2015 Kawasaki W800 Owner Manual

GENERAL INFORMATION j
Quick Reference Guide

HOW TO RIDE THE MOTORCYCLE j
This Quick Reference Guide will SAFE OPERATION j
assist you in finding the information
you’re looking for. MAINTENANCE AND ADJUSTMENT j
STORAGE j
A Table of Contents is included after

the Foreword.
Whenever you see the symbols NOTICE
shown below, heed their instructions!
NOTICE is used to address prac-
Always follow safe operating and main-
tices not related to personal in-
tenance practices.
jury.
DANGER
DANGER indicates a hazardous NOTE
situation which, if not avoided, ○NOTE indicates information that may
will result in death or serious in- help or guide you in the operation or
jury. service of the vehicle.
WARNING
WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
NOTICE
THIS PRODUCT HAS BEEN
MANUFACTURED FOR USE IN A
REASONABLE AND PRUDENT
MANNER BY A QUALIFIED OP-
ERATOR AND AS A VEHICLE
ONLY.
TAMPERING WITH NOISE CONTROL SYSTEM
PROHIBITED
Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any person other than for purposes
of maintenance, repair 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; and
(b) The use of the vehicle after such device or element of design has been
removed or rendered inoperative by any person.
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 vehi-
cle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.
To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-
formation on their Kawasaki Motorcycle, a Service Manual is available for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-
tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.
Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.
This manual should be considered a permanent 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
prior written permission.
This publication includes the latest information available at the time of printing.
However, there may be minor differences between the actual product and illustra-
tions and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company
© 2014 Kawasaki Heavy Industries, Ltd. Jun. 16, 2014. (1)

TABLE OF CONTENTS
SPECIFICATIONS............................... 10 Fuel .................................................. 33

LOCATION OF PARTS ....................... 14 Fuel Requirement: ........................ 33
LOADING INFORMATION.................. 17 Filling the Tank:............................. 35
GENERAL INFORMATION................. 20 Stands .............................................. 37
Meter Instruments ............................ 20 Seat.................................................. 38
Speedometer and Tachometer ..... 21 Helmet Hook/Holding Cable............. 40
LCD (Clock, Odometer, Trip Tool Kit ............................................. 41
Meter) ........................................ 22 Document Compartment .................. 42
Warning/Indicator Lights ............... 25 Tying Hooks ..................................... 42
Key ................................................... 27 Rear View Mirror .............................. 43
Ignition Switch/Steering Lock ........... 27 BREAK-IN ........................................... 44
Right Handlebar Switches................ 29 HOW TO RIDE THE MOTORCYCLE . 46
Engine Stop Switch: ..................... 29 Starting the Engine .......................... 46
Starter Button: .............................. 30 Jump Starting ................................... 48
Left Handlebar Switches .................. 30 Moving Off........................................ 51
Dimmer Switch: ............................ 30 Shifting Gears .................................. 52
Turn Signal Switch:....................... 31 Braking ............................................. 53
Horn Button: ................................. 31 Stopping the Engine......................... 55
Brake/Clutch Lever Adjuster ............ 31 Stopping the Motorcycle in an
Fuel Tank Cap .................................. 32 Emergency ................................... 55
Parking ............................................. 56 Clutch ............................................... 95
Catalytic Converter........................... 58 Drive Chain ...................................... 97
SAFE OPERATION............................. 60 Brakes .............................................. 105
Safe Riding Technique ..................... 60 Brake Light Switch ........................... 110
Daily Checks .................................... 63 Front Fork......................................... 112
Additional Considerations for High Rear Shock Absorber....................... 113
Speed Operation .......................... 66 Wheels ............................................. 116
MAINTENANCE AND ADJUSTMENT 68 Spoke and Rim: ............................ 119
Periodic Maintenance Chart............. 68 Battery.............................................. 120
Engine Oil ........................................ 78 Headlight Beam................................ 127
Spark Plugs...................................... 84 Fuses ............................................... 128
Kawasaki Clean Air System ............. 85 General Lubrication.......................... 131
Valve Clearance ............................... 86 Cleaning Your Motorcycle ................ 132
Air Cleaner ....................................... 86 STORAGE........................................... 138
Throttle Control System ................... 91 ENVIRONMENTAL PROTECTION..... 141
Engine Vacuum Synchronization ..... 93 OWNER SATISFACTION ................. 142
Idle Speed ........................................ 94 LOCATION OF LABELS..................... 144
10 SPECIFICATIONS
SPECIFICATIONS
PERFORMANCE
Maximum Horsepower 35 kW (48 PS) @6 500 r/min (rpm)
Maximum Torque 60 N·m (6.1 kgf·m, 44.3 ft·lb) @2 500 r/min (rpm)
Minimum Turning Radius 2.7 m (8.9 ft)
DIMENSIONS
Overall Length 2 190 mm (86.22 in.)
Overall Width 790 mm (31.10 in.)
Overall Height 1 075 mm (42.32 in.)
Wheelbase 1 465 mm (57.68 in.)
Road Clearance 125 mm (4.92 in.)
Curb Mass 217 kg (478 lb)
ENGINE
Type SOHC, 2-cylinder, 4-stroke, air-cooled
Displacement 773 cm3 (47.2 cu in.)
Bore × Stroke 77.0 × 83.0 mm (3.03 × 3.27 in.)
SPECIFICATIONS 11
Compression Ratio 8.4 : 1

Starting System Electric starter
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
Fuel System FI (Fuel Injection)
Ignition System Battery and coil (transistorized ignition)
Ignition Timing 0° BTDC @1 200 r/min (rpm)
Spark Plug NGK CR8E
Lubrication System Forced lubrication (wet sump)
Engine Oil Type : API SG, SH, SJ, SL or SM with JASO MA, MA1
or MA2
Viscosity: SAE 10W-40
Capacity : 3.2 L (3.4 US qt)
TRANSMISSION
Transmission Type 5-speed, constant mesh, return shift
Clutch Type Wet, multi disc
Driving System Chain drive
12 SPECIFICATIONS
Primary Reduction Ratio 2.095 (88/42)

Final Reduction Ratio 2.467 (37/15)
Overall Drive Ratio 4.403 (Top gear)
Gear Ratio 1st 2.353 (40/17)
2nd 1.591 (35/22)
3rd 1.240 (31/25)
4th 1.000 (28/28)
5th 0.852 (23/27)
FRAME
Caster 27°
Trail 108 mm (4.3 in.)
Tire Size: Front 100/90-19M/C 57H
Rear 130/80-18M/C 66H
Rim Size: Front J19 × 2.15

Rear J18M/C × MT2.75
Fuel Tank Capacity 14 L (3.7 US gal)
SPECIFICATIONS 13
ELECTRICAL EQUIPMENT
Battery 12 V 10 Ah (10 HR)
Headlight High beam 12 V 60 W
Low beam 12 V 55 W
Brake/Tail Light 12 V 21/5 W
Specifications are subject to change without notice.

14 LOCATION OF PARTS
LOCATION OF PARTS
1. Clutch Lever 6. Right Handlebar Switches

2. Left Handlebar Switches 7. Front Brake Lever
3. Starter Lockout Switch 8. Ignition Switch/Steering Lock
4. Meter Instruments 9. Throttle Grip
5. Brake Fluid Reservoir (Front)
LOCATION OF PARTS 15
1. Front Fork 11. Tying Hook

2. Headlight 12. Tail/Brake Light
3. Turn Signal Lights 13. Brake Disc
4. Fuel Tank Cap 14. Shift Pedal
5. Idle Adjusting Screw 15. Center Stand
6. Air Cleaner Element 16. Side Stand
7. Junction Box (Fuse Box) 17. Battery
8. Seat Lock 18. Muffler
9. Helmet Hook 19. Rear Shock Absorber
10. Grab Rail 20. Drive Chain
16 LOCATION OF PARTS
1. Helmet Holding Cable 8. Rear Brake Light Switch

2. Tool Kit 9. Oil Filler Cap
3. Air Cleaner Element 10. Oil Level Inspection Window
4. Seat 11. Oil Drain Bolt
5. Rear Brake Pedal 12. Oil Filter
6. Spark Plugs 13. Horn
7. Brake Lining Wear Indicator 14. Brake Caliper
LOADING INFORMATION 17
LOADING INFORMATION
WARNING In selecting and using accessories,

and in loading the motorcycle, you are
Incorrect loading, improper in-
personally responsible for your own
stallation or use of accessories,
safety and the safety of other persons
or modification of your motorcy-
involved.
cle may result in an unsafe riding
condition. Before you ride the NOTE
motorcycle, make sure it is not
overloaded and that you have
○Kawasaki Parts and Accessories
have been specially designed for
followed these instructions. use on Kawasaki motorcycles. We
strongly recommend that all parts
With the exception of genuine
and accessories you add to your
Kawasaki Parts and Accessories,
motorcycle be genuine Kawasaki
Kawasaki has no control over the
components.
design or application of accessories.
In some cases, improper installation Because a motorcycle is sensitive to
or use of accessories, or motorcycle changes in weight and aerodynamic
modification, will void the motorcycle forces, you must take extreme care
warranty, can negatively affect per- in carrying cargo, passengers and/or
formance, and can even be illegal. in the fitting of additional accessories.
18 LOADING INFORMATION
The following general guidelines have on the motorcycle center of gravity.

