Manual Propietario ZX-10R 2013

8/12/2019 Manual Propietario ZX-10R 2013

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110 MAINTENANCE AND ADJUSTMENT

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 beable to carry out many of the maintenance items described in this chapter. If youlack proper experience or doubt your ability, all adjustments, 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.


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MAINTENANCE AND ADJUSTMENT 111

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporatedcrankcase 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 System

This system eliminates the release of crankcase vapors into the atmosphere.Instead, the vapors are routed through an oil separator to the intake side of 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 fuelinjection system.

2. Exhaust Emission Control SystemThis system reduces the amount of pollutants discharged into the atmosphereby 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 motor-

cycle includes a catalytic converter system.


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

ation fuel hoses and fuel tank.3. Evaporative Emission Control System (California model only)

Vapors caused by fuel evaporation in the fuel system are not vented into theatmosphere. 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 Information

High Altitude adjustment is not required.


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MAINTENANCE AND WARRANTY

Proper maintenance is necessary to ensure that your motorcycle will continue tohave low emission levels. This Owners 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 thisOwners 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 ownersobligations it contains.

You should keep a maintenance record for your motorcycle. To assist you inkeeping this record, we have provided space on pages 224 through 227 of thismanual where an authorized Kawasaki dealer, or someone equally competent, can

record the maintenance. You should also retain copies of maintenance work orders,bills, etc., as verification of this maintenance.


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TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) the removal orrendering 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 or

element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:* Replacement of the original exhaust system or muffler with a component not in

compliance with Federal regulations.* Removal of the muffler(s) or any internal portion of the muffler(s).* Removal of the air box or air box cover.* Modifications to the muffler(s) or air intake system by cutting, drilling, or other

means if such modifications result in increased noise levels.

Periodic Maintenance ChartK : Should be serviced by an authorized Kawasaki dealer.

* : For higher odometer readings, repeat at the frequency interval established here.

# : Service more frequently when operating in severe conditions: dusty, wet, muddy,

high speed, or frequent starting/stopping.(e): Emission Related Item


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Frequency Whichevercomes

first *Odometer Readingkm 1 000 (mile 1 000)

Operation(Engine Items)

Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

K Fuel hoses damage

- inspect year

KFuel hosesinstallation

condition - inspect

year

Coolant level -inspect 135Coolant leak -

inspect

year

133

Radiator hosesdamage - inspect

year 133Radiator hosesinstallationcondition - inspect

year

133


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first *Odometer Readingkm 1 000 (mile 1 000)

Operation(Engine Items)

Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Evaporativeemission controlsystem - function(California modelonly) (e)

140

KAir suction systemdamage - inspect(e)

142


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2. Periodic Inspection (Chassis Related Items)

Frequency Whichevercomesfirst

*Odometer Readingkm 1000 (mile 1000)

Operation(Chassis Items) Every

1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Clutch and drive train:

Clutch operation(play, engagement,

disengagement) -inspect 153

Drive chainlubricationcondition - inspect#

every 600 km (400 mile) 163

Drive chain slack -inspect #

every 1 000 km (600 mile) 156

Drive chain wear -

inspect # 160


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first *Odometer Readingkm 1000 (mile 1000)

Operation(Chassis Items)

Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

K Drive chain guide

wear - inspect Wheels and tires:

Tire air pressure -inspect year 185Wheels/tiresdamage - inspect 186Tire tread wear,

abnormal wear -inspect 186

K Wheel bearings

damage - inspect year


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Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Brake system:

Brake fluid leak -inspect

year 165Brake hosesdamage - inspect year 165Brake pad wear -inspect # 164Brake hoses

installationcondition - inspect

year 165

Brake fluid level -inspect

6months 165


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Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Brake operation(effectiveness,play, drag) - inspect

year 167

Brake light switch

operation - inspect 168

Suspensions:

Front forks/rearshock absorber

operation(damping andsmooth stroke) -inspect

171/177

Front forks/rear

shock absorber oilleak - inspect

year 171/

177


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Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Electrical system:

Lights andswitches operation- inspect

year

Headlight aiming -inspect

year 195Side stand switchoperation - inspect

year

Engine stop switchoperation - inspect

year


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Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Chassis:

K Chassis parts -

lubricate year 201

K Bolts and nuts

tightness - inspect 209


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3. Periodic Replacement

Frequency Whichevercomes first *Odometer Reading

km 1 000 (mile 1 000)

Change/Replacement Items Every

1(0.6)

12(7.5)

24(15)

36(22.5)

48(30)

SeePage

Air cleaner element - replace# (e)

every 18 000 km (11 250 mile) 144

K Engine oil - change # year 130K Oil filter - replace year 130K Fuel hoses - replace 5 years

K Coolant - change 3 years 138

K Radiator hoses and O-rings -replace 3 years K Brake hoses - replace 4 years K

Brake fluid (front and rear) -change

2 years

167


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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 replace the oilfilter in accordance with the Periodic

Maintenance Chart. Not only do dirtand metal particles collect in the oil, butthe oil itself loses its lubricative qualityif used too long.

WARNINGMotorcycle operation with insuf-ficient, deteriorated, or contam-inated engine oil will cause ac-celerated wear and may result inengine or transmission seizure,accident, and injury. Check theoil level before each ride andchange the oil according to the

periodic maintenance chart inthe Owners Manual.

Oil Level Inspection

If the oil has just been changed, start

the 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.

NOTICE

Racing 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 to

drain down.


