2009 KLX 250 Owners Manual

Quick Reference GuideGENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

This Quick Reference Guide willassist you in finding the informationyou’re looking for.

A Table of Contents is included afterthe Foreword.

Whenever you see the symbolsshown below, heed their instructions!Always follow safe operating and main-tenance practices.

WARNINGThis warning symbol identifiesspecial instructions or proce-dures which, if not correctly fol-lowed, could result in personalinjury, or loss of life.

CAUTIONThis caution symbol identifiesspecial instructions or proce-dures which, if not strictly ob-served, could result in damageto or destruction of equipment.

NOTE○This note symbol indicates points ofparticular interest for more efficientand convenient operation.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,and continuous striving for superior reliability, safety and performance.

Please read this Owner’s Manual carefully before riding so that you will bethoroughly familiar with the proper operation of your motorcycle’s controls, its fea-tures, capabilities, and limitations. This manual offers many safe riding tips, but itspurpose is not to provide instruction in all the techniques and skills required to ridea motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-cle enroll in a motorcycle rider training program to attain awareness of the mentaland physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care andmaintenance described in this manual. For those who would like more detailed in-formation on their Kawasaki Motorcycle, a Service Manual is available for purchasefrom any authorized Kawasaki motorcycle dealer. The Service Manual contains de-tailed disassembly and maintenance information. Those who plan to do their ownwork should, of course, be competent mechanics and possess the special toolsdescribed in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you canrefer to it whenever you need information.

This manual should be considered a permanent part of the motorcycle and shouldremain with the motorcycle when it is sold.

All rights reserved. No part of this publication may be reproduced without ourprior written permission.

This publication includes the latest information available at the time of printing.However, there may be minor differences between the actual product and illustra-tions and text in this manual.All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.Consumer Products & Machinery Company

© 2008 Kawasaki Heavy Industries, Ltd. Jan. 2008. (1) (CR, Ke).

TABLE OF CONTENTS

SPECIFICATIONS............................... 8SERIAL NUMBER LOCATIONS......... 12LOCATION OF PARTS ....................... 13LOCATION OF LABELS..................... 16LOADING INFORMATION .................. 19GENERAL INFORMATION ................. 22Meter Instruments ............................ 22Meter Instruments:........................ 23Tachometer Gauge: ...................... 23Speedometer : .............................. 23Odometer/Trip Meter AB/FuelWarning Message (ODO/TRIPAB): ........................................... 24

Indicator/Warning Light:................ 28Key................................................... 29Ignition Switch/Steering Lock........... 30Right Handlebar Switches................ 31Engine Stop Switch: ..................... 31Starter Button: .............................. 32

Left Handlebar Switches .................. 32

Dimmer Switch: ............................ 32Turn Signal Switch:....................... 33Horn Button: ................................. 33

Fuel Tank Cap.................................. 33Fuel Tank ......................................... 34Fuel Requirement: ........................ 35

Fuel Tap ........................................... 39Stand................................................ 40Helmet Hook .................................... 41Tool Kit Bag/Tool Kit ......................... 42Seat.................................................. 42

BREAK-IN ........................................... 44HOW TO RIDE THE MOTORCYCLE . 46Starting the Engine .......................... 46Jump Starting ................................... 49Moving Off........................................ 52Shifting Gears .................................. 53Braking............................................. 55Stopping the Engine......................... 56

Stopping the Motorcycle in anEmergency ................................... 57

Parking............................................. 58Catalytic Converter........................... 59

SAFE OPERATION............................. 61Safe Riding Technique ..................... 61Daily Safety Checks......................... 63Additional Considerations for OffRoad Operation ............................ 65

MAINTENANCE ANDADJUSTMENT 66Periodic Maintenance Chart............. 71Engine Oil ........................................ 81Cooling System................................ 86Spark Plugs...................................... 91Kawasaki Clean Air System............. 92Evaporative Emission ControlSystem (California model only)..... 93

Valve Clearance ............................... 94Air Cleaner ....................................... 95Throttle Grip ..................................... 100Carburetors ...................................... 103

Clutch............................................... 104Spark Arrester .................................. 107Drive Chain ...................................... 108Brakes.............................................. 114Brake Light Switches........................ 118Front Fork......................................... 120Rear Shock Absorber....................... 123Wheels ............................................. 125Battery.............................................. 129Headlight Beam................................ 134Fuses ............................................... 136General Lubrication.......................... 137Cleaning Your Motorcycle ................ 139Bolt and Nut Tightening.................... 143

STORAGE ........................................... 145TROUBLESHOOTING GUIDE............ 148OWNER SATISFACTION.................... 149REPORTING SAFETY DEFECTS ...... 151ENVIRONMENTAL PROTECTION ..... 152MAINTENANCE RECORD ................. 153LABEL INFORMATION ...................... 158

8 SPECIFICATIONS

SPECIFICATIONS

DIMENSIONSOverall Length 2 200 mm (86.62 in.)

Overall Width 820 mm (32.28 in.)

Overall Height 1 205 mm (47.44 in.)

Wheelbase 1 430 mm (56.30 in.)

Road Clearance 285 mm (11.22 in.)

Dry Weight 126 kg (278 lb)

ENGINEType DOHC, single-cylinder, 4-stroke, liquid-cooled

Displacement 249 cm³ (15.2 cu in.)

Bore x Stroke 72.0 × 61.2 mm (2.83 × 2.41 in.)

Compression Ratio 11.0 : 1

Starting System Electric starter

Carburetors KEIHIN CVK34

Ignition System CDI

SPECIFICATIONS 9

Ignition Timing(Electronically advanced)

10° BTDC @1 300 r/min (rpm) ∼ 25° BTDC @5 000r/min (rpm)

Spark Plugs NGK CR8E

Lubrication System Forced lubrication (wet sump)

Engine Oil

Type: API SE, SF or SG

API SH, SJ or SL with JASO MA

SAE 10W-40

Capacity: 1.5 L (1.6 US qt)

Coolant Capacity 1.3 L (1.4 US qt)

TRANSMISSIONTransmission Type 6-speed, return shift

Clutch Type Wet, multi disc

Driving System Chain drive

Primary Reduction Ratio 2.800 (84/30)

Final Reduction Ratio 3.000 (42/14)

Overall Drive Ratio 8.000 (Top gear)

10 SPECIFICATIONS

Gear Ratio

1st 3.000 (30/10)2nd 2.000 (30/15)3rd 1.500 (27/18)4th 1.250 (25/20)5th 1.050 (21/20)6th 0.952 (20/21)

FRAMECastor 26.5°

Trail 105 mm (3.31 in.)

Tire Size:

Front 3.00-21 51P

Rear 4.60-18 63P

Rim Size:

Front 21 × 1.60

Rear 18 × 2.15

Fuel Tank Capacity 7.7 L (2.04 US gal)

SPECIFICATIONS 11

ELECTRICAL EQUIPMENTBattery 12 V 6 Ah

Headlight 12 V 60/55 W

Tail/Brake Light 12 V 5/21 W

Turn Signal Light 12 V 21 W

Specifications subject to change without notice.

12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. Theyare the only means of identifying your particular machine from others of the samemodel type. These serial numbers may be needed by your dealer when orderingparts. In the event of theft, the investigating authorities will require both numbersas well as the model type and any peculiar features of your machine that can helpthem identify it.

Frame No.

A. Frame Number

Engine No.

A. Engine Number

LOCATION OF PARTS 13LOCATION OF PARTS

1. Clutch Lever2. Meter Instruments3. Brake Fluid Reservoir (Front)4. Front Brake Lever

5. Left Handlebar Switches6. Ignition Switch/Steering Lock7. Right Handlebar Switches8. Throttle Grip

14 LOCATION OF PARTS

9. Front Fork10. Headlight11. Turn Signal Light12. Fuel Tank Cap13. Fuel Tank14. Choke Knob15. Fuel Tap

16. Rear Shock Absorber17. Tool Kit Bag18. Tool Kit19. Helmet Hook20. Brake Disc21. Brake Caliper22. Radiator

23. Horn24. Shift Pedal25. Side Stand26. Side Stand Switch27. Drive Chain28. Coolant Reserve Tank29. Battery

LOCATION OF PARTS 15

30. License Plate Light31. Tail/Brake Light32. Muffler33. Seat34. Air Cleaner Element35. Carburetor

36. Idle Adjusting Screw37. Front Brake Light

Switch38. Radiator Cap39. Brake Fluid Reservoir

(Rear)

40. Rear Brake LightSwitch

41. Oil Level Gauge42. Rear Brake Pedal43. Speedometer Cable

16 LOCATION OF LABELS

LOCATION OF LABELS

1. Brake Fluid (Front)2. Important Drive Chain Information3. Tire and Load Data

(For further information of label,refer to the “LABEL INFORMATION”chapter.)

LOCATION OF LABELS 17

4. Brake Fluid (Rear)5. Weight and Manufacture6. Vehicle Emission Control Information7. Daily Safety Cheeks*8. Vacuum Hose Routing Diagram


*: Only on California model

18 LOCATION OF LABELS

9. Noise Emission Control Information*10. Fuel Level11. Battery Poison/Danger


*: Only on California model

LOADING INFORMATION 19LOADING INFORMATION

WARNINGIncorrect loading, improper in-stallation or use of accessories,or modification of your motorcy-cle may result in an unsafe rid-ing condition. Before you ridethe motorcycle, make sure thatthe motorcycle is not overloadedand that you have followed theseinstructions.

With the exception of genuineKawasaki Parts and Accessories,Kawasaki has no control over thedesign or application of accessories.In some cases, improper installationor use of accessories, or motorcyclemodification, will void the motorcycle

warranty. In selecting and using acces-sories, and in loading the motorcycle,you are personally responsible for yourown safety and the safety of other per-sons involved.

NOTE○Kawasaki Parts and Accessorieshave been specially designed foruse on Kawasaki motorcycles. Westrongly recommend that all partsand accessories you add to yourmotorcycle be genuine Kawasakicomponents.

Because a motorcycle is sensitive tochanges in weight and aerodynamicforces, you must take extreme carein carrying cargo, passengers and/orin the fitting of additional accessories.

20 LOADING INFORMATION

The following general guidelines havebeen prepared to assist you in makingyour determinations.

1. Any passenger should be thor-oughly familiar with motorcycle op-eration. The passenger can affectcontrol of the motorcycle by im-proper positioning during corneringand sudden movements. It is impor-tant that the passenger sit still whilethe motorcycle is in motion and notinterfere with the operation of themotorcycle. Do not carry animalson your motorcycle.

2. You should instruct any passengerbefore riding to keep his feet on thepassenger footpegs and hold on tothe operator, seat strap or grab rail.Do not carry a passenger unless heor she is tall enough to reach thefootpegs and footpegs are provided.

3. All baggage should be carried aslow as possible to reduce the effecton the motorcycle center of gravity.Baggage weight should also be dis-tributed equally on both sides of themotorcycle. Avoid carrying baggagethat extends beyond the rear of themotorcycle.

4. Baggage should be securely at-tached. Make sure that the baggagewill not move around while you areriding. Recheck baggage securityas often as possible (not while themotorcycle is in motion) and adjustas necessary.

5. Do not carry heavy or bulky items ona luggage rack. They are designedfor light items, and overloading canaffect handling due to changes inweight distribution and aerodynamicforces.

LOADING INFORMATION 21

6. Do not install accessories or carrybaggage that impairs the perfor-mance of the motorcycle. Makesure that you have not adverselyaffected any lighting components,road clearance, banking capability(i.e., lean angle), control operation,wheel travel, front fork movement,or any other aspect of the motorcy-cle’s operation.

7. Weight attached to the handlebar orfront fork will increase the mass ofthe steering assembly and can re-sult in an unsafe riding condition.

8. Fairings, windshields, backrests,and other large items have the ca-pability of adversely affecting stabil-ity and handling of the motorcycle,not only because of their weight, butalso due to the aerodynamic forcesacting on these surfaces while themotorcycle is in operation. Poorly

designed or installed items can re-sult in an unsafe riding condition.

9. This motorcycle was not intendedto be equipped with a sidecar or tobe used to tow any trailer or othervehicle. Kawasaki does not manu-facture sidecars or trailers for mo-torcycles and cannot predict the ef-fects of such accessories on han-dling or stability, but can only warnthat the effects can be adverse andthat Kawasaki cannot assume re-sponsibility for the results of suchunintended use of the motorcycle.Furthermore, any adverse effects onmotorcycle components caused bythe use of such accessories will notbe remedied under warranty.

