H-~E Kawasaki Includes: = Important Safety Information = Operating Instructions ~ Maintenance and Storage ELIMINATOR 125 Motorcycle [Be fe fe ii (UN iS MANUAL4 WARNING Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. A Table of Contents is included after the Forword. General ote toda} Lledo tle(-3 the Motorcycle Safe Operatio WET lara} Adjustment BEC) tele ) GuideWhenever you see the symbols shown below, heed their instructions! Always follow safe operating and main- tenance practices. This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. 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. NOTICE THIS PRODUCT HAS BEEN MAN- UFACTURED FOR USE IN A REASON- ABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.FOREWORD Congratulations on your purchase of a new Kawasaki Motorcycle. Your new motorcycle is the product of Kawasaki's advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner's Manual carefully before riding so thai you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its features, capabilities, and limitations. This manual offers many safe riding tips, but its purpose is not to provide instruction in all the techniques and skills required to ride a motorcycle safely. Kawasaki strongly recommends that all operators of this vehicle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle operation. To ensure a long, trouble-free life for your motorcycle, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their Kawasaki Motorcycle, a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer. The Service Manual contains detailed disassembly and maintenance information. Those who plan to do their own work should, of course, be competent mechanics and possess the special tools described in the Service Manual. Keep this Owner's Manual aboard your motorcycle at all times so that you can refer to it whenever you need information. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold.All rights reserved. No part of this publication may be reproduced without our prior written permission. ‘This publication includes the latest information available at the time of printing, However, there may be minor differences between the actual product and illustrations and text in this manual. All products are subject to change without prior notice or obligation. KAWASAKI HEAVY INDUSTRIES, LTD. Consumer Products & Machinery Company © 2004 Kawasaki Heavy Industries, Ltd. June 2004. (1)»o»mmmmmm»n»nMM” TABLE OF CONTENTS «Hececacccaacudanannd Specifications . Serial Number Locations .. Location of Parts..... Location of Labels Loading Information General Information Speedometer Indicator Lights. Key. Ignition Switel Right Handlebar Switches .. Engine Stop Switch.. Starter Button Left Handlebar Switches Dimmer Switch .. Tum Signal Switch Horn Button. Fuel Tank Cap Fuel Tank.. Fuel Tap. eeeeeperee Bis Baa Side Stand Helmet Hook Side Covers Tool Kit Compartment Steering Lock. How to Ride the Motorcyc! Starting the Engine Jump Starting Moving Off Shifting Gears . Braking... ‘Stopping the Engine ‘Stopping the Motorcycle in an Emergency Parking... Safe Operation Safe Riding Technique. Daily Safety Checks.Maintenance and Adjustment Periodic Maintenance Chart .. Engine Oi ‘Spark Piug Valve Clearance Evaporative Em Control System Kawasaki Clean Air Syste Air Cleaner. Throttle Grip... Carburetor. Clutch.. Drive Chain Brakes. Brake Light Switches .. Rear Shock Absorbers. Wheels. Battery nee ecnne Headlight Beam . Fuses. General Lubrication .... 116 Cleaning Your Motorcycle Bolt and Nut Tightening. ‘Storage ... Troubleshooting Guide... 127 ‘Owner Satisfaction . Reporting Safety Defects Environmental Protection .. Maintenance Recordd»wyy999HHY9HHNYYYDNMMY SPECIFICATIONS CK CCMEECKEEMEMEEEKEEEE DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Dry Weight ENGINE ‘Type Displacement Bore X Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing (Electronically advanced) 2,150 mm (84.65 in.) 780 mm (30.71 in.) 1,050 mm (41.34 in.) 1,470 mm (87.87 in.) 155 mm (6.10 in.) 132 kg (291 Ib) SOHC, single-cylinder, 4-stroke, air-cooled 424 mL (7.60 cu in.) 55.0 X 52.4mm (2.17 X 2,06 in.) 96:1 Electiic starter Mikuni BS28 col 10° BTDC @1,300 r/min (rpm) ~ 30° BTDC @4,500 r/min (rpm)‘Spark Plug Lubrication System Engine oil Type: Capacity: TRANSMISSION ‘Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Gear Ratio: ist 2nd 3rd 4th Sth FRAME Castor Trail Tire Size: Front Rear Fuel Tank Capacity NGK CR7E Forced lubrication (wet sump) API SE, SF, or SG API SH or SJ with JASO MA SAE 10W-40 1.4L (1.5 US at) 5-speed, constant mesh, return shift Wet, multi disc Chain drive 3.666 (77/21) 3.066 (46/15) 10.708 (Top gear) 2.700 (27/10) 1.705 (29/17) 1.300 (26/20) 1.090 (24/22) 0.952 (20/21) 34° 121 mm (4.76 in.) 90/90-17M/C 49P Tube-type 190/90-15M/C 66P Tube-type 13L (3.4 US gal)ELECTRICAL EQUIPMENT Battery 12V9 Ah Headlight 12 V 60/55 W TaiV/Brake Light 12V 5/21 W Tum Signal Lights 12V21Wx4 Specifications subject to change without notice. 10»»»DYyYY»Y»YDI” SERIAL NUMBER LOCATION €«Kaq@QKMKEM KEKE The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. in the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it. Engine No. 1yoMMyyOPyODDNO»MDMD — LOCATION OF PARTS «K«KmCUMMKEKEEKEEKEE . Clutch Lever . Speedometer }. Front Brake Fluid Reservoir . Front Brake Lever 3. Left Handlebar Switches . Indicator Lights . Fuel Tank Cap . Right Handlebar Switches . Throttle Grip ene penome 1210. Front Fork 11. Tum Signal Light 12. Headlight 13. Hom 14. Ignition Switch 15. Fuel Tank 16. Fuel Tap 17. Choke Lever 18. Seat 19, Helmet Hook 20. Speedometer Cable 21. Shift Pedal 22. Side Stand Switch 23. Side Stand 24. Air Cleaner Element 25, Drive Chain 26. Rear Shock Absorber8 8 . Tail/Brake Light , Main Fuse . Battery , Carburetor . Spark Plug . Steering Lock . Brake Lining Wear Indicator . Muffler . Oil Level Gauge . Rear Brake Light Switch , Rear Brake Pedal 38. Brake Caliper 39. Brake Disc BSRRSRESBB8 2 g> mmyHMPM MMMM LOCATION OF LABELS Kacaaaanaccecacanecce opens Important Drive Chain Information . Tire and Load Data . Engine Oil and Oil Filter . Weight & Manufacture Noise Emission Control Information . Vehicle Emission Control Information 157. Break-In Caution 8. Battery Vent Hose Routing 9. Battery Poison/Danger 10. Brake Fluid (Front) 11. Daily Safety Checks (attached to the inside of the right side cover) 16® IMPORTANT DRIVE CHAIN INFORMATION To provent an accident ander damage to the molowyde, the dive chain must be properly ‘maintained. it should “ba lubricated every 600km (400m) and adjusted as often ae naceseary to keep chain slack a! about 25-40nm (1.0-1.6 in) measured mdway between sprockets on the lower chain’ run wit the motorcycle on the side. stand. Tne -stancaré chan isan. Enuma EK42BS4A with ostimated service lite of 6000~15000km » (S000~s409m), depending “on the severiy of use and tho. frequency ol Libretion and sdlustmore. For safety, replace the chain. with’ only the standard chain any, time it wears to over 259mm (10.2 in), measured over a 204ink. porton pulled straight with 98N (Okg!, 2ibf) of tension. See the Owner's Manual for chain information, 1718 ® TIRE AND LOAD DATA “The stably and handling characteristics ofthis motorcycle could become unsale by the use of improper {ire inflation pressures, overwom tires, unsuitable replacement tires, or overtoading. When tire tread wears down to the limit, replace the tire with only the standard tire, Maintain the inflation pressure specified. “Ar Presse (Col) SHEE Mo Te Minn Trad Dep (st | cao. temic aor ons 407 ‘ime(0.04 in} Flop sshgtms amare] “OPP oan | Sn] _aomnavowor | _ooBSSHE or tmn(0.04 19)@ ENGINE OIL AND OIL FILTER Engine Oil Change -- when filter is nol removed : 1.1 liters (1.2 US at) when filter is removed: 1.2 liters (1.3 US at) Engine Oil Type API SE, SF or SG ‘API SH or SJ with JASO MA ‘SAE 10W-40 Owner's Manual for engine oil/tilter information and change intervals. 