VULCAN 500 Motorcycle Owner's ManualEMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorgorated crankcase ion (1) and exhaust emission (2) control systems in compliance with applicable reg- ulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki fnas incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicle sold in Califomia only, 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into the combustion chember, where they are burned along with the fuel and air supplied by the carburetors. . Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fual system are not vented into the atmos- phere. Instead, fuel vapors are routed into the running engine to be bumed, or stored in a canister when the engine is stopped. Liquid fue! is caught by a vapor separator and returned to the fuel tank. High Altitude Performance Adjustment Information High altitude adjustment is not required for this motorcycle. MAINTENANCE AND WARRANTY Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels, This Owner's Menual contains those maintenance recommendations for your motorcycle. Those items identified by the Periodic Maintenance Chart are neces- saty to ensure compliance with the applicable standards.As the owner of this motorcycle, you have the responsibility to make sure that the re- ‘commended maintenance is carried out according to the instructions in this Owners Man- ual at your own expense. The Kawasaki Limited Emission Control System Warranty requires thet you retum your motorcycle to an authorized Kawasaki dealer for remedy under warranty, Please read the waranty carefully, and keep it valid by complying with the owners obligations it contains. You should keop a maintenance record for your motorcycle, To assist you in keeping this record, we have provided space on pages 124 through 127 of this manual where an authorized Kawasaki desler, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, bils, etc,, €s verification of this maintenance.TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or ren- dering inoperative by any person other than for purposes of maintenance, pair, or replace- ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle ater such device or element of design has been removed or ren- dered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: Replacement of the original exhaust system or muffler with a component not in compli- ance with Federal regulations. Removal of the muffler(s) or any intemal portion of the muffler(s) Removal of the air box or air box cover. Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. AWARNING This warning symbol identifies special in- structions or procedures which, if not cor- rectly followed, could result in personal injury, or loss of life. NOTE OThis note symbol indicates points of partic- ular interest for more efficient and conven- ent operation, NOTICE THIS PRODUCT HAS BEEN MANUFAC- TURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALI- FIED OPERATOR AND AS A VEHICLE ONLY. structions or procedures which, strictly observed, could result in damage to or destruction of equipment. it notFOREWORD We wish to thank you for choosing this fine Kawasaki Motorcycle. Your new motorcycle is the product of Kawasaki's advanced engineering, exhaustive tasting, and continuous striving for superior reliability, safety, and performance. Read this Owner's Manual before riding so you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its features, capabilities and limitations. This manual of- fors many safe riding tips, but its purpose is not to provide instruction in al the techniques and skills required to ride a motorcycle safely. Kawasaki strongly recommends that all operators of this vehicle enroll in a motorcycle rider training program to attain awareness of the mental and phys- ical requirements necessary for safe motorcycle operation. To ensure a long, trouble-free life for your motorcycle, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their Kawasaki Motorcycle, a Service Manual is available for purchase from any Kawasaki dealer. The Service Manual contains detailed disassembly and maintenance information Due to improvements in design and performance during production, in some cases there may be minor dis- crepancies between the actual vehicle and the illustrations and text in this manual. KAWASAKI HEAVY INDUSTRIES, LTD. CONSUMER PRODUCTS & COMPONENTS GROUP © Kawaseki Heavy Industries, Ltd, 1992 May 1992. (1). (S)>» opp 29999999 9999993999999999 999999999, TABLE OF CONTENTS cececec cee ace eee a eee Specifications... aparece’ 10 Serial Number Locations... 