EL 250 Motorcycle Owner's ManualWhenever you see the symbols shown below, heed thair instructions! Always follow safe operating and main tenance practices. da WARNING This warning symbol identifies special instructions. or procedures which, Hl not correctly followed, could result in personal injury, or loga of life. ACAUTION This caution symbol identifies special instructions or procedures which, |f not strictly observed. could result in damage to or destruction of equip- ment, NOTE OTAis note symbo/! indicates points of particular interest for more efficrent and canvenient aparation. NOTICE THIS PRODUCT HAS BEEN MANU- FACTURED FOR USE IN & REASON. ABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.FOREWORD We wish to thank you for choosing this fing Kawasaki Motorcycle. Your new motorcy cle is the product of Kawasaki's advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety, and perfonnance, Read this Owner's Manual before riding so you will be thoraughly tamiliar with the proper operation of your motarcycle’s cantrals, its features, capabilities and limitations. This manual offers many safe riding tips, but its purpose i§ NOt to provide instruction jn all the techniques and skills required to nde a motorcycle safely. Kawasaki strongly recam- rends that all operators of this vehiclé enroll in a motorcycle rider training program ta at- tain awareness of the mantal and physical requirements necessary for safe motorcycle Operation. To ensure. a long. trouble-free life for your motorcycle, give it the proper care and main- tenance described in this manual. For those who would lika more detailed information on their Kawasaki Motorcycle, a Service Manual is available for purchase from any Kawasaki dealer, The Service Manual contains detailed disassembly and maintenance information. Due te improvements in design and pertormance during production, in some cases there may be rmi- nar discrepancies between the actual vehicle and the illustrations and text in this manual. KAWASAKI HEAVY INDUSTRIES, LTD. CONSUMER PRODUCTS & COMPONENTS GROUP Kawasaki Heavy Industries, Ltd, 1990 Dec, 1980. (75. 1M)= : maa. TABLE OF CONTENTS cuccancancnannnaunan Specifications ‘cam Fuel Tank Location af Parts ........000 eee 9 Fuel Paes: General Information.. Ta Stand .. ag Safe Operation 40 Brake Light Switches. i Daily Safety Checks... sepa at Rear Shack Absorbers... Additional Considerauons fer WHOIS... Meter Instruments pele Beats ‘ ee High Speed Operation Battery... Speedometer and Tachometer . ita Helmet Hook... Maintenance and Adjustment Headlight Bear... Indicator Lights ...... 2 Tol Kit. centres : a Periodic Maintenance Chart Fuses ..... Bi coins cateiorserrecai 4 Tying Hooks et Engine Oil... sae Fuel ‘Synteim... Ignition Switch/ Steering Lock. wat Break-In dB Cooling System a2 Cleaning Right Handlabar Switches eis} How. ta Ride the Motorcycle a2 Spark Plugs... . BB Storage wins Engine Stop Swnteh......... 16 Starting the Engine......... ae Valve Clearance ... Wiring Diagram................. ‘Inside back cover Starter Bumon.......- Jump Starting. wedi ( hbcoresees Aut Cleaner ...... Headlight Switch... Moving Off ..... Throtie Grip... Laft Handlebar Switches. lB Shifting Geers. Choke Lever.. Dimmar Switch.......... wl B Braking .. Carburetors ...... Tum Signal Switch. 18 Stopping the Engine Cluten... i Horm Button ........ 8 Stopping the Motorcycle Drive Char... Passing Button. Fuel Tank Cap invam Emergancy20200 PERFORMANCE Maximum Horsepower Maximum Torque Minimum Turing Radius DIMEN SIONS Overall Langth Chverall Width Overall Height Wheelbase Road Clearance Dry Weight ENGINE Type Displacement Bore x Stroke Compression Rata Starting System Cylinder Numbering Method Finng Order ‘Carburetors Ignition: System SPECIFICATIONS concacuwncanacnnn acenag 13.9 KW C27 PS) 71,800 ¢/min (rpm) VPS Nem (178 kg-m, 12:9 ft-lb) 9,800 min frp) 2.8m (170.2 inj 2.240 mm (88,19 in) 765 mm (30.12 in.) 1.900 mir (43.31 in.) 1.490 mm (56,66 in.) 750 mm (5.91 in.) 147 kg (324 Ib) DOHC. 2-cyinder, 4-stroke, liquid-cooled 2d8omL ¢15.9 cu in} 62.0 x 41.2 mm (2.44 x 1,62 in.) 12.0:1 Electric starter Left te mgt, 1-2 1-2 Kehr CVKSO x 2 Battery and ocail (transistarized ignitian) Ignition Timing (Electronically advanced) Spark Plugs Lubrication System Engine Ol Engine Oi\ Capacity Caciant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio Overall Orive Ratio Gear Ratio: 1st 2nd 3rd 4th 5th th 10° BTDC et 300 renin, (yin) = 42" ATOC m4 500 rimin (rpm) NGE CRBHSA o NO U24F5R-L Forced lubrication (wet surmp} SE or SF class SAE 1OWa4O. TOWS0, 20NV40. of ZOWED TIL (20 US qth VOL (1.1 Un 6-speed, constant mesh. return shit Wet, multi disc Chain drive S.458(89/24) 3.142 (44/14) 9.704 (Top gear) 2.600 (39/154 1789 (3419) 1,408 (31/22) 1.4160 (28/25) 1.000: (27/27) O.B92 (25/28)FRAME Castor 28" ; Trail 112 mm (4.417 in.) Tire Size: Frans 100/90-17 565 Tubeless Hear 140/490-1715 MAC 705 Tubetess Fuel Tank Capacity TLOL (2.9 US gal) ELECTRICAL EQUIPMENT iran Batt Headlaht 12 V 60/55 W Tail/ Brake Light 12 5/21 W Turn Signal Light 221 W Specifications subject ta change without notice. MED LOCATION OF PARTS «canccnnacaecnancaaec 1. Cluteh Lever 2. Speedometer 2: Indicator Lights 4. Tachometer 5 Brake Flurd Roeservorr {Front] 6. Front Grake Lever f. Left Handlebar Siwetches 8. iqnitian Switch/Steer ng Lock 9. Right Handlebar Switenes: O. Throttle GripT1. 12, 1a. 14. 15. 16. 7. is. 19, 20, 21. at. 23. 24. Front Fork Headlight Turn Signal Light Spark Plugs Fuel Tap Junetion Box (Fuses) Air Cleaner Tying Hooks Helmet Hook Radiator shift Pedal Side Stand Brive Chain Rear Shock Absorber ®@@ @ OG » @® D ? @@ POO OOO @ ao 8 @H606 en © @ Tail Brake Light License Plate Ligh Passengers Seat . Rider's Seat Battery Main Fuse Idle Adjusting Screw . Carburetors Fuel Tank . Fuel Tank Cap . Brake Lining Wear Indicator . Mufler » Fool Kit . Coolant Reserve Tank . Rear Brake Light Switch . Ol Level Gauge Rear Brake Pedal . Horm . Brake Caliper » Broke Dise 41YP Bo oe Meter Instruments crea rm mmo 0 OF GENERAL INFORMATION «cccacccncannnnane . Speedomater . Laft Turn Signal Indicator Light . Right Turn Signal Indicator Light Tachometer . Red Zone . Goolant Temperature Warning Light . High Beam Indicator Light . Of Pressure Warning Light . Neutral Indicator Light . Trip Meter Reset Knob . Odometer Speedometer and Tachometer The speedometer shows the spaed al the vehicle. [in the speedometer face are the odometer and trip meter. The odom eter shows the total distance that the ve- hicle has been ridden. The trip meter shows the distance traveled since it was last reset to zero, The trip meter can be reset to zero by turning the reset knob counterclockwise. 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 igs above maximum recom- mended enging speed and is also above the range for geod parformance. A CAUTION Engine rimin (rpm} should not be al- lowed fo enter the red zone: operation in the red zone will overstress the en- gine and may causa serious angine damage. Indicator Lights TURAN: When the turn stqnal switch is turned to laft or right, the correspanding turn signal indicatar light flashes on and ott, NEUTRAL: When the transmission is in neutral, the nevtral indicator fight is lit. HIGH BEAM: When the headlight is on high beam, the high beam indicatar light #8 lit. BIL: The oi! pressure warning light goes on whenever the oil pressurc is danger- ously low or the ignitian switch is in the ON pesition with the engine not turning, and gaes off when the engine oil pres- 13gure is high enough. Refer to the Main- tenance and Adjustment chapter for more detailed engine oil information. TEMP: The coolant temperature warning light (LED-Light Emitting Diode) goss on when the ignition switch 15 turned on and goes off soon after the engine starts running ta ensure that its circult func- tions properly. The warning light also goes on whenever the coolant temper- ature rises to 120°C or higher when the motorcycle is in operation. If it stays on, stop the engine and check the coolant level in the reserve tank after the engine cools down, Do not let the englie continue running when the warning light goes on. Pro- longed engine oparation will result In severe damage from overheating. 14 Key wes This matorcycle has a combination key, which is used for the ignition switch; steering lack, right lower side cover, helmet hook, and fuel tank cap. Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need. using yaur original key a5 @ master, ignition Switch/Steering Lock This is a four-position, key-operated switch. The key can be removed from the switch when it ts in the OFF, LOCK, or P(PARK) position, Bo mA eT a A. Ignition Switeh/Steering Lock B. LOCK position C. OFF paositian D. ON position E.P (Park) position Engine att All electrinal circuits off, Engine an All electrical equipment can be used, Steering locked. Engine off. All electrical circuits off. Steering locked. Engine off. City, tail and leense plata lights an, All other | electrical circuits cut off. NOTE off you leave the PARK position on fora fong time fone four), the battery may Sacome tudally discharged. 16To operate the ignition switch: OFF <> ON [Za > P(PARK) 2 4. Turn the handlebar fully to the left A 2. a. For parking push down the key in the ON positian and LOCK tum it to P (Park) b. For locking push down the key in the OFF position and turn itte LOCK. Right Handlebar Switches Engine Stop Switch . In addition to the ignition switch, the engine stop switch must be in the RUN position for the motorcycle to operate. The engine stop switch is for emer- gency use. If some emergency fequires stopping the engine, move the engin stop switch to the OFF position. NOTE OAlthough the engine stop switen stops fhe engine, it does not turn off alf the electrical cireuits. Ordinarily, the t- nition switch should fe used fo stop the engine. A, Engine Stop Switch B. Headlight Switch C, Starter Button Starter Button The starter button operates the eléetric starter when pushed with the clutch lever pulled in or the transmission in neutral. Refer to the Starting the Engine sec- tion of the "How to Ride the Motorcycle" chapter for starting instructions. Headlight Switch The headlight is off with the switch in the © position, The city, tail, license plate and meter lights come an if the switch is pushed to the P position with the ignition switch in the ON position The head, city, tail, license plate and mater lights came on if the switeh is pushed forward to the H position with the ignition switch in the ON position.Left Handlebar Switches Dimmer Switch High or low beam can be selected with the dimmer switch, Whan the headlight is an high beam (HI), the high beam indicstar light is lit, A. Dimmar Switch B. Turn Signal Switch C. Horn Button D. Passing Button Turn Signal Switch When tha turn signal switch is turned to L (left) or R (right), the corresponding turn signals flash on and off. To stop flashing, push the switch in. Horn Button When the horn button is pushed, the horn sounds. Passing Button When the passing button ts pushed, the headlight high beam (passing beam) comes.on to signal the driver of the vehi- cla ahead that you area about to pass him The passing light shuts off as soon aa the switch released. Fuel Tank Cap To open the fuel tank cap, insert the ignition switch key into the lock and turn the kay to the right, Ta clase the cap, push it down into place with the key insarted, The key can be removed by turning it counterclock- wise to the original position, NOTE Ofhe tank cap cannot be closed without the key inserted, and the key cannot be removed unless the cap is focked prap- erty. ODe fot push the cap down with the key, or the cap cannol be lacked 18 A. Ignition Switch Key B. Fuel Tank Cap 14Fuel Tank The following octane rating gasoline is recarnmended in the fuel tank. Avoid fillimg the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. 1. Tank Cap 2. Fuel Tank 3. Top Level 4, Filler Neck 20 Gasoline is extremely flammable and can be explosive under certain condl- tlons. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilaled and free from any source of flame or sparks; this includes any ap- pliance with a pilot light. Never fill ihe tank so the tue! level rises Inte the filler neck. If the tank is over- filled, heat may cause the fuel fo ex- pand and overflow through the vents In the tank cap. Aiter refueling, make sure tha tank cap is closed securely. it gasoline Is spillad on the. fuel tank, wipe il off immediately. Fuel Requirement: Your Kawasaki engine is designed to usé Unleaded gasolino. However, except for Australian models, if suitable gasoline ig not available than PREMIUM, SUPER, or FOUR-STAR gasolines may be used. Use of leaded gasoline is illegal in some countries, slates or territories. Check local regulations before using leaded gasoline. Ociane Rating The octane rating of a gagaline is a measure of tts resistance to detonation or “knocking.” The term commonly used to describe a gasoline’s octane rating is the Research Octane Number (RON), Al Ways US@ a gasoline with an octane rat- ing equal ta, or higher than. Research Octane Number (RON) 91, NOTE OF “knocking” ar “siaging” occurs, ose a different brand of gasaline or Aigher Gelarte rating. i |Fuel Tap The fuel tap has three positions: OFF, ON, and RES (reserve). Wf the fuel runs out with the tap in the ON position, the last 3.0 L (0.8 US gal) of fuel can be used by turning the fuel tap ta RES. C. OFF position D..OM position A. Fuel Tap B. ARES position 22 NOTE OSinee. riding distance is fimled wher on RES, refuel at the earifest apportu- nity. O Make certain that the fuel tap fs tuned to ON (Not RES) after filling up the fuel tank. AWARNING Practice operating the fuel tap wiih the motercycle stopped. To prevent an ac- cident you should ba able to operate the iuel tap while riding without taking your ayes off the road. Be careiul not to touch the hot angine while operating the fuel tap. Stand The motorcycle is equipped with a side stand. A. Side Stand NOTE OWhen using the sida stand, tura fhe handlebar to the left, Whenever the side stand is used, make ita practice to kick the stand fully up be- fore sitting on the motoreyele. Pe Le Forgetting and leaving the side stand down and riding away could cause an aceldent. 231) Seats 2, Remove the left and right upper side 3. Remove the license plate mounting 4. Pull ihe passenger's seat rearward a Tao remove the seat, follow this step, Eesels wats: ieee 5. Remove the rider's seat mounting bolts, 1. Remove the left and right lower side covers (right with the ignition switch key). A. Licansa Plate A. Upper Side Cover B. Screw B. Bolts A. Seat B. Bolt B_ Lock 6. Pull the seat up and to the rear 24 25Helmet Hook A helmet can be secured to the motor- cycle using the helmet hook. The helmet hook can be unlocked by inserting the ignition switch key inte the lack, and turning the key to the reg ht, AWARNING Do not ride the motorcycle with helmet attached to the hook. The helmet could ¢ause an accident by distracting the operator or interfering with normal ve- hiclée operation. 26 , Helmet Hook Tool Kit The taol kit is stored under the battery case inside the right side cover secured with a rubber band. The minor adjust ments and replacement of parts ex plained in this manual can be performed. es A, Tool Kit 4. Tying Hooks a Tying Hooks When tying wp ligt / ¢ ght loads to the seat use the hooks on the left and right sickes of the rear fender. 2?a pee BEE AL =- TIN ccc cc eced 0k Ge ta Ce AC CO The first 1.600 km (1,000 mi) that the motorcycle is ridden is designated ag the break-in period. i the motorcycle is not used carefully during this period, you may very well end up witha "broken down” instead af a “broken in” motorcycle after a few thau said kilometers The following rules should be observed during the break in peried. @The table shows maximum recommended engine speed during the break in period Maximum engine speed 4,000 r/min (ppm) 6,000 r/min (rpm) Distance traveled 0 ~ B00 km (0 ~ 500 mi) “800 ~ 1,600 km (500 ~ 1,000 mi) ® 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 oi) a chance to wark up inta.all the engine parts. Do not race the engine while the transmission is in neutral. in addition ta the above, al 800 km (500 mi) it is extremely important that the owner Have the initial maintenance service performed by an authorized Kawasaki dealer. prepa HOW TO RIDE THE MOTORCYCLE acucannnnanane Starting the Engine @ vu the fuel tap to the ON pasition. B. ON position A. Fuel Tap @Check that the engine stap switch is in the RUN position, @ Turn the ignition switch an. @Make certain the transmission is in neutral or the clutch is disengaged, A. Engine Stop Switch 8. Starter Button ¢€, Neutral Indicator Light D. ignition Switch E. ON position @lf the angine is cold, pull the choke levar all the way. 25NOTE Oo When the engine is already warm ar ofr hot days (36°C, 95°F or more), open the throttle part way instead of using the choke, and then start the engine. A. Choke Lever @Leaving the throttle completely