all harsh chemicals, solvents, Washing Your Motorcycle
detergents, and household cleaning
products such as ammonia-based •Rinse your bike with cold water from
a garden hose to remove any loose
window cleaners.

dirt.
Gasoline, brake fluid, and coolant
will damage the finish of painted and •Mix a mild neutral detergent (de-
signed for motorcycles or

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MAINTENANCE AND ADJUSTMENT 147

automobiles) and water in bucket.


Use a soft cloth or sponge to wash
• Lubricate
rusting.
the drive chain to prevent

your motorcycle. If needed, use a


mild degreaser to remove any oil or NOTE
grease build up. ○ After riding in an area where the
• After washing, rinse your motorcycle
thoroughly with clean water to re-
roads are salted or near the ocean,
immediately wash your motorcycle
move any residue (residue from the with cold water. Do not use warm
detergent can damage parts of your water as it accelerates the chemical
motorcycle). reaction of the salt. After drying, ap-
• Use a soft cloth to dry your motor-
cycle. As you dry, inspect your mo-
ply a corrosion protection spray on
all metal and chrome surfaces to pre-
torcycle for chips and scratches. Do vent corrosion.
not let the water air dry as this can
damage the painted surfaces.
○ Condensation may form on the in-
side of the headlight lens after riding
• Start the engine and let it idle for sev-
eral minutes. The heat from the en-
in the rain or washing the motor-
cycle. To remove the moisture, start
gine will help dry moist areas. the engine and turn on the headlight.
• Carefully ride your motorcycle at a
slow speed and apply the brakes
Gradually the condensation on the
inside of the lens will clear off.
several times. This helps dry the
brakes and restores them to normal
operating performance.

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148 MAINTENANCE AND ADJUSTMENT
Painted Surfaces
After washing your motorcycle, coat NOTICE
painted surfaces, both metal and plas- Plastic parts may deteriorate and
tic, with a commercially available mo- break if they come in contact with
torcycle/automotive wax. Wax should chemical substances or house-
be applied once every three months or hold cleaning products such as
as conditions require. Avoid surfaces gasoline, brake fluid, window
with “satin” or “flat” finishes. Always cleaners, thread-locking agents,
use non-abrasive products and apply or other harsh chemicals. If a
them according to the instructions on plastic part comes in contact with
the container. any harsh chemical substance,
Windshield and Other Plastic Parts wash it off immediately with
After washing use a soft cloth to gen- water and a mild neutral deter-
tly dry plastic parts. When dry, treat the gent, and then inspect for dam-
windshield, headlight lens, and other age. Avoid using abrasive pads
non-painted plastic parts with an ap- or brushes to clean plastic parts,
proved plastic cleaner/polisher prod- as they will damage the part's fin-
uct. ish.

Chrome and Aluminum


Chrome and uncoated aluminum
parts can be treated with a

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MAINTENANCE AND ADJUSTMENT 149

chrome/aluminum polish. Coated alu-


minum should be washed with a mild WARNING
neutral detergent and finished with a Rubber protectants can be slip-
spray polish. Aluminum wheels, both pery and, if used on the tread
painted and unpainted can be cleaned area, cause loss of traction re-
with special non-acid based wheel sulting in accident causing injury
spray cleaners. or death. Do not apply rubber
Leather, Vinyl, and Rubber protectant to any tread area.
If your motorcycle has leather acces-
sories, special care must be taken.
Use a leather cleaner/treatment to
clean and care for leather accessories.
Washing leather parts with detergent
and water will damage them, shorten-
ing their life.
Vinyl parts should be washed with
the rest of the motorcycle, then treated
with a vinyl treatment.
The sidewalls of tires and other rub-
ber components should be treated with
a rubber protectant to help prolong
their useful life.

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150 MAINTENANCE AND ADJUSTMENT
Bolt and Nut Tightening
In 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 cotter
pin is in place and in good condition. Please ask your authorized Kawasaki dealer
for torque values.

1. Front Fork Upper Clamp 15. Side Stand Mounting Bolt


Bolts 16. Rear Sprocket Mounting Nuts
2. Steering Nut 17. Spoke Nipples
3. Stem Head Nut
4. Handlebar Mounting Bolts
5. Engine Mounting Bolts and
Nuts
6. Rear Frame Mounting Bolts
7. Rear Shock Absorber
Mounting Bolts
8. Brake Disc Mounting Bolts
9. Front Axle Nut
10. Brake Caliper Mounting
Bolts
11. Fuel Tap Bolt
12. Swing-Arm Pivot Nut
13. Step Holder Mounting
Bolts
14. Side Stand Switch Mount-
ing Bolt

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MAINTENANCE AND ADJUSTMENT 151

18. Brake Pedal Mounting Bolt


19. Rear Axle Nut
20. UNI TRACK Lever Rod
Nuts
21. Front Axle Clamp Bolts
22. Rear Shock Absorber
Mounting Nut

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152 STORAGE
STORAGE

Preparation for Storage:


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

WARNING
Motorcycle oil is a toxic substance. Dispose of used oil properly. Contact
your local authorities for approved disposal methods or possible recy-
cling.

• Put in fresh engine oil.