Maximum LoadWeight of rider, passenger, baggage,and accessories must not exceed 181 kg(399 lb).

22 GENERAL INFORMATIONj GENERAL INFORMATION

Meter Instruments

A. MODE ButtonB. RESET ButtonC. Tachometer GaugeD. Odometer/Trip Meter

AB/Fuel Warning MessageE. SpeedometerF. ClockG. Coolant Temperature

Warning LightH. High Beam Indicator LightI. Neutral Indicator LightJ. Turn Signal Indicator LightK. Red Zone

GENERAL INFORMATION 23j

Meter Instruments:The meter displays all segments for

a few seconds when the ignition key isturned to “ON”. The tachometer mo-mentarily goes from the minimum tothe maximum, then goes back from themaximum to the minimum reading tocheck its operation. If any meter instru-ments or tachometer does not operateor display correctly, have it checked byan authorized Kawasaki dealer.

Tachometer Gauge:The tachometer shows the engine

speed in revolutions per minute (r/min,rpm). On the right side of the tachome-ter face is a portion called the “redzone”. Engine r/min (rpm) in thered zone is above maximum recom-mended engine speed and is alsoabove the range for good performance.

NOTE○This motorcycle is equipped with theengine speed limitter to prevent theexcesive high engine speed. Whenoperating this limitter, the segmentsof the tachometer indicate the differ-ent engine speed and stops at about5000 r/min (rpm) for the ignition con-trol, but this operation is not a failure.

CAUTIONEngine r/min (rpm) should notbe allowed to enter the red zone;operation in the red zone willoverstress the engine and maycause serious engine damage.

Speedometer :The speedometer shows the speed

of the vehicle in digital values.

24 GENERAL INFORMATIONj

Odometer/Trip Meter AB/FuelWarning Message (ODO/TRIPAB):

This meter displays the odometer,the trip meter AB, and the fuel warningmessage.The odometer and the trip meter AB

can be shifted pushing the MODE but-ton.

A. OdometerB. Trip meter AC. Trip meter BD. MODE Button

NOTE○Do not shift the odometer/trip meterwhile riding for safe operation.

Odometer -The odometer shows the total dis-

tance in kilometers or miles that the ve-hicle has been ridden. This meter can-not be reset.

NOTE○The data is maintained even if thebattery is disconnected.

○When the figures come to 999999,they are stopped and locked.

Trip Meters A/B -The trip meter shows the distance in

kilometers or miles traveled since it waslast reset to zero.To reset the trip meter:

GENERAL INFORMATION 25j• Push the MODE button to display the

trip meter A or B.• Push the RESET button and hold itin.• After two second, the figure displayturns to 0.0, and then starts countingwhen the vehicle is operated. Themeter counts until it is next reset.

NOTE○The data is maintained by the back-up power if the ignition key is turnedoff.

○When the trip meter reaches 999.9(TRIP A) or 9999.9 (TRIP B) whileriding, the meter resets to 0.0 andcontinues counting.

○When the battery is disconnected,the meter display resets to 0.0.

Mile/Km Display:Mile/Km Display can alternate be-

tween English and metric modes (mphand km/h) in the meter unit. Make surethat km/h or mph according to localregulations is correctly displayed be-fore riding.

26 GENERAL INFORMATIONj NOTE

○Do not operate the vehicle withthe meter unit displaying in thewrong unit (km/h or mph). Shiftthe km/h·mph display in the meterunit as follows.

• Display the odometer.• The km/h·mph display shifts by push-ing the RESET button while theMODE button pushed in.

A. Km/h·Mph Display

• The km/h/mph display shifts as fol-lows.

A. Km/hB. MphC. Push RESET Button with MODE Button in

NOTE○The data is maintained even if thebattery is disconnected.

Clock:To adjust hours and minutes:• Turn the ignition key to “ON”.• Push the RESET button for morethan two seconds. Both the hour andminute displays start flashing.


• Push the RESET button. The hourdisplay only flashes. Push theMODE button to advance the hours.

• Push the RESET button. The hourdisplay stops flashing and the minutedisplay starts flashing. Push theMODE button to advance the min-utes.

• Push the RESET button. Both thehour and minute displays start flash-ing again.• Push the MODE button. The dis-plays stop flashing and the clockstarts working.

NOTE○Pushing the MODE button momen-tarily advances the hour or minutestep by step. Pushing and hold-ing the button advances the hour orminute continuously.

○The clock works normally from theback-up power while the ignitionswitch is turned off.

28 GENERAL INFORMATIONj ○When the battery is disconnected,

the clock resets to 1:00 and startsworking again when the battery isconnected.

Indicator/Warning Light:N : When the transmission is in neutral,the neutral indicator light is lit.

: When the turn signal switch isturned to left or right, the turn signalindicator light flashes on and off.

: When the headlight is on highbeam, the high beam indicator light islit.

The coolant temperature warninglight goes on when the ignition keyis turned to “ON” and goes off soonafter ensuring that its circuit function

properly. The warning light also goeson whenever the coolant temperaturerises too high when the motorcycle isin operation. If it stays on, stop theengine and check the coolant level inthe reserve tank after the engine coolsdown.

CAUTIONDo not let the engine continuerunning when the warning lightgoes on. Prolonged engine op-eration will result in severe dam-age from overheating.

GENERAL INFORMATION 29jKey

This motorcycle has a combinationkey, which is used for the ignitionswitch/steering lock, helmet hook, andfuel tank cap.Blank keys are available at your

Kawasaki dealers. Ask your dealer tomake any additional spare keys youmay need, using your original key as amaster.Record the code from the tag with

your keys here. Participating Kawasakidealers can use the code to make anew key in the event that your originalkeys are lost.

Write your key number here.

30 GENERAL INFORMATIONj Ignition Switch/Steering Lock

This is a three-position, key-operatedswitch. The key can be removed fromthe switch when it is in the OFF orLOCK position.

A. Ignition Switch/Steering LockB. ON positionC. OFF positionD. LOCK position

ON Engine on. All electricalequipment can be used.

OFF Engine off. All electricalcircuits off.

LOCK Steering locked. Engine off.All electrical circuits off.

NOTE○The headlight and taillight are onwhenever the ignition key is in theON position. To avoid battery dis-charge, always start the engine im-mediately after turning the ignitionkey to "ON".

To lock the steering:1. Turn the handlebar fully to the left.2. For locking, push down the key inthe OFF position and turn it to Lockposition.

3. Pull the key out.

GENERAL INFORMATION 31jNOTE

○If the steering is hard to lock, turn thehandlebar slightly to the left or theright.

Right Handlebar SwitchesEngine Stop Switch:In addition to the ignition switch, the

engine stop switch must be in theposition for the motorcycle to operate.The engine stop switch is for emer-

gency use. If some emergency re-quires stopping the engine, push theengine stop switch to the position.

NOTE○Although the engine stop switchstops the engine, it does not turn offall the electrical circuits. Ordinarily,the ignition switch should be used tostop the engine.


Starter Button:The starter button operates the elec-

tric starter when the transmission is inneutral.Refer to the Starting the Engine sec-

tion of the "How to Ride the Motorcycle"chapter for starting instructions.

A. Engine Stop SwitchB. Starter Button

Left Handlebar SwitchesDimmer Switch:High or low beam can be selected

with the dimmer switch. When theheadlight is on high beam , thehigh beam indicator light is lit.High beam.......( )Low beam.......( )

A. Dimmer SwitchB. Turn Signal SwitchC. Horn Button


Turn Signal Switch:When the turn signal switch is turned

to the left or right , the corre-sponding 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 CapTo open the fuel tank cap, insert the

ignition key into the fuel tank cap, turnthe key to the right.To close the cap, push it down into

place with the key inserted. The keycan be removed by turning it to the leftto the original position.

A. Ignition KeyB. Fuel Tank Cap

34 GENERAL INFORMATIONj NOTE

○The fuel tank cap cannot be closedwithout the key inserted, and the keycannot be removed unless the cap islocked properly.

○Do not push on the key to close thecap, or the cap cannot be locked.

Fuel TankThe following octane rating gasoline

is recommended in the fuel tank. Avoidfilling the tank in the rain or whereheavy dust is blowing so that the fueldoes not get contaminated.

A. Tank CapB. Fuel TankC. Top LevelD. Filler Neck


WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions. Turn the igni-tion key to "OFF". Do not smoke.Make sure the area is well ven-tilated and free from any sourceof flame or sparks; this includesany appliance with a pilot light.Never fill the tank so the fuellevel rises into the filler neck. Ifthe tank is overfilled, heat maycause the fuel to expand andoverflow through the vents inthe tank cap.After refueling, make sure thefuel tank cap is closed securely.If gasoline is spilled on the fueltank, wipe it off immediately.

CAUTIONCalifornia models only: Neverfill the tank so the fuel level risesinto the filler neck. If the tank isoverfilled, heat may cause thefuel to expand and flow into theEvaporative Emission ControlSystem resulting in hard start-ing and engine hesitation andin compliance with the emissionregulation.

Fuel Requirement:Fuel TypeUse clean, fresh unleaded gasoline

with a minimum Antiknock Index of 87.The Antiknock Index is posted on ser-vice station pumps. The octane ratingof a gasoline is a measure of its resis-tance to detonation or "knocking." TheAntiknock Index is an average of theResearch Octane Number (RON) and


the Motor Octane Number (MON) asshown in the table.

MinimumOctane Rating Method

Rating(RON + MON)Antiknock

Index 287

CAUTIONIf engine "knocking" or "ping-ing" occurs, use a differentbrand of gasoline of a higheroctane rating. If this condition isallowed to continue it can leadto severe engine damage.Gasoline quality is important.Fuels of low quality or not meet-ing standard industry specifi-cations may result in unsatis-factory performance. Operatingproblems that result from theuse of poor quality or nonrecom-mended fuel may not be coveredunder your warranty.

Fuels Containing OxygenatesGasoline frequently contains oxy-

genates (alcohols and ethers) espe-cially in areas of the U.S. and Canada


which are required to sell such refor-mulated fuels as part of a strategy toreduce exhaust emissions.The types and volume of fuel oxy-

genates approved for use in unleadedgasoline by the U.S. EnvironmentalProtection Agency include a broadrange of alcohols and ethers, but onlytwo components have seen any signif-icant level of commercial use.Gasoline/Alcohol Blends - Gasoline

containing up to 10% ethanol (alco-hol produced from agricultural productssuch as corn), also known as "gasohol"is approved for use.

CAUTIONAvoid using blends of unleadedgasoline and methanol (woodalcohol) whenever possible, andnever use "gasohol" contain-ing more than 5% methanol.Fuel system damage and perfor-mance problems may result.

Gasoline/Ether Blends - The mostcommon ether is methyl tertiary butylether (MTBE). You may use gasolinecontaining up to 15% MTBE.

NOTE○Other oxygenates approved for usein unleaded gasoline include TAME(up to 16.7 %) and ETBE (up to17.2 %). Fuel containing these oxy-genates can also be used in yourKawasaki.

38 GENERAL INFORMATIONj CAUTION

Never use gasoline with an oc-tane rating lower than the mini-mum specified by Kawasaki.Never use "gasohol" with morethan 10% ethanol, or more than5% methanol. Gasoline con-taining methanol must also beblended with cosolvents andcorrosion inhibitors.Certain ingredients of gasolinemay cause paint fading or dam-age. Be extra careful not to spillgasoline or gasoline oxygenateblends during refueling.When not operating yourKawasaki for 30 to 60 days, mix afuel stabilizer (such as STA-BIL)with the gasoline in the fuel tank.Fuel stabilizer additives inhibitoxidation of the fuel which mini-mizes gummy deposits.

CAUTIONNever store this product with"gasohol" in the fuel system.Before storage it is recom-mended that you drain all fuelfrom the fuel system. See theStorage section in this manual.

GENERAL INFORMATION 39jFuel Tap

The fuel tap has three positions:OFF, ON, and RES (reserve). For no-mal operation, turn the tap lever to theON position. If the fuel runs out withthe tap in the ON position, the last 1.9L (0.50 US gal) of fuel can be used byturning the fuel tap lever to RES.