closed, push the starter button with the clutch laver pulled in until the engine starts, 30 - 31 | Do nol operate the starter continuously for more than 5 seconds, or the starter will overheat and the baittery power will drop temporarily. Walt 15 seconds between each operation of the starter to let It cool and the battery power re- cover. NOTE Cf the engine is floaded, crank the an- gine over with ihe throttle fully open until the engine starts. OFAhe motorcyele is equipped with the starter fockouf switch. This syeritch prevents the electric starter fram oper- ating when the clutch is engaged and the vansmission is not in neutral, r ; A. Clutch Laver B. Starter Lockout Switch @Gradually return the choke toward the off position a little at a time as neces sary to keep the engine speed below 2,500 r/min (rpm) during warm-up. @When the engine is warmed up enaugh to idle without using the choke, return the chake to the off position. NOTE Off you drive the motorcycle before the engine is warmed up, return the choke to the off position after you have driven the motorcyere for the length of time shown io the table. Do not let the engine idle longer than five minules, or engine overheating and damage may occur. Choke off atter running for Ambient temperature 20°C (68°F) ~ 35°C (95°F) Below 20°C (68°F) Below 5°C (40°F)Jump Starting lf your motorcycle battery is “run down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may he used to start the engine. AWARNING Battery acid generales hydrogen gas which Is flammable and explosive un- der certain conditions. It is present within a battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away from tha battery. Wear eye protection when working with a battery. In the event of battery acid contact with skin, ayes, oF clothing, wash the allected areas im- madiately with water for at least five minutes, Seak medical atlention. Cannecting Jumper Cables @ Make sure the ignition switch is turned “OFF.” az @ Remove the right side covers. @ Connect a jumper cable from the pasi tive (+) terminal of the booster battery ta the positive (4 } terminal of the ma torcycle battery. A. Motorcycle Battery Positive (+) Terminal 8. To Booster Battery Positive (+) Terminal ¢. Unpainted Metal Surface D, To Booster Battery Negative {-) Terminal @ Connect another jumper cable from the negative (—} terminal of the booster battery to your motorcycle rear brake pedal or other unpainted metal surfave, Do not use the negative ( ) terminal of the battery. AWARNING Do not make this last connection at ihe carburetor or battery. Take care thal do nol touch the positive and nega- five cables together, and do not lean over the batlery when making this last connection. Do not jump start a frozen battery. It could explode. Do not reverse polarity by connecting positive (+) to negative (—), or a bal- tery explosion and serious damage to the alectrical system may occur. @Follow the standard engine starting procedure. ACAUTION Do not operate the starter continuously for more than 5 seconds or the starter will overheat and the batlery power will drop jemporarily, Wall 15 seconds between each operation of the starter to let it cool and the battery power re- cover. @After the engine starts, disconnect the jumper cables. Disconnect the nega tive (—) cable fram the motorcycle tirst.NOTE Shifting Gears NOTE @Close the throttle while pulling in the clutch lever. Shift into the next Higher or lawer gear, Moving Off @ Check thal the side stand is up. @Pull in the clutch lever, @Shift into 1st gear. Ove motorcyele is equipped with a serie stand switeh, This switch is designer so that the engine stops if te clutch j; © The (ansmissian (5 Squioned with a Positive neutral finder, When the mg foreyele is standing still, the trans Open the throttle a little, and start to let out the clutch lever very slowly @As the cluich starts to engage, open the throttle a little more, giving the -en- gine just enough fuel to keep it fram stalling. A. Shift Pedal i, =| # engaged with the transmission in gear when the side stand fas been fat; down. AWARNING When shifting down io 4 lower gear, do not shiff al such a high speed that the engine r/min (rpm) jumps excessively. Not only can this cause engine dam- age, but the rear whee! may skid and cause an accident. Downshifting should be dona below 5,000 rimin (rpm) for each gear. @Open the throttle part way, while re- feasing the clutch lever. Mission cannot be shifted east neutret fram Tst.gear. To use the positive-nec. tral finder, shift down to Ts¢ gear, then Aftwp on the shift pedal white Standing sti, The transmussion will spyfr ony inte neutralBraking @Ciose the throttle completely, leaving the clutch engaged [except when shifting gears) so that the angine will help slow down the motorcycle. @Shift down ane gear at a time so that YOU are in Tstqear when you come ta a complete stop. @When stopping, always apply both brakes at the same time, Normally the frant brake should be applied. a little more than the rear, Shitt dawn or fully disengage the clutch as necessary to keep the engine from stalling. @WNever lock the brakes, or it will cause the tires to skid. When turning a cor- ner, itis better not to brake at all. Re duce your speed before you get into the corner. @For. emergency braking, disregard downshifting, and concentrate an ap- plying the brakes as hard as possible without skidding: 36 A. Rear Brake Pedal A. Front Brake Lever Stopping the Engine ® Close the throttle completaly. @ Shift the transmission into neutral. @Turn the ignition switch off, @Turn the fuel tap to the OFF positian @Support the motorcycle an a firm level surface with the side stand. @Lock the steering, 37Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been | designed and manufactured to provide y¥OU optimum safety and convenience. Hawever, in order to fully benefit from Kawasaki's safaty engineering and craftsmanship, it is essantial that you, the | owner and operator, properly maintain your motorcycle and become thoroughly | familiar with its operation. improper maintenance and insufficient riding skills Can create a dangerous situation known as throttle failure. Two of the most com- mon causes of throttle failure are: 1. During removal of the air cleaner by the owner, dirt 15 allawed to enter and jam the carburetor. 2. A nowice may Torget which direction the throttle rotates: then jerk the throttle wide open thinking he has shut it off, He may panic when the machine accelerates suddenly instead of slowing down; and “freeze,” hold- ing the throttle wide open | 38 In an emergency situation such as throttle failure, your motercycla may be stopped by disengaging the clutch and applying the brakes. Once this stopping procedure ts initiated, the engine stop switch may be used to stop the engine. lf the engine stop switch is used, turn off the ignition switch after stopping the motorcycle. Parking eShift the transmission into meutral and turn the ignition switch off. @7urn the fuel tap to the OFF pasitian eSupport the motorcycle on a firm level surface with the side stand. Do not park on a soft or steeply inclined surface, or the motorcycle may fall over. elf parking inside a garage or other structure, be sure it is well ventilated and the matorcycle is not close to any source of flame or sparks; this includas any appliance with a pilot light. AWARNING Gasoline ig extremely Hammable and can be explosive under certain condi- tons. @Lock the steering to help prevent theft NOTE OWhen stopping near traffic at night, you can feave fhe faiigat an for greater visibility by turning te ignition switeh to the P (park) position. C90 net leave ihe switeh at Po pesition too fong, of the Battery will discharge. 39Dee SAFE OPERATION «ncaenacnndunanamacid Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks wiil help ensure you a safe, reliable ride. If any irrequiarities are found during these checks, refer to the Maintenance and Ad- justment chapter or see your dealer for the action required to return the motorcycle to 4 sate Operating condition. Failure to perform these checks every day belore you ride may result in serious dam- Age OF a Severe accident. FERED son soy oe ot ee Adequate supply in tank, no leaks, Engine ail... . Oiflevel between level lines. WEES crac meget y sanntryca nesta” eh psn Ar pressure (when cold): 200 kPa (2.0 kg/cm?, 28 psi} Drive Chain... ne Slack 35 ~ 45 mm (1.4 ~ 1.8 in.) Nuts, bolts, fasteners... Check that steering and suspension components, axies, and all cantrols are properly tightened or fastened SEEMING Action smooth but not loose from lack ta lock. No binding of cantrol cables. BYOB scp cenraicennnen Brake pedal play 20 ~ 30mm (0.8 ~ 12 in} Brake lining wear: Indicator within “USABLE RANGE.” Brake pad wear = Lining thickness more than 7 mm (0.04 im.) lett No brake fluid leakage. TIC Tactics ng Soot ead Throttle grip play 2 ~ 3 rom (0.08 + 0.72 in.