Wer P ZX-6 Motorcycle Owner's ManualWhenever you see the symbols shown below, heed their instructions! Always follow safe operating and main- tenance practices. This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. A.CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equip- ment. NOTE OThis nate symbol indicates points of particular interest for more efficient and convenient operation. NOTICE THIS PRODUCT HAS BEEN MANU- FACTURED FOR USE IN A REASON- ABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) contro! systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incor- porated an evaporative emission control system (3) in compliance with applica- ble regulations of the California Air Resources Board on vehicle sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into the combustion chamber, where they are burned along with the fuel and air sup- plied by the carburetors. . Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmos- phere by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an effi- cient engine with low exhaust pollutant levels.3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of vehicles operated above 4,000 feet, Kawasaki recommends the following Environmental Protection Agency (EPA) approved modification. NOTE © When properly performed, these specified modifications only are nat consid- ered to be emissions system "tampering" and vehicle performance is generally unchanged as a result. Installation Instructions: High altitude adjustment requires replacement of certain carburetor compo- nents. Installation of these optional parts may be performed by an authorized Kawasaki dealer, or the consumer, following repair recommendations specified in the appropriate Kawasaki Service Manual.MAINTENANCE AND WARRANTY Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels. This Owner's Manual contains those maintenance recommendations for your motorcycle. Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards. As the owner of this motorcycle, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. The Kawasaki Limited Emission Control System Warranty requires that you teturn your motorcycle to an authorized Kawasaki dealer for remedy under war- ranty. Please read the warranty carefully, and keep it valid by complying with the owner's obligations it contains. You should keep a maintenance record for your motorcycle. To assist you in keeping this record, we have provided space on pages 126 through 128 of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, bills, etc., as verification of this maintenance.TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the re- moval or rendering inoperative by any person other than for purposes of mainte- nance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. Removal of the muffler(s) or any internal portion of the muffler(s). Removal of the air box or air box cover. Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.WARNING CONTAINS ASBESTOS Breathing asbestos dust is dangerous to health Follow safety instructions This warning may apply to any of the following components or any assembly containing one or more of these components: — Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS @Operate if possible out of doors or in a well ventilated place. @Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped. If possible, dampen before cutting or drilling. @Dampen dust and place it in properly closed receptacle and dispose of it safely.FOREWORD We wish to thank you for choosing this fine Kawasaki Motorcycle. Your new motorcy- cle is the product of Kawasaki's advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety, and performance. Read this Owner's Manual before riding so you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its features, 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 recom- mends that all operators of this vehicle enroll in a motorcycle rider training program to at- tain 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 main- tenance described in this manual. For those who would like 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 to improvements in design and performance during production, in some cases there may be mi- nor 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, 1991 Jan, 1991, (2). (8)yoyo» DDD» TABLE OF CONTENTS caccneeeeeeeee anne Fuel Tank. Fuel Tap.. Stands. Tying Hooks. Helmet Hook Fairing Pocket. Tool Kit... Seat... Side Cover: Electric Accessory Leads.. 25 Break-In........ 26 How to Ride ‘tha Motorcycle 26 Starting the Engine.......0...... 28 Jump Starting 28 Moving Off... 28 Shifting Gears . Braking... ‘Stopping the Engine. Stopping the Motorcycle in an Emergency Specifications...... Consumer Information Serial Number Locations Location of Parts. Location of Labels Loading Information General Information Meter Instruments. Speedometer and Tachometer Coolant Temperature Gauge. Indicator Lights Key... Ignition ‘Switch/Steering Lock Right Handlebar Switches Engine Stop Switch Starter Button Left Handlebar Switches Dimmer Switch... Turn Signal Switch Horn Button..... Hazard Switch, Parking ......-. Brake/Clutch Lever Adjusters Safe Operation . Fuel Tank Cap... Safe Riding Technique...........-...0.....56Daily Safety Checks... Additional Considerations Yor High Speed Operation ..... Maintenance and Adjustment. Periodic Maintenance Chart Engine Qil... Cooling System Spark Plugs... Valve Clearance Evaporative Emission Control System Kawasaki Clean Air System . Air Cleaner .... Throttle Gri Choke Lever ... Carburetors. 5 Clutch.. 6 Drive Cha 8 Brakes 4 Brake Light Switches Rear Shock Absorber. Wheels. Battery... Headlight Beam Fuses .... Fuel System ... General Lubrication, Cleaning... Bolt and Nut Tightening Storage... Troubleshooting Guide Reporting Safety Defects Owner Satisfaction Maintenance Record ............ 1 26DD YY DD Dd DD DD Dd D> DDD} DP DD IDDD ID DID IPDD DDD DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Dry Weight ENGINE Type Displacement Bore x Stroke Compression Ratio Starting System Cylinder Numbering Method Firing Order Carburetors Ignition System 10 SPECIFICATIONS cece eee 2,075 mm (81.69 in.) 700 mm (27.6 in.) 1,170 mm (46.06 in.) 1,440 mm (56.69 in.) 110 mm (4.33 in.) 195 kg (430 tb) 195.5 kg (431 Ib) DOHC, 16-valve, 4-cylinder, 4-stroke, liquid-cooled 599 mL (36.6 cu in.) 64.0 x 46.6 mm (2.52 x 1.83 in.) 11:68:21 Electric starter Left to right, 1-2-3-4 1-2-4-3 Keihin CVKD36 x 4 Battery and coil (transistorized ignition)Ignition Timing (Electronically advanced) Spark Plugs Lubrication System Engine Oil Engine Oil Capacity Coolant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Gear Ratio. Ist 2nd 3rd 4th 5th 6th 12.5" BTDC @1,050 r/min (rpm) [ 7.5° BTDC @1,300 r/min (rpm)] ~ 40° BTDC @3,000 r/min (rpm) NGK CSE or ND U27ES-N NGK CRIE or ND U27ESR-N Forced lubrication (wet sump) SE or SF class SAE 10W40, 10W50, 20W40, or 20/50 3.7 L (3.9 US qt) 2.5 L (2.6 US qt) 6-speed, constant mesh, return shift Wet, multi disc Chain drive 1.792 (95/53) 3,000 (45/15) 5,825 (Top gear) 3.166 (38/12) 2.125 (34/16) 1.666 (35/21) 1,380 (29/21) 1.217 (28/23) 1,083 (26/24) 11FRAME Castor Trail Tire Size: Front Rear Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light : Canadian model ; California model 24.5° 95 mm (3.74 in.) 120/60VR17-V250 + 120/602R17 or 110/70V17-V250 Tubeless 160/60VR17-V250, 160/602R17 or 160/60VB17 Tubeless 18 L (4.8 US gal) 12V12Ah 12 V 60/55 W+ 12 V 8/27Wx2 Specifications subject to change without notice. 