Manual Cyclone 150
Manual Cyclone 150
Manual Cyclone 150
TABLE OF CONTENTS
Specifications .. .. .. . ... .. . .. ... ... .. ... . .. .. . ... .. ... .. . . 6 Fuel Tap ... .. ... ... .. .. . . .. . . . .. . .. . . . ... .. . .. ... .. ... .. ... . 19
Location of Parts .. ... ... .. ... ... .. ... . .. .. . .. . .. ... ... . 9 Fuel Tank Cap ... .. ... . .. .. . .. . . . .. . . .. .. ... ... .. . 20
General Information .. ... .. ... ... .. ... ... .. ... . .. .. . 12 Fuel Tank .. ... ... .. ... .. . . . ... . .. .. . ... .. . .. ... .. ... . 21
Meter Instruments . ... .. ... ... .. ... ... .. ... . .. .. . 12 Stands .. .. ... .. . .. ... ... .. ... ... .. ... . .. .. . .. . .. . .. ... . 22
Speedometer and Tachometer ... .. 13 Tool Kit Compartment/Tool Kit . ... .. . .. ... 24
Water Temperature Gauge . .. .. . .. . .. 13 Break-In . . .. .. . .. . .. ... ... .. ... .. . .. ... .. . .. . .. . . . .. . ... .. .. 25
Indicator Lights .. ... ... .. ... ... .. ... ... .. ... . 14 How to Ride the Motorcycle . . ... ... .. ... ... .. . 26
Key . ... .. ... ... .. . .. ... .. ... . .. .. . ... .. . .. .. . .. ... .. . .. .. 15 Starting the Engine ... .. . .. ... . .. .. . ... .. . .. ... . 26
Ignition Switch/Steering Lock ... .. ... . .. .. . 15 Moving Off . .. .. . .. . .. ... .. ... ... .. ... ... .. ... . . . .. . .. 28
Right Handlebar Switches . ... .. ... ... .. ... . 16 Shifting Gears . . ... .. ... .. . .. ... .. . .. . .. ... . . . .. . .. 29
Engine Stop Switch ... .. ... .. ... ... .. . .. .. 16 Braking . ... ... .. ... . . . .. . .. . . . ... .. ... ... ... ... .. ... .. . 29
Headlight Switch . .. . .. .. . ... .. ... ... .. ... .. 17 Stopping the Engine ... .. ... ... .. . .. ... . .. .. . .. 31
Left Handlebar Switches .. . ... .. ... ... .. ... .. 18 Stopping the Motorcycle
Dimmer Switch . .. ... .. . .. . .. .. . ... .. ... ... .. 18 in an Emergency .. ... .. . .. ... ... ... .. . .. . .. 31
Turn Signal Switch . . . .. . .. .. . ... .. ... ... .. 18 Parking . .. . .. ... ... . . .. . . .. .. . .. .. . .. . .. ... ... ... .. ... . 32
Horn Button ... .. ... .. . .. ... .. . .. . . . .. . ... .. ... 18 Safe Operations .. . .. .. . .. .. . .. ... ... . . . .. .. . ... ... .. . 33
Passing Button ... .. . .. ... .. . .. . .. .. . ... .. ... 18 Daily Safety Checks . .. ... .. ... ... .. ... .. ... ... . 33
SPECIFICATIONS
DIMENSIONS
Overall Length 1,960 mm
Overall Width 715 mm
Overall Height 1,085 mm
Wheelbase 1,320 mm
Road Clearance 130 mm
Dry Weight 115 kg
ENGINE
Type 2-stroke, single cylinder, liquid-cooled, crankcase reed valve
with Super-KIPS (Kawasaki Integrated Power-valve System)
Displacement 148 cc
Bore x Stroke 59 .0 x54.4 mm
Compression Ratio 6.8 :1
Ignition System DC . CDI
Ignition Timing 10° BTDC @ 1,000 rpm
21 ° BTDC @ 5,000 rpm
SPECIFICATIONS
DIMENSIONS
Overall Length 1,960 mm
Overall Width 715 mm
Overall Height 1,085 mm
Wheelbase 1,320 mm
Road Clearance 130 mm
Dry Weight 115 kg
ENGINE
Type 2-stroke, single cylinder, liquid-cooled, crankcase reed valve
with Super-KIPS (Kawasaki Integrated Power-valve System)
Displacement 148 cc
Bore x Stroke 59 .0 x54 .4 mm
Compression Ratio 6 .8 : 1
Ignition System DC . CDI
Ignition Timing 10° BTDC @ 1,000 rpm
21 ° BTDC @ 5,000 rpm
ELECTRICAL EQUIPMENT
Battery 12 V3AH
Headlight 12 V 35/36.5 W
Tail/Brake Light 12V5/18W
Turn Signal Light 12V10W
LOCATION OF PARTS
10
Meter Instruments
12
CAUTION
13