} CHURCH occ ceeeeere eee neers Clutch lever play 2? ~ 2mm (0.08 ~ 0.12 in.). Clutch lever operates smoothly. COI Te ieigeiewes ess had No cooiant leakage. Coolant level between level lines (when engine s cold} Property installed, All lights and hern werk Stops engine. Returns to its fully up positian by soring tension, Return spring notweak or not damaged, Radiator Gap cere eee Electrical equipment......,... Engine stop swith... Side staal... cee Refer to the "Daily Safety Checks” caution label attached to The rear fender under the seat. 41Additional Considerations for High Speed Operation Brakes; The importance of the brakes, aspacially during high speed operation, cannoy be overemphasized. Check to see that they are correctly adjusted and functioning properly. Steering: Loogeness in the steering can cause loss-of control. Check ta see that the handlebar turns freely but has no play. Tires: High speed operation is hard on tires, and good tires are crucial tor riding safety Examina their overall conditian, inflate to the proper pressure, and check the wher balance Fuel: Have sufficient fuel for the high fuel consumption during high speed operation, Engine Qil: To avoid seizure and resulting loss of cantrol, make certain the oil level ig at the upper level line. Coolant: To avaid overheating. check that the coolant lewal is at the upper level line. Electrical Equipment: Make certain that the headlight, tail/brake light, turn signals horn, étc., all work properly, Miscellaneous: Make certain that all nuts and bolts are tight and that all safety related parts are in good condition, eee Handling characteristics of a motorcycle at high speeds may Vary from those you are familiar with at legal highway speeds. Do not aitempt high speed oparation unless you have recelved sufficient training and have the requlred skills, APHID» MAINTENANCE AND ADJUSTMENT CHK KOM The maintenance and adjustments outlined in this chapter are easily carried out anc must be done in accordance with the Periodic Maintenance Chart to keep the motorcy cle in good running condition. The initial maintenance is vitally important and must not be neglected. Ifyou are in doubt as to any adjustment or vehiele operation, please ask yOUr Author- jzed Kawasaki dealer to check the motorcycie. Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect maintenance or improper adjustment done by the owner. 43Periodic Maintenance Chart (Woche Frequency = [comes first *Odamueter Reaciney kerr Crea} comes first Wine naver "Odometer Reading km {mi} Frequency z Z 2 7 = § op Operation eee: oof. Operation ce age Brake fluid favel check + K Carburetorsyncohranizatiorn check 7 lole spend check + Throttle arip play- -check | . Spark plug-clean ano gau tT K Valve slegrance-check T Sir cleaner slement- -cleant Fuel system=check Battery vlectrolyte fevel-check + Brake light switch check + Brake lining and pad wear-cheek | Brake play--check. > K Brake fluid “a hranige Clutch--ad just K Steering check 3 Drive chain wear--check + Nuts, bolts, and fasteners Tightness—chack + Tire weer--check + Engine oil--change Oil filter--replace General labrigayan.portorm Front fork oil-- -change Swing arm Alwot- -lUbricate Codlant-- -change Aladiator hoses, connectinna —theek +Whichever eomes first PPS es Frequency : a oe é # : Operation | every | # / a K Brake camehatt--lubricate 2 yeers| | | 7 | ali K Steering stem bearing-lubricute | 2 years facie os K Master cylinder cup and dust Si | ; seal--reglace K Caliper piston seal and dust sAal—_replace K Brake hose --replace 4 years 4 years | Every 200 km (200 mit Ever y BOO km iS00 wi) K Fuel hose--replace 2 years a Z venta Brive chain--lubricare Drive chain stack--check + Ko; Should be serviced by an authorized Kawasaki dealer, : For higher odometer readings, repeat at the frequency interval established here, + ; Replace. add, adjust, or torque if necessary, 46 Engine Oil In order for the enging. transmission, and clutch to functian properly, maintain the engine oil at the proper level, and change the oil and oil filter in accordance with the Periodic Maintenance Chart. Not only do dirt and metal particlas cal- lect in the oil, but the ail itself loses its lubricative quality if used too long. Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in angina or transmission selzure, aceldent, and Injury. OW Level fnapection @lf the oil has just been changed, start the engine and run it for several min- utes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes unt! the oil settles, Racing the engine before the oil reaches every part can cause engine selzure. @lf the motorcycle has just been used, wait several minutes for all the o#l to drain down @®Check the engine ail level through the oil level gauge. With the motorcycle held level, the oil level should come up between the lines next ta the gauge. 47A. O71 Filler Cap ; 6, Upper Level B. Oil Level Gauge D. Lower Level @/f the oil level is too high, remove the excess ail, using a syringe or some other suitable device, through the oil filler opening, @lf the oil level is ton low, arid the cor- rect amount of ail, Use the same tyoe and brand of oil that is already in the engine. the oil pump or oll passages clog up or otherwise do not function properly, the oll pressure warning light will light. H this light slays on when the engine speed is: above 1,500 rimin (rpm), stop the engine immediately and find the Cause. 4. Oil Prassure Warning Light OW andor Ol Filter Change @Warm up the engine thoroughly, and then stop the engine. @Place an oil pan beneath the engine. @ Remove the engine drain plug. A. Grain Plug B. Oil Filter Mounting Bolt @With the motercycie pernendicular to the ground, let the oil completely drain. @if the oil filter is to be changed, remove the lower fairing. A. Fairing B. Bolts ® Remove the oil filter mounting bolt and drop out the-ail filter, @Replace the ail filter clament with a new ong. 49Hoge ¢ >>> Go A. Mounting Boit E. Element 8. Filter Cover F. Grommet €. Spring G. Element Fence D, Flat. Washer H. O-ring NOTE OCheck for O-ring damage ff meces- sary. replace them with new anes. OlVhen onstaiing the of fitter, make sure the O-rings are in place, @Apply a litte engine oil ta the O-ring on the filter mounting bolt, fit the filter a4} cover on the bolt, and install the spring and flat washer. ®Apoly a little engine ail to the gram- mets on both sides of the element, anc turn the filter to work the element inte place. Be careful that the element grommets do not slip out of place. #® install the element fence on the bolt. @lnstall the ofl filter, tightening its mounting bolt to the specified torque, @After the oil has completely drained aut, install the engine drain plug with its gasket. Proper torque for it is shown in the table. NOTE GAReplace the damaged gasket with a few ane, @Fill the engine up to the upper level with 4 good quality motor oil spacified in the table, @ Check the oil level, @® Reinstall the lower fairing. Tightening Torque Engine Brain Plug: 20 N-m (2.0 kg-m, 14.5 ft-lb} Oil Filter Mounting Bolr: 20 N-m (2.0 kg-m, 14.5 ft-lb) Engine Oil Grade: SEor SF class Viscosity: SAE 10W40, 1050, 20W40, of 20W50 Capacity. 1.5141.6 US qn [when filter is not removed] 1.9L (2.0 US at) [when filter is removed] Cooling System Radiator and Cooling Fan: Check the radiator fins for obstruction by insects or mud. Clean off any obh- structians with a stream of low-pressure water A WARNING The cooling fan turns on automatically, even with the ignition switch off. Keep your hands and clothing away from the fan blades al all times. 