Owners Manual
Page 8
... Maintenance Chart ...24 Engine Oil ...29 Cooling System ...34 Spark Plug ...38 Air Cleaner ...45 Throttle Cable ...51 Throttle Body Assy ...52 Clutch ...63 Valve Clearance ...70 Exhaust System ...75 Drive Chain ...79 Handlebar ...86 Brakes ...87 Steering ...91 Front Suspension ...94 Rear Suspension (UNI-TRAK®) ...136 Wheels ...142 Hoses Inspection ...145 Tightening Torques of Nuts and Bolts ...146 Cleaning Your Motorcycle ...151 Lubrication ...153 DFI Self-Diagnosis ...156 TROUBLESHOOTING GUIDE ...161 TUNING ...168 Suspension...
... Maintenance Chart ...24 Engine Oil ...29 Cooling System ...34 Spark Plug ...38 Air Cleaner ...45 Throttle Cable ...51 Throttle Body Assy ...52 Clutch ...63 Valve Clearance ...70 Exhaust System ...75 Drive Chain ...79 Handlebar ...86 Brakes ...87 Steering ...91 Front Suspension ...94 Rear Suspension (UNI-TRAK®) ...136 Wheels ...142 Hoses Inspection ...145 Tightening Torques of Nuts and Bolts ...146 Cleaning Your Motorcycle ...151 Lubrication ...153 DFI Self-Diagnosis ...156 TROUBLESHOOTING GUIDE ...161 TUNING ...168 Suspension...
Owners Manual
Page 9
... 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 TRANSMISSION Transmission Type 2 170 mm (85.4 in.) 820 mm (32.3 in.) 1 270 mm (50.0 in.) 1 475 mm (58.1 in.) 330 mm (13.0 in.) 105.6 kg (233 lb) 7.2 L (1.9 US gal) 4-stroke, DOHC, single-cylinder, liquid-cooled...
... 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 TRANSMISSION Transmission Type 2 170 mm (85.4 in.) 820 mm (32.3 in.) 1 270 mm (50.0 in.) 1 475 mm (58.1 in.) 330 mm (13.0 in.) 105.6 kg (233 lb) 7.2 L (1.9 US gal) 4-stroke, DOHC, single-cylinder, liquid-cooled...
Owners Manual
Page 16
... the vents in the tank cap. Fuels Containing Oxygenates Fuel Type Use clean, fresh unleaded gasoline with a pilot light. The Antiknock Index is posted on the fuel tank, wipe it can be covered under certain conditions. Gasoline containing up to 10% ethanol (alcohol produced from the use . this condition is spilled on service station pumps in areas of a higher octane rating. If gasoline is...
... the vents in the tank cap. Fuels Containing Oxygenates Fuel Type Use clean, fresh unleaded gasoline with a pilot light. The Antiknock Index is posted on the fuel tank, wipe it can be covered under certain conditions. Gasoline containing up to 10% ethanol (alcohol produced from the use . this condition is spilled on service station pumps in areas of a higher octane rating. If gasoline is...
Owners Manual
Page 18
.... A. Starting the Engine • Shift the transmission into neutral. Any riding conditions that increase engine temperature will further reduce idling time before operation, or leaving idling with the transmission in the engine overheating, too. Do not start the engine or attempt to ride the motorcycle when the side stand is equipped with a primary kick starting system. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. When the clutch lever...
.... A. Starting the Engine • Shift the transmission into neutral. Any riding conditions that increase engine temperature will further reduce idling time before operation, or leaving idling with the transmission in the engine overheating, too. Do not start the engine or attempt to ride the motorcycle when the side stand is equipped with a primary kick starting system. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. When the clutch lever...
Owners Manual
Page 23
The time required is minimal, and habitual performance of these checks, refer to the appropriate section and take the action required to return the motorcycle to a safe operating condition. DO NOT run the engine in serious damage or an accident. Always perform daily safety checks before you ride. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Engine Engine Oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Cover ...Clutch ...Air Cleaner ...Muffler ... GENERAL...
