Post on 05-Apr-2018
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172 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 made by the owner.
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MAINTENANCE AND ADJUSTMENT 173
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporatedcrankcase emission (1) and exhaust emission (2) control systems in compliance
with applicable regulations of the United States Environmental Protection Agencyand California Air Resources Board. Additionally, Kawasaki has incorporated anevaporative emission control system (3) in compliance with applicable regulationsof the United States Environmental Protection Agency.
1. Crankcase Emission Control SystemThis system eliminates the release of crankcase vapors into the atmosphere.
Instead, the vapors are routed through an oil separator to the intake side of theengine. While the engine is operating, the vapors are drawn into the combustionchamber, where they are burned along with the fuel and air supplied by the fuelinjection system.
2. Exhaust Emission Control System
This 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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174 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)Vapors caused by fuel evaporation in the fuel system are not vented into the
atmosphere. Instead, fuel vapors are routed into the running engine to be burned,or stored in a canister when the engine is stopped. Liquid fuel is caught by a vaporseparator and returned to the fuel tank.
High Altitude Performance Adjustment InformationHigh altitude adjustment is not required.
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.
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MAINTENANCE AND ADJUSTMENT 175
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 265 through 268 of thismanual where an authorized Kawasaki dealer, or someone equally competent, canrecord the maintenance. You should also retain copies of maintenance work orders,bills, etc., as verification of this maintenance.
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176 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 orelement of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:* Replacement of the original exhaust system or muffler with a component not 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.
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MAINTENANCE AND ADJUSTMENT 177
Periodic Maintenance Chart1. Periodic Inspection (Engine Related Items)
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Operation(Engine Items)
Every1
(0.6)6
(3.75)12
(7.5)18
(11.25)24
(15)30
(18.75)36
(22.5)
SeePage
Valve clearance- inspect 204Throttle controlsystem (play,smooth return,no drag) -inspect
year 213
Engine vacuumsynchronization
- inspect 215
Idle speed -inspect 216
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178 MAINTENANCE AND ADJUSTMENT
Frequency Whichevercomes first *Odometer Reading
km 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
KFuel leak (fuelhose and pipe) -inspect
year
K
Fuel hoses
damage -inspect
year
K
Fuel hosesinstallationcondition -inspect
year
Coolant level -inspect 200Coolant leak -inspect
year 198
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MAINTENANCE AND ADJUSTMENT 179
Frequency Whichevercomes first *Odometer Reading
km 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
Radiator hosedamage -inspect
year 198
Radiator hoses
installationcondition -inspect
year 198
Evaporativeemissioncontrol system- function
(Californiamodel only)
203
Air suctionsystem damage- inspect
205
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180 MAINTENANCE AND ADJUSTMENT
2. Periodic Inspection (Chassis Related Items)
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Operation(ChassisItems)
Every1
(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
217
Clutch fluid level- inspect
6 months 218
Clutch fluid leak- inspect year Clutch hosedamage -inspect
year
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MAINTENANCE AND ADJUSTMENT 181
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Operation(ChassisItems)
Every1
(0.6)6
(3.75)12
(7.5)18
(11.25)24
(15)30
(18.75)36
(22.5)
See
Page
Clutch hoseinstallationcondition -inspect
year
Final gear caseoil level - inspect#
194
Wheels and tires:
Tire air pressure- inspect
year 232Wheels/tiresdamage -inspect
233
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182 MAINTENANCE AND ADJUSTMENT
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Operation(ChassisItems)
Every1
(0.6)6
(3.75)12
(7.5)18
(11.25)24
(15)30
(18.75)36
(22.5)
See
Page
Tire tread wear,abnormal wear -inspect
233
K Wheel bearingsdamage -inspect
year
Brake system:
Brake fluid leak- inspect
year 220
Brake hosesand pipedamage -inspect
year 219
Brake pad wear- inspect # 219
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MAINTENANCE AND ADJUSTMENT 183
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Operation(ChassisItems)
Every1
(0.6)6
(3.75)12
(7.5)18
(11.25)24
(15)30
(18.75)36
(22.5)
See
Page
Brake hoseinstallationcondition -inspect
year 219
Brake fluid level- inspect
6 months 220Brake operation(effectiveness,play, drag) -inspect
year 221
Brake lightswitch operation- inspect
222
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184 MAINTENANCE AND ADJUSTMENT
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Operation(ChassisItems)
Every1
(0.6)6
(3.75)12
(7.5)18
(11.25)24
(15)30
(18.75)36
(22.5)
See
Page
Suspensions:
Front forks/rearshock absorber
operation(damping andsmooth stroke) -inspect
224/228
Front forks/rearshock absorberoil leak - inspect
year 224/228
KUni-trak rockerarm operation -inspect
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MAINTENANCE AND ADJUSTMENT 185
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Operation(ChassisItems)
Every1
(0.6)6
(3.75)12
(7.5)18
(11.25)24
(15)30
(18.75)36
(22.5)
See
Page
KUni-trak tierods operation -inspect
Steering system:
KSteering play -inspect
year
KSteering stembearings -lubricate
2 years
Electrical system:Lights andswitchesoperation -inspect
year
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186 MAINTENANCE AND ADJUSTMENT
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Operation(ChassisItems)
Every1
(0.6)6
(3.75)12
(7.5)18
(11.25)24
(15)30
(18.75)36
(22.5)
See
Page
Headlightaiming - inspect
year 245Side stand
switch operation- inspect year Engine stopswitch operation- inspect
year
Chassis:
Chassis parts -lubricate
year 249Bolts and nutstightness -inspect
256
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MAINTENANCE AND ADJUSTMENT 187
3. Periodic Replacement
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Change/Replacement ItemsEvery
1(0.6)
12(7.5)
24(15)
36(22.5)
48(30)
SeePage
Air cleaner element # - replace every 18 000 km (11 250 mile) 207
K Engine oil # - change year 191
K Oil filter - replace year 191K Fuel hoses - replace 4 years K Coolant - change 3 years 202K
Radiator hoses and O-rings -replace
3 years
K Brake or clutch hoses - replace 4 years K
Brake or clutch fluid (front andrear) - change
2 years 218/221
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188 MAINTENANCE AND ADJUSTMENT
Frequency Whichevercomes first *Odometer Reading
km 1 000 (mile 1 000)
Change/Replacement ItemsEvery 1
(0.6)12
(7.5)24
(15)36
(22.5)48
(30)
SeePage
KRubber parts of mastercylinder and caliper (or slavecylinder) - replace
4 years
Spark plug - replace 202Final gear case oil - change 195
K: 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.