A. Fuel TapB. ON positionC. OFF positionD. RES position

NOTE○Since riding distance is limited whenon RES, refuel at the earliest oppor-tunity.

○Make certain that the fuel tap lever isturned to ON (Not RES) after fillingup the fuel tank.

WARNINGPractice operating the fuel tapwith the motorcycle stopped. Toprevent an accident you shouldbe able to operate the fuel tapwhile riding without taking youreyes off the road.Be careful not to touch the hotengine while operating the fueltap.

40 GENERAL INFORMATIONj Stand

The motorcycle is equipped with aside stand.

A. Side Stand

NOTE○When using the side stand, turn thehandlebar to the left.

Whenever the side stand is used,make it a practice to kick the stand fullyup before sitting on the motorcycle.

NOTE○The motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine dose notstart if the transmission is in gear andthe side stand is left down.

GENERAL INFORMATION 41jHelmet Hook

Helmet can be secured to the motor-cycle 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.

A. Helmet Hook

WARNINGDo not ride themotorcycle with ahelmet attached to the hook. Thehelmet could cause an accidentby distracting the operator or in-terfering with normal vehicle op-eration.

42 GENERAL INFORMATIONj Tool Kit Bag/Tool Kit

The tool kit is stored in the tool kitbag.The kit contains tools that can be

helpful in making roadside repairs, ad-justments, and some maintenance pro-cedures explained in this manual.

A. Tool KitB. Tool Kit Bag

SeatSeat Removal• Remove the mounting bolts.

A. SeatB. Mounting Bolts

• Remove the seat band and pull theseat up and to the rear.


A. BoltB. SeatC. Tandem Band

Seat Installation• Align the front hook with the front re-ceiver and slide the seat forward.• Slide the seat forward so that thecenter hook and the center receiverengages.

A. SeatB. Front HookC. Front ReceiverD. Center HookE. Center Receiver

• Tighten the tandem band bolts.• Pull up the rear end of the seat tomake sure it is securely tightened.• Reinstall the parts removed.

44 BREAK-IN

BREAK-IN

The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as thebreak-in period. If the motorcycle is not used carefully during this period, you mayvery well end up with a "broken down" instead of a "broken in" motorcycle after afew thousand kilometers.The following rules should be observed during the break-in period.• The table shows maximum recommended engine speed during the break-in pe-riod.Distance traveled Maximum engine speed

0 ∼ 800 km (0 ∼ 500 mi) 4 000 r/min (rpm)

800 ∼ 1 600 km (500 ∼ 1 000 mi) 6 000 r/min (rpm)

• Do not start moving or race the engine immediately after starting it, even if theengine is already warm. Run the engine for two or three minutes at idle speed togive the oil a chance to work up into all the engine parts.• Do not race the engine while the transmission is in neutral.

BREAK-IN 45

WARNINGNew tires are slippery and may cause loss of control and injury.A break-in period of 160 km (100 miles) is necessary to establish normaltire traction. During break-in, avoid sudden and maximum braking andacceleration, and hard cornering.

In addition to the above, at 1 000 km (600 mi) it is extremely important that theowner have the initial maintenance service performed by an authorized Kawasakidealer.

46 HOW TO RIDE THE MOTORCYCLE

j

HOW TO RIDE THE MOTORCYCLE

Starting the Engine• Turn the fuel tap lever to "ON".

A. Fuel TapB. ON position

• Check that the engine stop switch isin the position.

A. Engine Stop SwitchB. Starter Button

HOW TO RIDE THE MOTORCYCLE 47

j• Turn the ignition key to "ON".• Make certain the transmission is inneutral.

A. Neutral Indicator LightB. Ignition SwitchC. ON position

• If the engine is cold, pull out thechoke knob all the way.

A. Choke Knob

NOTE○When the engine is already warm oron hot days (35°C, 95°F or more),close the throttle completely withoutusing the choke knob, and then startthe engine.


j• Leaving the throttle completelyclosed, push the starter button.

CAUTIONDo not operate the starter con-tinuously for more than 5 sec-onds or the starter will overheatand the battery power will droptemporarily. Wait 15 secondsbetween each operation of thestarter to let it cool and the bat-tery power recover.

NOTE○If the engine is flooded, crank the en-gine over with the throttle fully openuntil the engine starts.

○The motorcycle is equipped with astarter lockout switch. This switch isdesigned so that the engine does notstart if the transmission is in gear and

the side stand is down. However, theengine can be started if the clutchlever is pulled and the side stand isfully up.

A. Clutch LeverB. Starter Lockout Switch

• When the engine is warmed upenough to idle without using thepush, return the choke knob all theway back.


jNOTE

○If you drive the motorcycle before theengine is warmed up, push the chokeknob all the way back as soon as youstart moving.

CAUTIONDo not let the engine idle longerthan five minutes, or engineoverheating and damage mayoccur.

Jump StartingIf your motorcycle battery is "run

down", it should be removed andcharged. If this is not practical, a 12volt booster battery and jumper cablesmay be used to start the engine.


jWARNING

Battery acid generates hydro-gen gas which is flammable andexplosive under certain con-ditions. It is present within abattery at all times, even in adischarged condition. Keep allflames and sparks (cigarettes)away from the battery. Wear eyeprotection when working with abattery. In the event of batteryacid contact with skin, eyes, orclothing, wash the affected ar-eas immediately with water for atleast five minutes. Seek medicalattention.


jConnecting Jumper Cables• Remove the left side cover.• Make sure the ignition switch isturned "OFF".• Connect a jumper cable from thepositive (+) terminal of the boosterbattery to the positive (+) terminal ofthe motorcycle battery.

A. Motorcycle Battery Positive (+) TerminalB. From Booster Battery Positive (+) TerminalC. Unpainted Metal SurfaceD. From Booster Battery Negative (–)

Terminal

• Connect another jumper cable fromthe negative (–) terminal of thebooster battery to your motorcy-cle foot peg or other unpainted metalsurface. Do not use the negative (–)terminal of the battery.

WARNINGDo not make this last connec-tion at the carburetor or battery.Take care that you do not touchthe positive and negative cablestogether, and do not lean overthe battery whenmaking this lastconnection. Do not jump start afrozen battery. It could explode.Do not reverse polarity by con-necting positive (+) to negative(−), or a battery explosion andserious damage to the electricalsystem may occur.


j• Follow the standard engine startingprocedure.

CAUTIONDo not operate the starter con-tinuously for more than 5 sec-onds or the starter will overheatand the battery power will droptemporarily. Wait 15 secondsbetween each operation of thestarter to let it cool and the bat-tery power recover.

• After the engine has started, discon-nect the jumper cables. Disconnectthe negative (−) cable from the mo-torcycle first.• Reinstall the parts removed.

Moving Off• Check that the side stand is up.• Pull in the clutch lever.• Shift into 1st gear.• Open the throttle a little, and start tolet out the clutch lever very slowly.• As the clutch starts to engage, openthe throttle a little more, giving the en-gine just enough fuel to keep it fromstalling.

A. Shift Pedal


jNOTE

○The motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine does notstart if the transmission is in gear andthe side stand is down.

Shifting Gears• Close the throttle while pulling in theclutch lever.• Shift into the next higher or lowergear. For smooth riding, shift up ordown when the motorcycle is oper-ated the speeds shown in the tablebelow.

WARNINGWhen shifting down to a lowergear, do not shift at such a highspeed that the engine r/min(rpm) jumps excessively. Notonly can this cause engine dam-age, but the rear wheel may skidand cause an accident. Down-shifting should be done below 5000 r/min (rpm) for each gear.

• Open the throttle part way, while re-leasing the clutch lever.


jVehicle speed when shifting

Shifting up km/h (mph) Shifting down km/h (mph)1st → 2nd 15 ( 9) 6th → 5th 30 (19)2nd → 3rd 25 (15) 5th → 4th 25 (15)3rd → 4th 35 (21) 4th → 3rd 20 (12)4th → 5th 45 (27) 3rd → 2nd 15 ( 9)5th → 6th 55 (34) 2nd → 1st 15 ( 9)


jBraking• Close the throttle completely, leav-ing the clutch engaged (except whenshifting gears) so that the engine willhelp slow down the motorcycle.• Shift down one gear at a time so thatyou are in 1st gear when you cometo a complete stop.• When stopping, always apply bothbrakes at the same time. Normallythe front brake should be applied a lit-tle more than the rear. Shift down orfully disengage the clutch as neces-sary to keep the engine from stalling.• Never lock the brakes, or it will causethe tires to skid. When turning a cor-ner, it is better not to brake at all. Re-duce your speed before you get intothe corner.

• For emergency braking, disregarddownshifting, and concentrate onapplying the brakes as hard as pos-sible without skidding.

A. Front Brake Lever


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A. Rear Brake Pedal

Stopping the Engine• Close the throttle completely.• Shift the transmission into neutral.• Turn the ignition key to "OFF".• Support the motorcycle on a firmlevel surface with the side stand.• Lock the steering.• Turn the fuel tap lever to the OFFposition.


jStopping the Motorcycle in an

EmergencyYour Kawasaki Motorcycle has been

designed and manufactured to pro-vide you optimum safety and conve-nience. However, in order to fully ben-efit from Kawasaki’s safety engineeringand craftsmanship, it is essential thatyou, the owner and operator, properlymaintain your motorcycle and becomethoroughly familiar with its operation.Improper maintenance can create adangerous situation known as throt-tle failure. Two of the most commoncauses of throttle failure are:1. An improperly serviced or cloggedair cleaner may allow dirt and dustto enter the carburetor and stack thethrottle open.

2. During removal of the air cleaner,dirt is allowed to enter and jam thecarburetor.

In an emergency situation such asthrottle failure, your vehicle may bestopped by applying the brakes anddisengaging the clutch. Once thisstopping procedure is initiated, the en-gine stop switch may be used to stopthe engine. If the engine stop switch isused, turn off the ignition switch afterstopping the motorcycle.


jParking• Shift the transmission into neutraland turn the ignition key to "OFF".• Support the motorcycle on a firm,level surface with the side stand.

CAUTIONDo not park on a soft or steeplyinclined surface, or the motorcy-cle may fall over.

• If parking inside a garage or otherstructure, be sure it is well ventilatedand the motorcycle is not close toany source of flame or sparks; thisincludes any appliance with a pilotlight.

WARNINGThe muffler and exhaust pipeare very hot while the engine isrunning and just after the enginestops. This can ignite a fire, re-sulting in property damage orsevere personal injury.Do not idle or park your vehi-cle in an area where flammablematerials such as grasses or dryleaves may contact with muffleror exhaust pipe.

WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions.

• Lock the steering to help preventtheft.


j• Turn the fuel tap lever to the OFFposition.

Catalytic ConverterThis motorcycle is equipped with

a catalytic converter in the exhaustsystem. Platinum and rhodium in theconverter react with carbon monoxideand hydrocarbons to convert them intocarbon dioxide and water resulting inmuch cleaner exhaust gases to be dis-charged into the atmosphere.For proper operation of the catalytic

converter, the following cautions mustbe observed.


jWARNING

The muffler and exhaust pipeare very hot while the engine isrunning and just after the enginestops. This can ignite a fire, re-sulting in property damage orsevere personal injury.Do not idle or park your vehi-cle in an area where flammablematerials such as grasses or dryleaves may contact with muffleror exhaust pipe.

• Use only unleaded gasoline. Neveruse leaded gasoline. Leaded gaso-line significantly reduces the capabil-ity of the catalytic converter.

• Do not coast the vehicle with the igni-tion switch and/or engine stop switchoff. Do not attempt to start the en-gine by rolling the vehicle if the bat-tery is discharged. Do not operatethe vehicle with the engine or anyone cylinder misfiring. Under theseconditions unburned air/fuel mixtureflowing out of engine excessively ac-celerates reaction in the converter al-lowing the converter to overheat andbecome damaged when the engineis hot, or reduces converter perfor-mance when the engine is cold.

SAFE OPERATION 61

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SAFE OPERATION

Safe Riding TechniqueThe 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 ahelmet are strongly recommended.Gloves and suitable footwearshould also be used for added pro-tection in case of a mishap.

A motorcycle does not providethe impact protection of an auto-mobile, so defensive riding in addi-tion to wearing protective apparelis extremely important. Do not letprotective apparel give you a falsesense of security.

