Owners Manual
Page 8
... ...Engine Oil...Cooling System ...Spark Plug...Air Cleaner ...Throttle Cable ...Throttle Body Assy ...Clutch ...Valve Clearance ...Exhaust System ...7 10 10 13 14 15 17 17 19 20 21 21 22 23 25 26 26 31 36 40 47 53 54 64 71 76 Drive Chain...Handlebars ...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...DFI Self-Diagnosis ...TROUBLESHOOTING GUIDE...TUNING ...Suspension...Gearing...
... ...Engine Oil...Cooling System ...Spark Plug...Air Cleaner ...Throttle Cable ...Throttle Body Assy ...Clutch ...Valve Clearance ...Exhaust System ...7 10 10 13 14 15 17 17 19 20 21 21 22 23 25 26 26 31 36 40 47 53 54 64 71 76 Drive Chain...Handlebars ...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...DFI Self-Diagnosis ...TROUBLESHOOTING GUIDE...TUNING ...Suspension...Gearing...
Owners Manual
Page 14
Rear Brake Fluid Reservoir 3. Oil Level Inspection Window 8. Muffler 2. Rear Brake Pedal 9. Exhaust Pipe 12 GENERAL INFORMATION j 1. Rear Shock Absorber Gas Reservoir 4. Kick Pedal 5. Uni-Trak® Tie-Rod and Rocker Arm 7. DFI Setting Data Selection Connector 6.
Rear Brake Fluid Reservoir 3. Oil Level Inspection Window 8. Muffler 2. Rear Brake Pedal 9. Exhaust Pipe 12 GENERAL INFORMATION j 1. Rear Shock Absorber Gas Reservoir 4. Kick Pedal 5. Uni-Trak® Tie-Rod and Rocker Arm 7. DFI Setting Data Selection Connector 6.
Owners Manual
Page 19
... results in possible engine damage. A. Starting the Engine • Shift the transmission into neutral. When the clutch lever is installed. Furthermore, warming the engine up excessively before coolant loss occurs. Any riding conditions that increase engine temperature will further reduce idling time before operation, or leaving idling with no airflow through the radiator can cause a crash resulting in any gear. WARNING Riding with a primary kick starting system. GENERAL INFORMATION...
... results in possible engine damage. A. Starting the Engine • Shift the transmission into neutral. When the clutch lever is installed. Furthermore, warming the engine up excessively before coolant loss occurs. Any riding conditions that increase engine temperature will further reduce idling time before operation, or leaving idling with no airflow through the radiator can cause a crash resulting in any gear. WARNING Riding with a primary kick starting system. GENERAL INFORMATION...
Owners Manual
Page 24
..., each cable elongation, brake play, chain slack and spoke tightness. Change the engine oil, oil filter and front fork/rear shock absorber oil to obtain the proper operating clearances in the engine and transmission, which are necessary for performance and reliability. 6. 7. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep the engine trouble-free. Stop and let the engine cool completely. Break in...
..., each cable elongation, brake play, chain slack and spoke tightness. Change the engine oil, oil filter and front fork/rear shock absorber oil to obtain the proper operating clearances in the engine and transmission, which are necessary for performance and reliability. 6. 7. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep the engine trouble-free. Stop and let the engine cool completely. Break in...
Owners Manual
Page 25
.... 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 Air Cleaner ...Clean Apply oil to a safe operating condition. DO NOT run the engine in a well-ventilated area. Inhaling carbon monoxide can cause serious brain injury or death. WARNING Failure to perform these checks will help ensure a safe, reliable ride. DANGER Exhaust gas...
.... 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 Air Cleaner ...Clean Apply oil to a safe operating condition. DO NOT run the engine in a well-ventilated area. Inhaling carbon monoxide can cause serious brain injury or death. WARNING Failure to perform these checks will help ensure a safe, reliable ride. DANGER Exhaust gas...
Owners Manual
Page 33
... the oil to the gauge. the engine and run the engine at the proper level, and change the oil according to the periodic maintenance chart in engine or transmission seizure, accident, and injury. Stop the engine and wait several minutes at • Start idle speed. To ensure a proper reading of the semi-dry sump lubrication system, the engine oil level indicated on the oil level inspection window will...
... the oil to the gauge. the engine and run the engine at the proper level, and change the oil according to the periodic maintenance chart in engine or transmission seizure, accident, and injury. Stop the engine and wait several minutes at • Start idle speed. To ensure a proper reading of the semi-dry sump lubrication system, the engine oil level indicated on the oil level inspection window will...
Owners Manual
Page 34
Oil and/or Oil Filter Change The engine oil and/or oil filter should be in the oil level inspection window, j tip the motorcycle slightly to the right until oil is a toxic substance. A. B. Oil Level Inspection Window High Level Line Low Level Line Oil Filler Plug WARNING Engine oil is visible then return to an upright position. Drain Bolt A. C. D. Dispose of oil. up any sediment and drain easily. If no oil appears...
