Owners Manual
Page 8
... Maintenance Chart ...Engine Oil...Cooling System ...Spark Plug...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Hot Starter Cable...Valve Clearance ...Exhaust System ...8 11 11 14 14 17 17 20 21 21 22 23 25 26 26 31 35 39 43 48 49 56 63 64 69 Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor ...Suspension...Gearing...
... Maintenance Chart ...Engine Oil...Cooling System ...Spark Plug...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Hot Starter Cable...Valve Clearance ...Exhaust System ...8 11 11 14 14 17 17 20 21 21 22 23 25 26 26 31 35 39 43 48 49 56 63 64 69 Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor ...Suspension...Gearing...
Owners Manual
Page 9
8 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Ignition Timing Lubrication System Spark Plug Spark Plug Terminal 4-stroke, DOHC, single-cylinder, liquid-cooled 77.0 × 53.6 mm (3.0 × 2.1 in.) 249 cm³ (15.2 cu in.) 13.2:1 Carburetor KEIHIN FCR-MX37 Primary kick Digital AC-CDI 8° BTDC @2 000 r/...
8 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Ignition Timing Lubrication System Spark Plug Spark Plug Terminal 4-stroke, DOHC, single-cylinder, liquid-cooled 77.0 × 53.6 mm (3.0 × 2.1 in.) 249 cm³ (15.2 cu in.) 13.2:1 Carburetor KEIHIN FCR-MX37 Primary kick Digital AC-CDI 8° BTDC @2 000 r/...
Owners Manual
Page 19
... can be started with no airflow through the radiator can cause coolant loss and engine overheating resulting in any gear. The accelerator pump may foul the spark plug with excess fuel. żWhen the clutch lever is thoroughly warmed up excessively before coolant loss occurs. When engine is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Any riding conditions that...
... can be started with no airflow through the radiator can cause coolant loss and engine overheating resulting in any gear. The accelerator pump may foul the spark plug with excess fuel. żWhen the clutch lever is thoroughly warmed up excessively before coolant loss occurs. When engine is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Any riding conditions that...
Owners Manual
Page 22
Shift down progressively to the OFF position. Stopping the Engine transmission into the neutral position. • Shift the the throttle completely and push the engine • Close stop . Engine Stop Button • Turn the fuel tap lever to ensure good engine response at all speeds. Independent use of the front or rear brake may be advantageous in the clutch lever as the motorcycle comes to a stop button. Pull in certain circumstances. A. GENERAL INFORMATION 21 j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes.
Shift down progressively to the OFF position. Stopping the Engine transmission into the neutral position. • Shift the the throttle completely and push the engine • Close stop . Engine Stop Button • Turn the fuel tap lever to ensure good engine response at all speeds. Independent use of the front or rear brake may be advantageous in the clutch lever as the motorcycle comes to a stop button. Pull in certain circumstances. A. GENERAL INFORMATION 21 j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes.
Owners Manual
Page 23
.... 4. Ride the motorcycle for about 20 minutes within 3/4 throttle opening . 3. Be sure to fully check the tightness of operation, run the engine at low and moderate engine speeds. See details below. Stop and let the engine cool completely. Change the engine oil, oil filter and front fork/rear shock absorber oil to check the tightness of nuts and bolts, oil leakage, and any following parts have been...
.... 4. Ride the motorcycle for about 20 minutes within 3/4 throttle opening . 3. Be sure to fully check the tightness of operation, run the engine at low and moderate engine speeds. See details below. Stop and let the engine cool completely. Change the engine oil, oil filter and front fork/rear shock absorber oil to check the tightness of nuts and bolts, oil leakage, and any following parts have been...
Owners Manual
Page 24
... cause serious brain injury or death. Engine Engine Oil ...No leakage Level correct Coolant ...No leakage Level correct (engine cold) Radiator Cap ...Properly installed Spark Plug ...Correctly torqued Cylinder Head Cover ...Correctly torqued Clutch ...Functions properly Carburetor ...Properly tuned Air Cleaner ...Clean Apply oil to perform these checks before operation may result in enclosed areas. The time required is minimal, and habitual performance of these checks, refer to...
