e SPECIFICATIONS.

S'P'ECIFICATIONS

PERFORMANCE ~...1aximum Horsepower

, ... 1aximum Torque f'<."av::rl':.Jm Turning R::.rljl,;:;:

Spark Plug LUDrication System Engine Oil

Type:

Capacity:

21kW (Z9 PSl @10 000 r/min (rpm) .21 Nrn {2.2 Kgf'm) @.9 SOD r/min (rpm)

Cnol~nt Capacity

"r;':~N e:,iIS~.:vN Transmission Type , Clutch Type

Driving Sys,lem .

Primary Reduction Rallo Final Reduction Ra~io Overall Drive Ratio Gear RattQ

tst 2nd ~,rd 4th 5th 6th Type:

Overaii Length Overall Width Overau Height

Vheelbase Road Clearance Dry Weight ENGINE

Type

1 960 mm 725 mrn

1 OB5 mm 1 31.0 rnm 135 mm 122 kg

2.siroke,. single cylinder, crankcase teed valve,

IIQujd~cooled 148mL

59.0 x 54.4 rnm 6.8: 1

Primary kick . I

KEIHIN PWL2B

DeCDI

10"BTDC @1 50.0 r/min (rpm)- 20"BTDC@4 000 r!min

Capaoity:

O!splac'ement

Bore x Stroke Comp,Fession Ratio Starting System carburetors Ignition System Ignjtipn Timing

Transmission Oil

SP'E(:I.FICATIONS 7

NGK B9ES

Superlube (oil injection) JASO Fe

1.2 L

1.3 L

- 6-speed, constant mesh. return ~i:; I Wet, . multi. disc

Chain drive

3.272 (72122)

.2.786 (39/14)

7,873 (Top gear)

2.7QO (27f10) \

1.706 (29/17)

1 .30D (26/20) .

1 .090 (24122) 0.95:2 "(20/21) 0.863 (19122) . API! SE, SF or 8G

.API SH or SJ withJASO MA

SAE 10W-40 1.2 L

8 SPECIFICATI'ONS

FRAM' Castor Trail

Tire S.ize:

LOCATION OF FARTS 9

coc 'TI. N OF PA' T,

Front Rear

25"

89 mm

9Q/90-17 M/C 498 ,,100/90. 8 M/C 56S 10.3 L

. Fuel Tank Capacity

,,"" EC.".. .... r ,~ "c

..... '" "i ., ........ L EQ:Ul?MEN:

Sattery Headright Tail/Brake Light Turn Signal Ugh

12 V 4 Ah 12 32/3.2 t 12 V 5118 W 12 V 10 W

Specj,fications subject to change wit out notice.

1. 'Clutch Lever

2. Me.ter lnstrurnems

3. lndlcator Lights

4: Brake ~luid Reservoir (Front) 5. Front Brake Lever

6, Left Handlebar Switches

7. Ignition switch/Steering Lock

8. Right Handlebar S vitches

9. Throttle Grip

LOCA.TION OF PARTS 11

10. Headlight

11. Turn Signal light

12. Fuel Tan Cap

13. Fuel Tap

1 .. Rear Shock Absorber 15. Engine Oil Tan.

- 6. Seat

17. Helmet Hook

18. Speedometer Gable

19. Radiator Cap 20.: Radiator

21. Choke Knob

22. Gil Pump

23 Center Stand 2 r, Shift Pedal

25. Side Stand

26. Drive Chain

27. Tall/Brake Light

28. Tool KIt

29.8aHe~ ..

30. Coolant Reserve Tank

31. Carburetor 3.2. Fuel Tanio;

33. Hom

34. Calipe

35. Disc

36. Muffier . .

31. Rear Brake Light SWitch

36. Rear Brake Pedal

39. Orl Level Gauge

410. Kkk Pedal

2 GENERAl. rNFORMATION GENERAltNFORMAT"ON

Metr Ins ruments A: Speedometer B : Tachomete C : Red Zone

D· ;-"" .... ·1·-_. or

_ r : llo" ? .. '. am;~I.!furp

Gauge E : Trip Reset Knob F: Odometer G : Trip Meter H . Oillevel Warning Ugh! I : Neutral IndIcator Light J :. -r.0P Gc.ar Indicator Light K:. urn Srgnalilldicalor Light

l .. Lo,w FL:lef Warning, Light _

M. High Beam ilindicator Ughl

- Speedometer and Tael omelet

-------- The speedometer shows the speed

of the vehicle. In the speedometer face are the odometer and trip meter. The odometer shows the total distance that the vehicle has been ridden. The tiip I neter shows th3 distance traveled since it was last reset to zero. The tnp meter can be reset to ze 0 by turning the reset knob ceunterclcckwise.

CAUTION

To avoid·d~ma.ge, the reset knob must be turned countereleck .. wise.

The tacbometer shows the engine speed in the revolutions per minute {r/min, rpm), On the right side of the tachometer face is a portion called the "red ZOI':l8." Engine r/min (rpm) in

GE' ERAL IN'FORMATION' 13 the red lane is above maximum raeom'mendedengine speed and is also above the ra.ng.e for good performance.

CAUTION,

Engine r/min (rpm) should not bea,HoweG !c enter tt!:;; red zone; operation in the red zone will overstress the engme and may 'cause serious engine damage.

Coolant Terrsperature Gauge (TEMP)

This gauge s'~Dws the temperature of coolant, Ordinarily, the needle should stay within the cool zone. If the needt-e reaches the "Ho (red)" zone, stop the engine and check the coolant level in the reserve ank a er the enaine cools

- - - .....

down.

14 GENERAL INFORMATION

CAUTION

00 not let the engine continue running when the gauge needle reaches the 'Hot . (red)" zone. Prolonged engine operation will result in severe damage from

I coverhe;jtinig. .--I

Indicator Lig:hts,

OIL: The engine oil level warning liight goes on. whenever the ignition switch is in the ON position with the engine in neutral. and goes off when the transmission is in any gear. If the engine oil lsvelqets too low, the l'ig,ht ~W not go offand will stay on even in any gear. In this case, add the engine oil as soon as

possible. '

NEUTRAL: When the transmission ls lin neutral, the neutral indicator light is ,jt.

TOP: When the trans~is~'.onis .int~P~Ke .. .., '.

(.6th) gear. the top gear indicator light. IS T~iS motorcycle has a com~m~t~on

lit. .key, which is used for 1helgnltlon

switch/steering lock, he~met ~ook. fuel, tank cap and left and nght Side cover

locks. .' b. .~,' ur

BlanK keys are avalla Ie .?; ~ ~ c •. '

Kawasaki dealers. AsK your dealer to make any additional s~a~lek~Ys you may need, using your ongma.1 key as a

master.

TURN:When the turn signal switch is turned to leftar right, the tum signal indicator lig h t flasl .es on 811d off.

-

GE'NERAL IN FOR\\' AnON 15

I,gnition SwitchIS~~ering Lock".

-This is a three-poSitIon, key·operated

switch .. The key can ,be, removed trorn the switch when it IS In the OFF .or

LOCK position.

--nr:::-----")1

A. Ignition S\\fitch/Steeriog Lock B, ON position

C. OFF position

.D. LOCK position

FUEL: The low fuet warning light goes on whenever the ignition switoh is in the ON position with the engi~ne in neutral, and goes off when the transmission lis in any gear-If the fuellevet gas too low, the ight will: not go off and witl stay on even in any gear .. 111 this case. 'add the rue I at the earliest opportunity.

HIGH BEAM : When the headlight is on high beam, the beam indlcator Irght is lit.

16 GENERAL INFORMATION

'ON

.Engineoff. AU electrical circuits off.

Engine on. All electrical equjp:m~nt can be used. (The head, tall and meter Ilghts do not came an if the engine is

! 11,J~ j"l.nni, I~ ) . 1

,LOCK

Steering locked. Engine off. All electrical circuits off.

PCPark)

Steering locked. Engine off. All other ete-ctrical circuits cut off.

To lock the steering:

1. Set the motorcycle up on the center stand.

2. ~urn the handlebar fully to the len or

rtght. '

3. ~'V'ith tne ignition key in the OFF position, push down and release the k'ey.

4. Turn the key to LOCK position.

5. Pull' the key out

.: 5·

:RightHandlebar Switches' 'Engine' Stop Switch

In addition to the ignition switch, the

engine stop swilCh must be in the RUN , position for the motorcycle to o.perate.

i The engine stop switc:h ~. for emergepc.y use. If some tl'merg8r.cy re. quires stoppin.g the engine, mov~ .the engine stop switch to the OFF position,

'" NOTE

() Although the engine stop switch stops the engine, it does not tum off aU the le.lectric~1 circuits. Ordinarily, the ignition'switch should be used to stop the engine.