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MAINTENANCE AND ADJUSTMENT 189
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 PeriodicMaintenance Chart. Not only do dirtand metal particles collect in the oil, butthe oil itself loses its lubricative qualityif used too long.
WARNING
Motorcycle 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 theperiodic maintenance chart inthe Owners Manual.
Oil Level Inspection
If the oil has just been changed, startthe engine and run it for several min-utes at idle speed. This fills the oil
filter with oil. Stop the engine, thenwait several minutes until the oil set-tles.
NOTICE
Racing the engine before the oil
reaches every part can cause en-gine seizure.
If the motorcycle has just been used,wait several minutes for all the oil todrain down.
Check the engine oil level throughthe oil level gauge. With the motor-cycle held level, the oil level shouldcome up between the upper andlower level lines next to the gauge.
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190 MAINTENANCE AND ADJUSTMENT
A. Oil Level GaugeB. Oil Filler CapC. Upper Level LineD. Lower Level Line
If the oil level is too high, remove theexcess oil through the oil filler open-ing using a syringe or some other
suitable device.
If the oil level is too low, add oil toreach the correct level. Use thesame type and brand of oil that isalready in the engine.
NOTICE
If the engine oil gets extremelylow or if the oil pump does notfunction properly or oil pas-sages are clogged, the oil pres-
sure warning indicator lightwill go on. If it stays on whenthe engine speed is above idle,stop the engine immediately andhave it serviced. Failure to doso could cause serious engine
damage.
191
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MAINTENANCE AND ADJUSTMENT 191
A. Oil Pressure Warning Indicator Light
Oil and/or Oil Filter Change
To change the engine oil and replaceoil filter, the engine oil drain bolt andoil filter must be removed. The oil
change and oil filter replacementshould be done by an authorizedKawasaki dealer.
A. Engine Oil Drain Bolt
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192 MAINTENANCE AND ADJUSTMENT
A. Oil Filter
WARNING
Motor oil is a toxic substance.Dispose of used oil properly.Contact your local authorities
for approved disposal methodsor possible recycling.
Tightening Torque
Engine Oil Drain Bolt:30 Nm (3.1 kgfm, 22 ftlb)
Oil Filter:
17 Nm (1.7 kgfm, 13 ftlb)
Recommended Engine Oil
Type:Kawasaki Performance 4-StrokeMotorcycle Oil*Kawasaki Performance 4-Stroke
Semi-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
MAINTENANCE AND ADJUSTMENT 193
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MAINTENANCE AND ADJUSTMENT 193
Engine Oil Capacity
Capacity:4.0 L (4.2 US qt) (when filter is notremoved)
4.4 L (4.7 US qt) (when filter isremoved)4.7 L (5.0 US qt) (when engine iscompletely dry)
NOTE
Do not add any chemical additive tothe oil. Oils fulfilling the above re-quirements are fully formulated and
provide adequate lubrication for boththe engine and the clutch.
Although 10W-40 engine oil is the
recommended oil for most condi-tions, the oil viscosity may need tobe changed to accommodate atmo-spheric conditions in your riding area.
*Kawasaki Performance Oils and Lu-bricants have been specifically engi-neered for your vehicle. Consistentuse of these products meets or ex-ceeds warranty and service require-ments and can help to extend the lifeof your Kawasaki.
194 MAINTENANCE AND ADJUSTMENT
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194 MAINTENANCE AND ADJUSTMENT
Final Gear Case OilIn order for the pinion and ring gears
in the final gear case to function prop-erly, check the oil level, and change
the oil in accordance with the PeriodicMaintenance Chart.
WARNING
Motorcycle operation with insuf-ficient, deteriorated, or contam-
inated oil causes acceleratedwear of the differential, pinion,and ring gears and may resultin seizure. Seizure can lock therear wheel and skid the rear tire,with consequent loss of control.Check the differential oil accord-
ing to the periodic maintenancechart.
Oil Level Inspection
Use the center stand by holding themotorcycle vertical on level ground.
Remove the filler cap.
NOTICE
Be careful not to allow any dirtor foreign materials to enter thegear case.
MAINTENANCE AND ADJUSTMENT 195
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MAINTENANCE AND ADJUSTMENT 195
Check the oil level. If it is low, addoil as necessary. The oil level shouldcome to the top thread of the filleropening with the motorcycle held ver-
tical on level ground.
A. Top Thread
B. Filler Cap
NOTE
Use the same type and brand of oilthat is already in the final gear case.
Oil Change
NOTE
Final gear case oil drains easily andpicks up any sediment when the oilis warmed up by running the motor-cycle.
Put the motorcycle on its side stand. Place an oil pan beneath the gear
case.
Remove the filler cap and drain bolt.WARNING
Gear case oil is a toxic sub-stance. Dispose of used oilproperly. Contact your local au-
thorities for approved disposalmethods or possible recycling.
196 MAINTENANCE AND ADJUSTMENT
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196 MAINTENANCE AND ADJUSTMENT
A. Drain BoltB. Oil Filler Cap
WARNING
Oil on tires can make them slip-pery which can cause an acci-
dent and injury. When drainingor filling the gear case, be care-ful that no oil gets on the tires orrims. Clean off any oil that inad-vertently gets on them with soapand water.
After the oil has completely drainedout, install the drain bolt and a newgasket.
With the motorcycle held vertical on
level ground, fill the gear case up tothe top thread of the filler openingwith the oil specified below withoutturning the rear tire.
If the rear tire is turned, it is neces-sary to leave it for about six minutes.
Final Gear Case Oil
Oil Capacityabout 160 mL (5.41 USoz.)
Oil Type
API GL-5Hypoid gear oilabove 5C (41F) SAE 90below 5C (41F) SAE 80
NOTE
GL-5 indicates a quality and addi-tive rating. GL-6 rated hypoid gearoils can also be used.
