Kawasaki W800 Owner's Manual PDF

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ENGLISH
Motorcycle
Owner's Manual
Original instructions
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Whenever you see the symbols NOTE

shown below, heed their instructions!
Always follow safe operating and main-
○ NOTE indicates information that may
help or guide you in the operation or
tenance practices. service of the vehicle.
DANGER
DANGER indicates a hazardous
situation which, if not avoided,
will result in death or serious in-
jury.
WARNING
WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
NOTICE
NOTICE is used to address prac-
tices not related to personal in-
jury.
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NOTICE
THIS PRODUCT HAS BEEN MAN-
UFACTURED FOR USE IN A
REASONABLE AND PRUDENT
MANNER BY A QUALIFIED OP-
ERATOR AND AS A VEHICLE ON-
LY.
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FOREWORD
Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-
torcycle is the product of Kawasaki's advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety and performance.
Please read this Owner's Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycle's controls, its fea-
tures, capabilities, and limitations. This manual offers many safe riding tips, but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this ve-
hicle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.
To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-
formation on their Kawasaki Motorcycle, a Service Manual is available for pur-
chase from any authorized Kawasaki motorcycle dealer. The Service Manual
contains detailed disassembly and maintenance information. Those who plan to do
their own work should, of course, be competent mechanics and possess the spe-
cial tools described in the Service Manual.
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Keep this Owner's Manual aboard your motorcycle at all times so that you can re-
fer 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 pri-
or written permission.
This publication includes the latest information available at the time of printing.
However, there may be minor differences between the actual product and illustra-
tions and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company
© 2013 Kawasaki Heavy Industries, Ltd. Jun. 20, 2013. (1)

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TABLE OF CONTENTS
SPECIFICATIONS ................................ 10 Fuel Requirement: ......................... 32

LOCATION OF PARTS ........................ 13 Filling the Tank: .............................. 34
LOADING INFORMATION ................... 16 Stands ................................................ 35
GENERAL INFORMATION .................. 19 Seat .................................................... 37
Meter Instruments .............................. 19 Helmet Hook/Holding Cable .............. 38
Speedometer and Tachometer ...... 20 Tool Kit ............................................... 40
LCD (Clock, Odometer, Trip Meter) 21 Document Compartment ................... 40
Warning/Indicator Lights ................ 24 Tying Hooks ....................................... 41
Key ..................................................... 26 Rear View Mirror ................................ 41
Ignition Switch/Steering Lock ............ 26 BREAK-IN ............................................ 43
Right Handlebar Switches ................. 28 HOW TO RIDE THE MOTORCYCLE .. 45
Engine Stop Switch: ...................... 28 Starting the Engine ............................ 45
Starter Button: ................................ 29 Jump Starting ..................................... 47
Left Handlebar Switches .................... 29 Moving Off .......................................... 50
Dimmer Switch: .............................. 29 Shifting Gears .................................... 51
Turn Signal Switch: ........................ 30 Braking ............................................... 52
Horn Button: ................................... 30 Stopping the Engine .......................... 53
Brake/Clutch Lever Adjuster .............. 30 Stopping the Motorcycle in an Emer-
Fuel Tank Cap .................................... 31 gency .............................................. 54
Fuel .................................................... 32 Parking ............................................... 55
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Catalytic Converter ............................ 57 Spoke and Rim: ............................. 120

SAFE OPERATION .............................. 59 Battery ................................................121
Safe Riding Technique ....................... 59 Headlight Beam .................................127
Daily Checks ...................................... 62 Fuses .................................................129
Additional Considerations for High General Lubrication ...........................131
Speed Operation ............................ 65 Cleaning Your Motorcycle ..................132
MAINTENANCE AND ADJUSTMENT 67 STORAGE ............................................ 138
Periodic Maintenance Chart .............. 68 ENVIRONMENTAL PROTECTION ..... 140
Engine Oil .......................................... 78 LOCATION OF LABELS ...................... 141
Spark Plugs ....................................... 84
Kawasaki Clean Air System .............. 85
Valve Clearance ................................. 86
Air Cleaner ......................................... 87
Throttle Control System ..................... 91
Engine Vacuum Synchronization ....... 94
Idle Speed .......................................... 94
Clutch ................................................. 96
Drive Chain ........................................ 97
Brakes ................................................105
Brake Light Switch .............................110
Front Fork ..........................................112
Rear Shock Absorber ........................113
Wheels ...............................................117
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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.)
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)
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SPECIFICATIONS 11
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
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
Castor 27°
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12 SPECIFICATIONS
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)
ELECTRICAL EQUIPMENT
Battery 12 V 10 Ah
Headlight High beam 12 V 60 W
Low beam 12 V 55 W
Tail/Brake Light 12 V 5/21 W
Specifications are subject to change without notice, and may not apply to every
country.
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LOCATION OF PARTS 13
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)
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14 LOCATION OF PARTS
1. Front Fork 8. Seat Lock 15. Center Stand

2. Headlight 9. Helmet Hook 16. Side Stand
3. Turn Signal Lights 10. Grab Rail 17. Battery
4. Fuel Tank Cap 11. Tying Hook 18. Muffler
5. Idle Adjusting Screw 12. Tail/Brake Light 19. Rear Shock Absorber
6. Air Cleaner Element 13. Brake Disc 20. Drive Chain
7. Junction Box (Fuse Box) 14. Shift Pedal
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LOCATION OF PARTS 15
1. Helmet Holding Cable 7. Brake Lining Wear Indica- 11. Oil Drain Bolt
2. Tool Kit tor 12. Oil Filter
3. Air Cleaner Element 8. Rear Brake Light Switch 13. Horn
4. Seat 9. Oil Filler Cap 14. Brake Caliper
5. Rear Brake Pedal 10. Oil Level Inspection Win-
6. Spark Plugs dow
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16 LOADING INFORMATION
LOADING INFORMATION
accessories, and in loading the motor-

WARNING cycle, you are personally responsible
Incorrect loading, improper in- for your own safety and the safety of
stallation or use of accessories, other persons involved.
or modification of your motor- NOTE
cycle may result in an unsafe rid-
ing condition. Before you ride the
○ Kawasaki Parts and Accessories
have been specially designed for
motorcycle, make sure it is not
use on Kawasaki motorcycles. We
overloaded and that you have fol-
strongly recommend that all parts
lowed these instructions.
and accessories you add to your mo-
torcycle be genuine Kawasaki com-
With the exception of genuine Kawa- ponents.
saki Parts and Accessories, Kawasaki
has no control over the design or appli- Because a motorcycle is sensitive to
cation of accessories. In some cases, changes in weight and aerodynamic
improper installation or use of acces- forces, you must take extreme care in
sories, or motorcycle modification, will carrying cargo, passengers and/or in
void the motorcycle warranty, can neg- the fitting of additional accessories.
atively affect performance, and can The following general guidelines have
even be illegal. In selecting and using
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LOADING INFORMATION 17
been prepared to assist you in making Baggage weight should also be dis-
your determinations. tributed equally on both sides of the
1. Any passenger should be thor- motorcycle. Avoid carrying baggage
oughly familiar with motorcycle op- that extends beyond the rear of the
eration. The passenger can affect motorcycle.
control of the motorcycle by improp- 4. Baggage should be securely at-
er positioning during cornering and tached. Make sure that the bag-
sudden movements. It is important gage will not move around while
that the passenger sit still while the you are riding. Recheck baggage
motorcycle is in motion and not in- security as often as possible (not
terfere with the operation of the mo- while the motorcycle is in motion)
torcycle. Do not carry animals on and adjust as necessary.
your motorcycle. 5. Do not carry heavy or bulky items
2. You should instruct any passenger on a luggage rack. They are de-
before riding to keep his feet on the signed for light items, and overload-
passenger footpegs and hold on to ing can affect handling due to
the operator or grab rail. Do not changes in weight distribution and
carry a passenger unless he or she aerodynamic forces.
is tall enough to reach the footpegs 6. Do not install accessories or carry
and footpegs are provided. baggage that impairs the perform-
3. All baggage should be carried as ance of the motorcycle. Make sure
low as possible to reduce the effect that you have not adversely af-
on the motorcycle center of gravity. fected any lighting components,
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18 LOADING INFORMATION
road clearance, banking capability vehicle. Kawasaki does not manu-
(i.e., lean angle), control operation, facture sidecars or trailers for mo-
wheel travel, front fork movement, torcycles and cannot predict the
or any other aspect of the motorcy- effects of such accessories on han-
cle's operation. dling or stability, but can only warn
7. Weight attached to the handlebar that the effects can be adverse and
or front fork will increase the mass that Kawasaki cannot assume re-
of the steering assembly and can sponsibility for the results of such
result in an unsafe riding condition. unintended use of the motorcycle.
8. Fairings, windshields, backrests, Furthermore, any adverse effects
and other large items have the ca- on motorcycle components caused
pability of adversely affecting stabil- by the use of such accessories will
ity and handling of the motorcycle, not be remedied under warranty.
not only because of their weight, Maximum Load
but also due to the aerodynamic
Weight of rider, passenger, baggage, and
forces acting on these surfaces
accessories must not exceed 183 kg (403
while the motorcycle is in operation. lb).
Poorly designed or installed items
can result in an unsafe riding condi-
tion.
9. This motorcycle was not intended
to be equipped with a sidecar or to
be used to tow any trailer or other
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GENERAL INFORMATION 19
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 Indi-
cator 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)
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20 GENERAL INFORMATION
Speedometer and Tachometer
The speedometer shows the speed NOTICE
of the vehicle. The needle of the Engine r/min (rpm) should not be
speedometer and tachometer momen- allowed to enter the red zone; op-
tarily sweeps from the minimum to eration in the red zone will over-
maximum and back to minimum when stress the engine and may cause
the ignition switch is turned to “ON”. serious engine damage.
This checks the operation of the meter
needles. So if they do not operate cor-
rectly, have the function checked by an
authorized Kawasaki dealer.
The tachometer shows the engine
speed in the revolutions per minute
(r/min, rpm). On the right side of the
tachometer face is a portion called the
“red zone.” Engine r/min (rpm) in the
red zone is above maximum recom-
mended engine speed and is also
above the range for good perform-
ance.
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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 button
shifts the display through the following
three modes: CLOCK, ODO, and TRIP.
When the ignition switch is turned to
“ON”, all the LCD segments are dis-
played for three seconds, then the
clock or meters operate normally de-
pending on the mode selected. A. MODE Button
B. RESET Button
Clock -
To adjust the hours and minutes:
• Turn the ignition switch to “ON”.
• Push the MODE button to display
the clock.
NOTE
○ For safe operation do not press the
MODE button or RESET button
while riding.
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• Push the RESET button for more