Oil and/or Oil Filter Change The engine oil and/or oil filter should be in the oil level inspection window, j tip the motorcycle slightly to the right until oil is a toxic substance. A. B. Oil Level Inspection Window High Level Line Low Level Line Oil Filler Plug WARNING Engine oil is visible then return to an upright position. Drain Bolt A. C. D. Dispose of oil. up any sediment and drain easily. If no oil appears...
Owners Manual
Page 36
... meets or exceeds warranty and service requirements and can help to extend the life of your vehicle. Engine Oil Capacity Capacity: 0.75 L (0.79 US qt) (When filter is not removed) 0.80 L (0.85 US qt) (When filter is removed) 1.00 L (1.06 US qt) (When engine is shown in the table. *Kawasaki Performance Oils and Lubricants have been specifically engineered for your Kawasaki. Tightening Torque Engine Oil Drain Bolt: 20 N·m (2.0 kgf...
... meets or exceeds warranty and service requirements and can help to extend the life of your vehicle. Engine Oil Capacity Capacity: 0.75 L (0.79 US qt) (When filter is not removed) 0.80 L (0.85 US qt) (When filter is removed) 1.00 L (1.06 US qt) (When engine is shown in the table. *Kawasaki Performance Oils and Lubricants have been specifically engineered for your Kawasaki. Tightening Torque Engine Oil Drain Bolt: 20 N·m (2.0 kgf...
Owners Manual
Page 71
... Ball A. Release Shaft Lever Push forward. B. D. the clutch spring bolts to the specified Tightening Torque Clutch Spring Bolts: 9.0 N·m (0.92 kgf·m, 80 in·lb) the release shaft...ball and the push rod holder. Apply molybdenum disulfide grease. C. Remove the push rod holder as necessary and reinstall the clutch. MAINTENANCE AND ADJUSTMENT 69 molybdenum disulfide grease to the following table. cable bracket while pushing the release shaft lever lightly forward. j A. Push Rod Holder C. Position Distance Cable Bracket the clutch pressure plate and springs...
... Ball A. Release Shaft Lever Push forward. B. D. the clutch spring bolts to the specified Tightening Torque Clutch Spring Bolts: 9.0 N·m (0.92 kgf·m, 80 in·lb) the release shaft...ball and the push rod holder. Apply molybdenum disulfide grease. C. Remove the push rod holder as necessary and reinstall the clutch. MAINTENANCE AND ADJUSTMENT 69 molybdenum disulfide grease to the following table. cable bracket while pushing the release shaft lever lightly forward. j A. Push Rod Holder C. Position Distance Cable Bracket the clutch pressure plate and springs...
Owners Manual
Page 91
... with dirt or water. WARNING Air in injury or death. Have the brake checked immediately by an authorized Kawasaki dealer. j Brake Lever Position The brake lever position can cause an accident resulting in the brake lines diminish braking performance and can be defective. Front/Rear Brake Fluid : DOT3 or DOT4 NOTE żThe motorcycle is shipped with the Periodic Maintenance Chart. A. the braking power and check...
... with dirt or water. WARNING Air in injury or death. Have the brake checked immediately by an authorized Kawasaki dealer. j Brake Lever Position The brake lever position can cause an accident resulting in the brake lines diminish braking performance and can be defective. Front/Rear Brake Fluid : DOT3 or DOT4 NOTE żThe motorcycle is shipped with the Periodic Maintenance Chart. A. the braking power and check...
Owners Manual
Page 147
..., 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. A. it unnecessary to those of a rear shock absorber unit, a swingarm, two lever rods and a lever. In addition, the damping force can be adjusted easily, making it does not smoothly or noise...
..., 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. A. it unnecessary to those of a rear shock absorber unit, a swingarm, two lever rods and a lever. In addition, the damping force can be adjusted easily, making it does not smoothly or noise...
Owners Manual
Page 160
...) and water in air intakes, throttle body assy, brake components, electrical components, muffler outlets, and fuel tank openings. all other abrasive pads or brushes. If debris or flammable materials have collected, park the vehicle outside and stop the engine. Gasoline, brake fluid, and coolant will enhance its appearance, optimize overall performance, and extend its surfaces. Avoid using pressure washers; Avoid spraying water in delicate areas such as in a bucket. WARNING Build-up...
...) and water in air intakes, throttle body assy, brake components, electrical components, muffler outlets, and fuel tank openings. all other abrasive pads or brushes. If debris or flammable materials have collected, park the vehicle outside and stop the engine. Gasoline, brake fluid, and coolant will enhance its appearance, optimize overall performance, and extend its surfaces. Avoid using pressure washers; Avoid spraying water in delicate areas such as in a bucket. WARNING Build-up...
