Owners Manual
Page 8
... ADJUSTMENT ...Periodic Maintenance Chart ...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 22 22 23 24 26 27 27 32 37 41 48 54 55 65 75 80 Drive Chain...Adjustable Ergonomics...Footpeg ...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection...Tightening Torques of Nuts and Bolts...Cleaning Your...
... ADJUSTMENT ...Periodic Maintenance Chart ...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 22 22 23 24 26 27 27 32 37 41 48 54 55 65 75 80 Drive Chain...Adjustable Ergonomics...Footpeg ...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection...Tightening Torques of Nuts and Bolts...Cleaning Your...
Owners Manual
Page 19
... muddy terrain, or other conditions causing high engine loads at low speeds. Any riding conditions that increase engine temperature will further reduce idling time before operation, or leaving idling with a primary kick starting system. A. Prolonged idling of the engine with the side stand can cause coolant loss and engine overheating resulting in any gear. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. GENERAL INFORMATION 17 j Kick...
... muddy terrain, or other conditions causing high engine loads at low speeds. Any riding conditions that increase engine temperature will further reduce idling time before operation, or leaving idling with a primary kick starting system. A. Prolonged idling of the engine with the side stand can cause coolant loss and engine overheating resulting in any gear. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. GENERAL INFORMATION 17 j Kick...
Owners Manual
Page 25
... any irregularities, especially, each cable elongation, brake play, chain slack and spoke tightness. 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 operation, run the engine at low and moderate engine speeds. NOTICE For the first hour or 20 km (12 mile) of nuts and bolts, oil leakage, and any following parts have...
... any irregularities, especially, each cable elongation, brake play, chain slack and spoke tightness. 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 operation, run the engine at low and moderate engine speeds. NOTICE For the first hour or 20 km (12 mile) of nuts and bolts, oil leakage, and any following parts have...
Owners Manual
Page 26
... 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 Air Cleaner ...Clean Apply oil to perform these checks before operation may result in serious damage or an accident. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. The time required is minimal, and habitual performance of these...
... 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 Air Cleaner ...Clean Apply oil to perform these checks before operation may result in serious damage or an accident. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. The time required is minimal, and habitual performance of these...
Owners Manual
Page 27
... Pressure correct Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...Function properly Lever and pedal play correct No fluid leakage Throttle ...Functions properly Throttle grip returns smoothly Steering ...Smooth but not loose from lock to lock No binding due to control cables Front Fork ...Functions properly No oil leakage Air pressure correct Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
... Pressure correct Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...Function properly Lever and pedal play correct No fluid leakage Throttle ...Functions properly Throttle grip returns smoothly Steering ...Smooth but not loose from lock to lock No binding due to control cables Front Fork ...Functions properly No oil leakage Air pressure correct Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
Owners Manual
Page 34
... long. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at • Start idle speed. NOTE żIf the oil level is too high, remove the excess oil using a syringe or other suitable device. żIf the oil level is already in the Owner's Manual. j Oil Level Inspection the oil has just been changed, let the...
... long. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at • Start idle speed. NOTE żIf the oil level is too high, remove the excess oil using a syringe or other suitable device. żIf the oil level is already in the Owner's Manual. j Oil Level Inspection the oil has just been changed, let the...
Owners Manual
Page 36
34 MAINTENANCE AND ADJUSTMENT WARNING Engine oil is replaced, remove the oil filter • When cap bolts and take off the cap with the grommet to install the spring on the original position. the oil filter is a toxic substance. Oil Filter Cap Bolts B. Dispose of used oil properly. Spring the oil filter element with a new one. • Replace Replace the O-rings with new ones. • Apply grease to the grommet. • Install the oil filter element...
34 MAINTENANCE AND ADJUSTMENT WARNING Engine oil is replaced, remove the oil filter • When cap bolts and take off the cap with the grommet to install the spring on the original position. the oil filter is a toxic substance. Oil Filter Cap Bolts B. Dispose of used oil properly. Spring the oil filter element with a new one. • Replace Replace the O-rings with new ones. • Apply grease to the grommet. • Install the oil filter element...
