Owners Manual
Page 8
......Periodic Maintenance Chart ...Engine Oil...Cooling System ...Spark Plug ...Air Cleaner ...Throttle Cable...Throttle Body Assy ...Clutch ...Valve Clearance ...Exhaust System ...8 11 11 16 19 20 21 23 23 25 26 27 28 28 29 30 32 33 33 38 43 47 54 60 61 72 79 84 Rear Axle Nut ...Drive Chain...Adjustable Ergonomics...Footpeg ...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning...
......Periodic Maintenance Chart ...Engine Oil...Cooling System ...Spark Plug ...Air Cleaner ...Throttle Cable...Throttle Body Assy ...Clutch ...Valve Clearance ...Exhaust System ...8 11 11 16 19 20 21 23 23 25 26 27 28 28 29 30 32 33 33 38 43 47 54 60 61 72 79 84 Rear Axle Nut ...Drive Chain...Adjustable Ergonomics...Footpeg ...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning...
Owners Manual
Page 19
DFI Setting Data Selection Connector 6. Oil Level Inspection Window 8. 18 GENERAL INFORMATION j 1. Muffler 2. Uni-Trak® Tie-Rod and Rocker Arm 7. Rear Brake Pedal 9. Rear Shock Absorber Gas Reservoir 4. Exhaust Pipe Rear Brake Fluid Reservoir 3. Kick Pedal 5.
DFI Setting Data Selection Connector 6. Oil Level Inspection Window 8. 18 GENERAL INFORMATION j 1. Muffler 2. Uni-Trak® Tie-Rod and Rocker Arm 7. Rear Brake Pedal 9. Rear Shock Absorber Gas Reservoir 4. Exhaust Pipe Rear Brake Fluid Reservoir 3. Kick Pedal 5.
Owners Manual
Page 24
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 a primary kick starting system. When the clutch lever is equipped with the hot engine temperature after operation results in the engine overheating, too. NOTICE This motorcycle is installed. Prolonged idling of the engine with no airflow through the radiator can be started with...
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 a primary kick starting system. When the clutch lever is equipped with the hot engine temperature after operation results in the engine overheating, too. NOTICE This motorcycle is installed. Prolonged idling of the engine with no airflow through the radiator can be started with...
Owners Manual
Page 30
..., Valve, Valve lifter, Camshaft, Crankshaft, Mission gear, etc. Change the engine oil, oil filter and front fork/rear shock absorber oil to obtain the proper operating clearances in the engine as the new motorcycle must be carried out for one . NOTICE For the first hour or 20 km (12 mile) of nuts and bolts, oil leakage, coolant leakage and any irregularities, especially, each cable elongation, brake play, chain...
..., Valve, Valve lifter, Camshaft, Crankshaft, Mission gear, etc. Change the engine oil, oil filter and front fork/rear shock absorber oil to obtain the proper operating clearances in the engine as the new motorcycle must be carried out for one . NOTICE For the first hour or 20 km (12 mile) of nuts and bolts, oil leakage, coolant leakage and any irregularities, especially, each cable elongation, brake play, chain...
Owners Manual
Page 31
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. WARNING Failure to air cleaner element Properly installed Muffler ...No damage DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. 30 GENERAL INFORMATION...
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. WARNING Failure to air cleaner element Properly installed Muffler ...No damage DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. 30 GENERAL INFORMATION...
Owners Manual
Page 32
... damage 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 Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
... damage 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 Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
Owners Manual
Page 39
... particles collect in engine or transmission seizure, accident, and injury. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at the proper level, and change the oil according to the periodic maintenance chart in the Owner's Manual. Check the engine oil level with insufficient, deteriorated, or contaminated engine oil will fluctuate depending on the lower right side...
... particles collect in engine or transmission seizure, accident, and injury. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at the proper level, and change the oil according to the periodic maintenance chart in the Owner's Manual. Check the engine oil level with insufficient, deteriorated, or contaminated engine oil will fluctuate depending on the lower right side...
Owners Manual
Page 40
.... The engine oil and/or oil filter should be in the oil level inspection window, tip the motorcycle slightly to the right until oil is a toxic substance. If no oil appears in the transmission and crankcase, reinstall the drain bolt and refill with the specified amount of used oil properly. Oil Level Inspection Window High Level Line Low Level Line Oil Filler Plug WARNING Engine oil is visible...
.... The engine oil and/or oil filter should be in the oil level inspection window, tip the motorcycle slightly to the right until oil is a toxic substance. If no oil appears in the transmission and crankcase, reinstall the drain bolt and refill with the specified amount of used oil properly. Oil Level Inspection Window High Level Line Low Level Line Oil Filler Plug WARNING Engine oil is visible...
Owners Manual
Page 78
...release shaft lever lightly forward. Position Distance Cable Bracket the clutch pressure plate and springs. • Install Tighten • torque. MAINTENANCE AND ADJUSTMENT 77 molybdenum disulfide grease to the following table. j A. Remove the push rod holder as necessary and reinstall the clutch. B. C. D. the clutch spring bolts to the specified Tightening Torque Clutch Spring Bolts...ac- • cording to the steel • Apply ball and the contact area of the push rod holder. • Install the steel ball and the push rod holder. Apply molybdenum disulfide grease....
...release shaft lever lightly forward. Position Distance Cable Bracket the clutch pressure plate and springs. • Install Tighten • torque. MAINTENANCE AND ADJUSTMENT 77 molybdenum disulfide grease to the following table. j A. Remove the push rod holder as necessary and reinstall the clutch. B. C. D. the clutch spring bolts to the specified Tightening Torque Clutch Spring Bolts...ac- • cording to the steel • Apply ball and the contact area of the push rod holder. • Install the steel ball and the push rod holder. Apply molybdenum disulfide grease....