Before changing lanes, look overyour shoulder to make sure the wayis clear. Do not rely solely on therear view mirror; you may misjudgea vehicle’s distance and speed, oryou may not see it at all.

When going up steep slopes, shiftto a lower gear so that there is plentyof power to spare rather than over-loading the engine.

When applying the brakes, useboth the front and rear brakes. Ap-plying only one brake for sudden

62 SAFE OPERATION

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braking may cause the motorcycleto skid and lose control.

When going down long slopes,control vehicle speed by closingthe throttle. Use the front and rearbrakes for auxiliary braking.

On rainy days, rely more on thethrottle to control vehicle speed andless on the front and rear brakes.The throttle should also be used ju-diciously to avoid skidding the rearwheel from too rapid acceleration ordeceleration.

Riding at the proper rate of speedand avoiding unnecessarily fast ac-celeration are important not only forsafety and low fuel consumption butalso for long vehicle life and quieteroperation.

When riding in wet conditions oron loose roadway surfaces, the abil-ity to maneuver will be reduced. Allof your actions should be smoothunder these conditions. Sudden ac-celeration, braking or turning maycause loss of control.

On rough roads, exercise caution,slow down, and grip the fuel tankwith the knees for better stability.

When quick acceleration is neces-sary as in passing, shift to a lowergear to obtain the necessary power.

Do not downshift at too high anr/min (rpm) to avoid damage to theengine from overrevving.

Avoiding unnecessary weaving isimportant to the safety of both therider and other motorists.

SAFE OPERATION 63

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Daily Safety ChecksCheck the following items each day before you ride. The time required is minimal,

and habitual performance of these checks will help ensure you a safe, reliable ride.If any irregularities are found during these checks, refer to the Maintenance and

Adjustment chapter or see your dealer for the action required to return the motor-cycle to a safe operating condition.

WARNINGFailure to perform these checks every day before you ride may result inserious damage or a severe accident.

Fuel ............................. Adequate supply in tank, no leaks.Engine oil .................... Oil level between level lines.Tires ............................ Air pressure (when cold):

Front – – – 150 kPa (1.50 kg/cm², 22 psi)

Rear Up to 97.5 kg (215 lb)Load 150 kPa (1.50 kg/cm², 22 psi)

97.5 ∼ 181 kg (215 ∼399 lb) Load 175 kPa (1.75 kg/cm², 25 psi)

Install the air valve cap.

64 SAFE OPERATION

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Drive chain .................. Slack 35 ∼ 45 mm (1.4 ∼ 1.8 in.).Lubricate if dry

Nuts, bolts, fasteners .. Check that steering and suspension components, axles,and all controls are properly tightened or fastened.

Steering ...................... Action smooth but not loose from lock to lock. No bindingof control cables.

Brakes ........................ Brake pad wear: Lining thickness more than 1 mm (0.04in.) left.No brake fluid leakage.

Throttle ....................... Throttle grip play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).Clutch ......................... Clutch lever play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).

Clutch lever operates smoothly.Coolant ....................... No coolant leakage

Coolant level between level lines (when engine is cold).Electrical equipment ... All lights (Head, Tail/Brake, Turn Signal, Warning/Indica-

tor) and horn work.Engine stop switch ...... Stops engine.Side stands ................. Return to its fully up position by spring tension.

Return springs not weak or not damaged.

Refer to the "Daily Safety Checks" caution label attached to the back of the leftside cover.

SAFE OPERATION 65

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Additional Considerations for Off Road OperationBrakes: The importance of reliable brakes is obvious. Check to see that they

are correctly adjusted and functioning properly.Steering: Looseness in the steering can cause loss of control. Check to see that

the handlebar turns freely but has no play.Tires: Due to the extra stress to the tires on rough roads, be sure to examine

their overall condition, and inflate to the proper pressure.Drive Chain: When not adjusted properly, the severe stress on rough roads can

cause damage to the sprockets and cause the chain to be thrown. Examine thechain slack and alignment, and lubricate if necessary.Fuel: Have sufficient fuel for the high fuel consumption on rough roads.Engine Oil: To avoid seizure and resulting loss of control, make certain the oil

level is at the upper level line.Coolant: To avoid engine overheating, check that the coolant level is at the upper

level line.Miscellaneous: Check to see that the electrical equipment is functioning prop-

erly, all nuts and bolts are tight, and all safety related parts are in good condition.

66 MAINTENANCE AND ADJUSTMENT

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MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out inaccordance with the Periodic Maintenance Chart to keep the motorcycle in goodrunning condition. The initial maintenance is vitally important and must not beneglected.With a basic knowledge of mechanics and the proper use of tools, you should

be able to carry out many of the maintenance items described in this chapter. Ifyou lack proper experience or doubt your ability, all adjustment, maintenance, andrepair work should be completed by a qualified technician.Please note that Kawasaki cannot assume any responsibility for damage result-

ing from incorrect or improper adjustment done by the owner.

MAINTENANCE AND ADJUSTMENT 67

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EMISSION CONTROL INFORMATIONTo protect the environment in which we all live, Kawasaki has incorporated

crankcase emission (1) and exhaust emission (2) control systems in compliancewith applicable regulations of the United States Environmental Protection Agencyand California Air Resources Board. Additionally, Kawasaki has incorporatedan evaporative emission control system (3) in compliance with applicable regu-lations of the United States Environmental Protection Agency and California AirResources Board.

1. Crankcase Emission Control SystemThis system eliminates the release of crankcase vapors into the atmosphere.

Instead, the vapors are routed through an oil separator to the intake side of theengine. While the engine is operating, the vapors are drawn into the combustionchamber, where they are burned along with the fuel and air supplied by the car-buretors.

2. Exhaust Emission Control SystemThis system reduces the amount of pollutants discharged into the atmosphere

by the exhaust of this motorcycle. The fuel, ignition and exhaust systems of thismotorcycle have been carefully designed and constructed to ensure an efficientengine with low exhaust pollutant levels. The exhaust system of this model mo-torcycle includes a catalytic converter system.


j

3. Evaporative Emission Control SystemThe evaporative emission control system for this vehicle consists of low per-

meation fuel hoses and a fuel tank.

3. Evaporative Emission Control System (California)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 vaporseparator and returned to the fuel tank.

High Altitude Performance Adjustment InformationTo improve the EMISSION CONTROL PERFORMANCE of vehicles operated

above 4 000 feet, Kawasaki recommends the following Environmental ProtectionAgency (EPA) approved modification.

NOTE○When properly performed, these specified modifications only are not consideredto be emissions system “tampering” and vehicle performance is generally un-changed as a result.

Installation Instructions:High altitude adjustment requires replacement of certain carburetor components.

Installation of these optional parts may be performed by an authorized Kawasaki


j

dealer, or the consumer, following repair recommendations specified in the appro-priate Kawasaki Service Manual.

MAINTENANCE AND WARRANTYProper maintenance is necessary to ensure that your motorcycle will continue to

have low emission levels. This Owner’s Manual contains those maintenance rec-ommendations for your motorcycle. Those items identified by the Periodic Mainte-nance 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 thisOwner’s Manual at your own expense.The Kawasaki Limited Emission Control System Warranty requires that you re-

turn 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’sobligations it contains.You should keep a maintenance record for your motorcycle. To assist you in

keeping this record, we have provided space on pages 153 through 157 of thismanual where an authorized Kawasaki dealer, or someone equally competent, canrecord themaintenance. You should also retain copies of maintenance work orders,bills, etc., as verification of this maintenance.


j

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or the causing thereof: (1) the removal or

rendering inoperative by any person other than for purposes of maintenance, re-pair, or replacement, of any device or element of design incorporated into any newvehicle for the purpose of noise control prior to its sale or delivery to the ultimatepurchaser or while it is in use, or (2) the use of the vehicle after such device orelement 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 incompliance with Federal regulations.

* Removal of the muffler(s) or any internal portion of the muffler(s).* Removal of the air box or air box cover.* Modifications to the muffler(s) or air intake system by cutting, drilling, or othermeans if such modifications result in increased noise levels.


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Periodic Maintenance ChartK: Should be serviced by an authorized Kawasaki dealer.*: For higher odometer readings, repeat at the frequency interval established here.†: Replace, add, adjust, or torque if necessary.#: Service more frequently when operating in severe conditions: dusty, wet, muddy,high speed, or frequent starting/stopping.

e: Emission Related Item

1. Periodic Inspection (Engine Related Items)Frequency Whichever

comesfirst

*Odometer Readingkm × 1000 ( mile × 1000)

SeePage

Operation (Engine Items) Every 1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Air cleaner element - clean (e) • • • 95

Valve clearance - inspect (e) • • • 94


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1. Periodic Inspection (Engine Related Items)Frequency Whichever

comesfirst


SeePage


6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Throttle control system (play,smooth return, no drag) -inspect (e)

year • • • • 100

Idle speed - inspect (e) • • • • 103

Spark arrester - clean Every 5 000 km (3 000 mi) 107

K Fuel leak (fuel hose andpipe) - inspect year • • • • –

K Fuel hoses damage - inspect year • • • • –

K Fuel hoses installationcondition - inspect year • • • • –

Coolant level - inspect • • • • 89


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Frequency Whichevercomesfirst


SeePage


6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Coolant leak - inspect year • • • • 87

Radiator hose damage -inspect year • • • • 87

Radiator hoses installationcondition - inspect year • • • • 87

Air suction system damage -inspect (e) • • • 92

Evaporative emission controlsystem - function (Californiamodel only) (e)

• • • • • • • 93


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2. Periodic Inspection (Chassis Related Items)Frequency Whichever

comesfirst


SeePage

Operation (Chassis Items) Every 1(0.6)

6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Clutch and drive train:Clutch operation(play, engagement,disengagement) - inspect

• • • • 104

Drive chain lubricationcondition - inspect # every 600 km (400 mile) 113

Drive chain slack - inspect # every 1 000 km (600 mile) 109

Drive chain wear - inspect # • • • 111

K Drive chain guide wear -inspect • • • –

Wheels and tires:

Tire air pressure - inspect year • • • 125


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SeePage


6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Wheels/tires damage -inspect • • • 127

Tire tread wear, abnormalwear - inspect • • • 127

K Wheel bearings damage -inspect year • • • –

K Spoke tightness and rimrunout - inspect • • • • • • • –

Brake system:

Brake fluid leak - inspect year • • • • • • • 116

Brake hoses damage -inspect year • • • • • • • 116

Brake pad wear - inspect # • • • • • • 114


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SeePage


6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Brake hose installationcondition - inspect year • • • • • • • 115

Brake fluid level - inspect 6 month • • • • • • • 116

Brake operation(effectiveness, play, drag) -inspect

year • • • • • • • 117

Brake light switch operation- inspect • • • • • • • 118

Suspensions:Front forks/rear shockabsorber operation (dampingand smooth stroke) - inspect

• • • 120/123

Front forks/rear shockabsorber oil leak - inspect year • • • 120/123


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SeePage


6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

K Uni-trak rocker arm bearings- lubricate • –

K Uni-trak rocker arm operation- inspect • • • –

K Uni-trak tie rods operation -inspect • • • –

K Uni-trak tie rods bearings -lubricate • –

K Swing arm pivot - lubricate • –

Steering system:

K Steering play - inspect year • • • • –

K Steering stem bearings -lubricate 2 years • –


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SeePage


6(4)

12(7.5)

18(12)

24(15)

30(20)

36(24)

Electrical system:Lights and switches operation- inspect year • • • –

Headlight aiming - inspect year • • • 134

Side stand switch operation- inspect year • • • –

Engine stop switch operation- inspect year • • • –

Chassis:

Chassis parts - lubricate year • • • 137

Bolts and nuts tightness -inspect • • • • 143


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3. Periodic ReplacementFrequency Whichever

comesfirst


SeePage

Change/Replacement Item Every 1(0.6)

12(7.5)

24(15)

36(24)

48(30)

Air cleaner element # (e) 2 year 95

Engine oil # year • • • • • 82

Oil filter year • • • • • 82

K Fuel hoses 4 years • –

K Coolant 3 years • 90

K Radiator hoses and O-rings 3 years • –

K Brake hoses 4 years • –

K Brake fluid (front and rear) 2 years • • 117


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SeePage

Change/Replacement Item Every 1(0.6)

12(7.5)

24(15)

36(24)

48(30)

K Rubber parts of master cylinderand caliper 4 years • –

Spark plug (e) • • • • 91


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Engine OilIn order for the engine, transmission,

and clutch to function properly, main-tain the engine oil at the proper level,and change the oil and oil filter in accor-dance with the Periodic MaintenanceChart. Not only do dirt and metal par-ticles collect in the oil, but the oil itselfloses its lubricative quality if used toolong.

