Owners Manual
Page 7
... INFORMATION ...GENERAL INFORMATION ...Meter Instruments ...Speedometer and Tachometer: ...Coolant Temperature Gauge: ...Indicator Lights: ...Key ...Ignition Switch/Steering Lock ...To lock the steering:...Right Handlebar Switches...Engine Stop Switch: ...Starter Button: ...Left Handlebar Switches ...Dimmer Switch: ...Turn Signal Switch:...Horn Button: ...7 11 12 15 18 21 21 22 22 23 23 25 25 26 26 27 27 27 28 28 Fuel Tank Cap ...Fuel Tank ...Fuel Tap ...Stand...Helmet Hook ...Rear Carrier ...Tool Kit Container/Tool Kit ...Tying Hooks ...BREAK-IN...
... INFORMATION ...GENERAL INFORMATION ...Meter Instruments ...Speedometer and Tachometer: ...Coolant Temperature Gauge: ...Indicator Lights: ...Key ...Ignition Switch/Steering Lock ...To lock the steering:...Right Handlebar Switches...Engine Stop Switch: ...Starter Button: ...Left Handlebar Switches ...Dimmer Switch: ...Turn Signal Switch:...Horn Button: ...7 11 12 15 18 21 21 22 22 23 23 25 25 26 26 27 27 27 28 28 Fuel Tank Cap ...Fuel Tank ...Fuel Tap ...Stand...Helmet Hook ...Rear Carrier ...Tool Kit Container/Tool Kit ...Tying Hooks ...BREAK-IN...
Owners Manual
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......MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart...Engine Oil ...Cooling System ...Spark Plugs...Evaporative Emission Control System (California model only)...Kawasaki Clean Air System ...Valve Clearance ...Air Cleaner ...Throttle Control System ...Choke Lever...Idle Speed ...Clutch ...Spark Arrester ...Drive Chain ... 59 59 62 65 67 71 84 90 96 97 98 99 100 104 107 108 109 112 114 Brakes ...Brake Light Switches...Front Fork...Rear Shock Absorbers ...Wheels ...Tires -...Battery...Headlight Beam...Rear Turn Signal Light ...Fuses ...General Lubrication...Cleaning Your Motorcycle ...Bolt...
......MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart...Engine Oil ...Cooling System ...Spark Plugs...Evaporative Emission Control System (California model only)...Kawasaki Clean Air System ...Valve Clearance ...Air Cleaner ...Throttle Control System ...Choke Lever...Idle Speed ...Clutch ...Spark Arrester ...Drive Chain ... 59 59 62 65 67 71 84 90 96 97 98 99 100 104 107 108 109 112 114 Brakes ...Brake Light Switches...Front Fork...Rear Shock Absorbers ...Wheels ...Tires -...Battery...Headlight Beam...Rear Turn Signal Light ...Fuses ...General Lubrication...Cleaning Your Motorcycle ...Bolt...
Owners Manual
Page 9
SPECIFICATIONS 7 SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Carburetion System Ignition System DOHC, 4-valve, 1-cylinder, 4-stroke, liquid-cooled 651 cm³ (39.7 cu in.) 100.0 × 83.0 mm (3.94 × 3.27 in.) 9.8 : 1 Electric starter KEIHIN CVK 40 × 1 Battery and coil (transistorized ignition) 2 295 mm (90.4 in.) 960 mm (37.8 in.) 1 350 mm (53.1 in.) 1 480 mm (58.3 in.) 210 mm (8.3 in.) 196 kg (432 lb)
SPECIFICATIONS 7 SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Carburetion System Ignition System DOHC, 4-valve, 1-cylinder, 4-stroke, liquid-cooled 651 cm³ (39.7 cu in.) 100.0 × 83.0 mm (3.94 × 3.27 in.) 9.8 : 1 Electric starter KEIHIN CVK 40 × 1 Battery and coil (transistorized ignition) 2 295 mm (90.4 in.) 960 mm (37.8 in.) 1 350 mm (53.1 in.) 1 480 mm (58.3 in.) 210 mm (8.3 in.) 196 kg (432 lb)
Owners Manual
Page 14
Right Handlebar Switches Front Brake Lever Throttle Grip Ignition Switch/Steering Lock 12 LOCATION OF PARTS LOCATION OF PARTS 1. 2. 3. 4. Clutch Lever Left Handlebar Switches Meter Instruments Brake Fluid Reservoir (Front) 5. 6. 7. 8.