than two seconds. Both the hour and
• Push the RESET button. The hour
display stops blinking and the minute
minute displays start blinking. display starts blinking. Push the
MODE button to advance the mi-
nutes.
• Push the RESET button. The hour

display only blinks. Push the MODE
button to advance the hours. • Push the RESET button. Both the
hour and minute displays start blink-
ing again.
• Push
plays
the MODE button. The dis-
stop blinking and the clock
starts working.
NOTE
○ Pushing the MODE button momen-
tarily advances the hour or minute
step by step. Pushing and holding
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the button advance the hour or mi- NOTE

nute continuously.
○ The clock works normally from the ○ The data is maintained even if the
battery is disconnected.
back-up power while the ignition
switch is turned off.
○ When the figures come to 999999,
they are stopped and locked.
○ When the battery is disconnected,
the clock resets to 1:00 and starts Trip Meter -
working again when the battery is The trip meters show the distance in
connected. kilometers traveled since it was last re-
set to zero.
Odometer - To reset the trip meter:
The odometer shows the total dis-
tance in kilometers the vehicle has • Push the MODE button to display
the trip meter.
been ridden. This meter cannot be re-
set. • 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.
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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.
Refer to the Maintenance and Adjust-
ment chapter for more detailed engine
oil information.
: When the headlight is on high

beam, the high beam indicator light is
lit.
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: When the turn signal switch is : The fuel level warning indicator
turned to left or right, the turn signal in- light goes on when the ignition switch
dicator light blinks on and off. is turned to “ON” and goes off soon
after ensuring that its circuit functions
N : When the transmission is in neutral, properly.
the neutral indicator light goes on. The warning indicator light also goes
on and “FUEL” blinks in the LCD when
FI: The fuel injection (FI) warning indi- approximately 3.1 L (0.8 US gal) of fuel
cator light goes on when the ignition remains.
switch is turned to “ON” and goes off
soon after ensuring that its circuit func-
tions properly.
The warning indicator light also goes
on whenever the troubles occur in digi-
tal fuel injection system (DFI). If the
warning indicator light blinks on, have Refuel at the earliest opportunity
the DFI system checked by an author- when the fuel level warning indicator
ized Kawasaki dealer. light goes on and “FUEL” blinks.
When vehicle stands with side stand,
fuel level warning indicator light cannot
show the amount of fuel in the fuel tank
exactly. Stand upright the vehicle to
check the fuel level.
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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 Ka-
wasaki 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
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Engine off. Electrical circuits

OFF
off.
Engine on. All electrical equip-
ON
ment can be used.
Steering locked. Engine off.
LOCK
Electrical circuits off.
Steering locked. Engine off. Tail
P (Park) and city lights on. Other electri-
cal circuits cut off.
NOTE
○ The tail and city lights are on when-
ever the ignition 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”.
○ If you leave the P (Park) position on
for a long time (one hour), the battery
may become totally discharged.
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Right Handlebar Switches NOTE
Engine Stop Switch:
In addition to the ignition switch, the
○ Although the engine stop switch
stops the engine, it does not turn off
engine stop switch must be in all the electrical circuits. Ordinarily,
the position for the motorcycle to the ignition switch should be used to
operate. stop the engine.
The engine stop switch is for emer-
gency use. If 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 Motor- high beam indicator light is lit.
cycle" chapter for starting instructions. High beam.......( )
Low beam.......( )
A. Dimmer Switch
B. Turn Signal Switch
C. Horn Button
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Turn Signal Switch: Brake/Clutch Lever Adjuster
When the turn signal switch is turned There are adjusters on both the
to the left ( ) or right ( ), the brake and clutch levers. The brake lev-
corresponding turn signal blinks on er adjuster has 4 positions and the
and off. clutch lever adjuster has 5 positions so
To stop blinking, push the switch in. that the released lever position can be
Horn Button: adjusted to suit the operator's hands.
When the horn button is pushed, the Push the lever forward and turn the
horn sounds. adjuster to align the number with the
triangular mark on brake lever and the
triangular mark on the clutch lever.
The distance from the grip to the re-
leased lever is minimum at Number 4
for the brake lever and Number 5 for
the clutch lever, and maximum at Num-
ber 1 for both.
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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 to the right.
To close the cap, push it down into
place with the key inserted. The key
can be removed by turning it to the left
to the original position.
NOTE
A. Brake Lever Adjuster

○ The fuel tank cap cannot be closed
without the key inserted, and the key
B. Mark
C. Clutch Lever Adjuster
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 to
cap, or the cap cannot be locked.
use only unleaded gasoline with a min-
imum 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 detonation
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 NOTICE
Do not use leaded gasoline, as
this will destroy the catalytic con-
verter. (For further information,
refer to the “Catalytic Converter”
section in the “How to Ride the
Motorcycle” chapter.)
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equal to or higher than that shown in

NOTICE the table.
If engine “knocking" or “pinging"
occurs, use a different brand of Fuel Type Unleaded Gasoline
gasoline of a higher octane rat- Ethanol Content E10 or less
ing. If this condition is allowed to Research Octane Num-
continue, it can lead to severe en- Minimum
ber (RON)
gine damage.Gasoline quality is Octane Rating
91
important. Fuels of low quality or
not meeting standard industry
specifications may result in un-
NOTICE
satisfactory performance. Oper- Do not use any fuel that contains
ating problems that result from more ethanol or other oxygen-
the use of poor quality or no rec- ates than specified for E10 fuel*
ommended fuel may not be cov- in this vehicle. Damage to the en-
ered under your warranty. gine and fuel system, or engine
starting and/or performance
problems may result from the use
Fuel Type and Octane Rating of improper fuel.
Use clean, fresh unleaded gasoline
with an ethanol volume content not
more than 10% and an octane rating *E10 means fuel containing up to
10% ethanol as specified by European
directive.
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Filling the Tank:
Avoid filling the tank in the rain or WARNING
where heavy dust is blowing so that Gasoline is extremely flammable
the fuel does not get contaminated. and can be explosive under cer-
tain conditions, creating the po-
tential 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 in-
cludes any appliance with a pilot
light. Never fill the tank com-
pletely to the top. If the tank is
filled completely to the top, heat
may cause the fuel to expand and
A. Tank Cap overflow through the vents in the
B. Fuel Tank tank cap. After refueling, make
C. Top Level
D. Filler Neck sure the tank cap is closed se-
curely. If gasoline is spilled on
the fuel tank, wipe it off immedi-
ately.
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NOTICE Stands
The motorcycle is equipped with two
Certain ingredients in gasoline stands: a center stand and a side
may cause paint fading or dam- stand.
age. Be extra careful not to spill
fuel during refueling.
A. Side Stand
NOTE
○ When using the side stand, turn the
handlebar to the left.
Do not sit on the motorcycle while it
is on its side stand or centre stand.
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Always kick the stand fully up before To set the motorcycle up on the cen-
sitting on the motorcycle. ter stand, step down firmly on the
stand, and then lift the motorcycle up
NOTE and to the rear using the grab rail as a
○ The motorcycle is equipped with a handhold. Don't pull up on the seat to
side stand switch. This switch is de- lift as this will damage the seat.
signed so that the engine stops if the
clutch is engaged with the transmis-
sion in gear when the side stand is
down.
A. Center Stand
B. Step down
C. Grab Rail
D. Lift up
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Seat Seat Installation

Seat Removal •Insert the tab on the front of the seat
•Remove the seat by inserting the
ignition key into the seat lock and
into the hole on the frame, and the
projections on the middle of the seat
turning it clockwise. into the hole in the frame.
A. Seat A. Seat
B. Seat Lock B. Tab
C. Ignition Key C. Hole
D. Turn Clockwise D. Projections
E. Holes
• Push
clicks.
down the seat until the lock
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• Pull up the front and rear end of the

seat to make sure they are securely
Helmet Hook/Holding Cable
Helmets can be secured to the mo-
locked. torcycle using the helmet hook located
at the left side of the motorcycle or the
helmet holding cable located under the
seat.
Helmet Hook -
To unlock the helmet hook, insert the
ignition key into the lock and turning it
clockwise.
A. Helmet Hook
B. Ignition Key
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Helmet Holding Cable -

Helmet can be secured to the motor- WARNING
cycle using the helmet holding cable. Riding with helmets attached to
Securely hook the helmet ring with the the hooks could cause an acci-
helmet holding cable and install the dent by distracting the operator
seat. or interfering with normal vehicle
operation. Do not ride the motor-
cycle with helmets attached to
the hooks.
A. Helmet Holding Cable

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Tool Kit Document Compartment
The tool kit is located under the seat. The document compartment is pro-
The kit contains tools that are helpful vided at the rear under the seat. Use
in making roadside repairs, adjust- the compartment to keep the owner's
ments, and some maintenance proce- manual and any papers or documents
dures explained in this manual. Keep that should be kept with the motor-
the tool kit in the original place. cycle.
A. Tool Kit A. Document Compartment

B. Band B. Band
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Tying Hooks Rear View Mirror

When tying up light loads to the seat, Rear View Mirror Adjustment
use the tying hooks located on the left
and right sides under the seat.
•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
Lower Hexagonal Area:
30 N·m (3.1 kgf·m, 22 ft·lb)
Upper Hexagonal Area:
30 N·m (3.1 kgf·m, 22 ft·lb)
A. Tying Hooks
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A. Lower Hexagonal Area for Tightening

B. Upper Hexagonal Area
C. Cover
D. Rear View Mirror
NOTE
○ If a torque wrench is not available,
this item should be serviced by a Ka-
wasaki dealer.
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BREAK-IN 43
BREAK-IN
The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the
break-in period. If the motorcycle is not used carefully during this period, you may
very well end up with a "broken down" instead of a "broken in" motorcycle after a
few thousand kilometers.
The following rules should be observed during the break-in period.
• The table shows maximum recommended engine speed during the break-in peri-
od.
Distance traveled Maximum engine speed
0 ~ 800 km (0 ~ 500 mi) 4 000 r/min (rpm)
800 ~ 1 600 km (500 ~ 1 000 mi) 6 000 r/min (rpm)
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.
Black plate (44,1)
44 BREAK-IN
WARNING
New tires are slippery and may cause loss of control and injury.
A break-in period of 160 km (100 miles) is necessary to establish normal
tire traction. During break-in, avoid sudden and maximum braking and ac-
celeration, and hard cornering.
In addition to the above, at 1 000 km (600 mi) it is extremely important that the
owner have the initial maintenance service performed by an authorized Kawasaki
dealer.
Black plate (45,1)
HOW TO RIDE THE MOTORCYCLE 45
HOW TO RIDE THE MOTORCYCLE
Starting the Engine