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Check the engine oil level throughthe oil level inspection window. With

the motorcycle held level, the oil levelshould come up between the upperand lower level lines next to the in-spection window.

A. Oil Level Inspection WindowB. Oil Filler CapC. Lower Level LineD. Upper Level Line

If the oil level is too high, remove theexcess oil through the oil filler open-

ing using a syringe or some othersuitable device.

If the oil level is too low, add the oilto reach the correct level. Use the

same type and brand of oil that isalready in the engine.

129


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NOTICE

If the engine oil gets extremelylow or if the oil pump does notfunction properly or oil pas-sages are clogged, the warningindicator light in the meter in-

strument and oil pressure warn-ing symbol ( ) in the multi-function meter will go on. If theygo on when the engine speed isabove idle, stop the engine im-mediately and have it serviced.Failure to do so could cause se-rious engine damage.

A. Oil Pressure Warning Symbol ( )

B. Warning Indicator Light (Red)



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Oil and/or Oil Filter Change

To change the engine oil and replace

oil filter, the engine oil drain bolt andoil filter must be removed. The oilchange and oil filter replacementshould be done by an authorizedKawasaki dealer.

A. Engine Oil Drain Bolt

A. Oil Filter

WARNING

Engine oil is a toxic substance.Dispose of used oil properly.

Contact your local authoritiesfor approved disposal methodsor possible recycling.



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Tightening Torque

Engine Oil Drain Bolt:29 Nm (3.0 kgfm, 21 ftlb)

Oil Filter:17 Nm (1.7 kgfm, 13 ftlb)

Recommended Engine Oil

Type:Kawasaki Performance 4-StrokeMotorcycle Oil*Kawasaki Performance 4-StrokeSemi-Synthetic Oil*Kawasaki Performance 4-Stroke FullSynthetic Oil*or other 4-stroke oils with API SG, SH,SJ, SL, SM and JASO MA, MA1, MA2rating

Viscosity:SAE10W-40

*Kawasaki Performance Oils and Lu-bricants have been specifically engi-

neered for your vehicle. Consistent

use of these products meets or ex-ceeds warranty and service require-

ments and can help to extend the lifeof your Kawasaki.

NOTE

Do not add any chemical additive tothe oil. Oils fulfilling the above re-quirements are fully formulated andprovide adequate lubrication for boththe engine and the clutch.

Engine Oil CapacityCapacity:

2.9 L (3.1 US qt)[when filter is not removed]3.3 L (3.5 US qt)

[when filter is removed]3.7 L (3.9 US qt)[when engine is completely dry]

Although 10W-40 engine oil is the

recommended oil for most condi-tions, the oil viscosity may need to



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be changed to accommodate atmo-spheric conditions in your riding area.

Cooling System

Radiator and Cooling Fan -Check the radiator fins for obstruc-tion by insects or mud. Clean offany obstructions with a stream oflow-pressure water.

WARNING

The cooling fan spins at highspeed and can cause serious

injuries. Keep your hands andclothing away from the coolingfan blades at all times.


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accumulates rust and scale in the wa-ter jacket and radiator. This will clog

up the coolant passages, and con-siderably reduce the efficiency of thecooling system.

WARNING

Coolant containing corrosion in-hibitors for aluminum enginesand radiators include harm-ful chemicals for human body.

Drinking coolant can result inserious injury or death. Usecoolant in accordance with theinstructions of the manufacturer.

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

NOTICE

If 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 freezing

point and strength directed on the con-tainer.



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NOTICE

Permanent types of antifreeze onthe market have anti-corrosionand anti-rust properties. When itis diluted excessively, it loses itsanti-corrosion property. Dilute a

permanent type of antifreeze inaccordance with the instructionsof the manufacturer.

NOTEA permanent type of antifreeze is in-stalled in the cooling system whenshipped. It is colored green and con-tains ethylene glycol. It is mixed at

50% and has the freezing point of35C (31F).

Coolant Level Inspection

Situate the motorcycle so that it isperpendicular to the ground.

Check the coolant level through thecoolant level gauge on the reserve

tank located to the left of the engine.The coolant level should be betweenthe F (Full) and L (Low) level lines.

A. Reserve TankB. F (Full) Level LineC. L (Low) Level Line



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NOTE

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

If the amount of coolant is insuffi-cient, add coolant into the reserve

tank.

Remove the cap from the reservetank and add coolant through thefiller opening to the F (Full) levelline.

Coolant Filling

Remove the bolts and quick rivets. Detach the tabs and remove the right

fairing and cover.

A. Bolts

B. Quick RivetC. Large Quick RivetD. TabsE. Right Fairing and Cover

NOTEThe right fairing and cover uses thequick rivets and large quick rivet.

The large quick rivet can be removedby pulling the center pin with a screw

driver. When installing it, insert thelarge quick rivet into the hole on the



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fairing and push the center pin to se-cure them.

The quick rivets can be removed bypushing the center pin into the quickrivets, and when installing them, pullthe center pin fully up first, and thenpush into the center pin after insert-ing them.

Quick Rivet Removal

A. Quick Rivet

B. Center PinC. Push in.

Quick Rivet Installation

A. Quick RivetB. Center PinC. Pull up fully.D. Push in.



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Remove the cap from the reservetank and add coolant through the

filler opening to the F (Full) levelline.

A. Reserve Tank 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 addition

of antifreeze concentrate as soon aspossible.