Indicator Lights FUEL : The low fuel warning light goes on
whenever the ignition switch is in the ON posi-
HIGH BEAM : When the headlight is on tion with the engine in neutral, and goes off
high beam, the high beam indicator light is lit. when the transmission is in any gear . If the fuel
level gets too low, the light will not go off and will
NEUTRAL: When the transmission is in stay on even in any gear . In this case, add the
neutral, the neutral indicator light is lit. fuel at the earliest opportunity.
14
15
Right Handlebar Switches
OFF Engine off. All electrical circuits Engine Stop Switch
off. In addition to the ignition switch, the engine
stop switch must be in the RUN position for the
ON Engine on . All electrical motorcycle to operate.
equipments can be used . (The The engine stop switch is foremergency use.
head, tail and meter lights do If some emergency requires stopping the engine,
not come on if the engine is move the engine stop switch in the OFF position .
not running) .
16
Headlight Switch
17
Left Handlebar Switches
Dimmer Switch
High or low beam can be selected with
the dimmer switch . When the headlights is
on high beam (HI), the high beam indicator
light is lit.
18
AWARNINC,
19
Fuel Tank Cap
To open the fuel cap, pull up the key hole
cover. Insert the ignition switch key into the
lock and turn the key to the right .
To close the cap, push it down into place
with the key inserted. The key can be re-
moved by turning it counterclockwise to the
original position .
NOTE
20
21
Fuel Requirement: Stands
Your Kawasaki engine is designed to use The motorcycle is equipped with two stands :
unleaded gasoline . However, if suitable gaso- a center stand and a side stand.
line is not available then PREMIUM, SUPER or
FOUR-STAR gasoline can be used .
Octane Rating
The octane rating of a gasoline is a measure
of its resistance to detonation or " knocking".
The term commonly used to describe a gaso-
line's octane rating is the Research Octane No .
(RON). Always use a gasoline with an octane
rating equal to, or higher than, Reseach Octane
No . (RON) 91 .
22
AWARNING
Forgetting and leaving the side stand
down and riding away could cause an
accident .
23
Tool Kit Case
The tool kit case is located in the right side
cover behind the battery.
Store the tool kit with tool kit cases.
Tool Kit
The minor adjustment and replacement of
parts explained in this manual can be performed
with the tool kit.
A. Tool Kit
B. Tool Kit Cases
24
BREAK-IN
The first 1,600 km 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 period .
NOTE
o When operating on public roadways, keep maximum speed under traffic law limits.
" 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.
In addition to the above, at 1,000 km it is extremely important that the owner have the initial
maintenance service performed by an authorized Kawasaki dealer .
25
HOW TO RIDE THE MOTORCYCLE
A . Ignition Switch
B . ON position
A . Fuel Tap C . Neutral Indicator Light
B . ON position
C . Engine Stop Switch " If the engine is cold, pullout the choke knob
all the way (ON posiition) .
26
NOTE
NOTE
o When the engine is already warm or on hot o If the engine is flooded, kick the engine over
days (higher than 35°C), open the throttle with the throttle fully open until the engine
part way instead of using the choke, and starts .
then start the engine .
" Use the choke as necessary to keep the
engine runing during warm-up .