12yyy» yn» DYDD” CONSUMER INFORMATION «cccanancnceaanne Vehicle Minimum Stopping Distance on Dry Pavement These figures indicate braking performance that can be met or exceeded by the vehicle to which they apply, without locking the wheels, under different condi- tions of loading. The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions. Description of vehicle to which this table applies: Model ZX600-D2 A. Fully Operational Service Brake Light RQ Load: 50 100 150 Stopping distance in feet from 60 mph. Oo Manufacturer: Kawasaki Heavy Industries, Ltd. 13»yoy»pyaaopyyn»y? SERIAL NUMBER LOCATIONS ccannnacananec The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it. A. Frame Number A. Engine Number 14>ypyypanyynypnnpnnn LOCATION OF PARTS cacanccnceKneKnnene wry ~ Onn . Clutch Lever . Meter Instruments . Brake Fluid Reservoir (Front) Front Brake Lever . Left Handlebar Switches . Ignition Switch/Steering Lock . Right Handlebar Switches . Throttle Grip 159, Front Fork 10. Headlight 11. Turn Signal/Running Position Light 12. Spark Plugs 13. Idle Adjusting Screw 14, Air Cleaner 15. Fuel Tap Button 16. Battery 17. Junction Box (Fuses) 18. Helmet Hook 19. Tying Hooks 20. Turn Signal Light 21. Brake Disc 22. Brake Caliper 23. Radiator 24. Shift Pedal 25. Side Stand 26. Center Stand 27. Drive Chain 28. Muffler 16}. Tail/ Brake Light . Coolant Level Sighthole . Rear Brake Fluid Level Sighthole . Fuel Tank . Fuel Tank Cap . Rear Brake Light Switch . Rear Shock Absorber . Rebound Damping Force Adjuster . Rear Brake Pedal . Oil Level Gauge 7yop pyypyyDyyDIPMD LOCATION OF LABELS ccc eaeennceead 1. Engine Oil and Oil Filter 2. Air Intake "3. Vehicle Emission Control Information “*4. Vacuum Hose Routing Diagram . Tire and Load Data . Important Drive Chain Information . Brake Fluid (Rear) . Daily Safety Checks . Battery Vent Hose *: only on US model ** > only on California model Caryan“10. Break-In Caution 11. Brake Fluid (Front) 12. Noise Emission Control Information 13, Battery Poison/ Danger “"14, Fuel Level only on US model : only on California model 19yyppopynyny»yyn»ny» LOADING INFORMATION «cacacacccnecannan AWARNING Incorrect loading, improper installa- tion or use of accessories, or modifi- cation of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure that the motorcycle is not overloaded (refer to page 102 for maximum load information) and that you have fol- lowed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no contro! over the design or application of accessories. In some cases, improper installation or use of ac- cessories, or motorcycle modification, will void the motorcycle warranty. In selecting and using accessories, and in loading the motorcycle, you are per- sonally responsible for your own safety and the safety of other persons involved. 20 NOTE OKawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accesso- ries you add to your motorcycle be genuine Kawasaki components. Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in the fitting of additional accessories. The following general guidelines have been prepared to assist you in making your determinations1, Any passenger should be thoroughly familiar with motorcycle operation, The passenger can affect control of the motorcycle by improper position- ing during cornering and sudden movements. It is important that the passenger sit still while the motorcy- cle is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motor- cycle. You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator, seat strap or grab rail. Do not carry a passenger unless he or she is tall enough to reach the footpegs and footpegs are provided. All baggage should be carried as low as possible to reduce the effect on the motorcycle center of gravity. Baggage weight should also be dis- tributed equally on both sides of the motorcycle. Avoid carrying baggage that extends beyond the rear of the motorcycle. Baggage should be securely at- , tached. Make sure that the baggage will not move around while you are riding. Recheck baggage security as often as possible (not while the mo- torcycle is in motion) and adjust as necessary. Do not carry heavy or bulky items on a luggage rack. They are designed for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces. Do not install accessories or carry ‘ baggage that impairs the perform- ance of the motorcycle. Make sure that you have not adversely affected any lighting components, road clear- ance, banking capability (i-e., lean angle), control operation, wheel travel, front fork movement, or any 2122 other aspect of the motorcycle’s op- eration. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in an unsafe riding condition. Fairings, windshields, backrests, and other large items have the capability of adversely affecting stability and handling of the motorcycle, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly designed or installed items can result in an un- safe riding condition. 9. This motorcycle was not intended to be equipped with a sidecar or to be used to tow any trailer or other vehi- cle. Kawasaki does not manufacture sidecars or trailers for motorcycles and cannot predict the effects of such accessories on handling or sta- bility, but can only warn that the ef- fects can be adverse and that Kawasaki cannot assume responsi- bility for the results of such unin- tended use of the motorcycle. Furthermore, any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty.»»»»»p yyy yD») GENERAL INFORMATION ccacneecneancaneae Meter Instruments -Z @n m 9 omP J. K. L. M. . Speedometer . Tachometer . Fuel Level Warning Lights . Oil Pressure Warning Light High Beam Indicator Light . Red Zone . Coolant Temperature Gauge . Trip Meter . Right Turn Signal Indicator Light Neutral Indicator Light Left Turn Signal Indicator Light Reset Button Odometer 23Speedometer and Tachometer The speedometer shows the speed of the vehicle. In the speedometer face are the odometer and trip meter. The odometer shows the total distance that the vehicle has been ridden. The trip meter shows the distance traveled since it was last reset to zero. The trip meter can be reset to zero by pushing the reset button. 