1920 FD, BY KAWASAKI MOTORS ENTERPRISE (THAILAND) CO,, LTD. THIS VEHICLE CONFORMS: TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE. GVWR 668 LBS. GAWR F 228 LBS. WITH 90/90-17 MIC 49P TIRE, 17x1, 85 RIM, AT 21 PSI. COLD. GAWR R 440 LBS. WITH 130/90-15M/C 66P TIRE, 15MICx2. 75 RIM, AT 25 PSI. COLD. JKABNRA1 MOTOR CYCLE (BN125A) MADE IN THAILANDMOTORCYCLE NOISE EMISSION CONTROL INF, ‘THIS 2004 MOTORCYCLE MEETS EPA NOISE EMISSION REQUIREMENTS BY THE FEDERAL TEST PROCEDURE. MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE TO EXCEED FEDERAL NOISE STANDARDS ARE PROHIBITED: BY FEDERAL LAW. SEE OWNER'S MANUAL. (BN125A) MODEL SPECIFIC CODE : KAW4150125 VIN: JKABNRA1 NOISE LIMIT/CLOSING RPM:80DBA/9025RPM 2122 ve WA awa INE ESTER, eS pone ox, vero sae at "TiS VENIGLE GONFORUS TO USEPA REGULATIONS ‘APPLICABLE T0 2004 MODEL YEAR NEW MOTORCYCLES. [RAWASAN MOTORS ENTERPRISE (TMALAND) CO. LTD. ® BREAK-IN CAUTION To ensure proper vehicle parformance, do not ‘exceed the breakin ims shown beow. ig — | tet [and [5 [am [StH 0500 | 9 | 15 | 10 | 2 | 26 soo 1.000 | | 22 [2a | 34 [39 'Note) When operating on puble roadways, keop max. speed under trafic aw limits.— WARNING — USE ONLY DOT4 BRAKE FLUID FROM A SEALED CONTAINER. CLEAN FILLER CAP BEFORE REMOVING. N'UTILISER QUE DU FLUIDE DE FREIN DOT4. 23A DANGER/POISON > FLUSH Eves : (Cz | IMMEDIATELY SHIELD suceuRic | WITH WATER EYES | ACID GET EXPLOSIVE + spanks ‘ GASES CAN CAUSE '* FLAMES BLINDNESS OR INJURY; ® SMOKING | SEVERE BURNS. INUSA., YUASA INC. | SERVICED BY : READING, PA. 24Clutch lever play correct, releases ‘roger, no Sippage Rear vew miror adjustment Heaaignt wor, ‘Tum sgnals work Shearing uns. —— Tred but nas vttin USABLE RANGE No abnormal engine nose: Engine ol ievel corect No abnormal exhaust noise @ Kawasaki DAILY SAFETY CHECKS ‘wth proper sack, lif pecessary resin goos condton, ‘wear win servoo ii, ‘i prossurecorect 25yoynnnyyn»»D») LOADING INFORMATION «&6Ceaaceeeeeaceeee A\WARNING Incorrect loading, improper installation or use of accessories, or modification of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure that the motorcycle Is not overloaded and that you have followed these instructions. With the exception of genuine Kawa- saki Parts and Accessories, Kawasaki has no control over the design or appli- cation of accessories. In some cases, improper installation or use of accesso- ries, or motorcycle modification, will void the motorcycle warranty. In selecting and using accessories, and in loading the motorcycle, you are personally responsible for your own safety and the safety of other persons involved. 26 NOTE © Kawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accessories you add to your motorcycle be genuine Kawasaki components. Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in the fitting of additional accessories. The following general guidelines have been prepared to assist you in making your determinations.1. Any passenger should be thoroughly familiar with motorcycle operation. The passenger can affect control of the motorcycle by improper positioning during cornering and sudden movements. It is important that the passenger sit still while the motorcycle Is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motorcycle. 2. You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator, seat strap or grab rail. Do not carry a passenger unless he or she is tall enough to reach the footpegs and footpegs are provided. 2 All baggage should be carried as low as possible to reduce the effect on the motorcycle center of gravity. Baggage weight should also be distributed equally on both sides of the motorcycle. Avoid carrying baggage x e 2 that extends beyond the rear of the motorcycle. Baggage should be securely attached, Make sure that the baggage will not move around while you are riding. Recheck baggage security as often as possible (not while the motorcycle is in motion) and adjust as necessary. Do not carry heavy or bulky items on a luggage rack. They are designed for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces. . Do not install accessories or carry baggage that impairs the performance of the motorcycle. Make sure that you have not adversely affected any lighting components, road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any other aspect of the motorcycle's operation. 277. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in an unsafe riding condition @ Fairings, windshields, backrests, and other large items have the capability of adversely affecting stability and handling of the motorcycle, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly designed or installed items can result in an unsafe riding condition. 9. This motorcycle was not intended to be equipped with a sidecar or to be used to tow any trailer or other vehicle. Kawasaki does not manufacture sidecars or trailers and cannot predict the effects of such accessories on handling or stability, but can only wam that the effects can be adverse and that Kawasaki cannot assume responsibility 28 for the results of such unintended use of the motorcycle. Furthermore, any adverse effects on motorcycle components caused by the use of such Accessories will not be remedied under warranty. Maximum Load Weight of rider, passenger, baggage, and accessories must not exceed 155 kg (342 Ib).yoyymnmomy yyy» GENERAL INFORMATION («acm eeadeucaaKmu Speedometer The speedometer shows the speed of the vehicle. In the speedometer face are the odometer and trip meter. The odometer shows the total distance that the vehicle has been ridden. The trip meter shows the distance traveled since it was last reset to zero. The trip meter can be reset to zero by turning the reset knob counterclockwise. ‘A Speedometer C. Trip Meter B. Odometer D. Reset KnobIndicator Lights <2 : When the turn signal switch is turned to left or right, the turn signal indicator light flashes on and off. N : When the transmission is in neutral, the neutral indicator light is lit. 3D: When the headlight is on high beam, the high beam indicator light is lit. 30 A. Turn Signal Indicator Light B. Neutral indicator Light €. High Beam Indicator LightKey This motorcycle has a combination key, which is used for the ignition switch, fuel tank cap, right side cover, helmet hook and steering lock. Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a master. Record the code from the tag with your keys here. Participating Kawasaki dealers can use the code to make a new key in the event that your original keys are lost. Write your key number here. vnIgnition Switch The ignition switch is located at the left side of the frame forward the cylinder. This is a three-position, key-operated switch, The key can be removed from the switch when it is in the OFF or P (Park) position. A. Ignition Switch B. OFF position C. ON position D. P (Park) position 32 OFF Engine off. All electrical cir- cuits off. ON Engine on. All electrical ‘equipment can be used. Engine off. Taillight on. All other electrical circuits cut off. P(Park) NOTE © For parking push down the key in the ON position and turn it to P (Park) position. © The head, tail and meter lights are on whenever the ignition key is in the ON position. To avoid battery discharge, always start the engine immediately after turning the ignition key to "ON". © If you leave the P (Park) position on for a long time (one hour), the battery may become totally discharged.Right Handlebar Switches Engine Stop Switch In addition to the ignition switch, the engine stop switch must be in the “Q” position for the motorcycle to operate. The engine stop switch is for emergency use. If some emergency requires stopping the engine, move the engine stop switch to the “ §%” position. NOTE © Although the engine stop switch stops the engine, it does not tum off the electrical circuits. Oridinarily, the ignition switch should be used to stop the engine. ‘A. Engine Stop Switch B. Starter Button Starter Button The starter button operates the electric starter when pushed with the clutch lever pulled in or the transmission in neutral. Refer to the Starting the Engine section of the "How to Ride the Motorcycle" chapter for starting instructions.Left Handlebar Switches Dimmer Switch High or low beam can be selected with the dimmer switch. When the headlight is on high beam (#0), the high beam indicator light is lit. High beam ....... Low beam A. Dimmer Switch B. Turn Signal Switch C. Horn Button Turn Signal Switch When the turn signal switch is tured to left (<2) or right (>), the corresponding turn signals flash on and off. To stop flashing, push the switch in. Horn Button When the horn button is pushed, the horn sounds.Fuel Tank Cap To open the fuel tank cap, insert the ignition key into the lock and turn the key to the right. To close the cap, push it down into place with the key inserted. The key can be removed by tuming it counterclockwise to the original position. NOTE O The tank cap cannot be closed without the key inserted, and the key cannot be removed unless the cap is locked properly. | © Do not push the cap down with the key, or the cap cannot be locked. A. Ignition Key B. Fuel Tank Cap 35Fuel Tank The following octane rating gasoline is recommended in the fuel tank. Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. @® @ 0) of SZ 1. Tank Cap 2. Fuel Tank 3. Top Level 4. Fillter Neck AWARNING Gasoline is extremely flammable and can be explosive under certain condi- tions. Turn the ignition key to "OFF". Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.CAUTION California models only: Never fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and flow into the Evaporative Emission Control System resulting in hard starting and Octane Rating Method | Minimum | Rating Antiknock Index on ven # Research Octane Number (RON), 91 engine hesitation. Fuel Requirements: Fuel Type Use clean, fresh unleaded gasoline with a 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 or "knocking". The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON) as shown in the table. CAUTION If engine "knocking" or "pinging" oc- curs, use a different brand of gasoline of @ higher octane rating. If this condition is allowed to continue it can lead to severe engine damage. Gasoline quality is important. Fuels of low quality or 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. 37Fuels Containing Oxygenates Gasoline frequently contains oxygen- ates (alcohols and ethers) especially in areas of the U.S. and Canada which are required to sell such reformulated fuels as part of a strategy to reduce exhaust emis- ‘sions. The types and volume of fuel oxygen- ates approved for use in unleaded gaso- line by the US Environmental Protection Agency include a broad range of alcohols and ethers, but only two com- ponents have seen any significant level of commercial use. Gasoline/Alcohol Blends — Gasoline containing up to 10% ethanol (alcohol Produced from agricultural products such as corn), also known as "gasohol" is ap- proved for use. CAUTION Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever possible, and never use “gasohol" containing more than 5% methanol, Fuel system damage and performance problems may result. Gasoline/Ether Blends — The most common ether is methyl tertiary buty! ether (MTBE). You may use gasoline containing up to 15% MTBE. NOTE © Other oxygenates approved for use in unleaded gasoline 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 tating lower than the minimum specified by Kawasaki. Never use "gasohol" with more than 10% ethanol, or more than 5% metha- nol. Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors. Certain ingredients of gasoline may cause paint fading or damage. Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling. When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer {such as STA-BIL) with the gasoline in the fuel tank. Fuel stabilizer additives inhibit oxydation of the fuel which minimizes gummy deposits. Never store this product with "gasohol" in the fuel system. Before storage it is recommended that you drain all fuel from the fuel tank and carburetors. See the Storage section in this manual. Fuel Tap The fuel tap is an automatic type which shuts off the fuel supply when the engine is stopped in the ON or RES position. A. Fuel Tap B. ON position ©. PRI position D. RES position The fuel tap has three positions: ON, RES (reserve), and PRI (prime). If the fuel runs out with the tap in the ON position, turn the tap lever to PRI, leave it for a few seconds, and then turn it to 39RES. The last 2.5 L (0,66 US gal) of fuel can be used by turning the fuel tap lever to the RES position. The PRI position bypasses the auto- matic control and is useful for priming the engine after running out of gas, or for completely draining the fuel tank. NOTE © Since riding distance is limited when on RES, refuel at the earliest opportunity. © Make certain that the fuel tap lever is tumed to ON (Not RES) after filling up the fuel tank. 0 To start a cold engine atter the motor- cycle has been stored for a long time, first turn the tap lever to PRI, leave it fora moment, and return it to ON. PNW) Practice operating the fuel tap with the motorcycle stopped. To prevent an accident you should be able to operate the fuel tap while riding without taking your eyes off the road. Be careful not to touch the hot engine while operating the fuel tap. Do not leave the fuel tap in the PRI (prime) position while riding or parking the motorcycle. The engine may become flooded or fuel may spill onto the ground and create a fire hazard, if the vehicle falls over.Side Stand NOTE The motorcycle is equipped with aside 4 The motorcycle is equipped with a side stand. stand switch. This switch is designed 80 that the engine stops if the clutch is engaged with the transmission in any gear when the side stand has been left down. A. Side Stand NOTE © When using the side stand, turn the handlebar to the left. Whenever the side stand is used, make it a practice to kick the stand fully up before sitting on the motorcycle. a4Helmet Hook A helmet can be secured to the mo- torcycle using the helmet hook. The helmet hook can be unlocked by inserting the ignition key into the lock, and turning the key to the right. AWARNING Do not ride the motorcycle with a hel- met attached to the hook. The helmet could cause an accident by distracting the operator or interfering with normal vehicle operation. 42 A. Helmet HookSide Covers The left and right side covers are removed for the air cleaner element cleaning and battery charging. To open the right side cover, insert the ignition key into the lock, turn the key to the right, and pull the right side cover backward. A. Right Side Cover B. Ignition Key To remove the left side cover, unscrew the side cover mounting screws, and pull the side cover backward. A. Left Side Cover B. ScrewsTool Kit Compartment The tool kit compartment with a lid is provided behind the right side cover. Store the tool kit in this compartment. The minor adjustment and replacement of part explained in this manual can be performed with the tools in the kit. A. Tool Kit Compartment Lid B. Tool Kit Steering Lock The motorcycle is equipped with the steering lock at the right side of the head pipe. To lock the steering: Turn the handlebar to the left. Push open the key hole cover. . Insert the ignition key. . Turn the key to the left . Push the key in turning the handlebar slightly to the right, and turn the key to the right. Pull the key out. anova ° FINNS) Unlock the steering before starting the engine. Attempting to drive with the steering locked could cause an acci- dent.A. Steering LockPPYMMMMMMMMMYNMDVNMMMMMMD BREAKIN CCECKKEKEMEEEEEKMMEEEEEEE The first 1,600 km (1,000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down" instead of a “broken in” motorcycle after a few thousand kilometers. The following rules should be observed during the break-in period. @ The table shows maximum recommended vehicle speed in km/h (mph) during the break-in period. km/h (mph) , Gear position | ss | and | ard | atn | sth Distance traveled B= ] e 14 24 31 7 42 eee eee ) ale (23) | (6) 23 35 47 55 63 800 ~ 1,600 km (500 ~ 1,000 mi) (14) | (22) | (29) | (34) | (39)NOTE © When operating on public roadways, keep maximum speed under traffic law limits. © Do not start moving or race the engine immediately after starting it, even if the engine is already warm. Run the engine for two or three minutes at idle speed to give the oil a chance to work up into all the engine parts. ® Do not race the engine while the transmission is in neutral. New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. During break-in, avoid sudden and maximum braking and acceleration, and hard cornering. In addition to the above, at 1,000 km (600 mi) it is extremely important that the owner have the initial maintenance service performed by a competent mechanic following the procedures in the Service Manual. 