WARNINGMotorcycle operation with insuf-ficient, deteriorated, or contami-nated engine oil will cause accel-erated wear andmay result in en-gine or transmission seizure, ac-cident, and injury.

Oil Level Inspection• Situate the motorcycle so that it isperpendicular to the ground.

• If the oil has just been changed, startthe engine and run it for several min-utes at idle speed. This fills the oilfilter with oil. Stop the engine, thenwait several minutes until the oil set-tles.

CAUTIONRacing the engine before the oilreaches every part can cause en-gine seizure.

• If the motorcycle has just been used,wait several minutes for all the oil todrain down.• Check the engine oil level throughthe oil level gauge in the lower rightside of the engine. The oil levelshould come up between the up-per and lower level lines next to thegauge.


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• If the oil level is too high, remove theexcess oil through the oil filler open-ing using a syringe or same othersuitable device.• If the oil level is too low, add the oilto reach the correct level. Use thesame type and brand of oil that isalready in the engine.

A. Oil Level GaugeB. Upper Level LineC. Lower Level Line

Oil and/or Oil Filter Change• Warm up the engine thoroughly, andthen stop it.• Set the motorcycle up on its sidestand.• Place an oil pan beneath the engine.• Remove the engine oil drain plug.

A. Drain Plug

• Let the oil completely drain withthe motorcycle perpendicular to theground.


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WARNINGMotor oil is a toxic substance.Dispose of used oil properly.Contact your local authoritiesfor approved disposal methodsor possible recycling.

• If the oil filter is to be changed, re-move the oil filter cover bolts andtake off the cover with O-ring.

A. BoltsB. Oil Filter Cover


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• Replace the element with a new one.

A. ElementB. Grommet

• Apply a little grease around the ele-ment fence hole against the grommetside, and put the spring on the ele-ment fence hole.• Install the element with the spring sothat the spring fits into the proper po-sition.

• Apply a little engine oil to the grom-met, and install the oil filter cover andtighten its bolts.

NOTE○Install the oil filter cover while align-ing the holes of the cover.

A. Holes

• After the oil has completely drainedout, install the engine oil drain plug


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with its gasket. Proper torque for it isshown in the table.

NOTE○Replace the any gasket with a newone.

• Fill the engine up to the upper levelline with a good quality motor oilspecified in the table.• Start the engine.• Check the oil level and for oil leak-age.

Tightening TorqueEngine Oil Drain Plug:

15 N·m (1.5 kgf·m, 11 ft·lb)

NOTE○If a torque wrench is not available,this item should be serviced by aKawasaki dealer.

Recommended Engine OilType: API SE, SF or SG

API SH, SJ or SL with JASOMA

Viscosity: SAE 10W-40

Engine Oil CapacityCapacity: 1.3 L (1.4 US qt)

[when filter is not removed]1.4 L (1.5 US qt)[when filter is removed]

1.5 L (1.6 US qt)[when engine is completelydry]


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Although 10W-40 engine oil is therecommended oil for most condi-tions, the oil viscosity may need tobe changed to accommodate atmo-spheric conditions in your riding area.

Cooling SystemRadiator and Cooling Fan -Check the radiator fins for obstruc-

tion by insects or mud. Clean offany obstructions with a stream oflow-pressure water.

WARNINGKeep your hands and clothingaway from the fan blades at alltimes.


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CAUTIONUsing high-pressure water, asfrom a car wash facility, coulddamage the radiator fins and im-pair the radiator’s effectiveness.Do not obstruct or deflect air-flow through the radiator byinstalling unauthorized acces-sories in front of the radiator orbehind the cooling fan. Inter-ference with the radiator airflowcan lead to overheating and con-sequent engine damage.

Radiator Hoses -Check the radiator hoses for leakage,

cracks or deterioration, and connec-tions for leakage, or looseness eachday before riding the motorcycle, andin accordance with the Periodic Main-tenance Chart.

Coolant -Coolant absorbs excessive heat from

the engine and transfers it to the airat the radiator. If the coolant level be-comes low, the engine overheats andmay suffer severe damage. Check thecoolant level each day before ridingthe motorcycle, and in accordance withthe periodic maintenance chart, andreplenish coolant if the level is low.Change the coolant in accordance withthe Periodic Maintenance Chart.

Information for CoolantTo protect the cooling system (con-

sisting of the aluminum engine andradiator) from rust and corrosion, theuse of corrosion and rust inhibitorchemicals in the coolant is essential. Ifcoolant containing corrosion and rustinhibitor chemicals is not used, over aperiod of time, the cooling system ac-cumulates rust and scale in the water


j

jacket and radiator. This will clog upthe coolant passages, and consider-ably reduce the efficiency of the coolingsystem.

WARNINGUse coolant containing corro-sion inhibitors made specificallyfor aluminum engines and ra-diators in accordance with theinstructions of themanufacturer.Chemicals are harmful to the hu-man body.

Soft or distilled water must be usedwith the antifreeze (see below for an-tifreeze) in the cooling system.

CAUTIONIf hard water is used in the sys-tem, it causes scale accumula-tion in the water passages, andconsiderably reduces the effi-ciency of the cooling system.

If the lowest ambient temperature en-countered falls below the freezing pointof water, use permanent antifreeze inthe coolant to protect the cooling sys-tem against engine and radiator freeze-up, as well as from rust and corrosion.Use a permanent type of antifreeze

(soft water and ethylene glycol plus cor-rosion and rust inhibitor chemicals foraluminum engines and radiators) in thecooling system. On the mixture ratioof coolant, choose the suitable one re-ferring to the relation between freezingpoint and strength directed on the con-tainer.


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CAUTIONPermanent types of antifreeze onthe market have anti-corrosionand anti-rust properties. When itis diluted excessively, it loses itsanti-corrosion property. Dilute apermanent type of antifreeze inaccordance with the instructionsof the manufacturer.

NOTE○A permanent type of antifreeze is in-stalled in the cooling system whenshipped. It is colored green and con-tains ethylene glycol. It is mixed at50% and has the freezing point of–35°C (–31°F).

Coolant Level Inspection• Check the coolant level with the mo-torcycle held level. The coolant level

should be between the F(FULL) andL(LOW) level lines.

NOTE○Check the level when the engine iscold (room or atmospheric tempera-ture.)

A. Reserve TankB. F(FULL) Level LineC. L( LOW) Level LineD. Tank CapE. Left Side Cover


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• If the amount of coolant is insuffi-cient, after removing the left sidecover, unscrew the cap from the re-serve tank and add coolant throughthe filler opening to the F(FULL) levelline.• Install the cap.

NOTE○In an emergency you can add wa-ter alone to the coolant reserve tank,however it must be returned to thecorrect mixture ratio by the additionof antifreeze concentrate as soon aspossible.

CAUTIONIf coolant must be added of-ten, or the reserve tank com-pletely runs dry, there is proba-bly leakage in the system. Havethe cooling system inspectedby your authorized Kawasakidealer.

Coolant ChangeHave the coolant changed by an au-

thorized Kawasaki dealer.


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Spark PlugsThe standard spark plug is shown in

the table. The spark plug should betaken out in accordance with the Pe-riodic Maintenance Chart for cleaning,inspection, and resetting of the pluggap.

MaintenanceIf the plug is oily or has carbon built

up on it, have it cleaned, preferably ina sand-blasting device, and then cleanoff any abrasive particles. The plugmay also be cleaned using a high flash-point solvent and a wire brush or othersuitable tool. Measure the gap with awire-type thickness gauge, and adjustthe gap if incorrect by bending the outerelectrode. If the spark plug electrodesare corroded or damaged, or if the insu-lator is cracked, replace the plug. Usethe standard plug.

Spark Plug

Standard Plug NGK CR8E,ND U24ESR-N

Plug Gap 0.7 ∼ 0.8 mm(0.028 ∼ 0.031 in.)

TighteningTorque

13 N·m(1.3 kgf·m, 115 in·lb)

A. Plug Gap


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CAUTIONFor cold weather and/or lowspeed riding, a hotter spark plugshown in the table may be usedfor quicker warm-ups and moreefficient engine operation. How-ever, for normal temperaturesand/or high speed use, the stan-dard spark plug must be used toprevent engine damage.

Hotter Spark PlugNGK CR7E

Kawasaki Clean Air SystemThe Kawasaki Clean Air System

(KCA) is a secondary air suction sys-tem that helps the exhaust gases toburn more completely. When the spentfuel charge is released into the ex-haust system, it is still hot enough toburn. The KCA System allows extraair into the exhaust system so that thespent fuel charge can continue to burn.This continued burning action tends toburn up a great deal of the normallyunburned gases, as well as chang-ing a significant portion of the carbonmonoxide into carbon dioxide.

Air Suction Valves -The air suction valve is essentially a

check valve which allows fresh air toflow only from the air cleaner into theexhaust port. Any air that has passedthe air suction valve is prevented fromreturning. Inspect the air suction valves


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in accordance with the Periodic Main-tenance Chart. Also, inspect the airsuction valves whenever stable idlingcannot be obtained, engine power isgreatly reduced, or there are abnormalengine noises.Air suction valve removal and inspec-

tion should be done only by a compe-tent mechanic following the instructionsin the Service Manual.

Evaporative Emission ControlSystem (California modelonly)

This system routes fuel vapors fromthe fuel system into the running engineor stores the vapors in a canister whenthe engine is stopped. Although no ad-justments are required, a thorough vi-sual inspection must be made at the in-tervals specified by the Periodic Main-tenance Chart.

Inspection• Check that the hoses are securelyconnected.• Replace any kinked, deteriorated, ordamaged hoses.


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Valve ClearanceValve and valve seat wear decreases

valve clearance, upsetting valve timing.

CAUTIONIf valve clearance is left un-adjusted, wear will eventuallycause the valves to remainpartly open, which lowers per-formance, burns the valves andvalve seats, and may cause seri-ous engine damage.

Valve clearance for each valveshould be checked and adjusted inaccordance with the Periodic Mainte-nance Chart.Inspection and adjustment should be

done only by a competent mechanicfollowing the instructions in the ServiceManual.


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Air CleanerA clogged air cleaner restricts the en-

gine’s air intake, increasing fuel con-sumption, reducing engine power, andcausing spark plug fouling.The air cleaner element must be

cleaned in accordance with the Peri-odic Maintenance Chart. In dusty ar-eas, the element should be cleanedmore frequently than the recom-mended interval. After riding throughrain or on muddy roads, the elementshould be cleaned immediately. Theelement should be replaced if it is dam-aged.

Element Removal• Remove the seat.• Unscrew the air cleaner intake capbolts and remove the air cleaner in-take cap.

A. Air Cleaner Intake CapB. Bolts


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• Remove the wing bolt, and take outthe element.

A. ElementB. Wing Bolt

• Remove the element from the frame.

A. Element

• Put a clean, lint-free towel over theair cleaner housing to keep dirt orother foreign material from entering.• Inspect the element material for dam-age. If any part of the element isdamaged, the element must be re-placed.


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WARNINGIf dirt or dust is allowed to passthrough into the carburetor, thethrottle may become stuck, pos-sibly causing accident.

CAUTIONIf dirt gets through into the en-gine, excessive engine wear andpossibly engine damage will oc-cur.

NOTE○Element installation is performed inthe reverse order of removal.

○When installing the element, coat thelip of the element with a thick layer ofall purpose grease to assure a com-plete seal against the air cleaner el-ement base. Also, coat the basewhere the lip of the element fits.

A. Grease


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Element Cleaning• Clean the element in a bath of a highflash-point solvent.

• Dry the element with compressed airor by squeeze it.• After cleaning, saturate the elementwith engine oil or high-quality foam-air-filter oil, squeeze out the excessoil, then wrap it in a clean rag andsqueeze it as dry as possible. Becareful not to tear the element.