12 Consumer Information Location of Parts wo... Location of Labels. Loading Information General Information Meter Instruments Speedometer Indicator Lights. Key... Ignition Switch 2 Right Handlebar Switches Engine Stop Switch. Stater Button, Left Handlebar Switches... Dimmer Switch... Tur Signal Switch Hom BUtON .o.sn Fuel Tenk Cap... Fuel Tank... Fuel Tap Side Stand 33 Seat Lock....... ' 34 Too! Kit Companment.. 36 Helmet Hook. 35 Steating Lock 36 Bectric Accessory Leads .....ncrssnnnnne 37 Breakin... ; 39 How to Ride the Motoroycle .. 41 Starting the Engine a Jump Starting ‘Stopping the Motorcycle in an Emergency 51 Parking .. 52 ‘Safe Operation iresenonane 53 Safe Riding Technique serene S Dally Safety Checks ....cocesestenen BS ‘Adcitional Considerations for High Speed Operation 57Maintenance and Adjustment ........:..58 Boh and Nut Tightening Periodic Maintenance Chan... Cleaning, Engine Ol Storage .... Cooling System Troubleshooting Guide ... Spark Plugs. Reporting Safety Defects... Valve Clearance Kawasaki Cisan Air System Evaporative Emission Control System... Air Cleaner Throttle Grip. Carburetors Clutch Drive Belt Brakes Brake Light Svntches Rear Shock Absorber . Wheels Battery. Headlight Beam... FUSES Fuel System, General Lubsication ‘Owner Satisfaction Maintenance Record .......... sed, AN6 18 120 421 122 od 24999999999999 999999999999 )9 99999999999 99999 DIMENSIONS EN 10 Overall Length Overall Width Overall Height Wheelbase Road Cleerance Dry Weight IGINE ‘Type Displacement Bore x Stoke Compression Ratio Starting System Cylinder Numbering Method Firing Order Carburetors lanition System Ignition Timing (Elecrronically advanced) Spark Plugs Lubrication System Engine Oi Engine Oil Capacity SPECIFICATIONS ccc ceeeCe CMM 2.265 mm (89.17 in), 840 mm (3307 in.) 1,230 mm (48.43 in) 1,555 mm (61.22 in) ©1,550 mm (61.02 in) 170 mm (6.69 in.) 185 kg (410 Ib), 186.5 kg (411 Ib) DOHC, 2-cyinder, 4-stroke, liquid-cooled 498 mL (30.4 cu in.) 740 x 58.0 mm (281 x 2.28 in) 107:1 ©108:1 Electric starter Left to right, 1-2 1-2 Keihin CVK34 x 2 Battery and coil (tansistorized ignition) 10° BTDC @1,200 ( 1,300) ¢/min (rpm) ~ 37.5° BTDC @10,000 r/min (rpm) INGK D9EA or ND X27ES-U NGK DRBES or ND X27ESR-U Forced lubrication (wet sump) SE or SF class SAE 1040, 10W50, 20WW40, or 20W50 34 L (36 US at)Coolant Capacity 14L (1.5 US qi) TRANSMISSION Transmission Type 6-speed, consiant mesh, return shift Clutch Type Wet mutt dise Driving System Balt chive Primary Reduction Ratio 2652 (61/23) Final Reduction Ratio 2720 (68/25) Overall Drive Ratio 6145 (Top gear) Gea Ratio: Ist 2571 (36/14) 2nd 1.777 (32/18) 3d 1.380 (29/21) ah 1.125 (27/24) Sth 0961 (25/26) 6th 0851 (23/27) FRAME Casior 32° Trail 142 mm (559 in.) Tre Size: Front 100/90-19 57S Tubeless Rear 140/90-15 M/C 70S Tubeless Fuel Tank Capacity 11 L (28 US gal) ELECTRICAL EQUIPMENT Battery 12V 12 Ah Headlight 12 V 60/55 W Tall/Brake Light 12V 9/27 W : Cariadian model + California model Specifications subject to change without notice. 11»99999)999999999399999)999999, SERIAL NUMBER LOCATIONS caaccncenmenennne The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the event of theft, the investi gating authorities will require both numbers as well as the model type and ary peculiar features of your machine that can ————— them identify it ‘A. Engine Number 12»yayyommom» 9? CONSUMER INFORMATION «cancaaKcannaacne Me icle Minimum Stopping Distance on Dry Pavement ‘These figures indicate braking performance that can be met or exceeded by the vehicle to which they apply, without locking the wheels, under different conditions of loading. The information presented represents results obtainable by skilled drivers under contolied road and vehicle conditions, and the information may not be comect under other conditions. Description of vehicle to which this table applies: Model EN500-A4 A. Fully Operational Service Brake | Load lign [2ZZZEZEEEZZEeZA 188 Maximum eee BO 0 50 100 150 200 Stopping distance in feet from 60 mph. Manufacturer: Kawasaki Heavy Industries, Ltd. 1399999999999 999999999 9999999999999) 999999 « Front Fork . Horn . Headlight Tum Signal/Running Position Light Radiator Cap Fuel Tap ‘Choke Knob . Junction Box . Battery 10. Rear Shock Absorber 11, Seat Lock 12 Tool Kit Container 13, Helmet Hook 14, Tum Signal Light 15. Broke Disc 16. Breke Caliper 17. Radiator 18. Shift Pedal 19. Side Stand Switch 20, Side Stand 21. Main Fuse 22. Drive Belt 23. Muffler eRe 14 LOCATION OF PARTS «aacemceaeeeee eae24. Tail/Brake Light 25. Seat 2B Ak Caner Beant: 27. Fual Tank Cap Fuel Tank Coolent Reserve Tank Brake Lining Waar indicator 31. Carburetor 32. Oil Level Gauge 33, Rear Brake Light Switch 34. Rear Brake Pecial 35. Ignition Switch 36. Steerng Lock BBB 1537. Qitch Lever 38, Dimmer Switch 39, Starter