" Leaving the throttle completely closed, kick
" When the engine is warmed up enough to
the engine over until the engine starts .
idle without using the choke, return the
choke to the off position .
27
NOTE Moving Off
" Check that the side stand is up .
0 If you drive the motorcycle before the en- " Pull in the clutch lever.
gine is warmed up, return the choke to the " Shift into 1 st gear
offposition as soon as you start moving " Open the throttle a little, and start to let out
(20 °C - 35 °C). In cold weather, use the clutch lever very slowly .
choke until you have driven the length of " As the clutch starts to engage, open the
time shown in the table. throttle a little more, giving the engine just
enough fuel to keep it from stalling .
Ambient temperature Choke off after
running for
Below 20° 20 seconds
CAUTION
28
29
A . Front Brake Lever A. Rear Brake Pedal
30
31
In an emergency situation such as throttle Parking
failure, your motorcycle may be stopped by " Shift the transmission into neutral and turn
disengaging the clutch and applying the brakes . the ignition switch OFF .
Once this stopping procedure is initiated, the " Support the motorcycle on a firm level sur-
engine stop switch may be used to stop the face with the side or center stand.
engine . If the engine stop switch used, turn off
the ignition switch after stopping motorcycle . CAUTION
32
SAFE OPERATION
Failure to perform these checks every day before you ride may result in serious damage
or a severe accident .
Fuel ... . .. .. . .. . . . ... .. . .. ... .. ... .. . .. ... ... .. ... . .. .. Adequate supply in tank, no leaks.
Engine OII .. ... .. ... .. . .. ... .. . .. ... . . . .. . .. .. . ... . Adequate supply in tank .
Transmission Oil ... ... .. ... ... .. . .. .. . ... .. . .. . Oil level between level lines.
Tires .. . ... .. ... ... .. ... ... .. ... .. . .. ... . . . .. . .. . . . ... . Air pressure (when cold)
33
Drive chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slack 30 - 40 mm .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No brake fluid leakage.
Brake pad wear : Lining thickness more than 1 mm left .
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle grip play 2 - 3 mm .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch lever play 2 - 3 mm .
Clutch lever operates smoothly .
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No coolant leakage
Coolant level between level line (when engine is cold) .
Radiator cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Properly installed .
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All lights and horn work .
Engine stop switch . . . . . . . . . . . . . . . . . ., . . . . . . . . . . Stop engine .
Side and center stands . . . . . . . . . . . . . . . . . . . . . . . . . Return to their fully up positions by spring tension . Return
springs not weak or not damaged .
34
tOdometer Reading km
\ Frequency Whichever »
comes first
00°
Operation + 00° # o
°° o
°° See
Every Page
Idle speed-check t 0 0 0 54
Throttle grip play-check t " " 0 0 50
Oil pump and carburetor
synchronization-check t 0 0 0 52
Spark plug-clean and gap t " 0 " " 0 0 0 45
Air cleaner element-clean t 0 " 0 49
Air cleaner element-replace 5 . cleanings 0 47
Fuel system-check " 0 " 76
K Cylinder head nuts
tightness-check t 0 " " 0 -
Battery electrolyte
level-check t month 0 " 0 72
Brake fluid level-check t month 0 0 0 0 0 0 0 63
K Brake fluid-change 2 years 0 64
Brake light switch-check t " 0 " " 0 0 0 65
36
X
comes first
37
tOdometer Reading km
Frequency Whichever »
comes first /
i
Operation \ \ \ + o
° See
Every Page
K Caliper piston seal and dust
seal-replace 2 years -
K Master cylinder cup and
dust seal-replace 2 years -
K Brake hose-replace 4 years -
K Fuel hose-replace 4 years -
Drive chain-lubricate Every 300 km 61
Drive chain slack-check Every 800 km 57
38
Engine Oil
Do not use ordinary motor oil, transmission
oil, or an inferior grade of oil as a replacementfor
the proper oil. The use of improper oil will lead to
engine trouble.
The engine oil tank is located under the seat .
Adding Oil
" Check the oil level in the engine oil tank .