The time required is minimal, and habitual performance of these checks, refer to the appropriate section and take the action required to return the motorcycle to a safe operating condition. DO NOT run the engine in serious damage or an accident. Always perform daily safety checks before you ride. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Engine Engine Oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Cover ...Clutch ...Air Cleaner ...Muffler ... GENERAL...
Owners Manual
Page 31
... change the oil and oil filter periodically. the engine and run the engine at • Start idle speed. Check the oil level before the oil reaches every part can cause engine seizure. The oil level should come up between the high and low level lines next to function properly, maintain the engine oil at the proper level, and change the oil according to settle. Oil Level Inspection • • WARNING...
... change the oil and oil filter periodically. the engine and run the engine at • Start idle speed. Check the oil level before the oil reaches every part can cause engine seizure. The oil level should come up between the high and low level lines next to function properly, maintain the engine oil at the proper level, and change the oil according to settle. Oil Level Inspection • • WARNING...
Owners Manual
Page 32
... the oil filler plug. • Remove Remove the oil drain bolt and position the vehicle • perpendicular to the ground to allow all the oil to ensure long engine life. High Level Line C. Oil and/or Oil Filter Change The engine oil and/or oil filter should be in the oil level gauge, tip the mo- Drain Bolt A. Oil Filler Plug WARNING Motor oil is visible then return to empty any oil that the oil will...
... the oil filler plug. • Remove Remove the oil drain bolt and position the vehicle • perpendicular to the ground to allow all the oil to ensure long engine life. High Level Line C. Oil and/or Oil Filter Change The engine oil and/or oil filter should be in the oil level gauge, tip the mo- Drain Bolt A. Oil Filler Plug WARNING Motor oil is visible then return to empty any oil that the oil will...
Owners Manual
Page 34
... "Kawasaki Performance 4-Stroke Semi-Synthetic Oil*" 10W-40 or "Kawasaki Performance 4-Stroke Motorcycle Oil*" 10W-40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for it is completely dry) A. O-ring C. 32 MAINTENANCE AND ADJUSTMENT the spring to the oil filter cap. • Install Install the oil filter cap with a new one. NOTE ○ Replace the gasket and O-ring with the grease applied to a • new O-ring and tighten its new gasket. Engine Oil Capacity Capacity...
... "Kawasaki Performance 4-Stroke Semi-Synthetic Oil*" 10W-40 or "Kawasaki Performance 4-Stroke Motorcycle Oil*" 10W-40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for it is completely dry) A. O-ring C. 32 MAINTENANCE AND ADJUSTMENT the spring to the oil filter cap. • Install Install the oil filter cap with a new one. NOTE ○ Replace the gasket and O-ring with the grease applied to a • new O-ring and tighten its new gasket. Engine Oil Capacity Capacity...
Owners Manual
Page 41
... the center electrode. Radiator Shroud NOTE ○ If the engine performance drops, try replacing the spark plug to regain performance. the seat (see Air Cleaner section). • Remove Remove the bolts and take off the radiator shroud • on both sides. Spark Plug Removal and Installation If the ceramic is shown in the table below. Optional Spark Plug Colder NGK CPR9EB-9 A. The standard spark plug is light brown, the spark plug...
... the center electrode. Radiator Shroud NOTE ○ If the engine performance drops, try replacing the spark plug to regain performance. the seat (see Air Cleaner section). • Remove Remove the bolts and take off the radiator shroud • on both sides. Spark Plug Removal and Installation If the ceramic is shown in the table below. Optional Spark Plug Colder NGK CPR9EB-9 A. The standard spark plug is light brown, the spark plug...
Owners Manual
Page 90
...; The motorcycle is no • Test brake drag. Check for brake hose damage. WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in accordance with the Periodic Maintenance Chart. Disc Brake Fluid Inspect the brake fluid level in the front and rear brake reservoirs and change the brake fluid in injury or death. Do not use fluid from a container that has been left...
