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FURY 125

FURY 125R

Motorcycle
Assembly & Preparation
Manual

Foreword
In order to ship Kawasaki vehicles as
efficiently as possible, they are partially
disassembled before crating. Since some of the
most commonly removed parts have a direct
bearing on a vehicle's reliability and safety,
conscientious
pre-sale
assembly
and
preparation becomes extremely important. Good
setup procedures can prevent needles warranty
claims and give customers a greater sense of
confidence in Kawasaki and their Kawasaki
Dealers.
This Assembly and Preparation Manual
explain step by step procedures of the following
item for all Kawasaki Fury125.

1. Uncrating
2. Assembly
3. Preparation

The
selling
dealers
assumes
sole
responsibility for any unauthorized modifications
prior to sale. Refer to your Service Binder for
any Service Bulletins specifying Factory
Directed Modifications (Special Claims) which
must be performed before the vehicle is ready
for sale.
Whenever you see the following symbols need
their instruction! Always follow safe operating
and maintenance practice.

WARNING

WARNING indicates a hazardous situation


which, if not avoided, could result in death or
serious injury.
!

CAUTION

CAUTION indicates a hazardous situation


which, if not avoided, could result in minor or
moderate injury.

NOTICE
NOTICE is used to address practices not
ralated to personal injury.

NOTE
This note symbol indicates points of
particular
ti l
i t
interest
t for
f
more efficient
ffi i t and
d
convenient operation.

Kawasaki Motor Philippines Corporation accepts


no liability for any inaccuracies or omissions in this
publication, although every possible measure has
been taken to make it as complete and accurate as
possible. All procedures and specifications subject
to change without notice.

Table of Contents
Uncrating ..........................................................................................4
Opening Crate....................................................................................4
Parts Check ......................................................................................5-6
Assembly ............................................................................................7
Handlebar .........................................................................................7
Front Fender .....................................................................................7
Front wheel Installation.......................................................................8
Brake Disc Cleaning ...........................................................................8
Rear View Mirrors ( Left and Right) ....................................................9
Preparation ........................................................................................10
Battery Service .................................................................................10
Battery Activation .................................................................................11-12
Front Brake Fluid ................................................................................13
Rear Brake Fluid. .................................................................................14
Drive Chain ........................................................................................15
Rear Shock Absorber ..........................................................................17
Tire Air Pressures ...............................................................................17
Fuel .................................................................................................17
Engine Oil (4-Stroke) ..................................................................................18
Throtle Grip and Cable ...............................................................................19
Idle Speed Adjustment ...............................................................................19
Choke Lever and Cable ..............................................................................20
Rear Brake Light Switch ..............................................................................20
20
Headlight Aim .............................................................................................20
Fastener Check .............................................................................................21-22
Standard Torque Table ................................................................................23
Test Ride the Motorcycle .............................................................................23
A & P Check List ...........................................................................................23

UNCRATING

Uncrating
Opening Crate
!

WARNING

Crates have sharp edges and may have nails


or screws that can cause cuts and injury.
Always wear protective gloves, boots and eye
protection when uncrating to prevent injury.

NOTICE
When you remove the crate bracket from the
motorcycle, be careful not to drop any parts
and bracket onto the fuel tank and other
components, and not to scratch the fuel tank
by the crate bracket. This could dama-ge the
fuel tank or components.
Remove first the two lower flange bolts (D= 8,
L=25) at the steering stem and discard it.
Remove the two upper bolts (D= 8, L=60 ) and
washer (D=24.5) to take off the crate bracket and
foam pad and discard them.

WARNING

The steel crate panel plates and fasteners


have sharp edges. Always wear protective
gloves, boots and eye protection when
uncrating to prevent injury.

A. Upper FlangeBolt (D= 8 , L=60 )


B. Lower FlangeBolt (D= 8 , L=25 )
C. Crate Bracket
D. Washer (D=24.5 )
Remove the top and sides of the crate.

Clear a space about 6m (20ft) square to give


your self plenty of space to work.
Place the crate upright on its base.
Remove the parts box.