GENERAL INFORMATION 17

A. Eng:ine ·Stop Swit<:h

B. Headlight Switch

To unloc.k the steering':

1. I~s~ert t~eignition key into theignition switch.

2. Turn the key to OFF position,

18aENERAL rUFORMATJON. Headlight. Switch

OFF . The! eadlight is off with the switch in the OFF position ..

. --

. The lailand meter lights come

:1 on ii' ihe switch b pushed tc the :J posit jon while the engine IS running.

ON

left Handlebar Switches i

Dimmer Switch Turn Signal S,witch -..

.High or low beam can be selectee When the turn sig'nal switch is turned w~th ~he dimmer switch. When th~O the left. (L) or ri,ght (Rl', the correheadlr~ht,ls on ~jgh beamfHI). the higliiPonding turn signa.ls flash on and off.

b~am indicator h9htis lit To stop flashing. push the yellow but-

High heam.... (Hli ton in.

Low beam , (LO) H '8

~ em Button

B~r'-~~~~~~ When the horn button is pushed, the

sounds. "

GENERAL INFORMATION 19

Fuel Tank Cap

To open the fuel tank cap. pull up the keyhole cover. Insert the ignition key into the fuel tank cap and tum the key

to the ight .

To close th~ cap, push !t dow!" in o place with the key inserted. I ne key can be removed by turning it to he left tothe orIginal positlon.

OTE

o The fue! tank cap cannot be closed without the key inserted, and the ke cannot be re,(icivea 'I.}nless the cap is

locked properly. .

o Do not push on the key to close the cap, or the cap cennotoe locked.

The head, tall. and meter lights i' come on rflhe swi en is pushed

, downward to the ON position . while the engine is running.

-----~-------------- __ ~ __ -J

, Passing Button

When the passing button is pushed. . e headlight high beam (passing beam) comes on to signal the driver of the vehicle ahead that you are about to pass him. The passlnglg.ht shuts off as SOOrl as the button is released.

,B. F:uel Tank Cap

Fuel Tank

Avoid filling the tank in 'the rain Gasoline is extremely ftamnlable

where heavy dust is blowing so that (I,nd can be explosive under cer-

"rfU_eJ __ d~o_e_'s_n_o_t_g_e_t _c_o_nt_a_rTI_i_n_8_te_d_, __ ~j taln conditions. Turn the ign ilion ~ key to ilOFF~"

~ Do not smoke. Make sure th~ .l area is well ventilated and free t frem any source o·f flame or r sparks'; this }n,cludes any appli~ ~ anee w}tb a pllet figt;1f.

t 1\l'ever till the tank SO th.s fuel . level rises into the flller neck. ff - ... .. t the tank is QverfUl.ed,. heat mav.-.

I, r,,,k CU' iT

12. FLJD I hnk .4-. F,. l e-r Null: --"1' ...... \1.12\1QI822. C. l' cause the fuel to expand and

'------...:.-....;----=:..::.......::..::.:::.:~-...:.....:.....:....:.:.::-=-=-, 0vetflow hrough the vents in

~ the' tank cap. . .

1 After ·ref'l.lelirlg, maks sure U\.e \ fueJ taMk cal' is dosed secure.I),. llfgasoline is '&l!iUed on the fuel

tar't~. wipe it off~mmed'jately.

GENERAL INFORMATION 2.1

Fuel Requirem·ent:

Your Kawasakl engine is designed to use unleaded gasoline·,

Octane Rating

Tile octane ratin~ of agasaiili~' is ~ measure of its resistance to detcna .. tion or "knockinq." The term commonly used to describe a gasoline's octane rating is the Research Octane Num·ber (RON). Always use a gasolin~ with an octane rati'ng equal to, or higher then, RON 91,

o if "knocking" Of 'pingiMtf occurs, use a ·df:fferenl brand of gasoline or,higher octane rating ..

22GENE,RAlINFOfU,ATlON . Fuel Tap

The fuel tap has three positions:

OFF, ON,a,nd.RES (reserve). If the f~t~1 runs out with the tap in the ON posmon, t.he I~st .2.1 l of fuel can be used ::- y rurnlt1g the fuel t3:J !ever to ~ES.

C. ON position

D. RES positi.on

nds .

The motorcycle Is equipped with two a. center stand and a side

NOTE

o Since riding distance is limited on RES, reluel at iheesttiest tunity. . C Mal,e cettein hat the fuel tap fevgr6~R!w~-~ turned to OM. (Not RES) after . up the fuel tank

P~acUce, operating the fuel tap" .. ,,",).110,:,,,,

with the motorcycle stopped. lo prevent an accident you' ShOLdd' .",~~nE;",.~:;"'-'l'

be ,abl: ~o op~rate -the fuel t~p .

whlle ndmg without tak.ing your ~. __ ~_;:;....---:;;;~-:;.;...--~=~.:;iIiI

eyes off the road. It. 8Jde Sta:nd

Be, ~areful not to touch the hot

engine while 'operating the fuei

tap. .' - .0 When using the side' stand, tum the

~==------_""- __ - handlebar to tile left.

NOTE

GENERAL IN'FORMATION .23

Whenever the side stand or center stand is used, make ita practice to kicK the stand fully up before sluing on the motorcycle.

Forgetting and leaving the side stand 'downand riding away . could cause an accident,

To set the motorcycle up on the center stand, step down firmly on ·the stand, and then lift the motorcycle up and to the reel[ using the g(.ab rail as a hand-hold. Don't pull up 'On the "eat to lift as this will damage the seat.

24 GENERAL INFORMATION

A. Center Stand

B. Step down.

aENERAl.lNFORMATIO ~ .. 25

A. Stde Cover e. L.ock

C. 19 itlon KE!y

'I~~~;;~~~~~~~~~de Covers

~ The left and right side covers are re-

;"",....."" .. ",,rt for the engine oil and coolant ,re~ I,and seat, tool kit and battery reI.

S. Uft up.

Side Cover 'Removal:

;'f . Insert the ignition k,ey Into the 10 k" i and turn the key to the right.

2. Pull the 'Side cover front end outward, and pull the side cover toward the rro·nt.

26 G NERAL I 'FORMATION

Seat.

To erno e ,he seat, follow his step.

1. Remove the left and right side covers.

2. Unscre the left and right seat mounting belts.

Z. P:_I.I the SI::::" up and to the real.

.A. Seat

B. Boll

00 not: ride, th!,e'motorcycle with helmet attached ,0 the hook: The he met could cause on aC(:1d~nt ,:by distracting. the operat~r or Interfering with normal vehicle op-

eration,

A. Tool Kit

GENERAL INfORMATION 21

A. Helmet Hook

21 BREAK-IN

BREA.K~N 29

BREA.:K-IN

New tires are slippery and may cause 'loss of con~rol and inJu.ry. "" ~, ~

A break .. in period of 160 km is necessary .t!oestabhS~ normal tire tract~on.

. inc I.. , " k-lr avo· Old sudden and maximum braking and acceleration,

Durmgprea . 10. . " "

arid h~.rd c,omering:. .J

lnaddition:tu the abo e, at 800 km it is extremely im~?rtant that th~ owne~ have

the initial maintenance ~ervice performed by an authorized Kawasaki dealer.

The first 1 600km that the motorcycle is ridden is designated as the" break-in period. If the motorcycle is not used carefully dUfjngthis period" you may very veil end up with a "broken down" instead of a 'broken in" motorcycle after a few

t"t:~U~~:-la kii,)meters. '

The following rules should be observed during the break-in period. .

• The table shows maximum recommended engine speed du"ring. the break-in pe-

rind. "

, Distance traveled Maximum engine speed
I 0 - 800 km . 4 000 rim in (rpm}
,I 800 - l' 600 km 6000 rlmin (rpm)
- • Do not start moving Of race t,heengine immediately after starti.ng it, even i 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 whBe the transmission is in neutral.

30 "0"'10 RIDE iHE MOTORCYCLIE

HOW TO ! • E THE·P 'or

Sta.rting the Engine

• T.u.fn the fuel tap fever a the ON posmon.

, -_._----

B ON position

~heck that the engine stop switch is In the' RUN position.

• Tum the ignition key to -ON."

eye E

NOT'

o When the engine is alrea,dy wa.rm or on hot days [35"C or more}, open the throttle part way instead of using the choke. and then start me ,engine.

HOW TO RIO,E THE. .. ,mTORCYClE 31

NOTE

o If the engi~a IS noooeo. kick he engine c,war with a throttte {ully open. until the engine starts.

• Use .. the chose as necessary 10 kee the engine running during warm-up.

• When the engine is warmed up enough to ,idie winout using th~ choke, push the choke knob all he way down.