27Using high-pressure water, as from a Car wash facility, could damage the ra- dilator fins and impair the radiator’s ef- fectiveness. Do net obstrucl of deflect airflow through the radiator by installing unau- thorized accessories in front of ihe ra- diater of behind the cooling fan. Interference with the radiator airllow can lead to overheating and conse- quent engine damage, Radialor Hoses: Check the -adiator hoses sor cracks or Gee Grat an. and connections ter loose Nese In accordance woth the Periodic Ma nienance Chart: 52 Coolant: Coolant absorbs excessive feat fram the engines and transters ite the air at the midiatar Tf the enalant lewe oecormes low, the engine overheats and may suller severe damage. Check the coulant level aoe day bertore nding the motorcycle, and replenish coclant Wf the bevel is cen Changs the coolant in accordance with the Periodic Maistecaraue Chart. intonation for Contant To protect the voolirg system feon sisting at the aluminum engine and radi- atar) from rust ard corresior, the use ol gorrasion and ust inbibitar chermicels in the conarnt is essential |! coolant con- laning carasioen and rust inhibiter chemicals s not used, over a period of time, the eoolng syste accumulates fust end scaln in the waster jaceet avd ra diator This wil clog un the coolant pas- sages, and cansiderably reduce the efficiency of tc cooling system. Use coolant containing corrosion inhibitors made specifically for alumi- num engines and radiators in accord- ance with the instructions of the manu- facturer. Chemicals are harmilul to the human body, Soft or distilled water must be used with the antitreeze {see below for anti- reeze) in the cooling system ACAUTION hard waler is used in the system, it causes scale accumulation |n the water Passages, and considerably reduces the efficiency of the cooling syslem, If the lowest ambient temperatura er courtered Talls below the freezing point ol water, use permanent antifreeze on the coolant to protect the cacling system against enging and radiator freeze- saps, as well as from rust and corrosion Use a nermanent type of antifrenze (soll water ard ethylene giyeol plus car- rosion and rust inhibitor chemica’s for MUMnuMm engines and racators) in the caning system. On the mixturs ratia of cogiant, chaose the suitable one referring ta the relation between [reezing paint and strength directed on the container, A.CAUTION Permanent types of antifreeze on the market have anti-corrosion and anti-rust properties. When it is diluted excessively, il loses its anti-corrosion Property, Dilute a permanent lype of antifreeze In accordance with the in- structions of the manufaclurer. BaNOTE GA permanent type of antifreeze is if- stalled in the cooling system wan shipped. (tis calored green, contains a 50% salution ef ethylene glycol and has the freezing point of —3iC far Fy. Coolant Level frspection @Situate the motorcycle so that it is per- sendicular to the ground. @Check the coolant ievel through the coolant level gauge on the reserve tank from behind the right side of the mo toreycla. The coolant level should be between the F (FULL) and L (LOW) marks, o4 NOTE Otheck the fevel when the engine is cola froam of atmospheric temper- ature}, r ois! i . Reserve Tank B. F (FULL) Mark cL (LOW) Mark @lf the amount of coolant is insufficient, unscrew the cap from the reserve tank, and add coolant through the filler opening to the F (FULL) mark. Install the cap. A. Reserve Tank 8. Cap NOTE Off an emergency you can add water afone to the coolant reserve lann, how- ever it must be returned ta the cerrect mixture ratia by the addition of anti freeze cancentralée as soon as possible. ACALITION H coolant must be added offen, or the reserve tank completely runs dry, Ihere is probably leakage in the sys- tem. Have the cooling system in- spected by your authorized Kawasaki dealer. Conant Change Have the coolant changed by an au- thorized Kawasaki dealer,Spark Plugs The standard spark plug is shown in the table, The spark plugs should be taken out periodically in accordance with the Periodic Maintenance Chart for ciganing, Inspection, and resetting of the plug gap. Spark Plug Removal # Remove the seat (see the Seats section in the General Informatian chapter). @Turn the fuel tap-to the OFF position. @Pull the fuel hoses off the fuel tap. @Take off the fuel tank mounting bolt and remove the fuct tank, 56 B. Bolt | A. Fuel Tank @ Carefully gull the spark plug caps fram the spark plugs. A. Spark Plug Cap @®Unserew the spark plugs witt a plug wrench in the toal kit. NOTE aSpark plug instafiation is performed in the reverse arder of removal. Maintenance IF the plug is oly or tas carbon built up on it, have it cleaned, preferably in a sand-blasting device, and then clean olf any abrasive particles. The plug may also be cleaned using a high flash-point sol- yent and a wire brush or other suitable tool. Measure the gap with a wire type thickness gauge, and adjust the gap Ifin correct hy bending the outer electrode. If the spark plug electrodes are corroded or damaged. or if the insulator is cracked, replace the plug. Use tha standard plug. io.024 ~ = “0.028 ind 57Spark Plug Standard NGK CRSHSAcr Plug ND U24FSR-U Plug 0.6 ~ 0.7 mm Gap ; {0.024 ~ 0.026 in.) Tightening ‘aN Tarque (1 ke. m, 70.0 ft-lb} | For cald weather and/or low speed rid- ing, a hotter spark plug shown In the ta- ble may be used far quicker warm-ups and more efficient engine operation. However, for mormal temperatures and/or high speed use, the standard spark plug must be used lo prevent en- gine damage. Kotter Spark Plug NGK CA7HSA or ND U22FSR U 58 Valve Clearance Valve and valve seat wear decreascs valve clearance, upsetting valve timing. _ A CAUTION — Ht valve clearance is lett 6 lett unadjusted, the wear will eventually cause the valves to remain partly open; which lowars performance, burns the valves and valve seats, and may cause serl- ousg engine damage. Valve clearance for gach valve should be checked and adjusted in accordance with the Periodic Maintenance Chart. Inspection and adjustment should be done only by your autharizad Kawasaki dealer. Air Cleaner A clogged air cleaner restricts the engine's air intake, increasing fuel con- sumption, reducing engine power, and causing spark plug fouling. The air cleaner element must be cleaned and replaced in accordance with the Periodic Maintenance Chart. In dusty areas, the element should be cleaned more frequently than the recom- mended interval. After riding through fain or on muddy roads, the element should be cleaned immediately, The ele- ment should be replaced if it is damaged. Flament Removal @Remove the seat (see Seats section in the General Information chapter}. @ Unscrew the air cleaner housing cap. 4, Air Cleaner Housing Cap 8. Screws 59@Pull aut the element. 4, Elame 60 @Remove the outer frame from the ele ment then the inner frame &. Outer Frame C. Inner Frame B. Element @ Push a clean, lint-free tawel into the air cleaner houging ta keep dirt or other foreign material from entering. @inspect the clement material for dam- age. If any part of the element is dam aged, the element must be replaced. Pe ie | If dirt or dust l¢ allowed to pass through into the carburetors, the throttle may become stuck, possibly causing acci- dant. dé CAUTION If dirt gets through into the angine, ex- cessive engine wear and possibly en- gine damage will occur. NOTE Oflement installation is pertormed in the reverse order of remaval Flement Cleaning e@Clean the clement in.a bath of a high flash point solvent. e@Dry the element with compressed ait oF squeece It @Atter cleaning, saturate the element with SE class SAE 30 motor oil, squeeze out the excess, tren wrap il in a clean rag and squeere it as dry as possible, Be careful mot to tear the ele- ment. Clean the alement in a well ventilated area, and lake care that there are no sparks or flame anywhere near the working area; this Includes any appll- ance with a plloi light. Do not use gas- oline or a low flash-polni solvent lo clean the element. A fire or explosion could result. 