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 im- 4. Baggage should be securely at-
proper positioning during cornering tached. Make sure that the baggage
and sudden movements. It is impor- will not move around while you are
tant that the passenger sit still while riding. Recheck baggage security
the motorcycle is in motion and not as often as possible (not while the
interfere with the operation of the motorcycle is in motion) and adjust
motorcycle. Do not carry animals as necessary.
on your motorcycle. 5. Do not carry heavy or bulky items on
2. You should instruct any passenger a luggage rack. They are designed
before riding to keep his feet on the for light items, and overloading can
passenger footpegs and hold on to affect handling due to changes in
the operator or grab rail. Do not weight distribution and aerodynamic
carry a passenger unless he or she forces.
is tall enough to reach the footpegs 6. Do not install accessories or carry
and footpegs are provided. baggage that impairs the perfor-
3. All baggage should be carried as mance of the motorcycle. Make
low as possible to reduce the effect sure that you have not adversely
LOADING INFORMATION 19
affected any lighting components, be used to tow any trailer or other

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 ef-
or any other aspect of the motorcy- fects of such accessories on han-
cle’s operation. dling or stability, but can only warn
7. Weight attached to the handlebar or that the effects can be adverse and
front fork will increase the mass of that Kawasaki cannot assume re-
the steering assembly and can responsibility for the results of such
sult in an unsafe riding condition. unintended use of the motorcycle.
8. Fairings, windshields, backrests, Furthermore, any adverse effects on
and other large items have the ca- motorcycle components caused by
pability of adversely affecting stabil- the use of such accessories will not
ity and handling of the motorcycle, be remedied under warranty.
not only because of their weight, but Maximum Load
also due to the aerodynamic forces
Weight of rider, passenger, baggage,
acting on these surfaces while the and accessories must not exceed 183 kg
motorcycle is in operation. Poorly (403 lb).
designed or installed items can re-
sult in an unsafe riding condition.
9. This motorcycle was not intended
to be equipped with a sidecar or to
20 GENERAL INFORMATION
j GENERAL INFORMATION
Meter Instruments
A. Speedometer
B. MODE Button
C. RESET Button
D. Tachometer
E. Red Zone
F. FI Warning Indicator Light
G. Oil Pressure Warning
Indicator Light
H. Right Turn Signal Indicator
Light
I. Fuel Level Warning
Indicator Light
J. Neutral Indicator Light
K. High Beam Indicator Light
L. Left Turn Signal Indicator
Light
M. LCD (Odometer/Trip
Meter/Clock)
GENERAL INFORMATION 21
j
Speedometer and Tachometer tachometer face is a portion called
The speedometer shows the speed the “red zone.” Engine r/min (rpm) in
of the vehicle. The needle of the the red zone is above maximum rec-
speedometer and tachometer momen- ommended engine speed and is also
tarily sweeps from the minimum to above the range for good performance.
maximum and back to minimum when
the ignition switch is turned to “ON”. NOTICE
This checks the operation of the meter Engine r/min (rpm) should not
needles. So if they do not operate cor- be allowed to enter the red zone;
rectly, have the function checked by an operation in the red zone will
authorized Kawasaki dealer. overstress the engine and may
The tachometer shows the engine cause serious engine damage.
speed in the revolutions per minute
(r/min, rpm). On the right side of the
j
LCD (Clock, Odometer, Trip Meter)
The LCD (Liquid Crystal Display) lo-
cated in the speedometer face is used
to display the Clock, Odometer and
Trip Meter. Pushing the MODE but-
ton shifts the display through the fol-
lowing three modes: CLOCK, ODO,
and TRIP. When the ignition switch is
turned to “ON”, all the LCD segments
are displayed for three seconds, then
the clock or meters operate normally A. MODE Button
depending on the mode selected. B. RESET Button
Clock -
To adjust the hours and minutes:
• Turn the ignition switch to “ON”.
• Push the MODE button to display the
clock.
WARNING • Push the RESET button for more
than two seconds. Both the hour and
For Safety, do not operate the minute displays start blinking.
meter buttons while riding the
motorcycle.
j
• Push the RESET button. The hour

display only blinks. Push the MODE
• Push the RESET button. Both the
hour and minute displays start blink-
button to advance the hours. ing again.
• Push the MODE button. The dis-
plays stop blinking and the clock
starts working.
NOTE
○Pushing the MODE button momen-
• Push the RESET button. The hour
display stops blinking and the minute
tarily advances the hour or minute
step by step. Pushing and hold-
display starts blinking. Push the ing the button advance the hour or
MODE button to advance the min- minute continuously.
utes. ○The clock works normally from the
back-up power while the ignition
switch is turned off.
j
○When the battery is disconnected, ○When the figures come to 999999,
the clock resets to 1:00 and starts they are stopped and locked.
working again when the battery is
connected. Trip Meter -
The trip meters show the distance in
Odometer - kilometers traveled since it was last re-
The odometer shows the total dis- set to zero.
tance in kilometers the vehicle has To reset the trip meter:
been ridden. This meter cannot be
reset.
• Push the MODE button to display the
trip meter.
• Push the MODE button and hold it in.
• After two seconds, the figure display
turns to 0.0, and then starts counting
when the vehicle is operated. The
meter counts until it is reset.
NOTE
○The data is maintained even if the
battery is disconnected.
j
NOTE
○The data is maintained even if the
battery is disconnected.
○When the trip meter reaches 9999.9
while running, the meter reset to 0.0
and continues counting.
Warning/Indicator Lights
: The oil pressure warning indica-
tor light goes on whenever the oil pres-
sure is dangerously low or the ignition
switch is in the ON position with the en-
gine not running, and goes off when the
engine oil pressure is high enough. Re-
fer to the Maintenance and Adjustment
chapter for more detailed engine oil in-
formation.
: When the headlight is on high

beam, the high beam indicator light is
lit.
j
: When the turn signal switch is turned to “ON” and goes off soon after
turned to left or right, the turn signal ensuring that its circuit functions prop-
indicator light blinks on and off. erly.
The warning indicator light also goes
N : When the transmission is in neutral, on and “FUEL” blinks in the LCD when
the neutral indicator light goes on. approximately 3.1 L (0.8 US gal) of fuel
remains.
FI: The fuel injection (FI) warning in-
dicator light goes on when the ignition
switch is turned to “ON” and goes off
soon after ensuring that its circuit func-
tions properly.
The warning indicator light also goes
Refuel at the earliest opportunity
on whenever the troubles occur in dig-
when the fuel level warning indicator
ital fuel injection system (DFI). If the
light goes on and “FUEL” blinks.
warning indicator light blinks on, have
When vehicle stands with side stand,
the DFI system checked by an autho-
fuel level warning indicator light cannot
rized Kawasaki dealer.
show the amount of fuel in the fuel tank
exactly. Stand upright the vehicle to
: The fuel level warning indicator
check the fuel level.
light goes on when the ignition switch is
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Key Ignition Switch/Steering Lock
This motorcycle has a combination This is a four-position, key-operated
key, which is used for the ignition switch. The key can be removed from
switch/steering lock, seat lock, helmet the switch when it is in the OFF, LOCK
hook and fuel tank cap. or P (Park) position.
Blank keys are available at your
Kawasaki dealers. Ask your dealer to
make any additional spare keys you
may need, using your original key as a
master.
A. Ignition Switch/Steering Lock

B. LOCK position
C. OFF position
D. ON position
E. P (Park) position
j
OFF
Engine off. Electrical circuits ○If you leave the P (Park) position on
off. for a long time (one hour), the battery
Engine on. All electrical may become totally discharged.
ON
equipment can be used.
Steering locked. Engine off.
LOCK
Electrical circuits off.
Steering locked. Engine off.
P (Park) Tail and city lights on. Other
electrical circuits cut out.
NOTE
○The taillight is on whenever the igni-
tion switch is in the ON position. One
headlight goes on when the starter
button is released after starting the
engine. To avoid battery discharge,
always start the engine immediately
after turning the ignition switch to
“ON”.
j
Right Handlebar Switches NOTE
Engine Stop Switch:
In addition to the ignition switch,
○Although the engine stop switch
stops the engine, it does not turn off
the 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 required, move the switch
to the position.
A. Engine Stop Switch

B. Starter Button
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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 Motorcycle" high beam indicator light is lit.
chapter for starting instructions. High beam.......( )
Low beam.......( )
A. Dimmer Switch
B. Turn Signal Switch
C. Horn Button
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NOTE Brake/Clutch Lever Adjuster
○Do not allow anything to cover the There are adjusters on both the brake
and clutch levers. The brake lever ad-
headlight lens when the headlight is
on. If covered, heat can build up in juster has 4 positions and the clutch
the headlight lens causing lens dis- lever adjuster has 5 positions so that
coloration or melting, as well as dam- the released lever position can be ad-
age to the item covering the lens. justed to suit the operator’s hands.
Push the lever forward and turn the
Turn Signal Switch: adjuster to align the number with the
When the turn signal switch is turned triangular mark on brake lever and the
triangular mark on the clutch lever.
to the left ( ) or right ( ), the
The distance from the grip to the re-
corresponding turn signal blinks on and
leased lever is minimum at Number 4
off.
for the brake lever and Number 5 for
To stop blinking, push the switch in.
the clutch lever, and maximum at Num-
Horn Button: ber 1 for both.
When the horn button is pushed, the
horn sounds.
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Fuel Tank Cap
To open the fuel tank cap, insert the
ignition key into the fuel tank cap and
turn the key clockwise while pushing
down the fuel tank cap.
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
A. Brake Lever Adjuster
B. Mark ○The fuel tank cap cannot be closed
C. Clutch Lever Adjuster without the key inserted, and the key
cannot be removed unless the cap is
locked properly.
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NOTE Fuel
○Do not push on the key to close the Fuel Requirement:
Your Kawasaki engine is designed
cap, or the cap cannot be locked.
to use only unleaded gasoline with a
minimum octane rating shown below.
Never use gasoline with an octane rat-
ing lower than the minimum specified
by Kawasaki to prevent severe engine
damage.
The octane rating of a gasoline is a
measure of its resistance to detona-
tion or “knocking”. The term commonly
used to describe a gasoline’s octane
rating is the Research Octane Number
(RON).
A. Ignition Key
B. Fuel Tank Cap
j
NOTICE NOTICE
Do not use leaded gasoline, as If engine “knocking" or “ping-
this will destroy the catalytic ing" occurs, use a different
converter. (For further infor- brand of gasoline of a higher
mation, refer to the “Catalytic octane rating. If this condition is
Converter” section in the “How allowed to continue, it can lead
to Ride the Motorcycle” chap- to severe engine damage.Gaso-
ter.) line quality is important. Fuels
of low quality or not meeting
standard industry specifications
may result in unsatisfactory per-
formance. Operating problems
that result from the use of poor
quality or no recommended fuel
may not be covered under your
warranty.
Fuel Type and Octane Rating

Use clean, fresh unleaded gasoline
with an ethanol volume content not
more than 10% and an octane rating
j
equal to or higher than that shown in Filling the Tank:
the table. Avoid filling the tank in the rain or
where heavy dust is blowing so that the
Fuel Type Unleaded Gasoline fuel does not get contaminated.
Ethanol Content E10 or less
Research Octane
Minimum
Number (RON)
Octane Rating
91
NOTICE
Do not use any fuel that con-
tains more ethanol or other oxy-
genates than specified for E10
fuel* in this vehicle. Damage A. Tank Cap
to the engine and fuel system, B. Fuel Tank
or engine starting and/or per- C. Top Level
D. Filler Neck
formance problems may result
from the use of improper fuel.
*E10 means fuel containing up to