...; The motorcycle is no • Test brake drag. Check for brake hose damage. WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in accordance with the Periodic Maintenance Chart. Disc Brake Fluid Inspect the brake fluid level in the front and rear brake reservoirs and change the brake fluid in injury or death. Do not use fluid from a container that has been left...
Owners Manual
Page 138
... progressive springing characteristics. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. The operating characteristics of the UNI-TRAK® suspension are similar to change the oil viscosity. inspect the rear shock absorber for oil • Visually leakage. In addition, the damping force can be replaced with a flat-head screwdriver. ○ Tighten the two clamp bolts alternately two times to...
... progressive springing characteristics. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. The operating characteristics of the UNI-TRAK® suspension are similar to change the oil viscosity. inspect the rear shock absorber for oil • Visually leakage. In addition, the damping force can be replaced with a flat-head screwdriver. ○ Tighten the two clamp bolts alternately two times to...
Owners Manual
Page 153
... neutral detergent (designed for motor• Mix cycles or automobiles) and water in air intakes, throttle body assy, brake components, electrical components, muffler outlets, and fuel tank openings. Start the engine and let it accelerates the chemical reaction of the salt. Avoid applying degreaser to prevent rusting. Use care when washing the plastic parts as ammonia-based window cleaners. your motorcycle thoroughly with cold water. The heat from...
... neutral detergent (designed for motor• Mix cycles or automobiles) and water in air intakes, throttle body assy, brake components, electrical components, muffler outlets, and fuel tank openings. Start the engine and let it accelerates the chemical reaction of the salt. Avoid applying degreaser to prevent rusting. Use care when washing the plastic parts as ammonia-based window cleaners. your motorcycle thoroughly with cold water. The heat from...
Owners Manual
Page 161
MAINTENANCE AND ADJUSTMENT 159 Service Code Table Service Code 11 12 13 14 21 25 31 41 46 51 FI Indicator Light Problems Throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Gear position switch malfunction, wiring open or short Vehicle-down sensor malfunction, wiring open or short Fuel injector malfunction...
MAINTENANCE AND ADJUSTMENT 159 Service Code Table Service Code 11 12 13 14 21 25 31 41 46 51 FI Indicator Light Problems Throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Gear position switch malfunction, wiring open or short Vehicle-down sensor malfunction, wiring open or short Fuel injector malfunction...
Owners Manual
Page 163
... spring broken • Kick ratchet gear not engaging • Improper installation of vehicle-down sensor • fuel in troubleshooting for each problem listed. It is not exhaustive and does not give every possible cause for some of a fuel injector • Fuel does not flow: Engine does not turn over: Spark missing or weak: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap...
... spring broken • Kick ratchet gear not engaging • Improper installation of vehicle-down sensor • fuel in troubleshooting for each problem listed. It is not exhaustive and does not give every possible cause for some of a fuel injector • Fuel does not flow: Engine does not turn over: Spark missing or weak: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap...
Owners Manual
Page 164
... not installed Fuel tank cap air vent obstructed Throttle body assy holder loose Air cleaner duct loose Fuel pump defective Other: ECU defective Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive chain trouble Poor or no high-speed performance Firing incorrect: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect ECU defective Ignition coil defective Crankshaft sensor defective...
... not installed Fuel tank cap air vent obstructed Throttle body assy holder loose Air cleaner duct loose Fuel pump defective Other: ECU defective Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive chain trouble Poor or no high-speed performance Firing incorrect: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect ECU defective Ignition coil defective Crankshaft sensor defective...
Owners Manual
Page 165
TROUBLESHOOTING GUIDE 163 Fuel/air mixture incorrect: Air cleaner element clogged, poorly sealed, or not installed Fuel contaminated with water or foreign matter Fuel tank cap air vent obstructed Throttle body assy holder loose Air cleaner duct loose Fuel line clogged Fuel pump defective Compression low: oil level too high • Engine Engine oil viscosity too high • Crankshaft worn or damaged • Drive chain bearing trouble • Knocking: Carbon built up in combustion chamber Fuel quality...