Right Handlebar Switches Front Brake Lever Throttle Grip Ignition Switch/Steering Lock 12 LOCATION OF PARTS LOCATION OF PARTS 1. 2. 3. 4. Clutch Lever Left Handlebar Switches Meter Instruments Brake Fluid Reservoir (Front) 5. 6. 7. 8.
Owners Manual
Page 22
... weight, but can only warn that the effects can be adverse and that Kawasaki cannot assume responsibility for motorcycles and cannot predict the effects of such accessories on handling or stability, but also due to tow any other aspect of the steering assembly... riding condition. 9. Maximum Load Weight of such accessories will increase the mass of the motorcycle's operation. 7. 20 LOADING INFORMATION affected any lighting components, road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any trailer or other vehicle. This...
... weight, but can only warn that the effects can be adverse and that Kawasaki cannot assume responsibility for motorcycles and cannot predict the effects of such accessories on handling or stability, but also due to tow any other aspect of the steering assembly... riding condition. 9. Maximum Load Weight of such accessories will increase the mass of the motorcycle's operation. 7. 20 LOADING INFORMATION affected any lighting components, road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any trailer or other vehicle. This...
Owners Manual
Page 25
... may be stamped on a separate plate. Included with a plate, store it in neutral, the neutral indicator light is lit. : When the turn signal switch is turned to left or right, the turn signal indicator light flashes on high beam, the high beam indicator light is used for the ignition switch/steering lock, seat lock, helmet hook and fuel tank cap. If your keys came with the key is a key number, which is lit.
... may be stamped on a separate plate. Included with a plate, store it in neutral, the neutral indicator light is lit. : When the turn signal switch is turned to left or right, the turn signal indicator light flashes on high beam, the high beam indicator light is used for the ignition switch/steering lock, seat lock, helmet hook and fuel tank cap. If your keys came with the key is a key number, which is lit.
Owners Manual
Page 59
... hot, or reduces converter performance when the engine is discharged. Never • Use use leaded gasoline. HOW TO RIDE THE MOTORCYCLE 57 WARNING Operating or parking the vehicle near flammable materials can cause a fire, and can cause serious burns. Do not idle or park your vehicle in the converter allowing the converter to start the engine by rolling the vehicle if the battery is cold. only unleaded...
... hot, or reduces converter performance when the engine is discharged. Never • Use use leaded gasoline. HOW TO RIDE THE MOTORCYCLE 57 WARNING Operating or parking the vehicle near flammable materials can cause a fire, and can cause serious burns. Do not idle or park your vehicle in the converter allowing the converter to start the engine by rolling the vehicle if the battery is cold. only unleaded...
Owners Manual
Page 62
... long slopes, control vehicle speed by closing the throttle. When going up steep slopes, shift to a lower gear so that there is plenty of speed and avoiding unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for sudden braking may cause loss of control, especially when riding in wet conditions or on the front and rear brakes. 60 SAFE...
... long slopes, control vehicle speed by closing the throttle. When going up steep slopes, shift to a lower gear so that there is plenty of speed and avoiding unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for sudden braking may cause loss of control, especially when riding in wet conditions or on the front and rear brakes. 60 SAFE...
Owners Manual
Page 65
... to lock. Drive chain ...Slack 35 a 45 mm (1.4 a 1.8 in .). No binding of control cables. Coolant level between level lines (when engine is cold). Nuts, bolts, fasteners .. Throttle ...Throttle grip play 8 a 12 mm (0.31 a 0.47 in .) left. Clutch ...Clutch lever play 2 a 3 mm (0.08 a 0.12 in .) Lubricate the dive chain if dry. Check that steering and suspension components, axles, and all controls are properly tightened or fastened. Coolant ...No coolant leakage. Brakes ...Brake pad...