10% ethanol.
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WARNING NOTICE
Gasoline is extremely flammable Certain ingredients in gasoline
and can be explosive under cer- may cause paint fading or dam-
tain conditions, creating the po- age. Be extra careful not to spill
tential for serious burns. Turn fuel during refueling.
the ignition switch to “OFF”. Do
not smoke. Make sure the area
is well-ventilated and free from
any source of flame or sparks;
this includes any appliance with
a pilot light. Never fill the tank
completely to the top. If the tank
is filled completely to the top,
heat may cause the fuel to ex-
pand and overflow through the
vents in the tank cap. After re-
fueling, make sure the tank cap
is closed securely. If gasoline is
spilled on the fuel tank, wipe it
off immediately.
j
Stands Do not sit on the motorcycle while
The motorcycle is equipped with two it is on its side stand or centre stand.
stands: a center stand and a side Always kick the stand fully up before
stand. sitting on the motorcycle.
NOTE
○The motorcycle is equipped with a
side stand switch. This switch is de-
signed so that the engine stops if the
clutch is engaged with the transmis-
sion in gear when the side stand is
down.
A. Side Stand
NOTE
○When using the side stand, turn the
handlebar to the left.
j
To set the motorcycle up on the Seat
center stand, step down firmly on the
Seat Removal
stand, and then lift the motorcycle up
and to the rear using the grab rail as a •Remove the seat by inserting the ig-
nition key into the seat lock and turn-
handhold. Don’t pull up on the seat to
ing it clockwise.
lift as this will damage the seat.
A. Center Stand A. Seat

B. Step down B. Seat Lock
C. Grab Rail C. Ignition Key
D. Lift up D. Turn Clockwise
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Seat Installation • Push down the seat until the lock
•Insert the tab on the front of the seat clicks.
into the hole on the frame, and the
projections on the middle of the seat
• Pull up the front and rear end of the
seat to make sure they are securely
into the hole in the frame. locked.
A. Seat
B. Tab
C. Hole
D. Projections
E. Holes
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Helmet Hook/Holding Cable Helmet Holding Cable -
Helmets can be secured to the mo- Helmet can be secured to the mo-
torcycle using the helmet hook located torcycle using the helmet holding ca-
at the left side of the motorcycle or the ble. Securely hook the helmet ring with
helmet holding cable located under the the helmet holding cable and install the
seat. seat.
Helmet Hook -
To unlock the helmet hook, insert the
ignition key into the lock and turning it
clockwise.
A. Helmet Holding Cable
A. Helmet Hook
B. Ignition Key
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WARNING Tool Kit
The tool kit is located under the seat.
Riding with helmets attached to
The kit contains tools that are help-
the hooks could cause an ac-
ful in making roadside repairs, adjust-
cident by distracting the oper-
ments, and some maintenance proce-
ator or interfering with normal
dures explained in this manual. Keep
vehicle operation. Do not ride
the tool kit in the original place.
the motorcycle with helmets at-
tached to the hooks.
A. Tool Kit
B. Band
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Document Compartment Tying Hooks
The document compartment is pro- When tying up light loads to the seat,
vided at the rear under the seat. Use use the tying hooks located on the left
the compartment to keep the owner’s and right sides under the seat.
manual and any papers or documents
that should be kept with the motorcycle.
A. Tying Hooks
A. Document Compartment
B. Band
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Rear View Mirror
Rear View Mirror Adjustment
•Adjust the rear view mirror by slightly
moving only the mirror portion of the
assembly.
•If the rear visibility can not be as-
sured by moving the mirror, slide the
cover and loosen the upper hexago-
nal area and turn the stay by hand.
Tightening Torque
A. Lower Hexagonal Area for Tightening
Lower Hexagonal Area: B. Upper Hexagonal Area
C. Cover
30 N·m (3.1 kgf·m, 22 ft·lb) D. Rear View Mirror
Upper Hexagonal Area:
30 N·m (3.1 kgf·m, 22 ft·lb) NOTE
○If a torque wrench is not available,
this item should be serviced by a
Kawasaki dealer.
44 BREAK-IN
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 pe-
riod.
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)
NOTE
○When operating on public roadways, keep maximum speed under traffic law lim-
its.
• 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.
BREAK-IN 45
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
acceleration, 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 an authorized Kawasaki
dealer.
46 HOW TO RIDE THE MOTORCYCLE
HOW TO RIDE THE MOTORCYCLE
j
Starting the Engine
• Check that the engine stop switch is
in the position.
• Make
tral.
sure the transmission is in neu-
• Without holding the throttle grip, push

the starter button to start the engine.
A. Engine Stop Switch

B. Starter Button
C. Neutral Indicator Light
D. Ignition Switch
E. ON position
HOW TO RIDE THE MOTORCYCLE 47
NOTE NOTICE
○The FI warning indicator light may Do not operate the starter con- j
stay on for a few seconds. However, tinuously for more than 5 sec-
as long as it goes off soon, there is no onds or the starter will overheat
problem with the motorcycle riding. and the battery power will drop
○While the engine is cold, the fast idle temporarily. Wait 15 seconds
system automatically raises the en- between each operation of the
gine idling speed. At this time, the starter to let it cool and the bat-
engine warning indicator light may go tery power recover.
on if you operate the throttle grip un-
necessarily.
○The motorcycle is equipped with a NOTE
vehicle-down sensor, which causes ○The motorcycle is equipped with a
the engine to stop automatically. starter lockout switch. This switch is
designed so that the engine does not
start if the transmission is in gear and
the side stand is down. However, the
engine can be started if the clutch
lever is pulled and the side stand is
fully up.
Jump Starting
j If your motorcycle battery is “run
down,” it should be removed and
charged. If this is not practical, a 12
volt booster battery and jumper cables
may be used to start the engine.
A. Clutch Lever
B. Starter Lockout Switch
NOTICE
Do not let the engine idle longer
than five minutes, or engine
overheating and damage may
occur.
DANGER Connecting Jumper Cables

Battery acid generates hydro- •Remove the seat. j
gen gas which is flammable and •Make sure the ignition switch is
turned to OFF.
explosive under certain con-
ditions. It is present within a •Remove the bracket and move the
ECU aside without disconnecting the
battery at all times, even in a
connectors from the ECU. (Refer to
discharged condition. Keep all
the Battery section of the “Mainte-
flames and sparks (cigarettes)
nance and Adjustment” chapter.)
away from the battery. Wear eye
protection when working with a •Connect a jumper cable from the
positive (+) terminal of the booster
battery. In the event of battery
battery to the positive (+) terminal of
acid contact with skin, eyes, or
the motorcycle battery.
clothing, wash the affected ar-
eas immediately with water for
at least 5 minutes. Seek medical
attention.
DANGER
j Batteries contain sulfuric acid
that can cause burns and pro-
duce hydrogen gas which is
highly explosive. Do not make
this last connection at the fuel
system or battery. Take care not
to touch the positive and nega-
tive cables together, and do not
lean over the battery when mak-
A. Motorcycle Battery Positive (+) Terminal ing this last connection. Do not
B. From Booster Battery Positive (+) Terminal
C. Unpainted Metal Surface
connect to a frozen battery. It
D. From Booster Battery Negative (–) could explode. Do not reverse
Terminal polarity by connecting positive
(+) to negative (–), or a battery
• Connect another jumper cable from
the negative (–) terminal of the
explosion and serious damage
to the electrical system may oc-
booster battery to your motorcy- cur.
cle rear shock absorber upper mount
nut or other unpainted metal surface.
Do not use the negative (–) terminal
• Follow the standard engine starting
procedure.
of the battery.
NOTICE Moving Off

Do not operate the starter con- • Check that the side stand is up. j
tinuously for more than 5 sec- • Shift into 1stclutch
Pull in the lever.
onds or the starter will overheat • Open the throttlegear.
and the battery power will drop • let out the clutch lever
a little, and start to
very slowly.
temporarily. Wait 15 seconds
between each operation of the
starter to let it cool and the bat-
• As the clutch starts to engage, open
the throttle a little more, giving the en-
tery power recover. gine just enough fuel to keep it from
stalling.
• After the engine has started, discon-
nect the jumper cables. Disconnect
the negative (–) cable from the mo-
torcycle first.
• Reinstall the parts removed.
A. Shift Pedal
NOTE Shifting Gears

j ○The motorcycle is equipped with a • Close the throttle while pulling in the
clutch lever.
side stand switch. This switch is de-
signed so that the engine does not • Shift
gear.
into the next higher or lower
start if the transmission is in gear and
the side stand is down. • Open the throttle half way, while re-
leasing the clutch lever.
WARNING
Downshifting to a lower gear at
high speed causes engine rpm
to increase excessively, poten-
tially damaging the engine and
it may also cause the rear wheel
to skid and cause an accident.
Downshifting should be done
below 5 000 rpm for each gear.
NOTE Braking
○The transmission is equipped with a • Close the throttle completely, leav-
ing the clutch engaged (except when
j
positive neutral finder. When the mo-
torcycle is standing still, the transmis- shifting gears) so that the engine will
sion cannot be shifted past neutral help slow down the motorcycle.
from 1st gear. To use the positive • Shift down one gear at a time so that
you are in 1st gear when you come
neutral finder, shift down to 1st gear,
then lift up on the shift pedal while to a complete stop.
standing still. The transmission will • When stopping, always apply both
brakes at the same time. Normally
shift only into neutral.
the front brake should be applied a lit-
tle more than the rear. Shift down or
fully disengage the clutch as neces-
sary to keep the engine from stalling.
• Never lock the brakes, or it will cause

the tires to skid. When turning a cor-
j
ner, it is better not be brake at all. Re-
duce your speed before you get into
the corner.
• For emergency braking, disregard
downshifting, and concentrate on
applying the brakes as hard as pos-
sible without skidding.
A. Rear Brake Pedal
A. Front Brake Lever

Stopping the Engine Stopping the Motorcycle in an

• Close the throttle completely. Emergency j
• Shift the transmission into neutral. Your Kawasaki Motorcycle has been
• Turn the ignition switch to “OFF”. designed and manufactured to pro-
• Support the motorcycle on a firm,
level surface with the side stand or
vide you optimum safety and conve-
nience. However, in order to fully ben-
center stand. efit from Kawasaki’s safety engineering
• Lock the steering. and craftsmanship, it is essential that
you, the owner and operator, properly
NOTE maintain your motorcycle and become
○The motorcycle is equipped with a thoroughly familiar with its operation.
vehicle-down sensor, which causes Improper maintenance can create a
the engine to stop automatically. dangerous situation known as throt-
tle failure. Two of the most common
causes of throttle failure are:
1. An improperly serviced or clogged
air cleaner may allow dirt and dust
to enter the throttle body and stick
the throttle open.
2. During removal of the air cleaner,
dirt is allowed to enter and jam the
throttle body.
In an emergency situation such as Parking

j throttle failure, your vehicle may be
stopped by applying the brakes and WARNING
disengaging the clutch. Once this Operating or parking the vehi-
stopping procedure is initiated, the en- cle near flammable materials can
gine stop switch may be used to stop cause a fire, and can result in
the engine. If the engine stop switch is property damage or severe per-
used, turn off the ignition switch after sonal injury.
stopping the motorcycle. Do not idle or park your vehicle
in an area where tall or dry veg-
etation, or other flammable ma-
terials could come into contact
with the muffler or exhaust pipe.
WARNING and the motorcycle is not close to

any source of flame or sparks; this j
The engine and exhaust system
includes any appliance with a pilot
get extremely hot during normal
light.
operation and can cause serious
burns. Never touch a hot engine,
exhaust pipe, or muffler during WARNING
operation or after stopping the Gasoline is extremely flammable
engine. and can be explosive under cer-
tain conditions.
• Shift the transmission into neutral
and turn the ignition switch to “OFF”. • Lock the steering to help prevent
• Support the motorcycle on a firm,
level surface with the side stand or
theft.
center stand. NOTE