MAINTENANCE AND ADJUSTMENT 197
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MAINTENANCE AND ADJUSTMENT 197
Install the filler cap. Cooling SystemRadiator and Cooling Fan -
Check the radiator fins for obstruc-
tion by insects or mud. Clean offany obstructions with a stream oflow-pressure water.
WARNING
The cooling fan spins at highspeed and can cause seriousinjuries. Keep your hands andclothing away from the coolingfan blades at all times.
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198 MAINTENANCE AND ADJUSTMENT
NOTICE
Using high-pressure water, asfrom a car wash facility, could
damage the radiator fins and im-pair the radiators effectiveness.Do not obstruct or deflect air-flow through the radiator byinstalling unauthorized acces-sories in front of the radiator orbehind the cooling fan. Inter-
ference with the radiator airflowcan lead to overheating and con-sequent engine damage.
Radiator Hoses -Check the radiator hoses for leakage,
cracks or deterioration, and connec-tions for leakage, or looseness eachday before riding the motorcycle, andin accordance with the Periodic Main-tenance Chart.
Coolant -Coolant absorbs excessive heat from
the engine and transfers it to the airat the radiator. If the coolant level be-
comes low, the engine overheats andmay suffer severe damage. Check thecoolant level each day before riding themotorcycle, also in accordance with theperiodic maintenance chart and replen-ish coolant if the level is low. Changethe coolant in accordance with the Pe-riodic Maintenance Chart.
Information for CoolantTo protect the cooling system (con-
sisting of the aluminum engine andradiator) from rust and corrosion, theuse of corrosion and rust inhibitor
chemicals in the coolant is essential. Ifcoolant containing corrosion and rustinhibitor chemicals are not used, overa period of time, the cooling system
MAINTENANCE AND ADJUSTMENT 199
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MAINTENANCE AND ADJUSTMENT 199
accumulates rust and scale in the wa-ter jacket and radiator. This will clogup the coolant passages, and con-siderably reduce the efficiency of the
cooling system.
WARNING
Coolant containing corrosion in-hitors for alminum engines andradiators include harmful chem-
icals for human body. Drinkingcoolant can result in serious in-
jury or death. Use coolant in ac-cordance with the instractions ofthe manufacturer.
Soft or distilled water must be used
with 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 in
the 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 the
cooling system. On the mixture ratioof coolant, choose the suitable one re-ferring to the relation between freezingpoint and strength directed on the con-tainer.
200 MAINTENANCE AND ADJUSTMENT
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NOTICE
Permanent types of antifreeze onthe market have anti-corrosion
and anti-rust properties. When itis diluted excessively, it loses itsanti-corrosion property. Dilute apermanent 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 at50% and has the freezing point of
35C (31F).
Coolant Level Inspection
Position the motorcycle so that it isperpendicular to the ground.
Check the coolant level through thecoolant level gauge on the reservetank located to the left of the engine.The coolant level should be between
the F (Full) and L (Low) level lines.
A. F (Full) Level Line
B. L (Low) Level LineC. Reserve Tank
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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 reservetank.
Coolant Filling
Remove the rear middle fairing (see
Air Cleaner section).
Remove the cap from the reservetank and add coolant through thefiller opening to the F (Full) level line.
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
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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 Kawasaki
dealer.
Install the reserve tank cap. Install the removed parts.Coolant Change
Have the coolant changed by an au-
thorized Kawasaki dealer.
Spark PlugsThe standard spark plug is shown in
the table. The spark plugs should bereplaced in accordance with the Peri-
odic Maintenance Chart.Spark plug removal should be done
only by a competent mechanic follow-ing the instructions in the Service Man-ual.Spark Plug
StandardPlug NGK CR9EIA-9
Plug Gap0.8 a 0.9 mm(0.031 a 0.035 in.)
TighteningTorque
13 Nm (1.3 kgfm, 115 inlb)
MAINTENANCE AND ADJUSTMENT 203
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A. 0.8 0.9 mm (0.031 0.035 in.)
Evaporative Emission ControlSystem (California modelonly)
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.
NOTICEIf valve clearance is left un-adjusted, wear will eventuallycause the valves to remainpartly open; which lowers per-formance, burns the valves and
valve 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.
MAINTENANCE AND ADJUSTMENT 205
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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 to
burn 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 valvesin accordance with the Periodic Main-tenance Chart. Also, inspect the air
suction 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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Air CleanerA clogged air cleaner restricts the en-
gines air intake, increasing fuel con-sumption, reducing engine power, and
causing spark plug fouling.This motorcycles air cleaner element
consists 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 11013-0014 or equiva-lent type). Using the any otherair cleaner element will wear theengine prematurely or lower theengine performance.
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Air Cleaner Element Removal
Remove the fuel tank front cover byremoving the bolts.
A. BoltsB. Fuel Tank Front Cover
Open the storage case lid. Remove the inner cover by removing
the bolts and quick rivet.
A. BoltsB. Quick RivetC. Inner Cover
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Remove the bolts and quick rivets. Pull the rear part of the rear middle
fairing slowly to detach the projec-tion, and then pull the rear middle
fairing backward to detach the tabs.
A. Bolts
B. Quick RivetsC. ProjectionD. TabsE. Rear Middle Fairing
Remove the bracket by removing thebolts.
A. BoltsB. Bracket
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Remove the air cleaner elementcover by removing the bolts.
A. BoltsB. Air Cleaner Element Cover
Pull out the air cleaner element.
A. Air Cleaner Element
WARNING
If dirt or dust is allowed to pass
through into the fuel injectionsystem, the throttle may stick orbecome inoperable resulting in ahazardous operating condition.
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NOTICE
If dirt gets through into the en-gine, excessive engine wear andpossibly engine damage will oc-cur.
Air Cleaner Element InstallationElement and the removed parts in-
stallation is performed in the reverse or-der of removal, and make sure that the
lead does not pinch with any parts.
Install the air cleaner element coverso that arrow mark faces upward.
A. Arrow MarkB. Air Cleaner Element Cover
Insert the tabs on the lower part of therear middle fairing, and then insert
the tab on the upper part of the rearmiddle fairing, and attach the projec-tion. Make sure the front end of therear middle fairing is inserted into thehook of the front middle fairing.