• Check
in the
that the engine stop switch is
position.
• Turn the ignition switch to “ON”.
• Make
neutral.
sure the transmission is in
• 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
NOTE
○ The FI warning indicator light may
stay on for a few seconds. However,
as long as it goes off soon, there is
Black plate (46,1)
46 HOW TO RIDE THE MOTORCYCLE

no problem with the motorcycle rid- NOTE
ing.
○ While the engine is cold, the fast idle ○ The motorcycle is equipped with a
starter lockout switch. This switch is
system automatically raises the en- designed so that the engine does not
gine idling speed. At this time, the start if the transmission is in gear
engine warning indicator light may and the side stand is down. How-
go on if you operate the throttle grip ever, the engine can be started if the
unnecessarily. clutch lever is pulled and the side
○ The motorcycle is equipped with a stand is fully up.
vehicle-down sensor, which causes
the engine to stop automatically.
NOTICE
Do not operate the starter contin-
uously for more than 5 seconds
or the starter will overheat and
the battery power will drop tem-
porarily. Wait 15 seconds be-
tween each operation of the
starter to let it cool and the bat-
tery power recover. A. Clutch Lever
B. Starter Lockout Switch
Black plate (47,1)
NOTICE Jump Starting

If your motorcycle battery is “run
Do not let the engine idle longer down,” it should be removed and
than five minutes, or engine over- charged. If this is not practical, a 12
heating and damage may occur. volt booster battery and jumper cables
may be used to start the engine.
DANGER
Battery acid generates hydrogen
gas which is flammable and ex-
plosive under certain conditions.
It is present within a battery at all
times, even in a discharged con-
dition. Keep all flames and sparks
(cigarettes) away from the bat-
tery. Wear eye protection when
working with a battery. In the
event of battery acid contact with
skin, eyes, or clothing, wash the
affected areas immediately with
water for at least 5 minutes. Seek
medical attention.
Black plate (48,1)

Connecting Jumper Cables
•Remove the seat.
•Make sure the ignition switch is
turned to OFF.
•Remove the bracket and move the
ECU aside without disconnecting the
connectors from the ECU. (Refer to
the Battery section of the “Mainte-
nance and Adjustment” chapter.)
•Connect a jumper cable from the
positive (+) terminal of the booster
battery to the positive (+) terminal of A. Motorcycle Battery Positive (+) Terminal
B. From Booster Battery Positive (+) Terminal
the motorcycle battery. C. Unpainted Metal Surface
D. From Booster Battery Negative (–) Termi-
nal
• Connect another jumper cable from

the negative (–) terminal of the boos-
ter battery to your motorcycle rear
shock absorber upper mount nut or
other unpainted metal surface. Do
not use the negative (–) terminal of
the battery.
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DANGER NOTICE
Batteries contain sulfuric acid Do not operate the starter contin-
that can cause burns and pro- uously for more than 5 seconds
duce hydrogen gas which is or the starter will overheat and
highly explosive. Do not make the battery power will drop tem-
this last connection at the fuel porarily. Wait 15 seconds be-
system or battery. Take care not tween each operation of the
to touch the positive and nega- starter to let it cool and the bat-
tive cables together, and do not tery power recover.
lean over the battery when mak-
ing this last connection. Do not
connect to a frozen battery. It
• After the engine has started, discon-
nect the jumper cables. Disconnect
could explode. Do not reverse po- the negative (–) cable from the mo-
larity by connecting positive (+) torcycle first.
to negative (–), or a battery explo-
sion and serious damage to the
• Reinstall the parts removed.
electrical system may occur.
• Follow the standard engine starting

procedure.
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Moving Off NOTE
• Check that the side stand is up. ○ The motorcycle is equipped with a
• Pull in the clutch lever. side stand switch. This switch is de-
• Shift into 1st gear. signed so that the engine does not
• Open the throttle a little, and start to
let out the clutch lever very slowly.
start if the transmission is in gear
and the side stand is down.
• As the clutch starts to engage, open
the throttle a little more, giving the
engine just enough fuel to keep it
from stalling.
A. Shift Pedal
Black plate (51,1)
Shifting Gears motorcycle is standing still, the trans-

• Close the throttle while pulling in the
clutch lever.
mission cannot be shifted past neu-
tral from 1st gear. To use the positive
• Shift into the next higher or lower
gear.
neutral finder, shift down to 1st gear,
then lift up on the shift pedal while
• Open the throttle half way, while re-
leasing the clutch lever.
standing still. The transmission will
shift only into neutral.
WARNING
Downshifting to a lower gear at
high speed causes engine rpm to
increase excessively, potentially
damaging the engine and it may
also cause the rear wheel to skid
and cause an accident. Down-
shifting should be done below 5
000 rpm for each gear.
NOTE
○ The transmission is equipped with a
positive neutral finder. When the
Black plate (52,1)

Braking • Never lock the brakes, or it will cause
• Close the throttle completely, leaving
the clutch engaged (except when
the tires to skid. When turning a cor-
ner, it is better not be brake at all.
shifting gears) so that the engine will Reduce your speed before you get
help slow down the motorcycle. into the corner.
• Shift down one gear at a time so that
you are in 1st gear when you come
• For emergency braking, disregard
downshifting, and concentrate on ap-
to a complete stop. plying the brakes as hard as possible
• When stopping, always apply both
brakes at the same time. Normally
without skidding.
the front brake should be applied a

little more than the rear. Shift down
or fully disengage the clutch as nec-
essary to keep the engine from stall-
ing.
A. Front Brake Lever

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Stopping the Engine

• Close the throttle completely.
• Turn the transmission
Shift the into neutral.
• Support ignition switch to “OFF”.
• level surface
the motorcycle on a firm,
with the side stand or
center stand.
• Lock the steering.
NOTE
A. Rear Brake Pedal ○ The motorcycle is equipped with a
vehicle-down sensor, which causes
the engine to stop automatically.
Black plate (54,1)

Stopping the Motorcycle in an In an emergency situation such as
Emergency throttle failure, your vehicle may be
Your Kawasaki Motorcycle has been stopped by applying the brakes and
designed and manufactured to provide disengaging the clutch. Once this stop-
you optimum safety and convenience. ping procedure is initiated, the engine
However, in order to fully benefit from stop switch may be used to stop the
Kawasaki's safety engineering and engine. If the engine stop switch is
craftsmanship, it is essential that you, used, turn off the ignition switch after
the owner and operator, properly main- stopping the motorcycle.
tain your motorcycle and become thor-
oughly familiar with its operation.
Improper maintenance can create a
dangerous situation known as throttle
failure. Two of the most common
causes of throttle failure are:
1. An improperly serviced or clogged
air cleaner may allow dirt and dust
to enter the throttle body and stick
the throttle open.
2. During removal of the air cleaner,
dirt is allowed to enter and jam the
throttle body.
Black plate (55,1)
Parking
WARNING
WARNING The engine and exhaust system
Operating or parking the vehicle get extremely hot during normal
near flammable materials can operation and can cause serious
cause a fire, and can result in burns.
property damage or severe per- Never touch a hot engine, ex-
sonal injury. haust pipe, or muffler during op-
Do not idle or park your vehicle in eration or after stopping the
an area where tall or dry vegeta- engine.
tion, or other flammable materials
could come into contact with the
muffler or exhaust pipe.
• Shift the transmission into neutral
and turn the ignition switch to “OFF”.
• Support the motorcycle on a firm,
level surface with the side stand or
center stand.
NOTICE
Do not park on a soft or steeply
inclined surface, or the motor-
cycle may fall over.
Black plate (56,1)
• Ifstructure,
parking inside a garage or other
be sure it is well ventilated
○ Do not leave the ignition switch at P
position too long, or the battery will
and the motorcycle is not close to discharge.
any source of flame or sparks; this
includes any appliance with a pilot
light.
WARNING
Gasoline is extremely flammable
and can be explosive under cer-
tain conditions.
• Lock
theft.
the steering to help prevent
NOTE
○ When stopping near traffic at night,
you can leave the taillight and city
light on for greater visibility by turning
the ignition switch to the P (Park) po-
sition.
Black plate (57,1)
Catalytic Converter
This motorcycle is equipped with a WARNING
catalytic converter in the exhaust sys- Operating or parking the vehicle
tem. The converter reacts with carbon near flammable materials can
monoxide, hydrocarbons and nitrogen cause a fire, and can result in
oxides to convert them into carbon di- property damage or severe per-
oxide, water, nitrogen and oxygen re- sonal injury.
sulting in much cleaner exhaust gases Do not idle or park your vehicle in
to be discharged into the atmosphere. an area where tall or dry vegeta-
For proper operation of the catalytic tion, or other flammable materials
converter, the following cautions must could come into contact with the
be observed. muffler or exhaust pipe.
WARNING
The engine and exhaust system
get extremely hot during normal
operation and can cause serious
burns.
Never touch a hot engine, ex-
haust pipe, or muffler during op-
eration or after stopping the
engine.
Black plate (58,1)
• Use only unleaded gasoline. Never

use leaded gasoline. Leaded gaso-
line significantly reduces the capabil-
ity of the catalytic converter.
• Do not operate the vehicle with the
engine or any one cylinder misfiring.
Under these conditions unburned
air/fuel mixture flowing out of engine
excessively accelerates reaction in
the converter allowing the converter
to overheat and become damaged
when the engine is hot, or reduces
converter performance when the en-
gine is cold.
Black plate (59,1)
SAFE OPERATION 59
SAFE OPERATION
Safe Riding Technique