47»»»ym»nynny»»»D» HOW TO RIDE THE MOTORCYCLE «accnccaaaccand Starting the Engine e@Tum the fuel tap lever to the ON position. : A. Engine Stop Switch B. Starter Button C. Ignition Switch D. ON position A. ON position @ Make certain the transmission is in © Check that the engine stop switch is in neutral. the "CQ" position. Turn the ignition key to "ON". 48A. Neutral Indicator Light A. Choke Lever @lf the engine is cold, push down the NOTE ition). : choke lever all the way (ON postion) © When the engine is already warm or on hot days [35°C (95°F) or more], close the throttle completely and do not use the choke for siarting the engine. © Leaving the throttle completely closed, push the starter bution. 49CAUTION Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. NOTE Olf the engine is tlooded, crank the engine over with the throttle fully open uniil the engine starts. © The motorcycle is equipped with a starter lockout switch. This switch prevents the electric starter from operating when the clutch is engaged and the transmission is not in neutral. A. Clutch Lever B. Starter Lockout Switch © Gradually pull the choke lever up a little at a time as necessary to keep the engine running properly during warm- up. @ When the engine is warmed up enough to idle without using the choke, pull the choke lever all the way up.NOTE © If you drive the motorcycle before the engine is warmed up, pull the choke lever all the way up as soon as you start moving. CAUTION Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. Jump Starting if your motorcycle battery is “run down", it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. CLS) Battery acid generates hydrogen gas which is flammable and explosive under certain conditions. It is present within a battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away from the battery. Wear eye protection when working with a battery. In the event of battery acid contact with skin, eyes, or clothing, wash the affected areas immediately with water for at least five minutes. Seek medical attention. 51Connecting Jumper Cables @ Remove the right side cover. @ Make sure the ignition key is turned to "OFF". Connect a jumper cable from the positive (+) terminal of the booster battery to the positive (+) battery terminal of the motorcycle battery. Positive (+) Terminal ittery Positive (+) B, From Booster Terminal C. Unpainted Metal Surface D. From Booster Battery Negative (-) Terminal 52 ‘© Connect another jumper cable from the negative (—) terminal of the booster battery to your motorcycle rear brake pedal or other unpainted metal surface. Do not use the negative (-) terminal of the battery. AWARNING Do not make this last connection at the carburetor or battery. Take care that you do not touch the positive and neg- ative cables together, and do not lean ‘over the battery when making this last connection. Do not jump start a frozen battery. It could explode. Do not reverse polarity by connecting Positive (+) to negative (-) or a battery explosion and serious damage to the electrical system may occur. Follow the standard engine starting procedure.CAUTION Moving Off Do not operate the starter continuousl © Check that the side stand is up. y © Pull i lutch lever, for more than 6 seconde or the startet Pull in the clutch lever. © Shift into 1st gear. dro termeat anc the pattery power will | @ Open the throttle a litle, and start to let between each operation of the starter to out the clutch lever very slowly. let teool and the battery powerresever, | © As the clutch starts to engage, open the throttle a little more, giving the engine Just enough fuel to keep it from stalling. @ After the engine starts, disconnect the jumper cables. Disconnect the negative (©) cable from the motorcycle first. @ Install the right side cover. A. Shift PedalNOTE ©The motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine stops if the clutch is engaged with the transmission in gear when the side stand has been left down. Shifting Gears ®@Close the throttle while pulling in the clutch lever. @ Shift into the next higher or lower gear. @Open the throttle part way, while releasing the clutch lever. AWARNING When shifting down to a lower gear, do not shift at such a high speed that the engine r/min (rpm) jumps excessively. Not only can this cause engine damage, but the rear wheel may skid and cause an accident. Downshifting should be done below the vehicle speeds is for each gear shown in the table.km/h (mph) Sth — 4th 50 (31) 4th — Sid 40 (25) 3rd + 2nd 30 (19) 2nd — ist 2013) | Braking © Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. @ Shift down one gear at a time so that you are in 1st gear when you come to a complete stop. @When stopping, always apply both brakes at the same time. Normally the front brake should be applied a little more than the rear. Shift down or fully disengage the clutch as necessary to keep the engine from stalling. @ Never lock the brakes, or it will cause the tires to skid. When turing a comer, it is better not to brake at all. Reduce your speed before you get into the comer. For emergency braking, disregard downshifting, and concentrate on applying the brakes as hard as possible without skidding,A. Front Brake Lever 56Stopping the Engine Close the throttle completely. © Shift the transmission into neutral. @ Tur the ignition key to “OFF”. © Support the motorcycle on a firm, level surface with the side stand. © Lock the steering. Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to provide you optimum safety and convenience. However, in order to fully benefit from Kawasaki's safety engineering and craftsmanship, it is essential that you, the owner and operator, properly maintain your motorcycle and become thoroughly familiar with its operation. Improper maintenance can create a dangerous situation known as throttle failure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air Cleaner may allow dirt and dust to enter the 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 57disengaging the clutch. Once this stopping procedure is initiated, the engine stop switch may be used to stop the engine. If the engine stop switch is used, turn off the ignition switch after stopping the motorcycle. Parking © Shift the transmission into neutral and tum the ignition key to “OFF”. Support the motorcycle on a firm, level surface with the side stand. CAUTION Do not park on a soft or steeply inclined surface or the motorcycle may fall over. © If parking inside a garage or other structure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this includes any appliance with a pilot light. AWARNING Gasoline is extremely can be explosive ui condition:© Lock the steering to help prevent theft. NOTE © When stopping near traffic at night, you can leave the taillight on for greater visibility by turing the ignition key to the P (Park) position. © Do not leave the ignition switch at P Position too long, or the battery will discharge. 