• Make certain 'te transmission is in neutral.

A. Eng'ine St.,,, S\vitch 8. Ignition Switch

C. ON posItion

D. Neutral IndIcator light

A. Choke Knob

e leaving the throttle complet.ely otossd,ki,ck thee:nglne over until the engine starts.

'" II the engine is cold, pull the choke

knob aU the way up. .

32 HOWle RIDE THE MOTORCYCLE

CAUTION

-

0,0 not let the engine idle longer

than _ fi'v~ minutes, or eng i-n e overheallngiand damape may occur.

-- ----------

Moving Off .. Che~k that the side stand is up. , • Pull In the clutch Ie er.

• Shift into 1 st gear.

• Open the throttle a little, and start to' let out the ::!U!ct. lever '3:'/ slowlv,

As the clutch. starts to engage, open ",'!ji"~ - ~ I

t~e t~rottle ahtU? more, giving theen"i ~i __ -.-~~- ~~~tiIII~_ IIIrIU gms.lust enough fuel to keep it rom -"hen shifting. down, to a lower

stall'mg. 'gear, do ot shift at such a high speed that the engine rlmin (rpm jumps ext:essively. Not only can this cause engine darnaqe, but the rear whee" may skid and cause an accident. Downshifting should be done below 5 000 r'min (r m) for each gear.

. .

-, ShiftfngGears

• Close the throttle . ~ hlle pulling in the

clutch lever,

Shift into the ne.xt higher or lower

. HOW TO RIDe THE MOTORCYCLE 33

Br-aking

Close- the throttle completely .• leav-

ing the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle.

• Shift dov none qear at a time sa that you. are ill 1 st gi?~r wr,-=-n you C0,r;~ 'to a complete stop.

When stopping. always apply both

< brakes at the same time .. Normally the front brake should be applied a littJe more than the rear. Shift down or fully disengag.e the clutch as .nacessarv to keli/p the engine from staBing.

• Never lod<.\the brakes, or it will cause the tires to skid. When turn~ng a corner, it is batter not to brake at all. Recuce your speed before you get lnto

the corner.

o Foernerg'ency braking, disregard

downshifting, and concent ate on applying the, brakes as hard as possible without skidding.

'I Open the throttle part way. while releasing the clu enlever.

54 HOW TO R10E THE MO~rORCYCLE

A. Front Brake Lever

CAUTION

In order to protect the erntsstori ~o~t~ol parts, do no t.u n off the IgnItion switch when the motorcycle is. In motion.

HOW TO RIDE THE' OT'O:RCYCLE 35

Stoppin ,th otoreycls inan

Emer9"'cy

Your Kawasaki Motorcycle has. been

designed and manufactured to provide you optimum safety and convenience. 'However, in. order to fully benefit from Kawasaki's safsty ~ngineering and crartsmanship, it is assential thei you, the owner and operator. properly rnaintain your motorcycle and become thoroughly familiar \vith its operation. Improper maintenance can create a dangerous situation known as nrotUe failure. Two of the most common cause~ of thr~t e failure are:.

1. An Improperly serviced or clo,gged alr cleaner may allo"1 dirt and dust to enter the carburetor and stick the throttle open.

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

~~_ ... nO[J1Dlng th ngine

. Close the throttecompletely,

, Shift the transmission into neu ral.

Tum tile ignition key to "OFF.." Support the motorcycle on a firm, level surface with he side stand or center stand.

I LOG t.he steering.

Iii Tum the fuel tap lever ,0 the OFF , posltlon.

. \

A. Rear Brake Pedal

36 HOW TO RIO,E THE MOTORCYCLE

In an emergency situation such <as throttle faUure .• your vehjcle may be stopped by apply·ing the brakes and disengaging the ctu(oh.. Once this stopping procedure 'IS initiated, the engina stop switch may be used to stop the engine. If theenginp stop switch is ~;;ed. tum off the ignition SWI[ch after stopping the motorcycle.

HOW TO RIDE THE MOTORCYCLE 37

Parking

• Shift the. tr~ns~i$Sjon . Inl~ ne • . . ... is extremely flammable

and turn the IgnitIon key to OFF. j...... .•.. bex '. losive under cer-

• Support the rnotorcycis on a firta~d can.e, P

level surface with, the side stand rt~a::ln~c:o:n~d:.. :.:,tl:..:O..:.,":...::S_,. --:

. center stand. f Lock the steering to help prevent

....----------,..--- ---:"" .-' theft.

CAUTION

Donat park on a so·ft -or steeplyl incl'ined surface~ er ,the motQrcy~ clemay fall over ..

• !'f parking jnsidea g,arage or oth. structure, be sure it is wet! ventilaf€' a.nd the motorcycle ~,s not close .. any source' ot flame or sparks;th incl:udes any appliance with a pi! tight.

38 SAFE OP.ERATJON

SAFE OPERATION 39

SAFE. OPE:RATION

' .. hJt.S. bolts. fasteners ... Check that steerin.g ~nd sus~ension components, axles. r·"andall controls are properly tightened or faste.n.ed .....

OaiJy Saf,ety Checks. ~£" ,Action smooth but nat loose from lock to lock. No bmdmg

Ch '.. , ",', neerlng ..... ,................ '

.",' 'eCk. the following Items each day before you ride. The time required ,is minim" of control cabtes,

and hab~tual pe~~rmance ofthese~hecks witl help ensure you a safe.reliable ri~rakes Brake pad wear: Lining thickness more than 1 mm {O.04

If any Irregulantles are found dunng these checks, refer to the Maintenance a( , in.) ·Ieft

Adjustment chapter or SA'":: your d~.!ler for the action required to return fh~ mOle, No brake fluid leakage.

cycle to a safe operating condition. rhmttJe " Throttle grip play 2 - 3 rnrn

lutch , ; Clutch lever play 2 - 3 mm ' Clutch lever operates smoothly.

Fai~ure to perform these checks every day before you ride may r-es,ultin:.oolant ., No COQlantleakage,., ." .. '. ,. .,'.. . i colo)

sanous damage or. a: severe accldent, Coolant level between level hoes (wh.en engme IS co .

·~~~~~~~~~~~~~~~~~~~~~~~~~~~~~='ectrl~1 e~uip~6nt All lights and horn work.

Fue~ Adequate supply in tank, no leaks. Engine stop switch Stops engine. '. ' .

Engine Oil Adequate supply in tank. SIde and center sjanda . ..(. , '." ..

Tra n S· mission 0"1'1 Oif t ve I b k~," I·' oJ j' I' _" ,., w.... R·' etu rn to . th eir 'fun"" up' p oSition by spnng tenston.

, , " .•. ,:t). .• ., , t ('Cl"0;;; 'elVVsen eve' Ines: 1

TIres AI'f p' '( h Id R.· .stum sp rin,gs. not weak Of not da,mag:ed .

. ' . . · .. · .. ··....................Jessure wen co:

Front 20.0 kPa (2.0 kaflcm2)

Install the air valve cap.

Drive chain Slack 30 - 40 mm .

40 MAINTENANCE AND ADJUSTMENT

MAINTENANCE AND ·ADJUSTMENT

MAiNTENANCE AND ADJUSTMENT 41

··leriod;c Maintenance Chart

•

ThrottIegnp play-cheek t

The maintenance and adjustments outlined in this chapter areeasHy carried 0. and must be done in accordance with the Periodic Maintenance Chart to keep tl motorcycle in good running condi ion. The initi.al maintenance is vitaUy impc tant and must not be neglected.

If you are in doubt. as to any adjustrnent or vehicleoperation, pll!:a'S6 ask v~.