MAINTENANCE AND ADJUSTMENT 211
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A. Tabs (Lower Part)B. Tab (Upper Part)C. ProjectionD. HookE. Rear Middle FairingF. Front Middle Fairing
Be sure the storage case lid lock islocked correctly after installing the in-ner cover.
NOTE
The inner cover and the rear middlefairing use the quick rivets. The quick
rivets can be removed by pushing thecentral pin into the quick rivets, andwhen installing them, pull the central
pin fully up first, and then push into
the central pin after inserting them.Quick Rivet Removal
A. Quick RivetB. Central PinC. Push in.
212 MAINTENANCE AND ADJUSTMENT
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Quick Rivet Installation
A. Quick RivetB. Central PinC. Pull up fully.D. Push in.
Oil Draining
Inspect the transparent reservoir lo-cated under the left side of the engineto see if any oil has run down by re-moving the rear middle firing (see AirCleaner Element Removal).
A. Reservoir
If there is any oil in the reservoir, re-move the reservoir and drain the oil.
WARNING
Oil on tires will make them slip-
pery and can cause an accidentand injury. Be sure to install thereservoir in the drain hose afterdraining.
MAINTENANCE AND ADJUSTMENT 213
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Throttle Control SystemCheck the throttle grip play each day
before riding the motorcycle, and 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 eithercable stretch or maladjustment, it will
cause a delay in throttle response, es-pecially at low engine speed. Also, thethrottle valve may not open fully at fullthrottle. On the other hand, if the throt-tle grip has not play, the throttle will behard to control, and the idle speed willbe erratic.
Inspection
Check that the throttle grip play iscorrect by lightly turning the throttlegrip back and forth.
A. Throttle GripB. Throttle Grip Play
Throttle Grip Play
2 a 3 mm (0.08 a 0.12 in.)
If there is improper play, adjust it.
Adjustment
Loosen the locknuts at the lowerends of the throttle cables, and screw
214 MAINTENANCE AND ADJUSTMENT
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both throttle cable adjusters in com-pletely so as to give the throttle gripplenty of play.
Turn out the decelerator cable ad-juster until there is no play when thethrottle grip is completely closed.Tighten the locknut against the ad-
juster.
A. Decelerator CableB. Accelerator CableC. AdjustersD. Locknuts
Turn out the accelerator cable ad-juster until 2 a 3 mm (0.08 a 0.12in.) of throttle grip play is obtained.Tighten the locknut against the ad-
juster.
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 bedone by a competent mechanic fol-
lowing the instructions in the ServiceManual.
With the engine idling, turn the han-dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improp-erly adjusted or in correctly routed,
or they may be damaged. Be sureto correct any of these conditions be-fore idling.
MAINTENANCE AND ADJUSTMENT 215
WARNING E i V S h i ti
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WARNING
Operation with improperly ad-justed, incorrectly routed ordamaged cables could result inan unsafe riding condition. Fol-low the service manual to makesure to correct any of these con-ditions.
Engine Vacuum SynchronizationEngine vacuum synchronization
must be checked and adjusted period-ically in accordance with the Periodic
Maintenance Chart by a competentmechanic following the instructions inthe Service Manual.
NOTE
Poor engine vacuum synchronizationwill cause unstable idling, sluggish
throttle response, and reduce enginepower and performance.
216 MAINTENANCE AND ADJUSTMENT
Idl S d
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Idle SpeedThe idle speed adjustment should be
performed in accordance with the Pe-riodic Maintenance Chart or whenever
the idle speed is disturbed.Adjustment
Start the engine, and warm it up thor-oughly.
Adjust the idle speed by turning theidle adjusting screw.
Idle Speed1 050 a 1 150 r/min (rpm)
A. Idle Adjusting Screw
Open and close the throttle a fewtimes to make sure that the idlespeed does not change. Readjust ifnecessary.
With the engine idling, turn the han-dlebar to each side. If handlebar
movement changes the idle speed,the throttle cables may be improperlyadjusted or incorrectly routed, or theymay be damaged. Be sure to correctany of these conditions before riding.
MAINTENANCE AND ADJUSTMENT 217
WARNING Clutch
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WARNING
Operation with damaged cablescould result in an unsafe ridingcondition. Replace damagedcontrol cables before operation.
ClutchThe motorcycle is equipped with a
hydraulically operated clutch that re-quires no adjustment except fluid level
and clutch operation inspection eachday before riding the motorcycle inaccordance with the Periodic Mainte-nance Chart.
Clutch Operation Inspect
If the clutch lever play becomes ex-cessive and the motorcycle creeps orstalls when shifted into gear, there isprobably air in the clutch system andit must be bled out by an authorizedKawasaki dealer.
218 MAINTENANCE AND ADJUSTMENT
Fluid Level Inspection NOTE
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Fluid Level Inspection
With the clutch fluid reservoir heldhorizontal, the clutch fluid level mustbe kept between the upper and lower
level lines. If the fluid level is lower than thelower level line, check for fluid leaksin the clutch line, and fill the clutchfluid reservoir to the upper level line.
A. Upper Level LineB. Lower Level LineC. Clutch Fluid Reservoir
NOTE
Use the same fluid as is used in thebrakes and keep the same require-ments mentioned in the Brakes sec-
tion.
MAINTENANCE AND ADJUSTMENT 219
Brakes Disc Brake Fluid
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Brakes
Brake Wear InspectionInspect the brakes for wear. For each
front and rear disc brake caliper, if the
thickness of either pad linning is lessthan 1 mm (0.04 in.), replace both padsin the caliper as a set. Pad replace-ment should be done by an authorizedKawasaki dealer.
A. Lining ThicknessB. 1 mm (0.04 in.)
Disc Brake Fluid -In accordance with the Periodic Main-
tenance Chart, inspect the brake fluidlevel in both the front and rear brake
fluid reservoirs and change the brakefluid. The brake fluid should also bechanged if it becomes contaminatedwith dirt or water.