59»ymopy»mmonoyony»yon»” SAFE OPERATION Safe Riding Technique EMME MME MME The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a helmet are strongly recommended. Gloves and suitable footwear should also be used for added protection in case of amishap. A motorcycle does not provide the impact protection of an automobile, so defensive riding in addition to wearing protective apparel is extremely important. Do not let protective apparel give you a false sense of security. Before changing lanes, look over your shoulder to make sure the way is clear. Do not rely solely on the rear view mirror; you may misjudge a 60 vehicle's distance and speed, or you may not see it at all. When going up steep slopes, shift to a lower gear so that there is plenty of power to spare rather than overloading the engine. When applying the brakes, use both the front and rear brakes. Applying only one brake for sudden braking may cause the motorcycle to skid and lose control. When going down long slopes, control vehicle speed by closing the throttle. Use the front and rear brakes for auxiliary braking.On rainy days, rely more on the throttle to control vehicle speed and less on the front and rear brakes. The throttle should also be used judiciously to avoid skidding the rear wheel from too rapid acceleration or deceleration. Riding at the proper rate of speed and avoiding unnecessarily fast acceleration are important not only for Safety and low fuel consumption but also for long vehicle life and quieter operation. When riding in wet conditions or on loose roadway surfaces, the ability to maneuver will be reduced. All of your actions should be smooth under these conditions. Sudden acceleration, braking or turning may cause loss of control. On rough roads, exercise caution, slow down, and grip the fuel tank with the knees for better stability. When quick acceleration is ne- cessary as in passing, shift to a lower gear to obtain the necessary power. Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrewing. Avoiding unnecessary weaving is important to the safety of both the rider and other motorists. 61Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habit- ual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motorcycle to a safe operating condition. Failure to perform these checks every day before you ride may result in serious damage or a severe accident. Fuel Adequate supply in tank, no leaks. Engine oi Oil level between level lines. Tires... : .sussuAit Pressure (when cold) Front 150 kPa (1.5 kgicm®, 21 psi) Rear 175 kPa (1.75 kg/om?, 25 psi) Install the air valve cap. 62Drive chain Nuts, bolts, fasteners Steering... Brakes..... Throttle Clutch .. Electrical equipment Engine stop switch Side stand... Slack 25 ~ 40 mm (1.0 ~ 1.6 in.). Check that steering and suspension components, axles, and all ontrols are properly tightened or fastened. Action smooth but not loose from lock to lock. No binding of contro! cables. No brake fluid leakage. Brake pedal play 20 ~ 30 mm (0.8 ~ 1.2in.). Brake pad wear: Lining thickness more than 1 mm (0.04 in.) left. Brake lining wear: Indicator within "USABLE RANGE". Throttle grip play 2 ~ 3 mm (0.08 ~ 0.12 in.). Clutch lever play 2 ~ 3 mm (0.08 ~ 0.12 in.). Clutch lever operates smoothly. All lights and horn work. Stops engine. Returns to its fully up position by spring tension, Return spring not weak or not damaged. 63»»»»»m»»ynnym” MAINTENANCE AND ADJUSTMENT ««cacaccaaaccad The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. If you are in doubt as to any adjustment or vehicle operation, please ask your authorized Kawasaki dealer to check the motorcycle. Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect maintenance or improper adjustment done by the owner. 64EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicle sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into the combustion chamber, where they are burned along with the fuel and air supplied by the carburetors. 2, Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. High Altitude Performance Adjustment Information High altitude adjustment is not required for this motorcycle. MAINTENANCE AND WARRANTY Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels. This Owner's Manual contains those maintenance recommendations for your motorcycle. Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards. ‘As the owner of this motorcycle, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. The Kawasaki Limited Emission Control System Warranty requires that you return your motorcycle to an authorized Kawasaki dealer for remedy under warranty.Please read the warranty carefully, and keep it valid by complying with the owner's obligations it contains. You should keep a maintenance record for your motorcycle. To assist you in keeping this record, we have provided space on pages 132 through 136 of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, bills, etc., as verification of this maintenance. 67TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the re- moval or rendering inoperative by any person other than for purposes of mainte- nance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. ‘Among those acts presumed to constitute tampering are the acts listed below: Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. Removal of the muffler (s) or any internal portion of the muffler (s). Removal of the air box or air box cover. Modifications to the mulffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.Periodic Maintenance Chart Odometer Reading km(miy Whichever Fresney | a ~ S S/ESYES Operati 4 SIES Sy SS peration SL oytn oN Boog JSTOR AY Pago Idle speed-adjust e e e oe | a7 Throttle grip play—checkT e e e @ | 34 g ‘Spark plug-clean and gap T @i|;@l|elj;e!le|;e|7 @|K Valve clearance—check t e e e@ | 7% 51k Air suction valve check t @elele|le|]e|e|s I Air cleaner element-clean?# e e @ | 3 iG] Evaporative emission control Bystom (G) check el/elelel/e|e]|e | Cylinder head bolts tightness =cheokt | © = evil i: Brake play—checkt @l|e|le/!e|e|e|e | io Brake light switch—checkt elelelele|lele |i Brake lining or pad wear terete elelelelele|sa Brake fluid level—check T month @le@el|ele;e|e|s K Brake fluid—change 2years e 99 69Frequency Operation Which comes first WOdometer Reading _km(mi) 7320, K Brake hose, connections-check 1] K Fuel hose, connections-check f| Clutch-adjust K Steering-check t Drive chain wear~check T# Nut, bolt, and fastener tighiness—checkt K Spoke tightness and rim runoult-check" Tire wear-check t Engine oil-change # Non-Emission Related Oilfilter-replace K General lubrication—perform K Front fork ol—change 2years| Front fork oil leak—chack T Rear shock absorber il leak—check @ |elel\e\e\e|e|e | @ \ele\e|e\e| <7 70Whichor > Odometer Reading _km(mi) comes fst = VES S Ss g SSVSL/SE Operation POS yo/vn fe Every /NN/ORS NON K Swingarm pivot-lubricate e Ek Stesring stom bearing-lubrcata 2years [ 2K Master cylinder cup and dust eS soak replace 4years 3] K Caliper piston seal and dust a Nea repace years 5 [K Brake cable-replace 2years | __Drive chain-lubricate # Every 600 km (400 mi) Drive chain slack—check t# Every 1,000 km (600 mi) K : Should be serviced by an authorized Kawasaki dealer. % 1 For higher odometer readings, repeat at the frequency interval established here. t Replace, add, adjust, or torque if necessary. # Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, oF frequent starting/stopping. (C) : California model only 71Engine Oil 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 long. PN ZAGNIGd Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result In engine or transmission seizure, accident, and injury. Oil Level Inspection @ 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. CAUTION Racing the engine before the oil reaches every part can cause engine seizure. @ If the motorcycle has just been used, wait several minutes for all the oil to drain down. Check the engine oil level through the oil level gauge. With the motorcycle held level, the oil level should come up between the lines next to the gauge.A. OilFiller Cap —_C. Upper Level B. Oil Level Gauge D. Lower Level ‘@ If the oil level is too high, remove the excess oil, using a syringe or some other suitable device, through the oil filler opening. @ If the oil level is too low, add the oil to reach the correct level. Use the same type and brand of oil that is already in the engine. Oil and/or Oil Filter Change, Oil Screen Cleaning Warm up the engine thoroughly, and then stop the engine. @ Place an oil pan beneath the engine. ‘@ Remove the engine drain plug. A. Drain Plug Let the oil completely drain with the motorcycle perpendicular to the ground. 