○When stopping near traffic at night,
NOTICE you can leave the taillight on for
Do not park on a soft or steeply greater visibility by turning the igni-
tion switch to the P (Park) position.
inclined surface, or the motorcy-
cle may fall over. ○Do not leave the ignition switch at P
position too long, or the battery will
discharge.
• Ifstructure,
parking inside a garage or other
be sure it is well ventilated
Catalytic Converter WARNING

j This motorcycle is equipped with a
Operating or parking the vehi-
catalytic converter in the exhaust sys-
cle near flammable materials can
tem. The converter reacts with car-
cause a fire, and can result in
bon monoxide, hydrocarbons and nitro-
property damage or severe per-
gen oxides to convert them into carbon
sonal injury.
dioxide, water, nitrogen and oxygen re-
Do not idle or park your vehicle
sulting in much cleaner exhaust gases
in an area where tall or dry veg-
to be discharged into the atmosphere.
etation, or other flammable ma-
For proper operation of the catalytic
terials could come into contact
converter, the following cautions must
with the muffler or exhaust pipe.
be observed.
WARNING
The engine and exhaust system
get extremely hot during normal
operation and can cause serious
burns. Never touch a hot engine,
exhaust pipe, or muffler during
operation or after stopping the
engine.
• Use only unleaded gasoline. Never

use leaded gasoline. Leaded gaso-
air/fuel mixture flowing out of engine
excessively accelerates reaction in j
line significantly reduces the capabil- the converter allowing the converter
ity of the catalytic converter. to overheat and become damaged
• Do not operate the vehicle with the
engine or any one cylinder misfiring.
when the engine is hot, or reduces
converter performance when the en-
Under these conditions unburned gine is cold.
60 SAFE OPERATION
SAFE OPERATION
Safe Riding Technique

j 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
You should be aware of and verify feet on the footpegs. Removing
the applicable safety regulations in your hands from the handlebars or
force prior to riding your motorcy- feet from the footpegs while riding
cle. Gloves and suitable footwear can be hazardous. If you remove
should also be used for added pro- even one hand or foot, you can
tection in case of a mishap. reduce your ability to control the
motorcycle.
A motorcycle does not provide
the impact protection of an auto- Before changing lanes, look over
mobile, so defensive riding in addi- your shoulder to make sure the way
tion to wearing protective apparel is clear. Do not rely solely on the
is extremely important. Do not let rear view mirror; you may misjudge
protective apparel give you a false a vehicle’s distance and speed, or
sense of security. you may not see it at all.
SAFE OPERATION 61
In general your actions should In wet conditions, rely more on the

be 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- j
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 plenty and avoiding unnecessarily fast ac-
of power to spare rather than over- celeration are important not only for
loading 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 sary as in passing, shift to a lower
the throttle. Use the front and rear gear to obtain the necessary power.
brakes for auxiliary braking.
62 SAFE OPERATION
Do not downshift at too high an Avoiding unnecessary weaving is

r/min (rpm) to avoid damage to the important to the safety of both the
engine from overrevving. rider and other motorists.
j
SAFE OPERATION 63
Daily Checks
Check the following items each day before you ride. The time required is minimal,
and habitual performance of these checks will help ensure you a safe, reliable ride.
If any irregularities are found during these checks, refer to the Maintenance and j
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 checks before operation.
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.
64 SAFE OPERATION
Tires ............................ Air pressure (when cold):

Up to 183 kg (403 lb)
Front 200 kPa (2.00 kgf/cm², 28 psi)
Load
j Up to 97.5 kg (215 lb)
225 kPa (2.25 kgf/cm², 32 psi)
Load
Rear
97.5 ∼ 183 kg (215 ∼
250 kPa (2.50 kgf/cm², 36 psi)
403 lb) Load
Install the air valve cap.
Drive chain .................. Slack 25 ∼ 35 mm (1.0 ∼ 1.4 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 2 ∼ 3 mm (0.08 ∼ 0.12 in.). Clutch lever
operates smoothly.
Electrical equipment ... All lights (Headlight, Tail/Brake Lights, Turn Signal Lights,
Warning/Indicator Lights) and horn work.
Engine stop switch ...... Stops engine.
SAFE OPERATION 65
Side stand and center

stand ....................... Returns to their fully up position by spring tension. Returns
springs not weak or not damaged.
j
66 SAFE OPERATION
Additional Considerations for High Speed 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-
j 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.
Fuel: Have sufficient fuel for the high fuel consumption during high speed oper-
ation.
Engine Oil: To avoid engine seizure and resulting loss of control, make sure that
the oil level is at the upper level line.
Electrical Equipment: Make sure that the headlight, tail/brake light, turn signals,
horn, etc., all work properly.
Miscellaneous: Make sure that all nuts and bolts are tight and that all safety
related parts are in good condition.
SAFE OPERATION 67
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 j
required skills.
68 MAINTENANCE AND ADJUSTMENT
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-
j 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
repair work should be completed by a qualified technician.
Please note that Kawasaki cannot assume any responsibility for damage result-
ing from incorrect or improper adjustment done by the owner.
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.
MAINTENANCE AND ADJUSTMENT 69
1. Periodic Inspection (Engine Related Items)

Frequency Whichever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
j
Operation (Engine 1 6 12 18 24 30 36
Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Air cleaner element -
clean • • • 86
K
Valve clearance -
inspect • • • 86
Throttle control system

(play, smooth return, no
drag) - inspect
year • • • • 91
Engine vacuum
K synchronization -
inspect
• • • 93
Idle speed - inspect • • • • 94

Fuel leak (fuel hose
and pipe) - inspect
year • • • • –
Frequency Whichever
first km × 1 000 (mile × 1 000) See
Page
Operation (Engine 1 6 12 18 24 30 36
j Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Fuel hoses damage -
inspect
year • • • • –
Fuel hoses installation

condition - inspect
year • • • • –
K
Air suction system
damage - inspect • • • 85
2. Periodic Inspection (Chassis Related Items)

Frequency Whichever
first km × 1000 (mile × 1000) See
Page
j
Operation (Chassis 1 6 12 18 24 30 36
Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Clutch and drive train:
Clutch operation
K
(play, engagement,
disengagement) - • • • • 95
inspect
Drive chain lubrication
every 600 km (400 mile) 104
condition - inspect #
Drive chain slack -
every 1 000 km (600 mile) 97
inspect #
Drive chain wear -
inspect # • • • 102
K
Drive chain guide
wear - inspect • • • –
Frequency Whichever
Page
j Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Wheels and tires:
Tire air pressure -
inspect
year • • • 116
Wheels/tires damage
- inspect • • • 117
Tire tread wear,

abnormal wear -
inspect
• • • 117
K
Wheel bearings
damage - inspect
year • • • –
K
Spoke tightness and
rim runout - inspect • • • • • • • –
Frequency Whichever
Page
Every j
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Brake system:
Brake fluid leak -
inspect
year • • • • • • • 106
Brake hoses damage

- inspect
year • • • • • • • 106
Brake pad wear -

inspect # • • • • • • 105
Brake hose installation

condition - inspect
year • • • • • • • 106
Brake fluid level -

inspect
6
months • • • • • • • 107
Brake operation
(effectiveness, play,
drag) - inspect
year • • • • • • • 106,
110
Frequency Whichever
Page
j Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Brake lining wear -
inspect # • • • • • • 105
Brake light switch

operation - inspect • • • • • • • 110
Suspensions:
Front forks/rear shock
absorbers operation
(damping and smooth • • • 112,
113
stroke) - inspect
Front forks/rear shock
absorbers oil leak -
inspect
year • • • 112,
113
K
Swingarm pivot
lubricate • –
Frequency Whichever
Page
Every j
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Steering System:
K Steering play - inspect year • • • • –
K
Steering stem
bearings - lubricate
2 years • –
Electrical System:
Lights and switches
operation - inspect
year • • • –
Headlight aiming -
inspect
year • • • 127
Side stand switch

operation - inspect
year • • • –
Engine stop switch

operation - inspect
year • • • –
Frequency Whichever
Page
j Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Chassis:
K
Chassis parts -
lubricate
year • • • –
K
Bolts and nuts
tightness - inspect • • • • –
3. Periodic Replacement
Frequency Whichever
first km × 1 000
(mile × 1 000) See
Page
j
1 12 24 36 48
Every
Change/Replacement Items (0.6) (7.5) (15) (22.5) (30)
K Air cleaner element - replace # 2 years 86
Engine oil - change # year • • • • • 80
Oil filter - replace year • • • • • 80
K Fuel hoses - replace 5 years –
K Brake hoses - replace 4 years –
K Brake fluid (front) - change 2 years • • 108
K
Rubber parts of master cylinder
and caliper - replace
4 years • –
K Spark plug - replace • • • • 84

