Includes: -Important Safety Information -Operating Instructions -Maintenance and Storage HE Kawasaki BAYOU* 220 All Terrain Vehicle Read this manual carefully. It contains safety information. A child under 16 years old should never be allowed to operate this vehicle OUTER WSN : 4 Ib STAWARNING Engine exhaust, some of its constituents, and certain vehicle compo- nents contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm,General . . ULE Na Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. tallest (3 Safe Operation Maintenance ER As Ui Troubleshooting Guide A Table of Contents is included after the Foreword.Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and ‘maintenance practices, AWARNING HAZARD Failure to heed WARNINGS, WHAT CAN HAPPEN WARNINGS identify special instructions or proce- dures which, if not correctly followed, could result in personal injury, or loss of life, HOW TO AVOID THE HAZARD Read all WARNINGS in this manual carefully and for your safety be sure to follow their instructions. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. NOTE ©This note symbol indicates points of particular interest for more efficient and convenient operation, IMPORTANT Off-road vehicle riding is @ wonderful sport, and we hope you will enjoy it to the fullest Read this manual carefully and completely before starting your new Kawasaki. It contains important safety information Never operate an ATV without proper instruction, ‘Take a training course, Beginners should receive training from a certified instructor. Contact an authorized ATV dealer ot call 1-800-887-2887 to find out about the ‘raining courses nearest you, ‘Never allow 2 child under the age of 16 years to oper ate this ATV. Use of this ATV by children under 16 years of age can lead to severe injury or death of the child, Even youths starting at age 16 may not have the skills, abilities, or judgement needed to operate this ATV safely. ‘Therefore youths starting at age 16 should have adult supervision even after they attend a rider training course. ‘And parents should never allow continued use of this ATV if the youth does not have the abilities and matu. rity to operate it safely Failure to follow the warnings contsined in this ‘manual can result in SERIOUS INJURY or DEATH. To protect the future of your sport, make sure you Use your vehicle legally, show concern for the environ- ment, and respect the rights of other people. If improperly conducted, the sport has the potential ‘to cause environmental problems as well as conflicts with other people. Responsible use of your off-road vehicle will ensure that these problems and conflicts do rot ocour.wmue SAFE RIDING INFORMATION AN_ATW IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehi {es including motoreyeles and ears. A collision or rollover ean occur quickly, even during routine maneuvers such as turning and driving om hills or aver obstacles, if you fail to take proper precautions, SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described, ‘The Owner's Manual should be kept in the waterproof plastic bay and stored in the compartment provided. [Never operate an ATV without proper instruction, Take @ training course, Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you, Never allow a child under age 16 to operate this ATV, ‘Never carry a passenger on an ATV. [Never operate an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets ‘Never operate an ATV on any public strect, road or highway, even a dirt or gravel one. Never operate en ATV without wearing an approved motorcycle helmet that fits properly, You should also wear oye protection (goggles or face shield), gloves, boots, longsleeved shirt or jacket, and long pants Never consume alcohol or drugs before or while operating this ATV, Alcohol and drugs impair your judgement and reaction time, Before starting: put transmission in neutral and check the throttle control for peaper operation, ‘Remember to apply the parking brake before getting off your ATV, Never operate at excessive speeds. Always go at a speed that is proper for the terrain, visibility and operating condi tions, and your experience, Never attempt wheelies, jumps, or other stunts Always inspect your ATV each time you use it to make sure it ‘sin safe operating condition, Always follow the Inspection and maintenance procedures and schedules described in this manual, Always keep both hands on the hanidlebars and both feet on the footpegs of the ATV during operation, Always go slowly und be extra careful whon operating on unfamiliar terrain, Always be alert to changing terrain concitions wien operating the ATV. Never operate on excessively rough, slippery oF loase terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.Always follow proper procedures for turning a described in this manual. Practice turning at low specs before attempting to turn at faster speeds. Do not turn at excessive speed, "Never operate the ATV on hills to0 steep for the ATV ot for your abilities, Practice on smaller hills before attempting larger hills © Always follow proper procedures for climbing hills as described in this manual, Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward, Never open ‘the throtle suddenly or make sudden gear changes. Never go over the top of any hill at high speed, Always follow proper procedures for going down hills and for braking on hills as described in vhis manual. Cheek the terrain carefully betore you start down any hill, Shift your weight backward, Never go down a hill at high speed. ‘Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side, Go straight down the hill where possible ‘Always follow proper procedures for crossing the side of a hill as deseribed in this manual, Avoid hills with exces: sively sliopery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground, Avoid crossing the side of a steep hill if possible ‘Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climbing a hill, If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill, Turn the ATV around and remount, following the procedure described in this manual ‘Always check for obstacles before operating in a new area, Never attempt to operate over large obstacies, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual ‘Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and fon level, smooth terrain. On extremely slippery surfaces, such as jee, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of contiol.. [Never operate an ATV in fast Flowing water er in water deeper than that specified in this manual. Remember that wet brakes may have reduced stopping ability, Test your brakes after leaving water, If necessary, apply them several times to et friction dry out the linings. ‘Always be sure there are no obstacies or people behind you when you operate (n reverse, When itis safe to proceed in reverse, go stowly. ‘Always use the size and type tires specified in this manual. Always maintain proper tire prossure as described in this manual, Type of tire and inflation can affect vehicie handling, ‘A tire pressure gauge 's provided in the tao! kit container. Keep it with the vehicle at all timesNever modify an ATV through improper installation wr ue uf wexenories, Installation of accessory items may affect Vehicle handling, Refer'to the Loading lifarmation chapter in this manual. ‘Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached, edu speed ancl follow instructions in this manual for carrying cargo or pulling trailer. Allow greater distanco for braking ‘Preserve the environment, ride responsibly and always know and obey laws and regulations governing ATV operation, Refueling: Shut engine aff and make sure the area is well ventilated and free from any source of flame or sparks. ©Use an antenna flag in hilly terrain and sand dune areas, FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638- 2772, or the ATV Distributors* Safety Hotline at 1-800-852-5344,EMISSION CONTROL INFORMATION To protect the environment in which we al ive, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) contro! systems (EM) in compliance with applicable regulations of the California Air Resources Board 1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase. Then; itis led to the ar cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned tack to the bottom of crankcase. 2, Exhaust Emission Control System The exnaust emission control system applied to this engine family is engine modifications that consist of s modified carburetor and an ignition system having optimum ignition timing characteristics. The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with 2 suitable air cleaner and exhaust system ‘A maintenance free ignition system provides the most favorable ignition timing and helps maintain @ thorough com- bustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere. High Altitude Performance Adjustment information To improve the EMISSION CONTROL PERFORMANCE of vehicles operated above 4,000 feet, Kawasaki recommends the following California Air Resources Board approved modification NOTE ‘When properly performed, these specified modifications only are not considered to be emissions system "tampering" and vehicle performance is generally unchanged as a result Installation Instructions: High attitude adjustment requires replacement of certain carburetor components. Installation of these optional parts may bbe performed by an authorized Kawasaki dealer, or the consumer, following repair recommendations specified in the appro- priate Kawasaki Service ManualMaintenance and Warranty Proper maintenance is necessary to ensure thet your vehicle will continue to have low emission levels. This Owner's Manual contains those maintenance recommendations for your vehicle. Those items identified by the Periodic Maintenance ‘Chart are necessary to ensure compliance with the applicable standards. ‘As the owner of this vehicle, you have the responsibilty to make sure thet the recommended maintenance is carried out ‘according to the instructions in this Owner's Manual at your own expense, ‘You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided space ‘on pages 125 through 129 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, bls, etc, ¢s verification of this maintenance. ‘Tampering with Emission Control System Prohibited California State law prohibits the following acts or the causing thereof: (1) the ramovai or rendering inoperative by any Person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into {any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while iti in use, (r (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: Do not tamper with the original emission related parts: ‘© Carburetor and internal parts ©F vel filter element Spark plugs @Air cleaner element ‘© Magneto or electronic battery ignition system PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM ‘To minimize the noise emissions from this product. Kawaseki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any way which results in an inerease in noise levelFOREWORD Congratulations on your choice of a new Kawasaki KLF. It is the result of Kawasaki engineering expertise and a tradition of manufacturing high-quality recreational products. Please read this manual carefully before starting your new vehicle. Be sure you understand its controls, ca- pabilites, limitations, and proper operating procedures. Observe the maintenance requirements listed in this book as well More detailed service information is contained in the service manual for this model, which is available from Kawasaki dealers. KAWASAKI HEAVY INDUSTRIES, LTD. Consumer Products & Machinery Company All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form ‘or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Kawasaki Heavy Industries, Ltc., Consumer Products & Machinery Company. No liabilly can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without prior notice or obligation. Ilustrations in this publication are intended for reference use only and may not depict actual mode! component parts. © Kawasaki Heavy Industries, Lid. 2001 ‘Aug. 2001. (4). (8)Number Locations. Jn of Labels. Location of Parts. Loading Information. General Information ‘Auiliary Lighting Connectors, Electrical Accessory Connectors. Choke Lever Compression Releasing Lever... Brake Lever Lock (Parking Brake). Brake Levors and Pedal Front and Rear Racks. Fuel fank Fuel Tap, Fuel Gauge. Ignition Switch... Indicator Lights Loft Handlebar Switches, Light/Dimmer Switch AWARNING WARNINGS indicate a potential hazard that could result in personal injury or death, ev TABLE OF CONTENTS ‘rverninnnnnnnennnnin Engine Stop Switch Starter Button Recoil Starter... Reverse Knob. Shift Pedal Soxt.. Too! Kit : Trailer Hitch Bracket Throttle Lever. Throttle Limiter Break-In How to Ride... Daily Safety Checks... Starting the Engine Moving off. Shitting Gears, Braking . ‘Stopping the Engine Parking the KLF. Stopping the KLF in an Emergency‘Safe Operation Road the Owners Manus Obey Local Laws wer ‘Adult Supervision Boginning Ric Off- Road Use Only. Dress Properly Operator Only.. Ride Cacfully and with Good done: Never Drink and Drive. Keep Your Feet on the Pegs and Hands on the Handlebars 58 Betore Starting the Engine, 58 Use the Parking Brake. 