Lockout Switch 40, Speedometer 41. Indicator Lights 42. Front Broke Fluid Reservoir 43, Engine Stop Switch 44, Front Brake Lever 45, Hon Button 46. Tum Signal Switch 47. Staner Button 48, Throttle Grip 16»p»mmvr nn LOCATION OF LABELS «ccm edie meee meen med “1, Important Break-In Instructions "2. Fuel Level “3. Vehicle Emission Contro! information "4, Vacuum Hose Routing Diagram 5, Daily Safety Checks 6 Battery Vent Hose 7. Drive Balt Waming 8. Tire and Load Data 9. Engine Oil and Oi Fiter “10, Noise Emission Contot Information * : only on US model * only on California model 7"11. Break-In Caution 12. Brake Fluid 13. Battay Poison/Danger *: only on US model 18ym» d999999999999999999 LOADING INFORMATION cecceceee cee eee AWARNING Incorrect loading, improper installation or use of accessories, or modification of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure that the motorcycle is not over- loaded (refer to page 98 for maximum load information) and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no con- trol over the design or application of accesso- ties. In some cases, improper installation or use of accessories, or motorcycle modification, will void the motorcycle warranty. In select- ing and using accessories, and in loading the motorcycle, you are personally responsible for your own safety and the safety of other per- sons involved NOTE OKawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accessories you add to your motorcycle be genuine Kawasaki compo- nents. Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in canying cargo, passengers and/or in the fitting of additional accessories. The following general guidelines have been prepared to assist you in making your determinations. 1920 ‘Any passenger should be thoroughly fa- miliar with motorcycle operation. The passenger can affect control of the motor- cycle by improper positioning during cor- nering and sudden movements. It is important that the passenger sit still while the motorcycle is in motion and not inter- fere with the operation of the motorcycle. Do not carry animals on your motoreyele. You should instruct any passenger before riding to keep his feet on the passenger foctpegs and hold on to the operator, seat strap or grab rail Do not cany a passenger unless he or she is tall enough to reach the footpegs and footpegs are provided, All baggage should be carried as low es possible to reduce the effect on the mo- torcycle center of gravity. Baggage weight should also be distributed equally on both sides of the motorcycle. Avoid carrying baggage that extends beyond the rear of the motorcycle. Baggage should be securely attached, Make sure that the baggage will not move around while you are riding, Re- check baggage security as often as possi- ble (not while the motorcycle is in motion) and adjust as necessary. Do not carry heavy or bulky items on a luggage rack. They ae designd for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces. Do not install accessories or cary bag- gage that impairs the performance of the motorcycle. Make sure that you have not adversely affected any lighting compo- nents, road clearance, banking capability (ice,, lean angle), contol operation, wheeltravel, front fork movement, or any other aspect of the motorcycle's operation. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in an unsafe tid- ing condition. Fairings, windshields, backrests, and other large items have the capability of ad- versely affecting stability and handling of the motoroyele, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly de- signed or installed items can result in an unsafe riding condition. 9. This motorcycle was not intended to be equipped with a sidecar or to be used to tow any trailer or other vehicle. Kawasaki does not manufacture sidecars or trailers for motorcycles and cannot predict the ef- fects of such accessories on handling or stability, but can only wam that the ef- fects can be adverse and that Kawasaki cannot assume responsibility for the re- sults of such unintended use of the mo- torcycle. Furthermore, any adverse effects ‘on motorcycle components caused by the use of such accessories will not be reme- died under warranty. 