The points given below are applicable for everyday motorcycle use and should
be carefully observed for safe and effective vehicle operation.
For safety, eye protection and a When riding always keep both
helmet are strongly recommended. hands on the handlebars and both
You should be aware of and verify feet on the footpegs. Removing your
the applicable safety regulations in hands from the handlebars or feet
force prior to riding your motor- from the footpegs while riding can
cycle. Gloves and suitable footwear be hazardous. If you remove even
should also be used for added pro- one hand or foot, you can reduce
tection in case of a mishap. your ability to control the motor-
cycle.
A motorcycle does not provide the
impact protection of an automobile, Before changing lanes, look over
so defensive riding in addition to your shoulder to make sure the way
wearing protective apparel is ex- is clear. Do not rely solely on the
tremely important. Do not let protec- rear view mirror; you may misjudge
tive apparel give you a false sense a vehicle's distance and speed, or
of security. you may not see it at all.
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60 SAFE OPERATION
In general your actions should be In wet conditions, rely more on the
smooth as sudden acceleration, throttle to control vehicle speed and
braking or turning may cause loss less on the front and rear brakes.
of control, especially when riding in The throttle should also be used ju-
wet conditions or on loose roadway diciously to avoid skidding the rear
surfaces, when the ability to maneu- wheel from too rapid acceleration or
ver will be reduced. deceleration.
When going up steep slopes, shift Riding at the proper rate of speed
to a lower gear so that there is and avoiding unnecessarily fast ac-
plenty of power to spare rather than celeration are important not only for
overloading the engine. safety and low fuel consumption but
also for long vehicle life and quieter
When applying the brakes, use operation.
both the front and rear brakes. Ap-
plying only one brake for sudden On rough roads, exercise caution,
braking may cause the motorcycle slow down, and grip the fuel tank
to skid and lose control. with the knees for better stability.
When going down long slopes, When quick acceleration is neces-

control vehicle speed by closing the sary as in passing, shift to a lower
throttle. Use the front and rear gear to obtain the necessary power.
brakes for auxiliary braking.
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SAFE OPERATION 61
Do not downshift at too high an

r/min (rpm) to avoid damage to the
engine from overrevving.
Avoiding unnecessary weaving is

important to the safety of both the
rider and other motorists.
Black plate (62,1)
62 SAFE OPERATION
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
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.
Tires ............................ Air pressure (when cold):
Black plate (63,1)
SAFE OPERATION 63
Up to 183 kg (403 lb)

Front 200 kPa (2.00 kgf/cm², 28 psi)
Load
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, City light, Tail/Brake Lights, Turn Sig-
nal Lights, Warning/Indicator Lights) and horn work.
Engine stop switch ...... Stops engine.
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64 SAFE OPERATION
Side stand and center
stand ........................ Returns to their fully up position by spring tension. Re-
turns springs not weak or not damaged.
Black plate (65,1)
SAFE OPERATION 65
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-
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 opera-
tion.
Engine Oil: To avoid engine seizure and resulting loss of control, make sure that
the oil level is at the upper level line.
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 re-
lated parts are in good condition.
Black plate (66,1)
66 SAFE OPERATION
WARNING
Handling characteristics of a motorcycle at high speeds may vary from
those you are familiar with at legal highway speeds. Do not attempt high
speed operation unless you have received sufficient training and have the
required skills.
Black plate (67,1)
MAINTENANCE AND ADJUSTMENT 67
MAINTENANCE AND ADJUSTMENT
The maintenance and adjustments outlined in this chapter must be carried out
and must be done in accordance with the Periodic Maintenance Chart to keep the
motorcycle in good running condition. The initial maintenance is vitally impor-
tant and must not be neglected.
With a basic knowledge of mechanics and the proper use of tools, you should be
able to carry out many of the maintenance items described in this chapter. If you
lack proper experience or doubt your ability, all adjustments, maintenance, and re-
pair work should be completed by a qualified technician.
Please note that Kawasaki cannot assume any responsibility for damage result-
ing from incorrect or improper adjustment done by the owner.
Black plate (68,1)
68 MAINTENANCE AND ADJUSTMENT
Periodic Maintenance Chart

K: Should be serviced by an authorized Kawasaki dealer.
*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions: dusty, wet, muddy, high
speed, or frequent starting/stopping.
1. Periodic Inspection (Engine Related Items)
Frequency Whic-
hever
comes *Odometer Reading
first km × 1 000 (mile × 1 000) See
Page
Operation (Engine Every 1 6 12 18 24 30 36

Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Air cleaner element -
clean • • • 87
K
Valve clearance - in-
spect • • • 86
Throttle control sys-

tem (play, smooth re-
turn, no drag) -
year • • • • 91
inspect
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Frequency Whic-
hever
first km × 1 000 (mile × 1 000) See
Page
Operation (Engine Every 1 6 12 18 24 30 36

Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
K
Engine vacuum syn-
chronization - inspect • • • 94
Idle speed - inspect • • • • 94

Fuel leak (fuel hose
and pipe) - inspect
year • • • • –
Fuel hoses damage -

inspect
year • • • • –
Fuel hoses installa-

tion condition - in-
spect
year • • • • –
K
Air suction system
damage - inspect • • • 85
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2. Periodic Inspection (Chassis Related Items)
Frequency Which-
ever
first km × 1000 (mile × 1000) See
Page
Operation (Chas- 1 6 12 18 24 30 36
Every
sis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Clutch and drive train:
Clutch operation
K
(play, engagement,
disengagement) - • • • • 96
inspect
Drive chain lubrica-
tion condition - in- every 600 km (400 mile) 104
spect #
Drive chain slack -
every 1 000 km (600 mile) 98
inspect #
Drive chain wear -
inspect # • • • 102
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Frequency Which-
ever
Page
Operation (Chas- 1 6 12 18 24 30 36
Every
sis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
K
Drive chain guide
wear - inspect • • • –
Wheels and tires:

Tire air pressure -
inspect
year • • • 117
Wheels/tires dam-
age - inspect • • • 118
Tire tread wear, ab-

normal wear - in-
spect
• • • 118
K
Wheel bearings
damage - inspect
year • • • –
Black plate (72,1)
Frequency Which-
ever
Page
Operation (Chas- 1 6 12 18 24 30 36
Every
sis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Spoke tightness
K and rim runout - in-
spect
• • • • • • • –
Brake system:
Brake fluid leak - in-
spect
year • • • • • • • 107
Brake hoses dam-

age - inspect
year • • • • • • • 107
Brake pad wear - in-

spect # • • • • • • 105
Brake hose installa-

tion condition - in-
spect
year • • • • • • • 107
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Frequency Which-
ever
Page
Operation (Chas- 1 6 12 18 24 30 36
Every
sis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Brake fluid level - in-
spect
6 months• • • • • • • 108
Brake operation (ef-

fectiveness, play,
drag) - inspect
year • • • • • • • 106, 110
Brake lining wear -

inspect # • • • • • • 106
Brake light switch

operation - inspect • • • • • • • 110
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Frequency Which-
ever
Page
Operation (Chas- 1 6 12 18 24 30 36
Every
sis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Suspensions:
Front forks/rear
shock absorbers
operation (damping
and smooth stroke)
• • • 112,113
- inspect
Front forks/rear
shock absorbers oil
leak - inspect
year • • • 112,113
K
Swingarm pivot lu-
bricate • –
Steering System:
K
Steering play - in-
spect
year • • • • –
Black plate (75,1)
Frequency Which-
ever
Page
Operation (Chas- 1 6 12 18 24 30 36
Every
sis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
K
Steering stem bear-
ings - 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 • • • –
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Frequency Which-
ever
Page
Operation (Chas- 1 6 12 18 24 30 36
Every
sis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Chassis:
K
Chassis parts - lu-
bricate
year • • • –
K
Bolts and nuts tight-
ness - inspect • • • • –
Black plate (77,1)

3. Periodic Replacement
Frequency Whichev-
er comes *Odometer Reading
first km × 1 000
(mile × 1 000) See
Page
1 12 24 36 48
Every
Change/Replacement Items (0.6) (7.5) (15) (22.5) (30)
K Air cleaner element - replace # 2 years 87
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 • • 109
K
Rubber parts of master cylinder
and caliper - replace
4 years • –
K Spark plug - replace • • • • 84

Black plate (78,1)

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

the oil level inspection window. With
opening using a syringe or some oth-
er suitable device.
the motorcycle held level, the oil lev-
el should come up between the
• If the oil level is too low, add the oil to
reach the correct level. Use the
upper and lower level lines next to same type and brand of oil that is al-
the oil level inspection window. ready in the engine.
NOTICE
If the engine oil gets extremely
low or if the oil pump does not
function properly or oil passages
are clogged, the warning indica-
tor light will light. If it stays on
when the engine speed is above
idle, stop the engine immediately
and have it serviced. Failure to do
so could cause serious engine
A. Oil Level Inspection Window damage.
B. Upper Level Line
C. Lower Level Line
D. Oil Filler Cap
• Ifexcess
the oil level is too high, remove the
oil through the oil filler
Black plate (80,1)
• 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.
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WARNING • Ifmove
the oil filter is to be replaced, re-
the oil filter cover.
Engine oil is a toxic substance.
Dispose of used oil properly.
Contact your local authorities for
approved disposal methods or
possible recycling.
A. Bolts
B. Oil Filter Cover
• Remove the oil filter cartridge

replace it with a new one.
and
NOTE
○ If a torque wrench or required Kawa-
saki special tool is not available, this
Black plate (82,1)

item should be serviced by an au-
thorized Kawasaki dealer.
• Apply a thin film of oil to the packing
and tighten the cartridge to the
specified torque.
A. Oil Filter
A. Packing
• Install the oil filter cover.

