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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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112 MAINTENANCE AND ADJUSTMENT
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 ADJUSTMENT 113
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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114 MAINTENANCE AND ADJUSTMENT
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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116 MAINTENANCE AND ADJUSTMENT
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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MAINTENANCE AND ADJUSTMENT 117
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
Evaporativeemission controlsystem - function(California modelonly) (e)
140
KAir suction systemdamage - inspect(e)
142
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118 MAINTENANCE AND ADJUSTMENT
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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MAINTENANCE AND ADJUSTMENT 119
Frequency Whichevercomes
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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120 MAINTENANCE AND ADJUSTMENT
Frequency Whichevercomes
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
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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MAINTENANCE AND ADJUSTMENT 121
Frequency Whichevercomes
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
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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MAINTENANCE AND ADJUSTMENT 123
Frequency Whichevercomes
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
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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124 MAINTENANCE AND ADJUSTMENT
Frequency Whichevercomes
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
Chassis:
K Chassis parts -
lubricate year 201
K Bolts and nuts
tightness - inspect 209
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MAINTENANCE AND ADJUSTMENT 125
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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MAINTENANCE AND ADJUSTMENT 127
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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128 MAINTENANCE AND ADJUSTMENT
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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MAINTENANCE AND ADJUSTMENT 129
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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MAINTENANCE AND ADJUSTMENT 131
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
132 MAINTENANCE AND ADJUSTMENT
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132 MAINTENANCE AND ADJUSTMENT
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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134 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 135
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MAINTENANCE AND ADJUSTMENT 135
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
MAINTENANCE AND ADJUSTMENT 137
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MAINTENANCE AND ADJUSTMENT 137
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.
MAINTENANCE AND ADJUSTMENT 141
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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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MAINTENANCE AND ADJUSTMENT 153
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.
154 MAINTENANCE AND ADJUSTMENT
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
MAINTENANCE AND ADJUSTMENT 155
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.
156 MAINTENANCE AND ADJUSTMENT
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
MAINTENANCE AND ADJUSTMENT 157
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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MAINTENANCE AND ADJUSTMENT 159
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.
160 MAINTENANCE AND ADJUSTMENT
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
MAINTENANCE AND ADJUSTMENT 161
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.)
162 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 163
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.
164 MAINTENANCE AND ADJUSTMENT
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.)
MAINTENANCE AND ADJUSTMENT 165
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
166 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 167
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.
168 MAINTENANCE AND ADJUSTMENT
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.)
MAINTENANCE AND ADJUSTMENT 169
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.
170 MAINTENANCE AND 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.
MAINTENANCE AND ADJUSTMENT 171
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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MAINTENANCE AND ADJUSTMENT 173
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.
174 MAINTENANCE AND ADJUSTMENT
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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176 MAINTENANCE AND ADJUSTMENT
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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178 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 179
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.
180 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 181
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
182 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 183
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)
184 MAINTENANCE AND ADJUSTMENT
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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186 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 187
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.
188 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 189
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
190 MAINTENANCE AND ADJUSTMENT
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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192 MAINTENANCE AND ADJUSTMENT
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).
MAINTENANCE AND ADJUSTMENT 193
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.
194 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 195
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.
196 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 197
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.
198 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 199
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A. Fuse Box A. Fuse BoxB. Fuse Box (for models equipped with KIBS)
C. Main Fuse
200 MAINTENANCE AND ADJUSTMENT
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
MAINTENANCE AND ADJUSTMENT 201
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
202 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 203
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.
204 MAINTENANCE AND ADJUSTMENT
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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206 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 207
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.
208 MAINTENANCE AND ADJUSTMENT
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.
MAINTENANCE AND ADJUSTMENT 209
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
210 MAINTENANCE AND ADJUSTMENT
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
MAINTENANCE AND ADJUSTMENT 211
20. Silencer Mounting Bolt21. Brake Pedal Bolt
22. Exhaust Pipe MountingBolt and Nuts
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