Fluid RequirementUse DOT4 rated heavy-duty brake
fluid only.NOTICE
Do not spill brake fluid onto anypainted surface.Do not use fluid from a containerthat has been left open or that
has been unsealed for a longtime.Check for fluid leakage aroundthe fittings.Check brake hose for damage.
220 MAINTENANCE AND ADJUSTMENT
Fluid Level Inspection
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Fluid Level Inspection
With the brake fluid reservoirs heldhorizontal, the brake fluid level mustbe kept between the upper and lower
level lines.
A. Front Brake Fluid ReservoirB. Upper Level Line
C. Lower Level Line
A. Rear Brake Fluid Reservoir
B. 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, andfill the reservoir to the upper level
line.
MAINTENANCE AND ADJUSTMENT 221
WARNING
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WARNING
Mixing brands and types ofbrake fluid can reduce the brakesystems effectiveness and
cause an accident resulting ininjury or death. Do not mix twobrands of brake fluid. Changethe brake fluid in the brake linecompletely if the brake fluidmust be refilled but the type
and brand of the brake fluid thatis already in the reservoir areunidentified.
NOTE
First, tighten until slight resistance isfelt indicating that the cap is seatedon the reservoir body; tighten the capan additional 1/6 turn while holdingthe brake fluid reservoir body.
A. Reservoir
B. 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.
222 MAINTENANCE AND ADJUSTMENT
So there are no parts that require ad- Brake Light Switches
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So there are no parts that require adjustment on the front or 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 maybe defective. Have the brakechecked immediately by an au-thorized Kawasaki dealer.
Brake Light SwitchesWhen either the front or rear brake is
applied, the brake light goes on. Thefront brake light switch requires no ad-
justment, but the rear brake light switchshould be adjusted in accordance withthe Periodic Maintenance Chart.
Inspection
Turn the ignition key to ON. The brake light should go on when
the front brake is applied. If it does not, ask your authorizedKawasaki dealer to inspect the frontbrake light switch.
MAINTENANCE AND ADJUSTMENT 223
Check the operation of the rear brake Adjustment
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Check the operation of the rear brakelight switch by depressing the brakepedal. The brake light should go onafter the proper pedal travel.
A. Brake PedalB. 10 mm (0.39 in.)
If the light does not go on, adjust therear brake light switch.Brake Pedal Travel
10 mm (0.39 in.)
Adjustment
To adjust the rear brake light switch,move the switch up or down by turn-ing the adjusting nut.
A. Rear Brake Light SwitchB. Adjusting NutC. Lights sooner
D. Lights later
224 MAINTENANCE AND ADJUSTMENT
NOTICE Front Fork
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NOTICE
To avoid damaging the electricalconnections inside the switch,be sure that the switch body
does not turn during adjustment.
Front ForkThe front fork operation and oil leak-
age should be checked in accordancewith the Periodic Maintenance Chart.
Front Fork Inspection
Holding the brake lever, pump thefront fork up and down several timesto inspect smooth stroke.
Visually inspect the front fork for oilleakage, scoring or scratches on theouter surface of the inner tube.
MAINTENANCE AND ADJUSTMENT 225
If any doubt about the front fork, it adjusted for different riding and loading
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y ,should be done by an authorizedKawasaki dealer.
A. Inner Tube
On top of each front fork leg are aspring preload adjuster and a rebound
damping force adjuster, so that thespring force and damping force can be
j g gconditions. Weaker spring force anddamping force are for comfortable rid-ing, but they should be increased for
high speed riding or riding on roughroads.
A. Spring Preload Adjuster
B. Rebound Damping Force Adjuster
226 MAINTENANCE AND ADJUSTMENT
NOTICE
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Do not force to turn the rebounddamping force adjuster from thefully seated position, at the ad-
justing mechanism may be dam-aged.
Spring Preload Adjustment
Turn the spring preload adjusters intothe nut to increase spring force and
out to decrease spring force usingthe wrench. The adjusting range ismeasured from the top of each ad-
juster. Be sure to turn both adjustersto the same position.
A. Spring Preload Adjuster
B. WrenchC. Adjustable Range
Adjusting Range
4 a 19 mm (0.16 a 0.75 in.)
Rebound Damping Force Adjustment
Turn the rebound damping force ad-juster clockwise. This makes thedamping force greatest.
MAINTENANCE AND ADJUSTMENT 227
Turn the adjuster counterclockwise passenger and no accessories are as
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jto decrease damping force. Be sureto turn both adjusters by the samenumber of turns.
WARNING
If both spring preload adjustersand both rebound and compres-sion damping force adjustersare not adjusted equally, han-
dling may be impaired and haz-ardous condition may result.Always adjust the suspensioncomponents equally.
The standard setting positions of thespring preload adjuster, and rebound
damping force adjuster for an average-build rider of 68 kg (150 lb) with no
p gfollows:
Spring PreloadAdjuster
14 mm (0.55 in.)from top of adjuster
Rebound DampingForce Adjuster
5 clicks*
*: counterclockwise from the fullyseated position (strongest position)
228 MAINTENANCE AND ADJUSTMENT
Rear Shock Absorber If any doubt about the rear shock ab-
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The rear shock absorber operationand oil leakage should be checked inaccordance with the Periodic Mainte-
nance Chart.Rear Shock Absorber Inspection
Press down on the seat several timesto inspect the stroke.
Visually inspect the rear shock ab-sorber for oil leakage.
sorber, it should be done by an au-thorized Kawasaki dealer.
A. Rear Shock Absorber
The rear shock absorber can be ad-justed by changing the spring preload
and rebound damping force for variousriding and loading conditions.Before making any adjustments,
however, read the following proce-dures:
MAINTENANCE AND ADJUSTMENT 229
NOTICE Spring Preload Adjustment
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Do not force to turn the rebounddamping force adjuster from thefully seated position or the ad-
justing mechanism may be dam-aged.
Turn the adjuster in or out to the de-sired position.
Turning the adjuster clockwise in-creases the spring preload, and turn-ing it counterclockwise decreasesthe spring preload.
A. Adjuster
230 MAINTENANCE AND ADJUSTMENT
Rebound Damping Force AdjustmentTh b d d i f dj t
Turn the adjuster counterclockwiset d d i f
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The rebound damping force adjusteris located at the lower end of the rearshock absorber.