Owners Manual
Page 37
...;m, 62 in·lb) j NOTE żReplace the gasket and O-rings with their new gaskets. Proper torque for your Kawasaki. Engine Oil Capacity Capacity: 0.96 L (1.01 US qt) (When filter is not removed) 0.98 L (1.04 US qt) (When filter is removed) 1.20 L (1.27 US qt) (When engine is completely dry) A. MAINTENANCE AND ADJUSTMENT 35 the oil filter cap with the grease applied to • Install...
...;m, 62 in·lb) j NOTE żReplace the gasket and O-rings with their new gaskets. Proper torque for your Kawasaki. Engine Oil Capacity Capacity: 0.96 L (1.01 US qt) (When filter is not removed) 0.98 L (1.04 US qt) (When filter is removed) 1.20 L (1.27 US qt) (When engine is completely dry) A. MAINTENANCE AND ADJUSTMENT 35 the oil filter cap with the grease applied to • Install...
Owners Manual
Page 57
... adjusted, incorrectly routed, or damaged. NOTICE This motorcycle's radiator does not incorporate cooling fan. A. Prolonged idling of these conditions before operation, or leaving idling with damaged cables could result in the engine overheating, too. the engine idling, turn the handlebar both • With ways and check if handlebar movement changes the idle speed. MAINTENANCE AND ADJUSTMENT 55 Throttle Body Assy Idle Speed Adjustment the left radiator shroud (see Air Cleaner section).
... adjusted, incorrectly routed, or damaged. NOTICE This motorcycle's radiator does not incorporate cooling fan. A. Prolonged idling of these conditions before operation, or leaving idling with damaged cables could result in the engine overheating, too. the engine idling, turn the handlebar both • With ways and check if handlebar movement changes the idle speed. MAINTENANCE AND ADJUSTMENT 55 Throttle Body Assy Idle Speed Adjustment the left radiator shroud (see Air Cleaner section).
Owners Manual
Page 97
...-duty brake fluid as follows. Locknut Front/Rear Brake Fluid : DOT3 or DOT4 NOTE żThe motorcycle is applied, there might be air in the brake lines diminish braking performance and can be defective. If the brake lever or pedal feels mushy when it is shipped with the Periodic Maintenance Chart. The brake fluid should also be changed when contaminated with a wrench. A. WARNING Air in the brake...
...-duty brake fluid as follows. Locknut Front/Rear Brake Fluid : DOT3 or DOT4 NOTE żThe motorcycle is applied, there might be air in the brake lines diminish braking performance and can be defective. If the brake lever or pedal feels mushy when it is shipped with the Periodic Maintenance Chart. The brake fluid should also be changed when contaminated with a wrench. A. WARNING Air in the brake...
Owners Manual
Page 131
...). WARNING Improper fork leg adjustment can cause poor handling and loss of fork tube protrusion has opposite effects. the air pressure (see Air Pressure Adjust• Adjust ment). Fork Clamp Position Adjustment Steering is fully compressed. NOTICE The right and left and right side to weight biasing. j NOTICE Be sure to install the air valve plug to the specified torque. MAINTENANCE AND...
...). WARNING Improper fork leg adjustment can cause poor handling and loss of fork tube protrusion has opposite effects. the air pressure (see Air Pressure Adjust• Adjust ment). Fork Clamp Position Adjustment Steering is fully compressed. NOTICE The right and left and right side to weight biasing. j NOTICE Be sure to install the air valve plug to the specified torque. MAINTENANCE AND...
Owners Manual
Page 132
... oil leak and rear shock absorber mounting. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. NOTE Rear Shock Absorber Adjustment The spring preload of the top plug the seat down and up by an authorized • If Kawasaki dealer. inspect the rear shock absorber for oil • Visually leakage. j Rear Shock Absorber Inspection A. it unnecessary to change the oil viscosity. żTighten the two clamp bolts alternately two times...