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 performance. In the tachometer face is the addi- tional trip meter which can be reset to zero by turning the reset button clock- wise. 24 Engine r/min (rpm) should not be al- lowed to enter the red zone; operation in the red zone will overstress the en- gine and may cause serious engine damage. Coolant Temperature Gauge This gauge shows the temperature of coolant. Ordinarily, the needle should stay within the white zone. If the nee- dle reaches the "H" line, stop the engine and check the coolant level in the reserve tank after the engine cools down. Do not let the engine continue running when the gauge needle reaches the "H" line. Prolonged engine operation will result in severe damage from overheating.Indicator Lights. FUEL: The fuel warning lights flash on and off whenever the fuel in the fuel tank has decreased to 6.5 L (1.7 US gal) or less when riding or the ignition switch is in the ON position with the engine not running, and goes off when there is more than 6.5 L of fuel in the tank. If either light bulb has burnt out, the remaining one flashes on and off at more frequent interval. HIGH BEAM: When the headlight is on high beam, the high beam indicator light is lit. OIL: The oil pressure warning light goes on whenever the oil pressure is danger- ously low or the ignition switch is in the ON position with the engine not run- ning, and goes off when the engine oil pressure is high enough. Refer to the Maintenance and Adjustment chapter for more detailed engine oil information. TURN: When the turn signal switch is turned to left or right, the corresponding turn signal indicator light flashes on and off. NEUTRAL: When the transmission is in neutral, the neutral indicator light is lit. 25Key This motorcycle has a combination key, which is used for the ignition switch/ steering lock, fuel tank cap, and helmet hook. Blank keys are available at your Kawasaki dealers. Ask your Dealer to make any additional spare keys you may need, using your original key as a mas- ter. 26 Ignition Switch/Steering Lock This is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF, LOCK, or P(PARK) position. A. Ignition Switch/Steering Lock B. LOCK position EP (Park nosiélaniEngine off. All electrical circuits off. Engine on. All electrical equipment can be used. Steering locked. Engine off. All electrical circuits off. P(Park)| Steering locked. LOCK Engine off. Taillight and license plate light on. Turn signal circuit on. All other elec- trical circuits cut off. NOTE OThe tail. running position, and license plate lights are an whenever the ig- nitian switeh is in the ON position. The headlight goes on when the Starter button is released after starting the engine. To avoid battery dis- charge, always start the engine imme- diately after turning the ignition switeh ta ON. O/f you leave the PARK position on for a long time (one hour), the battery may become totally discharged. To operate the ignition switch: OFF <> ON P(Park) 2 1. Turn the handlebar fully to the b left 2. a. For parking push down the key in the ON position and turn it to P (Park). b. For locking push down the key in the OFF position and turn it to LOCK. LOCK 27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 requires stopping the engine, move the engine stop switch to the OFF position. NOTE OAlthough the engine stop switch Stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine. 28 A. Engine Stop Switch B. Starter Button Starter Button The starter button operates the elec- tric 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 Motorcy- cle” chapter for starting instructions.Left Handlebar Switches Dimmer Switch High or low beam can be selected with the dimmer switch, When the headlight is on high beam (HI), the high beam indicator light is lit. A. Dimmer Switch B, Turn Signal Switch C. Horn Button D. Hazard Switch Turn Signal Switch When the turn signal switch is turned to L (left) or R (right), the correspond- ing turn signals flash on and off. To stop flashing, push the switch in. Horn Button When the horn button is pushed, the horn sounds. Hazard Switch |f an emergency requires you to park on the highway shoulder, turn on the hazard lights to warn other drivers of your location. Push in the hazard switch with the ignition switch in the ON or PARK posi- tion. All the turn signals and turn signal indicator lights will flash on and off. 29Hf you leave the switch on for a long time, the battery may become totally discharged. So be careful not to use the hazard lights for more than 30 minutes. 30 Brake/Clutch Lever Adjusters There is an adjuster on both the brake and clutch levers. Each adjuster has 4 positions so that the released lever posi- tion can be adjusted to suit the operator's hands. Push the lever for- ward and turn the adjuster to align the number with the triangular mark on the lever holder. The distance from the grip to the released lever is minimum. at Number 4 and maximum at Number 1. A. AdjusterFuel Tank Cap To open the fuel tank cap, pull up the key hole cover. Insert the ignition switch key into the lock and turn the key to the right. To close the cap, push it down into place with the key inserted. The key can be removed by turning it counterclock- wise to the original position. NOTE OThe tank cap cannot be closed with- out the key inserted, and the key can- not be removed unless the cap is locked properly. ODo not push the cap down with the key, or the cap cannot be lacked. A. Key Hole Cover C. Fuel Tank Cap B. Ignition Switch Key 31Fuel Tank The following octane rating gasoline is recommended in the fuel tank. Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. 3. Top Level 4. Filler Neck 1, Tank Cap 2, Fuel Tank 32 PNET NET Gasoline is extremely flammable and can be explosive under certain condi- tions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this in- cludes any appliance with a pilot light. Never fill the tank so the fue! level rises into the filler neck. If the tank is overtilled, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.California models only: Never fill the tank so the fuel level rises into the filler neck. if the tank is overfilled, heat may cause the fuel to expand and flow into the Evaporative Emission Control System resulting in hard start- ing and engine hesitation. Fuel Requirement: Octane Rating The octane rating of a gasoline is a measure of its resistance to detonation or "knocking." Use a gasoline with an octane rating equal to or higher than that shown in the table below. Octane Rating Method Rating (RON + MON) Antinock Index —————. 87 2 Research Octane Number (RON) The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON) The Antiknock Index is posted on ser- vice station pumps in the U.S.A. Re- search Octane Number is a commonly used term describing a gasoline’s octane rating. NOTE O If “knocking” or “pinging” occurs, use a different brand of gasoline or higher octane rating. Gasoline and Alcohol Blends Blends of gasoline and alcohol called "gasohol” can be used on an occasional basis, however continued use is not re- commended. Switch back immediately to gasoline which does not contain al- cohol if you experience any operating ir- regularities. Any deterioration of fuel 33system components or degradation of performance resulting from the use of gasohol will not be covered by Kawasaki's Limited Warranty, Emissions Warranties, or Good Times Protection Plan. If you decide to use gasohol, be sure to follow these simple cautions: 34 Never use gasohol with an octane rat- ing lower than the minimum octane rating specified by Kawasaki for this product. Never use gasohol containing more than 10% ethanol (grain alcohol). Never use gasohol containing more than 5% methanol (wood alcohol). Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors. Never use gasohol for extended peri- ods and never store this product with gasohol in the fuel system. Gasoline containing alcohol can cause paint damage. Be extra careful not to spill gasohol during refueling.Fuel Tap NOTE The fuel tap is an automatic type which shuts off the fuel supply when the engine is stopped. OTo start a cold engine after the mator- cycle has been stored for a long time, push the fuel tap button for a few seconds to prime the carburetors. A. Fuel Tap Button Pushing the fuel tap button bypasses the automatic control and is useful for priming the engine after running out of gas, or for completely draining the tank. 35Stands The motorcycle is equipped with two stands: a center stand and a side stand. A. Side Stand NOTE OWhen using the side stand, turn the handlebar to the feft. Whenever the side or center stand is used, make it a practice to kick the stand fully up before sitting on the motorcycle. 36 AWARNING _ Forgetting and leaving the side stand down and riding away could cause an accident. To set the motorcycle up on the cen- ter stand, step down firmly on the stand, and then lift the motorcycle up and to the rear using the grab rail as a handhold. Don’t pull up on the seat to lift as this will damage the seat.Tying Hooks When tying up light loads to the seat, pull up the hooks on the left and right side covers. C. Grab Rail D. Lift up A. Center Stand B, Step down A. Tying Hooks 37Helmet Hook A heimet can be secured to the mo- torcycle using the helmet hook. The helmet hook can be unlocked by inserting the ignition switch key into the lock, and turning the key to the right. AWARNING Do not ride the motorcycle with a hel- met attached to the hook. The helmet could cause an accident by distracting the operator or interfering with normal vehicle operation. 38 B. Helmet HookFairing Pocket The fairing pocket is located to the left of the instrument panel inside the fairing. To open the fairing pocket lid, insert the ignition switch key into the lock, turn the key clockwise, and pull the lid up. To close the lid, turn the key counter- clockwise and pull it out. A. Fairing Pocket Keep the owner's manual and any pa- pers or documents that should be kept with the motorcycle in this pocket. AWARNING It is dangerous to open the fairing pocket while riding the motorcycle. The motorcycle must be stopped in a safe place to open the fairing pocket. 39Tool Kit The tool kit is stored in the fairing pocket. The minor adjustments and replace- ment of parts explained in this manual can be performed with the tools in the kit. 40 Seat The seat is removed by removing the seat mounting bolts at both sides of the seat rear portion and pulling the seat up and to the rear.Side Covers The left and right side covers are re- moved for the brake fluid and coolant refilling. First unscrew the passenger's grab rail. a VW ZS A. Side Cover C. Tying Hooks B. Screws A. Grab Rail B. Screws Remove the side cover mounting screws shown and pull the side covers outward. The two of the screws on each side cover are located behind the tying hooks. 41Electric Accessory Leads The electric power of the battery can be used through the electric accessory leads regardless of ignition switch posi- tion. Observe and follow the notes listed below. Electric Accessory Leads Polarity Lead Color White/Blue Whenever you leave the motorcycle, stop using the electric accessories. Be careful not to discharge the battery totally. For example, if a current of 10 amperes is continuously taken out with the engine stopped, even an originally-fully-charged battery may become totally discharged in about 20 minutes. Under +) Seat ‘€=} Black/Yellow Maximum Current: 10A PASSE} Take care not to pinch any lead be- tween the seat and the frame or be- tween other parts to avoid a short circuit. 42 A. Accessory Leads 1D>) 99 909) D099 90 9 D090 9999 9999 99999999999099209999 BREAK-IN cece cece eee Cenc 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 period 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) @Do not start moving or race the engine immediately after starting it, even if the en- gine is already warm. Run the engine for two or three minutes at idle speed to give the oll a chance to work up into all the engine parts. @Do not race the engine while the transmission is in neutral. In addition to the above, at 800 km (500 mi) it is extremely important that the owner have the initial maintenance service performed by a competent mechanic fol- lowing the procedures in the Service Manual. 43DY YD YD DDD DD DD DD DDD? D9 DDD DD. Starting the Engine @Check that the engine stop switch is. in the RUN position. Turn the ignition switch on. @Make certain the transmission is in neutral or the clutch is disengaged. . Engine Stop Switch . Starter Button . Neutral Indicator Light . Ignition Switch A B c D E. ON position 44 HOW TO RIDE THE MOTORCYCLE «canccnaanaaad @lf the engine is cold, pull the choke lever all the way. NOTE OWhen the engine is already warm or on hot days (35°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 lever pulled in until the engine starts. Do not operate the starter contin- uously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. NOTE Olf the engine is flooded, crank the en- gine aver with a throttle fully open until the engine starts. OThe motorcycle is equipped with a Starter lockout switch. This switch prevents the electric starter from oper- ating when the clutch is engaged and the transmission is not in neutral. A. Clutch Lever 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 2,000 r/min (rpm) during warm-up. @When the engine is warmed up enough to idle without using the choke, return the choke to the off po- sition, 45NOTE O/f you drive the motorcycle before the engine is warmed up, return the choke to the off position as soon as you start moving. Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. 46 Jump Starting If your motorcycle battery is “run down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. AWARNING Battery acid generates 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 the battery. Wear eye protection when working with a battery. In the event of battery acid contact with skin, eyes, or clothing, wash the affected areas im- mediately with water for at least five minutes. Seek medical attention. Connecting Jumper Cables @Make sure the ignition switch is turned "OFF,"@Remove the seat and air cleaner intake duct. B. Screws A. Duct @Connect a jumper cable from the posi- tive (+) terminal of the booster bat- tery to the positive (+) terminal of the motorcycle battery. ive (+) Terminal B. To Booster Battery Positive (+) Terminal C. 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 surface. Do not use the nega- tive (—) terminal of the battery. 