E'llhorize4 Ka~asakj dealer to check the ~otorcyde. ~o~p:er:~:jc:n~~~~~~~~~~~~~~~~~~~~~~~~~~~

.~Iease. note that'K~wasaki cann?tassumea.ny respcnsibility for damage resu- oa ur~ and carburetor Ing from Incorrect mamtenancs or lrnproperaejustment done by' the owneL - 5yn~rO~izat;on-'Check t

~====~==~+---4-~~~--T--r~--~:I . Idle speed-check t

Spark plug-dean and g.ap t

WhleheJjler See
comes + 'Odometer Reading, Page
first km Ie 1000
+
I 30
Every 1 5 I it) 2.0 25
• • • 61
• Q e' .' 67
'. • • , • 61
• • • • • 55
• ' . '. • • 57
• • 58 KAirsuction valve-check t

Air cleaner element -clean t#

42 MAINTENANCE ANO ADJUSTMENT

MAINTENANCE AND ADJUSTMENT 43

Whh::he,vGr comes first

Se. ·OdometerReading

- km :I: t.oeo P,agl

Whichever comes firsl

Every

5

10

15

20 2'5 30

See 'Odometer Reading Page

km )I 1000

10 15 20 fa ., -
Operation E ... lluy • • • '0 I
I
K Brake hose, connections • .. • • • 90
-check t • •
Clutch-ad just • • • • • • K Sleeri ng-G heck t • • • • • •
,
Battery electrolyte 6 mon.th • • • • • • 84 t# -. • • • • • 73
level-check Drive chain wear-check
-
Brake light switch-check, t • • • • • • • 79 KNut. bolt and fastener • • ~ .' •
Bra~e pad wear-check t# • • • • • 76 • • ., • • • 82
Tire wear-ch-eck t
fluid level-check t month , 71 , • • • i 49
Brake • • • • • • Transmission oH-change# 6 months I • •
.
K Brake fluid-change 2 years • 78 t • • • 44 MA!LNTENANCE AND ADJUST,M'ENT

MAINTENA.NCE AND AO~lISTMENT 45

~.-------------------,.-------~~--------------------~--~

• Whleh.v~r

Whichever comes fir '

Operation

Every

1

5

~Od~metei' Readin-g

km x1(JOO' See Page

flnt

*OdometerReaciing See km )C 1000 Page

Operation

30

20

25

10

15

1

Every

56

'K: Should be serviced by an ,authoriLed Ka'lJasaki dealer.

,. : For higher odome:~el" readinqs, repeat at the frequency interval es,labHshed here.

t Replace. add, adjust. clean or torque if necessary.

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

high speed. or frequent staringlstopping.

52

46 MAINTENANCE AND ADJUSTMENT Eng,ine Ol

Do not use ordinary motor oil, transmission oil, or an inferior Jade of oil as a replacement for the proper oiL The use of improper oil will lead to eng'ine trouble.

Ine t;!ngine 011 tank is located In the left sloe COV!3-L

Adding Oil

• Remove the left side cover.

Check the engine oi lev I

~ Before you run of oil. add oil. It will

take abou 1.2 L. .

o Since mixing d,fferent bra ds of 'oil oeterioretes th tubricetive roperties of the oil. always add oil (2~stroke engine oil which is recommended for JASO Fe class) only of the same brand as is a/read in the tank.

B .. Engine au Tan Cap

41

If the engine oil 9 ts eX"femely low, e.ngine oil leve warning HghtW come on and stay on even inany gear. In his case,

nd the engine oil asoonas posstnle ..

If the engine is run without the engine oil. it wit! be severely damaged. If the 'oil tank is eomplet,el'y dry, a _ d the o.H~n,d bleed U e ai from· heol! line by a Kay, asakl dealer.

48 MAI'NTENANCE AND ADJUSTMENT Transmlsston ,on

In order for the 'transmission and clutch to function property, maintain the transmission oil at the proper level, and change the oil in accordance with tha Pericdlc 'v1aintenance Chart

Motorcyc~e operation with insufficient. deerioratad, or centamlnated engine oil \l ill cause accel-

erated wear and may result in eng'ine or transmtsston seizure, acc'idttn~! and injury:

Oil Level Inspection

.' if the oil has just been changed, start the engine and run it for several min-' utes at reHe speed. Stop the engine, then wait several minutes until the oil settles.

f

• ;If th~ motorcycle has just been usedlo 11lhe olt Ievel is too high~ remove the w~it several. minutes for aU the oil k . excess oil-through the 011 filler opendrain down. . ; iog using a syringe or some. other

• Check. the oil level through the oj suitable device. .

level gauge. With the motorcycle. If the oil level is too low, add oll,to held iAvel, ti;,,:; :Jil' le .... e! should "orne reacrr the correct leve~ !J!:ie t~e up between the upper and lower l.eve. same type and brand of 011 that IS

Imes next to the gauge. already in the engine.

MAINl1!NANCE A.ND ADJUSTMENT 49

A. Drain Plug

IJ Let the 0(1 'completely drain with the'motorc'Yc'le perpendicular to the

ground.

Motor aU ts toxic. substance. Dispose of used 011 p~op~~ '1. Contact your local autnont1es for approved disposal methods

...

. Oil Chancre

• Warm up the engine thoroughly1and

then stop it. .

• Place an oil pan ben-eath the engme.

-Remove the lransmission oil drain plug at the right engine cover lower_ portion,

A. Oil Lev.el G.auge ' e. Upper level Line

c. lower level tine D, OH FBler Cap

so MAl Nre,HANCE AND AO.JUSTMENT

• Install t~e. drain pJug with 'its gasKet.

TIghten It to 'the specified torque.

N,OTE

OReplaoe the damaged gasket with a new onf?

., ~ifI th~ ,engine up to the upper level line Ith a good quality motor oil specified in ttJe table.

• Start the engine,

• Check theolf levet for oil ieakage, Tfhten~1"I9 TOfqU~

Engine Drain Plug:

20 N'm (2 .. 0 kgi'm)

, Type: API SE, SF or SG

. API SH or SJ with JASO MA Viscosity: SAE 10W-40

SAE2DW40 '

T~ans mission pU Cape cily'

Capacity: 0.7 L

·20

o 20 30 40 fc)

68 86 104.;oF)

{when Qil is drained]

0.81 r-

[when engine rs c~mpjetsly , dry]

Although 1 OW~40 engIne oil is the recommended oil for most condl nons. the oil viscosity may need -to be changed to accommodate atrno spheric conditions in your riding area.

·4

MAINTENANCE AND ADJUSTMENT 51

Cooling System Radiator:

Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a stream' of low-pressure water.

----------_.- ------

C -UTION

Using high~:pressure water,as f'rom a car wash fadUty. could dam~ge the radiator fins and lrnpa.ir t.h -e radir. tor's ,effectivenes,s. Do not obs,ruct or deflect atrflow through the radiator by installing unauthorized acces-

. \' sorles in front of the radiator or behind the cooling fan.lnter~

(erence w,jth the radiator airfJow can lead to overheating' and eon-

sequent engine damage.

52 MAINT5NANCE AND ADJUSTMENT Radiator Hoses:

Check the radlator hoses for cracks or deterioration. and connections for looseness in accordance with the Periodic Maintenance Chart,

Coolant:

Gool;::m~ absorbs: El'l(ceSSIV€ heat frc.:n

neengme and transfers it to the air at the radiator. If the coolant level becomes low, the er:'gine overheats and may suffer severe damage, Check the coolant level each day before riding the motort.J,~le, and replerusn coolant If the level is low. Change the coolant in accordance with the Periodic Maintenance Chart.

Information for Coolant

To protect the cooHng system (conSisting of theatuminum eng:ine and radia.to,r) from rust and corrosion, the use ofaorrosion and rust inhibitor

MAINTENANCE A.ND ADJUSTMENT 53 CAUTI,ON

chernlcals in ,t~~coolant i~ essential. ~ CAUTION

?o~t~nt contal.nln~ .corrosion andru. If hard water is used In the sysinhibttor c~emlcal;, IS ~?t used, over i tern it causes seale accurnulapenod of tIme,. the coo/mg. systema~, tion' in the water passages, an~ ?umulates rust. and seal,e In ,the w~'e: considerably reduces theefflJacket and radtator. This Will c/o~ ~ .. ' .. ... fth:! ccoHng system.

the coolant pGssages2nd ccn&ideJ clancy 0 .. . ..

ably reduce the efficiency ofthe cuolirli If the lowest ambient temperature ensystem. :r ounte ed fatls below the freez.ing poi~t ~f water, use permanent antif~eeze I" . he coolant to protect the cooling sysUse coolant. containing cerro- ~1emagalnstengine and radiator fre~ze

ion inhibitors made specifi,caJly -up, as weUasfrom rust andcor~oSlon. for alumlnurn engines and ra ... : Use a permanent type otantifreeze diatorsin ·accordance with the (soft \J aterand ethylene glycol p:lus corinstructions of the manufacturer. rosion and rust inhibHor chemicals for Chemicals are harmful to the bu-alumloum eng'ines and radiators) in the mari body. ~ cooling system, On the mixture ratio

'-----------,---,----,; of coolant, choose the suitable one re-

Soft or djstiUed water must be useGferrlng 10 the relation between freezing with the antifreeza (see below for all-; poirrt and strength directed on the con-

tlfreeze) in the coo.ling system. lainer.

Permanent types of antifreeze on the market have anti~corrosio~ andantl-rust properties .. \l\Jhenlt is diluted excessively,. it loses jts ;nU~c.oroSionropp.rty. DHllte. a permanent type of ~ntifreez,e In accordance with the instructions of the manufacturer.