73FCT © Replace the oil filter element with a new one. Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling @ If the oil filter is to be changed, remove the oil filter element cap. A. Oil Filter Element B. Spring © Apply a little engine oil to the grommet. © Install the oil fitter element cap with the bolts. ® After the oil has completely drained out, install the engine drain plug with its A. Oil Filter Element Cap gasket. Pioper torque for ft ieshown in B. Bolts the table. 74NOTE © Replace the damaged gasket with a new one. Tightening Torque Engine Drain Plug: 15 ~ 20N-m (1.5 ~ 2.0 kg-m, 11.0 ~ 14.5 ft-lb) the oil screen is to be cleaned, clean it in a bath of a high flash-point solvent. Remove the oil screen as follows. © Disconnect the rear brake light switch lead connector. © Unscrew the rear brake pedal bracket mounting bolts, and take off the rear brake pedal bracket with the brake pedal and rear brake light switch. A. Rear Brake Light Switch B. Rear Brake Pedal Bracket CC. Mounting Bolts © Remove the oil screen cap by taking off the two bolts and pull out the oil screen. 75A. Oil Screen 76 @ Install the oil screen into the crankcase with the UP mark facing up. © Install the oil screen cap with the bolts. @ Install the parts removed. © Fill the engine up to the upper level with a good quality motor oil specified in the table. @ Check the oil level. Recommended Engine Oil Type: APISE, SF or SG API SH or SJ with JASO MA Viscosity: SAE 10W-40 Engine Oil Capacity Capacity: 1.1L (1.2 US qt) [when filter is not removed] 1.2L (1.3 US qt) [when filter is removed] 4.4L (1.5 US at) [when engine is completely dry]Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. [Sa 2oW-50 [sae 20W-a0 SAE TOW-50 SKE T0W-40 SAE oW-30 io 2630 ace Tat ee Se Thosezaoz ¢ Spark Plug The standard spark plug is shown in the table. The spark plug should be taken out in accordance with the Periodic Maintenance Chart for _ cleaning, inspection, and resetting of the plug gap. Maintenance If the plug is oily or has carbon built up on it, have it cleaned, preferably in a sand-blasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other 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. NOTE © Fit the plug cap securely onto the spark plug, and pull the cap lightly to make sure that it is properly installed. 71@® A. 0.7 ~ 0.8 mm (0.028 ~ 0.032 in.) Spark Plug Standard _| NGK CR7E Plug 0.7 - 0.8mm Gap ~ (0.028 ~ 0.032 in.) Tightening | 13 N-m Torque (1.3 kg-m, 9.4 ftb) NOTE © For demanding high speed operation, install spark plug with one heat colder range NGK CRE or ND U24ESR-N. 78 Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. CAUTION If valve clearance is left unadjusted, wear will eventually cause the valves to remain partly open; which lowers performance, burns the valves and valve seats, and 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 only by a competent mechanic following the instructions in the Service Manual.Evaporative Emission Control System (California model only) This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart. Inspection @Check that the hoses are securely connected. @ Replace any kinked, deteriorated, or damaged hoses. VACUUM HOSE ROUTING DIAGRAM 79Kawasaki Clean Air System The Kawasaki Clean Air System (KCA) is a secondary air suction system that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust system, it is still hot enough to burn. The KCA System allows extra air into the exhaust system 0 that the spent fuel charge can continue to burn. This continued buming action tends to burn up a great deal of the normally unburned gases, as well as changing a significant portion of the poisonous carbon monoxide into harmless carbon dioxide. Air Suction Valve: The air suction valve is essentially a check valve which allows fresh air to flow only from the air cleaner into the exhaust port. Any air that has passed the air suction valve is prevented from returning. Inspect the air suction valve in accordance with the Periodic Mainte- nance Chart. Also, inspect the air suction 80 valve whenever stable idling cannot be obtained, engine power is greatly reduced, or there are abnormal engine noises. Air suction valve removal and inspection should be done by a competent mechanic following the instructions in the Service Manual.Air Cleaner A clogged air cleaner restricts the engine's air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. The air cleaner element must be cleaned in accordance with the Periodic Maintenance Chart. In dusty areas, the element should be cleaned more frequently than the recommended interval. Aiter riding through rain or on muddy roads, the element should be cleaned immediately. The element should be replaced if it is damaged. Element Removal @ Remove the left side cover. @ Unscrew the air cleaner cover mount- ing screws, and remove the air cleaner cover. A. Screws B. Air Cleaner Cover © Pull out the element from the housing. 81A. Element @ Put a clean, lint-free towel over the air cleaner housing to keep dirt or other foreign material from entering. @ Inspect the element material for dam- age. If any part of the element is dam- aged, the element must be replaced. 82 If dirt or dust is allowed to pass through into the carburetor, the throttle may be- come stuck, possibly causing accident. CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. NOTE © Element installation is performed in the reverse order of removal. Element Cleaning Clean the element in a bath of a high flash-point solvent. © Dry the element with compressed air or squeeze it.@ After cleaning, saturate the element with SE, SF or SG class SAE 10W-40 motor oil, squeeze out the excess, then wrap it in a clean rag and squeeze it as. dry as possible. Be careful not to tear the element. A.WARNING Clean the element in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low fiash-point solvent to clean the element. A fire or explosion could result. Oil Draining @Inspect the transparent reservoir located on the bottom of the air cleaner housing. ‘A. Reservoir B. Plug if there is any oil in the reservoir, remove the plug from the lower end of the reservoir and drain the oil. PNAS) Be sure to install the plug on the reser- voir after draining. Oil on tires will make them slippery and can cause an accident and injury. 83Dust and/or Water Inspection ‘@ Remove the drain tube on the bottom of the air cleaner housing to expel dust and/or water accumulated inside. A. Drain Tube Throttle Grip The throttle grip controls the throttle valve. If the throttle grip has excessive play due to either cable stretch or malad- justment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Check the throttle grip play in accordance with the Periodic Maintenance Chart, and adjust the play if necessary. Inspection © Check that there is 2 ~ 3 mm (0.08 ~ 0.12 in.) throttle grip play when lightly turning the throttle grip back and forth. © if there is improper play, adjust it.A. Throttle Grip B.2~3 mm (0.08 ~ 0.12 in.) Adjustment @ Loosen the locknut at the throttle grip, and turn the cable adjuster until the proper amount of throttle grip play is obtained. A. Locknut B. Adjuster C. Throttle Cable (Accelerator Cable) Tighten the locknut. @lf the throttle cables can not be adjusted by using the cable adjuster at the throttle grip, use the upper and lower nuts at the lower ends of the throttle cables.