A. Rebound Damping Force Adjuster
Turn the rebound damping force ad-juster all the way clockwise with ascrewdriver to make the dampingforce greatest.
to decrease damping force.
The standard setting position of thespring preload adjuster and rebound
damping force adjuster for an average-build rider of 68 kg (150 lb) with nopassenger and no accessories is as fol-lows:
Spring PreloadAdjuster
13 clicks*
Rebound DampingForce Adjuster
1 1/4 turns out**
*: counterclockwise from the fullyseated position (weakest position)
**: clockwise from the fully seated
position (strongest position)
MAINTENANCE AND ADJUSTMENT 231
WheelsT b l ti i t ll d th
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Tubeless tires are installed on thewheels of this motorcycle. The indica-tions of TUBELESS on the tire side wall
and the rim show that the tire and rimare specially designed for tubeless use.
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.
232 MAINTENANCE AND ADJUSTMENT
WARNING Tire SealantsI t l ti l t i d
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Installing a tube inside a tube-less-type tire can create exces-sive heat build up that can dam-
age the tube and cause rapiddeflation. The tires, rims, andair valves on this motorcycle aredesigned only for tubeless typewheels. The recommended stan-dard tires, rims, and air valvesmust be used for replacement.Do not install tube-type tires ontubeless rims. The beads maynot seat properly on the rimcausing tire deflation. Do notinstall a tube inside a tubelesstire. Excessive heat build-up
may damage the tube causingtire deflation.
Internal tire sealants or repair prod-ucts can cause damage to the tire pres-sure sensor(s) and should not be used.
Tires -
Payload and Tire PressureFailure to maintain proper inflation
pressures or observe payload limits foryour tires may adversely affect han-dling and performance of your motorcy-cle and can result in loss of control. Themaximum recommended load in addi-tion to vehicle weight is 228 kg (503 lb),including rider, passenger, baggage,and accessories.
Remove the air valve cap.
Check the tire pressure often, usingan accurate gauge. Make sure to install the air valve cap
securely.
MAINTENANCE AND ADJUSTMENT 233
NOTE
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Measure the tire pressure when thetires are cold (that is, when the mo-torcycle has not been ridden more
than a mile during the past 3 hours).Tire pressure is affected by changesin ambient temperature and altitude,and so the tire pressure should bechecked and adjusted when your rid-ing involves wide variations in tem-
perature or altitude. A. Tire Pressure Gauge
Tire Air Pressure (when cold)
Front 290 kPa (2.90 kgf/cm, 42 psi)
Rear 290 kPa (2.90 kgf/cm, 42 psi)
Tire Wear, Damage
As the tire tread wears down, the tirebecomes more susceptible to punctureand failure. An accepted estimate isthat 90% of all tire failures occur duringthe last 10% of tread life (90% worn).
234 MAINTENANCE AND ADJUSTMENT
So it is false economy and unsafe touse the tires until they are bald
Minimum Tread Depth
1 (0 04
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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.
A. Tire Depth Gauge
Front 1 mm (0.04in.)
Under 130 km/h
(80 mph)
2 mm (0.08
in.)RearOver 130 km/h(80 mph)
3 mm (0.12in.)
Visually inspect the tire for cracksand cuts, replacing the tire in case ofbad damage. Swelling or high spotsindicate internal damage, requiringtire replacement.
Remove any imbedded stones orother foreign particles from the tread.
NOTE
Have the wheel balance inspectedwhenever a new tire is installed.
MAINTENANCE AND ADJUSTMENT 235
WARNING Standard Tire (Tubeless)M k T
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Tires that have been puncturedand 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.
NOTEWhen operating on public roadways,
keep maximum speed under trafficlaw limits.
Make, Type:BRIDGESTONE,BATTLAX BT021F U
Size:120/70 ZR17 M/C (58W)
Make, Type:BRIDGESTONE,BATTLAX BT021F M
Front
Size:120/70 ZR17 M/C (58W)
Make, Type:BRIDGESTONE,BATTLAX BT021R URear
Size:190/50 ZR17 M/C (73W)
236 MAINTENANCE AND ADJUSTMENT
WARNING BatteryThe battery installed in this motorcy-
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Mixing tire brands and types canadversely affect handling andcause an accident resulting in
injury or death. Always use thesame manufacturers tires onboth front and rear wheels.
WARNING
New tires are slippery and may
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.
The battery installed in this motorcy-cle is a sealed type, so it is not nec-essary to check the battery electrolytelevel or add distilled water.
The sealing strip should not be pulledoff once the specified electrolyte hasbeen installed in the battery for initialservice.
However, in order to maximize bat-tery life and ensure that it will provide
the 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
MAINTENANCE AND ADJUSTMENT 237
type of battery and ambient temper-ature As temperatures rise so does
Self-discharge
A b f d
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ature. As temperatures rise, so doesthe discharge rate. Every 15C (27F)doubles the rate.
Electrical accessories, such as digi-tal clocks and computer memory, alsodraw current from the battery evenwhen the key is switched off. Combinesuch key-off draws with hot temper-ature, and a battery can go from fullycharged to completely discharged in a
matter of days.
Approx. number of daysfrom 100% charged to100% discharged
Lead-Antimony
Lead-Calcium
Temperature
Battery Battery
40C(104F)
100 Days 300 Days
25C (77F) 200 Days 600 Days
0C (32F) 550 Days 950 Days
238 MAINTENANCE AND ADJUSTMENT
Current Drain
D f D f
Sulfation occurs when the battery isleft in a discharged condition for an ex-
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DischargingAmpere
Days from100%charged
to 50%discharged
Days from100%charged
to 100%discharged
7 mA 60 Days 119 Days
10 mA 42 Days 83 Days
15 mA 28 Days 56 Days
20 mA 21 Days 42 Days
30 mA 14 Days 28 Days
In extremely cold weather the fluid inan inadequately charged battery caneasily freeze, which can crack the caseand buckle the plates. A fully charged
battery can withstand sub-freezingtemperatures with no damage.