NO'TE

o A permanent type of antifreeZle is instal1ed in {he cooling system when shipped. It'is colored gre~n a~d contains ethylene glycol. It ,IS mfx~dat 50% and has the ireezioq pomt of -35~C.

Coolant Level Inspection

• Remove the right side cover. ..

• Situate the motorcycle so that It IS perpendicular to the around.

54 MAINTENANCE AND AOJUSTENT

• Check the coolant level through the coolant level g,auge On the reserve tank. The coofan level should be between the Hand L lines.

. ~

NOTE

a Check the level when the enoine is'

¥' - -.

cota (roorn 0fa:mospnenc rempera~ ture.)

A. Reserve Tank

B. H line

C., L Line O.Cap

Of

, IN.TENANCE ANOADJ\JSTMENT 55

~----------~~~- =

• If the amount of coolant is inSufitt·_---C...:...'.-A-U-.- ..... :'I-:-O-N- ... ·--;-:z:-::;-l cient, remove the cap from the ii', If coolant must be added ,of .. serve tank and' add coolant throug ten or the reserve tank comthe filler opening to the H levelline.ttPletely runs dryt there is pr~ba.

• Instal,1 the ,~ap. . ~ blylea,kage in the system. H.ave

• InstaUthe nght s1de cover, the cooling system inspecte~

by Y<;lur authorized Kawasd!t; dealer.

NOTE

a 'nan emerge'!cy you can add wOl

ter alone to the coolant reserve tan 'Coolant Change .

however it must be returned to thi' Have the ecotant changed by an aucorrect mixture ratio. by the additio'fhorized Kawasaki. dealer.

of antifreeze concentr&te as Soon a I ..

possible.

~

,

.

Spark P,lug. ... .... I .' .

The standard spark plug IS shown In

the table, The spark plug .should, be taken out in accordance with the Periodic Maintenance Ch~rt for cleamng, inspection. and resetanq of the plug gap.

Maintenance .

If the plug is oily or has ca bon bu!lt up on it, have it cleaned, preferably In ,8 sand-blasting device and then clean off any abrasive partic~es.~h.e plug may also be cleaned ~slng Clh!gh flash -point sOlvent,and a wire .brush or ~ther suitable tool.' Measure the gap wlt.h a wire-tvpe thickness gauge, and adjust the g~p if incorrect by bending the outer electrode. If the spark plug ~Iectr?des are corroded or damaged, or IJ the msulator is cracked, replace the plug. Use the standard' plug.

56 MAINTENANCE AND .ADJUSTMENT

A. !J.7 - O.B mm

Standard Plug NGK 89ES 1
Plug Gap 0.7 - 0.8 mm
Tightening .
Torque 27 N'm (2.8 kgf-m)
I MAITENANCE AND ADJUSTMENT 57 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 reh,..;-ning l'lspect. the; :':"!':' stJf't;-:-.I"1 '.1?iVf:!S in accordance with the Periodic Main~ t.enance Chart. Also, inspect the a'ir suction valves whenever stable idling cannot be obtained, engine power is greatly reduced, or there are abnormal engine noises .

. Air suction \.~Ive removal and inspection should be done by an authorized Kawasaki dealer.

awasakiCeanAir System

a Fit the plug cap securely onto The Kawasaki, Clean Air System

spark pfug. and pull the cap lightly CAl isa secondary air suction sysmake sure thet it is properly install . m that helps the exhaust gases to

r- -Ium more completely. When the spent

I ' CAUTION uel chsrge is released into the ex-

i------- _ aust svstern :t 1":' still .......... ':"'0110[1 to

. ,. _ .. __ • __ ,; b -i \ __ '_1 '1"'"' _ - ,~.,. ;l":_J~ ,.;.~. u ,,",'

For cold weather andlor lowum. The KCA System allows extra speed riding, a honer spark pl'ug. ir into the exha;ust system so that the show~ in the table may be used' pent rueJ chilrge can continue to burn. for quicker warm-ups and more, ,is continued burning action tends to

. efficient engine operation. How- urn up a .great deal of the normally eV~:~1 fo~ normal temperatures ,n~~u~ed gases,. as well as c~anging anchor high speed use, the stan- slgnrfic.ant portion of the potsonous

,-,dard .. spark p .. lug mu. st ... be used to .. rbon.m0('10Xide into harmless carbon

L?revent engine damage.. ioxide..

- - -- . -- - - --

NOTE

Hotter Spark Plug'

SSMAiNTENANCE A~~cO ADJUS, E

Air Clen. r

A clo9g'e air cleaner restricts the engine's air intake. increasil19 fuel consumption, reducing engine power, and causing spark plug fo,ling.

The air cleaner element mus be clear-ad in accordance wifh tbp P,eri. OdIC", laintcr.ance Chs -t. In dusty areas, the element should be cleaned more frequently than he recommended ioterval. After rloing hrough rain or on rnu dy roads, the element should be cleaned Immediate!iy. The eierne t should be replaced if it is dam-

aged. .

Elem9nt' Removal

• Remove the 'eft and righ side covers.

emove the seat.

Turn the fuel tap le fer to the "OF, Take oft the fuel hose from he

. '.

tap.

e· Remove the fuel tank mounting'

A. - el 1 ank B. Boll

Disconnect tne leads. under th fuel . tank.

Remove he fuel tank.

I Unscrew the a cleaner hotJslng cap screws and ~ake out the air cleaner

I

hou'&ing cao.

I .AJ' .TEfJANCE AtiD ADJUSTMENT 59

A. Air Cleaner Housing Cap S. Screws

4 Remove th element

50 MAINTENANCE AND ADJUSTMENT

A. iElemen.t

• Put a dean, lin -free towel over the air cleaner housing to keep dirt or other foreigf'l material rromentering.

• Inspect the element material for damage. If any part of he elerneru is damaged, the ·element must be replaced.

"MAINTENANCE AND AOJUSn,'ENT ~1

Throttle Control Cable

. The throttle control cable is actually an assembly of three cables: the throttle cable, the carburetor cable, and the oil pump cable. The throttle cable runs from the throttle grip to the cable 85-

. I' ... . -~~ it connects ,... :;crlI0'y Jur.::::\·on ..... r,;;;.'·o, . If' ........... ~ ....

both the carburetor cable which leads to the carburetor, and the oil pump cable which leads to the oil pump.

Cable stretch will cause delayed engine response and upset the 011 p.um.p synchronizatien, necessitating. periodi G adjus rnent. To compensate for cable stretch, -adjus~the throttle cable and the oil pump cable in accordance with the Periodic Ma!ntenance Chart.

L

DrY the element with comprE!ssed' air or squeeze 'it

After clea,ning. saturate the element with2-stroke oil or -higtl..-qua lity foam • .air-filter oil, squeeze out the excess oil. then wrap it ina clean rag and

-------------Ili- squeeze it oS dryas P05Slui€::. Be careful not to tear the element.

f dirt or dust. 1'$ allowed to . througih into the carburetor throttle may becomestuck, siblyc,a.u ingaccident.

CAUTI,ON

If ,dirt gets through into the e gina, excessive engine Y,."earan possibly engine damag:e wiu O( cur ..

CI~an "the element ina well ven- I tilated area, and take care that I 'there are no sparks or flame any- I

NOTE .' w~e~e near ·the. wor~in9 are,a; I

• .. .< . , ~ this Includes any appliance With

OElementmstallatlOn is perfor~edl a pilot lig.ht. Do not use gaso .. II

the rev,ersef!rde,r o{ r~moval. line Of a lowflash-polnt solvent

o When mstallmg the ctJr cleaner ho fo clean the element. .A fir or ing cap, fit it in the housing proper. explosion could result.

Element Cleaning

• Clean the element in a bath of a ..

flash lnt solvent.

62 MAINTE ANCE ANO ADJUSTMENT ThrotUe Cabie:

Inspection .

• Chacko see tha he outer cable ends of the throttle and carburetor cables are u'l'ly seated in each cable adjd:dHf

Check tha t:'e safety clip at .the lower end of he ca-buretor cable IS in place.

Check the thro tie cable :. lay. "Jhen hghtly turning the t..,rottieGnp t~H; grip shoulc hav6' 2 - J rnrn of play, I: the throttle cable has improper pia adjus it.

•

Adjustment· f NOTE

o Loosen the locknu on the uppere' . If he thro .. Ie ... np play cannot be ado e throle cable, and tu n the a' iLJsted with the sciuster at the ttrottte jLster until 'he proper a ound of thl': ·cab'e. Use tre c~rb(Jretor cable adtIe grip play is. ob ained T,ghten ~~ Juster at I-Je cerovretor After com-

loc nut. pletion of the adjust/lent. tighr,en the

\ lOcknut.