NOTICE

If 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 Change

Have the coolant changed by an au-thorized Kawasaki dealer.


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Evaporative Emission ControlSystem (California model

only)This system routes fuel vapors from

the 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.

NOTICE

If 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 becarried out only by a competent me-

chanic following the instructions in theService Manual.



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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 to

burn 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 passed

the air suction valve is prevented fromreturning. Inspect the air suction valves

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 carried out only by acompetent mechanic following the in-

structions in the Service Manual.



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Exhaust DeviceThis motorcycle is equipped with a

exhaust device system. This systemcontrols the valve in the exhaust pipeand produces stable engine power atlow and middle engine speed. This ex-haust device is controlled by the ECU,and adjustment or maintenance shouldbe done only by a competent mechanicfollowing the instructions in the ServiceManual.

A. Exhaust Device Cables

NOTICE

Do not adjust the exhaust devicesystem by yourself. The mal-adjustment will cause the poorengine performance and enginedamage.



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Air CleanerA clogged air cleaner restricts the en-

gines air intake, increasing fuel con-sumption, reducing engine power, andcausing spark plug fouling.

This motorcycles air cleaner elementconsists of a wet paper filter, which can-not be cleaned.

The air cleaner element must be re-placed in accordance with the PeriodicMaintenance Chart. In dusty, rainy, or

muddy conditions, the air cleaner el-ement should be serviced more fre-quently than the recommended inter-val.

NOTICE

Use only the recommended aircleaner element (Kawasaki partnumber 11013-0041). Using theother air cleaner elements willwear the engine prematurely or

lower the engine performance.



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Remove the riders seat (see Seatssection in the General Information

chapter). Remove the bolts on the left and right

fuel tank side covers.

A. BoltsB. Fuel Tank Side CoverC. ProjectionsD. Tab

Detach the projection by pulling thefront of the covers outward carefully.

Slide the covers forward to clear thetab from the slot and remove the fueltank side covers.

NOTE

On the left fuel tank side cover,pulling out it without disconnectingthe connectors from the relay box.



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Remove the bolts and fuel tank frontcover.

A. BoltsB. Fuel Tank Front Cover

Remove the fuel tank mounting bolts.

Disconnect the connector from the

sensor on the air cleaner housingcover.

A. Bolts

B. ConnectorC. Fuel Tank

Raise the front of the fuel tank anddisconnect the breather tubes fromthe fuel tank.

Support the fuel tank with a suitabletool carefully.



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Detach the connector brackets at therear of the air cleaner housing.

Remove the screws and lift the aircleaner housing cover with the har-ness and fuel hoses installed.

A. Connector BracketsB. ScrewsC. Air Cleaner Housing Cover

Pull out the air cleaner element.

A. Air Cleaner Element

Put a clean, lint-free towel over theair cleaner duct and housing to keepdirt or other foreign material from en-tering.



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WARNING

If dirt or dust is allowed to passthrough into the fuel injectionsystem, the throttle may stick orbecome inoperable resulting in ahazardous operating condition.

NOTICE

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

Element and fuel tank installation isperformed in the reverse order of re-moval.

Oil Draining

Inspect the transparent hose locatedon the left side of the engine to see

if any oil or water has run down fromthe air cleaner housing.

A. Transparent HoseB. Plug



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If there is any oil or water in the hose,remove the plug and drain the oil or

water.

WARNING

Oil on tires will make them slip-

pery and can cause an accidentand injury. Be sure to install theplug in the drain hose after drain-ing.

Throttle Control SystemCheck the throttle grip play each day

before riding the motorcycle, and carryout maintenance and adjustments inaccordance with the Periodic Mainte-nance Chart. Adjust it if necessary.

Throttle Grip -The throttle grip controls the butterflyvalves in the throttle body. If the throt-tle grip has excessive play due to ei-ther cable stretch or maladjustment, it

will cause a delay in throttle response,especially at low engine speed. Also,the throttle valve may not open fully atfull throttle. On the other hand, if thethrottle grip has no play, the throttle will

be hard to control, and the idle speedwill be erratic.



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Inspection

Check that the throttle grip play is

correct by lightly turning the throttlegrip back and forth.

A. Throttle Grip

B. Throttle Grip Play

Throttle Grip Play

2 3 mm (0.080.12 in.)

If there is improper play, adjust it.

Adjustment Loosen the locknuts at the upper of

the throttle cables, and screw boththrottle cable adjusters completely soas to give the throttle grip plenty of

play.

Turn out the decelerator cable ad-juster until it has no play when thethrottle grip is completely closed.Tighten the locknut.



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Turn out the accelerator cable ad-juster until the throttle grip has the

proper play. Tighten the locknut.

A. Decelerator CableB. Accelerator Cable

C. AdjusterD. Locknuts

If the throttle cables cannot be ad-justed with the adjuster at the upperof the throttle cable, further adjust-

ment of the throttle cables should be

done only by a competent mechanicfollowing the instructions in the Ser-

vice Manual. With the engine idling, turn the han-

dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improperly

adjusted or incorrectly routed, or theymay be damaged. Be sure to correctany of these conditions before idling.

WARNINGOperation with improperly ad-justed, incorrectly routed, ordamaged cables could result in

an unsafe riding condition. Besure the control cables are ad-justed and routed correctly, andare free from damage.


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Cl t h Ch k h l h l l h


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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 must be adjusted in accordancewith the Periodic Maintenance Chart.

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.

Check the clutch lever play as shownin the figure.