61Throttle Grip The throttle grip controls the throttle valves. If the throttle grip has excessive play due to either cable stretch or maladjustment, it will cause a delay in thrattle response, especially at low an- gine speed. Also. the throttle valves may net open fully at full throttle. On the other hand, if the throttle grip has na play, the throttle will be hard ta control, and the ide speed will be erratic. Check the throttle grip play periodically in ac- cordance with the Periodic Maintenance Chant, and adjust the play if necessary. inspectan @ Check that there ia 2 ~ 3mm (0.08 ~ 6.42 in} throtths grip play when lightly turning the throttle arp back and forth @/f there is improper play, adjust it. G2 4. Throttla Grip B.2~ 3mm (0.08 ~ 0.42 in} Adjustnent @Loosen the locknut at the throttle grip, and turn the adjuster until the praper amount of throttle grip play is ob tained. x ® @ A, Locknut C. Throttle Cable B. Adjuster (Accelerator Cable} @ Tighten the lacknut. @lf the throttle cables can not be ad- justed by using the cable adjuster at the uaper end of the throttle cable, use the upper and lower nuts at the lower ends of the thrattle cables. @Turn out both upper nuts and turn in both lower nuts as far‘as they will qo so as to give the throttle grip plenty of play C. Accelerator Cable D. Decalerator Cable A. Upper Nuts B. Lower Nuts @Loosen the locknut at the throttls grip and turn inthe adjuster fully. @®Tighten the lacknut. e\With the throttle grip completely closed, turn out the lower nut and turn in the Upper nut of the deceleratar ca- ble at its lower and until tne inner cable just becomes tight. @Turn aut the lower nut and turn in the upper nut of the accelerator cabie until the specified trea play is obtained, 63Pel Le Operation with improperly adjusted, in- correctly routed, or damaged cables could result in an unsafe riding candi- tion. 64 Choke Lever By pulling the choke lever, the carburetor provides a rich starting mix. lure that is necessary to enable easy starting when the engine is cold. If starting difficulty or rich fuel mixture trouble gecurs, inspect the choke lever, and adjust it if necessary. inspection @Check that the choke lever returns properly and that the inner cable slides smoothly. If there is any irregularity, have the choke cable checked by an authorized Kawasaki dealer, @Push the choke lever back all the way to Its released position. @Dctermine the amount of choke cable play at the lever. Pull the choke lever until the starter plunger lever at the cathuretor touches the starter plunger. the amount of choke lever travel is the amount of cable play. 4. Starter Plunger Laver B. Starter Plunger @7The proper amount of play is 2 ~ 3mm (0.08 ~ 0.12 in.) at the battom of the choke lever. If there is too much of toa little play, adjust the choke cable, 4. Choke Lever B,2~ 3mm (0.08 ~ 0.12 in.) Agtusimeant @Remove the fuel tank (see Spark Plug Removal in the Spark Plugs section). @Loasen the locknut at the middle of the choke cable, and turn the adjuster until the cable has the proper amount of play. eK* f Es B. Locknu A, Adjuster @Tighten the locknut alter adjustment. 66 Carburetors The carburetor adjustments, idle speed and synchronization, should be per formed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed. The following procedure covers the idle speed adjustment. Carburetor syn chronization should be done only by your authorized Kawasaki dealer. NOTE OFoar carburetar syoehranizatian well cause unstable idling, siuggist threttle rasoerise. and reduced engine power and performance. Adjustment @Start the engine, and warm it up thor- oughly. @® Adjust the idle speed to 1,200 ~ 1,400 rimin (rom) by turning the idle adjust- Ing Screw. A. Idle Adjusting Screw @Onen and close the throttle a few times to make sure that the idle speed does natchange. Readjust if necessary. eivith the engine idling, turn the handlebar to each side, If handlebar mavement changés the idle speed, the throttle cables may be improperly ad- justed ar incorrectly routed, or they may be damaged, Ge sure to correct any of these canditions before riding. Pre tate ee Operation with damaged cables could resull In.an unsate riding condition. 67Clutch Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accord ance with the Periodic Maintenance Chart AWARNING To avold a serious burn, never touch a hot engine or exhaust pipe during clutch adjustment. Inspection @Check that the clutch lever has 2? ~ 3 mm (0.08 « 0.72 in of play as shown in the figure. 63 A. Adjuster 8. Locknut C.2~ 3mm (0.08 ~ 0.12 in.) If it does not, adjust the lever play as follows. Aajustment @Loosen the locknut at the clutch lever. @®Turn the adjuster so that the clutch lever will have the specitied free play. AWARNING Be sure the upper end of the clutch outer cable is fully seated In its fitting, or It could slip into place later, creating enough cable play to pravent cluich disengagement, resulling In a hazard- ous riding condition. @Tighten the locknut. @lf it cannot be done, use the mounting nuts at the lower end of the cable, A. Mounting Nuts NOTE OAfter the adjustment is made, start the angine and check that the efutch does not sip and thats releases properly OFfor minor corrections, use the adjuster at the cluten lever. 63Drive Chain The drive cham must be checked, ad- justed, and lubricated in accordance with the Periodic Maintenance Chart for safety and ta prevent excessive wear. If the chain becomes badly worn oF maladjusted — either too loose or too tight the chain could jump off the sprockets or break. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, se- verely damaging the motorcycle and causing itio go out of control. Chan Sok inspection @ Set the motorcycle up on its side stand. @ Rotate the rear wheel to find the pos'- tior where the chain is tightest, and measure the vertical movement mid way between the sprockets. FO A035 ~ 45 mm {1 1.8 in.) @if the drivé chain is too tight or too loose, adjust it so that the chain slack will be within the standard value. Drive Chain Stack 35 ~ 40mm {1.4 ~1.6in) less than 35 mm Standard Tootight | (1.4in.) Tao laase more than 45mm .8ing Chain Slack Agustment @ Loosen the rear torque link nul Deo not forget to loosen Ihe torque link nut. A. Taorqua Link Nut. @Loosen tho leftand right cnain adjuster lacknuts. Cc. Locknut D. Adjusting Nut A. Axte Nut B. Cotter Pin @ Remove the cotter pin, and loosen the axié nut. @if the chain is too ioese, turn in the ler and right chain adjusting nuts evenly. @l[ the chain is tea tight, turn out the left and right chain adjusting nuts evenly, and kick the wheel forward.@®Turn both chain adjusting nuts evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch on the left wheal alignment indicator should align with the same swing arm mark thet the right indicator notch aligns with, A. Marks B, Notch €. Indicator D, Adjusting Nut E. Locknut 72 NOTE O Wheel alignment can also be checked using fhe sifaightedge oar string meiod. Previa a Ley Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. @Tightan both chain adjuster locknuts. @ Center the brake panel assembly in the brake drum. This is done by tightening the axle nut lightly, spinning the wheel, and depressing the brake pedal forcefully, The partially tightened axle nut allows the brake panel assembly to center itself within the brake drum, NOTE Ovfis procedure can prevent a soft or “spongy feeling” brake STighten the axle nul to the specified torque. Tightening Torque 110N-m |(11 kg-m, 80 #t-Ib) Axle Nut . | 29 N-m Torque Link Nut | (3 kg-m: 22 ft-lb) @Rotate tha wheel, measure the chain slack again at the tightest pasition, and readjust if necessary. @inserta new cotter pin through the-axle nut and axle, and spread its ends. @Tighten the rear torque link nut to the specitied torque. Pd ie If the axle nuf or torque link nut Is not securely tightanad, or the cotter pin is not installed, an unsafe riding condi- thon may result, eCheck the rear brake (see the Brakes section}. Vear Inspection @stratch the chain taut either by using the chain adjusters, or by hanging a 10 kg (20 ib) weight on the chain, @Maasure the Jength of 20 links on the Straight part of the chain from pin cen- ter of the Ist pin to pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places. aaA, Measure B. Weight @lf the langth exceeds the service limit, the chain should be replaced. Drive Chain 20-Link Length Service Limit: 323mm (12.7 in.) | 74 AWARNING For salety, use only the standard chain. it is an endless type and should not be cut for installation; have it installed by an authorized Kawasak! dealer. @Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose ping acd links, @®Also inspect the sprockets for un- evenly ar excessively worn teeth, and damaged teeth NOTE OSprocket wear is exaggerated for ilus- tratian. Ses Service Manual for weer darrnts. @Apply ol! to the sides of the rollers so that it Will penetrate to the rollers and bushings. Apply ail to the O-rings so that the O-rings will be coated with oil Wipe off any excess ail, Sprocket acm Tiansh ‘urn Toon LEnyeré Sprocket —_ DSi Of titan Dat @if there is any irregularity, have the drive chain and/or the sprockets re- placed by an authorized Kawasak\ dealer. Lubrication Lubrication is also necessary after rid- ing through rain or on wet roads, or any @/f the chain is especially dirty, clear it time thal the chain appears dry. A heavy using diesel ol! or kerosine and then oil such as SAE 90 is preferred to a apply ail as mentroned above, liqhter oj] because it will stay on the chain