" Before you run out of oil, add oil. It will take
about 1 .2L.
A. Engine Oil Tank
NOTE B. Engine Oil Tank Cap
39
Transmission Oil
In order for the transmission and clutch to
function properly, always maintain the transmis-
sion oil at the proper level and change the oil in
accordance with the Periodic Maintenance Chart .
AWARNING
40
Situate the motorcycle so that it is perpen- " If the oil level is too high, remove the excess
dicular to the ground . oil, using a syringe or some other suitable
Checkthe oil level through the oil level gauge . device .
The oil level should come up above the " If the oil level is too low, add of oil through the
center point . oil filler opening . Use the same type and
brand of oil that is already in the engine .
Oil Change
" Warm up the engine thoroughly so that the oil
will pick up any sediment and drain easily .
Then stop the engine .
Place an oil pan beneath the drain plug .
Remove the drain plug at the right engine
cover lower portion .
41
NOTE
" Pour the good quality motor oil into the en-
gine to 0 .7L .
" Check the oil level (see Oil Level Inspection) .
Tightening Torque
42
Coolant
excessive heat from the
Cooling system Coolant absorbs radiator . If
it to the air at the
Radiator engine and transfers over-
for obstruction by low, the engine
Check the radiator fins obstructions with a the coolant level becomes damage . Check the
off any severe
insects or mud . Clean heats and may suffer
water . each day before riding the motorcy -
low-pressure coolant level
stream of coolant if the level is low .
cle, and replenish accordance with the Peri-
CAUTION Change the coolant in
Chart .
odic Maintenance
water, as from a
Using high - pressure
could damage the NOTE
car wash facility, the radiator's
radiator fins and impair antifreeze is installed in
effectiveness . o A permanent type of
deflect airflow when shipped. It is colored
Do not obstruct or installing unau- the cooling system
glycol. It is mixed at
through the radiator by green, contains ethylene freezing point of -
in front of the ra- 50% solution and has
the
thorized accessories
with the radiator 0 F) .
diator . Interferance 350C (-31
overheating and con-
airflow can lead to
.
sequent engine damage Coolant Level Inspection perpen-
motorcycle so that it is
" Situate the center stand) .
(on its
Radiator Hoses dicular to the ground
for cracks or dete-
Check the radiator hoses looseness in ac-
for
rioration, and connections Maintenance chart .
with the Periodic
cordance
43
" Check the coolant level through the coolant " If the amount of coolant is insufficient, re-
level gauge on the reserve tank . The coolant move the front right side cover, take off the
level should be between the upper and lower cap from the reserve tank and add coolant
level lines . through the filler opening to the upper level
line .
NOTE
44
45
CAUTIONS
Plug Gap 0 .7 - 0 .8 mm
Tightening 27 N-m
Torque (2 .8 kg-m)
46
Air Cleaner
A clogged air cleaner restricts the engine's
air intake, increasing fuel consumption, reducing
engine power, and causing spark plug fouling .
The air cleanerelement must be cleaned and
replaced in accordance with the Periodic Mainte-
nance Chart . In dusty areas, the element should
be cleaned more frequently than the recom-
mended interval .
After riding through rain or on muddy roads,
the element should be cleaned immediately . The
element should be replaced if it is damaged .
A . Fuel Tap C. Bolt
B . Fuel Tank
Element Removal
" Remove the front left and front right side
" Disconnect the leads under the fuel tank .
covers .
" Remove the fuel tank .
" Remove the seat .
" Unscrew the air cleaner housing cap screws,
" Turn the fuel tap to the OFF position .
and take out the air cleaner housing cap .
" Take off the fuel hose from the fuel tap .
" Remove the fuel tank mounting bolt.
47
A . Air Cleaner Housing Cap A . Element
B . Screws
Put a clean, lint-free towel into the air cleaner
" Remove the element housing to keep dirt or other foreign material
from entering .
Inspect the element material for damage . If
any part of the element is damaged, the
element must be replaced .
48
Element Cleaning
" Clean the element in a bath of a high flash-
point solvent .