Owners Manual
Page 99
..., and turn the adjuster to suit the rider's preference. After adjustment, tighten the locknut securely. NOTE A. 98 MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brakes that require adjustment except brake lever position. j WARNING Air in the brake lines diminish braking performance and can be changed when contaminated with a wrench. The brake fluid should...
..., and turn the adjuster to suit the rider's preference. After adjustment, tighten the locknut securely. NOTE A. 98 MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brakes that require adjustment except brake lever position. j WARNING Air in the brake lines diminish braking performance and can be changed when contaminated with a wrench. The brake fluid should...
Owners Manual
Page 155
... rear shock absorber mounting. Clean the sliding surface after each ride. the seat down and up by an authorized • If Kawasaki dealer. However, a linkage system is called "UNI-TRAK®" and consists of the rear shock absorber with an optional one to suit various riding conditions. inspect the rear shock absorber for oil • Visually leakage. necessary, repair or replace by 4 or 5 times...
... rear shock absorber mounting. Clean the sliding surface after each ride. the seat down and up by an authorized • If Kawasaki dealer. However, a linkage system is called "UNI-TRAK®" and consists of the rear shock absorber with an optional one to suit various riding conditions. inspect the rear shock absorber for oil • Visually leakage. necessary, repair or replace by 4 or 5 times...
Owners Manual
Page 168
...; a soft cloth or sponge to seals, brake pads, • Avoid and tires. Avoid using pressure washers; If needed, use a mild degreaser to collect in and around the vehicle chassis, engine, and exhaust can damage parts of debris or flammable material in air intakes, throttle body assy, brake components, electrical components, muffler outlets, and fuel tank openings. When operating the vehicle in conditions that allow debris or flammable material...
...; a soft cloth or sponge to seals, brake pads, • Avoid and tires. Avoid using pressure washers; If needed, use a mild degreaser to collect in and around the vehicle chassis, engine, and exhaust can damage parts of debris or flammable material in air intakes, throttle body assy, brake components, electrical components, muffler outlets, and fuel tank openings. When operating the vehicle in conditions that allow debris or flammable material...
Owners Manual
Page 178
... problem is solved, all service codes remain in the ECU. Service Code Table Service Code 11 12 13 14 21 25 31 41 42 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...
... problem is solved, all service codes remain in the ECU. Service Code Table Service Code 11 12 13 14 21 25 31 41 42 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...
Owners Manual
Page 180
TROUBLESHOOTING GUIDE 179 TROUBLESHOOTING GUIDE ○This 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 Spark missing or weak: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap not contacting properly Spark plug type incorrect Crankshaft sensor defective ECU defective Ignition coil defective Engine stop button wiring defective Flywheel magneto damaged Wiring shorted...
TROUBLESHOOTING GUIDE 179 TROUBLESHOOTING GUIDE ○This 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 Spark missing or weak: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap not contacting properly Spark plug type incorrect Crankshaft sensor defective ECU defective Ignition coil defective Engine stop button wiring defective Flywheel magneto damaged Wiring shorted...
Owners Manual
Page 181
... • ECU Brake • Clutch dragging • Engineslipping overheating • Engine oil level too high • Engine oil viscosity • Drive chain trouble too high • Poor or no high-speed performance Other: j 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 Flywheel magneto defective Wiring connector not...
... • ECU Brake • Clutch dragging • Engineslipping overheating • Engine oil level too high • Engine oil viscosity • Drive chain trouble too high • Poor or no high-speed performance Other: j 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 Flywheel magneto defective Wiring connector not...
Owners Manual
Page 182
TROUBLESHOOTING GUIDE 181 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 181 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 184
TROUBLESHOOTING GUIDE 183 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 housing/friction plate clearance excessive • Clutch Clutch housing gear excessive • Metal chip jammed in clutch housing gear teeth • Transmission noise: Crankcase bearing worn or damaged Transmission gear worn...
TROUBLESHOOTING GUIDE 183 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 housing/friction plate clearance excessive • Clutch Clutch housing gear excessive • Metal chip jammed in clutch housing gear teeth • Transmission noise: Crankcase bearing worn or damaged Transmission gear worn...
Owners Manual
Page 185
... runout excessive Steering maladjusted Steering stem bent Front fork bent Shock absorption unsatisfactory (suspension too hard): Front fork oil excessive Front fork oil viscosity too high Front fork bent Front fork air pressure too high Tire air pressure too high Rear shock absorber improperly adjusted 184 TROUBLESHOOTING GUIDE Rear shock absorber noise: Shock absorber damaged j Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake cylinder damaged Other noise: Bracket, nut, bolt, etc.
... runout excessive Steering maladjusted Steering stem bent Front fork bent Shock absorption unsatisfactory (suspension too hard): Front fork oil excessive Front fork oil viscosity too high Front fork bent Front fork air pressure too high Tire air pressure too high Rear shock absorber improperly adjusted 184 TROUBLESHOOTING GUIDE Rear shock absorber noise: Shock absorber damaged j Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake cylinder damaged Other noise: Bracket, nut, bolt, etc.
Owners Manual
Page 196
... 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 198
.... the spark plug and spray fogging oil di• Remove rectly into the cylinder. j • • • Install the oil drain bolt and fill in for approved disposal methods. a few times to be stored for serious burns. Dispose of used oil properly. Kick the engine over the muffler to keep dampness away from the fuel tank by running the engine at idle speed until the engine stalls (If...
.... the spark plug and spray fogging oil di• Remove rectly into the cylinder. j • • • Install the oil drain bolt and fill in for approved disposal methods. a few times to be stored for serious burns. Dispose of used oil properly. Kick the engine over the muffler to keep dampness away from the fuel tank by running the engine at idle speed until the engine stalls (If...