21y99999999999999999999999939999999999, GENERAL INFORMATION caececec eee eae eaceaane Meter Instruments moog> on J. H. . Speedometer |. Odometer . Trip Meter . Reset Knob Left Turn Signal Indicator Light . Neutral Indicator Light . Right Turn Signal Indicator Light Oil Pressure Warning Light |, High Beam Indicator Light Coolant Temperature Warning LightSpeedometer The speedometer shows the spoed of the vehicle, In the speedometer face are the odometer and trip meter. The odometer shows the total distance that the vehicle has been ridden, The tip meter shows the distance traveled since it was last reset to zero. The trip meter can be re- set to zero by turing the rest knob counterclockwise. Indicator Lights NEUTRAL: When the transmission is in neutral, the neutral indicator light is lit. TURN: When the tum signal switch is turned to left or right, the corresponding turn signal indicator light flashes on and off, HIGH BEAM: When the headlight is on high beam, the high beam indicator light is lit. OIL: The oil pressure warning light goes on whenever the oil pressure is dangerously low or the ignition switch is in the ON position with the engine not running, and goes off when the engine oil pressure is high enough. Refer to the Maintenance and Adjustment chapter for more detailed engine oil information. TEMP: The coolant temperature warning light goes on when the ignition switch is tured on and goes off soon after the en- gine starts running to ensure that its circuit functions properly, The warning light also goes on whenever the coolant temperature tises to 120°C or higher when the motor- cycle is in operation. If it stays on, stop the engine and check the coolant level in the reverse tank after the engine cools down. 23Key This motorcycle has a combination key, which is used for the ignition switch, steering lock, fuel tank cap, seat lock, and helmet hook. Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a master. 24 Ignition Switch The ignition switch is on the right side behind the radiator, This is a three-position, key-operated switch. The key cen be removed from the switch when itis in the OFF or P(PARK) position. ©. ON position D. P(PARK) position A. Ignition Switch B. OFF positionOFF Engine off. All electrical cir- cuits off. ON Engine on. All electrical equipment can be used. P(PARK)| Engine off. Taillight on. All other electrical circuits cut off, NOTE OThe head, tail, and running position lights are on whenever the ignition switch is in the ON position. To avoid battery discharge, always start the en- gine immediately after tuming the ig- nition switch to ON. O/f you leave the PARK position on for a long time (one hour), the batery may become totally discharged. Right Handlebar Switches Engine Stop Switch In addition to the gnition switch, the engine stop switch must be in the RUN position for the motorcycle to operate. The engine stop switch is for emer- gency use. If some emergency requires stopping the engine, move the engine stop switch to the OFF position. NOTE Although the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily. the ignition switch should be used to stop the en- gine. 25A. Engine Stop Switch B. Starter Button Starter Button The starter button operates the electric starter when pushed with the clutch lever pulled in or the transmission in neutral. Refer to the Starting the Engine section of the “How to Ride the Motorcycle” chapter to start the engine. 26 Left Handlebar Switches Dimmer Switch High or low beam can be selected with the dimmer switch. When the headlight is on high beam (HI), the high beam indica- tor light is lit. A. Dimmer Switch B. Turn Signal Switch C. Horn ButtonTurn Signal Switch When the turn signal switch is turned to L (left) or R (right), the corresponding tur signals fiash on and off, Horn Button When the horn button is pushed, the horn sounds. Fuel Tank Cap To open the fuel tark cap, insert the ig- nition switch key into te lock and turn the key to the right. To close the cap, push it down into place with the key inserted. The key can be removed by turning it counterclockwise to the original position. NOTE ©The tank cap cannot be closed without the key inserted, and the key cannot be removed unless the cap is locked prop- erly. ©Do not push the cap down with the key, or the cap cannot be locked. 27Fuel Tank The following octane rating gasoline is recommended in the fue! tank. Avoid fill- ing the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. Tank Cap. Fuel Tank Top Level Filler Neck A. Ignition Switch Key B. Fuel Tank Cap 28AWARNING Gasoline is extremely flammable and can be explosive under certain condi- tions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appli- ance with a pilot light. Never fill the tank so the fuel level rises into the filler neck. If the tank is over- filled, heat may cause the fuel to expand and overtlow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. It gasoline is spilled on the fuel tank, wipe it off immediately. CAUTION California models only: Never fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and flow into the Evaporative Emission Control Sys- tem resulting in hard starting and engine hesitation. Fuel Requirement: Octane Rating The octane rating of a gesoline is a measure of its resistance to detonation or "knocking", Use a gasoline with an octane rating equal to or higher than that shown in the table below. 