A. AdjusterB. Clutch Lever Play

Clutch Lever Play

2

3 mm (0.08

0.12 in.)

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


Adj t t If it t b d th t t


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Adjustment

Turn the adjuster so that the clutchlever will have the proper play.

WARNING

Excess clutch cable play could

prevent clutch disengagementand cause a crash resulting inserious injury or death. Whenadjusting the clutch cable, besure the upper end of the outer

cable is fully seated in its fittingso that it doesnt slip into placelater and create excessive cableplay.

If it cannot be done, use the nuts atthe lower end of the clutch cable.

A. NutsB. Clutch Cable


WARNING DANGER


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WARNING

The engine and exhaust systemget extremely hot during normaloperation and can cause seriousburns. Never touch a hot engineor an exhaust pipe during clutch

adjustment.

NOTE

After the adjustment is made, start

the engine and check that the clutchdoes not slip and releases properly.

For minor corrections, use the ad-juster at the clutch lever.

DANGER

Exhaust gas contains carbonmonoxide, a colorless, odor-less poisonous gas. Inhalingcarbon monoxide can causeserious brain injury or death.

DO NOT run the engine in en-closed areas. Operate only in awell-ventilated area.


Drive Chain Chain Slack Inspection


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Drive ChainThe drive chain slack and lubrication

must be checked each day before rid-ing the motorcycle and must be main-tained in accordance with the PeriodicMaintenance Chart for safety and toprevent excessive wear. If the chain

becomes badly worn or maladjusted -either too loose or too tight - the chaincould jump off the sprockets or break.

WARNING

A chain that breaks or jumps offthe sprockets could snag on theengine sprocket or lock the rearwheel, severely damaging the

motorcycle and causing it to goout of control. Inspect the chainfor damage and proper adjust-ment before each ride.

Chain Slack Inspection

Set the motorcycle up on its sidestand.

Rotate the rear wheel to find the po-sition where the chain is tightest, andmeasure the maximum chain slack

by pulling up and pushing down thechain midway between the enginesprocket and rear wheel sprocket.

A. Chain Slack


If the drive chain is too tight or too Loosen the left and right chain ad


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If the drive chain is too tight or tooloose, adjust it so that the chain slack

will be within the standard value.Drive Chain Slack

Standard: 2535 mm (1.01.4 in.)

Chain Slack Adjustment

Remove the cotter pin, and loosenthe axle nut.

Loosen the left and right chain ad-juster locknuts.

A. Axle NutB. Cotter PinC. AdjusterD. Locknut

If the chain is too loose, turn out theleft and right chain adjusters evenly.

If the chain is too tight, turn in the leftand right chain adjusters evenly.


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Tightening Torque Install a new cotter pin through the


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Tightening Torque

Axle Nut:

127 Nm (13.0 kgfm, 93.7 ftlb)

NOTE

If a torque wrench is not available,this item should be serviced by anauthorized Kawasaki dealer.

Rotate the wheel, measure the chainslack again at the tightest position,

and readjust if necessary.

Install a new cotter pin through theaxle nut and axle, and spread its

ends.

A. Cotter Pin

NOTEWhen inserting the cotter pin, if theslots in the nut do not align withthe cotter pin hole in the axle shaft,tighten the nut clockwise up to the

next alignment.It should be within 30 degrees.


Loosen once and tighten again when Check the rear brake (see Brakes


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Loosen once and tighten again whenthe slot goes past the nearest hole.

A. Turn Clockwise

WARNING

A loose axle nut can lead to anaccident resulting in serious in-jury or death. Tighten the axlenut to the proper torque and in-

stall a new cotter pin.

Check the rear brake (see Brakessection in this chapter).

Wear Inspection

Remove the left front footpeg bracketbolts.

A. Front Footpeg BracketB. Bolts


Remove the bolts and chain cover If the length exceeds the service limit


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Remove the bolts and chain cover.

A. BoltsB. Chain Cover

Stretch the chain taut either by usingthe chain adjusters, or by hanging a

10 kg (22 lb) weight on the chain. Measure the length of 20 links on the

straight part of the chain from the pincenter of the 1st pin to the pin centerof the 21st pin. Since the chain may

wear unevenly, take measurementsat several places.

If the length exceeds the service limit,the chain should be replaced.

A. MeasureB. Weight

Drive Chain 20-Link Length

Service Limit:

319 mm (12.56 in.)


NOTE Rotate the rear wheel to inspect the


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NOTE

Install the chain cover and front foot-peg bracket in the reverse order ofremoval.

Reinstall the left footpeg bracket sothat both footpegs are same position.

Apply the nonpermanent lockingagent to the chain cover front sidebolt.

Tightening Torque

Front Footpeg Bracket Bolts:

25 Nm (2.5 kgfm, 18 ftlb)

WARNING

For 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, and

loose pins and links. Also inspect the sprockets for un-

evenly or excessively worn teeth,and damaged teeth.

NOTESprocket wear is exaggerated for il-

lustration. See Service Manual forwear limits.


any time that the chain appears dry. A


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A. Good TeethB. Worn TeethC. Damaged Teeth

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

dealer.

LubricationLubrication is also necessary after

riding through rain or on wet roads, or

y pp yheavy oil such as SAE 90 is preferred

to a lighter oil because it will stay on thechain longer and provide better lubrica-tion.