47Do not make this last connection at the carburetor or battery. Take care that you do not touch the positive and neg- ative cables together, and do not lean over the battery 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 bat- tery explosion and serious damage to the electrical system may occur. @Follow the standard engine starting procedure, 4xCAUTION Do not operate the starter contin- uously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. 48 @After the engine starts, disconnect the jumper cables. Disconnect the nega- tive (-) cable from the motorcycle first.Moving Off NOTE och shatthers de: etdcn ‘SUP. OThe motorcycle is equipped with a @Shift into 1st gear. side stand switch. This switch is de- @Open the throttle a little, and start to signed so that the engine stops if the let out the clutch lever very slowly. cluteh is engaged with the trans- @As the clutch starts to engage, open mission in gear when the side stand the throttle a little more, giving the has been left down. engine just enough fuel to keep it from stalling. A. Shift Pedal 49Shifting Gears ®@Close the throttle while pulling in the clutch lever, @Shift into the next higher or lower gear. For smooth riding, shift up or down when the motorcycle is oper- ated at the speeds shown in the table below. AWARNING When shitting down to a lower gear, do not shift at such a high speed that the engine r/min (rpm) jumps exces- sively, Not only can this cause engine damage, but the rear wheel may skid and cause an accident. Downshifting should be done below 5,000 r/min (rpm) for each gear. @Open the throttle part way, while re- leasing the clutch lever. 50Vehicle speed when shifting Shifting up | km/h (mph)$hifting downkm/h (mph) | ist > 2nd 15 (9) 6th — Sth 30 (19) 2nd — 3rd 25 (15) 5th > 4th 25 (15) 3rd — 4th 35 (21) 4th — 3rd 20 (12) 4th > Sth 45 (27) 3rd + 2nd 15 (9) 5th > 6th 55 (34) 2nd > 1st 15 (9) NOTE OThe transmission is equipped with a positive neutral finder. When the mo- torcycle is standing still, the trans- mission cannot be shifted past neutral from fst gear. To use the positive neutral finder, shift dawn to 7st gear, then lift up on the shift pedal while standing still, The transmission will shift only tate neutral. 51Braking @Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. @Shift down one gear at a time so that you are in 1st gear when you come to a complete stop. @When stopping, always apply both brakes at the same time. Normally the front brake should be applied a little more than the rear. Shift down or fully disengage the clutch as neces- sary to keep the engine from stalling. @Never lock the brakes, or it will cause the tires to skid. When turning a cor- ner, it is better not to brake at all. Re- duce your speed before you get into the corner. @For emergency braking, disregard downshifting, and concentrate on ap- plying the brakes as hard as possible without skidding. 52 A.CAUTION in order to protect the emission con- trol parts, do not turn off the ignition switch when the motorcycle is in mo- tion. A. Front Brake LeverA. Rear Brake Pedal Stopping the Engine @Close the throttle completely. @Shift the transmission into neutral. ®@Turn the ignition switch off. @®Support the motoreycle on a firm, level surface with the side or center stand. @Lock the steering. 53Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to provide you optimum safety and convenience. However, in order to fully benefit from Kawasaki's safety engineering and craftsmanship, it is essential that you, the owner and operator, properly main- tain your motorcycle and become thor- oughly familiar with its operation. Improper maintenance and insufficient riding skills can create a dangerous situ- ation known as throttle failure. Two of the most common causes of throttle fail~ ure are: 1. During removal of the air cleaner by the owner, dirt is allowed to enter and jam the carburetor. 2. A novice may forget 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 in- stead of slowing down; and “freeze,” holding the throttle wide open. 54 In an emergency situation such as throttle failure, your motorcycle may be stopped by disengaging the clutch and applying the brakes. Once this stopping procedure is initiated, the engine stop switch may be used to stop the engine. If the engine stop switch is used, turn off the ignition switch after stopping the motorcycle.Parking @Shift the transmission into neutral and turn the ignition switch OFF. @Support the motorcycle on a firm, level surface with the side or center stand. Do not park on a soft or steeply in- clined surface or the motorcycle may fall over. @lf parking inside a garage or other structure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this in- cludes any appliance with a pilot light. AWARNING Gasoline is extremely flammable and can be explosive under certain condi- tions, @Lock the steering to help prevent theft. NOTE OWhen stopping near traffic at night. you can leave the taillight on for greater visibility by turning the ig- nition switeh to the P (park) position. ©Do nat leave the switch at P position too long, or the battery will discharge. 55yoy» opr» o»»yyym»» SAFE OPERATION «canneneenmememeemeeninn 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 helmet are strongly recom- mended. Gloves and suitable footwear should also be used for added protection in case of a mishap. A motorcycle does not provide the impact protection of an auto- mobile, so defensive riding in ad- dition to wearing protective apparel is extremely important. Do not let protective apparel give you a false sense of security. Before changing lanes, look over your shoulder to make sure the way is clear. Do not rely solely on the rear view mirror: you may misjudge a vehicle's dis- tance and speed, or you may not see it at all. 56 When going up steep slopes, shift to a lower gear so that there is plenty of power to spare rather than overloading the en- gine. When applying the brakes, use both the front and rear brakes. Applying only one brake for sud- den braking may cause the mo- torcycle to skid and lose control. When going down long slopes, control vehicle speed by closing the throttle. Use the front and rear brakes for auxiliary braking.On rainy days, rely more on the throttle to control vehicle speed and less on the front and rear brakes. The throttle should also be used judiciously to avoid skidding the rear wheel from too rapid acceleration or deceler- ation. Riding at the proper rate of speed and avoiding unnecessarily fast acceleration are important hot only for safety and low fuel consumption but also for long vehicle life and quieter operation. When riding in wet conditions or on loose roadway surfaces, the ability to maneuver will be re- duced. All of your actions should be smooth under these condi- tions. Sudden acceleration, brak- ing or turning may cause loss of control. On rough roads, exercise cau- tion, slow down, and grip the fuel tank with the knees for bet- ter stability. When quick acceleration is necessary as in passing, shift to a lower gear to obtain the neces- sary power. 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. 57Daily Safety 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 motorcycle to a safe operating condition. AWARNING Failure to perform these checks every day before you ride may result in serious damage or a severe accident. Fuel ........ . Adequate supply in tank, no leaks. Engine oil. .. Oil level between level lines. Tires... . Air pressure (when cold): 250 kPa (2.5 kg/cm?, 36 psi) | Rear | 290 kPa (2.9 kg/cm’, 41 psi) 58Drive chain Nuts, bolts, fasteners SR@@TIAG oe eeeeeseceseseeseeeseenees Brakes oo. .scccesesesesereeneesenees Throttle Clutch . Coolant oo... eceesesesenetereeeees Radiator cap........... Electrical equipment. Engine stop switch...... Side and center stands Slack 35 ~ 45 mm (1.4 ~ 1.8 in.). Check that steering and suspension components, axles, and all controls are properly tightened or fastened. Action smooth but not loose fram lock to lock. binding of control cables. Brake pad wear: Lining thickness more than 1. mm (0.04 in.) left. No brake fluid leakage. Throttle grip play 2 ~ 3mm (0.08 ~ 0.12 in.). Clutch lever play 2 ~ 3mm (0.08 ~ 0.12 in.). Clutch lever aperates smoothly. No coolant leakage. Coolant visible within sighthale (when engine is cold). Properly installed. All lights and horn work. Stops engine. Return to their fully up positions by spring tension, Return springs not weak or not damaged. No Refer to "Daily Safety Checks” caution label attached to the back of the right side cover. 59Additional Considerations for High Speed Operation Brakes: The importance of the brakes, especially during high speed operation, can- not 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 to the proper pressure, and check the wheel balance. Fuel: Have sufficient fuel for the high fuel consumption during high speed operation. Engine Oil: To avoid seizure and resulting loss of control, make certain that the oil level is at the upper level line Coolant: To avoid overheating, check that the coolant level is at the upper level line (FULL mark). Electrical Equipment: Make certain that the headlight, tail/brake light, turn signals, horn, ete., all work properly. Miscellaneous: Make certain that all nuts and bolts are tight and that all safety re- lated parts are in good condition. 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. 60»yppym»pappy» MAINTENANCE AND ADJUSTMENT «acacacacanad The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motor- cycle in good running condition. The initial maintenance is vitally important and must not be neglected, If you are in doubt as to any adjustment or vehicle operation, please ask your au- thorized Kawasaki dealer to check the motorcycle. Please note the Kawasaki cannot assume any responsibility for damage resulting from incorrect maintenance or improper adjustment done by the owner. 61Periodic Maintenance Chart Whichever * Odometer Reading km (mi) Frequency [comes first a => > bs SS SSSI SIESES Operation PSL S/S SL/L S/R VME S/S o/s o oy o/s nw & & jee Every Sf Sf SP SS S/S Pagel Carburetor synchronization ° ° ° ° ~-check + ei = | 88 Idle speed--check + ° * ° e ° it ° ° 85 g |__Throttle grip play-check + e e ° ° | 80 =] Spark plug--clean and gap + e e ° ° ° . 73 2 Valve clearance--check + ® ° ° ° 75 5 | Air suction vaive--check + e ° ° ° ° ° 7 | Air cleaner element—clean . ° ° ° | 7a & Air cleaner element--replace 5 cleanings ° 78 Fuel system--check s ° . 112 Evaporative emission control ‘ ‘ 5 ‘ * ‘ system (c)--check + * bi Battery electralyte jevel-check + | month e e e ° . e° | 105 Brake light switch-check + ° ° ° ° e ° 98 Sq] Brake pad wear-check + ° ° ° ° e | 94 Brake fluid level--check + month| @ e ° e ° ° ° 95 62Non-Emission Related Whichever & * Odometer Reading FeeuEREy comes first! . /$3/$3 /$3/F. Operation S Sh S/) L/S ST/ Pye Every Bf af OL Bf OS < K Brake fluid--change 2 years s Clutch-adjust e ° ° ° ° K Steering--check + ° . e ® ° = — Drive chain wear--check + L e e se . e ° 91 Sutter eevee tightness ° ° ‘ 5 118 Tire wear--check # ° . ° ° ° e 103 Engine oil--change year . e® ° LC ° 65 K Oil filter-replace e ° ° _ |e | 65 General lubrication--perform ° ° e ° ° . 112 K Front fork oil-change L_ e = K Swingarm pivot, uni-trak linkage--lubricate * ® * ~ K Coolant-change 2 years . 72 Radiator hoses, connections check + year . ° ° e 69 63Whichever * Odometer Reading km (mi) Frequency comes first S) os ea/bs ba /8s/e5/88 ‘ SS/ 2.8/2 8/88 /P V/P oS r/ See Operation Every. & fc) © 2 s ‘s 2 Page K Steering stem bearing--lubricate 2 years e 9 ; | K Master cylinder cup and dust 2 yeare = seal--replace © 1k Caliper piston seal and dust Bivaure _ & seal--replace ¥ 2 K Brake hose--replace 4 years _ ¥ K Fuel hose--replace 4 years = 2 |_Drive chain--lubricate Every 300 km (200 mi) 93 Drive chain slack--check + Every 800 km (500 mi) 88 K : Should be serviced by an authorized Kawasaki dealer. * : For higher odometer readings, repeat at the frequency interval established here. tT : Replace, add, adjust, or torque if necessary. (c): California model only 64Engine Oil In order for the engine, transmission, and clutch to function properly, main- tain the engine oil at the proper level, and change the oil and oil filter in ac- cordance with the Periodic Maintenance Chart. Not only do dirt and metal parti- cles collect in the oil, but the oil itself loses its lubricative quality if used too long. AWARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level inspection @\f the oil has just been changed, start the engine and run it for several min- utes at idle speed. This fills the oil fil- ter with oil, Stop the engine, then wait several minutes until the oil set- tles. Racing the engine before the oil reaches every part can cause engine seizure. @lf the motorcycle has just been used, wait several minutes for all the oil to drain down. ®@Check the engine oil level through the oil level gauge. With the motorcycle held level, the oil level should come up between the lines next to the gauge. 65if the engine oil gets extremely low or if the oil pumps or oil passages clog up or otherwise do not function prop- erly, the oil pressure warning light will light. If this light stays on when the engine speed is above 1,200 r/min (rpm), stop the engine immediately and find the cause. A. Oil Filler Cap C. Upper Level Line B. Oil Level Gauge D. Lower Level Line @lf the oil level is too high, remove the excess oil, using a syringe or some other suitable device. @lf the oil level is too low, add the cor- rect amount of oil through the oil filler opening. Use the same type and brand of oil that is already in the en- gine. A. Oil Pressure Warning Light 66Ojl and/or Oil Filter Change @Warm up the engine thoroughly, and then stop the engine. @Place an oil pan beneath the engine oil drain plug. @Remove the drain plug. A. Drain Plug @With the motorcycle perpendicular to the ground, let the oil completely drain. @lf the oil filter is to be changed, have the function performed by an author- ized Kawasaki dealer. @Install the engine drain plug with its gasket. Tighten it to the specified torque. NOTE OfReplace the damaged gasket with a new ane. @Fill the engine up to the upper level line with a good quality motor oil specified in the table. ®Check the oil level. Tightening Torque Engine Drain Plug: 20 N-m (2.0 