longer and provide better lubri cation,Brakes Brake Wear inspection in accordance with the Periodic Main- tenance Chart, inspect the brakes for wear, For the front disc brake caliper, if the thickness of either pad is less than 1 mm (0.04 in.j, replace both pads in the caliper as a set. Pad replacement should be done by an authorized Kawasaki dealer. ate 1 Lirsag [ek 2 Tin 0.04 or TT On the rear brake panel is a brake lin- ing wear indicator, If the brake lining wear indicator does nat paint within the USABLE RANGE whan the brake is fully apolied, the brake shoe linings have worn past the senice limit. In this case, the brake shoes must be replaced and the drum and other brake parts examined by an authorized Kawasaki dealer. B. Brake Lining Wear Indicator Ludncaton In aceerdance with the Periodic Main- tenance Chart, the brake camshaft should be lubricated by an authorized Kawasaki dealer, Disc Brake Fluid: In accordance with the Periodic Main tenance Chart, inspect the brake fluid level in the reservoir and change the brake fluid, The brake fluid should alse be changed if it becomes contaminated with ditt or water, Fluid Requirement Recommended fluids are given in the table below. lf none of the recom- mended brake fluids are available, use extra heavy-duty brake fluid anly tram a container marked D-O.T, 3. Recommended Oisc Brake Fluid Atlas Extra Heavy Duty Shell Super Heavy Durty Texaco Super Heavy Duly Wagner Lockheed Heavy Duty Castral Girling-Universal Castro! GT (LMA) Castrol Disc Brake Fluid Bo not spill brake fluid onto any painted surface. Do nol use fluid from a container thal has been laft open or that has been un- sealed for a long time. Check for fluid Jeakage around the fit- tings. Check for brake hose damage. vfFittid Level faspection @The brake fluid level in the reservour must be kept above the lower level line (reservoir hald horizontal), A. Lower Level Lina @lf itis lower than the ‘evel ling, fill the reservalr to the upper level line inside the reservoir, A, Upper Level Line Do not mix twa brands of fluid. Change the brake fluid in the brake line com- plately if ihe brake fluid must be re- fled bui the type and brand of the brake fluld that le already in the reser- | voir are unidentified. Find Change Have the brake fluid changed by an authorized Kawasaki dealer, Front Brake: Disc and dise pad wear is automat ically compensated tor and has no effect on the brake lever action. So thare are no parts that require adjustment on the front brake. Pe ete H the brake lever feels mushy when it is applled, there might be air in the brake lines or the brake may be detec- tive, Since It is dangerous to operale the motorcycle under such conditions, have tha braka checked immediately by an authorized Kawasaki dealer, Rear Brake: Brake pedal position can be adjustac to-suit you. In accordance with the Peri- edic Maintenance Chart, inspect the brake pedal play. Pedal Positien Inspection @When the brake peda! is iin its rest posi tion, it should be O ~ 20 mm (0 ~ 0.5 in.) lower than the tap of the footpeg, A. Rear Brake Pedal B.0 ~ 20mm (0 ~ 0.8in.)Pedal Piay inspection @The brake pedal should have 20 ~ 30 mm (0.8 ~ 1.2 in.) of play when the pedal is pushed dawn lightly by hand, ®/{ itis not, adjust the pedal position. Pedal! Positian Adjustment @Loosen the facknut, and tum the ad- justing bolt to adjust the pedal posi tion. ®Tighten the locknut, &, Rear Brake Pedal 8.20 ~ 30mm (0.8 ~ 1.2in-) @Rotate the wheel to check for brake ; = eee, drag. A Adjusting Bolt EB. Locknut @Check the brake pedal play and opera tion of the rear brake light switch a0 @Operate the pedal 4 tow times to see that it returns to its-rest positian imme- diately upon release @Check braking effectiveness. @\f the pedal has improper play, adjust tt. Pedal Play Adjustment @Turn the adjusting nut at the brake cam lever so that the pedal has 20 ~ 30 mm (0.8 ~ 1.2 in.) of play. Brake Light Switches When either the front or rear brake is applied, the brake light goes on. The front brake light switch requires no ad justment, but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart. inspector @7Turn on the ignition switch. @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. eCheck the operation of the tear brake light switch by depressing the brake padal. The brake light should go on after about 15 mm (0.6 in.) of pedal travel 314. Brake Pada B15 mm (0.6 in.) @lf it does not. adjust the rear brake light switch. Adiustment @Aemove the right lower side cover. @To adjust the rear brake light switch, move the switch up or down by turn- ing the adjusting nut. 82 To avoid damaging the electrical con- neclions inside the switch, be sure that the switch body does moi turn during adjusiment. \. mi A. Rear Brake Light Switch B, Adjusting Mut C. Lights sooner. D. Lights later, Rear Shock Absorbers Searing Adjustment The spring adjusting sleeve on each rear shock absorber has 5 positions sa that the spring can be adjusted for diftar- ent road and laading conditians A, Adjusting Slaeve lf the spring action feels too saft ar too stiff, turn each adjusting sleeve by using the wrench in the tool kit in ac- cordance with the following table: Pasithon — + Stranger Spring Action | dé WARNING It both spring adjusting sleeves are not adjusted equally, handling may be im- paired and a hazardous condition may result.NOTE OB8s sure to turn back the adjusting sleeve counterclockwise from positien S when softening the spring action oa Wheels Tubeless tires are installed on the wheels of this motercycle. The indi cations of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. TUBELESS Mark A, TUBELESS Mark The tire and rim form a leakproof unit by making airtight cantacts at the tire chamfers and the rim flanges instead of using an inner tube AWARNING The tires, rims, and air valves on this motorcycle are designed only for tubeless type wheels. The recom- mended standard tires, rims. and air valves must be used tor replacement. Do mot Install tube-lype tires on tubeless rims. The beads may not seat properly on the rim causing tlre dailation. Do not install a tube inside a tubeless lire. Excessive heat build-up may damage the tube causing tlre defla- tion. Tires: Payload and Tire Pressure Failure to maintain proper intlation pressures ar observe payload limits for your tires may adversely affect handling and parformanece of your motorcycle and can result in loss of control, The maxi- mum recommended joad in addition ta vehicle weight is 186 kg {408 Ib}, tn- 35cluding tider, passenger, baggage, and accessories, @ Check the tire pressure often, using an AGCCUIATE Gauge, NOTE Difegsure ine re pressure when the tires are cold (that is, when lhe motar- cycle has not been ridden mare than @ mile during the past 2 hours). OTe pressure is affected by changes in ambient temperature and altitude, arte so The tire pressure Should be checked and adjusted when your riding invelves wide variations i temperature or alit- ade. Tira Air Pressure (when eald) Front and 200 kPa Roar (2.0kg/om?, 28 psi} 36 Ba 5 A. Tira Pressure Gauge Tre Wear, Samage As the tire tread wears down, the tire becomes more susceptible to puncture and failure, An accepted estimate ts that 50% of all tire failures occur during the last 10% of tread life (90% worn). Sa it is taisa aconomy and unsafe to use the tires until they are bald. @in accordance woth the Periodic Main- tenance Chart, measure the depth of the tread with a depth gauge, and re place any tire that has worn dawn to the minimum allowable tread depth. 4. Tire Depth Gauge Minimum Tread Depth Front | -———_ amen (0.04 in.) Rear | Under 130 kmsh 2mm (80 mph) - (0.08 in.