... cause serious brain injury or death. Engine Engine Oil ...No leakage Level correct Coolant ...No leakage Level correct (engine cold) Radiator Cap ...Properly installed Spark Plug ...Correctly torqued Cylinder Head Cover ...Correctly torqued Clutch ...Functions properly Carburetor ...Properly tuned Air Cleaner ...Clean Apply oil to perform these checks before operation may result in enclosed areas. The time required is minimal, and habitual performance of these checks, refer to...
Owners Manual
Page 31
... master cylinder cup and dust cover - replace • Every 4 years • †: Replace, add, adjust, clean or torque if necessary. replace K Piston and piston ring - replace Muffler baffle - replace K Rear shock absorber oil - Periodic Replacement (Engine and Chassis Related Item) Every 3 FREQUENCY After each race (or 2.5 races (or 7.5 hour) hour) OPERATION Engine oil - replace K Brake fluid - change K Fuel hose - K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. replace Spark plug - change Oil filter - 30 MAINTENANCE AND...
... master cylinder cup and dust cover - replace • Every 4 years • †: Replace, add, adjust, clean or torque if necessary. replace K Piston and piston ring - replace Muffler baffle - replace K Rear shock absorber oil - Periodic Replacement (Engine and Chassis Related Item) Every 3 FREQUENCY After each race (or 2.5 races (or 7.5 hour) hour) OPERATION Engine oil - replace K Brake fluid - change K Fuel hose - K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. replace Spark plug - change Oil filter - 30 MAINTENANCE AND...
Owners Manual
Page 32
... oil filler opening. Do not run it for the engine, transmission and clutch to function properly, maintain the engine oil at the proper level, and change the oil according to settle. Racing the engine before each ride and change the oil and oil filter periodically. MAINTENANCE AND ADJUSTMENT 31 NOTICE Engine Oil In order for several minutes for the • Stop oil to the periodic maintenance chart in the owner's manual...
... oil filler opening. Do not run it for the engine, transmission and clutch to function properly, maintain the engine oil at the proper level, and change the oil according to settle. Racing the engine before each ride and change the oil and oil filter periodically. MAINTENANCE AND ADJUSTMENT 31 NOTICE Engine Oil In order for several minutes for the • Stop oil to the periodic maintenance chart in the owner's manual...
Owners Manual
Page 34
... torque. Oil Filter Cap B. j NOTICE Inside-out installation stop oil flow, causing engine seizure. Bolts A. Grommet the spring to the oil filter cap. • Install Install oil filter cap with the grommet to- A. MAINTENANCE AND ADJUSTMENT 33 the oil filter is replaced, remove the oil filter • When cap bolts and take off the cap with a new one. • Replace Apply grease to the grommet. • Install the oil filter • ward the engine. the oil filter element...
... torque. Oil Filter Cap B. j NOTICE Inside-out installation stop oil flow, causing engine seizure. Bolts A. Grommet the spring to the oil filter cap. • Install Install oil filter cap with the grommet to- A. MAINTENANCE AND ADJUSTMENT 33 the oil filter is replaced, remove the oil filter • When cap bolts and take off the cap with a new one. • Replace Apply grease to the grommet. • Install the oil filter • ward the engine. the oil filter element...
Owners Manual
Page 51
... low speeds. the seat (see Air Cleaner section). • Remove Remove the tank (see Spark Plug section). • Remove the fuel left and right side covers and muffler • body (see Exhaust System section). Air Cleaner Duct Clamp Screw Loosen the air cleaner duct clamp screw. • A. 50 MAINTENANCE AND ADJUSTMENT WARNING j Operation with damaged cables could result in the engine overheating, too. Prolonged idling of the engine with...
... low speeds. the seat (see Air Cleaner section). • Remove Remove the tank (see Spark Plug section). • Remove the fuel left and right side covers and muffler • body (see Exhaust System section). Air Cleaner Duct Clamp Screw Loosen the air cleaner duct clamp screw. • A. 50 MAINTENANCE AND ADJUSTMENT WARNING j Operation with damaged cables could result in the engine overheating, too. Prolonged idling of the engine with...