kg- , 14.5 ft-lb) 67Engine Oil Grade: SE or SF class Viscosity: SAE 10W40, 10W50, 20W40, or 20W50 Capacity: 2.8 L (3.0 US at) [when filter is not removed] 3.2L (3.4 US qt) [when filter is removed] 68 Cooling System Radiator and Cooling Fan: Check the radiator fins for obstruction by insects or mud. Clean off any ob- structions with a stream of low-pressure water. PTS Me) The cooling fan turns on automatically, even with the ignition switch off. Keep your hands and clothing away from the fan blades at ail times.Using high-pressure water, as from a car wash facility, could damage the ra- diator fins and impair the radiator’s ef- fectiveness. Do not obstruct or deflect airflow through the radiator by installing un- authorized accessories in front of the radiator or behind the cooling fan. In- terference with the radiator airilow can lead to overheating and conse- quent engine damage. Radiator Hoses: Check the radiator hoses for cracks or deterioration, and connections for looseness in accordance with the Peri- odic Maintenance Chart. Coolant: Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level be- comes low, the engine overheats and may suffer severe damage. Check the coolant level each day before riding the motorcycle, and replenish coolant if the level is low. Change the coolant in ac- cordance with the Periodic Maintenance Chart. Information for Coolant To protect the cooling system (con- sisting of the aluminum engine and radi- ator) from rust and corrosion, the use of corrosion and rust inhibitor chemicals in the coolant is essential. If coolant con- taining corrosion and rust inhibitor chemicals is not used, over a period of time, the cooling system accumulates rust and scale in the water jacket and radiator, This will clog up the coolant passages, and considerably reduce the efficiency of the cooling system. 69AWARNING Use coolant containing corrosion inhibitors made specifically for alumi- num engines and radiators in accord- ance with the instructions of the manufacturer. Chemicals are harmful to the human body. Soft or distilled water must be used with the antifreeze (see below for anti- freeze) in the cooling system. lf hard water is used in the system, it causes scale accumulation in the wa- ter passages, and considerably re- duces the efficiency of the cooling system. |f the lowest ambient temperature en- countered falls below the freezing point of water, use permanent antifreeze in the coolant to protect the cooling system 70 against engine and radiator freeze-up, as well as from rust and corrosion. Use a permanent type of antifreeze (soft water and ethylene glyco! plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) in the cooling system. On the mixture ratio of coolant, choose the suitable one re- ferring to the relation between freezing point and strength directed on the con- tainer. Permanent types of antifreeze on the market have anti-corrosion and anti- rust properties, When it is diluted ex- cessively, it loses its anti-corrosion property. Dilute a permanent type of antifreeze in accordance with the in- structions of manufacturer.NOTE OA permanent type of antifreeze is in- stalled in the cooling system when shipped. It is colored green, contains a 50% solution of ethylene glycol, and has the freezing point of -—35°C (-37°F). Coolant Level Inspection @Situate the motorcycle so that it is perpendicular to the ground (on its center stand), @Check the coolant level through the sighthole in the right side cover. The coolant should be visible. NOTE OCheck the level when the engine is cold (room or atmospheric temper- ature). A. Right Side Cover 8B. Sighthole @lf the coolant is invisible within the sighthole, remove the right side cover, unscrew the filler cap from the reserve tank, and add coolant through the filler opening to the FULL mark. In- stall the cap and the side cover. 71Cc. FULL Mark D. LOW Mark NOTE O/n an emergency you can add water alone to the coolant reserve tank, however jt must be returned to the correet mixture ratio by the addition of antifreeze concentrate as saon as pos- sible. A. Cap B. Reserve Tank 72 If coolant must be added often, or the reserve tank completely runs dry, there is probably leakage in the sys- tem. Have the cooling system in- spected by your authorized Kawasaki dealer. Coolant 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 cleaning, inspection, and resetting of the plug gap. Maintenance If the plug is oily or has carbon built up on it, have it cleaned, preferably in a sand-blasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other suit- able tool. Measure the gap with a wire-type thickness gauge, and adjust the gap if incorrect by bending the outer electrode. lf the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard plug. Spark Plug Remaval @ Remove the seat. ®Remove each front mounting screw from the left and right side covers and pull on their front ends, @Remove the fuel tank mounting bolts from both the front and rear ends of the fuel tank. iN: B. Mounting Bolts A, Fuel Tank @Pull the fuel hoses off the fuel tap and fuel tank. @While raising the fuel tank front end, disconnect the fuel level sensor lead 73under the tank, and then remove the NOTE tank. ®Carefully pull the spark plug caps from the spark plugs. @Unscrew the spark plugs with a plug wrench. O Spark plug installation is performed in the reverse order of removal. * (0.028 ~ 0,032 in.) A. Spark Plug Cap 74Spark Plug Standard Plug Tightening Torque NGK C9E or ND U27ES-N ©NGK CRSE or ND U27ESR-N 0.7 ~ 0.8mm (0.028 ~ 0.032 in.) 14.N-m (1.4 kg-m, 10.0 ft-lb) © : Canadian model Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. If valve clearance is left unadjusted, the wear will eventually cause the valves to remain partly open; which lowers performance, burns the valves. and valve seats, and may cause seri- ous engine damage. Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Maintenance Chart. Inspection and adjustment should be done only by a competent mechanic fol- lowing the instructions in the Service Manual. 75Evaporative Emission Control System (California model only) This system routes fuel vapors from the fuel system into the running engine or Stores the vapors in a canister when the engine is stopped. Although no ad- justments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart inspection @Check that the hoses are securely connected. @Replace any kinked, deteriorated, or damaged hoses. 76 CONNECT TO #2 £93 VACUUM HOSE ROUTING DIAGRAM WHITE (CONNECT To 39462-1182Kawasaki Clean Air System The Kawasaki Clean Air System (KCA) is a secondary air suction system that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust sys- tem, it is still hot enough to burn. The KCA System allows extra air into the ex- haust system so that the spent fuel charge can continue to burn. This con- tinued burning action tends to burn up a great deal of the normally unburned gases, as well as changing a significant portion of the poisonous carbon monoxide into harmless carbon dioxide. Air Suction Valves: The air suction valve is essentially a check valve which allows fresh air to flow only from the air cleaner into the exhaust port. Any air that has passed the air suction valve is prevented from returning. Inspect the air suction valves in accordance with the Periodic Mainte- nance Chart. Also, inspect the air suction valves whenever stable idling cannot be obtained, engine power is greatly reduced, or there are abnormal engine noises. Air suction valve removal and in- spection should be done only by a com- petent mechanic following the instructions in the Service Manual. 