29Octane Rating Method ating (RON + MON) Antiknock Index, ————— 87 2 Research Octane Number (RON) 2 The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON). The Antiknock Index is posted on service sta- tion pumps in the U.S.A. Research Octane Number is a commonly used term describ- ing a gasoline’s octane rating. NOTE O/f "knocking" or "pinging" occurs, use a different brand of gasoline or higher octane rating. 30 Gasoline and Alcohol Blends Blends of gasoline and alcohol called "gasohol” can be used on an occasional basis, however continued use is not re- commended. Switch back immediately to gasoline which does not contain alcohol if you experience any operating irregularities. Any deterioration of fuel system compo- nents or degradation of performance re- sulting from the use of gasohol will not be covered by Kawasaki's Limited Warranty, Emissions Warranties, or Good Times Pro- tection Plan. If you decide to use gasohol, be sure to follow these simple cautions:CAUTION Never use gasohol with an octane rating lower than the minimum octane rating specified by Kawasaki for this product. Never use gasohol containing more than 10% ethanol (grain alcohol). Never use gasohol containing more than 5% methanol (wood alcohol). Gasoline containing methanol must also be blended with cosolvents and corro- sion inhibitors. Never use gasohol for extended periods and never store this product with gasohol in the fuel system. Gasoline containing alcohol can cause paint damage. Be extra careful not to spill gasohol during refueling. Fuel Tap The fuel tap has three positions: OFF, ON, and RES (reserve). For normal opera- tion turn the tap to the ON position. If the fuel runs out with the tap in the ON posi- tion, the last 2.0 L (053 US gal) of fuel can be used by tuming the fuel tap to the RES position A. Fuel Tap B. RES position C. ON position D. OFF position 31With the fuel tap in the ON or RES po- sition fuel flows to carburetors only when the engine is started or is running, and fuel supply is shut off when the engine is stopped Tum the fuel tap to the OFF position when the fuel tank is removed for mainte- nance and adjustments or the motorcycle is stored for a long time. NOTE ©Since riding distance is limited when on RES, refuel at the earliest opportunity. Make certain that the fuel tap is tuned to ON (Not RES) after filing up the fuel tank. When the carburetor is completely empty, it takes about 30 seconds for the engine to start. 32 CAUTION Do not operate the starter continuously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds be- tween each operation of the starter to let it cool and the battery power recover. AWARNING Practice operating the fuel tap with the motorcycle stopped. To prevent an acci- dent you should be able to operate the fuel tap while riding without taking your eyes off the road. Be careful not to touch the hot engine while operating the fuel tap.Side Stand Whenever the side stand is used, make The motorcycle is equipped with aside _it a practice to kick the stand fully up be- stand. fore sitting on the motorcycle NOTE OThe motorcycle is equipped with a side stand switch. This switch is designed so that the engine stops if the clutch is en- gaged with the transmission in gear when the side stand has been left dawn. A, Side Stand NOTE OWhen using the side stand, turn the handlebar to the left. 33Seat Lock To open the seat, insert the ignition switch key into the seat lock, turn the key to the right, and lift the front of the seat up and to the front. B, Seat Bracket A. Ignition Switch Key _B. Seat Lock To install the seat, insert the seat hook into the seat bracket, and push down the front of the seat. 34Tool Kit Container The tool kit container is located under the seat. Keep the tool kit in this container. A. Tool Kit Container B. Tool Kit Helmet Hook Helmet can be secured to the motorcy- cle using the helmet hook. The helmet hook can be unlocked by inserting the ignition switch key into the lock, and turning the key to the right. AWARNING Do not ride the motorcycle with a helmet attached to the hook. The helmet could cause an accident by distracting the op- erator or interfering with normal vehicle operation. 