Battery Sulfation -A common cause of battery failure is
sulfation.
left in a discharged condition for an extended time. Sulfate is a normal byproduct of the chemical reactions withina battery. But when continuous dis-charge allows the sulfate to crystallizein the cells, the battery plates becomepermanently damaged and will not holda charge. Battery failure due to sulfa-tion is not warrantable.
Battery Maintenance -
It is the owners responsibility to keepthe battery fully charged. Failure to doso can lead to battery failure and leaveyou stranded.
If you are riding your vehicle infre-quently, inspect the battery voltage
weekly using a voltmeter. If it dropsbelow 12.6 volts, the battery should becharged using an appropriate charger(check with your Kawasaki dealer).
MAINTENANCE AND ADJUSTMENT 239
If you will not be using the motorcy-cle for longer than two weeks, the
Attach the leads from the chargerand charge the battery at a rate (am-
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cle for longer than two weeks, thebattery should be charged using anappropriate charger. Do not use an au-tomotive-type quick charger that mayovercharge the battery and damage it.
Kawasaki-recommended chargersare:Battery Mate 150-9OptiMate PRO 4-S/PRO S/PRO 2Yuasa MB-2040/2060
Christie C10122S
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).
and charge the battery at a rate (amperagehours) 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,or the battery can be damaged.Do not install a conventionalbattery in this motorcycle, or the
electrical system cannot workproperly.
240 MAINTENANCE AND ADJUSTMENT
NOTE
If you charge the sealed batteryBattery Removal
Remove the bolt.
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If you charge the sealed battery,never fail to observe the instructionsshown in the label on the battery.
WARNING
Lead is a toxic substance. Bat-tery posts, terminals and relatedaccessories contain lead andlead compounds. Wash hands
after handling.
Remove the sub side cover by pullingout it to detach the projecton.
A. BoltB. ProjectionC. Sub Side Cover
MAINTENANCE AND ADJUSTMENT 241
Remove the battery cover by remov-ing the bolts.
Remove the battery () cable andframe ground cable by removing the
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g
A. BoltsB. Battery Cover
g y gbolt.
Pull the battery holder a little, andremove the battery (+) cable from thebattery.
Pull out the battery holder.
A. BoltB. Battery () CableC. Frame Ground CableD. Battery HolderE. Battery (+) Cable
242 MAINTENANCE AND ADJUSTMENT
NOTICE
Be careful not to drop the bat
Detach the hook, and separate thecover and holder.
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Be careful not to drop the bat-tery from the motorcycle whenpulling out it.
Do not give the battery tray astrong pull, or the cables may bedamaged.
Remove the battery () cable fromthe battery.
A. CoverB. HookC. Battery Holder
D. Battery () Cable
Clean the battery using a solution ofbaking soda and water. Be sure thatthe wire connections are clean.
MAINTENANCE AND ADJUSTMENT 243
Battery InstallationBattery and the removed parts instal-
First, install the battery (+) cable fromthe battery, and then install the bat-
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lation is performed in the reverse orderof removal, and make sure that the leador cable does not pinch with any parts.
Insert the projections on the batteryholder into the holes of the batteryholder compartment.
A. Battery HolderB. ProjectionsC. Holes
tery () cable from the frame.
A. Battery (+) CableB. Battery () Cable
244 MAINTENANCE AND ADJUSTMENT
NOTICE
Installing the () cable to the (+)
Insert the projections on the batterycover into the holes of the battery
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Installing the () cable to the (+)terminal of the battery or the(+) cable to the () terminal of
the battery can cause seriouslydamage to the electrical system.
holder.
A. Battery CoverB. ProjectionsC. Battery HolderD. Holes
MAINTENANCE AND ADJUSTMENT 245
Insert the tabs on the sub side coverinto the under of the rear middle fair-i d i t th j ti th
Headlight Beam
Horizontal Adjustment
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ing, and insert the projection on thesub side cover into the hole on thebattery cover.
A. TabsB. Projections
C. Sub Side Cover
Horizontal AdjustmentThe headlight beam is adjustable
horizontally. If not properly adjusted
horizontally, the beam will point to oneside rather than straight ahead.
Turn the horizontal adjuster in or outuntil the beam points straight ahead.
Vertical AdjustmentThe headlight beam is adjustable ver-
tically. If adjusted too low, neither lownor high beam will illuminate the roadfar enough ahead. If adjusted too high,the high beam will fail to illuminate theroad close ahead, and the low beamwill blind oncoming drivers.
246 MAINTENANCE AND ADJUSTMENT
Turn the vertical adjuster in or out toadjust the headlight vertically.
The proper angle is 0.4 degrees be-low horizontal. This is a 50 mm (2.0i ) d t 7 6 (25 ft) d
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A. Horizontal AdjusterB. Vertical Adjuster (Adjuster Knob)
NOTE
On high beam, the brightest pointshould be slightly below horizontal.
in.) drop at 7.6 m (25 ft) measuredfrom the center of the headlight, withthe motorcycle on its wheels and the
rider seated.
NOTICE
When handling the quartz-halogen bulbs, never touch theglass portion with bare hands.Always use a clean cloth. Oilcontamination from hands ordirty rags can reduce bulb life orcause the bulb to explode.
MAINTENANCE AND ADJUSTMENT 247
FusesFuses are arranged in the fuse boxes
located nder the seat The main f se
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A. 50 mm (2.0 in.)
B. Center of Brightest SpotC. 7.6 m (25 ft)D. Height of Headlight Center
located under the seat. The main fuseis located at the battery compartment.If a fuse fails during operation, inspect
the electrical system to determine thecause, and then replace it with a newfuse of proper amperage.
A. Fuse Boxes
248 MAINTENANCE AND ADJUSTMENT
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A. Main Fuse
WARNING
Substituting fuses can causewiring 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 boxesand main fuse.
A. Normal
B. Failed
MAINTENANCE AND ADJUSTMENT 249
General LubricationLubricate the points shown below,
with either motor oil or regular grease
Center StandClutch LeverFront Brake Lever
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with either motor oil or regular grease,in accordance with the Periodic Main-tenance Chart or whenever the vehicle
has 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.