Owners Manual
Page 82
... changed when contaminated with the Periodic Maintenance Chart. Have the brake checked immediately by an authorized Kawasaki dealer. Front/Rear Brake Fluid : DOT3 or DOT4 żThe motorcycle is applied, there might be air in the brake lines or the brake may be adjusted to either side with brake fluid DOT4 in the brake lines diminish braking performance and can be defective. Brake Lever B. WARNING Air in the brake...
... changed when contaminated with the Periodic Maintenance Chart. Have the brake checked immediately by an authorized Kawasaki dealer. Front/Rear Brake Fluid : DOT3 or DOT4 żThe motorcycle is applied, there might be air in the brake lines or the brake may be adjusted to either side with brake fluid DOT4 in the brake lines diminish braking performance and can be defective. Brake Lever B. WARNING Air in the brake...
Owners Manual
Page 90
... valve assembly to suit your preference under certain conditions. Front Fork Base Valve Assembly Make sure the front forks are fully extended with normal use, so the fork action stiffens during operation. Front Fork Cylinder Valve A. MAINTENANCE AND ADJUSTMENT 89 Air Pressure Adjustment The standard air pressure in each front fork base valve assembly. Air pressure in the fork legs increase with the front wheel off the ground using a jack...
... valve assembly to suit your preference under certain conditions. Front Fork Base Valve Assembly Make sure the front forks are fully extended with normal use, so the fork action stiffens during operation. Front Fork Cylinder Valve A. MAINTENANCE AND ADJUSTMENT 89 Air Pressure Adjustment The standard air pressure in each front fork base valve assembly. Air pressure in the fork legs increase with the front wheel off the ground using a jack...
Owners Manual
Page 115
... UNI-TRAK® suspension are similar to those of the steering stem head the seat down and up by an authorized • If Kawasaki dealer. Rear Shock Absorber Adjustment The spring preload of a rear shock absorber unit, a swingarm, two lever rods and a lever. it unnecessary to change the oil viscosity. żTighten the two clamp bolts alternately two times to achieve progressive springing characteristics. In...
... UNI-TRAK® suspension are similar to those of the steering stem head the seat down and up by an authorized • If Kawasaki dealer. Rear Shock Absorber Adjustment The spring preload of a rear shock absorber unit, a swingarm, two lever rods and a lever. it unnecessary to change the oil viscosity. żTighten the two clamp bolts alternately two times to achieve progressive springing characteristics. In...
Owners Manual
Page 130
... the painted surfaces. a mild neutral detergent (designed for motor• Mix cycles or automobiles) and water in an area where the roads are cool before washing. Start the engine and let it Be sure the engine and exhaust are salted NOTE or near the ocean, immediately wash your motorcycle with cold water. spraying water in • Avoid air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings...
... the painted surfaces. a mild neutral detergent (designed for motor• Mix cycles or automobiles) and water in an area where the roads are cool before washing. Start the engine and let it Be sure the engine and exhaust are salted NOTE or near the ocean, immediately wash your motorcycle with cold water. spraying water in • Avoid air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings...
Owners Manual
Page 135
... turn over: plug dirty, broken, or gap improperly ad• Spark justed plug cap or high-tension wiring defective • Spark Spark cap not contacting properly • Spark plug plug type incorrect • Crankshaft sensor defective • CDI unit defective • Stick coil defective • Engine stop button wiring defective • Flywheel magneto damaged • Neutral switch defective • Wiring shorted or interrupted • Spark missing or weak: Fuel/air mixture incorrect: Idle...
... turn over: plug dirty, broken, or gap improperly ad• Spark justed plug cap or high-tension wiring defective • Spark Spark cap not contacting properly • Spark plug plug type incorrect • Crankshaft sensor defective • CDI unit defective • Stick coil defective • Engine stop button wiring defective • Flywheel magneto damaged • Neutral switch defective • Wiring shorted or interrupted • Spark missing or weak: Fuel/air mixture incorrect: Idle...