35A. Helmet Hook 36 Steering Lock The motorcycle is equipped with the steering lock at the righi side of the head pipe. To lock the steering: 1. Tum the handlebar to the left 2. Push open the key hole cover counter- clockwise 3. Insert the ignition switch key. 4. Turn the key to the le't. 5. Push the key in turning the handlebar slightly to the right, and tun the key to the right 6. Pull the key out. DS Ue) Unlock the steering before starting the engine. Attempting to drive with the steering locked could cause an accident.A. Steering Lock Electric Accessory Leads The electric power cf the battery can be used through the electric accessory leads regardless of ignition switch position. Ob- serve and follow the nctes listed below. CAUTION Whenever you leave the motorcycle, stop using the electric accessories. Be careful not to discharge the battery totally. For example, if a current of 20 amperes is continuously taken out with the engine stopped, even an originally-fully-charged battery may be- come totally discharged in about 20 mi utes. WARNING Take care not to pinch any lead between the seat and the frame or between other parts to avoid a short circuit. 37Electric Accessory Leads Location | Polarity | Lead Color Under (+) White/Blue Seat (-) __ | Yellow/Black Inside (4) White/Blue Headlight Housing | (-) | Yellow/Black Maximum Current: 10A A. Electric Accessory Leads 38 A. Electric Accessory Leads>>I] IDIII BREAKIN cc CMM MMMM MMMM The first 1,600 km (1,000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a "broken down" instead of a “broken in” motorcycle after a few thousand kilometers The following rules should be observed during the break-in period @The table shows maximum recommended vehicle speed in km/h (mph) during the break-in period, km/h (mph) | pistonce wen a Gear position | ae | and | ard | ath | Sth | 6th 26 | 37 | 48 | 52 | 68 | 77 (16) | (23) | (30) | (36) | (42) | (48) 39 | 65 | 71 | 87 | 103 | 116 (24) | (ay | (44) | 64) | (64) | (72) 0 ~ 800 km (0 ~ 500 mi) 800 ~ 1,600 km (500 ~ 1,000 mi) 39NOTE OWhen operating on public roadways, keep maximum speed under traffick law limits. @Do not start moving or race the engine immediately after starting it, even if the engine is already warm. Run the engine for two or three minutes at idle speed to give the oil a chance to work up into all the engine parts. @Do not race the engine while the transmission is in neutral. In addition to the above, at 800 km (500 mi) it is extremely importent that the owner have the initial maintenance service performed by a competent mechanic following the pro- cedures in the Service Manual.»»yoy»o»999099 HOW TO RIDE THE MOTORCYCLE «acananaKannKd Starting the Engine @Turn the fuel tap to the ON position. A. Engine Stop Switch C. Ignition Switch B, Starter Button D. ON position A. ON position - @ Make certain the transmission is in neu- tral or the clutch is disengaged. @Check that the engine stop switch is in the RUN position. @Turn the ignition switch on. 4A. Neutral Indicator Light @lf the engine is cold, pull the choke knob all the way (ON position) 42 A. Choke Knob C. HALF position B. OFF position D.ON position NOTE When the engine is already warm or on hot days [higher then 35°C (95°F)], open the throttle part way instead of us- ing the choke, and then start the engine. @Leaving the throttle completely closed, push the starter button with the clutch lever pulled in until the engine starts.CAUTION Do not operate the starter continuously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds be- tween each operation of the starter to let | itcoo! and the battery power recover. NOTE Of the engine is flooded, crank the engine over with the throttle fully open until the engine starts. OThe motorcycle is equipped with the starter lockout switch. This switch pre- vents the electric starter from operating when the clutch is engaged and the transmission is not in neutral. A. Clutch Lever B. Starter Lockout Switch @Gradually return the choke toward the half or off position a little at a time as necessary to keep the engine running properly during warm-up. @When the engine is warmed up enough to idle without using the choke, return the choke to the off position. 43NOTE lf you drive the motorcycle before the engine is warmed up, return the choke to the off position as soon as you start moving when temperature is higher than 20°C (68°F), and es necessary when it is lower than 20°C (68°F). CAUTION Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. 