MAJrHENcANCE AND ADJUSTMENT 63

A. Carb-uretor Cable . C. Locknu.

B. Adjuster D. Sa.fety Clip .

• Check the oil pump cable .

Oil' Pump ca~!le:

lnspection

• Warm up the engine. and check tne encina idling (see the Carburetor

....

section)

.' Check. the throttle cable

64 MAINTENACE A o ADJUSTMENT

.• Unscre feengine sprocket- cover

bolts, and remove the engine sprocket cover.

A. Engine Sporocket Cover ,8. Bolts

• Unscrsv t <6 oil pump coyer screws, and remove the oil pump cover.

8. Adjust~r

•

• Check. 0 see that the outer cable e~' Chec to see that the tang on th?

o the oil pur~p cable is fully seats oil pump lever is bent to ~old the Oil

the cable adjuster. < pump in er cable.

'. Turn the tnrot le grip 'ully, and check to see if the 5 nchronizaticp mark on ;. the pup lever aligns 11th he mark on , the lever stop.

E ANO- OJUSTMENT 65

MAiNTENANC' -

NOTE

a The pump iever has tw.o "!Brks 01,1 it. One is the synchromzatlo~ mer« which is used to cheCK the 01/ ~ump synchron;zati~n. ,end the othe~.'s th~ idle mark INh/Ch IS to used dUring OIl

p mp s..'t·f1~hrorjizatjon. .

A. Mar" on Lever Stop e, l,dleN Lark.

c. Synchronh:atlon Mark

.66 MAINTENANce AND ADJUSTMENT

• The syocluonizatlon mark and the lever stop mark should be aligned. If they do not line up. adjust the ojl pump cable as follows. .

Adjustment

• ' '"'f'icop ,.~ ..... =11 .p .. 1'""'- ." ;;-!"-,',e :"IoJ': rster

-~..., , ~, ~ "-' . - •. 'I'-' ............. co ,",. . ....

locknut, and turn the adjuster to synchronize the pump with the carburetor. .

MAINTENANCE AND AOJ,USTMENT 67

., Tighten the locknut. and check arburetor -

pump .svnchronizetion, Readjus!. The idle speed should be performed necessary. . n accordance with the Periodic Mainnance Chart or whenever the idle peed is disturbed.

~:ijustmo ... )t _ .. . .

• Start the engine, and warm it up thor-

. oughly ..

t. Adiust the idle speed to 1 400 ~ 1 sao rtmin (rpm) by turning the Idle

adjusting screw.

-

t

.1.

t

>

A. Idle Adjusting S·crew

o Open and close the thronte a !ew times to m~ke sure that the. tdl~ speed does not change. Readjust I

necessary .

• With the eng.ine idling, turn the handlebar. to each side. If handlebar movement changes the idle speed .. the throttle cables may be improperly af:Jjusted or lncorrectly routed, or they

68 MAINTENANCE AND AOJUSTMEN

__ may be damaged, Be sure to correct any of these conditions before riding.

Operation w:ilh damaged cab'-es-couldresull In an un a.fe riding co n ci i ti 0 n,

MAIN, ENA ce AND ADJUSTMENi 69

_Turn the adjuster so that the, clutch lever will have 2 -3 mm of play.

Be sure the upper end of the clutch OlJtpr cablets fu!ly se-ated In its fitting, or it could slip into. plac later. creating enough cable play to prevent dutch disengagement, resulting in a hazardous i-idi;ng condition .

Clutch

Due to friction plate wear and c cable stretch over a long period of the clutch must be adjusted in a--""'·-'· dance with the Periodic Mainten.a Chart.

avoid a sericus burn, never touch a hot engine or exhaust pipe during clutch .adjustment.

• lighten the locknut.

• If it ca nn ot tk done I use the mounti ng nuts at the lower end of the cable.

Inspection

• Check that the clutch ',ever h~s 2 _ i .r I'f it does not, adjU~t the lever playas

mm of playas shown 10 the figure. ~ follows. .

t Adjustment.

, • Loosen the locl(nut at the clutch

lever.

70 MAINTENANCE AND DJUSTMENT

A. Mounting Nuts

NOTE

o After the eajusiment is made, start the engine and check that the clutch does not slip and thet it releases

properfy. 'f

o For minor corrections, use the etijuster at the clutch lever.

Drive Chain Rotate he rear wheel to find the po-

The drive chain must ilion where the chain is tig.htest. and

adjusted, and lubricated in accordan measure he axirnurn chain slack with the Periodic Mafntenance Cha 'i rtulli g! up and pushing. down~e for safety and to prevent excess! '""chain midway betvlJeen the engme wear, ff the chain becomes badly w 7' procket and rear wheel sprocket.

or maJadjL:sted- €ither too loess i''''gS~E~~I~ too tight - the chain could jump off rt

sprockets or break.

. A chain that breaks Jar jumps, the sprockets could snag on the ,engine sprocke,t or lock the re' wheel, severely damaging the motorcycle ad causing it to· go out of control.

MAINiEN:ANCE AND A.DJUST ~ENT 71

Drive Chain Slack

I Standard _30_-_4_0_m_m ~

Chain Slack Adjustment '.

Loosen the teft and ng.ht chain ad-

juster locknuts.

A. )lIe Nut C. Adjusting Nut

B. Cot~er Pin D. Locknut

• R.emove the cotter pin, and loosen the axle nut,

12 MAIHTE 'CE .AND 'ADJUSTMET

• If the chain 's too' loose, tum in the left and right chain adjusting nuts eenly.

• If .the chain is too tight. turn out the left and right char' - adjusting nuts evenly, and kick t Ie wheel forvvard. Turn in both chain adjusti!'lg nuts p.v~niy unrti !or::: c~, :: chai:--' has the correct arnoun of slack. To keep the chain and wheel properlyali.gned, the notch on the lef wheel alignment indicator shouldal gnwith the same swing,arm mark that the right indicator notch aligns w;~h.

< ..... " ........ ".ignmenl of the wheel , in abnormal wear, and ,ay i:nan \Jnsafe rid:ing condi-

n both chai .' adjuster locknuts. , ...... t ... '" the axle nut to the specified

Axle Nut.

88 N·m (9.0 kgf·m)

NOTE Rotate the wheel, measure the chain

o Wheel alJgnment can also slack again ~l the tightest position,

c~ecked using the 'straightedge ~nd readjust If necess,ary. . . . ..

strin.g method, " insert a new cotter pin through .t~e

axle nut and axle, and spread Its

MAINTENANCE AND ADJUSTMENT 73

f theaxlc" nut Is not securely tight.ened, or the cotter pin is not Installed, an unsafe ri'ding condition may res It.

If~ear tnsoec ior.

• Stretch the chain taut. either by using the chain adjusters, or by hanging a 1,0 kg Vi eig.ht on the chain,

• Measure the length 0 20 links on t.he straight part of the chain from pin center of the, t st pin to pin center of the 21, sf pin.' Since the chain may wear unevenly, take measurements at several places.

74 MAfNTENANCE AND AOJUS,T~ENT

e. Weignt

• Iftbe length exceeds the service limit

the chain should be replaced. - '

1

DriVe Chain20-!-ink Length

Service Limit 323 mm

For safeiy, use only the stan chain. .. Have. It. lnstalted by authonzedKawasaki dealer .

• R?tate th~ rear wheel to ,inspect drive c~a1nfor damaged ro lie rs, loose prns and iinks.

• Also inspect rhe sprockets evenly or excessively worn and damaged teeth.

,. If there is any irregularity, have the -drive chain and/or the sprockets replaced by an authorized Kawasaki dealer.

NOTE a Sprocket wear is e'xaggerated stailation. See Service Manual wear limits. .

Lubrication

lubrica ion 15 also necessary after riding through 'rain or on wet roads, or any time that the chain appears dry. A heavy oil such as SAE90 is preferred

MAINTENA'Nce AND ADJUSTMENi 75 to a lighter oil because it will stay on the chainlonger and provide better lubrica-

tion.· .

• Apply oil to the sides of the rollers so

that it will penetrate 0 the rollers and bushings. Wipe off any excess oil.

SPi:IDCKET

elf the: chain is especially dirty, clean it using diesel oH or kerosine and then a.pp\)'oH as oescnbed above.

76' MAINTENANC'EANO ADJUSTMENT Brakes

Brake Wear Inspection

In accordance with the Periodic Maintenance Chart, inspect the brakes for wear. For each front and rear disc brakr:' caliper, If the t ickness of eithe~ pad I~ less than 1 rnrn, replace both p=~~ ;j, the caliper as a set. Pad re~Iacement sho~ld be done by anauthonzed Kawasaki dealer.