Owners Manual
Page 137
... high-speed performance - 136 TROUBLESHOOTING GUIDE Other: CDI unit defective Brake dragging Clutch slipping Engine over heating Engine oil level too high Engine oil viscosity too high Ignition timing incorrect Drive chain trouble j contaminated with water or foreign matter • Fuel Fuel tank cap air vent obstructed • Carburetor loose • Air cleaner holder duct loose • Fuel tap clogged • Fuel line clogged • Hot starter plunger stuck open Air cleaner element clogged Muffler clogged Fuel contaminated with water...
... high-speed performance - 136 TROUBLESHOOTING GUIDE Other: CDI unit defective Brake dragging Clutch slipping Engine over heating Engine oil level too high Engine oil viscosity too high Ignition timing incorrect Drive chain trouble j contaminated with water or foreign matter • Fuel Fuel tank cap air vent obstructed • Carburetor loose • Air cleaner holder duct loose • Fuel tap clogged • Fuel line clogged • Hot starter plunger stuck open Air cleaner element clogged Muffler clogged Fuel contaminated with water...
Owners Manual
Page 138
TROUBLESHOOTING GUIDE 137 dragging • Brake Clutch • Engineslipping overheating • Engine oil level too high • Engine oil viscosity too high • Crankshaft bearing worn • Ignition timing incorrect or damaged • Crankshaft sensor defective • Hot starter plunger stuck open • built up in combustion chamber • Carbon quality poor or type incorrect • Fuel plug type incorrect • Spark CDI unit defective • Engine overheating Knocking: Compression high...
TROUBLESHOOTING GUIDE 137 dragging • Brake Clutch • Engineslipping overheating • Engine oil level too high • Engine oil viscosity too high • Crankshaft bearing worn • Ignition timing incorrect or damaged • Crankshaft sensor defective • Hot starter plunger stuck open • built up in combustion chamber • Carbon quality poor or type incorrect • Fuel plug type incorrect • Spark CDI unit defective • Engine overheating Knocking: Compression high...
Owners Manual
Page 139
... Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on the shaft Shift lever broken Pawl guide plate broken Shift return spring broken or weak Shift return spring pin loose Shift pawl broken Shift pawl spring weak Shift drum broken Transmission jumps out of gear: Shift fork worn Gear groove worn Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating...
... Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on the shaft Shift lever broken Pawl guide plate broken Shift return spring broken or weak Shift return spring pin loose Shift pawl broken Shift pawl spring weak Shift drum broken Transmission jumps out of gear: Shift fork worn Gear groove worn Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating...
Owners Manual
Page 140
...; Front fork noise: Oil level or viscosity too low Spring broken or weak Front fork air pressure high Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake cylinder damaged Other noise: improperly mounted or • Abnormal drive train noise - • • • Clutch noise: Clutch housing/friction plate clearance excessive Clutch housing gear excessive Metal chip jammed in clutch housing gear teeth Transmission noise: bearing worn or...
...; Front fork noise: Oil level or viscosity too low Spring broken or weak Front fork air pressure high Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake cylinder damaged Other noise: improperly mounted or • Abnormal drive train noise - • • • Clutch noise: Clutch housing/friction plate clearance excessive Clutch housing gear excessive Metal chip jammed in clutch housing gear teeth Transmission noise: bearing worn or...
Owners Manual
Page 160
... Throttle grip screw tightness Throttle grip operation Front and rear brake hose installation Front and rear brake fluid level Front and rear brake disc and caliper installation Front and rear brake function Fuel tank installation All control cable routings Engine mounting bolt torque Engine sprocket installation Shift pedal bolt torque Engine oil level Carburetor holder clamp screw torque Carburetor cap tightness UNI-TRAK® lever rod nut torque UNI-TRAK® lever nut torque Rear shock...
... Throttle grip screw tightness Throttle grip operation Front and rear brake hose installation Front and rear brake fluid level Front and rear brake disc and caliper installation Front and rear brake function Fuel tank installation All control cable routings Engine mounting bolt torque Engine sprocket installation Shift pedal bolt torque Engine oil level Carburetor holder clamp screw torque Carburetor cap tightness UNI-TRAK® lever rod nut torque UNI-TRAK® lever nut torque Rear shock...