• Install the drain bolt with a new gas-
ket. Tighten it to the specified tor-
que.
NOTE
○ Replace any gaskets with new ones.
Black plate (83,1)

Tightening Torque Engine Oil Capacity
Engine Oil Drain Bolt: Capacity:
20 N·m (2.0 kgf·m, 15 ft·lb) 2.7 L (2.9 US qt)
Oil Filter: (when filter is not removed)
18 N·m (1.8 kgf·m, 13 ft·lb) 2.9 L (3.1 US qt)
Oil Filter Cover Mounting Bolts: (when filter is removed)
12 N·m (1.2 kgf·m, 106 in·lb) 3.2 L (3.4 US qt)
(when engine is completely dry)
Recommended Engine Oil
Type: Although 10W-40 engine oil is the
API SG, SH, SJ, SL or SM with JASO recommended oil for most conditions,
MA, MA1 or MA2 the oil viscosity may need to be
Viscosity: changed to accommodate atmospheric
SAE10W-40 conditions in your riding area.
NOTE
○ Do not add any chemical additive to
the oil. Oils fulfilling the above re-
quirements are fully formulated and
provide adequate lubrication for both
the engine and the clutch.
Black plate (84,1)

Spark Plugs
The standard spark plug is shown in
the table. The spark plugs should be
replaced in accordance with the Peri-
odic Maintenance Chart.
Spark plug removal should be done
only by an authorized Kawasaki deal-
er.
Spark Plug
Standard Plug NGK CR8E
0.7 ~ 0.8 mm
Plug Gap
(0.028 ~ 0.032 in.)
13 N·m
Tightening Torque
(1.3 kgf·m, 115 in·lb)
Black plate (85,1)
Kawasaki Clean Air System

The Kawasaki Clean Air System
(KCA) is a secondary air suction sys-
tem that helps the exhaust gases to
burn more completely. When the spent
fuel charge is released into the exhaust
system, it is still hot enough to burn.
The KCA System allows extra air into
the exhaust system so that the spent
fuel charge can continue to burn. This
continued burning action tends to burn
A. Plug Gap up a great deal of the normally un-
burned gases, as well as changing a
significant portion of the carbon mon-
oxide into carbon dioxide.
Black plate (86,1)

Air Suction Valves - Valve Clearance
The air suction valve is essentially a Valve and valve seat wear de-
check valve which allows fresh air to creases valve clearance, upsetting
flow only from the air cleaner into the valve timing.
exhaust port. Any air that has passed
the air suction valve is prevented from NOTICE
returning. Inspect the air suction valves If valve clearance is left unad-
in accordance with the Periodic Main- justed, wear will eventually cause
tenance Chart. Also, inspect the air the valves to remain partly open,
suction valves whenever stable idling which lowers performance, burns
cannot be obtained, engine power is the valves and valve seats, and
greatly reduced, or there are abnormal may cause serious engine dam-
engine noises. age.
Air suction valve removal and in-
spection should be done only by an au-
thorized Kawasaki dealer. Valve clearance for each valve
should be checked and adjusted in ac-
cordance with the Periodic Mainte-
nance Chart.
Inspection and adjustment should be
done only by an authorized Kawasaki
dealer.
Black plate (87,1)
Air Cleaner
A clogged air cleaner restricts the
• Remove the left side cover from the
projection by pushing the side cover
engine's air intake, increasing fuel forward and pulling it outward.
consumption, reducing engine power,
and causing spark plug fouling.
The air cleaner element must be
cleaned in accordance with the Peri-
odic Maintenance 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. Left Side Cover
B. Screws
Element Removal
•
C. Projection
Remove the seat.
• Remove the screws on the left side
cover.
Black plate (88,1)
• Remove
cover.
the screws and right side • Pull out the air cleaner elements
from both side of the air cleaner
housing.
A. Right Side Cover

B. Screws A. Element
• Put a clean, lint-free towel into the air

cleaner housing to keep dirt or other
foreign material from entering.
NOTE
○ Do not try to separate the element
material and frame for cleaning.
Black plate (89,1)
• Inspect the element material for Element Cleaning

damage. If any part of the element
is damaged, the element must be re-
• Clean the element in a bath of a high
flash-point solvent.
placed. • Squeeze it dry in a clean towel. Do
not wring the element or blow it dry;
WARNING the element can be damaged.
If dirt or dust is allowed to pass
• Check all the parts of the element for
visible damage.
through into the throttle body as-
sembly, the throttle may become
• If any of the parts of the element are
damaged, replace them.
stuck, possibly causing accident.
Be sure to keep the dust from en-
• After cleaning, saturate the element
with a high-quality foam-air-filter oil,
tering during cleaning. squeeze out the excess, then wrap it
in a clean towel and squeeze it as
dry as possible.
NOTICE
• Be careful not to tear the sponge fil-
ter.
If dirt gets through into the en-
gine, excessive engine wear and
possibly engine damage will oc- NOTE
cur. ○ Element installation is performed in
the reverse order of removal.
○ Be sure to install the element with
the wire net facing up.
Black plate (90,1)

Oil Draining
WARNING
• Inspect the drain hose located on the
right side of the engine to see if any
Gasoline and low flash-point sol-
vents are extremely flammable oil or water has run down from the air
and may explode, causing severe cleaner housing.
burns. Do not use gasoline or a
low flash-point solvent to clean
the element. Clean the element in
a well-ventilated area. Be sure
there are no sparks or flame in
the work area, including any ap-
pliance with a pilot light.
A. Plug
B. Drain Hose
• Ifthethere is any oil in the hose, remove

plug and drain the oil.
Black plate (91,1)
Throttle Control System

WARNING Check the throttle grip play in ac-
Oil on tires will make them slip- cordance with the Periodic Mainte-
pery and can cause an accident nance Chart, and adjust it if necessary.
and injury. Be sure to install the Throttle Grip -
plug in the drain hose after drain- The throttle grip controls the butterfly
ing. valves in the throttle body. If the throttle
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.
Black plate (92,1)

Inspection Adjustment
• Check that the throttle grip play is
correct by lightly turning the throttle
•Loosen the locknuts at the upper of
the throttle cables, and screw both
grip back and forth. throttle cable adjusters completely
so as to give the throttle grip plenty
of play.
•Turn out the decelerator cable ad-
juster until it has no play when the
throttle grip is completely closed.
Tighten the locknut.
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.

Black plate (93,1)
• Turn out the accelerator cable ad-

juster until the throttle grip has the
done by an authorized Kawasaki
dealer.
proper play. Tighten the locknut. • With the engine idling, turn the han-
dlebar to each side. If handlebar
movement changes the idle speed,
the throttle cables may be improperly
adjusted or incorrectly routed, or
they may be damaged. Be sure to
correct any of these conditions be-
fore idling.
WARNING
Operation with improperly ad-
justed, incorrectly routed, or
A. Accelerator Cable
B. Decelerator Cable
damaged cables could result in
C. Adjuster an unsafe riding condition. Be
D. Locknuts sure the control cables are ad-
• Ifjusted
justed and routed correctly, and
the throttle cables cannot be ad- are free from damage.
with the adjuster at the upper
of the throttle cable, further adjust-
ment of the throttle cables should be
Black plate (94,1)

Engine Vacuum Synchronization Idle Speed
Engine vacuum synchronization The idle speed adjustment should be
must be checked and adjusted periodi- performed in accordance with the Peri-
cally in accordance with the Periodic odic Maintenance Chart or whenever
Maintenance Chart by an authorized the idle speed is disturbed.
Kawasaki dealer.
Adjustment
NOTE •Start the engine, and warm it up thor-
○ Poor oughly.
•
engine vacuum synchroniza-
tion will cause unstable idling, slug- Adjust the idle speed by turning the
gish throttle response, and reduce idle adjusting screw.
engine power and performance.
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)
Black plate (95,1)
WARNING • With the engine idling, turn the han-

dlebar to each side. If handlebar
The engine gets extremely hot movement changes the idle speed,
during normal operation and can the throttle cables may be improperly
cause serious burns. Never touch adjusted or incorrectly routed, or
a hot engine. they may be damaged. Be sure to
correct any of these conditions be-
fore riding.
WARNING
Operation with damaged cables
could result in an unsafe riding
condition. Replace damaged con-
trol cables before operation.
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.
Black plate (96,1)

Clutch
Due to friction plate wear and clutch
cable stretch over a long period of use,
the clutch operation should be checked
each day before riding the motorcycle,
and in accordance with the Periodic
Maintenance Chart.
Inspection
• Check that the clutch lever operates
properly and that the inner cable
slides smoothly. If there is any irregu- A. Adjuster
larity, have the clutch cable checked B. Locknut
by an authorized Kawasaki dealer. C. Clutch Lever Play
• Check the clutch lever play as shown

in the figure.
If the play is incorrect, adjust the lev-
er play as follows.
Clutch Lever Play Adjustment
2 ~ 3 mm (0.08 ~ 0.12 in.)
•Loosen the locknut at the clutch lev-
er.
•Turn the adjuster so that the clutch
lever will have the specified free
play.
Black plate (97,1)
Drive Chain
WARNING The drive chain slack and lubrication
Too much cable play can prevent must be checked each day before rid-
clutch disengagement and cause ing the motorcycle, and in accordance
an accident resulting in serious with the Periodic Maintenance Chart
injury or death. When adjusting for safety and to prevent excessive
the clutch or replacing the cable, wear. If the chain becomes badly worn
be sure the upper end of the or maladjusted - either too loose or too
clutch outer cable is fully seated tight - the chain could jump off the
in its fitting, or it could slip into sprockets or break.
place later, creating enough cable
play to prevent clutch disengage- WARNING
ment. A chain that breaks or jumps off
the sprockets could snag on the
• Tighten the locknut. engine sprocket or lock the rear
wheel, severely damaging the
NOTE motorcycle and causing it to go
○ After the adjustment is made, start out of control. Inspect the chain
the engine and check that the clutch for damage and proper adjust-
does not slip and that it releases ment before each ride.
properly.
Black plate (98,1)

Chain Slack Inspection • Ifloose,
the drive chain is too tight or too
•Set the motorcycle up on its side
stand.
adjust it so that the chain
slack will be within the standard val-
•Rotate the rear wheel to find the po-
sition where the chain is tightest, and
ue.
Drive Chain Slack
measure the maximum chain slack
Standard 25 ~ 35 mm (1.0 ~ 1.4 in.)
by pulling up and pushing down the
chain midway between the engine
sprocket and rear wheel sprocket. NOTE
○ Do not use the center stand for chain
slack inspection.
Chain Slack Adjustment

•Remove the cotter pin from the tor-
que link nut, and loosen the torque
link nut.
•Loosen the left and right chain ad-
juster locknuts.
A. Chain Slack
Black plate (99,1)
• Remove the cotter pin, and loosen

the rear axle nut.
• Ifandthe chain is too tight, turn in the left
right chain adjusting bolts
evenly.
• Turn both chain adjusting bolts
evenly until the drive chain has the
correct amount of slack.
A. Torque Link Nut

B. Cotter Pin
C. Axle Nut
D. Cotter Pin
E. Adjusting Bolt
F. Locknut
• Iflefttheand
chain is too loose, turn out the
right chain adjusting bolts
evenly.
Black plate (100,1)
• To keep the chain and wheel prop- NOTE

erly aligned, the notch on the left
wheel alignment indicator should
○ Wheel alignment can also be
checked using the straightedge or
align with the same swingarm mark string method.
that the right indicator notch aligns
with.
WARNING
Misalignment of the wheel will re-
sult in abnormal wear, and may
result in an unsafe riding condi-
tion. Align the rear wheel using
the marks on the swingarm or
measuring the distance between
the center of the axle and swing-
arm pivot.
• Tighten both chain adjuster locknuts.