44 Jump Starting If your motorcycle battery is “tun down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. Ea Nes Battery acid generates hydrogen gas which is flammable and explosive under certain conditions. It is present within 2 battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away from the battery. Wear eye protection when working with a bat- tery. In the event of battery acid contact with skin, eyes, or clothing, wash the af- fected areas immediately with water for at least five minutes. Seek medical at- tention.Connecting Jumper Cables @ Make sure the ignition switch is turned “OFF”. Connect a jumper cable from the posi- tive (+) terminal of the booster battery to the positive (+) battery cable at the starter relay terminal. A. Positive (+) Starter Relay Terminal B. To Booster Battery Positive (+) Terminat C. Unpainted Metal Surface D. To Booster Negative (—) Terminal @Connect another jumper cable from the negative (—) terminal of the booster bat- tery to your motorcycle rear brake pedal or other unpainted metal surface. Do Not use the negative (—) terminal of the battery, AWARNING Do not make this last connection at the carburetor or battery, Take care that you do not touch the positive and nega- tive cables together, and do not lean over the battery when making this last connection. Do not jump start a frozen battery. It could explode. Do not reverse polarity by connecting positive (+) to negative (~) or a battery explosion and serious damage to the electrical system may occur. 45@Follow the standard engine starting pro- cedure CAUTION Do not operate the starter continuously for more than § seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds be- tween each operation of the starter to let i cool and the battery power recover. @Ajfter the engine starts, disconnect the jumper cables. Disconnect the positive (+) cable from the motorcycle first. 46 Moving Off @Check that the side stand is up. @Pull in the clutch lever. @Shift into 1st gear. @Open the throttle a little, and start to let out the clutch lever very slowly. @As the clutch starts to engage, open the throttle a little more, giving the engine just enough fuel to keep it from stalling, A. Shift PedalNOTE OThe motorcycle is equipped with a side stand switch. This switch is designed so that the engine stops if the clutch is en- gaged with the transmission in gear when the side stand has been left down. Shifting Gears @Close the throttle while pulling in the clutch lever. @ Shift into the next higher or lower gear. For smooth riding, shift up or down when the motorcycle is operated at the speeds shown in the table below. AWARNING When shifting down to a lower gear, do not shift at such a high speed that the en- gine r/min (rpm) jumps excessively. Not only can this cause engine damage, but the rear wheel may skid and cause an accident. © Open the throttle part way, while releas- ing the clutch lever 47NOTE OThe transmission is equipped with a positive neutral finder. When the motor- cycle is standing sul, the wansmission cannot be shifted past neutral from 1st geat. To use the positive neutral finder, shift down to 1st gear, then lift up on the shift pedal while standing still, The transmission will shift only into neutral. Vehicle speed when shifting 48 Shifting up km/h (mph) | Shifting down | _ km/h (mph) Ast > 2nd 15 (8) 6th + 5th 30 (19) 2nd ~ 3rd 25 (15) Sth + 4th 25 (15) 3rd + 4th 35 (21) 4th + 3rd 20 (12) 4th > 5th 45 (27) 3rd + 2nd 18 (9) bth + 6th 55 (34) 2nd > Ist 18 (9)Braking @Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. @Shift down one gear at a time so that you are in 1st gear when you come to a complete stop. @When stopping, always apply both brakes at the same time. Normally the front brake should be applied a little more than the rear. Shift down or fully disengage the clutch as necessary to keep the engine from stalling. @ Never lock the brakes, or it will cause the tires to skid. When turning a corner, it is better not to brake at all. Reduce your speed before you get into the corer. @For emergency braking, disregard down- shifting, and concentrate on applying the brakes as hard as possible without skid- ding CAUTION In order to protect the emission control parts, do not turn off the ignition switch when the motorcycle is in motion. A. Front Brake Lever 49A. Rear Brake Pedal 50 Stopping the Engine © Close the throttle completely. @ Shift the transmission into neutral. @Turn the ignition switch off. @Suppon the motorcycle on a firm level surface with the side stand. @ Lock the steering.Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to provide you optimum safety and convenience. How- ever, in order to fully benefit from Kawasaki's safety engineering and craftsmanship, it is essential that you, the owner and operator, properly maintain your motorcycle and become thoroughly familiar with its operation. Improper main- tenance and insufficient riding skills can create a dangerous situation known as throttle failure. Two of the most common causes of throttle failure are: 1. During removal of the air cleaner by the owner, dirt is allowed to enter and jam the carburetor. 