49
Throttle Control Cable " Check that the safety clip at the lower end of
The throttle control cable is actually an as- the carburetor cable is in place .
sembly of three cables : the throttle cable, the " Check the throttle cable play . When lightly
carburetor cable, and the oil pump cable . The turning the throttle grip, the grip should have
throttle cable runs from the throttle grip to the 2-3 mm of play . If the throttle cable has
cable assembly junction where it connects to improper play, adjust it .
both the carburetor cable which leads to the
carburetor, and the oil pump cable which leads to
the oil pump .
Cable stretch will cause delayed engine re-
sponse and upset the oil pump synchronization,
necessitating periodic adjustment. To compen-
sate for cable stretch, adjust the throttle cable
and the oil pump cable in accordance with the
Periodic Maintenance Chart .
Throttle Cable :
Inspection
" Check to see that the outer cable ends of the
throttle and carburetor cables are fully seated A . Throttle Grip B. 2-3 mm
in each cable adjuster .
50
Adjustment NOTE
" Loosen the locknut on the upper end of the
throttle cable, and turn the adjuster until the o If the throttle grip play cannot be adjusted
proper amount of throttle grip play is ob- with the adjuster at the throttle cable, use the
tained . Tighten the locknut . carburetor cable adjuster at the carburetor .
After completion of the adjustment, tighten
the locknut.
A . Adjuster B . Locknut
A . Carburetor Cable C .Locknut
B . Adjuster D .Safety Clip
51
Oil Pump Cable : " Check to see that the outer cable end of the
Inspection oil pump cable is fully seated in the cable
Warm up the engine, and check the engine adjuster.
idling (See the Carburetor section) . " Check to see that the tang on the oil pump
Check the throttle cable . lever is bent to hold the oil pump inner cable .
Unscrew the engine sprocket cover bolts and " Turn the throttle grip fully, and check to see
remove the engine sprocket cover. if the synchronization mark on the pump
Unscrew the oil pump cover screws, and lever aligns with the mark on the lever stop .
remove the oil pump cover.
NOTE
52
53
Carburetor " Start the engine, and warm it up throughly.
The following procedure covers the idle ad- " Adjust the idle speed to 1200-1400 r/min
justment, which should be performed in accord- (rpm) by turning the idle adjusting screw .
ance with the Periodic Maintenance Chart or " Open and close the throttle a few times to
whenever the idle speed is disturbed . make sure that the idle speed does not
change . Readjust if necessary .
Adjustment " With the engine idling, turn the handlebar to
" First turn in the air screw until it seats lightly, each side . If handlebar movement changes
and back it out 1 1/4 turns . the idle speed, the throttle cable may be
improperly adjusted or incorrectly routed, or
it may be damaged . Be sure to correct any of
these conditions before riding .
AWARNING
54
Clutch
Due to friction plate wear and clutch cable
stretch over a long period of use, the clutch must
be adjusted in accordance with the Periodic
Maintenance Chart .
Adjustment
" Loosen the locknut at the clutch lever.
" Turn the adjuster so that the clutch lever will
have 2-3 mm of play .
55
AWARNING
56
Drive Chain
The drive chain must be checked, adjusted,
and lubricated in accordance with the Periodic
Maintenance Chart for safety and to prevent
excessive wear . If the chain becomes badly
worn or maladjusted - either too loose ortoo tight
- the chain could jump off the sprockets or break.
AWARNING
57
Adjustment
" Loosen the rear torque link nut .
CAUTION
" If the chain is too tight, back out the left and
right chain adjusting nuts evenly, and kick the
wheel forward until the chain is too loose .
" Turn both chain adjusting nuts evenly until
A . Torque Link Nut the drive chain has the correct amount of
slack . To keep the chain and wheel properly
" Loosen the left and right chain adjuster aligned, the notch on the left chain adjuster
locknuts . should align with the same swing arm mark
" Remove the cotter pin, and loosen the axle that the right chain adjuster notch aligns with .
nut . 58
59
Measure the length of 20 links on the straight Drive Chain 20-Link Length
part of the chain from pin center of the 1 st pin
to pin center of the 21 st pin . Since the chain Service Limit : 323 mm (12.7 in)
may wear unevenly, take measurements at
several places . AWARNING
If the length exceeds the service limit, the
chain should be replaced . For safety, use only the standard chain .