UNCRATING

Prats Check
Open the parts box, and check the parts against the illustrations. There may be minor differences between
these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in
millimeters, and L = length in millimeters.
1

UNCRATING

No.

Part Name

Qty.

Remarks
D = 8 , L = 50

CLAMP
CLAMP
BOLT-FLANGED

4
2
2
4
1
1
1
1
5
4
1
1
2

BATTERY ELCTROLYTE,

12 V 3 Ah

OWNERS MANUAL

1
1

1
2

HANDLEBAR MOUNTING BOLTS


SPACER
PLUGS
PLUGS
FRONT WHEEL
PIN-COTTER
COLLAR
FRONT FENDER
COLLAR
SCREW

TOOL KIT

D = 30
D = 14.5

D = 24 , L = 24.5
D = 16
D = 6 , L = 14
L = 78.8
D = 6 , L = 16

ASSEMBLY

Install the front fender on the fork legs, and


install the collar (D=16)(4) with screw(D=6, L=14)
(4) at the left and right of the fork legs.

Assembly
Handlebar
Handlebar Installation

Install the right handlebar with the mounting


bolts (D = 8 , L = 50) (2) in place.

B
A

A. Plastic Plugs (D=14) (4) , (D=30) (2)


B. Socket Bolt (D = 8 , L = 50) (4)
C. Left and Right Handlebar
D. Spacers
I t ll fi
Install
firstt the
th spacer and
d th
then th
the lleft
ft
handlebar in the same manner as the right
handlebar.Tighten the left and right handlebar
mounting bolts to the specified torque.
Torque: 23 Nm (2.3 kgfm, 17 ftlb)
Push the plastic plugs (D=14)(4) into the
handlebar mounting bolts and Install the platic
plug (D=30)(2) to left and right handlebar.

A. Boltflange (D=6,L=16)
B. Collar (D=16) and Screw (D=6,L=14)
C. Front Fender
D. Clamp
Install the flange bolt (D=6,L=16)at the right side
with collar (D=16) inside of front fender, and
install the clamp cable guide holder at the right
i t ll speedometer
install
d
t cable.
bl

A
B

Front Fender
Front Fender Installation
Install the front fender with its facing forward.
B

A. Speedometer Cable
B. Clamp
Install the front brake hose clamp on the left
side(L = 78.8) with flangebolt (D=6, L=16) inside
of the front fender and then tighten it.
A
B

A. Front Fender
B. Forward
C. Back

A. Brake Hose
B. Clamp

ASSEMBLY

Front Wheel Installation


Lift the motorcycle off the crate base and
support the motorcycle with a suitable stand or
jack to install the front wheel.

Discard the crate base.


C

C
E

A. Front Axle
B. Case-Assy-Meter
C. Axle Nut
D. Collar
E. Pin-Cotter

A. Axle Nut
B. Front Axle
C. Pin-Cotter
Loosen the left axle nut and remove the front
axle.
Check the wheel rotation mark on the front tire.

NOTE
The direction of the wheel is shown by an
arrow on the front tire. Install the wheel so that
the ratation mark coincides with wheel ratational
direction.

Tigten the front axle nut (D= 17) to the spe-cified


torque and install the pin-cotter.

Torque: 48 Nm (4.9 kgfm , 35 ftlb)


!

WARNING

It may take several application of the brake


pads contack the disc,,
lever before the brake p
which could result in increased stopping
distance and cause an accident resulting in
injury or death. Do not attempt to ride the
motorcycle until a firm brake lever is obtained
by pumping the lever unit the pads are against
the disc.

A
B

Brake Disc Cleaning


Clean the front brake disc using oilless solvent.
!

WARNING

An anticorrosive treatment applied to the brake


discs will increase braking distance and can
cause an accident resulting in se-rious injury or
death. Remove the anticor-rosive treatment
using an oilless solvent.
A. Front Wheel
B. Arrow
C. Rotation
Fit the axle collar on the left sides of the front
wheel hud. The collar are identical.
Position the front wheel assembly between the
fork leg.
Insert the front brake disk between the brake
pads of the caliper.
Insert the front axle from the right side of the
wheel and push it completely through.