Owners Manual
Page 169
... Service Code 11 12 13 14 21 25 31 Orange FI Warning 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 41 Downstream injector malfunction, wiring open or short MAINTENANCE...
... Service Code 11 12 13 14 21 25 31 Orange FI Warning 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 41 Downstream injector malfunction, wiring open or short MAINTENANCE...
Owners Manual
Page 171
... a quick guide to assist you in tank Fuel tank cap air vent obstructed Fuel line clogged Break down of a fuel pump Break down of vehicle-down sensor Fuel does not flow: No fuel in troubleshooting for each problem listed. Engine does not turn over: Valve seized Valve lifter seized Cylinder or piston seized Crankshaft seized Connecting rod small end seized Connecting rod big end seized Camshaft seized Transmission gear or bearing seized Kick...
... a quick guide to assist you in tank Fuel tank cap air vent obstructed Fuel line clogged Break down of a fuel pump Break down of vehicle-down sensor Fuel does not flow: No fuel in troubleshooting for each problem listed. Engine does not turn over: Valve seized Valve lifter seized Cylinder or piston seized Crankshaft seized Connecting rod small end seized Connecting rod big end seized Camshaft seized Transmission gear or bearing seized Kick...
Owners Manual
Page 172
... Spark plug type incorrect Crankshaft sensor defective ECU defective Ignition coil defective Flywheel magneto defective Wiring connector not in good contact Fuel/air mixture incorrect: Air cleaner element clogged, poorly sealed, or not installed Fuel tank cap air vent obstructed Throttle body assy holder loose Air cleaner duct loose Fuel pump defective Compression low: Spark plug loose Cylinder head insufficiently tightened Cylinder bolt loose Cylinder or piston worn No valve clearance Valve spring broken or weak not seating...
... Spark plug type incorrect Crankshaft sensor defective ECU defective Ignition coil defective Flywheel magneto defective Wiring connector not in good contact Fuel/air mixture incorrect: Air cleaner element clogged, poorly sealed, or not installed Fuel tank cap air vent obstructed Throttle body assy holder loose Air cleaner duct loose Fuel pump defective Compression low: Spark plug loose Cylinder head insufficiently tightened Cylinder bolt loose Cylinder or piston worn No valve clearance Valve spring broken or weak not seating...
Owners Manual
Page 173
TROUBLESHOOTING GUIDE 171 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 oil level too high • Engine oil viscosity too high • Engine bearing worn or damaged • Crankshaft • Drive chain trouble Compression low: Spark plug loose Cylinder head insufficiently tightened Cylinder bolt loose Cylinder or piston...
TROUBLESHOOTING GUIDE 171 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 oil level too high • Engine oil viscosity too high • Engine bearing worn or damaged • Crankshaft • Drive chain trouble Compression low: Spark plug loose Cylinder head insufficiently tightened Cylinder bolt loose Cylinder or piston...
Owners Manual
Page 175
TROUBLESHOOTING GUIDE 173 Engine noise abnormal Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating ECU defective chain, sprocket, chain guide worn • Camshaft spring broken • Decompression • Flywheel magneto loose 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: Crankcase bearing worn or damaged Transmission gear worn or chipped Metal...
TROUBLESHOOTING GUIDE 173 Engine noise abnormal Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating ECU defective chain, sprocket, chain guide worn • Camshaft spring broken • Decompression • Flywheel magneto loose 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: Crankcase bearing worn or damaged Transmission gear worn or chipped Metal...
Owners Manual
Page 176
... Brake cylinder damaged Other noise: Bracket, nut, bolt, etc. improperly mounted or tightened Exhaust smoke Excessively white: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner element clogged Brownish: Air cleaner duct loose Air cleaner poorly sealed or missing Poor handling and/or stability Handlebars hard to turn: Cable, hose, wiring incorrectly routed Steering stem nut too tight stem bearing...
... Brake cylinder damaged Other noise: Bracket, nut, bolt, etc. improperly mounted or tightened Exhaust smoke Excessively white: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner element clogged Brownish: Air cleaner duct loose Air cleaner poorly sealed or missing Poor handling and/or stability Handlebars hard to turn: Cable, hose, wiring incorrectly routed Steering stem nut too tight stem bearing...
Owners Manual
Page 187
... 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 189
... front and rear wheels to keep dust and dirt away from entering. Kick the engine over the muffler to prevent moisture from it . Install the spark plug. Lift the motorcycle on a box or stand so that both wheels are raised off the engine before working. Wipe any fuel off the ground (If this includes any source of time, it and drain the engine oil. Contact...
... front and rear wheels to keep dust and dirt away from entering. Kick the engine over the muffler to prevent moisture from it . Install the spark plug. Lift the motorcycle on a box or stand so that both wheels are raised off the engine before working. Wipe any fuel off the ground (If this includes any source of time, it and drain the engine oil. Contact...