Apply oil to the sides of the rollers sothat it will penetrate to the rollers and

bushings. 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 it Brakes


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p y y,using diesel oil or kerosine and then

apply oil as described above.Brake Wear Inspection

Inspect the brakes for wear. For eachfront and rear disc brake caliper, if thethickness of either pad is less than1 mm (0.04 in.), replace both pads

in the caliper as a set. Pad replace-ment should be done by an authorizedKawasaki dealer.

A. Lining Thickness

B. 1 mm (0.04 in.)


Brake Fluid - Fluid Level Inspection


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In accordance with the Periodic Main-

tenance Chart, inspect the brake fluidlevel in both the front and rear brakefluid reservoirs and change the brakefluid. The brake fluid should also bechanged if it becomes contaminated

with dirt or water.

Fluid RequirementUse heavy-duty brake fluid only from

a container marked DOT4.

NOTICE

Do 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 around

the fittings.Check brake hose for damage.

p

With the brake fluid reservoirs heldhorizontal, the brake fluid level mustbe kept between the upper and lowerlevel lines.

A. Front Brake Fluid ReservoirB. Upper Level LineC. Lower Level Line


WARNING


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A. Rear Brake Fluid ReservoirB. Upper Level LineC. Lower Level Line

If the fluid level in either reservoir islower than the lower level line, checkfor fluid leaks in the brake lines, and

fill the reservoir to the upper levelline.

Mixing brands and types ofbrake fluid can reduce the brakesystems effectiveness andcause an accident resulting ininjury or death. Do not mix two

brands of brake fluid. Changethe brake fluid in the brake linecompletely if the brake fluidmust be refilled but the typeand brand of the brake fluid that

is already in the reservoir areunidentified.

NOTE

First, tighten until slight resistance isfelt, which indicates that the cap isseated on the reservoir body, andtighten the cap an additional 1/6 turnwhile holding the brake fluid reservoir

body.


So there are no parts that require ad-


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A. ReservoirB. CapC. ClockwiseD. 1/6 turn

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.

justment on the front and rear brakes.

WARNING

Air in the brake lines diminishbraking performance and cancause an accident resulting ininjury or death. If the brake leveror pedal feels mushy when itis applied, there might be air inthe brake lines or the brake may

be defective. Have the brakechecked immediately by an au-thorized Kawasaki dealer.


Brake Light SwitchesWh ith th f t b k i

Check the operation of the rear brakeli ht it h b d i th b k


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When 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 when

the front brake is applied.

If it does not, ask an authorizedKawasaki dealer to inspect the frontbrake light switch.

light switch by depressing the brake

pedal. The brake light should go onafter the proper pedal travel.

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

If it does not, adjust the rear brakelight switch.

Brake Pedal Travel

10 mm (0.4 in.)


AdjustmentR th i ht f t f t


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Remove the right front footpegbracket bolts. Pull the front footpeg bracket a littlebit outward.

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 laterE. Viewed from behind the bracket

NOTICE

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


NOTE Electronic Steering DamperThis motorc cle is eq ipped ith a


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Install the front footpegs with sameheight on both sides. Refer to theFront Footpeg Position in General In-formation chapter.

This motorcycle is equipped with a

electronic steering damper unit.The steering operation should bechecked and the electronic steeringdamper unit should be inspected for oilleakage each day before riding, and

the maintenance must be carried outin accordance with the Periodic Main-tenance Chart.


Front ForkThe front fork operation and oil leak

Front Fork Inspection

Holding the brake lever pump the


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The front fork operation and oil leak-

age should be checked in accordancewith the Periodic Maintenance Chart.

For various riding or load conditionsthe front fork can be adjusted for:

Spring preload Rebound damping force Compression damping force

WARNING

Improper fork leg adjustmentcan cause poor handling andloss of stability, which couldlead to an accident. Always ad-

just the fork legs on the left andright side to the same setting.

Holding the brake lever, pump thefront fork up and down several timesto inspect smooth stroke.

Visually inspect the front fork for oilleakage, scoring or scratches on theouter surface of the inner tube.

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

A. Inner Tube


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Spring Preload Setting

Adj t P iti 0* 6 t i ** 15 t i **


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Adjuster Position 0* 6 turns in** 15 turns in**

Spring Action Weak Standard Strong

Setting Soft Standard Hard

Load Light Standard Heavy

Road Good Standard BadSpeed Low Standard High

*: This position is the fully seated position (turned fully counterclockwise).**: In from the fully seated position (turned fully counterclockwise). This adjust-

ment range may not exactly match the number shown in the table due to smalltolerance of production.


Compression Damping Force Adjusterand Rebound Damping Force


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and Rebound Damping Force

Adjuster AdjustmentThe compression damping force ad-juster and the rebound damping forceadjuster are located on top of each frontfork leg.

Turn the adjuster clockwise with ascrewdriver to increase dampingforce.

Turn the adjuster counterclockwiseto decrease damping force.

NOTICE

Do not force to turn the reboundand compression damping force

adjuster from the fully seated po-sition, or the adjusting mecha-nism may be damaged.

A. Compression Damping Force Adjuster(COM)

B. Rebound Damping Force Adjuster (TEN)C. Screwdriver


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The standard front fork setting positions are as follows:Standard Setting Position (Front Fork)


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g ( )

Spring Preload Adjuster 6 turns in*Compression Damping Adjuster 4 1/2 turns out**

Rebound Damping Adjuster 3 3/4 turns out**

*: In from the fully seated position (turned fully counterclockwise)**: Out from the fully seated position (turned fully clockwise)


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Rebound Damping Force AdjustmentThe rebound damping force adjuster

Using a screwdriver turn the rebounddamping force adjuster clockwise


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p g j

is located at the upper end of the rearshock absorber.