TROUBLESHOOTING GUIDE 163 Fuel/air mixture incorrect: Air cleaner element clogged, poorly sealed, or not installed Fuel contaminated with water or foreign matter Fuel tank cap air vent obstructed Throttle body assy holder loose Air cleaner duct loose Fuel line clogged Fuel pump defective Compression low: oil level too high • Engine Engine oil viscosity too high • Crankshaft worn or damaged • Drive chain bearing trouble • Knocking: Carbon built up in combustion chamber Fuel quality...
Owners Manual
Page 167
... excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner defective Camshaft chain, sprocket, chain guide worn Decompression spring broken Flywheel magneto loose Drive chain noise: Drive chain slack improperly adjusted Drive chain worn Rear and/or engine sprocket(s) worn Drive chain inefficiently lubricated Rear wheel misaligned Frame noise abnormal Front fork noise: Oil level or viscosity too low Spring broken or weak Front fork air pressure high • Shock absorber damaged Rear shock absorber noise: TROUBLESHOOTING GUIDE 165...
... excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner defective Camshaft chain, sprocket, chain guide worn Decompression spring broken Flywheel magneto loose Drive chain noise: Drive chain slack improperly adjusted Drive chain worn Rear and/or engine sprocket(s) worn Drive chain inefficiently lubricated Rear wheel misaligned Frame noise abnormal Front fork noise: Oil level or viscosity too low Spring broken or weak Front fork air pressure high • Shock absorber damaged Rear shock absorber noise: TROUBLESHOOTING GUIDE 165...
Owners Manual
Page 168
166 TROUBLESHOOTING GUIDE Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake cylinder damaged Other noise: bolt, etc. improperly mounted or • Tire air pressure too low worn • Tire sleeve or needle bearing damaged • Swingarm Rim warped out of balance • Front and/or or rear axle runout excessive • Wheel bearing worn • Handlebar clamp loose • Steering stem head nut loose • Spoke loose...
166 TROUBLESHOOTING GUIDE Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake cylinder damaged Other noise: bolt, etc. improperly mounted or • Tire air pressure too low worn • Tire sleeve or needle bearing damaged • Swingarm Rim warped out of balance • Front and/or or rear axle runout excessive • Wheel bearing worn • Handlebar clamp loose • Steering stem head nut loose • Spoke loose...
Owners Manual
Page 180
... rear brake function Fuel tank installation All control cable routings Engine mounting bolt torque Engine sprocket installation Shift pedal bolt torque Engine oil level UNI-TRAK® lever rod nut torque UNI-TRAK® lever nut torque Rear shock absorber nut torque Swingarm pivot shaft nut torque Rear axle nut torque Rear sprocket nut torque Rear brake pedal operation Seat installation Front and rear wheel spoke torque Front and rear tire air pressure Front fork air pressure Drive chain slack Coolant level Oil...
... rear brake function Fuel tank installation All control cable routings Engine mounting bolt torque Engine sprocket installation Shift pedal bolt torque Engine oil level UNI-TRAK® lever rod nut torque UNI-TRAK® lever nut torque Rear shock absorber nut torque Swingarm pivot shaft nut torque Rear axle nut torque Rear sprocket nut torque Rear brake pedal operation Seat installation Front and rear wheel spoke torque Front and rear tire air pressure Front fork air pressure Drive chain slack Coolant level Oil...
Owners Manual
Page 182
.... Wipe any length of time, it . Dispose of used oil properly. Kick the engine over the muffler to prevent moisture from any appliance with a pilot light. Dispose of gasoline properly. Clean the entire vehicle thoroughly. WARNING Gasoline is extremely flammable and can be explosive under the front and rear wheels to keep dampness away from the tire rubber.). Run the engine for about...
.... Wipe any length of time, it . Dispose of used oil properly. Kick the engine over the muffler to prevent moisture from any appliance with a pilot light. Dispose of gasoline properly. Clean the entire vehicle thoroughly. WARNING Gasoline is extremely flammable and can be explosive under the front and rear wheels to keep dampness away from the tire rubber.). Run the engine for about...