Engine Oil Oil Level Inspection

In order for the engine, transmission,
and clutch to function properly, main-
• If the oil has just been changed, start
the engine and run it for several min-
tain the engine oil at the proper level, utes at idle speed. This fills the oil
and change the oil and replace the oil filter with oil. Stop the engine, then
j 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 quality NOTICE
if used too long.
Racing the engine before the oil
WARNING reaches every part can cause en-
gine seizure.
Motorcycle operation with insuf-
ficient, deteriorated, or contam-
inated engine oil will cause ac- • Ifwait
the motorcycle has just been used,
several minutes for all the oil to
celerated wear and may result in drain down.
engine or transmission seizure,
accident, and injury. Check the
oil level before each ride and
change the oil according to the
periodic maintenance chart in
the owner’s manual.
• Check the engine oil level through

the oil level inspection window. With
• Ifexcess
the oil level is too high, remove the
oil through the oil filler open-
the motorcycle held level, the oil level ing using a syringe or some other
should come up between the upper suitable device.
and lower level lines next to the oil
level inspection window.
• If the oil level is too low, add the oil
to reach the correct level. Use the j
same type and brand of oil that is
already in the engine.
NOTICE
If the engine oil gets extremely
low or if the oil pump does not
function properly or oil pas-
sages are clogged, the warning
indicator light will light. If it
stays on when the engine speed
A. Oil Level Inspection Window
is above idle, stop the engine im-
B. Upper Level Line mediately and have it serviced.
C. Lower Level Line Failure to do so could cause se-
D. Oil Filler Cap rious engine damage.
• Remove the engine oil drain bolt.
A. Oil Pressure Warning Indicator Light
Oil and/or Oil Filter Change A. Engine Oil Drain Bolt
• Warm up the engine thoroughly, and

then stop it. • Let the oil completely drain with
the motorcycle perpendicular to the
• Place an oil pan beneath the engine. ground.
WARNING • Remove the oil filter cartridge and re-

place it with a new one.
Engine oil is a toxic substance.
Dispose of used oil properly. NOTE
Contact your local authorities
for approved disposal methods ○If a torque wrench or required
or possible recycling. Kawasaki special tool is not avail- j
able, this item should be serviced by
• Ifmove
the oil filter is to be replaced, re-
the oil filter cover.
an authorized Kawasaki dealer.
A. Oil Filter
A. Bolts
B. Oil Filter Cover
• Apply a thin film of oil to the packing

and tighten the cartridge to the spec-
Tightening Torque
Engine Oil Drain Bolt:
ified torque. 20 N·m (2.0 kgf·m, 15 ft·lb)
Oil Filter:
18 N·m (1.8 kgf·m, 13 ft·lb)
j Oil Filter Cover Mounting Bolts:
12 N·m (1.2 kgf·m, 106 in·lb)
Recommended Engine Oil

Type:
API SG, SH, SJ, SL or SM with JASO
MA, MA1 or MA2
Viscosity:
SAE10W-40
A. Packing
NOTE
• Install the oil filter cover.
○Do not add any chemical additive to
• ket. Tighten
Install the drain bolt with a new gas-
it to the specified torque.
the oil. Oils fulfilling the above re-
quirements are fully formulated and
provide adequate lubrication for both
NOTE
the engine and the clutch.
○Replace any gaskets with new ones.
Engine Oil Capacity

Capacity:
2.7 L (2.9 US qt)
(when filter is not removed)
2.9 L (3.1 US qt)
(when filter is removed) j
3.2 L (3.4 US qt)
(when engine is completely dry)
Although 10W-40 engine oil is the

recommended oil for most condi-
tions, the oil viscosity may need to
be changed to accommodate atmo-
spheric conditions in your riding area.
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.
j Spark plug removal should be done
only by an authorized Kawasaki dealer.
Spark Plug
Standard Plug NGK CR8E
0.7 ∼ 0.8 mm
Plug Gap A. Plug Gap
(0.028 ∼ 0.032 in.)
13 N·m
Tightening Torque
(1.3 kgf·m, 115 in·lb)
Kawasaki Clean Air System Air Suction Valves -

The Kawasaki Clean Air System The air suction valve is essentially a
(KCA) is a secondary air suction sys- check valve which allows fresh air to
tem that helps the exhaust gases to flow only from the air cleaner into the
burn more completely. When the spent exhaust port. Any air that has passed
fuel charge is released into the ex- the air suction valve is prevented from j
haust system, it is still hot enough to returning. Inspect the air suction valves
burn. The KCA System allows extra in accordance with the Periodic Main-
air into the exhaust system so that the tenance Chart. Also, inspect the air
spent fuel charge can continue to burn. suction valves whenever stable idling
This continued burning action tends to cannot be obtained, engine power is
burn up a great deal of the normally greatly reduced, or there are abnormal
unburned gases, as well as chang- engine noises.
ing a significant portion of the carbon Air suction valve removal and inspec-
monoxide into carbon dioxide. tion should be done only by an autho-
rized Kawasaki dealer.
Valve Clearance Air Cleaner

Valve and valve seat wear decreases A clogged air cleaner restricts the en-
valve clearance, upsetting valve timing. gine’s air intake, increasing fuel con-
sumption, reducing engine power, and
NOTICE causing spark plug fouling.
j If valve clearance is left un- The air cleaner element must be
adjusted, wear will eventually cleaned in accordance with the Peri-
cause the valves to remain odic Maintenance Chart. In dusty ar-
partly open, which lowers per- eas, the element should be cleaned
formance, burns the valves and more frequently than the recom-
valve seats, and may cause seri- mended interval. After riding through
ous engine damage. rain or on muddy roads, the element
should be cleaned immediately. The
Valve clearance for each valve element should be replaced if it is dam-
should be checked and adjusted in aged.
accordance with the Periodic Mainte- Element Removal
nance Chart.
• Remove the seat.
Inspection and adjustment should be
done only by an authorized Kawasaki
• Remove the screws on the left side
cover.
dealer.
• Remove the left side cover from the

projection by pushing the side cover
• Remove
cover.
the screws and right side
forward and pulling it outward.
A. Right Side Cover

B. Screws
A. Left Side Cover
B. Screws
C. Projection
• Pull out the air cleaner elements from

both side of the air cleaner housing.
• Inspect the element material for dam-
age. If any part of the element is
damaged, the element must be re-
placed.
j WARNING
If dirt or dust is allowed to pass
through into the throttle body
assembly, the throttle may be-
come stuck, possibly causing
accident. Be sure to keep the
dust from entering during clean-
A. Element
ing.
• Put a clean, lint-free towel into the air

cleaner housing to keep dirt or other NOTICE
foreign material from entering. If dirt gets through into the en-
gine, excessive engine wear and
NOTE possibly engine damage will oc-
○Do not try to separate the element cur.
material and frame for cleaning.
Element Cleaning ○Be sure to install the element with the

• Clean the element in a bath of a high
flash-point solvent.
wire net facing up.
• Squeeze it dry in a clean towel. Do

not wring the element or blow it dry; WARNING
the element can be damaged. Gasoline and low flash-point sol- j
• Check all the parts of the element for
visible damage.
vents are extremely flammable
and may explode, causing se-
• If any of the parts of the element are
damaged, replace them.
vere burns. Do not use gaso-
line or a low flash-point solvent
• After cleaning, saturate the element
with a high-quality foam-air-filter oil,
to clean the element. Clean the
element in a well-ventilated area.
squeeze out the excess, then wrap it Be sure there are no sparks or
in a clean towel and squeeze it as dry flame in the work area, including
as possible. any appliance with a pilot light.
• Be careful not to tear the sponge fil-
ter.
NOTE
○Element installation is performed in
the reverse order of removal.
Oil Draining WARNING

• Inspect the drain hose located on the
right side of the engine to see if any
Oil on tires will make them slip-
pery and can cause an accident
oil or water has run down from the air
and injury. Be sure to install the
cleaner housing.
plug in the drain hose after drain-
j ing.
A. Plug
B. Drain Hose
• Ifthethere is any oil in the hose, remove

plug and drain the oil.
Throttle Control System Inspection

Check the throttle grip play in accor-
dance with the Periodic Maintenance
• Check that the throttle grip play is
correct by lightly turning the throttle
Chart, and adjust it if necessary. grip back and forth.
Throttle Grip -
The throttle grip controls the butterfly j
valves in the throttle body. If the throt-
tle grip has excessive play due to either
cable stretch or maladjustment, it will
cause a delay in throttle response, es-
pecially at low engine speed. Also, the
throttle valve may not open fully at full
throttle. On the other hand, if the throt-
tle grip has not play, the throttle will be
hard to control, and the idle speed will
be erratic. A. Throttle Grip
B. Throttle Grip Play
Throttle Grip Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
• If there is improper play, adjust it.

Adjustment
•Loosen the locknuts at the upper of
the throttle cables, and screw both
throttle cable adjusters completely so
as to give the throttle grip plenty of
j play.
•Turn out the decelerator cable ad-
juster until it has no play when the
throttle grip is completely closed.
Tighten the locknut.
•Turn out the accelerator cable ad-
juster until the throttle grip has the
A.
B.
Accelerator Cable
Decelerator Cable
proper play. Tighten the locknut. C. Adjuster
D. Locknuts
• Ifjusted
the throttle cables cannot be ad-
with the adjuster at the up-
per of the throttle cable, further ad-
justment of the throttle cables should
be done by an authorized Kawasaki
dealer.
• With the engine idling, turn the han-

dlebar to each side. If handlebar
Engine Vacuum Synchronization
Engine vacuum synchronization
movement changes the idle speed, must be checked and adjusted period-
the throttle cables may be improperly ically in accordance with the Periodic
adjusted or incorrectly routed, or they Maintenance Chart by an authorized
may be damaged. Be sure to correct Kawasaki dealer. j
any of these conditions before idling.
NOTE
WARNING
○Poor engine vacuum synchronization
will cause unstable idling, sluggish
Operation with improperly ad- throttle response, and reduce engine
justed, incorrectly routed, or power and performance.
damaged cables could result in
an unsafe riding condition. Be
sure the control cables are ad-
justed and routed correctly, and
are free from damage.
Idle Speed WARNING

The idle speed adjustment should be
The engine gets extremely hot
performed in accordance with the Pe-
during normal operation and
riodic Maintenance Chart or whenever
can cause serious burns. Never
the idle speed is disturbed.
touch a hot engine.
j Adjustment
•Start the engine, and warm it up thor-
oughly.
•Adjust the idle speed by turning the
idle adjusting screw.
NOTE
○While the engine is cold, the fast idle
system automatically raises the en-
gine idling speed.
Idle Speed
1 150 ∼ 1 250 r/min (rpm) A. Idle Adjusting Screw
• 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
Clutch
Due to friction plate wear and clutch
movement changes the idle speed, cable stretch over a long period of use,
the throttle cables may be improperly the clutch operation should be checked
adjusted or incorrectly routed, or they each day before riding the motorcycle,
may be damaged. Be sure to correct and in accordance with the Periodic j
any of these conditions before riding. Maintenance Chart.
Inspection
WARNING • Check that the clutch lever operates
properly and that the inner cable
Operation with damaged cables
could result in an unsafe riding slides smoothly. If there is any irreg-
condition. Replace damaged ularity, have the clutch cable checked
control cables before operation. by an authorized Kawasaki dealer.
• Check the clutch lever play as shown
in the figure.
Clutch Lever Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
WARNING
Too much cable play can pre-
vent clutch disengagement and
cause an accident resulting in
serious injury or death. When
j adjusting the clutch or replac-
ing the cable, be sure the up-
per end of the clutch outer cable
is fully seated in its fitting, or it
could slip into place later, creat-
A. Adjuster ing enough cable play to prevent
B. Locknut
C. Clutch Lever Play
clutch disengagement.
If the play is incorrect, adjust the lever

play as follows.
• Tighten the locknut.
NOTE
Adjustment
•Loosen the locknut at the clutch ○After the adjustment is made, start
lever. the engine and check that the clutch
•Turn the adjuster so that the clutch
lever will have the specified free play.
does not slip and that it releases
properly.
Drive Chain Chain Slack Inspection