A. Rebound Damping Force AdjusterB. To increase damping force

C. To decrease damping force

p g j

to increase rebound damping oranti-clockwise to decrease it.

NOTICE

Do not turn the rebound damp-ing force adjuster beyond thefully seated position or the ad-justing mechanism may be dam-aged.


Rebound Damping Force Setting

Adj t P iti 0*1 3/4 turns

3 t t**


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Adjuster Position 0* 1 3/4 turns

out**

3 turns out**

Damping Force Strong Standard Weak

Setting Hard Standard Soft

Load Heavy Standard Light

Road Bad Standard Good

Speed High Standard Low

*: This position is the fully seated position (turned fully clockwise).

**: Out from the fully seated position (turned fully clockwise). This adjustmentrange may not exactly match the number shown in the table due to small toleranceof production.


Compression Damping ForceAdjustment

NOTE

Turning the high speed adjuster has


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The compression damping force ad-justers for high and low speeds are lo-cated on the gas reservoir at the leftside of the rear shock absorber.

A. High Speed AdjusterB. Low Speed Adjuster

Turning the high speed adjuster hasthe low speed adjuster turning. Al-though the low speed adjuster turnswith the high speed adjuster whenturning the high speed adjuster, thelow speed adjuster setting position

dose not change.

Low Speed Compression DampingAdjustment

Using a screwdriver turn the lowspeed compression adjuster screwclockwise to increase damping forceor counterclockwise to decrease it.

High Speed Compression DampingAdjustment

Turn the high speed compressiondamping force adjuster clockwise toincrease damping force or counter-

clockwise to decrease it.


NOTICE

Do not turn the compression


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Do not turn the compression

damping force adjuster beyondthe fully seated position or theadjusting mechanism may bedamaged.

A. Compression Damping Force Adjuster forHigh Speed

B. To increase damping forceC. To decrease damping force


Compression Damping Force Setting for High and Low Speeds

High Speed 0* 1 3/4 turns out** 5 turns out**Adjuster


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g pAdjuster

Positions Low Speed 0* 1 3/4 turns out** 5 turns out**

Damping Force Strong Standard Weak

Setting Hard Standard Soft

Load Heavy

Standard

LightRoad Bad Standard Good

Speed High Standard Low

*: This position is the fully seated position (turned fully clockwise).**: Out from the fully seated position (turned fully clockwise). This adjustmentrange may not exactly match the number shown in the table due to small toleranceof production.


The standard suspension setting positions are as follows:Standard Setting Position (Rear Shock Absorber)


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Rebound Damping Adjuster 1 3/4 turns out*High Speed 1 3/4 turns out*

Compression Damping AdjusterLow Speed 1 3/4 turns out*

*: Out from the fully seated position (turned fully clockwise)


WheelsTubeless tires are installed on the


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wheels of this motorcycle. The indica-tions of TUBELESS on the tire sidewall and the rim show that the tire andrim are specially designed for tubelessuse.

A. TUBELESS Mark

A. TUBELESS Mark

The tire and rim form a leakproof unitby making airtight contacts at the tirechamfers and the rim flanges insteadof using an inner tube.


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Tire pressure is affected by changesin ambient temperature and altitude,

Tire Air Pressure (when cold)

Front 250 kPa (2.50 kgf/cm, 36 psi)


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and so the tire pressure should bechecked and adjusted when your rid-ing involves wide variations in tem-perature or altitude.

A. Tire Pressure Gauge

Rear 290 kPa (2.90 kgf/cm, 42 psi)

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 to

use 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.


Visually inspect the tire for cracksand cuts, replacing the tire in case of


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A. Tire Depth Gauge

Minimum Tread Depth

Front 1 mm

(0.04 in.)

Under 130 km/h(80 mph)

2 mm(0.08 in.)

RearOver 130 km/h(80 mph)

3 mm(0.12 in.)

bad 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.


WARNING

Tires that have been punctured

Standard Tire (Tubeless)

120/70ZR17 M/C (58W)


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and repaired do not have thesame capabilities as undam-aged tires and can suddenly fail,causing an accident resultingin serious injury or death. Re-place damaged tires as soon aspossible. To ensure safe han-dling and stability, use only therecommended standard tires for

replacement, inflated to the stan-dard pressure. If it is necessaryto ride on a repaired tire, do notexceed 100 km/h (60 mph) untilthe tire is replaced.

NOTE

When operating on public roadways,keep maximum speed under traffic

law limits.

BRIDGESTONEFront BATTLAX BT016F CC190/55ZR17 M/C (75W)

BRIDGESTONERearBATTLAX BT016R CC

WARNING

Some replacement tires may

adversely affect handling andcause an accident resulting inserious injury or death. To en-sure proper handling and stabil-ity, use only the recommendedstandard tires for replacement,inflated to the standard pres-sure.


WARNING

New tires are slippery and may

BatteryThe battery installed in this motorcy-


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cause 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.

