Kawasaki Concours14abs

7/31/2019 Kawasaki Concours14abs

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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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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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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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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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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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km 1 000 (mile 1 000)


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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km 1 000 (mile 1 000)


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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2. Periodic Inspection (Chassis Related Items)


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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km 1 000 (mile 1 000)


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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km 1 000 (mile 1 000)


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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km 1 000 (mile 1 000)


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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km 1 000 (mile 1 000)


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

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Front forks/rearshock absorberoil leak - inspect

year 224/228

KUni-trak rockerarm operation -inspect


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km 1 000 (mile 1 000)


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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km 1 000 (mile 1 000)


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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3. Periodic Replacement


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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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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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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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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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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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



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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.



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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.



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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.



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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.



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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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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



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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.



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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)



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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.



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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.



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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.



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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.



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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



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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.


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.


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.


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.


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.


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.




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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.


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.


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.


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


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.


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


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.


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)


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:


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


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)


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.


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.


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).


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.


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)


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


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


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





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).


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.


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


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


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.


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


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


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.


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.


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



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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


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


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


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


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


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.


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.


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.


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


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


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

Kawasaki Concours14abs

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