The drive chain slack and lubrica-
tion must be checked each day be-
•Set the motorcycle up on its side
stand.
fore riding the motorcycle, and in accor-
dance with the Periodic Maintenance
•Rotate the rear wheel to find the po-
sition where the chain is tightest, and
Chart for safety and to prevent exces- measure the maximum chain slack j
sive wear. If the chain becomes badly by pulling up and pushing down the
worn or maladjusted - either too loose chain midway between the engine
or too tight - the chain could jump off sprocket and rear wheel sprocket.
the sprockets or break.
WARNING
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.
A. Chain Slack
• Ifloose,
the drive chain is too tight or too
adjust it so that the chain slack
will be within the standard value.
Drive Chain Slack
Standard 25 ∼ 35 mm (1.0 ∼ 1.4 in.)
j
NOTE
○Do not use the center stand for chain
slack inspection.
A. Torque Link Nut
Chain Slack Adjustment B. Cotter Pin
•Remove the cotter pin from the

torque link nut, and loosen the torque
C. Axle Nut
D. Cotter Pin
E. Adjusting Bolt
link nut. F. Locknut
•Loosen the left and right chain ad-
juster locknuts. • Iflefttheand
chain is too loose, turn out the
•Remove the cotter pin, and loosen
the rear axle nut. evenly.
right chain adjusting bolts
• If the chain is too tight, turn in the

left and right chain adjusting bolts
evenly.
• Turn both chain adjusting bolts

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 indicator should align with j
the same swingarm mark that the
right indicator notch aligns with.
A. Marks
B. Notch
C. Indicator
D. Adjusting Bolt
E. Locknut
NOTE
○Wheel alignment can also be
checked using the straightedge or
string method.
WARNING NOTE
Misalignment of the wheel will ○If a torque wrench is not available,
result in abnormal wear, and may this item should be serviced by an
result in an unsafe riding con- authorized Kawasaki dealer.
j
dition. Align the rear wheel us-
ing the marks on the swingarm • Rotate the wheel, measure the chain
slack again at the tightest position,
or measuring the distance be- and readjust if necessary.
tween the center of the axle and
swingarm pivot. • Tighten the torque link nut.
Tightening Torque
• Tighten both chain adjuster locknuts. Torque Link Nut:
• Tighten the rear axle nut to the spec-
ified torque.
34 N·m (3.5 kgf·m, 25 ft·lb)
Tightening Torque • Install a new cotter pin through the

torque link bolt, and bend its ends.
Axle Nut:
98 N·m (10 kgf·m, 72 ft·lb) • Install a new cotter pin through the
rear axle nut and axle, and spread its
ends.
A. Cotter Pin A. Turning Clockwise
NOTE
WARNING
○When inserting the cotter pin, if the A loose axle nut can lead to an
slots in the nut do not align with
the cotter pin hole in the axle shaft, accident resulting in serious in-
tighten the nut clockwise up to the jury or death. Tighten the axle
next alignment. nut to the proper torque and in-
stall a new cotter pin.
○It should be within 30 degrees.
○Loosen once and tighten again when
the slot goes past the nearest hole. • Check the rear brake (see the Brakes
section).
Wear Inspection the 21st pin. Since the chain may

•Remove the bolts and washers to
take off the chain cover.
wear unevenly, take measurements
at several places.
• Ifthethechain
length exceeds the service limit,
should be replaced.
j
A. Chain Cover
B. Bolts and Washers
• Stretch the chain taut either by using

the chain adjusters, or by hanging a
A. Measure
B. Weight
10 kg (22 lb) weight on the chain.
Drive Chain 20-Link Length
• Measure the length of 20 links on
the straight part of the chain from pin Service Limit 319 mm (12.56 in.)
center of the 1st pin to pin center of
WARNING
For safety, use only the standard
chain. It is an endless type and
should not be cut for installa-
tion; have it installed by an au-
thorized Kawasaki dealer. j
• 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,
A. Good Teeth
B. Worn Teeth
and damaged teeth. C. Damaged Teeth
NOTE • Ifdrive
there is any irregularity, have the
chain and/or the sprockets re-
○Sprocket wear is exaggerated for il- placed by an authorized Kawasaki
lustration. See Service Manual for dealer.
wear limits. • Install the chain cover.
Lubrication
Lubrication is necessary after riding
through rain or on wet roads, or any
time that the chain appears dry.
Use a lubricant for sealed chains to
j prevent deterioration of chain seals. If
the chain is especially dirty, clean it
using a cleaner for sealed chains fol-
lowing the instructions supplied by the
chain cleaner manufacturer.
• Apply lubricant to the sides of the
rollers so that it will penetrate to the • Wipe off any lubricant that gets on the
tire surface.
rollers and bushings. Apply lubricant
to the seals so that the seals will be
coated with lubricant. Wipe off any
excess lubricant.
Brakes Brake Lining Wear Inspection

Inspect the rear brake lining for wear
Brake Pads Wear Inspection
with the brake lining wear indicator on
Inspect the front disc brake pads for
the rear brake panel. If the brake lin-
wear. If the thickness of either pad is
ing wear indicator does not point within
less than 1 mm (0.04 in.), replace both
the USABLE RANGE when the brake j
pads as a set. Pad replacement should
is fully applied, the brake shoe linings
be done by an authorized Kawasaki
have worn past the service limit.
dealer.
In this case, the brake shoes must
be replaced, and the drum and other
brake parts examined by an authorized
Kawasaki dealer.
A. Lining Thickness
B. 1 mm (0.04 in.)
WARNING
Air in the brake lines diminish
braking performance and can
injury or death. If the brake lever
j or pedal feels mushy when it
is applied, there might be air in
the brake lines or the brake may
be defective. Have the brake
checked immediately by an au-
A. Rear Brake Panel thorized Kawasaki dealer.
B. USABLE RANGE
C. Brake Lining Wear Indicator
Brake Fluid -
Front Disk Brakes - In accordance with the Periodic Main-
Disc and disc pad wear is automat- tenance Chart, inspect the brake fluid
ically compensated for and has no ef- level in the front brake fluid reservoir
fect on the brake lever or pedal action. and change the brake fluid. The brake
So there are no parts that require ad- fluid should also be changed if it be-
justment on the front brake. comes contaminated with dirt or water.
Fluid Requirement
Use heavy-duty brake fluid only from
a container marked DOT4.
NOTICE Fluid Level Inspection

Do not spill brake fluid onto any • With the front brake fluid reservoir
held horizontal, the brake fluid level
painted surface.
in the front brake fluid reservoir must
Do not use fluid from a container
be kept above the lower level line
that has been left open or that
(lower level mark). j
has been unsealed for a long
time.
Check for fluid leakage around
the fittings.
Check brake hose for damage.
A. Front Brake Fluid Reservoir

B. Lower Level Mark
• Ifreservoir
the fluid level in front brake fluid
is lower than the lower level
WARNING
Mixing brands and types of
line, check for fluid leaks in the brake
brake fluid can reduce the brake
lines, and fill the reservoir to the up-
system’s effectiveness and
per level line. Inside the front brake
j fluid reservoir is a stepped line show-
injury or death. Do not mix two
ing the upper level line.
brands of brake fluid. Change
the brake fluid 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 Brake Fluid Reservoir Rear Drum Brake -
B. Upper Level Line In accordance with the Periodic Main-
tenance Chart, inspect the brake pedal
play.
Brake Pedal Play Inspection • Rotate the rear wheel to check for
• The brake pedal should have the cor- brake drag with the pedal released.
rect pedal play when the pedal is
pushed down lightly by hand.
• Operate the pedal a few times to see
that it returns to its rest position im-
mediately upon release.
• Check braking effectiveness. j
Brake Pedal Play Adjustment
• Turn the adjusting nut at the brake
cam lever so that the pedal has the
correct pedal play.
A. Brake Pedal
B. Pedal Play
Pedal Play
20 ∼ 30 mm (0.8 ∼ 1.2 in.)
• Ifit.the pedal has improper play, adjust

A. Adjusting Nut
Brake Light Switch

When either the front or rear brake is
applied, the brake light goes on. The
front brake light switch requires no ad-
justment, but the rear brake light switch
j should be adjusted in accordance with
the Periodic Maintenance Chart.
Inspection
• The brake light should go on when
the front brake is applied. A. Brake Pedal
• If it does not, ask your authorized B. Pedal Travel

Kawasaki dealer to inspect the front
brake light switch.
• Iflightit does not, adjust the rear brake
switch.
• Check the operation of the rear brake
light switch by depressing the brake
Brake Pedal Travel
pedal. The brake light should go on 15 mm (0.6 in.)
after the proper pedal travel.
Adjustment NOTICE
•To adjust the rear brake light switch,
move the switch up or down by turn-
To avoid damaging the electrical
connections inside the switch,
ing the adjusting nut.
be sure that the switch body
does not turn during adjustment.
j
A. Rear Brake Light Switch

B. Adjusting Nut
C. Lights sooner
D. Lights later
Front Fork
The front fork operation and oil leak-
age should be checked in accordance
with the Periodic Maintenance Chart.
Front Fork Inspection
j
• Holding the brake lever, pump the
front fork up and down by several
times for inspection of smooth stroke.
• Pull up the dust boots and visually
inspect the front fork for oil leakage,
scoring or scratches on the outer sur- A. Inner Tube
face of the inner tube.
• If any doubt about the front fork, it
should be done by an authorized
NOTE
○Set the dust boots with it end fits into
Kawasaki dealer. the groove on the front fork bottom
case.
Rear Shock Absorber

The rear shock absorbers should be
checked for operation and oil leakage
in accordance with the Periodic Main-
tenance Chart.
For various riding or load conditions j
the rear shock absorbers can be ad-
justed for Spring preload.
Rear Shock Absorber Inspection
•Press down on the seat several times
to inspect the stroke. A. Rear Shock Absorber
•Visually inspect the rear shock ab-

sorber for oil leaks. Spring Preload Adjustment
•If there is any doubt about the rear
shock absorber, it should be in-
Spring preload can be adjusted by
turning the preload adjuster on the
spected by an authorized Kawasaki rear shock absorber with the screw-
dealer. driver bit. To increase spring preload
and stiffen the suspension, turn the
preload adjuster to the left. To de-
crease preload and soften the suspen-
sion, turn the preload adjuster to the
right.
WARNING
If both spring preload adjusters
are not adjusted equally, han-
dling may be impaired and a
hazardous condition may result.
j Set all suspension adjusters
equally to the recommended
settings.
A. Preload Adjuster NOTE