A Ttl I ckness

B. lrrm

C. I nsu later

MAINTENANCE AND ADJUSTMENT 77

A. R'earBrake Fluid Reservoir

B. Upper leveJ Line

C. tower l,evel Une

.' If the fluid level in eIther reservoir is lower than lower Ie-vel tine, check 'for fluid leaks .i n the bra e lines, fill the reservoir to the upper level line.

DIsc ,rake F,I,uld: ,Leva1lnspection .

In accordance with the Periodic The brake fluid level in the reservoir

tenance Chart, 'inspect the brake must be kept between the upper and

level in both the front and rear blower fevellines (reservoir held hori-

flu~d ~eservoirand change the zontal).

flwd. The brake fluid ShOUI;adl:a~;I:~SO~JI;~~~1~~~~~~~~~~

changer! jf it becomes cents

wi h J!n or water,

Fluid Requirement

US.e ~eavy-duty brake flu:d onlY, a cont-B.lner marked DOT3.

CAUTION

Do not spUi brake fl-tJid Ol1to any ,

painted surfaco.

00 not us'efJuid from a coniain,er L ---------that -has been left open orth, ;"t; 4. Front Brake Fluid Reser.voir

h Q B. lower Le~el Line I

:.3:& been unse,aled for a long~' c. Up~r Level Lie

tmle "

- . t

Check for fluid ieakage around I th<! fittings.. ,

Check brake hose tor damage ..

7B MAINTENANCE AN ,6 ADJUSTMENT

Do not mfxtwo brands of brake flu:d. Change the brake fluid in the brake line completely if the brake fluid must be refiHed but the type and brand of the brake fluid that is a lire ady in the reSf!r,~

L voir are unidentified. .

Fluid Change ,

Hav~ thebrake fluid changed by an authorized Kawasaki dealer

Front and Rea,r Brakes: '

.' Disc and disc pad 'ear is automatIcally compensated for and has no effect on he brake lever or pedal action,

MAINTENANCE AND ADJUSTMENT 19

A. Brake Pedal

S.10 mm

. !3o there are no parts ,that require Light Switches . "

justmant on the front and rear bra When either the front or rear brake IS . ,.'. , the brake light goes on. The

, br~;ke li.ght. switch requires noad-

If the brak'e lever or pedal f'.·, ' " bu1,the re~r brake lights~it?h

mushy when it is applied, t~ere-', 10 ~e .adJus~e.d In :ccordance with

'mif'lh40 I-e a:r in th-, .... b ,j ,'. .,.. ~"1(3 Periodic M~t;"ena,.C(3: Chart, .

. .;0 .. ~ ""1, ',.... raKe unes , . - ..' .

o~ the, ~rake may be defective. Inspec.tion .

Slnca It IS dangerous to opera;te • Turn the ignition key to "ON',

t~~ motorcycle under such eon-, The brake. fight should go on when

?,t.ons! .have the brake checked the front brake is applied.

Imm,edla:tely by an auth'orizedee If it does not ask your authorized Kawasaki deal'er. ' ( Kawasaki dealer to inspect the front

brake 1,lght switch.

• Check the operation of the rear brake Ilgh swi en by depressing the brake pedal. The brake light shouldqo on after about 10 mm of pedal travel.

• If it does npt, adjust the rear brake light switch~

AdJustment - ,.,

• To adjust the rear brake light switch,

move the switch up or down by turning the adjusting, nut

SO' MAINTENANCE AND ADJUSTMENT CAUTION

To avoi~ damaging the electrica~1 connec~lons inside the switch, be sure that the switch body does not turn durrng adjustment.

A, Re;ar B·ra.ke light Switch S .. AdjustiMgNut.

c. Lights sooner

D. Ugh '9 later

fJI.'AINTENANCE AND ADJUSTMENT 81

• MaKe sure that the air valve cap is securely installed.

Rear Sho k Absorber -

. The rear shock absorber can be justed ~Y ch~n.ging the spMng pre]: .eS: f?f ,vanous rJdr~g an~ loading co .. y/oada'nd nre Pressure

tl0~S. If ~he spnng action feels too s=lFailure to maintain proper inflation ~r [,?o stiff, have it adiusted by en ~ essures or observe p.ayload limits for

mon7('.-II(·;H··..,,-aK·· '- "I' . .' ' f~'"

-- .... i.""_ ........ ·, ,!olea cL ur tires may ad'lt#lssly a leet nal~~

ing!and performance of your motorcyeand can result in loss of control. The . '.:aximum recommended load inaddi.n to vehicle wei~ht is 1~50 kg includlng rider, oassenser, bagg.age, end ac-

.tessories_

:-Remove the air valve cap.

,;. Cfieckhe tire pressure often, using

~ an accurate gauge,

~

N,QTE

.0 Measure the tire pressure when the tires are cold (that is, when the motarcycle has ;je! b~e" rlrja~11 " If}! t;' than a mile during the pes: 3 hours).

o Tire pressure is affected .by changes in ambient tempe'rature and. altitude . . and so the tire pressure should be ohecked and adjusted when },our riding mvolveswio'e variations In tern. pe-rature or altitude.

82 MAINTENANCE AND ADJUSTMENT

A. Tire Pressure Gauge

Tire Ai,. P,essure (when cold)

Front -
: I 220 kPa (.2.0 kgf/cmll)
Rear 225 kPa (2.25 kgfJcm2)
I TIre Vvear: Damage

As the tire tread wears dov n the tiro becomes more susceptrota .0 punctur;

and fai,lur,e. An' accepted '"" ...... - .... 1.~00!'!:'1I'!~~~~ that 90% of alt jre failures occur

the last i 0% of tread life (90 %

So it is falseeconomy and U' use the tires until hey are bald. • In accordance with the P

.taintenance Cha.rt,. rneasui e

depth of the treac with a gauge, and replace any tire

has worn down to the minim lowabJe tread deph,

, , th

Front 1 mm t f k

t-----t------~-_I' Visually inspect the tire ror craci s

Rear 2 mmand cuts, replacing~he ti:rei~case of

bad damage. Swellmg or hIgh spo s

. indicate internal damage, raqumnq 're replacement.

Rem011e any ~mbedded stones or other foreign particles from the tread.

MAINTENANCE AND ADJUSTMENT 83 NOTE

o Most counters may have their o~n regulations requiring a minimum tire thread depth: be sure to follow hem.

o Have the wheel .baJance inspec eo whenever a new tire is installed .

'T'~ lensure:- safe handling and stability, use only the rec~m~ mended standard tires for rei. placement, i.nflated to tne stan .. dard pressure.

Front gO/gOP 17 M/C 495

Rear I

84 MAINTENANCE AND ADJUSTMENT

New tires are slippery and may cause loss of control and inJ'ury .. A break .. in . period of 160 km is neeessary to estabtlsh normal' tire traction. During break-in, avoid sudden and maximum bra,king and acceleraUon, and hard cornering.

'Battery Battery Electrolyte Levet tnsoectkx

The battery electrolyte level m kept between the upper and lower lmes, Check the electrolyte I . each 'cell in accordance wi h th~ odic Maintenance Chart,

• Remove the battery from the cycle' (see Battery Removal).

• Check that the electrolyte I each ceIl is between the upper lower !evej lines.

• If the elect.folytelevel Is low in cell. fili with distilled water as

• Remove the bettery filler caps fill with diStilled water until the trolyte level In each cell reaches upper level line.

Add only disti.lIed water to thoe batte.ry. Ordinary ta? :-vater rs net a substitute for~lst~Ued wa- . I ter and will shorten tne life o~ the battery.

C. tower le el

CAUTION

AI.NTENANCE AND ADJUSTMENT 85 Battery Remov~/' , ...- _

Remove the nght side cover ...

., Take off the fuse case holder from the

battery ca.

A. Fuse Ca.se "1~lder

. Take off the turn signa.l relay from he battery case.

86 flAlNTEN Nee AND AOJUSTM:ENT

A. Turn Signal Relay B. Battery Band

• Unhook the both end Of the battery band from the battery case and take out the battery cap. '

• Disconnect the leads from the batery, first from the (-) lead and then the (+) lead.

A.Batte B. (+) Lend

" Take the battery out of the case ..

• Clean the battery using B baking soda and water. Be sure the lead connections are clean.

Grease

Put the battery in the batter ~se. Route the battery vent hose IS ke~t away from the drive. system and ex-

sust system. " , .

Put the ea ., eri cap on the battery and hOok the battery hand on the battery

Co~'ect the white/red lead to the (+) terminal lead, and then connect the

Battery Installation

• Put a tight coat of gre·ase on the minals to prevent corrosion.

lIAI,N1"EN NeE AND ,ADJUSTMENT 81 black/yellow lead to the (-) terminal lead.