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WARNINGClean the element in a well ven-tilated area, and take care thatthere are no sparks or flame any-where near the working area;this includes any appliance witha pilot light. Do not use gaso-line or a low flash-point solventto clean the element. A fire orexplosion could result.

Oil Draining• If there is any oil in the reservoir, re-move the plug from the lower end ofthe drain hose and drain the oil.

WARNINGBe sure to install the plug in thedrain hose after draining. Oil ontires will make them slippery andcan cause an accident any injury.

• Inspect the transparent reservoir lo-cated under the rear shock absorberto see if any oil has run down fromthe air cleaner housing.

A. ReservoirB. Drain HoseC. Plug


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Throttle GripThe throttle grip controls the throttle

valves. If the throttle grip has exces-sive play due to either cable stretch ormaladjustment, it will cause a delay inthrottle response, especially at low en-gine speed. Also, the throttle valvesmay not open fully at full throttle. Onthe other hand, if the throttle grip hasno play, the throttle will be hard to con-trol, and the idle speed will be erratic.Check the throttle grip play in accor-dance with the Periodic MaintenanceChart, and adjust the play if necessary.

Inspection• Check that there is 2 ∼ 3 mm (0.08∼ 0.12 in.) throttle grip play whenlightly turning the throttle grip backand forth.• If there is improper play, adjust it.

A. Throttle GripB. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)


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Adjustment• Loosen the locknut at the throttlegrip, and turn the adjuster until theproper amount of throttle grip play isobtained.

A. LocknutB. AdjusterC. Throttle Cable (Accelerator Cable)

• Tighten the locknut.

• If the throttle cable can not be ad-justed with the adjuster at the throttlegrip, use the nuts located at the car-buretor.• Loosen the locknut at the throttle gripand turn in the adjuster fully.• Tighten the locknut.• Loosen the nuts at the carburetor,and screw both throttle cable nutsfully so as to give the throttle gripplenty of play.• Turn the decelerator cable nut untilthere is no play when the throttle gripis completely closed. Tighten the nut.• Turn the accelerator cable nut until 2∼ 3 mm (0.08 ∼ 0.12 in.) of throttlegrip play is obtained. Tighten the nut.


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A. NutsB. Decelerator CableC. Accelerator Cable

• With the engine idling, turn the han-dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improp-erly adjusted or in correctly routed,or they may be damaged. Be sure

to correct any of these conditions be-fore riding.

WARNINGOperation with improperly ad-justed, incorrectly routed, ordamaged cables could result inan unsafe riding condition.


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CarburetorsThe following procedure covers the

idle speed adjustment, which should beperformed in accordance with the Pe-riodic Maintenance Chart or wheneveridle speed disturbed.

Adjustment• Start the engine, and warm it up thor-oughly.• Adjust the idle speed to 1 250 ∼ 1350 r/min (rpm) by turning the idleadjusting screw.

A. Idle Adjusting Screw

• Open and close the throttle a fewtimes to make sure that the idlespeed does not change. Readjust ifnecessary.


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• With the engine idling, turn the han-dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improperlyadjusted or incorrectly routed, or theymay be damaged. Be sure to correctany of these conditions before riding.

WARNINGOperation with damaged cablescould result in an unsafe ridingcondition.

ClutchDue to friction plate wear and clutch

cable stretch over a long period of use,the clutch operation should be checkedeach day before riding the motorcycle,and in accordance with the PeriodicMaintenance Chart.

WARNINGTo avoid a serious burn, nevertouch a hot engine or an exhaustpipe during clutch adjustment.

Inspection• Check that the clutch lever operatesproperly and that the inner cableslides smoothly. If there is any irreg-ularity, have the clutch cable checkedby an authorized Kawasaki dealer.• Side the dust cover.• Check the clutch lever play as shownin the figure.


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Clutch Lever Play2 ∼ 3 mm (0.08 ∼ 0.12 in.)

A. Clutch LeverB. Clutch Lever PlayC. LocknutD. AdjusterE. Dust Cover

If the play is incorrect, adjust the leverplay as follows.

Adjustment• Slide the dust cover at the clutchlever out of place.• Loosen the locknut at the clutchlever.• Turn the adjuster so that the clutchlever will have the proper play.

WARNINGBe sure the upper end of theclutch outer cable is fully seatedin its fitting, or it could slip intoplace later, creating enough ca-ble play to prevent clutch dis-engagement, resulting in a haz-ardous riding condition.

• Tighten the locknut.• If it cannot be done at the clutch lever,use the adjusting nut at the middle ofthe cable.


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• Loosen the locknut at the clutchlever.• Turn the adjuster in all the way, thentighten the locknut.• Loosen the locknut at the middle ofthe cable, and turn the adjusting nutso that the clutch lever has 2 ∼ 3 mm(0.08 ∼ 0.12 in.) of play.

A. Adjusting NutB. Locknut

• Tighten the locknut.• Slide the dust cover back into place.NOTE

○After the adjustment is made, startthe engine and check that the clutchdoes not slip and that it releasesproperly.

WARNINGDo not run the engine in aclosed area. Exhaust gasescontain carbon monoxide; a col-orless, odorless, poisonous gas.Breathing exhaust gas leads tocarbon monoxide poisoning, as-phyxiation, and death.


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Spark ArresterThis motorcycle is equipped with a

spark arrester approved for off-roaduse by the U.S. Forest Service. It mustbe properly maintained to ensure itsefficiency. In accordance with the Pe-riodic Maintenance Chart, clean thespark arrester.

CAUTIONThis spark arrester must be in-stalled correctly and functioningproperly to provide adequate fireprotection.

A. Spark Arrester

Spark Arrester Cleaning

WARNINGTo avoid burns, wear gloveswhile cleaning the spark ar-rester. Since the engine mustbe run during this procedure,the muffler will become hot.

• Remove the drain plug on themuffler.


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• In an open area away from com-bustible materials, start the enginewith the transmission in neutral.• Raise and lower engine speed whiletapping on the muffler with a rub-ber mallet until carbon particles arepurged from the muffler.

WARNINGDo not run the engine in aclosed area. Exhaust gasescontain carbon monoxide; a col-orless, odorless, poisonous gas.Breathing exhaust gas leads tocarbon monoxide poisoning, as-phyxiation, and death.

• Stop the engine.

Drive ChainThe drive chain slack and lubrica-

tion must be checked each day be-fore riding themotorcycle, and in accor-dance with the Periodic MaintenanceChart for safety and to prevent exces-sive wear. If the chain becomes badlyworn or maladjusted - either too looseor too tight - the chain could jump offthe sprockets or break.

WARNINGA chain that breaks or jumps offthe sprockets could snag on theengine sprocket or lock the rearwheel, severely damaging themotorcycle and causing it to goout of control.

Chain Slack Inspection• Set the motorcycle up on its sidestand.


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• Rotate the rear wheel to find the po-sition where the chain is tightest andmeasure the maximum chain slackby pulling up and pushing down thechain midway between the enginesprocket and rear wheel sprocket.• Measure the space between thechain and the swingarm upper sur-face at the rear of the chain slipper.It should be 35 ∼ 45 mm (1.4 ∼ 1.8in.)

A. 35 ∼ 45 mm (1.4 ∼ 1.8 in.)

• If the drive chain is too tight or tooloose, adjust it so that the chain slackwill be within the standard value.

Drive Chain SlackStandard 35 ∼ 45 mm (1.4 ∼ 1.8 in.)

Chain Slack Adjustment• Remove the cotter pin, and loosenthe axle nut.• Loosen the left and right chain ad-juster locknuts.


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A. Axle NutB. Cotter PinC. IndicatorD. Locknut

• Turn in the left and right chain ad-justers evenly to obtain the standardchain slack. To keep the chain andwheel properly aligned, the notch onthe right wheel alignment indicatorshould align with the same swingarmmark that the left indicator notch alignwith.

A. MarksB. NotchC. Axle NutD. AdjusterE. Locknut

NOTE○Wheel alignment can also bechecked using the straightedge orstring method.


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WARNINGMisalignment of the wheel willresult in abnormal wear, andmayresult in an unsafe riding condi-tion.

• Tighten both chain adjuster locknuts.• Tighten the axle nut to the specifiedtorque.

Tightening TorqueAxle Nut:110 N·m (11.0 kgf·m, 80 ft·lb)


• Rotate the wheel, measure the chainslack again at the tightest position,and readjust if necessary.

• Insert a new cotter pin through theaxle, and spread its ends.• Check the rear brake (see the Brakessection).

WARNINGIf the axle nut is not securelytightened or the cotter pin is notinstalled, an unsafe riding condi-tion may result.

Wear Inspection• Stretch the chain taut either by usingthe chain adjusters, or by hanging a10 kg (20 lb) weight on the chain.


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• Measure the length of 20 links onthe straight part of the chain from pincenter of the 1st pin to pin center ofthe 21st pin. Since the chain maywear unevenly, take measurementsat several places.• If the length exceeds the service limit,the chain should be replaced.

A. MeasureB. Weight

Drive Chain 20-Link LengthService Limit: 323 mm (12.7 in.)

WARNINGFor safety, use only the standardchain. It is an endless type andshould not be cut for installa-tion; have it installed by an au-thorized Kawasaki dealer.

• Rotate the rear wheel to inspect thedrive chain for damaged rollers, andloose pins and links.• Also inspect the sprockets for un-evenly or excessively worn teeth,and damaged teeth.


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NOTE○Sprocket wear is exaggerated for il-lustration. See Service Manual forwear limits.

A. Good TeethB. Worn TeethC. Damaged Teeth

• If there is any irregularity, have thedrive chain and/or the sprockets re-placed by an authorized Kawasakidealer.

LubricationLubrication is also necessary after

riding through rain or on wet roads, orany time that the chain appears dry. Aheavy oil such as SAE 90 is preferredto a lighter oil because it will stay on thechain longer and provide better lubrica-tion.


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• Apply oil to the sides of the rollers sothat it will penetrate to the rollers andbushings. Apply oil to the O-rings sothat the O-rings will be coated withoil. Wipe off any excess oil.

• If the chain is especially dirty, clean itusing diesel oil or kerosine and thenapply oil as described above.

BrakesBrake Wear InspectionInspect the brakes for wear. For each

front and rear disc brake caliper, if thethickness of either pad is less than1 mm (0.04 in.), replace both padsin the caliper as a set. Pad replace-ment should be done by an authorizedKawasaki dealer.

A. Lining ThicknessB. 1 mm (0.04 in.)


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Disc Brake Fluid -In accordance with the Periodic Main-

tenance Chart, inspect the brake fluidlevel in both the front and rear brakefluid reservoir and change the brakefluid. The brake fluid should also bechanged if it becomes contaminatedwith dirt or water.

Fluid RequirementUse heavy-duty brake fluid only from

a container marked DOT3 or DOT4.

CAUTIONDo not spill brake fluid onto anypainted surface.Do not use fluid from a containerthat has been left open or thathas been unsealed for a longtime.Check for fluid leakage aroundthe fittings.Check for brake hose damage.


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Fluid Level Inspection• The brake fluid level in the front brakefluid reservoir must be kept abovethe line (lower level line) next to thegauge and that in the rear brake fluidreservoir must be kept between theupper and lower level lines (reser-voirs held horizontal).

A. Front Brake Fluid ReservoirB. Lower Level Line

A. Rear Brake Fluid ReservoirB. Upper Level LineC. Lower Level LineD. Cap


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• If the fluid level in ether reservoir islower than the lower level line, checkfor fluid leaks in the brake lines, andfill the reservoir to the upper levelline. Inside the front reservoir is astepped line showing the upper levelline.

A. Front Brake Fluid ReservoirB. Upper Level Line

WARNINGDo not mix two brands of brakefluid. Change the brake fluid inthe brake line completely if thebrake fluid must be refilled butthe type and brand of the brakefluid that is already in the reser-voir are unidentified.

Fluid ChangeHave the brake fluid changed by an

authorized Kawasaki dealer.

Front and Rear Brakes -Disc and disc pad wear is automat-

ically compensated for and has no ef-fect on the brake lever or pedal action.So there are no parts that require ad-justment on the front and rear brakes.


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WARNINGIf the brake lever or pedal feelsmushy when it is applied, theremight be air in the brake linesor the brake may be defective.Since it is dangerous to operatethe motorcycle under such con-ditions, have the brake checkedimmediately by an authorizedKawasaki dealer.