A. Marks
B. Notch
• fied torque. rear axle nut to the speci-
Tighten the
C. Indicator
D. Adjusting Bolt Tightening Torque
E. Locknut
Axle Nut:
98 N·m (10 kgf·m, 72 ft·lb)
Black plate (101,1)
NOTE
○ If a torque wrench is not available,
this item should be serviced by an
• Rotate the wheel, measure the chain

slack again at the tightest position,
and readjust if necessary.
• Tighten the torque link nut.
Tightening Torque
Torque Link Nut: A. Cotter Pin
34 N·m (3.5 kgf·m, 25 ft·lb)
• Install a new cotter pin through the

torque link bolt, and bend its ends.
NOTE
○ When inserting the cotter pin, if the
• Install a new cotter pin through the
rear axle nut and axle, and spread its
slots in the nut do not align with the
cotter pin hole in the axle shaft, tight-
ends. en the nut clockwise up to the next
alignment.
○ It should be within 30 degrees.
○ Loosen once and tighten again when
the slot goes past the nearest hole.
Black plate (102,1)

Wear Inspection
•Remove the bolts and washers to
take off the chain cover.
A. Turning Clockwise
WARNING
A loose axle nut can lead to an A. Chain Cover
B. Bolts and Washers
accident resulting in serious in-
jury or death. Tighten the axle nut
to the proper torque and install a
• Stretch the chain taut either by using
the chain adjusters, or by hanging a
new cotter pin. 10 kg (22 lb) weight on the chain.
• Measure the length of 20 links on the
• Check the rear
Brakes section).
brake (see the straight part of the chain from pin
center of the 1st pin to pin center of
Black plate (103,1)
the 21st pin. Since the chain may

wear unevenly, take measurements WARNING
at several places. For safety, use only the standard
• If the length exceeds the service lim-
it, the chain should be replaced.
chain. It is an endless type and
should not be cut for installation;
have it installed by an authorized
Kawasaki dealer.
• Rotate the rear wheel to inspect the

drive chain for damaged rollers, and
loose pins and links.
• Also inspect the sprockets for un-
evenly or excessively worn teeth,
and damaged teeth.
A. Measure
B. Weight
Drive Chain 20-Link Length
Service Limit 319 mm (12.56 in.)
Black plate (104,1)

NOTE • Install the chain cover.
○ Sprocket wear is exaggerated for il- Lubrication
lustration. See Service Manual for Lubrication is necessary after riding
wear limits. through rain or on wet roads, or any
time that the chain appears dry.
Use a lubricant for sealed chains to
prevent deterioration of chain seals. If
the chain is especially dirty, clean it us-
ing a cleaner for sealed chains follow-
ing the instructions supplied by the
chain cleaner manufacturer.
• Apply lubricant to the sides of the
rollers so that it will penetrate to the
rollers and bushings. Apply lubricant
to the seals so that the seals will be
A. Good Teeth
coated with lubricant. Wipe off any
B. Worn Teeth excess lubricant.
C. Damaged Teeth
• Ifdrive
there is any irregularity, have the
chain and/or the sprockets re-
placed by an authorized Kawasaki
dealer.
Black plate (105,1)
Brakes
Brake Pads Wear Inspection
Inspect the front disc brake pads for
wear. If the thickness of either pad is
less than 1 mm (0.04 in.), replace both
pads as a set. Pad replacement should
be done by an authorized Kawasaki
dealer.
• Wipe off any lubricant that gets on

the tire surface.
A. Lining Thickness
B. 1 mm (0.04 in.)
Black plate (106,1)

Brake Lining Wear Inspection
Inspect the rear brake lining for wear
with the brake lining wear indicator on
the rear brake panel. If the brake lining
wear indicator does not point within the
USABLE RANGE when the brake is
fully applied, the brake shoe linings
have worn past the service limit.
In this case, the brake shoes must
be replaced, and the drum and other
brake parts examined by an authorized
Kawasaki dealer. A. Rear Brake Panel
B. USABLE RANGE
C. Brake Lining Wear Indicator
Front Disk Brakes -

Disc and disc pad wear is automati-
cally compensated for and has no ef-
fect on the brake lever or pedal action.
So there are no parts that require ad-
justment on the front brake.
Black plate (107,1)
Fluid Requirement
WARNING Use heavy-duty brake fluid only from
Air in the brake lines diminish a container marked DOT4.
braking performance and can
cause an accident resulting in in-
NOTICE
jury or death. If the brake lever or Do not spill brake fluid onto any
pedal feels mushy when it is ap- painted surface.
plied, there might be air in the Do not use fluid from a container
brake lines or the brake may be that has been left open or that
defective. Have the brake has been unsealed for a long
checked immediately by an au- time.
thorized Kawasaki dealer. Check for fluid leakage around
the fittings.
Check brake hose for damage.
Brake Fluid -
In accordance with the Periodic
Maintenance Chart, inspect the brake
fluid level in the front brake fluid reser-
voir and change the brake fluid. The
brake fluid should also be changed if it
becomes contaminated with dirt or
water.
Black plate (108,1)

Fluid Level Inspection • Ifreservoir
the fluid level in front brake fluid
• With the front brake fluid reservoir
held horizontal, the brake fluid level
is lower than the lower level
line, check for fluid leaks in the brake
in the front brake fluid reservoir must lines, and fill the reservoir to the
be kept above the lower level line upper level line. Inside the front
(lower level mark). brake fluid reservoir is a stepped line
showing the upper level line.
A. Front Brake Fluid Reservoir

B. Lower Level Mark A. Front Brake Fluid Reservoir
B. Upper Level Line
Black plate (109,1)
Brake Pedal Play Inspection

WARNING
• The brake pedal should have the
correct pedal play when the pedal is
Mixing brands and types of brake
fluid can reduce the brake sys- pushed down lightly by hand.
tem’s effectiveness and cause an
accident resulting in injury or
death. Do not mix two brands of
brake fluid. Change the brake flu-
id in the brake line completely if
the brake fluid must be refilled
but the type and brand of the
brake fluid that is already in the
reservoir are unidentified.
Fluid Change A. Brake Pedal

Have the brake fluid changed by an B. Pedal Play
Pedal Play
Rear Drum Brake - 20 ~ 30 mm (0.8 ~ 1.2 in.)
In accordance with the Periodic
Maintenance Chart, inspect the brake
pedal play.
• Ifit.the pedal has improper play, adjust
Black plate (110,1)
• Rotate the rear wheel to check for

brake drag with the pedal released.
Brake Light Switch
When either the front or rear brake is
• Operate the pedal a few times to see
that it returns to its rest position im-
applied, the brake light goes on. The
front brake light switch requires no ad-
mediately upon release. justment, but the rear brake light switch
• Check braking effectiveness. should be adjusted in accordance with
the Periodic Maintenance Chart.
Brake Pedal Play Adjustment
• Turn the adjusting nut at the brake Inspection
cam lever so that the pedal has the • Turn the ignition switch to “ON”.
correct pedal play. • The brake light should go on when
the front brake is applied.
• If it does not, ask your authorized
Kawasaki dealer to inspect the front
brake light switch.
A. Adjusting Nut
Black plate (111,1)
• Check the operation of the rear Adjustment

brake light switch by depressing the
brake pedal. The brake light should
•To adjust the rear brake light switch,
move the switch up or down by turn-
go on after the proper pedal travel. ing the adjusting nut.
A. Brake Pedal A. Rear Brake Light Switch

B. Pedal Travel B. Adjusting Nut
• Iflightit does
C. Lights sooner
not, adjust the rear brake D. Lights later
switch.
Brake Pedal Travel
15 mm (0.6 in.)
Black plate (112,1)
NOTICE Front Fork

The front fork operation and oil leak-
To avoid damaging the electrical age should be checked in accordance
connections inside the switch, be with the Periodic Maintenance Chart.
sure that the switch body does
Front Fork Inspection
• Holding
not turn during adjustment.
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 in-
spect the front fork for oil leakage,
scoring or scratches on the outer
surface of the inner tube.
Black plate (113,1)
• Ifshould
any doubt about the front fork, it
be done by an authorized Ka-
Rear Shock Absorber
The rear shock absorbers should be
wasaki dealer. checked for operation and oil leakage
in accordance with the Periodic Main-
tenance Chart.
For various riding or load conditions
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.
• Visually inspect the rear shock ab-
sorber for oil leaks.
A. Inner Tube
NOTE
○ Set the dust boots with it end fits into
the groove on the front fork bottom
case.
Black plate (114,1)
• Ifshock
there is any doubt about the rear
absorber, it should be in-
Spring Preload Adjustment
Spring preload can be adjusted by
spected by an authorized Kawasaki turning the preload adjuster on the rear
dealer. shock absorber with the screwdriver
bit. To increase spring preload and stif-
fen the suspension, turn the preload
adjuster to the left. To decrease pre-
load and soften the suspension, turn
the preload adjuster to the right.
A. Rear Shock Absorber
A. Preload Adjuster
B. Screwdriver Bit
C. Stopper
Black plate (115,1)
WARNING
If both spring preload adjusters
are not adjusted equally, handling
may be impaired and a hazardous
condition may result. Set all sus-
pension adjusters equally to the
recommended settings.
NOTE
○ Be sure to turn back the preload ad-
juster to the left from position 5 when
softening the spring action.
Black plate (116,1)
Spring Preload Setting

Adjuster Position 1 2 3 4 5
Spring Action Weak ← Standard → Strong
Setting Soft ← Standard → Hard
Load Light ← Standard → Heavy
Road Good ← Standard → Bad
Speed Low ← Standard → High
Black plate (117,1)
Wheels motorcycle has not been ridden

Tires - more than a mile during the past 3
hours).
Payload and Tire Pressure
Failure to maintain proper inflation ○ Tire pressure is affected by changes
pressures or observe payload limits for in ambient temperature and altitude,
your tires may adversely affect han- and so the tire pressure should be
dling and performance of your motor- checked and adjusted when your rid-
cycle and can result in loss of control. ing involves wide variations in tem-
The maximum recommended load in perature or altitude.
addition to vehicle weight is 183 kg
(403 lb), including rider, passenger,
baggage, and accessories.
• Remove the air valve cap.
• Check the tire pressure often, using
an accurate gauge.
• Make sure to install the air valve cap
securely.
NOTE
○ Measure the tire pressure when the
tires are cold (that is, when the A. Tire Pressure Gauge
Black plate (118,1)