59 Modifications and Accessories 59 Loading Your ATV a ‘ Perform the Daily Safety Checks.. cl Tire Air Pressure... Riding Terrain. Riding in Revers... Turing the Vehicle... Climbing Hills, Antenna Flag Traversing Hilsides . Descending Hills Sliding and Skidding Riding in Water Maintenance and Adjustment. Periodic Maintenance Chart Engine Oil, Final Gear Case Oil. Spark Plug... Valve Clearance. Air Clean ou Spark Avrester.. Throttle Cable.. Reverse Cab Carburetor. Cute Brakes Brake Light Switches, Wheels, Fuel System. Fuol Tank Vert... Headlight Beam General Lubrication. Cleaning nnn Bolt and Nut Tightening. StOFAGE os Transporting the KI Troubleshooting Guide. ‘Owner Satisfaction Environmental Protection. Maintenance RecordPERFORMANCE ‘Maximum Torque Minimum Turning Radius DIMENSIONS ‘Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Cearance Dry Weight ENGINE Type Displacement Bore x Stroke Compression Ratio ‘Starting System Carburetor Ignition System lanition Timing Spark Plug Terminal Lubrication System Engine Oil Type: Engine Oil Capacity 10 SPECIFICATIONS sivniiinneennmninininininnnnenninn 17.7 Nem (1.8 kg-m, 13.0 ft-lb) @6,000 r/min (rpm) 27m (891) 1,745 mm (68:70 in.) 1/020 mm (40.16 in) 1,040 mm (40.94 in.) 41,116 mm (43.90 in.) 764 mm (30.1 in.) 776 mm (308 in.) 185 mm (6.10 in.) 183 kg (404 Ib) ‘SOHC single cylinder, 4-stroke, air-cooled 215 mL (13.1 cuin) 67.0 x 61.0 mm (2.64 x 2.40 in) 93:1 Electric and recall starter Mikuni VM24SS cpl 10" BTDC @!,800 ¢/min (rom) ~ 36° BTDC @4,600 r/min (rpm) NGK DRAES: Solid post Forced! lubrication (wet sump) API SF or SG ‘API SH or SJ with JASO MA SAE 5W-30, 10W-40, 10W-50, 20W-40 or 20W-50 201 21 US qd)TRANSMISSION ‘Transmission Type Clutch Type: Primary Secondary Driving System Primary Reduction Ratio Final Reduction Ratio. Overall Drive Ratio Gear Ratio: 1st 2nd 23rd 4th 5th Reverse Final Gear Case Oil Final Gear Case Oil Capacity FRAME Type Caster Trail Tire Size: Front Rear Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail / Brake Light Specifications subject to change without notice, Srspeed plus reverse, constant mesh, return shift ‘Automatic centrifugal, wet ‘Automatic, multi dise, wet Shatt drive 3.450 (69/20) 4.680 (18/15 x 39/10) 12.686 (Top gear) 2.923 (38/13) 1.684 (32/19) 1.173 (27/23) 0.923 (24/26) 0.785 (22/28) 3.115 (27/13 x 33/22) APIGL-S SAE 90 [above 5°C (41°F)] SAE 80 [below 5°C (41°F)) 0.2L (0.21 US at) Tubular, double cradle e 17 mm (0.67 in.) AT21 x 8-9 Tubeless ‘AT22 x 10-10 Tubeless 10.0 L (2.6 US gal) 12vi1Ah 12V25/25 Wx2 12V 8/27 Wx2 n‘The engine and frame serial numbers are used to register the vehicle, 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 festures of your machine that can help them identify it. [Fam 7] eww A. Engine NumberAll warning labels which are on your ATV are re Read them and understand them thor- ‘oughly. They contain information which is important for your safety and the sefety of anyone else who may operate your ATV. Therefore, it is very important that all warning labels be on your ATV in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct position, NOTE ©The sample werning labels in this section have part numbers to help you and your dealer obtain the correct replacement, wm LOCATION OF LABELS sre 1. Front Rack (Cartier) Maximum Load 2. Shift Pattern 3. General Waring 4, Age Recommendation Warning 5. Storege/Transportation Warning 6. Roar Rack (Carrier) Maximum Load 7 8 3 10. Rattery Vant Hose Ranting . Overloading Waring Passenger Warning (The label Is printed on the seat.) Tire Prossure Waring #11. Vehicle Emission Control Information 12. Important Air Cleaner Information ‘only on California model 13O@e® ‘aa propria achniqes to ari eile ‘rere ens a oh ean an tn “rp paved nts paramest may erouty READTHE OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AN WARNINGS. e670 1781, MAXIMUM LOAD: 20k9(441bs) 1“ AAWARNING the aon of W6 inccots yous chon NEVER spate me ANY 4 you ow eee 16 Beau ae @ AWARNING NEVER re at pssenser “ 56070-1741 @ [ Maximum Loao: soKe(66ib) "p0ao.1265TIN 59409-1825, ‘36000-3262 ® IMPORTANT AIR CLEANER INFORMATION Peet ensue eg i Save eee pa ane ore (SEtvce he donate 15 do fant more oh mua ay weoaora7e 56033-1078 36031-1893 1516 |. Rear Brake Lever (Parking Brake) . Brake Lever Lock Choke Lever Indicator Lights Front Brake Lever Light/Dimmer Switch . Starter Button 3. Engine Stop Switch . Throttle Limiter . Throttle Lever|. Headlights Front Rack Fuel Tank Cap Fuel Tank Fuel Tap . Carburetor . Air Cleaner Battery Fuse . Rear Rack Shift Pedal Recoil Starter Final Gear Case ”Grab Rail & Rear Rack Seat Latch Storage Compartment Teo! Kit Tail/ Brake Lights Compression Releasing Lever lanition Switch . Muffler (Spark Arvester) |. Traler Hitch Bracket i Filler Cap . Clutch Release Adjusting Screw Oj) Level Gauge Rear Brake Pedal 1 FilterAWARNING AWARNING HAZARD, Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which could lead to an accident, -HOW TO AVOID THE HAZARD _ Never modify this ATV through improper installation fr use of accessories. All parts and accessories added to this vehicle should be genuine Kawasaki or equiva- lent components designed for use on this ATV and should be installed and used according to instruc- tions. If you have questions, consult an authorized ATV dealer. rmmmmannann LOADING INFORMATION WARNINGS indicate a potential hazard that could result in personal injury or death. AWARNING HAZARD. Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN. Could cause changes in vehicle handling which could lead to an accident. _HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securoly attached, Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions provided in this section for carrying cargo or pulling a trailer, 19With the exception of genuine Kawasaki Part ett Accessories, Kawasaki has no control ever the design or plication of accessories, In some cases, improper stallation or use of accessories, or vehicle modifica- tions, will void the vehicle warranty, In selecting end using accessories, and in loading the vehicle, you are personally responsible for your own safety’ and the safety of other persons involved. NOTE Kawasaki Parts and Accessories have been specially designed for use on Kawasaki vehicles. We strongly recommend that all parts and accessories you add to your vehicle be genuine Kawasaki components, Because, an all terrain vehicle is sensitive to increases in weight, changes in weight distribution, and aerody- namic forces, you must take extreme care in carrying cargo and/or in the fitting of accessories, The following ‘generel guidelines have been prepared to help you make your determinations. ‘@When adding cargo and pulling @ taller reduce speed. Braking distance is increased. Use extreme caution wher climbing and descending hills, and traversing slopes. Adding cargo and pulling a trailer can make the vehide difficult to steer and affect vehicle handling in ‘an unpredictable manner. ‘All cargo should be carried as low as possibie to reduce the effect on the whicle’s center of gravity. Cargo ‘weight should also be equally distributed from side to side, Place cargo to the rear of a front rack and to the front of @ rear rack. This helps maintain the stability of the vehicle by centralizing the weight, Avoid car- rying cargo that extends beyond the rear of the vehicle, Do not place more than 20 kg (44 Ib) on the front rack, nor more than 30 ky (66 Ib) on the rear rack. If non-standard racks are fitted, never exceed the rack manufacturer's stated load capacity. In any case, never exceed the limits stated above, Try to maintain front to rear balance by carrying twice as much weight (on the rear rack as on the front rack, ‘Cargo should be securely attached. Make sure the cargo will not move around while you are riding. Recheck cargo security as often as possible (not while the vehi- cle is in motion) and adjust as necessary. ©Do not carry heavy or bulky items even on a cargo rack, They are designed for light items, and over- loading can affect handling due to changes in weight distribution and aerodynamic forces. Do not install accessories or carry cargo that impairs the performance of the vehicle, Make sure that you have not adversely affected any lighting component, ground clesrance, brake or control operation, wheel movement, or any other aspect of the vehicle's opera- tion. Always subtract trailer tongue weight from the Max- imum Load capacity. Refer to the GENERAL IN- FORMATION chapter for details on tho trailer hitch bracket,‘eWeight attached to the handlsbar will inereace the mass Of the steering assembly and can result in an unsafe riding condition ‘Windshields, trunk boxes, and other large items have the capability of adversely affecting stability and handling of the vehicle, because of their weight and the ‘aerodynamic forces acting on these surfaces while the vehicle is in operation, Poorly designed or installed items can result in an unsafe riding condition. Maximurn Load Weight of ri (285 I), id cargo must not exceed 130 kg 2‘Auxiliary Lighting Connectors The auxliaty lighting connectors are located inside the front cover sbove the front fender. The light switch ‘operates any light connected to these connectors. Te connect an auxiliary headlight or other optional light, follow these steps: ‘Remove the front cover by removing the mounting serews. A, Front Cover B, Scrows, ‘Unfasten the straps of the vinyl cover and open the velero, 22 ‘A. Auxiliary Lighting ConnectorsConnect your auxiliary light to these connactars pop Sots ke 7 CAUTION Do not connect a light rated higher than 36W or the battery may become discharged, ‘Always install a fuse rated 10A or less in the aux ‘The KLF has only one fuse (20A) to protect the entire electrical systom. If this fuse fails, the ignition will not function, Electrical Accessory Connectors ‘The electrical accessory connectors are located under the seat. ‘To connect an accessory, follow these stops: ‘Remove the seat, A. Electric Accessory Connectors 23‘*Conrcet your accessory to these connectors. CAUTION Do not connect more than @ 35 W load to the electrical accessory connectors or the battery may become discharged. ‘Always install a fuse rated 10A or less in the electric accessory circuit. The KLF has only one fuse (20A) to protect the entire electrical system. If this fuse fails, the ignition will not function. Choke Lever ‘The choke lever on the left handlebar provides @ rich ‘mixture for cold starting conditions. Pall the choke lever all the way to the left to start the engine. Warm the engine up by operating the choke lever and throttle until the idle speed is stable, then push the choke lever all the way back to the right, NOTE lf the choke is left on (lever to the left) 00 fong after the engine has warmed up, it will cause spark plug fouling and poor fuel economy.Comprasion Releasing Lever ‘The compression releasing lever is located on the upper right side of the engine, Pull up the lever first for easy cranking each time the recoil starter is pulled up to start the ent Brake Lever Lock (Parking Brake) If the brake lever lock is used, the rear brake lever can be used as a parking brake, To lock the brake lever, first pull in the brake lever. ‘Then pull in the lock lever and while holding it against the brake lever, release the brake lever. When applied correctly the lock lever will contact @ projection on ‘the brake lever holder and prevent the brake lever from returning to the off position. To unlock the brake lever, pull in the brake lever further and release it. A. Lock Lever B, ProjectionBrake Levers and Pedal ‘Tho lover on the left side of the handlebar operates ‘the rear brake, and it can be used for a parking brake by using the brake lever lock at the brake lever (see Brake Lever Lock). A. Brake Lover ‘The foot pedal on the right side also operates the rear A. Breke Lever (Parking Brab B. Brake Lever Lock ‘The lover on the right side of the handlebar operates the front brake. ‘A. Brake Pedal 26Refer to the How To Ride and Safe Operation chapters for more instructions on braking, AWARNING HAZARD ‘Stalling, rolling backwards or improperly dismounting ‘while climbing a hil, WHAT CAN HAPPEN ‘Could rewit in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lor all forward speed: Keep weight uphill, after you are stopped. If you begin rolling backwards: ‘Keep meight uphill. Never apply the rear brake while rolling back- wards, Apply the front brake, When fully stopped, apply rear brake as well, and ‘then lock parking brake. Dismount on uphill side or to a side if pointed straight uphill, Turn the ATV around and remount, following the procedure described in the Safe Operation chapter. 