B. Screwdriver Bit
C. Stopper
○Be sure to turn back the preload ad-
juster to the left from position 5 when
softening the spring action.
Spring Preload Setting

Adjuster Position 1 2 3 4 5
Spring Action Weak ← Standard → Strong
Setting Soft ← Standard → Hard
Load Light ← Standard → Heavy j
Road Good ← Standard → Bad
Speed Low ← Standard → High
Wheels NOTE
Tires - ○Measure the tire pressure when the
tires are cold (that is, when the mo-
Payload and Tire Pressure torcycle has not been ridden more
Failure to maintain proper inflation than a mile during the past 3 hours).
j pressures or observe payload limits for ○Tire pressure is affected by changes
your tires may adversely affect han- in ambient temperature and altitude,
dling and performance of your motorcy- and so the tire pressure should be
cle and can result in loss of control. The checked and adjusted when your rid-
maximum recommended load in addi- ing involves wide variations in tem-
tion to vehicle weight is 183 kg (403 lb), perature or altitude.
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.
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). j
So it is false economy and unsafe to
use the tires until they are bald.
• In accordance with the Periodic
Maintenance Chart, measure the
A. Tire Pressure Gauge depth of the tread with a depth
gauge, and replace any tire that
Tire Air Pressure (when cold) has worn down to the minimum al-
Front
Up to 183 kg 200 kPa (2.00 lowable tread depth.
(403 lb) Load kgf/cm², 28 psi)
Minimum Tread Depth
Up to 97.5 kg 225 kPa (2.25
(215 lb) Load kgf/cm², 32 psi) 1 mm
Front
(0.04 in.)
Rear 97.5 ∼ 183 kg
250 kPa (2.50 Under 130 km/h 2 mm
(215 ∼ 403 lb)
kgf/cm², 36 psi) (80 mph) (0.08 in.)
Load
Rear
Over 130 km/h 3 mm
(80 mph) (0.12 in.)
NOTE
○Have the wheel balance inspected
whenever a new tire is installed.
j
WARNING
Tires that have been punctured
and repaired do not have the
same capabilities as undam-
aged tires and can suddenly fail,
A. Tire Depth Gauge causing an accident resulting
in serious injury or death. Re-
• Visually inspect the tire for cracks
and cuts, replacing the tire in case of
place damaged tires as soon as
possible. To ensure safe han-
bad damage. Swelling or high spots dling and stability, use only the
indicate internal damage, requiring recommended standard tires for
tire replacement. replacement, inflated to the stan-
• Remove any imbedded stones or
other foreign particles from the tread.
dard pressure. If it is necessary
to ride on a repaired tire, do not
exceed 100 km/h (60 mph) until
the tire is replaced.
NOTE WARNING
○When operating on public roadways, New tires are slippery and may
keep maximum speed under traffic cause loss of control and injury.
law limits. A break-in period of 160 km (100
Standard Tire (Tube-type) miles) is necessary to estab-
lish normal tire traction. During j
Front Size: 100/90-19M/C 57H
break-in, avoid sudden and max-
• DUNLOP imum braking and acceleration,
and hard cornering.
“TT100GP G”
Rear Size: 130/80-18M/C 66H
Spoke and Rim:
• DUNLOP
Inspection
“TT100GP” Spoke tightness and rim runout
should be inspected by an authorized
Kawasaki dealer in accordance with
WARNING the Periodic Maintenance Chart.
Mixing tire brands and types can
adversely affect handling and
injury or death. Always use the
same manufacturer’s tires on
both front and rear wheels.
Battery Due to their internal composition,

The battery installed in this motorcy- batteries continually self discharge.
cle is a sealed type, so it is not nec- The discharge rate depends on the
essary to check the battery electrolyte type of battery and ambient temper-
level or add distilled water. ature. As temperatures rise, so does
j The sealing strip should not be pulled the discharge rate. Every 15°C (59°F)
off once the specified electrolyte has doubles the rate.
been installed in the battery for initial Electrical accessories, such as digi-
service. tal clocks and computer memory, also
However, in order to maximize bat- draw current from the battery even
tery life and ensure that it will provide when the key is switched off. Combine
the power needed to start the motor- such “key-off” draws with hot temper-
cycle you must properly maintain the ature, and a battery can go from fully
battery’s charge. When used regularly, charged to completely discharged in a
the charging system in the motorcycle matter of days.
helps keep the battery fully charged. If
your motorcycle is only used occasion-
ally or for short periods of time, the bat-
tery is more likely to discharge.
Self-discharge Current Drain

Approx. Number of Days Days from Days from
Dis-
From 100% Charged to 100% charged 100% charged
charging
100% discharged to 50% to 100%
Ampere
Temperature Discharged Discharged
Lead Lead
-Antimony -Calcium 7 mA 60 Days 119 Days j
Battery Battery 10 mA 42 Days 83 Days
40°C (104°F) 100 Days 300 Days 15 mA 28 Days 56 Days
In extremely cold weather the fluid in

an inadequately charged battery can
easily freeze, which can crack the case
and buckle the plates. A fully charged
battery can withstand sub-freezing
temperatures with no damage.
Battery Sulfation
A common cause of battery failure is
sulfation.
Sulfation occurs when the battery is charged using an appropriate charger

left in a discharged condition for an ex- (check with your Kawasaki dealer).
tended time. Sulfate is a normal by If you will not be using the motorcy-
product of the chemical reactions within cle for longer than two weeks, the
a battery. But when continuous dis- battery should be charged using an
j charge allows the sulfate to crystallize appropriate charger. Do not use an au-
in the cells, the battery plates become tomotive-type quick charger that may
permanently damaged and will not hold overcharge the battery and damage it.
a charge. Battery failure due to sulfa-
tion is not warrantable.
NOTE
Battery Maintenance
○Leaving the battery connected
causes the electrical components
It is the owner’s responsibility to keep (clock etc) to make the battery dis-
the battery fully charged. Failure to do charged, resulting the over discharge
so can lead to battery failure and leave of the battery. In this case, the repair
you stranded. or replacement of the battery is not
If you are riding your vehicle infre- included in the warranty. If you do
quently, inspect the battery voltage not drive for four weeks or more, dis-
weekly using a voltmeter. If it drops connect the battery from the vehicle.
below 12.8 volts, the battery should be
Kawasaki-recommended
are:
chargers • The charger will keep the battery fully
charged until you are ready to re-
Battery Mate 150-9 install the battery in the motorcycle
OptiMate 4 (see Battery Installation).
Yuasa MB-2040/2060
Christie C10122S NOTICE j
If the above chargers are not avail- Never remove the sealing strip,
able, use equivalent one. or the battery can be damaged.
For more details, ask your Kawasaki Do not install a conventional
dealer. battery in this motorcycle, or the
Battery Charging electrical system cannot work
•Remove the battery from the motor-
cycle (see Battery Removal).
properly.
•Attach the leads from the charger

and charge the battery at a rate (am-
Make
Type
Yuasa Battery
YTX12-BS
perage × hours) that is indicated on
the battery. If it is not possible to read
the rate, charge the battery at an am- NOTE
perage that is about 1/10th of the bat- ○If you charge the sealed battery,
tery capacity. never fail to observe the instructions
shown in the label on the battery.
Battery Removal • Disconnect the cables from the bat-

•Make sure the ignition switch is
turned to OFF.
tery, first from the (-) terminal and
then the (+) terminal.
•Remove the seat and tool kit.
•Remove the screw and move the
ECU aside without disconnecting the
j
connectors from the ECU.
A. (+) Terminal
B. (–) Terminal
C. Ground Connector
A. Screw
B. Bracket
C. ECU
• Disconnect the ground connector of

the battery (–) cables.
NOTICE
Do not give the battery holder a
• Remove the left side cover (see Air
Cleaner section).
strong pull, or the leads may be-
come disconnected.
• Remove the battery holder bolts.
• Remove
holder.
the battery from the battery j
A. Battery Holder
B. Battery Holder Bolt (Shorter) and Washer
C. Battery Holder Bolt (Longer)
D. Battery (+) Cable A. Battery
E. Battery (–) Cable
• Pull out the battery holder and battery

(+) and (–) cables.
Battery Installation NOTICE

•Clean the battery using a solution of
baking soda and water. Be sure that
Installing the (–) cable to the (+)
terminal of the battery or the (+)
the cable connections are clean.
cable to the (–) terminal of the
•Place the battery in the battery case
with the pad under the battery.
battery can seriously damage
j the electrical system.
•Connect the red capped cable to the
(+) terminal from the rear, and then
connect the black cable to the (–) ter- • Put a light coat of grease on the ter-
minals to prevent corrosion.
minal.
• Cover the (+) terminal with its protec-
tive cap.
NOTE
○Install the battery in the reverse order • Reinstall the parts removed .
of the Battery Removal.
Headlight Beam Vertical Adjustment

The headlight beam is adjustable ver-
Horizontal Adjustment
tically. If adjusted too low, neither low
The headlight beam is adjustable
nor high beam will illuminate the road
horizontally. If not properly adjusted
far enough ahead. If adjusted too high,
horizontally, the beam will point to one
the high beam will fail to illuminate the j
side rather than straight ahead.
road close ahead, and the low beam
• Turn the horizontal adjuster clock-
wise or counterclockwise until the
will blind oncoming drivers.
beam points straight ahead. • Turn the vertical adjuster clockwise
or counterclockwise to adjust its ver-
tical angle.
A. Horizontal Adjuster
B. Vertical Adjuster
NOTE Fuses
○On high beam, the brightest point Fuses are arranged in the junction
box located inside the left side cover.
should be slightly below horizontal
with the motorcycle on its wheels and The main fuse is mounted on the starter
the rider seated. Adjust the headlight relay located inside the left side cover.
j to the proper angle according to local If a fuse fails during operation, inspect
regulations. the electrical system to determine the
cause, and then replace it with a new
fuse of proper amperage.
• Remove the seat.