ASSEMBLY

NOTICE

Rear View Mirror (Left and Rigth)


Conventional Type (Single Nut)
Loosen the lucknut completely.
Screw the rear view morror in completely, and
then back it two turns out.
Turn the mirror stay to assure visibility to the
rear with the operator sitting on the motorcycle
and tighten the locknut securely.
Adjust the rear view mirror by slightly moving
only the mirror portion of the assembly.
A

Do not force to tighten and / or loosen the


upper hexagonal area (adapter) with a spanner or wrench. Disassembly of this area is not
possible. Non-permanent locking agent is
already applied to the threads of this inner
area. Forcible loose- ning may damage the
adapter and/or the turning mecha-nism of the
stay.
Turn the stay to assure visibility to the rear with
the operator sitting on the motorcycle.
Adjust the rear view mirror by slightly moving
only the mirror portion of the assembly.

B
A
B

A. Locknut
B. Rear View Mirror (Right)
Installation and adjustment of the left side
mirror is common with the right side. Follow the
procedure specified for the right side.

Turning Stay Type


Screw the mounting area of the right rear view
mirror into the holder all the way, and tighten the
lower hexagonal area securely.

C
A

A. Lower Hexagonal Area for Tightening


B. Upper Hexagonal Area (Adapter)
C. Rear View Mirror (Right)

A. Stay
B. Mirror
Installation and adjustment of the left side mirror
is common with the right side. Follow the procedure
specified for the right side.

PREPARATION

Preparation
Battery Service

10

Seat Unlock
Insert the ignition key into the switch ignition and
turn counterclockwise to open the seat.

The battery used in this motorcycle is a sealed


type and never needs to be refilled. Follow the
procedure for activating a new battery to ensure
the best possible battery performance.
A

Activating the battery requires two steps, filling


the battery with electrolyte , and charging. Read
the electrolyte safety label and the following
procedure carefully before activation.

NOTICE
Incorrect Battery Activation will reduce
battery performance and service life. Be sure
to strictly follow the Battery Service
instructions in this Manual.

A. Seat
B. Seat Lock

Battery Removal
Take the battery out of the battery case.

Make sure to use the electrolyte


y packed
p
in the
crate with the unit.
Make sure that the model name of the electrolyte container matches the model name of the
battery. These names must be the same.
Battery Model Name for:
AX125A/B: YTX4L-BS

A. Model Name of the Electrolyte


B. Model Name of the Battery

NOTICE
Sealed battery electrolyte has a higher
cancentration of sulfuric acid. Each con-tainer
contains the proper amount of electrolyte for
its specific battery. Insu- fficient or incorrect
electrolytre will reduce battery performance
and service life. Electrolyte over capacity can
lead to battery cracking or leaking and result
in corrosion damage to the vehicle.

A. Rubber Band
B. Negative (-) Cable
C. Terminal Cap
D. Positive (+) Cable
E. Battery
Clean the terminals.

NOTICE
Be sure to disconnect the negative (-) cable
first.

Battery Specification
Make

Yuasa

Battery Type
Battery Capacity

YTX4L-BS
12 V 3 Ah

PREPARATION

11

Battery Activation
Filling the Battery with Electrolyte

NOTICE
Do not remove the alluminum sealing sheet
[A] from the filler ports [B] until just prior to
use. Be sure to used the dedica-ted
eloctrolyte container for correct elec-trolyte
volume.

Place the electrolyte container upside down with


the six sealed cells into the filler ports of the
battery. Hold the container level, push down the
break the seals of all six cells. You will see air
bubbles rising into each cell as the port fill.

NOTE
Do not tilt the electrolyte container.

Place the batterry on the a level surface.


Check to see that the sealing sheet [A] has no
peeling, tears, or holes in it.
Remove the sealing sheet [A].

NOTE
The battery is vacuum sealed. If the sealing sheet has leaked air into the battery,it
may required longer initial charge.

Remove the electrolyte container from the vinyl


bag.
Detach the strip of caps [A] from the con- tainer
and set asidem, these will be used later to seal
the battery.

NOTE
Do not pierce or otherwise open the sea-led
cells [B] of the electrolyte container. Donot
attemp to separate individual cells.