27Front and Rear Racks ‘This vehicle is equipped with racks on the front and HAZARD Overloading front and rear racks or carrying cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD. [Never exceed the stated load capacity for each rack, Cargo should be properly distributed and securely attached. Reduce eed when caring care, Aow areater distence for bra ‘Always, fllow the instructions in your Owner's ‘Manual for carrying cargo. Maximum Load (Rack) Front 20 kg (44 Tb) Rewr 30 kg (66 1b) Vohicle Maximum Load Weight of rider and cargo must not exceed 130 kg (285 Ib) A. Front Rack B, Rear RackPNAS NINE} WARNINGS indicate a potent Fuel Tank The following octane rating gasoline is recommended in the fue’ tank, Avoid filling the tank in the rain or where heaty dust is blowing so that the fuel does not get contaminated. A. Fuel Tank hazard that could result in personal injury or death. AWARNING HAZARD. Refueling without following proper precautions. WHAT CAN HAPPEN Gosoline is extremely flammable and can be explosive under certain conditions. AA fire or explosion can cause sev injury or doath, HOW TO AVOID THE HAZARD When refueling, do not smoke, Turn the ignition switch OFF, Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank completely to the top! Heat may cause the fuel to expand and overflow throush the vent 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Fuel Requirements: Fue! Type Use clean, fresh unleaded gasoline with @ minimum Antiknock Index of 87. The Antiknock Index is posted ‘on service station pumps in the U.S.A. The octane rating of a gasoline is a measure of its resistance to detonation fr “knocking.” The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON) as shown in the table below. Minimum Octane Rating Method fang (RON + MON) Antiknock index (RON * MON). 3% 2 | Research Octane Number (RON) 3 CAUTION if engine “knocking” or “pinging” occurs. use a dif- ferent brand of f a higher octane rating. If this condition is allowed to continue it can lead to ‘severe engine damage. Gaseline quality is Important. Fuels of low quality oF not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under your warranty 30 ‘Fuels Containing Oxygenates Gasoline frequently contains oxygenates (alcohols and. ethers) especialy in areas of the U.S. and Canada which are required to sell such reformulated fuels as part of a stratogy to reduce exhaust emissions. The types and volume of fuel oxygenates approved for use in unleaded gasoline by the U.S. Environmental Pro- tection Agency include a broad range of alechols and ethers, but only two components have seen any signif- icant level of commercial use. Gasoline/Alcohol Blends ~ Gasoline containing up to 10% ethanol (alcohol produced from agricultural products such 95 corn), also known as "gesohol” is approved for use. CAUTION Gasoline/Ether Blends ~ The most common ether is methy! tertiary butyl ether (MBE). You may use gasoline containing up to 15% MTBE. NOTE (©Other oxygenates approved for use in unleaded gaso- line include TAME (up to 16.7%) and ETBE (up to 17.2%). Fuel containing these oxygenates can also be ‘used in your Kawasaki,CAUTION "Never use gasoline with an octane rating lower than the minimum spocified by Kawasaki. "Never uso “gasohol” with more than 10% ethanol, oF ‘more then 5% methanol. Gasoline containing matha- ‘nol must also be blended with cosolvents and corro- sion inhibitors, fading ‘gasoline or ‘When not operating your Kawasaki for 30 to 60 days. ‘mix a fuel stabilizer (such as STA-BIL) with the gaso- line in the fue! tank. Fuel stabilizer additives inhibit ‘oxydation of the fuel which minimizes gummy depos: ite, Never store this product with “gasoho!” in the fuel system. Before storage it is recommended that you drain ail fuel from the fuel tank and carburetors. See the Storege section in this man Fuel Tap The fuel tap has three positions: OFF, ON, and RES (reserve). If the fuel runs out with the tap in the ON po- sition, the last 2.0 L (0.83 US gal) of fuel can be used by turning the tap to RES. When transporting or storing the vehicle, turn the tap OFF. A. Fuel Tep B. RES position OFF position . ON position NOTE ©Since riding distance is limited when an RES, refuel at the earliest opportunity. (Make certain that the fuel tap is turned to ON (Not RES), after fling the fuel tenk. 332 AWARNING HAZARD ‘Locking at fuel tap while riding. WHAT CAN HAPPEN. ‘Can cause loss of control and result in injury or death, HOW TO AVOID THE HAZARD Practice operating the fuel tap with the vehicle stopped. To provent an accident you should be able ‘to operate the fuel tap while riding without taking ‘your eyes off the t PIN ZANSI SII (e) HAZARD Hotengine. WHAT CAN HAPPEN. Can burn your hand, HOW TO AVOID THE HAZARD Be careful not to touch the hot engine while oper- ating the fuel tap. Fuel Gauge “The fuel gauge shows the amount of fuel in the fuel tank. When the needle comes near the Elempty) posi- tion, refuel at the earliest opportunity. A, Fuel GaugeIgnition Switch ‘The ignition switch is mounted in the right side of the fuel tank cover. It is a 2position, key-operated switch. ‘The key can be removed only when in an “OFF” posi- tion, The lights, ignition, and electric starter will oper- ate only when the key isin the “ON position, Remove the key to prevent unauthorized vehicle use, om A. lanition Switeh ©. OFF position 8. ON position Blank keye aro available at your Kawasaki dealer, ‘Ask your dealer to make any additional spare keys you may need,using your original key as a master,or using the key code on the tag with your keys, Record the code from the tag with your keys here Participating Kawasaki dealers can use the code to make a ‘new key in the evant that your original Kays are lost, es Write your key number here.Indicator Lights ‘The indicator lights are in the plastic cover at the ‘center of the handlebar. NEUTRAL: When the transmission Is in neutral, the ‘neutral indicator light is lit, reverse indicator light is it. A, Neutral Indicator Light B, Reverse Indicator Light Left Handlebar Switches LLight/Dimmer Switch ‘The switch positions are identified on the housing, Headlight, talight, and an auxiliary headlight or other optional light come on by turning the switch to LO (low bbeam) or HI (high beam) with the ignition key in the ON position. Select high or low beam as necessary. ‘A, Light/Dimmer Switch B. Engine Stop Switch ©. Starter Button 34nition switch, the engine stop switch must be in the “RUN"" position for the engine to operate, If some emergency requires stopping the engine, turn the engine stop switch to the “OFF” Position. Although the engine stop switch stops the engine, it does not turn off all the electrical circuits, If the engine stop switch is used, be sure to turn off the ignition switch after stopping the vehicle, Starter Button Refer to the Starting the Engine section of the “How to Ride" chapter for starting instructions To start the engine, push the starter button with the transmission in neutral. NOTE ©For the electric starter to operate, the engine stop switch must be set to the “RUN” position, the ignition ‘switch must be turned to the “ON” positian, and the transmission must be in neutral. Recoil Starter Refer to the Starting the Engine section of the “How to Ride" chapter for starting instructions. ‘The recoil starter is located on the left side of the engine, Always be sure the transmission is shifted into. neutral before starting the engine. Pull up the campres- sion releasing lever, then pull the handle all the way up vigorously to start the engine. A. Recoil Starter NOTE ln order for the engine to run, the engine stop switch ‘must be set to the “RUN” position and the ignition switch must be turned to the “ON” position, 35Reverse Knob This vehicle is equipped with @ reverse gear. The reverse knob Is mounted in the left side of the fuel tank To shift into reverse follow this procedure: tart the engine following the procedure in the “Starting the Engine" section, 2. Make cortain the vehicle is completely stopped, the trensmission is in neutral, and the engine is idling, 3, Turn the reverse knob clackwise and press down the shift pedal into reverse gear. 4, Release the reverse knob and shift pedal '5. The vehicle can now be operated in rover To shift out of reverse follow this procedure: 1. Stop the vehicle completely. 2. Lift the shift pedal up to neutral AWARNING 3F while moving in reverse, WHAT CAN HAPPEN. Can cause the vehicle to stop suddenly and go for- ward. This can lift the front wheels off the ground and cause the operator to lose control. Or the vehicle can tip over backwards causing an accident. HOW TO AVOID THE HAZARD Never operate the shift pedal to change gears while the vohicle is moving in reverse, AWARNING WHAT CAN HAPPEN. You could hit an obstacle or person behind you, resulting in serious injury oF death. HOW TO AVOID THE HAZARD. When you select reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.Shift Pedal The transmission is @ S:speed return shift type wit reverse, Neutral is located between first gear and reverse ‘ear as shown, ‘A. Shift Pedal A “return shift” means that to go back to first gear from a higher gear, you must shift back through the gears one ay one. ‘The same is true when upshifting: each gear must be engaged before the next higher ear may be selected. To engage firet gear from neutral (indicated by the neutral indicator light), lift up on the shift pedal then ase the shift pedal. Do likewise to shift into the next higher gear: To shift to the next lower gear, press down on the shift pedal and release the shift pedal Before shifting into reverse, put the transmission in ‘neutral, Then turn the reverse knob clockwise and press the shift pedal into reverse gear. Release the reverse knob and shift pedal. Refer to the “Reverse Knob” section for detailed instructions. If the engine is stopped, rolling the vehicle slightly while shifting will help shifting back to neutral. When the transmission is in neutral, the neutral indicator light ist, CAUTION When changing gears, press firmly on the shift pedal to ensure complete, positive shifting. Careless, incomplete shifts can cause the transmission to jump ‘out of gear and lead to engine damage. 37Seat Tool Kit To remove the seat, pull the seat latch at the rear left ‘The too! kit js stored in the compartment behind the of the seat, and lift the seat up to the rear. seat. The minor adjusiments and replacement of parts explained in this manual can be performed with the tools in the kit. Also keep this Owner's Manual in the same place so that itis always available for reference, ‘A. Compartment B, ToolTrailer Hitch Bracket This vehicle is equipped with a bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle, To avoid injury and property damage, observe the following precautions: ‘A. Trailer Hitch Bracket AWARNING HAZARD, Improperly attaching and loading a trai Overloading a trailer. WHAT CAN HAPPEN, Can cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Attach @ trailer to the trailer hitch bracket only, For ‘example, attaching a trailer to the grab rail can cause the vehicle to tip over. Never load more than 14 kg (0 Ib) tonaue weight on the towing bracket, Do not tow more than 204 kg (450 Ib) trailer weight (trailer plus cargo). AWARNING HAZARD Riding in a trailer, WHAT CAN HAPPEN, an cause the operator to lose control of the vehicle. ‘The passenger ean be thrown from the ti by shifting cargo in the trailer. HOW TO AVOID THE HAZARD. [Nover carry a passenger in a trail 39Throttle Lever ‘Tre throttle lever is located on the right side of the hanclebar. Pushing the lever forward increases engine spoed. When released, spring pressure returns the lever to the rear. Always check that the throttle lever returns normally before starting the engine. In addition, there ‘must be adequate throttle cable play, Refer to the MAINTENANCE AND ADJUSTMENT chapter for the throttle cable adjustment procedure, A. Throttle Lever Throttle Limiter The vehicle is equipped with a throttle limiter to decrease maximum engine power for an unskilled rider. ‘The limiter functions by restricting the moving distance of the throttle lever. AWARNING HAZARD, ‘Operating this ATV without proper instruction. WHAT CAN HAPPEN, ‘The risk of an accident is greatly increased if the ‘operator does not know how to operate the ATV properly in different situations and on different types of terrain, HOW TO AVOID THE HAZARD. Beginning and inexperienced operators should com- plete the certified training course offered by Kawasaki. They should then regularly practice the skills learned in the course and the operating tech- niques described in the Owner's Manual. 