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 pulledoff once the specified electrolyte has

been 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 thebatterys 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


type of battery and ambient temper-ature. As temperature rises, so does

Self-discharge

Approx. number of days


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the discharge rate. Every 15C (59F)doubles the rate.Electrical accessories, such as digi-

tal clocks and computer memory, alsodraw current from the battery even

when the key is switched off. Due toa combination of such key-off drawsand hot temperature, a battery can gofrom fully charged to completely dis-charged in a matter of days.

from 100% charged to100% discharged

Lead-Antimony

Lead-Calcium

Temperature

Battery Battery40C

(104F) 100 Days 300 Days

25C (77F) 200 Days 600 Days

0C (32F) 550 Days 950 Days


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If you will not be using the motorcy-cle for longer than two weeks, thebattery should be charged using an

Yuasa MB-2040/2060Christie C10122S


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y g gappropriate charger. Do not use an au-tomotive-type quick charger that mayovercharge the battery and damage it.

NOTE

Leaving the battery connectedcauses the electrical components(clock etc) to make the battery dis-charged, resulting the over discharge

of the battery. In this case, the repairor replacement of the battery is notincluded in the warranty. If you donot drive for four weeks or more, dis-connect the battery from the vehicle.

Kawasaki-recommended chargersare:Battery Mate 150-9OptiMate 4

If the above chargers are not avail-able, use equivalent one.

For more details, ask your Kawasakidealer.

Battery Charging

Remove the battery from the motor-cycle (see Battery Removal).

Attach the leads from the chargerand charge the battery at a rate (am-perage x hours) that is indicated onthe battery. If it is not possible to readthe rate, charge the battery at an am-perage that is about 1/10th of the bat-

tery capacity.

The charger will keep the battery fullycharged until you are ready to re-install the battery in the motorcycle(see Battery Installation).


NOTICE

Never remove the sealing strip,

WARNING

Battery posts, terminals and re-


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

NOTE

If you charge the sealed battery,never fail to observe the instructions

shown in the label on the battery.

lated accessories contain leadand lead compounds, chemicalsknown to the State of Californiato cause cancer and reproduc-tive harm. Wash hands after

handling.

Battery Removal

Remove the riders seat (see Seatssection in the GENERAL INFORMA-TION chapter).

Turn the ignition switch to OFF anddisconnect the () cable from the bat-tery.

Remove the red cap form the (+) ter-minal, and disconnect the (+) cablesfrom the battery.


NOTE

The battery is different in the model


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equipped with KIBS and the modelwithout KIBS. The (+) terminal and() terminal are right and left re-versed.

A. For models equipped with KIBSB. (+) TerminalC. () TerminalD. Rubber Band

A. For models without KIBSB. (+) Terminal

C. () TerminalD. Rubber Band

Unlock the rubber band. Take the battery out of the case.

Be sure that the cable connectionsare clean.Battery Installation

Place the battery in the battery case.


Connect the (+) cable to the (+) ter-minal, and then connect the () cableto the () terminal.

Headlight Beam


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NOTICE

Installing the () cable to the (+)terminal of the battery or the (+)cable to the () terminal of thebattery can seriously damagedthe electrical system.

Put a light coat of grease on the ter-minals to prevent corrosion. Cover the (+) terminal with the red

cap.

Reinstall the removed parts.

NOTEDo not turn the bolts because the re-flector in the headlight comes off.

A. Bolts

The left and right adjusters on theheadlight can move the direction ofthe headlight beam to up, down, left

and right by turning each adjuster it-self as the below table.


TurningDirection of

Adj t

MovingDirection of

Headlight

B


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A. Left AdjusterB. Right Adjuster

Adjuster Beam

Clockwise Left and

DownLeft Adjuster

Counter-

clockwise Right and Up

Clockwise Right and

DownRightAdjuster Counter-

clockwise

Left and Up

To move the headlight beam left-ward, turn the left adjuster clockwiseand turn the right adjuster counter-

clockwise same number as the leftadjuster was turned until the beampoints straight ahead.


To move the headlight beam upward,turn the both adjusters counterclock-wise same number.T h h dli h b d


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A. Left AdjusterB. Right Adjuster

To move the headlight beam right-ward, turn the left adjuster counter-clockwise and turn the right adjusterclockwise same number as the left

adjuster was turned until the beampoints straight ahead.

If not properly adjusted horizontally,the beam will point to one side ratherthan straight ahead.

To move the headlight beam down-ward, turn the both adjusters clock-wise same number.

If adjusted too low, neither low norhigh beam will illuminate the road farenough ahead. If adjusted too high,the high beam will fail to illuminatethe road close ahead, and the lowbeam will blind oncoming drivers.

NOTE

On high beam, the brightest pointsshould be slightly below horizontal.The proper angle is 0.4 degrees be-low horizontal. This is a 50 mm (2.0in.) drop at 7.6 m (25 ft) measuredfrom the center of the headlight, withthe motorcycle on its wheels and the

rider seated.


FusesFuses are arranged in the fuse boxes

located under the passengers seat andi th l ft f i i Th i f i


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A. 50 mm (2.0 in.)B. Center of Brightest Spot

C. 7.6 m (25 ft)D. Height of Headlight Center

in the left fairing. The main fuse islocated under the passengers seat.

If a fuse fails during operation, in-spect the electrical system to deter-

mine the cause, and then replace it witha new fuse of proper amperage.The main fuse removal should be

done by an authorized Kawasakidealer.



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A. Fuse Box A. Fuse BoxB. Fuse Box (for models equipped with KIBS)

C. Main Fuse


WARNING

Substituting fuses can cause

wiring to overheat catch fire


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wiring to overheat, catch fireand/or fail. Do not use any sub-stitute for the standard fuse.Replace the blown fuse with anew one of the correct capacity,

as specified on the fuse box andmain fuse.