Check the elctrolyte flow.


If no air bubbles [A] are coming up from the filler
ports, or if the container cells have not emptied
completely,
p
y tap
p [B]
[ ] the container a few times.

Keep the container in a place for 20 minutes or


more. Don't remove the container from the battery
untill it's empty, the battery requires all the
electrolyte from the container for proper operation.

NOTICE
Removal of the container before it is
completely empty can shorten the sevice life
of the battery. Do not remove the elec trolyte
container until it is completely empty and 20
minutes have elapsed.
Gently remove the container from the battery.
Let the battery sit for 30 minutes prior to
charging to allow the electrolyte to permeate into
the plate optimum performance.

PREPARATION

NOTE
Charging the battery immediately after filling
can shorten service life. Let the battery sit for
at least 30 minutes after filling.

Initial Charge
Place the strip of caps [A] loosely over the filler
ports.

12

NOTICE
Once the strip of caps [A] is installed on- to
the battery, never remove the caps, nor add
water or electrolyte to the battery.

NOTE
To ensure maximum battery life and
customer satisfaction, is recommended the
battery be load tasted at three times its amphour rating for 15 seconds.
Re-check valtage and if less than 12.8Volt
repeat the charging cycle and load test. If still
bellow 12.8 V the battery is effective.

Battery Instalation
Newly activated sealed batteries requred an
initial charge.

Standard Charge 0.4 A x 5 ~ 10 hours


If using a recommended battery charger, follow
the charger's
th
h
' iinstructions
t ti
ffor newly
l activated
ti t d
sealed battery.

Kawasaki- recommended chargers:


Opimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9

Turn the ignition switch OFF.


Visualy inspect the surface of the battery
container. If any signs of cracking or electrolyte
leakcage fron the battery, replace it.
Apply a little grease on the terminals to prevent corrosion.
Connect the positive (+) cable first
first, and
cover the terminal with the cap.
Connect the negative (-) cable.
Hook the rubber band.

If the above chargers are not available, use


equivalent one.

NOTE
Charging rates will vary depending on how
long the battery has been stored, temperature, and the type of the charger used. Let
battery sit 30 minutes after initial charge, then
check voltage using voltmeter. If it is not at
least 12.8 V, repeat charging cycle.
After charging is complete, press down firmly
with both hands to seat the strip of caps [A] into
the battery (don't pound or hammer) When properly installed, the strip of the caps will be level
with the top of the battery.

A. Rubber Band
B. Negative Cable (-)
C. Cap
D. Positive Cable (+)

PREPARATION

13

Front Brake Fluid


Front Brake Fluid Level Inspection
With the front brake fluid reservoir held horizontaly, check that the fluid lavel is above the
lower level line.

Operate the brake lever several times.


If it feel spongy, there might be air in the brake
line. If necessary,bleed the air in the front brake
line.Also check for fluid leakage around the
fitings and bleed the air in the front brake line.

Front Brake Line Air Bleeding


Remove the reservoir cap and diaphragm, and
that there a plenty of fluid in the reservior.

A. Front Brake Fluid Reservoir


B. Lower Level Line
C. Upper Level Line
If the fluid level is lower than the lower level
line, fill the brake fluid to the upper level line.
Loosen the screws to remove the front brake
fluid reservoir cap and diaphragh
diaphragh.
Fill the reservoir to the upper level line with
DOT3 or DOT4 brake fluid. Inside the front brake
reservior is a stepped line showing the upper
level line.

NOTE
Hold the reservior horizontal by turning the
handlebar when checking brake fluid level.
!

WARNING

NOTE
The fluid level must be checked several
times during the bleeding operation and
replenished as necessary. If the fluid in the
reservior runs completely out any time during
bleeding, the bleeding operation must be
repeated from the beginning since air will
have entered the line.
Attach a clear plastic hose to the bleed valve on
the front brake caliper and run the other end of
the hose into a container.
With the reservoir cap off, slowly pump the brake
lever several times until no air bubbles can be
seen rising up through the fluid from the holes at
the bottom of the reservoir.This bleed the air from
the brake master cylinder end of the line.
Pump the brake lever a few times until it becomes hard and then, holding the lever squeezed, quickly open ( turn counterclockwise) and
close the bleed valve. Then release the lever.
Repeat this operation until no more air can be
seen coming out into the plastic hose.