• Empty the fuel from the furl tank, and empty the carburetor by connecting a suit-
able hose to the fitting at the bottom of the carburetor and unscrewing the drain
screw next to the fitting. (If left in for a long time, the fuel will break down and
could clog the carburetor).

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STORAGE 153

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

• Empty the fuel system by running the engine at idle speed until the engine stalls.
(If left in for a long time, the fuel will break down and could clog the fuel system.)
• Reduce tire pressure by about 20%.
• Set the motorcycle on a box or stand so that both wheels are raised off the
ground. (If this cannot be done, put boards under the front and rear wheels to
keep dampness away from the tire rubber.)
• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on
rubber parts or in the brakes.
• Lubricate the drive chain and all the cables.
• Remove the battery, and store it where it will not be exposed to direct sunlight,
moisture, or freezing temperatures. During storage it should be given a slow
charge (one ampere or less) about once a month. Keep the battery well charged
especially during cold weather.
• Tie plastic bags over the mufflers to prevent moisture from entering.

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154 STORAGE

• Put a cover over the motorcycle to keep dust and dirt from collecting on it.
Preparation after Storage:
• Remove the plastic bags from the mufflers.
• Install the battery in the motorcycle and charge the battery if necessary.
• Fill the fuel tank with fuel.
• Check all the points listed in the Daily Safety Checks section.
• Lubricate the pivots, bolts, and nuts in General Lubrication section.

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TROUBLESHOOTING GUIDE 155

TROUBLESHOOTING GUIDE

Engine Does Not Start:


Starter Motor Won't Turn
• Battery discharged
• Engine stop switch off Engine Stalls:
• Transmission not in neutral Just When Shifting Into 1st Gear
• Fuse blown • Side stand has been left down
• Battery leads do not make good
electrical contact with battery termi-
• Clutch does not properly disengage
While Riding


nals
Battery discharged • Choke
off
is used too long after moving

Engine Cranks, But Won't Start • Fuel tap is turned off


• No fuel in tank • No fuel in tank
• Fuel line clogged • Fuel tank air vent is obstructed
• Fuel broken down • Overheating
• Choke
cold
is not used when engine is • Battery discharged
• Engine flooded
• Spark plugs not in good contact
• Spark plugs fouled or wet
• Incorrect spark plug gap
• Incorrect valve clearance

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156 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 Kawasa-
ki Motors Corp., U.S.A. If you have a problem concerning warranty or service,
please take 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. The
OWNER 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, all war-
ranty and service matters are handled and resolved through the authorized
Kawasaki dealer network.
If you are unsatisfied after working with your Kawasaki dealer and feel you still re-
quire further assistance, write to the address below. Please be certain to provide
the model, product identification number, mileage or hours of use, accessories,
dates that events occurred and what action has been taken by both you and your
dealer. Include the name and address of the dealership. To assist us in resolving
your inquiry, please include copies of related receipts and any other pertinent infor-
mation including the names of the dealership personnel with whom you have been
working in the resolution of your problem.
Upon receipt of your correspondence we will contact the dealership and work with
them in resolving your problem.

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Owner Satisfaction 157

In order to provide a permanent record, all warranty and service resolutions take
place only through written correspondence.
Please send your correspondence to:
CONSUMER RELATIONS
KAWASAKI MOTORS CORP., U.S.A.
P. O. Box 25252
SANTA ANA, CA. 92799-5252
(949) 460–5688

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158 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 could
cause injury or death, you should immediately inform the National Highway Traffic
Safety Administration (NHTSA) in addition to notifying Kawasaki Motors Corpora-
tion, U.S.A.
If NHTSA receives similar complaints, it may open an investigation, and if it finds
that a safety defect exists in a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems be-
tween you, your dealer, or Kawasaki Motors Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-
424-9393 (or 366-0123 in Washington, D.C. area) or write to: NHTSA, U.S. Depart-
ment of Transportation, Washington, D.C. 20590. You can also obtain other infor-
mation about motor vehicle safety from the Hotline.

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ENVIRONMENTAL PROTECTION 159

ENVIRONMENTAL PROTECTION

To protect our environment, properly discard used batteries, tires, engine oil, or
other vehicle components that you might dispose of in the future. Consult your au-
thorized Kawasaki dealer or local environmental waste agency for their proper dis-
posal procedure.

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160 LABEL INFORMATION
LABEL INFORMATION

(1)

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LABEL INFORMATION 161

(2)

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162 LABEL INFORMATION
(3)

(4)

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LABEL INFORMATION 163

(5)

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164 LABEL INFORMATION
(6)

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LABEL INFORMATION 165

(6) only on California model

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166 LABEL INFORMATION
(7) (8) only on California model

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LABEL INFORMATION 167

(9)

(10)

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168 LABEL INFORMATION
(11)

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LABEL INFORMATION 169

(12)

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170 LABEL INFORMATION
(13) only on California model

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MAINTENANCE RECORD 171

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.
Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

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172 MAINTENANCE RECORD

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

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MAINTENANCE RECORD 173

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

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174 MAINTENANCE RECORD

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

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MAINTENANCE RECORD 175

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

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176 MAINTENANCE RECORD

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

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MAINTENANCE RECORD 177

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

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