1-800-887-2887,AWARNING HAZARD. Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experi: Loosen the locknut and turn the serew in oF out, Turning in decreases the maximum engine power and ‘turning out increases the maximum engine power. A. Locknut In case the throtile limiter is adjusted, verify the changes in throttle in an open, non-traffie aes Never try to adjust the limiter by racing th neutral or in gear with brake on, or the engine or clutch may be damaged, a‘The first 10 hours of vehicle operation is designated {as the break-in period. Do not exceed ¥ throttle during breakin period. If the vehicle is not used carefully during this period, you may end up with ¢ “broken down’ instead of “broken in" vehicle, Breakin Period Fiist 10 hours Maximum Throttle Position % Throttle 42 rnmmumnmmnumnmn BREAKIN nnn NOTE ©Do not start moving or race the engine immediately after starting it, even if the angine is already warm. 2Do not race the engine while the transmission is in neutea, oft is important to pertorm the initial service after the first 10 hours of operation as described in this manual and the service manual for this vehicle. See the Peri ‘adic Maintenance Chart in the MAINTENANCE AND ADJUSTMENT chapter,AWARNING WARNINGS indicate a potential hazard that could result in personal injury or death. Daily Safety Checks Check the following items each day before yau ride, these checks will help ensure you a safe, reliable ride. 1» HOW TO. RIDE srvernnnannnennmennens ‘The time required is minimal, and habitual performance of If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition. AWARNING HAZARD. Failure to inspect the ATV before operating, Failure to properly maintain the ATV. WHAT CAN HAPPEN, Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to ‘make sure the ATV is in safe operating condition, ‘Always follow the inspection and maintenance procedures anc schedules described in the Owner's Manual. FINNS NIN} HAZARD ‘Exhaust gates are poisonous, WHAT CAN HAPPEN Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death HOW TO AVOID THE HAZARD Do not start or run the engine in a closed area such as ‘garage, Exhaust gases contain carbon monoxide; @ colorless, odorless, poisonous gas. 43Fuel... Engire Oil Tires Air Cleaner Element Nuts, Bolts, Fasteners Steering Brakes Throttle Final Gear Case. . Lights. ..... Engine Stop Switch Protective Clothing . 44 Enough tuel in tank, no leaks. Oil level between level lines, Air Pressure (when cold): Front and Rear 21 kPa (0.21 kg/em?, 3.0 psi) ‘Check for dirt; clean or replace as required. (Check that steering components, axles, and all controls are properly fastened, Action smooth but not loose from lock to lock. Control cables must not bind. Brake pedal free play 25 ~ 35 mm (1.0~ 1.4 in.) Front brake lever free play 1~ 2 mm (0.04 ~ 0.08 in.) Rear brake lever free play 2~ 3 mm (0,08 ~ 0.12 in.) Brake lining wear: Indicator within “USABLE RANGE.” Parking brake: Stops vehicle completely. Throttle lever free play 2~ 3 mm (0.08 ~ 0.12 in.). ‘Throttle lever snaps back to idle position when released, No oil leakage. Headlight and tail / bra ‘Stops engine. ‘The operator must wear a helmet and eye protection plus suitable protective clothing, such as boots, gloves, long trousers, and a long-sleeved shirt or jacket. ht work.AWARNING HAZARD Running the engine without ventilation. WHAT CAN HAPPEN. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. Exhaust gase contain carbon monoxide; a colorless, odorless, poisonous gas. HOW TO AVOID THE HAZARD Do not start or run the engine in a closed ar a gara (¢Turn the fuel tap to the "ON" position. ‘Check that the engine stop switch is in the "RUN position. Turn the ignition switch on, © Apply the parking brake. Make sure the transmission is in neutral, The neutr indicator light should be lit, ‘eWhen the engine is cold (same as outside temperature), pull the choke lever all the way to the left. Keep the throttle completely closed. NOTE ©Do not leave the choke lever pulled to the left longer than necessary or the spark plug may foul. When the engine is already warm or the weather is hot (35°C, 95°F or more), do not use the choke. Leave the throttle closed. ‘Push the starter button or pull up the compression’ Teleasing lever and vigorously pull the recoil starter handle all the way up. Repeat until the engine starts, CAUTION Do not operate the electric starter continuously for more than 5 seconds. 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, Do not let the engine idle longer than five minutes or engine overheating and dam: NOTE lf the engine is flooded, push the choke lever all the Way to the right. Then crank the engine over with the throttle fully open until the engine starts. Close the throttle immediately. 45Moving Off ‘Lift the shift pedal with your toe to engage 1st gear ‘@Relesse the parking brake. ‘®Gratually increase engine speed by pushing forward on the throttle lever NOTE Practice starting and stopping (using the brakes) until You are familiar with the controls. Shifting Gears ‘Release the throttle @Shift to the next higher or lower gear by pulling up ‘once or pushing down once on the shift pedal ase the shift pedal. ‘ePush the throttle lever forward AWARNING re way. HAZARD, Downshifting at high speeds, WHAT CAN HAPPEN. ‘Can cause the rear wheels to slide and the operator to lose balance. The operator may lose control of the vehicle and have an accident, HOW TO AVOID THE HAZARD Slow down before shifting down to a lower gear. Try to match vehicle speed with the corresponding engine speed of the lower gear before completing the shift. CAUTION | When shifting down to « lower gear, do not shift | such a high speed that the engine spoed jumps exces sively. This could cause engine damage. NOTE Do not keap your feat on the shift pedal after shifting gears, because the clutch remains disengaged.Braking ‘8Close the throttle completely. ‘Shift down one gear at a time so you are in tst gear ‘when you come to a complete stop, Under most conditions stop by pulling in the front brake lever and pressing down the rear brake pedal For emergency braking disregard downshifting, and concentrate on applying the brakes as hard as possible. ©To stop while riding in reverse, close the throttle and ‘gradually apply the brakes, Sudden application of the Fear brake can cause the front end of the vehicle to lift off the ground, @Refer to the Climbing Hills section in the SAFE OPERATION chapter for the braking and riding ‘techniques you must use when climbing hill, AWARNING “HAZARD. ‘Stalling, rolling backwards or improperly dismounting while climbing a hil WHAT CAN HAPPEN. Could result in ATV overturning, HOW TO AVOID THE HAZARD. Use proper gear and maintain steady speod when climbing a hill. If you lose all forward speed: Keep weight uphill, ‘Apply the bra Lock parking brake, after you aro stopped. If you begin rolling backwards: Keep weight uphill, Never apply the rear brake while rolli wards, Apply the front brake, When fully stopped, apply rear brake as well, and ‘thon lock parking bral Dismount on uphill side or to a side if pointed straight uphill Tur the ATV around and remount, following the procedure described in the Safe Operation chapter. 47‘Stopping the Engine Parking the KLF ‘Close the throttle completely, ‘Stop the vehicle on a level surface. ‘eshift the transmission into neutral, ‘eTurn the ignition switch off, ‘©Turn the fuel tap to the “OFF” position. AWARNING HAZARD. Parking on a steep incline, WHAT CAN HAPPEN May result in the vehicle overturning or rolling down ‘the hill and causing an accident. HOW TO AVOID THE HAZARD Do not park on steep inclines. If you must park on a hill, place the vehicle diagonally so that it never faces uphill, downhill or sideways, Set the parking brake securely. 48‘@Remove the ignition ewitch key to pravant unauthor use, If parking inside a garage or other structure, be sure it is well ventilated and the vehicle is not close to any source of flame or sparks; this includes any appliance with a pilot light. AWARNING HAZARD Parking near an appliance with a pilot light. Parking in a structure without ventilation. WHAT CAN HAPPEN Gasoline is extremely flammable and can be explosive under certain conditions. ‘A fire or explosion can cause severe injury or death. HOW TO AVOID THE HAZARD Park the vehicle in a well ventilated area away trom any source of flame or sparks. This includes any appliance with a plot light. ‘Stopping the KLF in an Emergency ‘Your Kawasaki vehicle has been designed and manu- factured to provide you optimum safety and conven- iene. However, in order to fully benefit from Kawataki’s safety engineering and craftsmanship, it is essential that you, the owner and operator, properly maintain your vehicle and become thoroughly fa ‘with its operation. Improper maintenance can cree dangerous situation known as throttle failure. Two of ‘the most common causes of throttle failure are: 1. An improperly serviced or clogged alr cleaner may allow dirt and dust to enter the carburetor and stick ‘the throttle open, 2. During removal of the air cleaner, dirt is allowed to enter and jam the carburetor. In an emergency situation such as throttle failure, your vehicle may be stopped by applying the brakes and turning the engine stop switch to the “OFF” Position. If the engine stop switch is used, turn off the ignition switch after stopping the vehicle, 49AWARNING WARNINGS indicate a potential hazard that could result in personal injury or death. Knowing and following these rules for safe riding will, increase your enjoyment of your new Kawasaki ATV and help avert serious injury or death. Refer also to page 2 for "Safe Riding Information.”" Read the Owner's Manual Read and understand this Owner’s Manual, and carry It with you when you ride, This Is especially important for younger riders and beginners, Refer to this Owner's Manual if you have any questions, Obey Local Laws Know and obey all laws and regulations governing the Use of offroad vehicles in your riding area, Respect private property; do not ride there without the express written permission of the owner. Always try to preserve nature and the environment. Adult Supervision This vehicle isnot a toy. It is an off-road motor vehi ele, Use by children under 16 years of age is not rec- ‘ommended, 50 » SAFE OPERATION mn Youths starting at age 16 should have adult super: vision even after they attend a rider training course, Parents must ensure that their child has the skills, abilities and judgement required to operate the ATV safely, Youngsters must continue to develop their riding skills and use proper riding techniques. Parents need to monitor their child's progress and make certain their child avoids unsafe situations,Always enwip your child with proper protective gear, It is important that your child rides an appropriate sized ATV, Never put your child on a vehicle that requires them to reach to put their fect on the footpegs and their hands on the handlebars. Study this manual with your child to be sure he or she fully understands all of the specia’ safety instructions, AWARNING HAZARD Failure to follow the age recommendations for this ATV. Failure to supervise children 16 years of age and old WHAT CAN HAPPEN, Use of this ATV by children under 16 years of age can lead to severe injury or death of the child, Even though a child may be within the age group for which this ATV is recommended, he or she may not have the skills, abilities, or judgement needed to operate the ATV safely and may be involved in @ serious accident, HOW TO AVOID THE HAZARD A child under 16 should never operate this ATV. Youths starting at age 16 should have adult super- vision even after they attend a rider training course, Never allow continued use of this ATV by a child if he or she does not have the at operate it safely. Beginning Riders Beginning riders should practice braking and turning in an open, off-road area away from other riders, The terrain should be flat and free of obstacles with 2 loose or hard dirt surface, but net @ mixture of both, Do not ride on pavement. ATV's are designed for off-road use only, AWARNING HAZARD. Operating this ATV without proper instruction, WHAT CAN HAPPEN ‘The risk of an accident is greatly increased if the ‘operator does not know how to operate the ATV properly in different situations and on different types of terrain, jOW TO AVOID THE HAZARD. Beginning and inexperienced operators should com- plete the certified training course offered by Kawasaki. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887, 51AWARNING WARNINGS indicate a potential hazard that could result in personal injury or death. Off-Road Use Only This vehicle is designed for off-road use only. Opera tion en public streets, roads, and highways is not ree- ‘ommended and is not safe ATV tires are not designed to operate on paved or concrete surfaces, The tires will not slip as necessary which may seriously affect control of the vehicle. AWARNING Including side- walks, paths, parking lots, driveways, and streets. WHAT CAN HAPPEN ATV tires are designed for off-road use. Paved sur- faces may seriously affect handling and control of the ATV, and may couse te vehicle to go out of control, HOWTO AVOID THE HAZARD aR i operating the ATV on pavement whenever pos- le. If you must ride on a paved surface, go slowly and ¢o not make sudden turns or stops 52na public rose you take the risk that with another vehicle, Also, in many streets i illegal, AWARNING HAZARD Operating this ATV on public str highways, WHAT CAN HAPPEN ‘You can collide with another vehicle, HOW TO AVOID THE HAZARD Never operate this ATV on eny public street, road oF highway, even a dirt or gravel one, In many states it i illegal to operate ATVs on public strocts, roads and highways, 53Dress Properly ‘Always wear an approved helmet, eve protection, and protective clothing. The proper ‘clothing can make riding more comfortable and reduce the chance of injury if you take spill. Long pants will also protect your legs from the hot exhaust system, AWARNING HAZARD. Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN. Operating without an approved motorcycle helmet inereases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Operating without protective clothing increases your ‘chances of severe injury in the event of an accident, HOW TO AVOID THE HAZARD_ Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face s gloves boots long-sleeved shirt or jacket Jong pants ld)Operator Only ‘This vehicle is designed to carry only the operator. It does not have a seat strap, passenger's grab rail, dual seat, or footpegs for a passenger. The long seat is needed for the operator to maintain vehicle control by shifting his or her body weight. A passenger interferes with the ‘operator's ability to control the vehicle which can cause harm to the operator. Also, a passenger will impair the steering response of the vehicle by shifting weight from the front wheels, causing loss of control which may cause an atcident. And without secure seating, a passen: ‘ger may lose his or her balance and fall off the vehicle, Never carry a passenger. Never ride at a passenger. AWARNING HAZARD. Carrying a passenger on this ATV. WHAT CAN HAPPEN Passengers affect balance and stecring and increase Carrying a passenger could cause an accident, result- Ing in harm to you and/or your passenger. HOW To AVOID THE HAZARD Never carry a passenger. The long seat isto allow the ‘operator to shift position as needed during operation. tis not for carrying passengers.Ride Carefully and with Good Judgement ‘We want you to enjoy your riding experiences, so ride carefully and safely, Exercise good judgement. Avoid wheelies and jumps. Also, don’ ride at excessive speeds, too fast for conditions, or faster than your skill level Riding too fast and trying unsafe stunts can cause you to lose control of the vehicle and have an accident. Prac- tice basic maneuvers so you can ride confidently and safely. AWARNING “HAZARD. Attempting wheelies, jumps, and other stunts, WHAT CAN HAPI Inereases the chance of an accident, overturn, including an HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps, Don't try to show off. AWARNING HAZARD. ‘Operating this ATV at excessive speeds. WHAT CAN HAPPEN, Inereases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, ting conditions, and your experiAWARNING te a potential hazard that could result in personal injury or death. Never Drink and Drive ‘Alcohol and drugs impair your judgement and slow your reactions, Even drugs prescribed by @ physician ‘can be dangerous. Check with your doctor. AWARNING HAZARD Operating this ATV after consuming aleohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgement. Could cause you to react more slowly, Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. 87Keep Your Feet on the Pegs and Hands on the Handlebars Always ride with your feet on the footpegs. If your feet touch the ground while you are moving, you could be inured. It is possible to have the rear wheel run over your foot, If you have @ lot of motorcycle experience, your natu reaction to the vehicle tipping or skidding may bbe to put a foot down, This is a reaction you must “unlearn." ‘Also, removing your feet from the footpegs and removing your hands from the handlebars can cause you to lose your balance and fall off the ATV. Keep your hands and feet on the ATV always, AWARNING HAZARD. Removing hands from handlebars or feet from footpegs during operation. WHAT CAN HAPPEN. Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footpeg, your foot or leg may come into contact with the rear wheels, which could injure ‘you or cause an accident, HOW TO AVOID THE HAZARD ‘Always koop both hands on the handlebars and both feet on the footpegs of your ATV during operation. Before Starting the Engine “Three “musts” before starting the engine are: 1) Set the parking brake, 2) Put the transmission in neutral, 3) Check the throttle for proper operation. It should snap closed when released with the handlebars in any position.Use the Parking Brake Always apply the parking brake before getting off your vehicle. If it should roll, it might be damaged or cause injury. Modifications and Accessories Installation of accessories may affect the handling of your ATV. See the Loading Information chapter of this manual for mote detailed information. Kawasaki does not recommend that you modify your ATV in any way. Unauthorized modifications may produce dangerous handling conditions or adversely affect vehicle reliabil- ity AWARNING HAZARD. Operating this ATV with improper modific WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident, HOW TO AVOID THE HAZARD. Never modify this ATV through improper installation fr use of accessories. All parts and accessories added 10 this vehicle should be genuine Kawasaki or equiv: int components designed for use on this ATV and. should be installed and used according to instruc. tions. If you have questions, consult an authorized ATV dealer. 589Loading Your ATV ‘Make sure all cargo is securely attached. Don’t carry hheavy or bulky items that exceed the cargo rack load capacity. Also, don’t overload your ATV. Rack Maximum Load Front | 20g (44 15) Rear | 30kg (66 1b) Vehicle Maximum Load Bo not toad more than 14 kg (30 ID) tongue weight, fon the trailer hitch bracket, Be sure to subtract this tongue weight from the Vehicle Maximum Load capac: ity. HAZARD Weight of rider and cargo must not exceed 130 kg (285 ib). Try to maintain front to rear balance by carrying twice as much weight on the rear rack as on the front rack, Reduce speed when cartying cargo or pulling a trailer and allow for more braking distance, Be sure to attach a trailer to the trailer hitch bracket only, Don't attach a trailer to any other location than the bracket, Also, don’t overload a traler. Maximum Trailor Weight (Trailer plus cargo weight) 208 kg (450 ib) Improperly attaching and loading a trailer. Overloading a trail WHAT CAN HAPPEN Can cause change lead to an accident. HOW TO AVOID THE HAZARD Attach a trailer to the trailer hitch bracket only. For example, attaching a trailer to the grab rail can cause the vehicle to tip over. Never load more than 14 kg (30 1b) tongue weight on the towing bracket, Do not tow more than 204 kg (450 Ib) trailer weight (trailer plus eargo).When towing @ trailer, don't cary @ passinye int wailer. AWARNING HAZARD. Riding ina tr WHAT CAN HAPPEN. Can cause the operator to lose control of the vehicle, ‘The passenger can be thrown from the trailer or hurt by shifting cargo in the trailer HOW TO AVOID THE HAZARD. Never carry a passenger in a t Refer to the instructions in the Loading Information chapter of this manual. Overloading this ATV or car- ‘ying or towing cargo improperly will adversely affect vehicle handling and could cause an accident. AWARNING "HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV, Cargo should be properly distributed and securely attached, Reduce speed when carrying cargo or pulling trailer. Allow greater distance for braking. Always follow the instructions in your Owner's Manual for carrying eargo or pulling a trai 61Perform the Daily Safety Checks Refer to the Daily Safety Checks section for list of items to check each day before you ride. Habitual performance of these checks will help to insure a safer, more reliable ride, Be sure that any irregularities found during these checks are corrected before riing, 62 AWARNING ZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possiblity of an accident or equipment damage. HOW TO AVOID THE HAZARD. ‘Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. ‘Always follow the inspection and maintenance procedures and schedules deseribed in the Owner's Manual.WARNINGS indicate a potential hazard that could result in personal injury or death. Tire Air Pressure This vehicle is equipped with low pressure tires, Tire inflation and type can affect the vehicle's handling characteristics. Check the tire pressure frequently, using the tire cauge in the tool kit, Use only the recom- mended tires for replacement, PINYNSINTINe} HAZARD, ‘Operating this ATV with improper tires, or with im- proper or uneven tire pressure, WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this vehicle. Aiways maintain proper tire pressure ‘the Owner's Manual deseribed in 63Riding Terr Before riding in a new area be sure to check for hhidden obstacles or hazards. Keep your speed down Until you know the area well, You must know the land you intend to ride on and be familiar with your machine and its handling characteristics to have a safe and enjoy able rding experience. Use existing trails and stay away from excessively rough, slippery or loose terrain, Don't attempt to ride over large obstacles. Hazardous condi tions such as these can cause loss of control and an accident. Be cautious when visibility is limited; you may ‘not be able to see obstacles in your path, AWARNING ‘HAZARD Failure to use extra care when operating this ATV on unfamiliar train, WHAT CAN HAPPEN, ‘You can come upon hidden rocks, bumps, of holes, }out enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain, ‘Always be alert t0 changing terrain conditions when operating the ATV. If you must ride over @ small obstacle, approach it slowly. As the vehicle goes up and over the obstacle, shift your weight to stay centered over the vehicle. Use careful throttle control. Stand up if necessary to main: tain. your balance,AWARNING HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a colli cause the ATV to overturn, HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles, Never attempt to ride over large obstacles, such az large rocks or fallen trees, When you go over obstacles, always follow proper described in the Owner's Manual. AWARNING lure to use extra care when operating on exces- sively rough, slippery or loose terrain, WHAT CAN HAPPEN, Could cause foe of traction or vahicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain, Always be especially cautious on these kinds of ter 65make sure there are no you. When it is safe toAWARNING WARNINGS indicate a potential hazard that could result in personal injury or death. Turning the Vehicle ‘The new rider must learn this turning technique to ‘make tums smoothly and quickly. Slide forward on the seat, and turn the handlebar in the diction of the tuen Lean your body to the inside of the turn while shifting your body weight onto the footpeg on the outside of the urn, AWARNING HAZARD. Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn, HOW TO AVOID THE HAZARD ‘Always ‘follow proper procedures for turning as describedin this section. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Practice turning at low speed in a large, open practice ‘area. Slow down before entering a turn and use the throttle to maintain an evan speed through the turn, When the turn is completed, straighten the handlebar and reposition your weight. Since both reer wheels of this ATV tum at the same speed, the inside wheel gives up traction (or “slips") on the ground during a tur. Sliding forward on the seat and shifting body weight onto the outside footpeg, help the ‘ear wheels turn easier and improve front wheel steering. wf © 67AWARNING HAZARD Removing hands from handlebars or feet from footpegs during operation, WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose ‘your balance and fall off of the ATV. If you remove a foot from a footpeg, your foot oF leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD ‘Always keep both hands on the handlebars and beth feet on the footpegs of your ATV during operation. ‘The type of riding terrain has a large effect on turing, (On loose surfaces the inside rear wheel will slip easily and the vehicle can be turned sharply. On hard surfaces the inside rear wheel will not sip as easily, and the vehicle's ‘tuming radius will increase. Thus you must allow more room to complete your tur. It the vehicle stats to tip in a turn, lean more to the in side ofthe tum. It may be necessary to reduce your speed land straighten out if possible. Don’t put your foot down; keep both fost on the footpags, Remember: (© Slow down before entering the turn. Sit forward on the seat © Lean into the turn. (© Put your weight on the outer footpeg, (© Maintain an even speed through the turn,Climbing Do not attempt to climb hills or steep inclines until you have mastered the controls and basic riding tech- niques of this vehicle. Then practice hill climbing techniques on gentle slopes first before you graduate to steeper hil AWARNING HAZARD. Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manual. ‘Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces. Shift your weight forward, Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards, Never go over the top of any hill at high speed, An. ‘obstacle, a sharp drop, or another vehicle or person could be cn the other side of the hill Don't attempt to climb hills that are too steep for the ATV or for your abilities. When climbing a fill, ean forward to keep the front wheels from lifting. On steeper hills you may need to stand and lean forward for even more weight transfer. The front wheels must be kept on the ground so you can steer and also to prevent the possibility of tipping over backwards, AWARNING HAZARD. Operating on excessively steep hills. WHAT CAN HAPPEN, The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills, HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hill 69Avoid hills with slippery sides that will eause you to lose traction. Do not climb hills where you cannot see far enough ahead. If you cannot see what is on the other side of the crest of a hill, slow down until you can get a clear view. Do not try to climb a hill in too high @ ‘ar. Speed up before ascending the hill. Select a low enough gear to reach the top without downshifting or losing momentum. Don't apply power suddenly or ‘change gears while climbing, or the front wheels might rise off the ground. If the vehicle doesn’t have enough ower to reach the top of a hill and starts to lose for- ward momentum, turn around and ride downbill if you hhave enough space, AWARNING HAZARD. Improperly turning on WHAT CAN HAPPEN ‘Could cause loss of control or couse ATV to overturn, HOV! TO AVOID THE HAZARD. ‘Never attempt to turn the ATV around on any hill until you have mastered the turning technique as doseribed in this manual on level ground. Be very careful when turning on any hill. If the vehicle stalls on « hill, apply the brakes before the vehicle starts to roll backwards, If the vehicle should start to roll backwards on a hill, dismount to the side immediately or try to stop using the front brake only. ‘You may tip the vehicle over backwards if you use the rear brake after the vehicle starts to roll backwards, or if you try to apply power while rolling backwards; use the front brake only to stop the vehicle, If you are stopped on a hillside, apply the parking brake and carefully dismount on the uphill side of the vehicle (so it cannot roll over onto you). To turn the machine around, drag the rear end of the ATV uphill as far as possible, Re- mount the ATV from the uphill side if i is nat facing straight downhill, Then, while keeping as much of your Weight as possible on the uphill side, turn the hendlebars downhill, Release the parking brake and ride downhill,AWARNING HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill, WHAT CAN HAPPEN. Could result in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill, If you lox all forward speed: Keep weight uphill ‘Apply the brakes. Lock parking brake, after you are stopped. If you begin rolling backwards: Keep weight uphill ‘Never apply the rear brake while rolling back- wards. Apply the front brake. When fully stopped, apply rear brake as well, and ‘then lock parking brak Dismount on uphill straight uphill, Turn the ATV around and remount, following the procedure described in this manual, le or to a side if pointed Remember: Some hills are to0 stoep. Use common sense, Never ride past your limit of visibility. If you can‘t see what is on the other side of the crest of a hill, slow down until you can get a clear view. Use a low gear Don't let the vehicte roll backward. If it does, use only the front brake. If you get stuck on a hill, set the parking brake and dismount on the uphill side, nAntenna Flag In hilly country, use an antenna flag s0 others can see you coming from the other side of a hill or sand dune. ‘Take extra care when approaching blind hill tops and corners. 2 ‘Traversing Hillsides When riding across the side of a hill, Keep your body weight toward the top of the hill. Avoid hills with slippery sides that will cause you to lose traction, Also avoid traversing hillsides covered with rocks or other obstacles which may cause you to lose your balance or tip over. If the vehicle begins to tip, steer downhill if possible to regain control. If you discover that the vehicle is in danger of rolling over, dismount on the uphill side.AWARNING HAZARD Improperly crossing hills. WHAT CAN HAPPEN. Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD ‘Avoid crossing the side of a steep hill if possible, When crossing the side of a hill: Always follow proper procedures as described in this manual, Avoid hills with excessively slippery of loose surfaces. Shift your weight to the uphill side of the ATV. 3Descending Hills Slow down or stop at the top of a hill so you ean pick: a safe path for descent where you can clearly see far enough shead to avoid any obstacles, PINS NINE] HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD ‘Always follow proper procedures for going down hills ‘a deseribed in thie manual, Note; a special tech- nique is required when braking as you go down a hill, ‘Always check the terrain carefully before you start down any hill. Shift your weight backward. over go down a hill at high speed, Avoid going down @ hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where poss 4 Normally you should descend straight down a hill, since riding at an angle could cause the vehicle to lean to fone side and possibly tip over. Shift into a low gear before beginning your descent. ‘Sit back on the seat and, brace yourself by straightening your arms. Hold your spoed down by keeping the throttle closed. Apply the brakes as necessary. Avoid excessive use of the front brake; it could cause the vehicle to overturn, Be careful if the surface is loose; the tires may skid and braking effectiveness will be reducedTurning while desconding a slope must be done very carefully and gradually to avoid tipping the vehicle over. The rider should keop his feet on the footpegs and transfer his weight to the rear of the vehicle, and on the Uphill side of the vehicle, Remember: Stop and look for obstacles before descending a hil, Go straight downhill, ‘Use a low gear, Shift your weight to the rear. eGo siowly. ©Mf you must turn, do so carefully and gradually, keeping your weight toward the top of the hill Sliding and Skidding On slippery or loose surfaces, special care is required, Sliding may be hazardous because the wheels may suddenly regain traction and cause the vehicle to tip or overturn and have an accident. Therefore, never ride “over your head” when you are unprepared for the riding surface. Often you can correct a skid by turning the wheels in the direction of the skid and placing additional body ‘weight on the front wheels. Do not apply heavy braking force or accelerate when skidding, since this may cause you to lose control altogether Learn to safely control skidding or sliding by prac: ticing at low speeds and on level, smooth terrain, AWARNING HAZARD, ‘Skidding or sliding improperly. WHAT CAN HAPPEN. ‘You may lose control of this ATV. You may also regain traction unexpectedly, which ‘may cause the ATV to overturn, HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by prac- ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding oF sliding out of control. 5Use caution and miintairy low speeds to avold uncon- trolled skidding on areas covered with clay, mud, ice, or snow. These conditions are particularly hazardous when descending a hill or making a turn, Remember that this vehick is not allowed on public streets, roads, or high- ways. On loose or slippery surfaces you may be able to improve steering control by moving forward on the seat, ‘This puts more of your weight over the front wheels, Remember: ‘Be especially careful on very slippery and very high traction surfaces. Steer in the direction of the skid. ‘Dont ride on public streets, roads, or highways. 76 Riding in Water Choose a location to enter and exit the water wher the banks are not too steep or slippery. Check the water before entering for rocks, holes or other obstacles which may cause you to overturn or become stuck or sub- merged, Observe the following rules for operating the vehicle in water: Never operate the vehicle in rivers or streams where ‘the water is flowing quickly. Such operation could lead to an accident if the vehicle loses traction and is swept into the current. Never operate the vehicle in deep water. The max- imum fording depth is 20 om (8 in.) in moving) water. Vehicle operation in di may be unpredictable and hazardous, and could lead to ‘an accident.AWARNING HAZARD. Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than 20 em (8 in), Remember thet wet brakes may have reduced stop- ping ability. Test your brakes after leaving water. If ‘necessary, apply them several times to let friction dry ut the linings, After the vehicle is operated in water, check the air cleaner. After prolonged exposure to water, the wheel bearings may lose their lubricant and require replace- Wash the vehicle in fresh water if it was exposed to salt water or operated in muddy conditions, Wet brakes provide little or no efficieney and could lead to an accident and injury. After operation in water, always apply the brakes long enough for the friction to dry the linings. Also, brakes that get wet may wear ‘out faster. Check for brake wear more frequently if the vehiale is Used in water. Rememb Don't ride in fast moving water oStay out of the water over 20 cm (B in.) deep, oDry out the brakes. Check the air cleaner for water AWARNING nPeriodic Maintenance Chart In addition to the following items, always perform the Daily Safety Checks listed in the HOW TO RIDE chapter. © = Emission Related Clean, adjust, lubricate, replace parts as necessary. D = Service to be performed by an authorized Kawasaki dealer. Fist Service Roguiar Service ‘Aftor 10 hrs. ofuse Every 10 days of use Every 30 days of use Every 90 days ‘of use Every ‘year of use CHASSIS ‘Brake wear--check* Cable adjustments* Battery--check Steering play--check General lubrication” [Nuts and bolts--tighten Final gear case oil--change Brake light switch--check™ ENGINE © Ai cleaner--service* © Throttle lever play--check Ciutch adjustment’ © Valve clearance--check © Fuel system cleanliness--check* Engine oil--change* Oi fiter--replace* © Spark plug--clean and gap Spark arester--clean v3oe eocecn “Service more frequently when operated in mud, dust. or other harsh riding conditions. 