Brake fluid that is contaminated by mois-ture


or dirt, mixed or contains air has a lower
boiling point and can cause the brake to be
ineffective or fail, and it may cause rubber
parts to deterioate, resulting in an accident
causing injury or death. Never re-use old brake
fluid. Do not use fluid from a container that
has been left unsealed or that has been open
for a long time. Do not mix two types and
brands of fluid for use in the brake. Don't leave
the reservior cap off for any length of time to
avoid moisture contamination of the fluid.
Don't add or cha-nge the fluid in the rain or
when a strong wind is blowing.

NOTICE
Brake fluid quikly ruins painted surfaces.
Wipe up any spilled fluid immediately.

A. Open Bleed Valve


B. Apply the Brake and Hold It
C. Close the Bleed Valve
D. Release the Brake

PREPARATION

When air bleeding is finished, check that the


fluid level is between the upper and lower lever
lines.
Install the diaphragm and reservior.

14

Tighten the bleed valve to the specified torque.

Torque: 78 Nm (0.80 kgfm, 69 inlb)


Apply the brake fiocefully for a few seconds, and
check that the fluid leakage around the fittings.

Rear Brake Fluid


Rear Brake Fluid Level Inspection
With the rear brake fluid reservior held horizontal, check that the fluid level is between the
upper and lower lines.

C
A

A. Rear Brake Fluid Reservoir


B. Reservoir Cup
C. Boltflange
Operate the brake pedal several times.
If it feels spongy, there might be air in the brake
line.
If necessary, bleed the air in the rear brake
line.
Also check for fluid leakage around the fitings.

Rear Brake Line Air Bleeding


Remove the reservoir cap and diaphragm, and
that there a plenty of fluid in the reservior.
A. Reservoir
B. Lower Level Line
C. Upper Level Line
If the fluid level in the reservior is lower than the
lower level line, check for the fluid leaks in the
brake line, and fill the reservoir.
Loosen the cap stopper screw to remove the
reservoir to the upper level line with DOT3 or
DOT4 brake fluid.

NOTICE
Brake fluid quick ruins painted surfaces.
Wipe up any spilled fluid immediately.

NOTE
First, tighten the rear brake fluid reser-voir
cap clockwise by hand until slight resista- nce
is felt indicating that the reservoir cap is
seated on the reservoir body, then screw to
tighten the reservoir cap while holding the
brake fluid reservoir body.

NOTE
The fluid level must be checked several
times during the bleeding operation and
replenished as necessary. If the fluid in the
reservior runs completely out any time during
bleeding, the bleeding operation must be
repeated from the beginning since air will
have entered the line.
Attach a clear plastic hose to the bleed valve on
the front brake caliper and run the other end of
the hose into a container.
With the reservoir cap off, slowly pump the
brake lever several times until no air bubbles
can be seen rising up through the fluid from the
holes at the bottom of the reservoir.This bleed the
air from the brake master cylinder end of the line.
Pump the brake lever a few times until it becomes hard and then, holding the lever squeezed, quickly open ( turn counterclockwise) and
close the bleed valve. Then release the lever.
Repeat this operation until no more air can be
seen coming out into the plastic hose.

PREPARATION

15

A. Open Bleed Valve


B. Close the Bleed Valve
When air bleeding is finished, check that the
fluid level is between the upper and lower level
lines.
Tighten the bleed valve to the specified torque.

Torque: 7.8 Nm (0.80 kgfm, 69 inlb)


Install the diaphragm and reservior cap.

NOTE
First, tighten the rear brake fluid reser-vior
First
cap clockwise by hand untill slight resistance
is felt indicating that the cap is seated on the
reservoir body, then tighten the cap an
additional 1/6 turn while holding the brake
fluid reservior body.

A. 20~25mm ( 0.79 ~ 1.18 in )


If the drive chain is too tight or too loose,
adjust so that the chain slack will be within the
standard value.
!