... to lock. Drive chain ...Slack 35 a 45 mm (1.4 a 1.8 in .). No binding of control cables. Coolant level between level lines (when engine is cold). Nuts, bolts, fasteners .. Throttle ...Throttle grip play 8 a 12 mm (0.31 a 0.47 in .) left. Clutch ...Clutch lever play 2 a 3 mm (0.08 a 0.12 in .) Lubricate the dive chain if dry. Check that steering and suspension components, axles, and all controls are properly tightened or fastened. Coolant ...No coolant leakage. Brakes ...Brake pad...
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Engine stop switch ...Stops engine. Refer to the "Daily Safety Checks" caution label attached to its fully up position by spring tension. Returns spring not weak or not damaged. Side stand ...Returns to the Left Side Cover. 64 SAFE OPERATION Electrical equipment ...All lights (Headlight, Tail/Brake Lights, Turn Signal Lights, Indicator Lights) and horn work.
Engine stop switch ...Stops engine. Refer to the "Daily Safety Checks" caution label attached to its fully up position by spring tension. Returns spring not weak or not damaged. Side stand ...Returns to the Left Side Cover. 64 SAFE OPERATION Electrical equipment ...All lights (Headlight, Tail/Brake Lights, Turn Signal Lights, Indicator Lights) and horn work.
Owners Manual
Page 80
78 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Brake fluid level inspect Brake operation (effectiveness, play, drag) inspect Brake light switch operation - inspect Suspensions: Front forks/rear shock absorber operation K (damping and smooth stroke) inspect Every 6 month 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • • • • • • • • • • 122 year 124 125 127
78 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Brake fluid level inspect Brake operation (effectiveness, play, drag) inspect Brake light switch operation - inspect Suspensions: Front forks/rear shock absorber operation K (damping and smooth stroke) inspect Every 6 month 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • • • • • • • • • • 122 year 124 125 127
Owners Manual
Page 86
... the proper level, and change the oil according to the periodic maintenance chart in accordance with oil. Check the oil level before the oil reaches every part can cause engine seizure. Oil Level Inspection If the oil has just been changed, start the engine and run it for several minutes for the engine, transmission, and clutch to function properly, maintain the engine oil at idle speed. the motorcycle has just...
... the proper level, and change the oil according to the periodic maintenance chart in accordance with oil. Check the oil level before the oil reaches every part can cause engine seizure. Oil Level Inspection If the oil has just been changed, start the engine and run it for several minutes for the engine, transmission, and clutch to function properly, maintain the engine oil at idle speed. the motorcycle has just...
Owners Manual
Page 121
... cut for damaged rollers, and • If the length exceeds the service limit, the chain should be replaced. • A. Also inspect the sprockets for il- See Service Manual for wear limits. Measure B. Drive Chain 20-Link Length Service Limit 319 mm (12.6 in.) WARNING For safety, use only the standard chain. Weight loose pins and links. MAINTENANCE AND ADJUSTMENT 119 wear unevenly, take measurements at...
... cut for damaged rollers, and • If the length exceeds the service limit, the chain should be replaced. • A. Also inspect the sprockets for il- See Service Manual for wear limits. Measure B. Drive Chain 20-Link Length Service Limit 319 mm (12.6 in.) WARNING For safety, use only the standard chain. Weight loose pins and links. MAINTENANCE AND ADJUSTMENT 119 wear unevenly, take measurements at...
Owners Manual
Page 127
MAINTENANCE AND ADJUSTMENT 125 Brake Light Switches When either the front or rear brake is applied. Pedal Travel it does not, ask your authorized Kawasaki dealer to "ON". Brake Pedal Travel 10 mm (0.4 in accordance with the Periodic Maintenance Chart. Inspection Turn the ignition key to inspect the front brake light switch. The brake light should go on . Brake Pedal B. The front brake light switch requires no adjustment, but the rear brake light switch should go...
MAINTENANCE AND ADJUSTMENT 125 Brake Light Switches When either the front or rear brake is applied. Pedal Travel it does not, ask your authorized Kawasaki dealer to "ON". Brake Pedal Travel 10 mm (0.4 in accordance with the Periodic Maintenance Chart. Inspection Turn the ignition key to inspect the front brake light switch. The brake light should go on . Brake Pedal B. The front brake light switch requires no adjustment, but the rear brake light switch should go...
Owners Manual
Page 128
NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. • A. D. Rear Brake Light Switch Adjusting Nut Lights sooner Lights later C. 126 MAINTENANCE AND ADJUSTMENT Adjustment To adjust the rear brake light switch, move the switch up or down. B.
NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. • A. D. Rear Brake Light Switch Adjusting Nut Lights sooner Lights later C. 126 MAINTENANCE AND ADJUSTMENT Adjustment To adjust the rear brake light switch, move the switch up or down. B.
Owners Manual
Page 144
The main fuse is mounted on the starter relay behind the cover. Spare Parts Counterclockwise C. Fuse Box B. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of the rear turn signal light, remove the screw and lightly twist the lens counterclockwise. Screw A. 142 MAINTENANCE AND ADJUSTMENT Rear Turn Signal Light To replace the bulb of proper amperage. Fuses C. A. Lens B. Fuses Fuses are located under the seat.
The main fuse is mounted on the starter relay behind the cover. Spare Parts Counterclockwise C. Fuse Box B. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of the rear turn signal light, remove the screw and lightly twist the lens counterclockwise. Screw A. 142 MAINTENANCE AND ADJUSTMENT Rear Turn Signal Light To replace the bulb of proper amperage. Fuses C. A. Lens B. Fuses Fuses are located under the seat.
Owners Manual
Page 148
When operating the vehicle in conditions that allow debris or flammable material to collect in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. WARNING Build-up of debris or flammable materials. Do not park or store the vehicle in an enclosed space prior to cool, then remove any collected debris. Covering your Kawasaki motorcycle will help protect its...
When operating the vehicle in conditions that allow debris or flammable material to collect in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. WARNING Build-up of debris or flammable materials. Do not park or store the vehicle in an enclosed space prior to cool, then remove any collected debris. Covering your Kawasaki motorcycle will help protect its...
Owners Manual
Page 149
... water in air intakes, fuel system, brake components, electrical components, muffler outlets, and fuel tank openings. applying degreaser to wash your bike with clean water to remove any residue (residue from a garden hose to remove any loose dirt. all other plastic parts as ammonia-based window cleaners. Use care when washing the windshield, headlight cover, and other abrasive pads or brushes. water can easily be scratched. MAINTENANCE AND...
... water in air intakes, fuel system, brake components, electrical components, muffler outlets, and fuel tank openings. applying degreaser to wash your bike with clean water to remove any residue (residue from a garden hose to remove any loose dirt. all other plastic parts as ammonia-based window cleaners. Use care when washing the windshield, headlight cover, and other abrasive pads or brushes. water can easily be scratched. MAINTENANCE AND...
Owners Manual
Page 153
... Bolts 2. Handlebar Mounting Bolts 5. Engine Mounting Bolts and Nuts 6. Stem Head Nut 4. Brake Disc Mounting Bolts 9. Rear Sprocket Mounting Nuts Step Holder Mounting Bolts 13. MAINTENANCE AND ADJUSTMENT 151 Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart, it is very important to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki dealer for torque values. 1. Side Stand Switch Mounting Bolt 14. Steering...
... Bolts 2. Handlebar Mounting Bolts 5. Engine Mounting Bolts and Nuts 6. Stem Head Nut 4. Brake Disc Mounting Bolts 9. Rear Sprocket Mounting Nuts Step Holder Mounting Bolts 13. MAINTENANCE AND ADJUSTMENT 151 Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart, it is very important to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki dealer for torque values. 1. Side Stand Switch Mounting Bolt 14. Steering...
Owners Manual
Page 154
UNI TRACK Lever Rod Nuts 21. Exhaust Pipe Holder Nuts 24. Brake Pedal Mounting Bolt 19. Front Axle Clamp Bolts 22. Spoke Nipples 18. Rear Shock Absorber Mounting Nut 23. 152 MAINTENANCE AND ADJUSTMENT 16. Rear Axle Nut 20. Muffler Body Mounting Nut Front Axle Nut 17.
UNI TRACK Lever Rod Nuts 21. Exhaust Pipe Holder Nuts 24. Brake Pedal Mounting Bolt 19. Front Axle Clamp Bolts 22. Spoke Nipples 18. Rear Shock Absorber Mounting Nut 23. 152 MAINTENANCE AND ADJUSTMENT 16. Rear Axle Nut 20. Muffler Body Mounting Nut Front Axle Nut 17.