7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 rain or on muddy roads, the element should be cleaned immediately. The el- ement should be replaced if it is dam- aged. Elemem Removal @Remove the fuel tank (see Spark Plug Removal). @Remove the air cleaner upper housing mounting screws and remove the housing. 78 ~ A. Upper Housing B. Screws @Take out the element.A. Element @Put a clean, lint-free towel over the carburetor intakes to keep dirt or other foreign material from entering. @Inspect the element material for dam- age. If any part of the element is damaged, the element must be re- placed. AWARNING If dirt or dust is allowed to pass through into the carburetors, the throt- tle may become stuck, possibly caus- ing accident. if dirt gets through into the engine, ex- cessive engine wear and possibly en- gine damage will occur. NOTE O£fement installation is performed in the reverse order of removal. Element Cleaning @Clean the element in a bath of a high flash-point solvent. @Dry the element with compressed air or squeeze it. @After cleaning, saturate the element with SE class SAE 30 motor oil, 79squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element. PM Nat SiS) Clean the element in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appli- ance with a pilot light. Do not use gas- oline or a low flash-point solvent to clean the element. A fire or explosion could result. 80 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 throttle response, especially at low en- gine speed. Also, the throttle valves may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Check the throttle grip play periodically in ac- cordance with the Periodic Maintenance Chart, and adjust the play if necessary. Inspection @Check that there is 2 ~ 3 mm (0.08 ~ 0.12 in.) throttle grip play when lightly turning the throttle grip back and forth. @lf there is improper play, adjust it.A. Throttle Grip B. 2 ~ 3 mm (0.08 ~ 0.12 in.) Adjustment @Loosen the locknut at the throttle grip, and turn the adjuster until the proper amount of throttle grip play is ob- tained, / = 0 or A. Locknut C. Throttle Cable B. Adjuster (Accelerator Cable) @Tighten the locknut @lf the throttle cables can not be ad- justed by using the cable adjuster at the upper end of the throttle cable, use the cable adjusters at the lower ends of the throttle cables. @Remove the fuel tank (see Spark Plug Removal). @Loosen the locknuts, and screw both throttle cable adjusters in fully at the lower ends of the throttle cables so as to give the throttle grip plenty of play. 81@Turn out the decelerator cable adjuster until there is no clearance between the cable and adjuster when the throttle grip is completely closed. @®Turn the accelerator cable adjuster un- til 2 ~ 3 mm (0.08 ~ 0.12 in.) of throttle grip play is obtained. Tighten the locknut. ~ ra A. Adjusters C. Decelerator Cabl B. Locknuts D. Accelerator Cable 82 PAT AS SIN Tes Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condi- tion.Choke Lever By pulling the choke lever, the carburetor provides a rich starting mix- ture that is necessary to enable easy starting when the engine is cald. If starting difficulty or rich fuel mix- ture trouble occurs, 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 irreg- ularity, have the choke cable checked by a competent mechanic following the instructions in the Service Manual. @Push the choke lever back all the way to its released position. ®Determine the amount of choke cable play at the lever. Pull the choke lever until the starter plunger lever at the carburetor touches the starter plunger; the amount of choke lever travel is the amount of cable play. A. Starter Plunger Lever B. Starter Plunger @The proper amount of play is 2 ~ 3 mm (0.08 ~ 0.12 in.) at the bottom of the choke lever. If there is too much or too little play, adjust the choke cable. 83A. Choke Lever B. 2 ~ 3 mm (0.08 ~ 0.12 in.) Adjustment @Remove the fuel tank (see Spark Plug Removal). @Loosen the locknut at the middle of the choke cable, and turn the adjust- ing nut until the cable has the proper amount of play. 84 A. Adjusting Nu B. Locknut ®@Tighten the locknut after adjustment. @ Install the fuel tank.Carburetors The carburetor adjustments, idle speed and synchronization, should be performed in accordance with the Peri- odic 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 a competent mechanic using vacuum gauges, following the instructions in the Service Manual. NOTE OPoor carburetor synchronization will cause unstable idling, sluggish throttle response, and reduced engine power and performance. Adjustment @Start the engine, and warm it up thor- oughly. @Adjust the idle speed to 1,000 ~ 1,100 (California model: 1,250 ~ 1,350) r/min (rpm) by turning the idle adjusting screw. A. Idle Adjusting Screw @Open and close the throttle a few times to make sure that the idle speed does not change. Readjust if neces- sary. @With the engine idling, turn the handlebar to each side. If handlebar movement changes the idle speed, the throttle cables may be improperly ad- justed or incorrectly routed, or they 85may be damaged. Be sure to correct any of these conditions before riding. AWARNING Operation with damaged cables could result in an unsafe riding condition. 86 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. PWNS STNG} To avoid 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 ~ 0.12 in.) of play as shown in the figure.A. Adjuster B. Locknut Cc. 2 ~ 3mm (0.08 ~ 0.12 in.) If it does not, adjust the lever play as follows. Adjustment @Loosen the locknut at the clutch lever. @Turn the adjuster so that the clutch le- ver will have 2 ~ 3 mm (0.08 ~ 0.12 in.) of play. PVE) Be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creat- ing enough cable play to prevent clutch disengagument, resulting in a hazardous riding condition. ®@Tighten the locknut. @ lf it cannot be done, use the mounting nuts at the lower end of the cable. A. Mounting Nuts 8. Clutch Cable 37NOTE OAfter the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly. 88 Drive Chain The drive chain must be checked, ad- justed, and lubricated in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the chain becomes badly worn or maladjusted — either too loose or too tight - the chain could jump off the sprockets or break. PONTE) 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 it to go out of control. Chain Slack Inspection @Set the motorcycle up on its center stand @Rotate the rear wheel to find the posi- tion where the chain is tightest, and measure the vertical movement mid- way between the sprockets.