WARNING

A chain that breaks or jump off the sprocket


could snag on the engine sprocket or lock the
rear wheel, severely damaging the mo- torcycle
and causing it to go out of control. Inspect the
chain for damage and proper adjustment.

Drive Chain Slack Adjustment


Remove the cotter pin, and loosen the rear axle
nut. Loosen the left and right chain adjus-ter lock
nut.

Tighten the reservior cap topper screw.


Apply the brake forcefully for a few seconds
and check for fluid leakage around the fittings.

Drive Chain
Drive Chain Slack and wheel Alignment
Inspection
Set the motorcycle up on its side stand.
Make sure that the drive chain has the specified
amount of play, and that the left and right notches
are on the same marks or points on tne left and
right of the swingarm.
!

WARNING

Misalignment of the wheel will result in abnormal wear, and may result in an unsafe
riding condition. Be sure the wheel is properly aligned.
Rotate the rear wheel to find the position where
the chain is tightest, and measure the maximum
chain slack by pulling up and puni-shing down the
chain midway between the engine sprocket and
rear sprocket.

A. Indicator
B. Adjuster
C. Notch
If the chain is too loose, turn out the left and
right chain adjusters evenly.
If the chain is too tight, turn in the left and right
chain adjusters evenly.
Turn both chain adjusters evenly until the
drivechain has the correct amount of slack. To
keep the chain and wheel alignment indicator
notches should align with the same marks on each
side of the swingarm.

PREPARATION

16

Loosen once and tighten again when the


slot goes past the nearest hole.

E
B

C
A
D

A. Cotter Pin
B. Chain Adjuster
C. Nut Adjuster
D. Axle Nut
E. AX125A Model

A. Cotter Pin
B. Turning Clockwise

A. Cotter Pin
B. Axle Nut
C. Chain Adjuster
D. Nut Adjuster
E. AX125B Model

NOTE
Wheel aligment can also be checked using
the straightendge or string method.
Tighten both chain adjuster locknuts.
Tighten the rear axle nut to the specified torque.

Torque: 53 Nm (5.4 kgfm, 39 ftlb)


Rotate the wheel, measure the chain slack
again at the tightest position, and readjust if
necessary.
Install a new cotter pin.

NOTE
When inserting the cooter pin if the slots in
the nut align with the cotter pin hole in the
axle, tighten the nut clockwise up to the next
Its should be within 30 degrees.

A. Cotter Pin
B. Turning Clockwise
Bend the cotter pin over the nut .
!

WARNING

A loose axle nut can lead to an accident


resulting in serious injury or death. Tighten the
axle nut to the proper torque and be sure the
cotter pin is installed correctly.
Check the rear brake effectiveness.

PREPARATION

17

Rrear Shock Absorder

Fuel

Spring Preload Inspection


Check the position of the spring preload on the
rear shockk absorber.

STD Spring Preload: 2nd Position

A. Spring Preload Adjuster


B. Wrench
Turn the preload adjaster to the 2nd position.

Tire Air Pressure


To prevent flat-spotting during shipment, the
tire are over-inflated before crating. Adjust the tire
pressures to the specified values in the front and
rear, and make sure to tighten the caps securely.

Tire Air Pressure


AX125A/B
Front: 175 kPa (1.75 kgf/cm, 25 psi)
Rear: 200 kPa (2.00 kgf/cm, 28 psi)

WARNING

Gasoline is extremely flamable and can be


explosive under certain conditions, creating
the potentials of serious burns. Do not smoke.
Make sure the area is well ventilated and free
from any source of flame or sparks; this
includes any appliance with a pilot light. Never
fill the tank completely to the top. If the tank is
filled completely to the top, heat may cause the
fuel to expand and overflow through the vents
in the tank cap. After refueling, make sure the
tank cap is closed securely. If gasoline is
spilled on the fuel tank, wipe it off immediately.
Fill the fuel tank with one gallon or four liters of
unleaded gasoline. Use a gasoline with a
minimum antiknock index rating according to the
recommendation of your country. Refer to the
following table.
The antiknock index is an average of the Research Octane Number (RON) and the Motor
Octane Number (MON), as shown in the table.