---=----C-A--:U=TI:-:-O-:-:N ---1

~J'ake sure the battery ve.nt hose is Kept away from the cl;-Ivesys .. tem and exhaust system. Battery electrolyte can corrode a.nd dangr usly weaken t~e dnve system. Do not let t~e vent hose become folded, pmched,

. m elted bv the exhaust sys,or ,""', " , 'U

tam. An unvented batte:ry, WI .

ot keep a, charge and Itm3)" crack frorm bunt .. up gas pres ..

sure.

Reinstall the removed. parts

a8

rNTENANCE AND OJUSTME.NT

JNTENANCE AND ADJUSTMENT as

. HeadUgt Beam Horizontal Adjustment

The headlight beam is adjustable ho~zonafly. If not properly ad1usted h.onzontally, the beam well point to one side rather than Sfraight Ahead.

Tum the huri..::ontai adjuster ln or out until the beam points straight ahead,

Vertical Adjustment N'OTE.

The headlight bea- is adjusb~ high beam. the brightest, point

tically. If adjusted too low, n In· ,.>:ir-I'ir .. k", . be slighrly' below honzontaJ

nor high beam will iIJuminate the the motorcyde on its~hee/s ~nd

far enough ahead. If adjusted to~ ',. rider seated, Adjust the headlight

the high' beam will fall to iIIumiiiat.e 0 thl? Jl''C~''2r anr1e a~cording totocs!

roar' close ahead, and the low regufations.

will blind oncoming drivers.

Turn the vertical adjuster in or adjust the headhght vertically.

Fuses

Fuse case and spare fuse are loca~ed

on-the battery cap. 'If a fuse fails dunng operation, inspect the electrical system. to determine the cause, .and then ew place it with a new fuse of oroper am-

A. iFtfSe Case

S. Spare Fuses

A. Horizontal Adjustcer

00 not use any substitute for the

standardfuse~ .

F~~~:~~'~~j~n of rnorstere or ~'Ieaning: Your Motorcycle Iment in thefue·1 system will res eneral Precautions

the flow of fuel and cause earbo Frequent and proper care of your malfunction. The system should vaseki motorcycle will enhance f'h7cke~ ir. aceo dance with the F . ~ppear3nc.; optimize 'Overall p.erodic Maintenance Chart. ormance. and extend its useful I~fe. . Inspection and cleaning shf; "'0 ering your motorcycle with a high be done by an authorized Kawa alfty, breathable motorcycle cove. dealer·ilI help protect its finish from harmful " V rays, poltutants, and reduce th.e -mount ofdust reachiilg its surfaces.

'n Be sure the·engtne and exhaust are t cool before washing.

r Avoid applying degreaser 1,0 $ea!s.'

brake pads, and tkes. .

Always use non-abrasive wa; and. cleaneripollsher.

Avoid all harsh chemicals. solvents, dHterg.ents. and househofd cle·aning products such as emmonia~based window cleaners.

I

,

I

MAfr-.nEUANCE AND ADJUSTMENT 91

o Gasolinel ·brake fluid, and coolant viii damage the finish· of painted ~nd plastlc surfaces: wash them off Im~ mediately.

• Avoid wire brushes, steel wool, and

al other ~bra~ive ;::::.1ds or brushes.

'. Use care when \~lashing lhp. headlight cover and the otber ptastic parts as they can easi'ly be scratched.

., Avoid using pressure washers; wa~ tar can penetrate seals and electrical components and damsqa your mo-

torcycle. .'

• AVOid spraying water In dell.cate. ar-

eas suches in air intakes, carbu-

ret.o.rs. b.r~. ',8 .c.o ... ~ponen.ts,. electrical componenl's. muffler outlets, and fuel

tank openinqs.

Normal

Failed

92 MAlNT'EN.I!\NCE ANOAOJUSTM:E~T Washing Your Motorcycle

• Rinse your bike with cold water from a garden hose to remove any loose dirt

• Mi.~ :::: mild neutral detergent (designed ror motorcycles or automebiles), and water in bucket, Use a soft cloth or sponge to wash your motorcycle. If needed, use a mild degreaser Ii), remove any. o~1 or grease

buti'd up. '

eAfter washing, rinse your rnotorcycia thoroughly wf h clean water to remove any residue (residue from the detergent can damaqe parts 01 your motorcycle) .

• Use a soft doth to dry your metorcyde. As you dry, inspect your motorcycle for chips and scrat-ches. 00 no leI the water airdry as this can damage the painted surfaces,

• Start ~he engine and ,Ie't it idJefor _ ainted Surfaces . _' ..

eral minutes .. The heat from the After washing your motorcycle,coat gin-e will he"lp dry moist areas, inted surfaces, both metal.a~d plas-

• Careful.ly ,ide your motorcycle i . with a commercially avallaole moslow soeec ';md apoly the b;~L .. :r)rC!a/8i.;:omoti';e wax. Vvax should several times. This helps dry "applied once every three, months or brakes and restores them to no . 'S oondttions require. AVOId surfaces

operating performance. lh "satin" or "nat" finishes .. AI.ways

• Lubricate the drive chain to . nonabrasive products an? apply

rusting. . according. to the i,nstructlons on

e container.

- - :If,

IMtrnc!Sn/.' '13/·1<1· and Other Plastic Parts

o After riding in an area where After washi'ng lise a soft cloth to .gen-

roads are salted or near the dry plastic. parts. When. dry, trea, t

imm,ediatelyw'ash your m .. dl" I-."t I ns and

windshield,. -hea Ign e'· .' ....

with cold water. Do riot uSe rt th

non-painted plastic ,pa'5 . WI '

water as it accelerates the- approved plastic deaner/polIsher

reaction of the salt. After

appJy a corrosion protection

on all meta/and chrome surfaces

pre vent corrosion.

NOTE

MAINTENANCE .AND ADJUSTMENT 93 CAUTION

. PlastiC parts may det~riorate and break if they come m contact with ·ch'smical substances

t· 10..01.-11 -f·ea,r.':"'il 'products

or lOUSEh.· ,,""' ..... , , ...... , - " .

such as g.asolIne,brake flUid,. windowcleane rs, th read~llo.ckl n~ ag.ents,or other harsh che":l~ eals. If a plastic part come~ In contact with a'ny harsh chemlc~1 I substance, wash it. off i!1'med~~ at,ely with water and,a,ml.ld,neu~ tral de'tergent! and the~ Inspect for damage.. Avoid uSing abra- I

sive .: pads ,at brushes.t? clea~ plastiC parts, as, they Will dam-

age the part's f] !nlst1. _

94

ltiTENANCE AND OJUST ... NT

Chrome and Aluminum

Chrome and uncoated aluminum parts can be treated wit' a chrome/alu. rninurn polish. Coated alumfnum should be wa,shed with a mild neutral detergent and finished with a spray polish. Aluminum wheels both ~e'ined anti unpainted can be ceaned wIth special non-acid based ,vheel spra cleaners.

Leather. Vinyl .. and Rubber

If your rnotorcycrs has leather accesscrtss, 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, shortening their life.

STORAGE 95

~----~- -S,TORAGE

Vinyl parts should be washed 1) ith f rest bf the motorcycle and then treal-,,""

with a vinyl treatment. eparation for Stora.ge: .' . " ..

Clean the entire vehicle thoroug~ly. . '"... the oil

The sidewalls of tires and other I'l!_ R' the e gine for. about five minutes to v" arm .

ber comp~qe.nts5hould be treatsd Vr~ transmlsslcn 011.

a rubber protectant to help prolong useful life.

shut it off, and drain the

' .• c·>··· . . .. '.sase of uaadotl properly. Contac~ your

~ 010. r 0-11 is a t. OXIC. suwstan ... ceo dD.,t p. .' -I ethods or pass] bls recyc hng.

.... f .... r ao·p·roved . Isposa." "

;:OCBlauthon~les . iV'. . . ':.'"

Special care must be taken not g,et any rubber p otectant on the tire's tread surface when treat. ing tires. This may decrease the tiresabil.ity to maintain co _ wah the road surface causlnq

• - - 'II!I

the rider to lese control

1, _ ••

Put in fresh transmission OIl. .'.' ntv the carburetor by unscrewing the drain Empty the fuel from the fuel ta~~ .. EITIP.~ .. time. the fuel will break down and screw at the float bowl. (If left In fora eng

collld clog the carburetor.) (

,

·

KR150 WIRING DIAGRAM

.-

r- ~~4!"'-O II!;:} I I"AI:. on It

r ;~'I IUj~ rfd , ~. UriC,

r.lIJU, ... • u,tI" Or fEllY

n'ltJt !Jw' p!,~, t .. J2rtc,

IJ,·,'{I" ,.,,"-

."rtil , 1ft;. «~

rQf i<JI sr 1117