Tire Air Pressure (when cold) worn down to the minimum allowable
Up to 183 kg 200 kPa (2.00 tread depth.
Front
(403 lb) Load kgf/cm², 28 psi) Minimum Tread Depth
Up to 97.5 kg 225 kPa (2.25 1 mm
(215 lb) Load kgf/cm², 32 psi) Front
(0.04 in.)
Rear 97.5 ~ 183 kg Under 130 km/h 2 mm
250 kPa (2.50
(215 ~ 403 lb) (80 mph) (0.08 in.)
kgf/cm², 36 psi) Rear
Load
Over 130 km/h 3 mm
(80 mph) (0.12 in.)
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).
So it is false economy and unsafe to
use the tires until they are bald.
• In accordance with the Periodic
Maintenance Chart, measure the
depth of the tread with a depth
gauge, and replace any tire that has
A. Tire Depth Gauge
Black plate (119,1)
• Visually inspect the tire for cracks

and cuts, replacing the tire in case of WARNING
bad damage. Swelling or high spots Tires that have been punctured
indicate internal damage, requiring and repaired do not have the
tire replacement. same capabilities as undamaged
• Remove any imbedded stones or
other foreign particles from the tread.
tires and can suddenly fail, caus-
ing an accident resulting in seri-
NOTE ous injury or death. Replace
damaged tires as soon as possi-
○ Have the wheel balance inspected ble. To ensure safe handling and
whenever a new tire is installed. stability, use only the recom-
mended standard tires for re-
placement, inflated to the
standard pressure. If it is neces-
sary to ride on a repaired tire, do
not exceed 100 km/h (60 mph) un-
til the tire is replaced.
NOTE
○ Most countries may have their own
regulations requiring a minimum tire
tread depth; be sure to follow them.
Black plate (120,1)

○ When operating on public roadways, WARNING
keep maximum speed under traffic
law limits. New tires are slippery and may
Standard Tire (Tube-type) cause loss of control and injury.
A break-in period of 160 km (100
Front Size: 100/90-19M/C 57H
miles) is necessary to establish
• DUNLOP normal tire traction. During
“TT100GP G” break-in, avoid sudden and maxi-
Rear Size: 130/80-18M/C 66H mum braking and acceleration,
•
and hard cornering.
DUNLOP
“TT100GP”
Spoke and Rim:
WARNING Inspection
Spoke tightness and rim runout
Mixing tire brands and types can should be inspected by an authorized
adversely affect handling and Kawasaki dealer in accordance with
cause an accident resulting in in- the Periodic Maintenance Chart.
jury or death. Always use the
same manufacturer's tires on
both front and rear wheels.
Black plate (121,1)
Battery temperature. As temperatures rise, so

The battery installed in this motor- does the discharge rate. Every 15°C
cycle is a sealed type, so it is not nec- (59°F) doubles the rate.
essary to check the battery electrolyte Electrical accessories, such as digi-
level or add distilled water. tal clocks and computer memory, also
The sealing strip should not be draw current from the battery even
pulled off once the specified electrolyte when the key is switched off. Combine
has been installed in the battery for ini- such “key-off” draws with hot tempera-
tial service. ture, and a battery can go from fully
However, in order to maximize bat- charged to completely discharged in a
tery life and ensure that it will provide matter of days.
the power needed to start the motor-
cycle you must properly maintain the Self-discharge
battery's charge. When used regularly, Approx. Number of Days
the charging system in the motorcycle From 100% Charged to
helps keep the battery fully charged. If 100% discharged
your motorcycle is only used occasion- Temperature
Lead-Anti- Lead-Calci-
ally or for short periods of time, the bat- mony um
tery is more likely to discharge. Battery Battery
Due to their internal composition,
batteries continually self discharge. 40°C (104°F) 100 Days 300 Days
The discharge rate depends on the 25°C (77°F) 200 Days 600 Days
type of battery and ambient 0°C (32°F) 550 Days 950 Days
Black plate (122,1)
Current Drain Sulfation occurs when the battery is

left in a discharged condition for an ex-
Days from Days from tended time. Sulfate is a normal by
100% 100%
Discharging product of the chemical reactions with-
charged to charged to
Ampere
50% 100% in a battery. But when continuous dis-
Discharged Discharged charge allows the sulfate to crystallize
in the cells, the battery plates become
7 mA 60 Days 119 Days permanently damaged and will not
10 mA 42 Days 83 Days hold a charge. Battery failure due to
15 mA 28 Days 56 Days sulfation is not warrantable.
20 mA 21 Days 42 Days Battery Maintenance
30 mA 14 Days 28 Days
It is the owner's responsibility to keep
the battery fully charged. Failure to do
In extremely cold weather the fluid in so can lead to battery failure and leave
an inadequately charged battery can you stranded.
easily freeze, which can crack the case If you are riding your vehicle infre-
and buckle the plates. A fully charged quently, inspect the battery voltage
battery can withstand sub-freezing weekly using a voltmeter. If it drops be-
temperatures with no damage. low 12.8 volts, the battery should be
charged using an appropriate charger
Battery Sulfation (check with your Kawasaki dealer). If
A common cause of battery failure is you will not be using the motorcycle for
sulfation.
longer than two weeks, the battery
Black plate (123,1)
should be charged using an appropri- If the above chargers are not avail-
ate charger. Do not use an automotive- able, use equivalent one.
type quick charger that may over- For more details, ask your Kawasaki
charge the battery and damage it. dealer.
NOTE Battery Charging
○ Leaving the battery connected •Remove the battery from the motor-
cycle (see Battery Removal).
•
causes the electrical components
(clock etc) to make the battery dis- Attach the leads from the charger
charged, resulting the over dis- and charge the battery at a rate (am-
charge of the battery. In this case, perage × hours) that is indicated on
the repair or replacement of the bat- the battery. If it is not possible to read
tery is not included in the warranty. If the rate, charge the battery at an am-
you do not drive for four weeks or perage that is about 1/10th of the
battery capacity.
•
more, disconnect the battery from
the vehicle. The charger will keep the battery
fully charged until you are ready to
Kawasaki-recommended chargers reinstall the battery in the motorcycle
are: (see Battery Installation).
Battery Mate 150-9
OptiMate 4
Yuasa MB-2040/2060
Christie C10122S
Black plate (124,1)

Battery Removal
NOTICE
Never remove the sealing strip,
•Make sure the ignition switch is
turned to OFF.
or the battery can be damaged. •Remove the seat and tool kit.
Do not install a conventional bat-
tery in this motorcycle, or the
•Remove the screw and move the
ECU aside without disconnecting the
electrical system cannot work connectors from the ECU.
properly.
Make Yuasa Battery

Type YTX12-BS
NOTE
○ If you charge the sealed battery,
never fail to observe the instructions
shown in the label on the battery.
A. Screw
B. Bracket
C. ECU
Black plate (125,1)
• Disconnect the cables from the bat-

tery, first from the (-) terminal and
• Disconnect the ground connector of
the battery (–) cables.
then the (+) terminal. • Remove the left side cover (see Air
Cleaner section).
• Remove the battery holder bolts.
A. (+) Terminal
B. (–) Terminal
C. Ground Connector A. Battery Holder
B. Battery Holder Bolt (Shorter) and Washer
C. Battery Holder Bolt (Longer)
D. Battery (+) Cable
E. Battery (–) Cable
• Pull out the battery holder and bat-

tery (+) and (–) cables.
Black plate (126,1)

Battery Installation
NOTICE
Do not give the battery holder a
•Clean the battery using a solution of
baking soda and water. Be sure that
strong pull, or the leads may be- the cable connections are clean.
come disconnected. •Place the battery in the battery case
with the pad under the battery.
• Remove the battery from the battery •Connect the red capped cable to the
(+) terminal from the rear, and then
holder.
connect the black cable to the (–) ter-
minal.
NOTE
○ Install the battery in the reverse or-
der of the Battery Removal.
NOTICE
Installing the (–) cable to the (+)
terminal of the battery or the (+)
cable to the (–) terminal of the
A. Battery battery can seriously damage the
electrical system.
Black plate (127,1)
• Put a light coat of grease on the ter-

minals to prevent corrosion.
Headlight Beam
Horizontal Adjustment
• Cover the (+) terminal with its protec-
tive cap.
The headlight beam is adjustable
horizontally. If not properly adjusted
• Reinstall the parts removed . horizontally, the beam will point to one
side rather than straight ahead.
• Turn the horizontal adjuster clock-
wise or counterclockwise until the
beam points straight ahead.
A. Horizontal Adjuster
B. Vertical Adjuster
Black plate (128,1)

Vertical Adjustment NOTE
The headlight beam is adjustable
vertically. If adjusted too low, neither
○ On high beam, the brightest point
should be slightly below horizontal
low nor high beam will illuminate the with the motorcycle on its wheels
road far enough ahead. If adjusted too and the rider seated. Adjust the
high, the high beam will fail to illumi- headlight to the proper angle accord-
nate the road close ahead, and the low ing to local regulations.
beam will blind oncoming drivers.
• Turn the vertical adjuster clockwise
or counterclockwise to adjust its ver-
tical angle.
Black plate (129,1)
Fuses • Remove the seat.