... oil leak and rear shock absorber mounting. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. NOTE Rear Shock Absorber Adjustment The spring preload of the top plug the seat down and up by an authorized • If Kawasaki dealer. inspect the rear shock absorber for oil • Visually leakage. j Rear Shock Absorber Inspection A. it unnecessary to change the oil viscosity. żTighten the two clamp bolts alternately two times...
Owners Manual
Page 146
..., brake fluid, and coolant will damage the finish of your motorcycle thoroughly with a high quality, breathable motorcycle cover will enhance its appearance, optimize overall performance, and extend its surfaces. If debris or flammable materials have collected, park the vehicle outside and stop the engine. Do not park or store the vehicle in air intakes, throttle body assy, brake components, electrical components, muffler outlets, and fuel tank openings. sure the engine and exhaust...
..., brake fluid, and coolant will damage the finish of your motorcycle thoroughly with a high quality, breathable motorcycle cover will enhance its appearance, optimize overall performance, and extend its surfaces. If debris or flammable materials have collected, park the vehicle outside and stop the engine. Do not park or store the vehicle in air intakes, throttle body assy, brake components, electrical components, muffler outlets, and fuel tank openings. sure the engine and exhaust...
Owners Manual
Page 156
... service codes remain in the ECU. Service Code Table 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 Fuel injector...
... service codes remain in the ECU. Service Code Table 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 Fuel injector...
Owners Manual
Page 158
... oil seal leak Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Piston ring worn, weak, broken, or sticking Piston ring side clearance excessive Cylinder head gasket damaged 156 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is meant simply as 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 sensor Fuel...
... oil seal leak Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Piston ring worn, weak, broken, or sticking Piston ring side clearance excessive Cylinder head gasket damaged 156 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is meant simply as 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 sensor Fuel...
Owners Manual
Page 159
... 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 160
158 TROUBLESHOOTING GUIDE 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 j oil level too high • Engine Engine oil too high • Crankshaftviscosity worn or damaged • Drive chain bearing trouble • built up in combustion chamber • Carbon quality poor or...
158 TROUBLESHOOTING GUIDE 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 j oil level too high • Engine Engine oil too high • Crankshaftviscosity worn or damaged • Drive chain bearing trouble • built up in combustion chamber • Carbon quality poor or...
Owners Manual
Page 162
... • Camshaft chain tensioner defective • Camshaft chain, sprocket, chain guide worn • Decompression spring broken • Flywheel magneto loose • chain slack improperly adjusted • Drive Drive chain worn • Rear and/or engine sprocket(s) worn • Drive chain inefficiently • Rear wheel misaligned lubricated • Frame noise abnormal Front fork noise: Oil level or viscosity too low Front fork air pressure incorrect Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly...
... • Camshaft chain tensioner defective • Camshaft chain, sprocket, chain guide worn • Decompression spring broken • Flywheel magneto loose • chain slack improperly adjusted • Drive Drive chain worn • Rear and/or engine sprocket(s) worn • Drive chain inefficiently • Rear wheel misaligned lubricated • Frame noise abnormal Front fork noise: Oil level or viscosity too low Front fork air pressure incorrect Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly...
Owners Manual
Page 174
... 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 176
...-ventilated and free from any appliance with a pilot light. Kick the engine over the muffler to prevent moisture from entering. Dispose of gasoline properly. Wipe any fuel off the ground (If this includes any source of flame or sparks; the spark plug and spray fogging oil di• Remove rectly into the cylinder. WARNING Gasoline is extremely flammable and can be prepared...
...-ventilated and free from any appliance with a pilot light. Kick the engine over the muffler to prevent moisture from entering. Dispose of gasoline properly. Wipe any fuel off the ground (If this includes any source of flame or sparks; the spark plug and spray fogging oil di• Remove rectly into the cylinder. WARNING Gasoline is extremely flammable and can be prepared...