A. NormalB. Failed


General LubricationLubricate the points shown below,

with either motor oil or regular grease,in accordance with the Periodic Main

Apply motor oil to the followingpivots -

Side StandClutch Lever


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in accordance with the Periodic Main-tenance Chart or whenever the vehiclehas been operated under wet or rainyconditions.

Before lubricating each part, clean offany 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.

Clutch Lever Front Brake Lever Rear Brake Pedal

Lubricate the following cables with apressure cable luber -

(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

Cleaning Your Motorcycle

General Precautions

Frequent and proper care of your


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(K) Throttle Inner Cable Upper Ends(K): Should be serviced by an authorized

Kawasaki dealer.

NOTE

After connecting the cables, adjustthem.

Frequent and proper care of yourKawasaki motorcycle will enhanceits appearance, optimize overall per-formance, and extend its useful life.Covering your motorcycle with a high

quality, breathable motorcycle coverwill help protect its finish from harmfulUV rays, pollutants, and reduce theamount of dust reaching its surfaces.


WARNING

Build-up of debris or flammable

material in and around the vehi-

Be sure the engine and exhaust arecool before washing.

Avoid applying degreaser to seals,brake pads and tires


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material in and around the vehi-cle chassis, engine, and exhaustcan cause mechanical problemsand increase the risk of fire.When operating the vehicle in

conditions that allow debris orflammable material to collect inand around the vehicle, inspectthe engine, electrical componentand exhaust areas frequently. Ifdebris or flammable materialshave collected, park the vehi-cle outside and stop the engine.Allow the engine to cool, then

remove any collected debris. Donot park or store the vehicle inan enclosed space prior to in-specting for build-up of debrisor flammable materials.

brake pads, and tires. Avoid all harsh chemicals, solvents,detergents, and household cleaningproducts such as ammonia-based

window 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 lens, and otherplastic parts as they can easily be

scratched.

Avoid using pressure washers; wa-ter can penetrate seals and electricalcomponents and damage your mo-torcycle.


Avoid spraying water in delicateareas such as in air intakes, fuelsystem, brake components, electri-cal components muffler outlets and

motorcycle. If needed, use a mild de-greaser to remove any oil or greasewhich build up.

After washing rinse your motorcy-


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cal components, muffler outlets, andfuel tank openings.

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 a bucket. Usea soft cloth or sponge to wash your

After washing, rinse your motorcycle thoroughly with clean water to re-move any residue (residue from thedetergent can damage parts of your

motorcycle). 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.


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several times. This helps the brakesdry and restores its normal operatingperformance.

Lubricate the drive chain to prevent

headlight. Gradually the condensa-tion on the inside of the lens will clearoff.


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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 chemical

reaction of the salt. After drying,apply a corrosion protection sprayon all metal and chrome surfaces toprevent corrosion.

Condensation may form on the insideof the headlight lens after riding in therain, washing the motorcycle or hu-mid weather. To remove the mois-ture, start the engine and turn on the

Semi-gloss FinishTo clean the semi-gloss finish;

When washing the motorcycle, al-ways use a mild neutral detergentand water.

The semi-gloss finish effect may belost when the finish is excessivelyrubbed.

If any doubt, consult an authorizedKawasaki dealer.Windshield and Other Plastic Parts

After washing use a soft cloth to

gently dry plastic parts. When dry,treat the windshield, headlight lens,and other nonpainted plastic parts withan approved plastic cleaner/polisherproduct.


NOTICE

Plastic parts may deteriorate

and break if they come in con-tact ith chemical s bstances

should be washed with a mild neu-tral detergent and finished with a spraypolish. Aluminum wheels, both paintedand unpainted can be cleaned with


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ytact with chemical substancesor household cleaning productssuch as gasoline, brake fluid,window cleaners, thread-locking

agents, 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 parts finish.

Chrome and AluminumChrome and uncoated aluminum

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

pspecial non-acid based wheel spraycleaners.

Leather, Vinyl, and Rubber

If 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 therest of the motorcycle, then treated with

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


WARNING

Rubber protectants can be slip-

pery and, if used on the treadarea cause loss of traction re


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p y ,area, cause loss of traction re-sulting in accident causing in-jury or death. Do not apply rub-ber protectant to any tread area.


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 cotter

pin is in place and in good condition. Please ask your authorized Kawasaki dealer


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p p g yfor torque values.

1. Clutch Lever Holder Bolts2. Steering Stem Head Nut

3. Handlebar Clamp Bolts4. Front Fork Clamp Bolts5. Brake Lever Mounting

Bolts


6. Front Fender MountingBolts

7. Engine Mounting Bolts

and Nuts8. Rear Frame Mounting Bolts


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8. Rear Frame Mounting Bolts9. Brake Disc Mounting Bolts10. Front Axle Clamp Bolts11. Front Axle Nut12. Caliper Mounting Bolts

13. Side Stand Bolt14. Suspension Likage

Tie-Rod Nuts15. Swingarm Pivot Shaft Nut16. Footpeg Mounting Bolts17. Rear Shock Absorber

Mounting Bolts18. Rear Axle Nut19. Rear Sprocket Nuts


20. Silencer Mounting Bolt21. Brake Pedal Bolt

22. Exhaust Pipe MountingBolt and Nuts


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Manual Propietario ZX-10R 2013

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