Fuses are arranged in the junction
box located inside the left side cover.
• Cleaner section).
Remove the left side cover (see Air
The main fuse is mounted on the start-

er relay located inside the left side cov-
er. If a fuse fails during operation,
inspect the electrical system to deter-
mine the cause, and then replace it
with a new fuse of proper amperage.
A. Battery Holder
B. Junction Box
C. Starter Relay
D. Main Fuse
Black plate (130,1)
A. Junction Box A. Normal

B. Fuses B. Failed
C. Spare Fuses
WARNING
Substituting fuses can cause wir-
ing to overheat, catch fire and/or
fail. Do not use any substitute for
the standard fuse. Replace the
blown fuse with a new one of the
correct capacity, as specified on
the junction box and main fuse.
Black plate (131,1)
General Lubrication • Front Brake Lever

Lubricate the points shown below,
with either motor oil or regular grease,
• Rear Brake Pedal
in accordance with the Periodic Main- Lubricate the following cables with
tenance Chart or whenever the vehicle a pressure cable luber -
has been operated under wet or rainy • (K) Clutch Inner Cable
conditions.
Before lubricating each part, clean
• (K) Throttle Inner Cables
off any rusty spots with rust remover

and wipe off any grease, oil, dirt, or
grime.
NOTE
○A few drops of oil are effective to
keep bolts and nuts from rusting and
sticking. This makes removal easier.
Badly rusted nuts, bolts, etc., should
be replaced with new ones.
Apply motor oil to the following piv- Apply grease to the followingpoints
ots - -
• Side Stand • (K) Clutch Inner Cable Upper End
• Clutch Lever • (K) Throttle Inner Cable Upper Ends
Black plate (132,1)

(K): Should be serviced by an author- Cleaning Your Motorcycle
ized Kawasaki dealer. General Precautions
Frequent and proper care of your Ka-
NOTE wasaki motorcycle will enhance its ap-
○ After connecting the cables, adjust pearance, optimize overall
them. performance, and extend its useful life.
Covering your motorcycle with a high
quality, breathable motorcycle cover
will help protect its finish from harmful
UV rays, pollutants, and reduce the
amount of dust reaching its surfaces.
Black plate (133,1)
WARNING • Be sure the engine and exhaust are

cool before washing.
Build-up of debris or flammable • Avoid applying degreaser to seals,
brake pads, and tires.
material in and around the ve-
hicle chassis, engine, and ex- • Always use non-abrasive wax and
cleaner/polisher.
haust can cause mechanical
problems and increase the risk of • Avoid all harsh chemicals, solvents,
detergents, and household cleaning
fire.
When operating the vehicle in products such as ammonia-based
conditions that allow debris or window cleaners.
flammable material to collect in
and around the vehicle, inspect
• Gasoline and brake fluid will damage
the finish of painted and plastic sur-
the engine, electrical component faces: wash them off immediately.
and exhaust areas frequently. If
debris or flammable materials
• Avoid wire brushes, steel wool, and
all other abrasive pads or brushes.
have collected, park the vehicle
outside and stop the engine. Al-
• Use care when washing the side
covers and other plastic parts as
low the engine to cool, then re- they can easily be scratched.
move any collected debris. Do
not park or store the vehicle in an
• Avoid using pressure washers; water
can penetrate seals and electrical
enclosed space prior to inspect- components and damage your mo-
ing for build-up of debris or flam- torcycle.
mable materials.
Black plate (134,1)
• Avoid spraying water in delicate

areas such as in air intakes, throttle
motorcycle for chips and scratches.
Do not let the water air dry as this
body, brake components, electrical can damage the painted surfaces.
components, muffler outlets, and fuel
tank openings.
• Start the engine and let it idle for sev-
eral minutes. The heat from the en-
gine will help dry moist areas.
Washing Your Motorcycle
•Rinse your bike with cold water from • Carefully ride your motorcycle at a
slow speed and apply the brakes
a garden hose to remove any loose
several times. This helps dry the
dirt.
•Mix a mild neutral detergent (de-
brakes and restores them to normal
operating performance.
signed for motorcycles or automo-
biles) and water in bucket. Use a soft • Lubricate the drive chain to prevent
rusting.
cloth or sponge to wash your motor-
cycle. If needed, use a mild degreas-
NOTE
er to remove any oil or grease build
up. ○ After riding in an area where the
•After washing, rinse your motorcycle
thoroughly with clean water to re-
roads are salted or near the ocean,
immediately wash your motorcycle
move any residue (residue from the with cold water. Do not use warm
detergent can damage parts of your water as it accelerates the chemical
motorcycle). reaction of the salt. After drying, ap-
•Use a soft cloth to dry your motor-
cycle. As you dry, inspect your
ply a corrosion protection spray on
Black plate (135,1)
all metal and chrome surfaces to pre- Painted Surfaces

vent corrosion. After washing your motorcycle, coat
○ Condensation may form on the in- painted surfaces, both metal and plas-
side of the headlight lens after riding tic, with a commercially available mo-
in the rain or washing the motor- torcycle/automotive wax. Wax should
cycle. To remove the moisture, start be applied once every three months or
the engine and turn on the headlight. as conditions require. Avoid surfaces
Gradually the condensation on the with “satin” or “flat” finishes. Always
inside of the lens will clear off. use non-abrasive products and apply
them according to the instructions on
Semi-gloss Finish the container.
To clean the semi-gloss finish;
•When washing the motorcycle, al-
ways use a mild neutral detergent
Plastic Parts
After washing use a soft cloth to gen-
tly dry plastic parts. When dry, treat the
and water.
•The semi-gloss finish effect may be
lost when the finish is excessively
headlight lens and other non-painted
plastic parts with an approved plastic
cleaner/polisher product.
rubbed.
•If any doubt, consult an authorized
Kawasaki dealer.
Black plate (136,1)

chrome/aluminum polish. Coated alu-
NOTICE minum should be washed with a mild
Plastic parts may deteriorate and neutral detergent and finished with a
break if they come in contact with spray polish. Aluminum wheels, both
chemical substances or house- painted and unpainted can be cleaned
hold cleaning products such as with special non-acid based wheel
gasoline, brake fluid, window spray cleaners.
cleaners, thread-locking agents, Leather, Vinyl, and Rubber
or other harsh chemicals. If a If your motorcycle has leather acces-
plastic part comes in contact with sories, special care must be taken.
any harsh chemical substance, Use a leather cleaner/treatment to
wash it off immediately with clean and care for leather accessories.
water and a mild neutral deter- Washing leather parts with detergent
gent, and then inspect for dam- and water will damage them, shorten-
age. Avoid using abrasive pads ing their life.
or brushes to clean plastic parts, Vinyl parts should be washed with
as they will damage the part's fin- the rest of the motorcycle, then treated
ish. with a vinyl treatment.
The sidewalls of tires and other rub-
Chrome and Aluminum ber components should be treated with
Chrome and uncoated aluminum a rubber protectant to help prolong
parts can be treated with a their useful life.
Black plate (137,1)
WARNING
Rubber protectants can be slip-
pery and, if used on the tread
area, cause loss of traction re-
sulting in accident causing injury
or death. Do not apply rubber
protectant to any tread area.
Black plate (138,1)
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 en-
gine oil.
WARNING
Engine oil is a toxic substance. Dispose of used oil properly. Contact your
local authorities for approved disposal methods or possible recycling.
• Put in fresh engine oil.

• Empty the fuel from the fuel tank by the pump or siphon.
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.
Black plate (139,1)
STORAGE 139
• Empty the fuel system by running the engine at idle speed until the engine stalls.
(If left in for a long time, the fuel will break down and could clog the fuel system.)
• Reduce tire pressure by about 20%.
• Set the motorcycle on a box or stand so that both wheels are raised off the
ground. (If this cannot be done, put boards under the front and rear wheels to
keep dampness away from the tire rubber.)
• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on
rubber parts or in the brakes.
• Lubricate the drive chain and all the cables.
• moisture, or battery,
Remove the and store it where it will not be exposed to direct sunlight,
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.
• 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.
• Fill the fuelbattery
Install the in the motorcycle and charge the battery if necessary.
• Check all thetankpoints
with fuel.
• Lubricate the pivots,listed in the Daily Checks section.
• bolts, and nuts.
Black plate (140,1)
140 ENVIRONMENTAL PROTECTION

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. Consult
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.
Black plate (141,1)
LOCATION OF LABELS 141
LOCATION OF LABELS
All warning labels which are on your

vehicle are repeated here. Read labels
on your vehicle and understand them
thoroughly. They contain information
which is important for your safety and
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 Ka-
1. Brake Fluid (Front)
wasaki dealer and install it in the cor-
rect position.
NOTE
○ The sample warning labels in this
section have part numbers to help
you and your dealer obtain the cor-
rect replacement.
Black plate (142,1)
142 LOCATION OF LABELS
2. Tire and Load Data

3. Important Drive Chain Information
4. Battery Poison/Danger
Black plate (143,1)
5. Unleaded Gasoline
Black plate (144,1)
(1) (2)
1. Read Owner's Manual

2. Tire Pressure, see page 118
3. Front tire size and manufacture, see
page 120
4. Rear tire size and manufacture, see
page 120
5. Maximum load, see page 18
Black plate (145,1)
(3) (4)

2. Drive Chain Slack, see page 98
Black plate (146,1)

(5)

2. Unleaded gasoline, see page 33

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Black plate (1,1)

Whenever you see the symbols NOTE

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

KAWASAKI HEAVY INDUSTRIES, LTD.

© 2013 Kawasaki Heavy Industries, Ltd. Jun. 20, 2013. (1)

SPECIFICATIONS ................................ 10 Fuel Requirement: ......................... 32

Catalytic Converter ............................ 57 Spoke and Rim: ............................. 120

Ignition System Battery and coil (transistorized ignition)

Rim Size: Front J19 × 2.15

1. Clutch Lever 6. Right Handlebar Switches

1. Front Fork 8. Seat Lock 15. Center Stand

accessories, and in loading the motor-

LCD (Clock, Odometer, Trip Meter)

• Push the RESET button for more

• Push the RESET button. The hour

the button advance the hour or mi- NOTE

: When the headlight is on high

A. Ignition Switch/Steering Lock

Engine off. Electrical circuits

A. Engine Stop Switch

Starter Button: Left Handlebar Switches

Fuel Tank Cap

A. Brake Lever Adjuster

equal to or higher than that shown in

Seat Seat Installation

• Pull up the front and rear end of the

Helmet Holding Cable -

A. Helmet Holding Cable

A. Tool Kit A. Document Compartment

Tying Hooks Rear View Mirror

A. Lower Hexagonal Area for Tightening

HOW TO RIDE THE MOTORCYCLE 45

HOW TO RIDE THE MOTORCYCLE

Starting the Engine

• Without holding the throttle grip,

A. Engine Stop Switch

46 HOW TO RIDE THE MOTORCYCLE

HOW TO RIDE THE MOTORCYCLE 47

NOTICE Jump Starting

48 HOW TO RIDE THE MOTORCYCLE

• Connect another jumper cable from

HOW TO RIDE THE MOTORCYCLE 49

electrical system may occur.

• Follow the standard engine starting

50 HOW TO RIDE THE MOTORCYCLE

HOW TO RIDE THE MOTORCYCLE 51

Shifting Gears motorcycle is standing still, the trans-

52 HOW TO RIDE THE MOTORCYCLE

the front brake should be applied a

A. Front Brake Lever

HOW TO RIDE THE MOTORCYCLE 53

Stopping the Engine

54 HOW TO RIDE THE MOTORCYCLE

HOW TO RIDE THE MOTORCYCLE 55

56 HOW TO RIDE THE MOTORCYCLE

HOW TO RIDE THE MOTORCYCLE 57

58 HOW TO RIDE THE MOTORCYCLE

• Use only unleaded gasoline. Never

Safe Riding Technique