Have it installed by an authorized
Kawasaki dealer .
NOTE
60
Dvect'on o! rotauon
61
Brakes Disc Brake Fluid :
Brake Wear Inspection In accordance with the Periodic Maintenance
In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in the reser-
Chart, inspect the brakes for wear . For each front voirs and change the brake fluid . The brake fluid
and rear disc brake caliper, if the thickness of should also be changed if it becomes contami-
either pad is less than 1 mm, replace both bads nated with dirt or water.
in the caliper as a set. Pad replacement should
be done by an authorized Kawasaki dealer. Fluid Requirement
Recommended fluids are given in the table .
If none of the recommended brake fluids are
available, use extra heavy-duty brake fluid only
from a container marked D.O .T . 3 or D .O .T .4 .
62
NOTE
63
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CAUTION
Adjustment
" To adjust the rear brake light switch, move
the switch up or down by turning the adjusting
nut .
66
Stable Steering System " Turn the adjuster clockwise for heavy
Adjustment steering handling condition, and the opposite
The stable steering system has 7 adjustable way for light steering handling condition .
way to rebound damping and to assure a smooth
and well controlled ride
A. Adjuster B. Mark
A. Adjusting Sleeve
If the spring action feels too soft or too stiff, A. Hook Wrench B. Wrench Bar
adjust it in accordance with the following table.
68
Wheels
AWARNING
Tires :
To avoid an injury, be careful not to hit Payload and Tire Pressure
your hand against the frame or other Failureto maintain properinflating pressures
parts when adjusting the rear shock or observe payload limits for your tires may
absorber . adversely affect handling and performance of
your motorcycle and can result in loss of control.
The maximum recommended load in addition to
vehicle weight is 150 kg, including rider, passen-
ger, baggage, and accessories .
69
NOTE Tire Wear, Damage
As the tire tread wears down, the tire becomes
0 Measure the tire pressure when the tires are more susceptible to puncture and failure. An
cold (that is, when the motorcycle has not accepted estimate is that 90% of all tire failures
been ridden more than a mile during the past occur during the last 10% of tread life (90%
3 hours). worn) . So it is false economy and unsafe to use
0 Tire pressure is affected by changes in ambi- the tires until they are bald .
ent temperature and altitude, and so the tire " In accordance with the Periodic Maintenance
pressure should be checked and adjusted Chart ; measure the depth of the tread with a
when your riding involves wide variations in depth gauge, and replace any tire that has
temperature or altitude. worn down to the minimum allowable tread
depth .
Front 1 mm
Rear 2 mm
AWARNING
Standard Tire
" Visually inspect the tire for cracks and cuts, Rear 100/90 - 18 56P
replacing the tire in case of bad damage . IRC NR55
Swelling or high spots indicate internal dam-
age, requiring tire replacement .
" Remove any imbedded stones or other for-
eign particles from the tread .
NOTE
72
Battery Installation
" Putthe battery in the batterycase, and route
the battery vent hose as shown on the
caution label .
" Put a light coat of grease on the terminals to
prevent corrosion .
73
Putthebattery cover on the battery, and hook Headlight Beam
the rubber band . Horizontal Adjustment
Connectthe white/red lead to the (+) terminal, The headlight beam is adjustable horizontally .
and then connectthe blackyellow lead to the If not properly adjusted horizontally, the beam
(-) terminal . will point the one side rather than straight ahead.
Install the parts removed.
CAUTION
74
Vertical Adjustment
The headlight beam is adjustable vertically,
If adjusted too low, neither low nor high beam
will illuminate the road far enough ahead. If
adjusted too high, the high beam will fail to
illuminate the road close ahead, and the low
beam will blind oncoming drivers .