@ Loosen the locknut at the throttle grip and turn in the adjuster fully. @ Tighten the locknut. @ Turn the upper and lower nuts at the lower end of the decelerator cable until there is no play when the throttle grip is completely closed. Tighten the nuts. Tur the upper and lower nuts at the lower end of the accelerator cable until 2 ~ 3 mm (0.08 ~ 0.12 in.) of throttle grip play is obtained. Tighten the nuts. ‘A. Upper Nuts B. Lower Nuts C. Decelerator Cable D. Accelerator Cable PAWNS} Operation with improperly adjusted, incorrectly routed, or damaged cables could result in’ an unsafe riding condition.Carburetor The carburetor idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed. The following procedure covers the idle speed adjustment. Adjustment @Start the engine, and warm it up thoroughly. ® Adjust the idle speed to 1,200 ~ 1,400 f/min (rpm) by turning the idle adjusting screw, A. Idle Adjusting Screw @ Open and close the throttle a few times to make sure that the idle speed does not change. Readjust if necessary. @With the engine idling, turn the handlebar to each side. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or they may be damaged. Be sure to correct any of these conditions before riding. 87Clutch Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accordance with the Periodic Maintenance Chart. PINGING) Operation with damaged cables could result in an unsafe riding conditiot CNG To avoid a serious burn, never touch a hot engine or an exhaust pipe during clutch adjustment. Inspection @Check that the clutch lever has 2 ~ 3 mm (0.08 ~ 0.12 in.) of play as shown in the figure.AAWARNING Be sure the upper end of the clutch ‘outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch di- engagement, resulting in a hazardous riding condition. @ Tighten the locknut. @ If it cannot be done, use the mounting nuts at the lower end of the clutch A. Adjuster me B. Locknut C. 2~ 3 mm (0.08 ~ 0.12 in.) if the play is incorrect, adjust the lever play as follows. ‘Adjustment ‘@ Loosen the locknut at the clutch lever. Turn the adjuster so that the clutch lever will have 2 ~ 3 mm (0.08 ~ 0.12 in.) of play.A. Mounting Nuts NOTE © After the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly. © For minor corrections, use the adjuster at the clutch lever. Drive Chain The drive chain must be checked, adjusted, and lubricated in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the chain becomes badly wom or malad- justed — either too loose or too tight — the chain could jump off the sprockets or break. AWARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, se- verely damaging the motorcycle and causing it to go out of control. Chain Slack Inspection ‘@ Set the motorcycle up on its side stand. © Rotate the rear wheel to find the posi- tion where the chain is tightest, and measure the maximum chain slack by pulling up and pushing down the chain midway between the engine sprocket and rear wheel sprocket.A. 25 ~ 40 mm (1.0 ~ 1.6 in.) @ If the drive chain is too tight or too loose, adjust it so that the chain slack will be within the standard value. Drive Chain Slack 25 ~ 40 mm Standard (1.0~1.8in) Chain Slack Adjustment @ Loosen the rear torque link nut. CAUTION Do not forget to loosen the torque link nut. 91‘A. Torque Link Nut A. Axle Nut C. Adjusting Nut B. Safety Clip B. Cotter Pin D. Locknut @ Loosen the left and right chain adjuster @ If the chain is too loose, tum in the left locknuts. and right chain adjusting nuts evenly. Remove the cotter pin, and loosen the © If the chain is too tight, turn out the left axle nut. and right chain adjusting nuts evenly, and kick the wheel forward. @Turn in both chain adjusting nuts evenly until the drive chain has the correct amount of slack. To keep the rear end of the left swingarm window should align with the same swingarm 92mark that the rear end of the right swingarm window aligns with. |. Rear end of the swingarm window . Locknut . Adjusting Nut NOTE © Wheel alignment can also be checked using the straightedge or string method. AWARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. @ Tighten both chain adjuster locknuts, and make sure the axle stays aligned. © Center the brake panel assembly in the brake drum. This is done by tightening the axle lightly, spinning the wheel, and depressing the brake pedal forcefully. The partially tightened axle allows the brake panel assembly to center itself within the brake drum. 93NOTE © This procedure can prevent a soft or “spongy feeling” brake. @ Tighten the axle nut to the specified torque. Tightening Torque Axle Nut 98 N-m (10 kg-m, 72 ft-b) 34 .N-m (3.5 kg-m, 25 ft-lb) Torque Link Nut © Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary. © Insert a cotter pin through the axle nut and axle, and spread its ends. @ Tighten the rear torque link nut to the specified torque. AAWARNING If the axle or torque link nut is not securely tightened, or safety clip or cotter pin is not installed, an unsafe riding condition may result. @ Check the rear brake (see the Brakes section). Wear Inspection @ Stretch the chain taut either by using the chain adjusters, or by hanging a 10 kg (20 Ib) weight on the chain. ®@ Measure the length of 20 links on the straight part of the chain from pin center of the 1st pin to pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places.B. Weight A. Measure @\f the length exceeds the service limit, the chain should be replaced. Drive Chain 20-Link Length Service Limit: 259 mm (10.2 in.) PUN ed For safety, use only the standard chait Have the drive chain installed by thorized Kawasaki dealer @ Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links, @ Also inspect the sprockets for unevenly or excessively worn teeth, and damaged teeth. NOTE © Sprocket wear is exaggerated for illustration. See Service Manual for wear limits. 95‘Sprocket ‘Wor Tooth Wom Tooth (Engine Sprocket) (Roar Sprocket) fH fmm Direction of rotation If there is any irregularity, have the drive chain and/or the sprockets replaced by an authorized Kawasaki dealer. Lubrication Lubrication is also necessary after rid- ing through rain or on wet roads, or any time that the chain appears dry. A heavy oil such as SAE 90 is preferred to a lighter cil because it will stay on the chain longer and provide better lubrication. 96 @ Apply oil to the sides of the rollers so that it will penetrate to the rollers and bushings. Wipe off any excess oil. © if the chain is especially dirty, clean it using diesel oil or kerosine and then apply oil as mentioned above.Brakes Brake Wear Inspection In accordance with the Periodic Main- tenance Chart, inspect the brakes for wear. For the front disc brake caliper, if the thickness of either pad is less than 1 mm (0.04 in,), replace both pads in the caliper as a set. Pad replacement should be done by an authorized Kawasaki dealer. ot A. Lining Thickness B. 1mm (0.04 in) On the rear brake panel is a brake lining wear indicator. If the brake lining wear indicator does not point within the USABLE RANGE when the brake is fully applied, the brake shoe linings have worn past the service limit. In this case, the brake shoes must be replaced and the drum and other brake parts examined by an authorized Kawasaki dealer. A. USABLE RANGE B. Brake Lining Wear Indicator 97Disc Brake Fluid: In accordance with the Periodic Main- tenance Chart, inspect the brake fluid level in the brake fluid reservoir for the front brake and change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Fluid Requirement Use only heavy-duty brake fluid from a container marked DOT4. 98 CAUTION Do not spill brake fluid onto any painted surface. Do not use fiuid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the fittings, Check brake hose for damage. Fluid Level Inspection @With the brake fluid reservoir held horizontal, the brake fluid level must be kept between the upper and lower level line.A. Brake Fluid Reservoir B. Lower Level Line C. Upper Level Line @ If the fluid level in the reservoir is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. PINE e} Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must refilled but the type and brand of brake fluid that is already in the reservoir are unidentified. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Front Brake: Disc and disc pad wear is automatically compensated for and has no effect on the brake lever action. So there are no parts that require adjustment on the front brake.PING) If the brake lever feels mushy when it is applied, there might be air in the brake lines or the brake may be defective. Since it is dangerous to operate the motorcycle under such conditions, have the brake checked immediately by an authorized Kawasaki dealer. Rear Brake: Brake pedal position can be adjusted to suit you. In accordance with the Periodic Maintenance Chart, inspect the brake pedal play. Pedal Position Inspection When the brake pedal is in its rest position, it should be 80 mm (3.15 in.) higher than the top of the footpeg. 100 ‘A. Rear Brake Pedal 0 mm (3. @ If it is not, adjust the pedal position. Pedal Position Adjustment @Loosen the locknut, and turn the adjusting bolt to adjust the pedal position. Tighten the locknut.B. Locknut A. Adjusting Bolt Check the brake pedal piay and oper- ation of the rear brake light switch. Pedal Play Inspection @The brake pedal should have 20 ~ 30 mm (0.8 ~ 1.2 in.) of play when the pedal is pushed down lightly by hand. A. Rear Brake Pedal B. 20 ~ 30 mm (0.8 ~ 1.2 in.) @ Rotate the wheel to check for brake drag. Operate the pedal a few times to see that it retums to its rest position imme- diately upon release. @ Check braking effectiveness. © If the pedal has improper play, adjust it. 101Pedal Play Adjustment Tum the adjusting nut at the brake cam lever so that the pedal has 20 ~ 30 mm (0.8 ~ 1.2in.) of play. A. Adjusting Nut 102 Brake Light Switches When either the front of rear brake is applied, the brake light goes on. The front brake light switch requires no adjustment, but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart. Inspection ‘© Tur the ignition key to "ON". © The brake light should go on when the front brake is applied. lf 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 15 mm (0.6 in.) of pedal travel. © If it does not, adjust the rear brake light ‘switch,‘A. Rear Brake Pedal B. 15 mm (0.6 in.) Adjusiment To adjust the rear brake light switch, move the switch up or down by turning the adjusting nut. CAUTION To avoid damaging the electrical con- nections inside the switch, be sure that the switch body does not turn during adjustment. A. Rear Brake Light Switch B. Adjusting Nut C. Lights sooner D. Lights later 103Rear Shock Absorbers Spring Adjustment The spring preload adjuster on each rear shock absorber has 5 positions so that the spring can be adjusted for different road and loading conditions. A. Spring Preload Adjuster It the spring action feels too soft or too stiff, tum each spring preload adjuster by using the wrench in the tool kit in accordance with the following table: 104 Position 1[2[s[4|[s Spring Action —— Stronger AWARNING If both spring preload adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result.NOTE © Be sure to turn back the spring preload adjuster counterclockwise from posi- tion 5 when softening the spring action. Wheels Tires: Payload and Tire Pressure Failure to maintain proper inflation pres- Sures or observe payload limits for your tires may adversely affect handling and perfor- mance of your motorcycle and can result in loss of control. The maximum recom- mended load in addition to vehicle weight is 155 kg (342 Ib), including rider, passenger, baggage, and accessories. Remove the air valve cap. © Check the tire pressure often, using an accurate gauge. © Make sure that the air valve cap is securely installed. NOTE © Measure the tire pressure when the tires are cold (that is, when the motoroy- cle has not been ridden more than a mile during the past 3 hours). © Tire pressure is affected by changes in ambient temperature and altitude, and 105so the tire pressure should be checked and adjusted when your riding involves wide variations in temperature or alti- tude. A. Tire Pressure Gauge Tire Air Pressure (when cold) 150 kPa (1.5 kg/om?, 21 psi) 175 kPa (1.75 kg/em?, 25 psi) Front Rear 106 Tire. Wear, Damage As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. © In accordance with the Periodic Mainte- nance Chart, measure the depth of the tread with a depth gauge, and replace any tire that has worn down to the mini- mum allowable tread depth. Minimum Tread Depth Front 1mm (0.04 in) Rear 1mm (0.04 in)A. Tire Depth Gauge © Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage. Swelling or high spots indicate internal damage, requiring tire replace- ment. Remove any imbedded stones or other foreign particles from the tread NOTE © Most countries may have their own regu- lations requiring a minimum tire tread depth; be sure to follow them. © Have the wheel balance inspected when- ever a new tire is installed. To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. Standard Tire (Tube-type) Front Size: 90/90-17M/C 49P OIRC NFS3 © DUNLOP D404F Rear Size: 130/90-15M/C 66P. olRC NR67 ODUNLOP D404 107AWARNING Use the same manufacture's tires on both front and rear wheels. New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. During break-in, avold sudden and maximum braking and accel- eration, and hard cornering. Battery RG) Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after han- dling. Baitery Electrolyte Level Inspection The battery electrolyte level must be kept between the upper and lower level lines. Check the electrolyte level in each cell in accordance with the Periodic Maintenance Chart. ‘@ Remove the battery from the motorcy- cle (see Battery Removal). © Check that the electrolyte level in each cell is between the upper and lower level lines.—o B eo : : OLS wrun Sess yeos A. Battery Filler Caps B. Upper Level Line C. Lower Level Line D. Battery Vent Hose @If the electrolyte level is low in any cells, remove the battery filler caps and fill with distilled water until the electrolyte level in any cells reaches the upper level line. CAUTION Add only distilled water to the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery. Battery Charging @ Remove the battery from the motorcy- dle (see Battery Removal). CAUTION Always remove the battery from the motorcycle for charging. If the battery is charged while still installed, battery electrolyte may spill and corrode the frame or other parts of the motorcycle. @ Before charging, check the electrolyte level in each cell. If the electrolyte level is low in any cell, fill to above the lower level line but not up to the upper level line since the level rises during charging. 109@ Remove the caps from all the cells, and connect the battery charger leads to the battery terminals (red to +, black to PGS Because the battery gives off an ex- plosive gas mixture of hydrogen and ‘oxygen, keep any sparks or open flame away from the battery during charging. When using a battery charger, connect the battery to the charger before turn- ing on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. 110 C. () Terminal D. (4) Terminal A. Battery Charger B. Filler Caps Charge the battery at a rate that is 1/10th of the battery capacity. For ex- ample, the charging rate for a 10Ah battery would be 1.0 ampere.CAUTION Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charging rate can be reduced to the level required for motorcycle batteries. Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can wrap the plates and cause internal shorting. Higher-than-normal charging tates also cause the plates to shed active meterial. will accumulate, and can cause internal shorting. If the temperature of the electrolyte rises above 45'C (115'F) during charging, Teduce the charging rate to lower the temperature, and increase charging time proportionately. After charging, check the electrolyte level in each cell. If the level has fallen, add distilled water to bring it back up to the upper level line. @ Install the caps on the cells. @ Install the battery. Battery Removal ‘@ Remove the right side cover. © Unscrew the battery holder screws and take off the battery holder. 1