• Cleaner section).
Remove the left side cover (see Air
A. Junction Box
B. Fuses
C. Spare Fuses
A. Battery Holder
B. Junction Box
C. Starter Relay
D. Main Fuse
WARNING
Substituting fuses can cause
wiring to overheat, catch fire
and/or fail. Do not use any sub-
stitute for the standard fuse.
j Replace the blown fuse with a
new one of the correct capacity,
as specified on the junction box
and main fuse.
A. Normal
B. Failed
General Lubrication Apply motor oil to the following

Lubricate the points shown below, pivots -
with either motor oil or regular grease, • Side Stand
in accordance with the Periodic Main- • Clutch Lever
tenance Chart or whenever the vehicle • Front Brake Lever
has been operated under wet or rainy
conditions.
• Rear Brake Pedal j
Before lubricating each part, clean off Lubricate the following cables with a
any rusty spots with rust remover and pressure cable luber -
wipe off any grease, oil, dirt, or grime. • (K) Clutch Inner Cable
NOTE • (K) Throttle Inner Cables
○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 Cleaning Your Motorcycle

points -
General Precautions
• (K) Clutch Inner Cable Upper End
Frequent and proper care of your
• (K) Throttle Inner Cable Upper Ends
Kawasaki motorcycle will enhance
(K): Should be serviced by an authorized its appearance, optimize overall per-
j formance, and extend its useful life.
Kawasaki dealer.
Covering your motorcycle with a high
NOTE quality, breathable motorcycle cover
will help protect its finish from harmful
○After connecting the cables, adjust UV rays, pollutants, and reduce the
them. amount of dust reaching its surfaces.
WARNING • Be sure the engine and exhaust are

cool before washing.
Build-up of debris or flammable
material in and around the vehi- • Avoid applying degreaser to seals,
brake pads, and tires.
cle chassis, engine, and exhaust
can cause mechanical problems • Always use non-abrasive wax and
cleaner/polisher.
and increase the risk of fire. j
When operating the vehicle in • Avoid all harsh chemicals, solvents,
detergents, and household cleaning
conditions that allow debris or
products such as ammonia-based
flammable material to collect in
window cleaners.
and around the vehicle, inspect
the engine, electrical component • Gasoline and brake fluid will damage
the finish of painted and plastic sur-
and exhaust areas frequently. If
faces: wash them off immediately.
debris or flammable materials
have collected, park the vehi- • Avoid wire brushes, steel wool, and
all other abrasive pads or brushes.
cle outside and stop the engine.
Allow the engine to cool, then • Use care when washing the side cov-
ers and other plastic parts as they
remove any collected debris. Do
can easily be scratched.
not park or store the vehicle in
an enclosed space prior to in- • Avoid using pressure washers; wa-
ter can penetrate seals and electrical
specting for build-up of debris
components and damage your mo-
or flammable materials.
torcycle.
• Avoid spraying water in delicate ar-

eas such as in air intakes, throttle
detergent can damage parts of your
motorcycle).
body, brake components, electrical
components, muffler outlets, and fuel
• Use a soft cloth to dry your motorcy-
cle. As you dry, inspect your motor-
tank openings. cycle for chips and scratches. Do not
j let the water air dry as this can dam-
Washing Your Motorcycle age the painted surfaces.
•Rinse your bike with cold water from
a garden hose to remove any loose • Start the engine and let it idle for sev-
eral minutes. The heat from the en-
dirt.
gine will help dry moist areas.
•Mix a mild neutral detergent (de-
signed for motorcycles or automo- • Carefully ride your motorcycle at a
slow speed and apply the brakes
biles) and water in bucket. Use
several times. This helps dry the
a soft cloth or sponge to wash your
brakes and restores them to normal
motorcycle. If needed, use a mild de-
operating performance.
greaser to remove any oil or grease
build up. • Lubricate the drive chain to prevent
rusting.
•After washing, rinse your motorcy-
cle thoroughly with clean water to re-
move any residue (residue from the
NOTE • When washing the motorcycle, al-

○After riding in an area where the ways use a mild neutral detergent
and water.
roads are salted or near the ocean,
immediately wash your motorcycle • The semi-gloss finish effect may be
lost when the finish is excessively
with cold water. Do not use warm
water as it accelerates the chemical rubbed. j
reaction of the salt. After drying, • If any doubt, consult an authorized
Kawasaki dealer.
apply a corrosion protection spray
on all metal and chrome surfaces to
prevent corrosion. Painted Surfaces
○Condensation may form on the inside After washing your motorcycle, coat
of the headlight lens after riding in the painted surfaces, both metal and plas-
rain or washing the motorcycle. To tic, with a commercially available mo-
remove the moisture, start the engine torcycle/automotive wax. Wax should
and turn on the headlight. Gradually be applied once every three months or
the condensation on the inside of the as conditions require. Avoid surfaces
lens will clear off. with “satin” or “flat” finishes. Always
use non-abrasive products and apply
Semi-gloss Finish them according to the instructions on
To clean the semi-gloss finish; the container.
Plastic Parts NOTICE

After washing use a soft cloth to gen-
Plastic parts may deteriorate
tly dry plastic parts. When dry, treat the
and break if they come in con-
headlight lens and other non-painted
tact with chemical substances
plastic parts with an approved plastic
or household cleaning products
j cleaner/polisher product.
such as gasoline, brake fluid,
window cleaners, thread-locking
agents, or other harsh chemi-
cals. If a plastic part comes in
contact with any harsh chemical
substance, wash it off immedi-
ately with water and a mild neu-
tral detergent, and then inspect
for damage. Avoid using abra-
sive pads or brushes to clean
plastic parts, as they will dam-
age the part’s finish.
Chrome and Aluminum Vinyl parts should be washed with the

Chrome and uncoated aluminum rest of the motorcycle, then treated with
parts can be treated with a chrome/alu- a vinyl treatment.
minum polish. Coated aluminum The sidewalls of tires and other rub-
should be washed with a mild neu- ber components should be treated with
tral detergent and finished with a spray a rubber protectant to help prolong their j
polish. Aluminum wheels, both painted useful life.
and unpainted can be cleaned with
special non-acid based wheel spray WARNING
cleaners. Rubber protectants can be slip-
Leather, Vinyl, and Rubber pery and, if used on the tread
If your motorcycle has leather ac- area, cause loss of traction re-
cessories, special care must be taken. sulting in accident causing in-
Use a leather cleaner/treatment to jury or death. Do not apply rub-
clean and care for leather accessories. ber protectant to any tread area.
Washing leather parts with detergent
and water will damage them, shorten-
ing their life.
138 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
engine oil.
j WARNING
Engine 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 fuel tank by the pump or siphon.
STORAGE 139
WARNING
Gasoline is extremely flammable and can be explosive under certain con-
ditions, creating the potential for serious burns. Turn the ignition switch
to “OFF”. Do not smoke. Make sure the area is well-ventilated and free
from any source of flame or sparks; this includes any appliance with a
pilot light. Gasoline is a toxic substance. Dispose of gasoline properly.
Contact your local authorities for approved disposal methods.
j
• 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 damp-
ness 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.
140 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.
• Lubricate
Check all the points listed in the Daily Checks section.
j
• the pivots, bolts, and nuts.
ENVIRONMENTAL PROTECTION 141
ENVIRONMENTAL PROTECTION
To help preserve the environment, properly discard used batteries, tires, oils and
fluids, or other vehicle components that you might dispose of in the future. Con-
sult your authorized Kawasaki dealer or local environmental waste agency for their
proper disposal procedure. This also applies to disposal of the entire vehicle at the
end of its life.
142 OWNER SATISFACTION
OWNER SATISFACTION
Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki

Motors Pty., Ltd. 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 an independent business person and is concerned
with your satisfaction and your future business. For this reason the owner is in the
best position to assist you. Also, all warranty 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
require further assistance, WRITE to the address below. Please be certain to pro-
vide 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.
OWNER SATISFACTION 143
Upon receipt of your WRITTEN correspondence we will contact the dealership and
work with them in resolving your problem.
In order to provide a permanent record, all warranty and service resolutions take
place only through WRITTEN correspondence.
Please send your correspondence to:
Customer Relations:
Technical Services Department
KAWASAKI MOTORS Pty., Ltd.
LOCKED BAG 802,
ERMINGTON. NSW. 1700.
A.C.N.: 002 840 315
144 LOCATION OF LABELS
LOCATION OF LABELS
All warning labels which are on your you and your dealer obtain the cor-
vehicle are repeated here. Read labels rect replacement.
on your vehicle and understand them ○Refer to the actual vehicle label for
thoroughly. They contain information model specific data grayed out in the
which is important for your safety and illustration.
the safety of anyone else who may op-
erate your vehicle. Therefore, it is very
important that all warning labels be on
your vehicle in the locations shown. If
any label is missing, damaged, or worn,
get a replacement from your Kawasaki
dealer and install it in the correct posi-
tion.
NOTE
○The sample warning labels in this
section have part numbers to help 1. Brake Fluid (Front)
LOCATION OF LABELS 145
2. Important Drive Chain Information

3. Tire and Load Data
4. Stationary Noise Test Information
5. Battery Poison/Danger
(1)
(2) only on Australia model

(2) only on Southeast Asia model

(3) only on Australia model

(3) only on Southeast Asia model

(4) (5)

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GENERAL INFORMATION j

Quick Reference Guide

A Table of Contents is included after

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

© 2014 Kawasaki Heavy Industries, Ltd. Jun. 16, 2014. (1)

SPECIFICATIONS............................... 10 Fuel .................................................. 33

Compression Ratio 8.4 : 1

Primary Reduction Ratio 2.095 (88/42)

Rim Size: Front J19 × 2.15

Specifications are subject to change without notice.

1. Clutch Lever 6. Right Handlebar Switches

1. Front Fork 11. Tying Hook

1. Helmet Holding Cable 8. Rear Brake Light Switch

WARNING In selecting and using accessories,

The following general guidelines have on the motorcycle center of gravity.

affected any lighting components, be used to tow any trailer or other

• Push the RESET button. The hour

: When the headlight is on high

A. Ignition Switch/Steering Lock

A. Engine Stop Switch

Fuel Type and Octane Rating

*E10 means fuel containing up to

A. Center Stand A. Seat

A. Helmet Holding Cable

• Without holding the throttle grip, push

A. Engine Stop Switch

DANGER Connecting Jumper Cables

NOTICE Moving Off

NOTE Shifting Gears

• Never lock the brakes, or it will cause

A. Rear Brake Pedal

A. Front Brake Lever

Stopping the Engine Stopping the Motorcycle in an

In an emergency situation such as Parking

WARNING and the motorcycle is not close to

center stand. NOTE

Catalytic Converter WARNING

• Use only unleaded gasoline. Never

Safe Riding Technique

In general your actions should In wet conditions, rely more on the

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

Do not downshift at too high an Avoiding unnecessary weaving is

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

Side stand and center

Additional Considerations for High Speed Operation

1. Periodic Inspection (Engine Related Items)

Throttle control system

Idle speed - inspect • • • • 94

Fuel hoses installation

2. Periodic Inspection (Chassis Related Items)

Tire tread wear,

Brake hoses damage

Brake pad wear -

Brake hose installation

Brake fluid level -

Brake light switch

Side stand switch

Engine stop switch

K Spark plug - replace • • • • 84

Engine Oil Oil Level Inspection

• Check the engine oil level through

• Remove the engine oil drain bolt.

A. Oil Pressure Warning Indicator Light