75
o Replace the blown fuse with anew one of AWARNING
the correct capacity, as specified on the
fuse case . Gasoline is extremely flammable and
can be explosive under certain condi-
tions . Turn the ignition switch OFF . Do
not smoke . Make sure the area is well
ventilated and free from any source of
flame or sparks ; this includes any ap-
pliance with a pilot light . Make sure the
engine is cold before working . Wipe
any fuel off the engine before starting
it .
Inspection
" Turn the fuel tap to the "OFF" position .
" Unscrew the sediment cup from the bottom
Fuel System of the fuel tap, and check to see if water or
Accumulation of moisture or sediment in the dirt gas accumulated in the sediment cup .
fuel system will restrict the flow of fuel and
cause carburetor mal Iuction . The system should
be checked in accordance with the Periodic
Maintenence Chart .
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A . Sediment Cup
A. Sediment Cup C. Filter
B . Gasket
" Being careful not to damage the gasket and
filter, remove them out of the fuel tap using
Using a piece of cloth, wipe out the inside of
a thin screwdriver .
the fuel tap, wash the cup and filter in a high
flash-point solvent .
If water has accumulated in the sediment
cup, holding a container under the fuel tap,
open the fuel tap until only fuel comes out,
then off the tuel tap .
Visually inspect the gasket and filter . Re-
place them with new ones if they are dam-
aged .
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" Rear opening of the muffler ; Cover with a Preparation for Washing
plastic beg secured with a rubber band . Before washing, precautions must be taken
to keep water off the following places :
NOTE " Rear opening of the muffler ; Cover with a
plastic beg secured with a rubber band .
o Turn the fuel tap lever to the RES position, " Clutch and brake levers, switch housings on
and check for fuel leaks .
the handlebar ; Cover with plastic bags .
o If any water or dirt apears during the above
" Ignition switch ; Cover the keyhole with tape .
operation, have the fuel system checked by
" Air cleaner intake ; Close up the intake with
an authorized Kawasaki Dealer. tape, or stuff with rags .
Cleaning
Where to be Careful
For the prolonged life of your motorcycle,
Avoid spraying water with any great force
wash it down immediately after it has been
near the following places :
splashed with seawater or exposed to sea " Speedometer and tachometer .
breeze ; operated on rainy days, rough roads, or
" Disc brake master cylinders and calipers .
in dusty areas ; or operated on roads on which
salt has been scattered for ice removal .
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" Under the fuel tank ; If water gets into the After Washing
ignition coil or into the spark plug cap, the " Remove the plastic bags and tape, and
spark will jump through the water and be clean the air cleaner intake .
grounded out . When this happens, the mo- " Lubricate the pivots, nuts, and bolts .
torcycle will not start and the affected parts " Test the brakes before motorcycle opera-
must be wiped dry tion .
" Front and rear hubs " Start the engine and run it for 5 miniutes .
" Steering pivot (steering stem head pipe)
" Swing arm pivot AWARNING
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t
STORAGE
Gasoline isextremely flammable and can beexplosive undercertain conditions . Turn the
free from
ignition switch OFF . Do not smoke . Make sure the area is well ventilated and
appliance with a pilot light .
any source of flame or sparks ; this includes any
Kick the
" Remove the spark plug and put several drops of SE class SAE 30 oil into the cylinder .
cylinder wall with oil, and install the spark plug .
engine over slowly a few times to coat the
" Reduce tire pressure by about 20% .
this cannot
" Set the motorcycle on a box or stand so that both wheels are raised off the ground . (If
rear wheels to keep dampness away from the tire rubber .)
be done, put boards under the front and
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" 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 itwhere it will not be exposed to direct sunlight, moisture, orfreezing
temperatures . During storage it should be given a slow charge (one ampere or less) about once
a month . Keep the battery well charged during cold weather so that the electrolyte does not freeze
and crack open the battery . The more discharged the battery becomes, the more easily it freezes .
" Tie a plastic bag over the exhaust pipe to prevent moisture from entering .
" Put a cover over the motorcycle to keep dust and dirt from collecting on it .
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