Brake Light SwitchesWhen either the front or rear brake is

applied, the brake light goes on. Thefront brake light switch requires no ad-justment, but the rear brake light switchshould be adjusted in accordance withthe Periodic Maintenance Chart.

Inspection• Turn the ignition key to "ON".• The brake light should go on whenthe front brake is applied.• If it does not, ask your authorizedKawasaki dealer to inspect the frontbrake light switch.


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• Check the operation of the rear brakelight switch by depressing the brakepedal. The brake light should go onafter about 10 mm (0.4 in.) of pedaltravel.

A. Brake PedalB. 10 mm (0.4 in.)

• If it does not, adjust the rear brakelight switch.

Adjustment• To adjust the rear brake light switch,move the switch up or down by turn-ing the adjusting nut.

A. Rear Brake Light SwitchB. Adjusting NutC. Lights soonerD. Lights later


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CAUTIONTo avoid damaging the electricalconnections inside the switch,be sure that the switch bodydoes not turn during adjustment.

Front ForkThe front fork operation and oil leak-

age should be checked in accordancewith the Periodic Maintenance Chart.

Front Fork Inspection• Holding the brake lever, pump thefront fork up and down by severaltimes for inspection of smooth stroke.• Visually inspect the front fork for oilleakage, scoring or scratches on theouter surface of the inner tube.


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• If any doubt about the front fork, itshould be done by an authorizedKawasaki dealer.

A. Inner Tube

Air PressureThe standard air pressure in the front

fork legs is atmospheric pressure. Theair pressure in the fork legs increases

as the fork heats up, so the fork actionwill get stiffer as the vehicle operationprogresses.

Compression Damping Adjustment• Using the jack under the frame, sta-bilize the motorcycle.• Place a stand or block under the en-gine so that the front wheel is raisedoff the ground.• Clean the bottom of the outer tubes.


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• To adjust compression damping, turnthe adjuster on the front fork cylindervalve with the blade of a screwdriveruntil you feel a click. Adjust the com-pression damping to suit your prefer-ence under special condition.

A. Adjuster

CAUTIONThe left and right fork legs musthave the same shock damping.

The standard setting position of thecompression damping force adjuster,for an average build rider of 68 kg (150lb) with no passenger and no acces-sories is as follows.

Compression DampingForce Adjuster 12 clicks*

* out from the fully seated position


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Rear Shock AbsorberThe rear shock absorber operation

and oil leakage should be checked inaccordance with the Periodic Mainte-nance Chart.

Rear Shock Absorber Inspection• Press down on the seat several timesto check if the rear shock absorberstroke is smooth.• Visually inspect the rear shock ab-sorber for oil leakage.• If any doubt about the rear shock ab-sorber, it should be done by an au-thorized Kawasaki dealer.

A. Rear Shock Absorber


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Rebound Damping AdjustmentTo adjust shock rebound damping,

turn the rebound damping adjuster onthe rear shock absorber lower end withthe blade of a screwdriver until you feela click.

A. Rebound Damping AdjusterB. Mark

Compression Damping AdjustmentTo adjust compression damping, turn

the compression damping adjuster onthe gas reservoir with the blade of ascrewdriver until you fell a click.

Rebound DampingForce Adjuster 12 turns out*

Compression DampingForce Adjuster 16 turns out*

* out from the fully seated position


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A. Compression Damping AdjusterB. Mark

Spring Preload AdjustmentThe rear shock absorber can be ad-

justed by changing the spring preloadfor various riding and loading condi-tions. If the spring action feels too softor too stiff, have it adjusted by an au-thorized Kawasaki dealer.

WheelsTires -Payload and Tire PressureFailure to maintain proper inflation

pressures or observe payload limits foryour tires may adversely affect han-dling and performance of your motorcy-cle and can result in loss of control. Themaximum recommended load in addi-tion to vehicle weight is 181 kg (399 lb),including rider, passenger, baggage,and accessories.


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• Remove the air valve cap.• Check the tire pressure often, usingan accurate gauge.• Make sure to install the air valve capsecurely installed.

A. Tire Pressure Gauge

NOTE○Measure the tire pressure when thetires are cold (that is, when the mo-torcycle has not been ridden morethan a mile during the past 3 hours).

○Tire pressure is affected by changesin ambient temperature and altitude,and so the tire pressure should bechecked and adjusted when your rid-ing involves wide variations in tem-perature or altitude.

Tire Air Pressure (when cold)

Front – – – 150 kPa (1.50kg/cm², 22 psi)

Rear Up to 97.5 kg(215 lb) Load

150 kPa (1.50kg/cm², 22 psi)

97.5 ∼ 181 kg(215 ∼ 399 lb)Load

175 kPa (1.75kg/cm², 25 psi)


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Tire Wear, DamageAs the tire tread wears down, the tire

becomes more susceptible to punctureand failure. An accepted estimate isthat 90% of all tire failures occur duringthe last 10% of tread life (90 % worn).So it is false economy and unsafe touse the tires until they are bald.

• In accordance with the PeriodicMaintenance Chart, measure thedepth of the tread with a depthgauge, and replace any tire thathas worn down to the minimum al-lowable tread depth.

A. Tire Depth Gauge

Minimum Tread DepthFront 2 mm (0.08 in.)

Rear 2 mm (0.08 in.)


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• Visually inspect the tire for cracksand cuts, replacing the tire in case ofbad damage. Swelling or high spotsindicate internal damage, requiringtire replacement.• Remove any imbedded stones orother foreign particles from the tread.

NOTE○Have the wheel balance inspectedwhenever a new tire is installed.

WARNINGTo ensure safe handling andstability, use only the recom-mended standard tires for re-placement, inflated to the stan-dard pressure.Tires that have been puncturedand repaired do not have thesame capabilities as undam-aged tires. Do not exceed 100km/h (60 mph) within 24 hoursafter repair, and 180 km/h (110mph) at any time after that.

NOTE○When operating on public roadways,keep maximum speed under trafficlaw limits.


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Standard TireFront Size: 3.00-21 51P

DUNLOP D605FG

Rear Size: 4.60-18 63P

DUNLOP D605G

WARNINGNew tires are slippery and maycause loss of control and injury.A break-in period of 160 km (100miles) is necessary to estab-lish normal tire traction. Duringbreak-in, avoid sudden and max-imum braking and acceleration,and hard cornering.

BatteryThe battery installed in this motorcy-

cle is a sealed type, so it is not nec-essary to check the battery electrolytelevel or add distilled water.The sealing strip should not be pulled

off once the specified electrolyte hasbeen installed in the battery for initialservice.However, in order to maximize bat-

tery life and ensure that it will providethe power needed to start the motor-cycle you must properly maintain thebattery’s charge. When used regularly,the charging system in the motorcyclehelps keep the battery fully charged. Ifyour motorcycle is only used occasion-ally or for short periods of time, the bat-tery is more likely to discharge.Due to their internal composition,

batteries continually self discharge.The discharge rate depends on the


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type of battery and ambient temper-ature. As temperatures rise, so doesthe discharge rate. Every 15°C (27°F)doubles the rate.Electrical accessories, such as digi-

tal clocks and computer memory, alsodraw current from the battery evenwhen the key is switched off. Combinesuch "key-off" draws with hot temper-ature, and a battery can go from fullycharged to completely discharged in amatter of days.

Self-discharge

Approx. Number of DaysFrom 100% Charged to100% dischargedLead-Antimony

Lead-Calcium

Temperature

Battery Battery

40°C(104°F) 100 Days 300 Days

25°C (77°F) 200 Days 600 Days

0°C (32°F) 550 Days 950 Days


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Current Drain

DischargingAmpere

Days from100%chargedto 50%Discharged

Days from100%chargedto 100%Discharged

7 mA 60 Days 119 Days





In extremely cold weather the fluid inan inadequately charged battery caneasily freeze, which can crack the caseand buckle the plates. A fully chargedbattery can withstand sub-freezingtemperatures with no damage.

Battery SulfationA common cause of battery failure is

sulfation.Sulfation occurs when the battery is

left in a discharged condition for an ex-tended time. Sulfate is a normal byproduct of the chemical reactions withina battery. But when continuous dis-charge allows the sulfate to crystallizein the cells, the battery plates becomepermanently damaged and will not holda charge. Battery failure due to sulfa-tion is not warrantable.

Battery MaintenanceIt is the owner’s responsibility to keep

the battery fully charged. Failure to doso can lead to battery failure and leaveyou stranded.If you are riding your vehicle infre-

quently, inspect the battery voltageweekly using a voltmeter. If it dropsbelow 12.6 volts, the battery should be


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charged using an appropriate charger(check with your Kawasaki dealer).If you will not be using the motorcy-cle for longer than two weeks, thebattery should be charged using anappropriate charger. Do not use an au-tomotive-type quick charger that mayovercharge the battery and damage it.

Kawasaki-recommended chargersare:OptiMate ΙΙΙYuasa 1.5 Amp Automatic chargerBattery Mate 150-9If the above chargers are not avail-

able, use equivalent one.For more details, ask your Kawasaki

dealer.

Battery Charging• Remove the battery from the motor-cycle (see Battery Removal).• Attach the leads from the chargerand charge the battery at a rate thatis 1/10th of the battery capacity. Forexample, the charging rate for a 10Ah battery would be 1.0 ampere.• The charger will keep the battery fullycharged until you are ready to re-install the battery in the motorcycle(see Battery Installation).

CAUTIONNever remove the sealing strip,or the battery can be damaged.Do not install a conventionalbattery in this motorcycle, or theelectrical system cannot workproperly.


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NOTE○If you charge the sealed battery,never fail to observe the instructionsshown in the label on the battery.

WARNINGBattery posts, terminals and re-lated accessories contain leadand lead compounds. Washhands after handling.

Battery Removal• Remove the left side cover.• Disconnect the leads from the bat-tery, first from the (–) terminal andthen the (+) terminal.

A. (–) TerminalB. (+) TerminalC. BatteryD. HolderE. Bolt

• Remove the battery holder, and takethe battery out of the battery case.


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• Clean the battery using a solution ofbaking soda and water. Be sure thatthe wire connections are clean.

Battery Installation• Put the battery in the battery case.• Connect the capped lead to the (+)terminal, and then connect the blacklead to the (–) terminal.• Put a light coat of grease on the ter-minals to prevent corrosion.• Cover the (+) terminal with its protec-tive cap.• Reinstall the parts removed.

Headlight BeamHorizontal AdjustmentThe headlight beam is adjustable

horizontally. If not properly adjustedhorizontally, the beam will point to oneside rather than straight ahead.• Turn the horizontal adjuster on theheadlight rim in or out until the beampoints straight ahead.

A. Horizontal AdjusterB. Vertical Adjuster


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Vertical AdjustmentThe headlight beam is adjustable ver-

tically. If adjusted too low, neither lownor high beam will illuminate the roadfar enough ahead. If adjusted too high,the high beam will fail to illuminate theroad close ahead, and the low beamwill blind oncoming drivers.• Turn the vertical adjuster on theheadlight rim in or out to adjust theheadlight vertically.

NOTE○On high beam, the brightest pointshould be slightly below horizontal.The proper angle is 0.4 degrees be-low horizontal. This is a 50 mm (2in.) drop at 7.6 m (25 ft) measuredfrom the center of the headlight, withthe motorcycle on its wheels and therider seated.


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CAUTIONWhen handling the quartz-halogen bulbs, never touch theglass portion with bare hands.Always use a clean cloth. Oilcontamination from hands ordirty rags can reduce bulb life orcause the bulb to explode.

FusesThe main fuse is mounted on the

starter relay located under the seat.The fuse case is located under theseat. If a fuse fails during operation,inspect the electrical system to deter-mine the cause, and then replace itwith a new fuse of proper amperage.

A. Main Fuse (20 A)B. Fuse Case


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WARNINGDo not use any substitute for thestandard fuse.Replace the blown fuse with anew one of the correct capacity,as specified on the junction box.

A. NormalB. Failed

General LubricationLubricate the points shown below,

with either motor oil or regular grease,in accordance with the Periodic Main-tenance Chart or whenever the vehiclehas been operated under wet or rainyconditions.Before lubricating each part, clean off

any rusty spots with rust remover andwipe off any grease, oil, dirt, or grime.