For US and Canadian Models


Octane Rating Method
Antiknock (RON + MON)
Index
___________
2

Minimun
Rating
87

For Other than US and Canadian Models


Octane Rating Method
Research Octane Number
(RON)

Minimun
Rating
91

Check the fuel tank cap, and check for any


leaks.

A. Tire Air Pressure Gauge

PREPARATION

18

Engine Oil (4-stroke)


Engine Oil Level Inspection
NOTE
This vehicle's engine is filled with 20W-40
oil from the factory. DO NOT DRAIN and
refill the crannkcase before use. Check oil
level and drain plug tightness.
Engine Oil Drain Plug Torque:
29 Nm ( 3.0 kgfm, 21 ftlb)
A. Oil Filller Cap
B. Oil Level Gauge
C. High Level Line
D. Low Level Line
When replacing the cap, be sure the O-ring is in
place, and tighten the cap.

Recommended Engine Oil


Type: API, SG, SH, SJ, SL or SM with
JASO MA,, MA1 or MA2
Viscosity: SAE 10W-40
A. Engine Oil Drain Plug
Park the vehicle on the level ground.
Before starting the engine, check that the
engine has oil.
With the motorcycle held level, check that
the engine has oil through the oil level sight
gauge in the lower left side of the engine.

NOTICE
If the engine is run without oil, it will be
severely damaged.
Start the engine and run it for several minutes at
idle speed. Stop the engine, then wait several
minutes until the oil settles.
With the motorcycle held level, check the engine
oil level through the oil level sight gauge. The oil
level should come up between the upper and lower
level lines next to the gauge.
If the oil level is too high, remove the excess oil
through the oil fillter opening, using a syringe or
some other suitable device.
If the oil level is too low, add oil to reach the
correct level. Use the same type of oil that is
already in the engine.

Capacity: 0.95 L (1.0 US qt)


[when filter is not removed]
1.0 L (1.0 US qt)
[when filter is removed]
1.1 L (1.2 US qt)
[when the engine is completely dry]
Although 10W-40 engine oil is the recommen-ded
oil for most conditions, the oil viscosity may need
to be changed to accomodate atmosphe-ric
condition in your area.

PREPARATION

19

Throttle Grip and Cable


Throttle Grip and Cable
Inspect the throttle grip free play. If the free play
is incorrect, adjust the throttle cables.

Throttle Grip Free Play:


2 ~ 3 mm (0.08 ~ 0.12 in)
Check that the throttle grip moves smoothly from
full open to close, and the throttle closes quikly
and completely in all steering positions by the
return properly, check the throttle cable routing,
grip free play, and for possible cable damage.
Then lubricate the throttle cables.

Loosen the locknut at upper end of the throttle


cable, and turn the adjusting nut until the proper
amount of throttle grip play is obtained.
Tighten the locknut.
!

WARNING

Operation with an improperly adjusted,


incorrectly routed, or damaged cable could
result in an unsafe riding condition.
Be sure the cables are routed correctly,
properly adjusted and are not damaged in any
way.

Idle Speed Adjustment


Start the engine, and warn it up thoroughly.
Adjust the idle speed by turning the idle
adjusting screw.

Idle Speed: 1 300 r/min (rpm)

A. Throttle Grip
B. Throttle Grip Play
2~3 mm (0.08 ~ 0.12 in.)
Run the engine at the idle speed, and turn the
handlebar all the way to the right and left to
ensure that the idle speed does not change. If the
idle speed increases, check the throttle grip free
play.

Throttle Grip and Cable

A. Idle Adjusting Screw


Open and close the throttle a few times to
make sure that the idle speed does not change.
Readjust if necesary.
With the engine idling, turn the handlebar to
each side. If handlebar movement change the
idle speed, the throttle throttle cable may be
improperly adjusted or incorrectly routed, or it
may be damage. Be sure to correct any of these
conditions before riding.
!

WARNING

Operation with damage cable could result in


an unsafe riding condition.

A. Locknut
B. Adjusting Nut
C. Throttle Cable

PREPARATION

Choke Lever and Cable

20

NOTICE

Choke Lever Free Play Inspection


B

To avoid damaging the electrical connec-tions


inside the switch, be sure that the switch body
does not turn during adjust-ment.