Apply motor oil to the followingpivots -
Side Stand
Front Brake LeverRear Brake Pedal
Lubricate the following cables with apressure cable lubber -
(K) Throttle Inner Cables
250 MAINTENANCE AND ADJUSTMENT
Apply grease to the followingpoints -
(K) Throttle Inner Cable Upper Ends
Cleaning Your Motorcycle
General Precautions
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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 enhance
its appearance, optimize overall per-formance, and extend its useful life.Covering your motorcycle with a highquality, breathable motorcycle coverwill help protect its finish from harmfulUV rays, pollutants, and reduce theamount of dust reaching its surfaces.
Be sure the engine and exhaust arecool before washing. Avoid applying degreaser to seals,
brake pads, and tires.
Avoid all harsh chemicals, solvents,detergents, and household cleaningproducts such as ammonia-basedwindow cleaners.
Gasoline, brake fluid, clutch fluid,and coolant will damage the finish of
MAINTENANCE AND ADJUSTMENT 251
painted and plastic surfaces: washthem off immediately.
Avoid wire brushes steel wool and After cleaning your motorcycle,
check the rubber boot covering theshift pedal ball joint for correct instal-
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Avoid wire brushes, steel wool, andall other abrasive pads or brushes.
Use care when washing the wind-
shield, headlight cover, and otherplastic parts as they can easily bescratched.
Avoid using pressure washers; wa-ter can penetrate seals and electricalcomponents and damage your mo-torcycle.
Avoid spraying water in delicateareas such as in air intakes, fuel sys-tem, brake components, electricalcomponents, electrical socket, muf-fler outlets, and fuel tank openings.
shift pedal ball joint for correct instal-lation. Be sure the sealing lip of therubber boot fits into the groove of the
ball joint.
A. Rubber Boot
252 MAINTENANCE AND ADJUSTMENT
If the boot is damaged, replace it witha new one. If the boot is not po-sitioned in the groove correctly re-
Mix a mild neutral detergent (de-signed for motorcycles or automo-biles) and water in a bucket Use
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sitioned in the groove correctly, replace it in the correct position.
A. Not PositionB. Correct Position
Washing Your Motorcycle Rinse your bike with cold water from
a garden hose to remove any loosedirt.
biles) and water in a bucket. Usea soft cloth or sponge to wash yourmotorcycle. If needed, use a mild de-
greaser to remove any oil or greasebuild up.
After washing, rinse your motorcy-cle thoroughly with clean water to re-move any residue (residue from thedetergent can damage parts of yourmotorcycle).
Use a soft cloth to dry your motorcy-cle. As you dry, inspect your motor-cycle for chips and scratches. Do notlet the water air dry as this can dam-age the painted surfaces.
Start the engine and let it idle for sev-eral minutes. The heat from the en-gine will help dry moist areas.
Carefully ride your motorcycle at aslow speed and apply the brakesseveral times. This helps dry the
MAINTENANCE AND ADJUSTMENT 253
brakes and restores them to normaloperating performance.
rain, washing the motorcycle or hu-mid weather. To remove the mois-ture, start the engine and turn on the
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NOTE
After riding in an area where theroads are salted or near the ocean,immediately wash your motorcyclewith cold water. Do not use warmwater as it accelerates the chemicalreaction of the salt. After drying,apply a corrosion protection spray
on all metal and chrome surfaces toprevent corrosion.
Condensation may form on the insideof the headlight lens after riding in the
ture, start the engine and turn on theheadlight. Gradually the condensa-tion on the inside of the lens will clear
off.
Windshield and Other Plastic PartsAfter 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.
254 MAINTENANCE AND ADJUSTMENT
NOTICE
Plastic parts may deteriorated b k if th i
should be washed with a mild neu-tral detergent and finished with a spraypolish. Aluminum wheels, both painted
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and break if they come in con-tact with chemical substances
or household cleaning productssuch as gasoline, brake fluid,window cleaners, thread-lockingagents, or other harsh chemi-cals. If a plastic part comes incontact with any harsh chemicalsubstance, wash it off immedi-
ately with water and a mild neu-tral detergent, and then inspectfor damage. Avoid using abra-sive pads or brushes to cleanplastic parts, as they will dam-age the parts finish.
Chrome and AluminumChrome and uncoated aluminum
parts can be treated with a chrome/alu-minum polish. Coated aluminum
p , pand unpainted can be cleaned withspecial non-acid based wheel spray
cleaners.
Leather, Vinyl, and RubberIf your motorcycle has leather ac-
cessories, special care must be taken.Use a leather cleaner/treatment toclean and care for leather accessories.
Washing leather parts with detergentand water will damage them, shorten-ing their life.
Vinyl parts should be washed with therest of the motorcycle, then treated witha vinyl treatment.
The sidewalls of tires and other rub-
ber components should be treated witha rubber protectant to help prolong theiruseful life.
MAINTENANCE AND ADJUSTMENT 255
WARNING
Rubber protectants can be slip-pery and if used on the tread
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pery and, if used on the treadarea, cause loss of traction re-
sulting in accident causing in-jury or death. Do not apply rub-ber protectant to any tread area.
256 MAINTENANCE AND ADJUSTMENT
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
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gpin is in place and in good condition. Please ask your authorized Kawasaki dealerfor torque values.
1. Clutch Lever Holder Bolts2. Steering Stem Head Bolt3. Handlebar Mounting Bolts4. Front Fork Clamp Bolts5. Brake Lever Holder Clamp
Bolts
MAINTENANCE AND ADJUSTMENT 257
6. Front Fender MountingBolts
7. Engine Mounting Boltsand Nuts
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and Nuts8. Rear Frame Mounting Bolts9. Brake Disc Mounting Bolts
10. Front Axle Clamp Bolts11. Front Axle12. Caliper Mounting Bolts13. Side Stand Bolt14. Swingarm Pivot Shaft Nut15. Uni-trak Lever Rod Nuts16. Footpeg Mounting Bolts17. Rear Shock Absorber
Mounting Nuts18. Front Gear Case Mounting
Bolts
258 MAINTENANCE AND ADJUSTMENT
19. Silencer Mounting Bolts20. Brake Pedal Bolt21. Rear Axle Nut22 Tetra Lever Bolts
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22. Tetra Lever Bolts23. Center Stand Bolts and
Nuts