| Over 130 km/h 3 mit (80 mph} (O12 in @Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage. Swelling ot high spots indi- cate internal damage. requiring Tire re- placement. @Remove any imbedded stands or other foreign particles fram the tread. NOTE OHdave the wheel balance inspected whenevera mew tire is instaffed,Pee ie bey To ansure sate handling and stability, use only the recommended siandard liras for replacement, inflated to the Standard pressura, Tires that have been punctured and re- pairad do not have the same capabili- ties as undamaged tires. Do nol exceed 100 km/h (60 mph) within 24 hours after repair- NOTE oWheo agerating on public roadways, keap maximum speed under traffic faw limits. Standard Tire 110/50 17 SBS DUNLOP Fi? Tubeless ; 140/90-15M/C 705 DUNLOP K425G Tubeless Battery Battery Electrolyte Level inspection The battery electrolyte level must be kept between the upper and lower level lines. Check the electrolyte level in each cell in accordance with the Periodic Maintenance Chart. @Remove the battery fram the motorcy- cle (see Battery Removal). @®Check that the electrolyte level in each cell is between the upper and lower leval lines. A. Filler Caps B. Upper Laval Line C. Lower Level Line @/{ the electrolyte level is low in any cell, fill with distilled water as follaws. @®Aemove the battery filler caps and fill with distilled water until the electrolyte level in each cell reaches the upper level fine.A CAUTION : Add only distilled water to the battery. Ordinary tap water Is not a substitute tor distilled water and will shorten the life of the battery. Battery Femaval @ Remove the right /ower and upper sida covers. @ Unscrew the battery holder 4. Battary Holder B. Screws C. (+) Tarminal BD. {—} Terminal ® Disconnect the leads from the battery, first from the (—) terminal and then the (+) terminal. @ Take the battery out of the case. @Clear ihe battery using a solution of baking soda and water. Be sure that ihe lad connections are clean, Battery installation @®Put the battery in the battery casa, and route the battery vent hose as shown on the caution label. @Connect the capped lead to the {-} terminal, and then connect the black lead to the {—) terminal. @®Put a light coat of grease on the termi- nals to prevent corrasion. @Cover the (4) terminal with its protec- tive cap. ACAUTION Make sure the battery vent hose Is kept away from the drive system and ex- haust system. Battery electrolyte can corrode and dangerously weaken the drive system, Do not let the vent hose become folded, pinched, or melted by the exhausi system. An unvented bat- fary will nol keep a charge and It may crack from buill-up gas pressure. Headlight Beam Hovizonial Adjustment The headlight beam is adjustable hor izontally. Tf not properly adjusted har izantally, the beam will point ta one side rather than straight ahead. @Take off the headlight fairing mounting boltand pull up the fairing to remove. A. Fairing B. Bolt @7Turn the adjusting screw on the head- lightrim in araut until the beam points straight ahead a1A, Adjusting Screw A. Headlight Bolt @Reinstall the headlight fairing @Push the headlight up or down to ad- just the headlight vertically, @Tighten the headlight bolt, Vertical Adiusiment The headlight beam is adjustable ver- tically. MH adjusted top low, neither jaw nor high beam will illuminate the road far enough ahead. [f adjusted tao high, the hgh beam will fail to iliuminate the road close anead, and the low beam will blind ancor ing drivers. @ Loosen the headlight bolt shawn. 92 eee NOTE COn figh beam, the brightest paint should be slightly belaw Aarizantal with (fe motarcyele an fis wheels and the rider seated, Adjust the headlight fo the proper angle according to lacal requisitions. Fuses. Fuses are arranged in the junction box located inside the left side cover, and the main fuse is mounted on the starter relay inside the right side cover. Ha fuse fails during operation, inspect the electrical system to determine the cause. and then replace it with a new fuse of proper amperage. A. Junction Box BE, FusesNormal Failed bis. A. Main Fuse 8, Starter Relay Do net use any substitute for the atand- ard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the junction box. 94 Fuel System Accumulation of moisture of sedi- ment in the fuel system will restrict the tlow of fuel and cause carburetar mal- function. The system should be checked in-accardance with the Periodic Mainte- nance Chart. Pre Le Gasoline ig extremely flammable and can be explosive under certain condl- tions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free irom any source of lame or sparks; this includes any ap- plilance with a pilot light. Make sure the engine is cold before working. Wipe any fuel off the engine before starting ik inspection @®Turn the fuel tap to the ON pasitian @ Run tne lower ends of the drain hoses inte 2 suitable container. @®Turn out each drain screw a few turns to drain the carburetors, and check to see if water or dirt has accumulated in the carburetors. A. Drain Screw B. Drain Hose @Tighten the drain screws.NOTE Off any water or dirt appears during the ebhove operation, have the fue! system checked by an authorzed Kawasakr dealer Cleaning For the prolonged lite of your mator- cycle. wash it down immediately alter it has bean splashed with seawater or ex posed to the saa breeze: operated an rainy days, rough roads, orin dusty areas; or operated on roads on which salt has been scattered for ice removal. Preparation for Washing Before washing. precautions must be taken to keep water off tha following places: @®Rear apéning of the muffler Cover with a plastic bag secured with a rub- ber band, @Clutch and brake levers, switch housings on the handlebar; Cover with plastic bags ®lgnition switch; Cover the keyhole with tape. @Air cleaner intake; Close up the intake with tape, or stuff with rags. Where to be Careful Avoid spraying water with any great force near the following places: @ Meter instruments . @ Disc brake master cylinder and caliper @ Rear hut: If water gets inside the hub, the rear brake will not function until it dries aut. @Under the fuel tank: If water gets into the ignition coils or inta the spark plug caps, the spark will jump through the waterand be grounded out. When this happens, the motorcycle will not start and the affected parts must be wiped dry. Front wheel hub ; @Steering pivat (steering stem head pipe) @Swing arm pivot NOTE OCoin operated, Aig pressure spray washers ara not recommended The water may be forced into bearings and other camponents causing eventual failure fram rust aad corrasion, Some af the soaps whieh are highly alkaline foave a residue or cause spolting. Afier Washing @ Remove the olastic bags and tape, and clean the air cleaner intake. @ Lubricate the points listed in the Gen eral Lubrication section. @ Test the brake before motorcycle aper- ation. ~ @® Start the engine and run it for & min- utes.A WARNING Never wax or lubricate the brake disc. Loss of braking and an accidant could resull. Clean the disc with an oilless solvent such as trichloroethylene or acetone. Observe the solvent manu- facturer’s warnings. PPP STORAGE «acccdennnnnnananncneennaed Preparation for Storage: @Claan the entire vehicle tharaughly, @ Empty the fuel from the fuel tank, and empty the carburetors by unscrewing the drain screw at each float bow! (If left in far along time, the fuel will break down and could clog the carburetors.) @Asmove the empty fuel tank, pour about 250 mL (% pint) of motor oil into the tank roll the tank araund to coat the inner surfaces thoroughly. and pour out the excess ail. AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not amoke. Make sure the area is well ventilaled and tree from any source of flame or sparks; this includes any appliance with a pilot Iighi, @ Remove the spark plugs and put several drops of SE class SAE 30 off into cach cylin- der, Push the starter button fora few seconds to coat the cylinder walls with oil, and install the spark plugs. @ Reduce tire pressure by about 20%. @Set the motorcycle on a box or stand so that both wheels are raised off the ground. {It this cannot be done, put boards under the front and rear wheels to keep dampness away fram the tire rubber.)@Spray oll on all unpainted metal surfaces to prevent rusting. Avoid getting ail on rub- bar parts or in the brakes, @ Lubricate the drive chain and all the cables. @Remove the battery, and store it where it will not be exposed te direct sunlight, moisture, or freezing temperatures, During storage it should be given a slow charge fane ampere or less) about once a month. Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged the battery becomes, the mare easily it freezes @7Tiea plastic bay over the exhaust pipe ta prevent moisture from entering. @Put a cover over the motorcycle to keep dust.and dirt fram collecting an It. Preparation after Storage: @ Check the electrolyte level in the battery, charge the battery if necessary, and install it inthe motercycle. Be careful that the battery vant hase is not pinched and that it is kept away from the driving system and other frame parts, @Maeke sure the spark plugs are tight. @ Fill the fuel tank with fel. @ Change the engine oil. @ Check all the points listed in the Daily Safety Checks section. @ Lubdricaté the points listed in the Generali Lubrication section. 100ES £1. 250-1 HEAVY NASA LTD.