Headlight Aim
Horizontal Adjustment
The headlight beam is adjustable horizontally. If
not properly adjusted horizontally,the beam will
point to one side rather than straight ahead.
A. Choke Cable Free Play
B. Choke Lever
Check that the choke lever returns properly
and that the inner cable slides smoothly.
Push that the choke lever back all the way to its
released possition.
Determine the amount of the choke cable play
the choke lever.

Choke Lever Free Play:


2 ~ 3 mm (0.08 ~ 0.12 in.)

A. Bolt

Rear Brake Light Switch


Rear Brake Light Switch Adjustment
Turn on the ignition switch. The brake light
shoult illuminate when the brake pedal is depressed.
If it does not, turn the adjusting nut at the rear
brake light switch as required.
A. Brightest Point

NOTE
On high beam, the brightest point should
be slightly below horizontal with the
motorcycle on its wheels and the rider seated.
Adjust the headlight to the proper angle
according to local regulation.
A. Rear Brake Light Switch
B. Adjusting Nut
C. Lights Sooner.
D. Lights Later.

PREPARATION

21

Fastener Check
The torque values listed are for assembly and preparation items only, see the appropriate Service Manual
for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery. Also
check to see that each cotter pin or circlip is in place.
1

9
16
3
11

11
6

5
13

15

10

14

12

PREPARATION

No.

Fastener

Steering
Handlebar mounting bolts
1
Steering stem head bolt
2
Brakes
Front master cylinder clamp bolts
3
Front caliper mounting bolts
4
Front brake bleed valve
5
Rear master cylinder mounting bolts
6
Rear caliper mounting bolts
7
Rear brake bleed valve
8
Suspension
Rear Shock Absorber Mounting Nuts
9
Others
Front footpeg bracket bolts (Left and Right)
10
Rear footpeg bracket bolts (Left and Right)
11
Engine oil drain
Engine oil drain bolt
12
C tt pins
Cotter
i or Ci
Circlips
li
Front axle nut cotter pin
13
Rear axle nut cotter pin
14
Rear master cylinder rod cotter pin
15
Rear footpeg pin circlip (Left and Right)
16
Letters used in the '' Remarks '' column means:
- G: Apply grease.

Torque
Nm

kgfm

ftlb

23
44

2.3
4.5

17
32

8.8
25
7.8
25
25
7.8

0.9
2.5
0.8
2.5
2.5
0.8

78 in.lb
18
69 in.lb
18
18
69 in.lb

49

36

25
25

2.5
2.5

18
18

29

21

22

Remarks

PREPARATION

Standard Torque Table

Electrical System:

This table relating tigtening torque to thread


diameter, list the basic torque for bolts and nuts.
Used this table for only the bolts and nuts which
do not require a specific torque value. All of the
values are for use with dry solvent cleaned
threads.

Headlight - check high and low beam.


Taillight - check operation.
Brake Light - check operation.
Turn Signal Lights - check operation.
Horn - check operation.
Instrument Lights and Inicator Lights - check
operation.

General Fasteners

23

Engine Stop Switch Works:


Starter Interlock Switch Works:
No Unusual Noises:
No Fuel, Oil Brake Fluid, Or Coolant Leaks:
PREPARATION COMPLETE.
!

Test Ride the Motorcycle

WARNING

New tires are slippery and may cause loss of


control and injury. A brake-in period of 160 km
(100miles) is necessary to establish normal tire
traction.
During brake-in, avoid sudden and maxi-mum
braking and accelaration, and hard cornering.

Complete the test ride checklist.

Control Cables:
Throttle control cables must work wiyhout binding
in any steering possition.

Steering:
Action is free from lock to lock.

Suspension:
Check the operation.

Engine:
Electric stater works properly and engine starts
promptly. Good throttle response and return.

Transmission and Clutch:


Smooth operation.

Brakes:
Adequate, smooth stopping power, No drag.

A & P Check List


Complete the A & P Check List.

Kawasaki Motor Philippines Corporation

Part No. 99939-1335-01