NOTE○A few drops of oil are effective tokeep bolts and nuts from rusting andsticking. This makes removal easier.Badly rusted nuts, bolts, etc., shouldbe replaced with new ones.


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Apply motor oil to the followingpivots -○Side Stand○Clutch Lever○Front Brake Lever○Rear Brake PedalLubricate the following cables with apressure cable lubber -○(K) Clutch Inner Cable○(K) Throttle Inner Cables

Apply grease to the followingpoints -○(K) Clutch Inner Cable Upper End○(K) Throttle Inner Cable Upper Ends(K): Should be serviced by an authorized

Kawasaki dealer.

NOTE○After connecting the cables, adjustthem.


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Cleaning Your MotorcycleGeneral PrecautionsFrequent and proper care of your

Kawasaki motorcycle will enhanceits appearance, optimize overall per-formance, and extend its useful life.Covering your motorcycle with a highquality, breathable motorcycle coverwill help protect its finish from harmfulUV rays, pollutants, and reduce theamount of dust reaching its surfaces.• Be sure the engine and exhaust arecool before washing.• Avoid applying degreaser to seals,brake pads, and tires.• Always use non-abrasive wax andcleaner/polisher.• Avoid all harsh chemicals, solvents,detergents, and household cleaningproducts such as ammonia-basedwindow cleaners.

• Gasoline, brake fluid, and coolantwill damage the finish of painted andplastic surfaces: wash them off im-mediately.• Avoid wire brushes, steel wool, andall other abrasive pads or brushes.• Use care when washing the wind-shield, headlight cover, and otherplastic parts as they can easily bescratched.• Avoid using pressure washers; wa-ter can penetrate seals and electricalcomponents and damage your mo-torcycle.• Avoid spraying water in delicate ar-eas such as in air intakes, carbu-retors, brake components, electricalcomponents, muffler outlets, and fueltank openings.


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Washing Your Motorcycle• Rinse your bike with cold water froma garden hose to remove any loosedirt.• Mix a mild neutral detergent (de-signed for motorcycles or automo-biles) and water in bucket. Usea soft cloth or sponge to wash yourmotorcycle. If needed, use a mild de-greaser to remove any oil or greasebuild up.• After washing, rinse your motorcy-cle thoroughly with clean water to re-move any residue (residue from thedetergent can damage parts of yourmotorcycle).• Use a soft cloth to dry your motorcy-cle. As you dry, inspect your motor-cycle for chips and scratches. Do notlet the water air dry as this can dam-age the painted surfaces.

• Start the engine and let it idle for sev-eral minutes. The heat from the en-gine will help dry moist areas.• Carefully ride your motorcycle at aslow speed and apply the brakesseveral times. This helps dry thebrakes and restores them to normaloperating performance.• Lubricate the drive chain to preventrusting.

NOTE○After riding in an area where theroads are salted or near the ocean,immediately wash your motorcyclewith cold water. Do not use warmwater as it accelerates the chemicalreaction of the salt. After drying,apply a corrosion protection sprayon all metal and chrome surfaces toprevent corrosion.


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Painted SurfacesAfter washing your motorcycle, coat

painted surfaces, both metal and plas-tic, with a commercially available mo-torcycle/automotive wax. Wax shouldbe applied once every three months oras conditions require. Avoid surfaceswith "satin" or "flat" finishes. Alwaysuse non-abrasive products and applythem according to the instructions onthe container.

Plastic PartsAfter washing use a soft cloth to gen-

tly dry plastic parts. When dry, treat theheadlight lens, and other non-paintedplastic parts with an approved plasticcleaner/polisher product.

CAUTIONPlastic parts may deteriorateand brake if they come in con-tact with chemical substancesor household cleaning productssuch as gasoline, brake fluid,window cleaners, thread-lockingagents, or other harsh chemi-cals. If a plastic part comes incontact with any harsh chemicalsubstance, wash it off immedi-ately with water and a mild neu-tral detergent, and then inspectfor damage. Avoid using abra-sive pads or brushes to cleanplastic parts, as they will dam-age the part’s finish.

Chrome and AluminumChrome and uncoated aluminum

parts can be treated with a chrome/alu-minum polish. Coated aluminum


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should be washed with a mild neu-tral detergent and finished with a spraypolish. Aluminum wheels, both paintedand unpainted can be cleaned withspecial non-acid based wheel spraycleaners.

Leather, Vinyl, and RubberIf your motorcycle has leather ac-

cessories, special care must be taken.Use a leather cleaner/treatment toclean and care for leather accessories.Washing leather parts with detergentand water will damage them, shorten-ing their life.Vinyl parts should be washed with the

rest of the motorcycle, then treated witha vinyl treatment.

The sidewalls of tires and other rub-ber components should be treated witha rubber protectant to help prolong theiruseful life.

WARNINGSpecial caremust be taken not toget any rubber protectant on thetire’s tread surface when treat-ing tires. This may decrease thetire’s ability to maintain contactwith the road surface causingthe rider to lose control.


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Bolt and Nut TighteningIn accordance with the Periodic Maintenance Chart, it is very important to check

the tightness of the bolts and nuts listed here. Also, check to see that each cotterpin is in place and in good condition. Please ask your authorized Kawasaki dealerfor torque values.

1. Front Fender MountingBolts

2. Front Fork Clamp Bolts3. Clutch Lever Pivot Bolts4. Handlebar Mounting Bolts5. Stem Head Nut6. Brake Disc Mounting Bolts7. Front Axle Nut8. Caliper Mounting Bolts9. Engine Mounting Bolts

and Nuts10. Pivot Shaft Nut11. Side Stand Bolt12. Rear Shock Absorber

Mounting Bolts13. Rear Sprocket Mounting

Bolts


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14. Rear Axle Nut15. Muffler Mounting Bolts

and Nuts

STORAGE 145

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STORAGE

Preparation for Storage:• Clean the entire vehicle thoroughly.• Run the engine for about five minutes to warm the oil, shut it off and drain theengine oil.

WARNINGMotor oil is a toxic substance. Dispose of used oil properly. Contact yourlocal authorities for approved disposal methods or possible recycling.

• Put in fresh engine oil.• Empty the fuel from the fuel tank, and empty the carburetors by unscrewing thedrain screw at each float bowl. (If left in for a long time, the fuel will break downand could clog the carburetors.)

146 STORAGE

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WARNINGGasoline is extremely flammable and can be explosive under certain con-ditions. Turn the ignition key to "OFF". Do not smoke. Make sure thearea is well ventilated and free from any source of flame or sparks; thisincludes any appliance with a pilot light.Gasoline is a toxic substance. Dispose of gasoline properly. Contact yourlocal authorities for approved disposal methods.

• Remove the spark plugs and spray fogging oil directly into each cylinder. Turnthe engine over several times with the starter button to coat the cylinder wall.Install the spark plug.

WARNINGDo not lean over the engine when performing this procedure. An air/oilmist may be forcibly ejected from the spark plug holes and could get intoyour eyes. if you do get some in your eyes, wash your eyes immediatelywith liberal amounts of clean, fresh water. Consult a physician as soonas possible.

• Reduce tire pressure by about 20%.

STORAGE 147

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• Set themotorcycle on a box or stand so that both wheels are raised off the ground.(If this cannot be done, put boards under the front and rear wheels to keep damp-ness away from the tire rubber.)• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil onrubber parts or in the brakes.• Lubricate the drive chain and all the cables.• Remove the battery, and store it where it will not be exposed to direct sunlight,moisture, or freezing temperatures. During storage it should be given a slowcharge (one ampere or less) about once a month. Keep the battery well chargedespecially during cold weather.• Tie plastic bag over the exhaust pipe to prevent moisture from entering.• Put a cover over the motorcycle to keep dust and dirt from collecting on it.

Preparation after Storage:• Remove the plastic bag from the exhaust pipe.• Install the battery in the motorcycle and charge the battery if necessary.• Make sure the spark plugs are tight.• Fill the fuel tank with fuel.• Check all the points listed in the Daily Safety Checks section.• Lubricate the pivots, bolts, and nuts in General Lubrication section.

148 TROUBLESHOOTING GUIDE

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TROUBLESHOOTING GUIDE

Engine Does Not Start -Starter Motor Won’t Turn• Engine stop switch• Transmission not in neutral• Fuse blown• Battery leads do not make good elec-trical contact with battery terminals• Battery dischargedEngine Cranks, But Won’t Start• No fuel in tank• Fuel line clogged• Fuel broken down• Choke is not used when engine iscold• Engine flooded• Spark plugs not in good contact• Spark plugs fouled or wet

• Incorrect spark plug gap• Incorrect valve clearance• Battery dischargedEngine Stalls -Just When Shifting Into 1st Gear• Side stand has been left down• Clutch does not properly disengageWhile Riding• Choke is used too long after movingoff• No fuel in tank• Fuel tank air vent is obstructed• Overheating• Battery discharged• Fuel tap is turned off

OWNER SATISFACTION 149OWNER SATISFACTION

(For Products Sold in the Continental United States of America Only)

Your satisfaction is important to your authorized Kawasaki dealer and to KawasakiMotors Corp., U.S.A. If you have a problem concerning warranty or service, pleasetake the following action:

Contact the owner and/or service manager of your authorized Kawasaki dealer.Fully explain your problem and ask for assistance in resolving the situation. TheOWNER of the dealership is concerned with your satisfaction and your future busi-ness. For this reason the owner is in the best position to assist you. Also, allwarranty and service matters are handled and resolved through the authorizedKawasaki dealer network.If you are unsatisfied after working with your Kawasaki dealer and feel you still re-quire further assistance, write to the address below. Please be certain to providethe model, product identification number, mileage or hours of use, accessories,dates that events occurred and what action has been taken by both you and yourdealer. Include the name and address of the dealership. To assist us in resolvingyour inquiry, please include copies of related receipts and any other pertinent infor-mation including the names of the dealership personnel with whom you have beenworking in the resolution of your problem.

150 OWNER SATISFACTION

Upon receipt of your correspondence we will contact the dealership and work withthem in resolving your problem.

In order to provide a permanent record, all warranty and service resolutions takeplace only through written correspondence.

Please send your correspondence to:CONSUMER RELATIONSKAWASAKI MOTORS CORP., U.S.A.P. O. Box 25252SANTA ANA, CA. 92799-5252(949) 460–5688

REPORTING SAFETY DEFECTS 151REPORTING SAFETY DEFECTS

(For Products Sold in the Continental United States of America Only)

If you believe that your vehicle has a defect which could cause a crash or couldcause injury or death, you should immediately inform the National Highway TrafficSafety Administration (NHTSA) in addition to notifying Kawasaki Motors Corpora-tion, U.S.A.

If NHTSA receives similar complaints, it may open an investigation, and if it findsthat a safety defect exists in a group of vehicles, it may order a recall and remedycampaign. However, NHTSA cannot become involved in individual problems be-tween you, your dealer, or Kawasaki Motors Corporation, U.S.A.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C. area) or write to: NHTSA, U.S. De-partment of Transportation, Washington, D.C. 20590. You can also obtain otherinformation about motor vehicle safety from the Hotline.

152 ENVIRONMENTAL PROTECTION

ENVIRONMENTAL PROTECTION

To protect our environment, properly discard used batteries, tires, engine oil, orother vehicle components that you might dispose of in the future. Consult yourauthorized Kawasaki dealer or local environmental waste agency for their properdisposal procedures.

MAINTENANCE RECORD 153MAINTENANCE RECORD

Owner Name.......................................................................................Address ..............................................................................................Phone Number ...................................................................................Engine Number ..................................................................................Vehicle Number..................................................................................Selling Dealer Name..........................................................................Phone Number ...................................................................................Warranty Start Date ...........................................................................Note: Keep this information and a spare key in a secure location.

OdometerReadingDate Maintenance Performed Dealer Name Dealer Address

154 MAINTENANCE RECORD

OdometerDate

ReadingMaintenance Performed Dealer Name Dealer Address

MAINTENANCE RECORD 155

OdometerDate


156 MAINTENANCE RECORD

OdometerDate


MAINTENANCE RECORD 157

OdometerDate


158 LABEL INFORMATION

LABEL INFORMATION

(1)/(4)

(2)

LABEL INFORMATION 159

(3)


(5)


(6)


(6) Only on California model


(7)


(8) Only on California model (9)




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2009 KLX 250 Owners Manual

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