7BEngine In order for the engine, transmission, and clutch to function 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 particles collect in the oil, but the oil itself loses its lubricative quality if used too jong. AWARNING HAZARD Engine or transmission seizure, WHAT CAN HAPPEN. Can lock the rear wheels causing an accident and injury. HOW TO AVOID THE HAZARD Do not operate this vehicle with insuffi rated, oF contaminated engine oil Oi Level Insoection ‘If the oil has just been changed, start the engine and run it for several minutes at idle speed, ‘This fills the oil filter with oil. Stop the engine, then wait several ‘minutes until the oil settles, Racing the engine before the oil reach ‘can cause engine seizure, Operation with insufficient, deteriorated, or contam- inated engine oil will cause accelerated engine wear. ‘very part IF the vehicle has just been used, wait several minutes for all the oll to drain down. ‘Check the engine oil evel through the oll level gauge in the: lower right side of the engine. With the vehicle level front-toxear and side-to-side, the oil lavel should ‘come up between the lines next to the gauge. A.Oil Filler Cap B. Oil Level Gauge ©. Upper Level Line D. Lower Level Line 79{@1F the oil level is too high, cemove the excess ail, using a sytinge or some other suitable device. IF the oil level is too low, add the correct amount of cil through the oil filer opening. Use the same type and brand of oll that is already in the engine, HAZARD Engire or transmission seizure. WHAT CAN HAPPEN Can lock the rear whesls causing an accident and in- jury. HOW TO AVOID THE HAZARD Check engine ol level before operating vehicle, and add oi fi is low. CAUTION Wf the engine is run without oi damaved. Oil andjor Oi Fiter Change (@Warm up the engine thoroughly, and then stop the en: gine. (@Place an oil pan beneath the engine. ‘@ Remove the engine drain plug A. Drain Plug ‘@With the vohicle on level ground, let the oll completely drain, AWARNING HAZARD Improper disposal of used motor oll WHAT CAN HAPPEN Used motor oil is @ toxic substance. which can pollute the environment HOW TO AVOID THE HAZARD. Contact your local authorities for approved disposal methods and follow those methods at al times.1F the oi filter is to be changed, remove the oil filter cover bolts and take off the cover with the O-ring. B. Oil Filter Cover ‘© Pull off the element with the element mounting pin. A. Oil Filter Element . Element Mounting Pi B. Grommet ‘@Pull the mounting pin off the element. ‘@ Replace the element with @ new one. ‘@ Apply a litte engine oil to the grommets on both sides ‘of the element, and push the mounting pin into the el- cement. Be careful that the grommets do not slip out of place. ‘Install them with the smaller end af the pin outsida, NOTE (Check for O-ring damage. If necessary, replace it with (© When installing the oil fiter, make sure the O-ring is in place. ar‘@ instal the ol iter cover and tighten its bolts. ‘@ After the oil has completely drained out, install the en- gine drain plug with its gasket. Proper torque for it is shown in the table. NOTE OReplece the damaged gasket with a new one. Tightening Torque Engine Drain Plug: 29 N-m (3.0 kg-m, 22 ft-lb) ‘@Fll the engine up to the upper level line with a good ually motor oil specified in the table. Engine Oil Type API SF or SG API SH or SJ with JASO MA SAE 5W-20, 10W-40, 10W-50, 20W-40 or 20W-50 Capacity: 2.0L (2.1 US ath [when filter is not removed] 2.1 L (2.2 US qd) [when filter is removed] ‘© Check the oil level Final Gear Case Oil In order for the pinion and ring gears to function properly, check the oil level and change the oil in accordance with the Periodic Maintenance Chart. AWARNING HAZARD. Operating this vehicle with insu oF contaminated gear case oil lent, deteriorated, HAT CAN HAPPEN ‘Seizure of ring and pinion gears in final gear case ‘can lock the rear wheels causing an accident and injury. HOW TO AVOID THE HAZARD Do not operate this vehicle with insufficient, deterio. rated, or contaminated gear case oil, CAUTION Vehicle operation with insufficient, deteriorated, or contaminated oil causes accelerated wear of ‘the pinion and ring gears.Oi Level inspection ‘@With the vehicle level front-to-rear and side-to-side, ccheck the oil level. If itis insufficient, add oll through the oll filer opening as necessary. Loosen the inspection bolt. The quantity of ol is cor- rect when the cil begins to flow out the inspection bolt hole. se A Inspection Bolt ©. Drain Plug 8. Filler Plug @Tighton the inopection bolt. NOTE (Use the same type and brand of oll that is already in the final gear case. 04 Chango NOTE Final gear case oll drains easily and picks up any sediment when the oil is warmed up by running the vehicle, ‘@With the vehicle level, place an oil pan beneath the gear case. ‘@ Remove the filer plug and the drain plug AWARNING HAZARD Proper disposal of used gear case oil WHAT CAN HAPPEN Used gear caso oil is a toxic substance, which ean pol lute the environment. HOW TO AVOID THE HAZARD Contact your local authorities for approved disposal methods and follow those methods at all times,‘@Aftor the oil hes completely drained out, install the drain plug and gasket. Replace a damaged gasket witha new one. AWARNING HAZARD Getting gear case oil on ties. WHAT CAN HAPPEN. ‘Can make them slippery whi and injury. ‘can cause an accident HOW TO AVOID THE HAZARD Clean up any spilled oil immediately using soap and. water ‘Fill the gear case with a good quality oil specified in the table. Final Gear Case Oil oir ‘about 200 mL Caracity | (0.21 US ath ‘API "GLB" oil Hypoid gear of! Type ‘above 5°C (41°F) SAE9O below 5°C (41°F) SAEBO Spark Plug ‘The standard spark plug is shown in the table. The spark plug should be taken out periodically in accord: ‘ance 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 ‘leaned, 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 fr other suitable tool, Measure the gap with a wire-type thickness gauge, and adjust the gap if incorrect by bending the outer electrode. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard plug. TL oe~0.7 mm *F 0.028~0.026 nu} install the fillor plug, 84Spark Plug Standart NGK DRBES Plug Plug 06 ~ 07 mm Gap (0.024 ~ 0.028 in) Tightening 14Nem Torque (1.4 kg-m, 10.0 ft-lb) Valve Clearance upsetting valve timing, CAUTION WT valve clearance is Teft unadjusted, the wear will eventually cause the valves to remain partly open, which lowers performance, burns the valves and Valve and vaive seat wear decrease valve clearance, id may cause serious 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 by an authorized Kawasaki dealer. Air Cleaner ‘A clogged air cleaner restricts the engine's air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling PINS} HAZARD, ‘A.clogged air cleaner. WHAT CAN HAPPEN May allow dirt and dust to enter the carburetor and stick the throttle open. This could cause an accident. HOW TO AVOID THE HAZARD Clean the air cleaner regularly and according to the Instructions in this section, CAUTION ‘A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possibly engine damage.‘The air cloaner slement must be cleaned periodically {see the Periodic Maintenance Chart). In dusty areas, the #lement should be cleaned more frequently than the recommended interval. After riding through rain for on muddy roads, the element should be cleaned immediately. Element Cleaning ‘eRemove the seat. ‘ePullup the snaps and remove the air cleaner cover. ‘A. Air Cleaner Cover 8. Snaps 86 ‘* Loosen the clamp seraw, rameve the alement mounting screw, then pull the air cleaner element up out of the air cleaner housing. A. Screws. B, Element Check inside the inlet tract and carburetor for dirt, If dirt is present, clean the intake tract and carburetor thoroughly. You may also need to replace the air filter and seal the airbox and inlet tract. Push a clean, lint-free towel into the inlet tract to keep dirt or other foreign material from entering. ‘Wipe out the inside of the airbox with a clean damp towel,AWARNING HAZARD Dirt or dust allowed into the carburetor. WHAT CAN HAPPEN Can cause the throttle to stick open, This could cause an accident. HOW TO AVOID THE HAZARD Be sure to cover the air cleaner opening to the car- bburetor after removing the element. CAUTION If dirt gets through into the engine, excessive engine 1nd possibly engine damage will occur. ‘@Remove the element stopper from the rear end of the element body by removing the serew. A. Serew B, Stopper ‘Pull the element off the body, then off the inner metal net. 87Clean the element in a bath of high flash-noir using a soft bristle brush, AWARNING HAZARD. Cleaning the air cleaner element with gasoline or low ‘lash-point solvent. WHAT CAN HAPPEN Gosoline or low flash-point solvents are extremely flammable and can be explosive under certain con ditions. A fire or explosion can cause severe injury or death. How To AVOID THE HAZARD Use a high flash-point solvent to clean the air cleaner element. Never use gasoline or low flash-point solvents, Clean the element in a well-ventilated area free from any source of flame or sparks; this includes any ‘appliance with a pilot light squeeze It dry in a clean towel. Do not wring the element or blow it dry; the element can be damaged. inspect the element for damage. If it is torn, pune: tured, or hardened, replace it. NOTE Replace the element after cleaning it five times or if it is damaged. ‘After cleaning, saturate the element with a high-quality foam air filter oil, squeeze out the excess, then wrap it in a clean rag and squeeze it at dry as possible, Be careful not to tear the element. install the element on the inner metal net. Coat the lips of the element with a thick layer of all purpose grease to assure a complete seal against the element body and stopper. install the element on the body, then install the element stopper. ‘Apply grease to all connections and screw holes in the airbox and intake tract. ‘@Remove the towel from the inlet trac. @lnstall the element in the airbox. Tighten the moun- ‘ting screw and clamp screw securely. ‘¢Smear grease around the clamp and particularly in any ‘gaps between the element body and the inlet tract. install the air cleaner cover and seat.Dust and/or Water Inspection Squeeze open the two drain hoses on the bottom of the air cleaner housing to expel dust and/or water ‘accumulated inside, A, Drain Hoses Spark Arrester This vehicle is equipped with a spark arrester ap- proved for off-oad use by the US. Forest Service, It must be properly maintained to ensure its efficiency. In ‘accordance with the Periodic Maintenance Chart, clean the spark arrester, AWARNING HAZARD. Incorrectly installed spark arrester, WHAT CAN HAPPEN, (Can emit sparks which can eause a fire, HOW TO AVOID THE HAZARD Be sure the spark arrester/mutfler and drain plug are installed seeu ‘Spark Arrester Cleaning AWARNING “HAZARD Hot muffler WHAT CAN HAPPEN. Can burn your hands HOW TO AVOID THE HAZARD Wear gloves while cleaning the spark arrester. The engine must be running during this procedure.WARNINGS indicate a potential hazard that could result in personal injury or death. ‘Remove the drain plug from the muffler in an open area away from combustible materials, start the engine with the transmission in neutral. AWARNING HAZARD, HOW TO AVOID THE HAZARD Never run the engine with the spark arrester dis sembled near combustible meterials. Hot carbon particles are emitted during the cleaning procedure. A. Spark Arrester —C, Drain Plug B. Bolt‘@Rise and lower engine speed while tapping on the ‘muffler with a rubber mallet until carbon particles are purged from the muffler, AWARNING | HAZARD. Running the engine without ventilation, WHAT CAN HAPPEN Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death, Exhaust gases ‘contain carbon monoxide; a colorless, odorless, poisonous gas. HOW TO AVOID THE HAZARD Do not start or run the engine in a closed area such as 2 garage. ‘9Stop the engine. install the drain plug ‘@Remove the spark arrester mounting bolt from the router ‘Pull the spark arrester out of the muffler. ‘Scrape carbon deposits off the spark arrester and slide it back into the muffler ‘install the mounting boit and tighten it securely. Throttle Cable ‘There must be free play in the throttle mechanism, Measure the distance the throttle lever moves before the tengine bogins to pick up spaed. Free play should be 2~ ‘3mm (0,08 ~ 0.12 in.) A.2~3 mm (0.08 ~ 0.12 in.) 1Adjusmont (elf the free play cannot be vet by edjusting the upper ‘Slide the rubber cover off of the adjuster at the throt: ccable adjuster, pull the rubber cover off of the carbure tle case, tor top. Make the necessary free play adjustment at Loosen the locknut and turn the throttle eable upper the lower cable adjuster, then tighten the locknut and adjuster to obtain the specified free play. reinstall the rubber cover. ‘Tighten the locknut and reinstall the rubber cover, A. Adjuster B. Locknut A. Adjuster B. LocknutReverse Cable ‘There must be free play in the reverse mechanism, Inspection Check that the reverse knob has 2 ~ 3 mm (0.08 ~ 0.12 in.) of free play as shown, A. Reverse Knob B.2~3 mm (0.08 ~ 0.12 in.) If itdoes not, adjust the knob play as follows. Aagjustment Loosen the locknuts at the lower end of the reverse ‘cable near the shift pedal, and turn them until the reverse knob has the proper amount of free play, Tighten the locknuts, A, LocknutsCarburotor Carburetor adjustment is done with the idle adjusting screw. Adjusiment AWARNING and exhaust pipe. Can burn your hands. HOW TO AVOID THE HAZARD. ‘Never touch @ hot engine or an exhaust pipe during carburetor adjustment. ‘@:Startthe engine and warm it up for five minutes. ‘© Adjust the idle speed to the proper speed specified in the table by turning the idle adjusting screw. Idle Speed: 1,250-1,360 rimin (rpm) A. Idle Adjusting Serow ‘®0pen and close the throttle a few times to make sure ‘that the idle speed dovs not change, Readjust if necessary. NOTE ‘With engine idling, turn the handlebar to each side. If ‘handlebar movement changes idle speed, the throttle ‘cable may be incorrectly routed, or it may be damaged.AWARNING HAZARD Failure to maintain the control cable. WHAT CAN HAPPEN Can result in control matfunetion and an accident, Without proper maintentance the cable can become frayed, kinked, pinched, and damaged so tha break or jam, HOW TO AVOID THE HAZARD Be sure the control cable is properly adjusted and correctly routed, Replace the cable if it is damaged. Clutch ‘The clutch is automatically disengaged during shit: ing. If it does not disengage properly, it may cause hard hifting and possible transmission damage. Adjust the clutch according to the interval listed in the Periodic Maintenance Chart. Adjustment AWARNING HAZARD Hot engine and exhaust pipe. WHAT CAN HAPPEN Can burn your hands. HOW TO AVOID THE HAZARD ‘Never touch @ hot engine or an exhaust pipe during clutch adjustment. @Remove the clutch release adjusting screw cover by removing the screws,Loosen the focknut, Turn the clutch release adjusting screw clockwise until it becomes hard to turn, then turn the screw back counterclockwise until it Becomes hard to turn. A, Locknut B. Adjusting Screw Tighten the locknut without changing the adjusting screw position, ‘instal the adjusting cover. Brakes Brake Wear Inspection In accordance with the Periodic Maintenance Chart, inspect the brakes for wear. On both the front and rear brake panels are brake lining wear indicators. If the indicator arrow points beyond the “Usable Range” specified in the figures when the brake is fully applied, the brake shoe linings are worn past the service limit. In this case, the brake shoes must be replaced and the drum and other brake parts examined by an authorized Kawasaki dealer. A. Front Brake Drum ©. USABLE RANGE 19 Wear IndicatorFront Brake: Brake Lever Free Play Adjustmant Loosen the locknut at the brake lever and turn in the adjuster as far as it will go to make the brake lever loose. A. Rear Brake Drum ©. USABLE RANGE B. Lining Wear Indicator(¢Turn in or out each winanut at both lower ends of the Turn out the adiuster at the brake lever until the brake cable so that each brake cam lever will have 2~ 3 mm lever has 1 ~ 2 mm (0.04 ~ 0.08 in.) of free play. (0.08~ 0.12 in.) of free play. Tighten the locknut, A, Wingnut ©. 2~3.mm (0,08 ~ 0.12 in.) B. Cam Lover AWARNING A. 1~2 mm (0.04 ~ 0.08 in.) HAZARD. Incorrect adjustment of brake lever free play. WHAT CAN HAPPEN 1n cause brake damage or malfunction and result in an accident, NOTE After the adjustment has been made once following the HOW TO AVOID THE HAZARD. ‘above procedures, ordinarily adjust the free play by ‘Always maintain proper le using the wingnuts at both /ower ends of the cable.Rear Brake: To adjust the pedal position, loosen the locknut, turn Rear brake adjustment consists of three separate the adjusting bolt, and then tighten the locknut. ‘adjustments: brake pedal position, brake pedal free play, ‘and brake lever free play. Always adjust the brake pedal position first Brake Pedel Position Adjustment ‘©The top of the brake pedal in its rest position should be level with the upper surface of the right footpeg. A. Adjusting Bolt B, Locknut ‘After adjusting the pedal position, check the operation of the rear brake light switch. Now adjust the brake pedal free play. A. Footpeg ©. Level B. Brake PedalBrake Pedul/Brake Lever Free Play Adjustment @Looven the locknut and turn in the adjuster at the braks lever as far as it will go. ‘©Turn in or out the wingnut at the rear end of the brake cable so that the brake pedat will have 25 ~ 35 mm (1.0 ~ 1.4 in.) of free play before the brake starts to take hold, 100 A. Brake Pedal B, 25~35 mm (1.0~ 1.4 in.) AWARNING -HAZARD_ Incorrect adjustment of the brake pedal and/or brake lever free play. WHAT CAN HAPPEN Can cause brake damage or malfunction and result in ‘an accident. HOW TO AVOID THE HAZARD. Always maintain proper pedal and/or lever free play.‘2Turn out the adjuster at the brake lever until the brake lever has 2~ 3 mm (0.08 ~ 0.12 in.) of free play. A.2~3mm (0.08 ~ 0.12 B. Locknut GC, Adjuster ighten the locknut. ‘After adjustments, check for brake drag (there should bbe none) and effectiveness. Brake Light Switches When the front, or rear brake is applied, the brake light goes on. The front light switch require no ‘adjustment, but the rear brake light switch should be ‘adjusted in accordance with the Periodic Maintenance Chart Inspection ‘@TTurn the ignition key to “ON.” 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, Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go ‘on after about 10 mm (0.4 in.) of pedal travel 101@1ritdows not, adjust the reur brake light switch. Adjustment '@7To adjust the rear brake light switch, move the switch por down by turning the adjusting nut. [ CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. ‘A, Roar Brake Light Switch BB Adiusting Nut Lights sooner 1. Lights later 102 Wheels Rims ‘The rims are a drop-center, tubeless tire design. Take ‘care not to damage the sealing surfaces of the tire or rim when removing or instaling tires. Note that the rims, like automotive rims, are not symmetrical and should be installed in one direction only. All wheels must be installed so that the valve stems are on the outside of the vehicle, Tires: The front tires are AT21 x 89 knobby tubeless tires; the rear tires are AT22 x 10-10 knobby tubeless tires. When replacing tires, check the valve stems and cores for damage. Take care not to damage the tire sei surfaces of the rims, Standard Tire Front rd Rear KT857 NOTE Tires are an important part of the suspension on your ATV. Tire construction characteristics and tire infla- tion pressure can greatly influence vehicle handling. Kawasaki recommends that you always replace tires with standard replacement tires as shown above. It is also very important to have tires of the same type and size, and at the same inflation pressure, on one axle,installation of non-standard tires, or use of differsnt tires on one axle, can change the handling of the vehicle ard possibly result in a loss of comtrol, installation of tubeless tires on rims requires com- pressed ait and is normally recommended as a dealer service operation. However, a tube can be inserted into the tire by the operator as an emergency repair. Payload and Tire Pressure Failure to maintain proper inflation pressures or ‘observe payload limits for your tires may adversely affect handling and performance of your vehicle and can result in loss of control, The maximum recom: mended load carrying capacity of this vehicle is 130 kg (285 1), Use the tire pressure gauge in the tool kit to accu: rately sot tire pressure, AWARNING HAZARD. Unequal tire pressure. WHAT CAN HAPPEN. an caust difficult and unpredictable steering re- sulting in an accident, HOW TO AVOID THE HAZARD. Inflate both front tires and both rear tires to the same pressure respectively. PINS INT HAZARD. Operating this ATV with improper tires, or with improper tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, oF operation of this ATV with improper tire pressure, may cause loss of control, increasing your risk of an accident. HOW TO AVOID THE HAZARD es specified in the in proper tire pressure as described in this Owner’s Manual. Tire Air Pressure (when cold) Normat | Fr" | oy kee Use Rear | (0-21 ko/em?, 3.0 psi) toma” | ‘ost | He 103AWARNING WARNINGS indicate a potential hazard that could result in personal injury or death, Battery The battery is located under the seat. MANGER iexevoawva Gases Cigorettes, 16 oF sparks could eause battery to explode ‘Always shield eyes and face from battery. _Do not charge without proper Instruction and traning, Connect eables to the proper terminals securely. Check vent tube to avoid any crimping or obstruction to the tube AWARNING KEEP FILLING PLUGS "HAZARD. , TIGHT AND LEVEL Batteries contain sulfuric aca, Batteries produce hydrogen gas. POISON CAUSES SEVERE BURNS WHAT CAN HAPPEN Contains sulfuric acid. Avoid contact with skin, ey Salferis’ld Gan Guise Gia clothing. In event of accidont flush with water and call « Hydrogen gas can cause an expos physician immediately. ot ie KEEP OUT OF REACH OF CHILOREN DISTR. BY -HOW TO AVOID THE HAZARD. KAWASAKI MOTORS CORP. Rea! and understand the hattery safety label shown P.0. ROX 25952 here, SANTA ANA, CA. 927995252 104AWARNING Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Battery Elsctrolyte Level Inspection ‘The battery electrolyte level must be kept between the upper and lower level lines. Check the electrolyte level in eech cell in accordance with the Periodic Main- tenance Chart ‘@Remove the battery from the vehicle (See Battery Removall ‘Check thet the electrolyte level in each cel is between the upper and lower level lines, A. Filler Cop B. Upper Level Line ©. Lower Level Line If the electrolyte level ic low in any coll, fill with distilled water as follows, ‘Remove the battery filler caps and fill with distilled water until the electrolyte level in each cell reaches the upper level line, CAUTION ‘Adal only distiled water to the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battory, Battery Charging @Remove the battery from the vehicle (See Battery Removal) CAUTION ‘Always remove the battery from the vehicle for charging. If the battery is charged while still in- stalled, battery electrolyte may spill and corrode the frame or other parts of the vehicle. 105ithe seevlye lel low nay el il above ‘the lower level line but not up to the upper level line NIN) se teal nding caro MAZARD sero tercae eral te eli mdicomect te; || ‘aroun podoc arngn gt. eury charger ads oie botany tominal Ud to Bick WHAT CAN HAPPEN Which can cause an explosion. HOW TO AVOID THE HAZARD ‘Charge the battery in a well ventilated aroa. Keep sparks, flame, and cigarettes away from the battery during charging. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. Charge the battery at a rate that is 1/10th of the A. Battery Charger ©. (~) Terminal battery capacity. For example, the charging rate for a B. Filler Caps D. (+) Terminal 10 Ah battery would be 1.0 ampere. 108