2. A novice may forget which direction the throttle rotates; then jerk the throttle wide open thinking he has shut it off. He may panic when the machine accelerates suddenly instead of slow- ing down; and “freeze”, holding the throttle wide open. In an emergency situation such as throttle failure, your motorcycle may be stopped by disengaging the clutch and ap- plying the brakes. Once this stopping pro- cedure is initiated, the engine stop switch may be used to stop the engine. If the en- gine stop switch is used, turn off the ig- nition switch after stopping the motorcycle. 51Parking @Shift the transmission into neutral and turn the ignition switch OFF. @Support the motorcycle on a firm level surface with the side stand. CAUTION Do not park on a soft or steeply inclined surface or the motorcycle may fall over. if parking inside a garage or other struc ture, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this includes any appli- ance with a pilot light. CN Na Nes Gasoline is extremely flammable and can be explosive under certain condi- tions. 52 @ Lock the steering to help prevent theft. NOTE When stopping near raffic at night, you can leave the taillight on for greater visi- bility by turning the ignition switch to the P (park) position. Do not leave the switch at P position too Jong. or the battery will discharge.yom nmwmm onan SAFE OPERATION KcaanccanK ance enn Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be care- fully observed for safe and effective vehicle operation. For safety, eye protection and a helmet are strongly recommended. Gloves and suitable footwear should also be used for added pro- tection in case of a mishap. A motorcycle does not provide the impact protection of an auto- mobile, so defensive riding in addi- tion to wearing protective apparel is extremely important. Do not let protective apparel give you a false sense of security. Before changing lanes, look over your shoulder to make sure the way is clear. Do not rely solely on the rear view mirror: you may misjudge a vehicle's distance and speed, or you may not see it at all. When going up steep slopes, shift to a lower gear so that there is plenty of power to spare rather than overloading the engine. When applying the brakes, use both the front and rear brakes. Ap- plying only one brake for sudden braking may cause the motorcycle to skid and lose control When going down long slopes, control vehicle speed by closing the throttle. Use the front and rear brakes for auxiliary braking, 53On rainy days, rely more on the throttle to contro! vehicle speed and less on the front and rear brakes. The throttle should also be used judiciously to avoid skidding the rear wheel from too rapid ac- celeration or deceleration. iding at the proper rate of speed and avoiding unnecessarily fast acceleration are important not only for safety and low fuel con- sumption but also for long vehicle life and quieter operation. When riding in wet conditions or on loose roadway surfaces, the ability to maneuver will be reduced. All of your actions should be smooth under these conditions, Sudden acceleration, braking or turning may cause loss of control. 54 On rough roads, exercise cau- tion, slow down, and grip the fuel tank with the knees for better sta- bility. When quick acceleration is nec- essary as in passing, shift to @ lower gear to obtain the necessary power. Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrevving Avoiding unnecessary weaving is important to the safety of both the rider and other motorists.Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjust- ment chapter or see your dealer for the action required to return the motorcycle to a safe operating condition Failure to perform these checks every day before you ride may result in serious damage or a severe accident. Fuel en .. Adequate supply in tank, no leaks. Engine oil... Oil level between level lines. THPES soscssesssneeetsnsnntesenen Air Pressure (when cold) 200 kPa (2.0 kg/cm?, 28 psi) Rear Up to 97.5 kg 200 kPa (2.0 (215 Ib) load kg/om?, 28 psi) 97.5 ~ 155kg (215 | 225 kPa (2.25 ~ 342 |b) load kg/cm?, 32 psi) 55Drive belt............+ Nuts, bolts, fasteners... Steering ..... Brakes........ Coolant..... Radiator cap... Electrical equipment... Engine stop switch Side stand ... Tension within usable range. Check that steering and suspension components, axles, and all controls are properly tightened or fastened. Action smooth but not loose from lock te lock. No binding of control cables. No brake fluid leakage. Brake pedal play 20 ~ 30 mm (08 ~ 1.2in). Brake pad wear: Lining thickness more than 1 mm (0.04 in) loft, Brake lining weer: Indicator within "USABLE RANGE”. Throttle grip play 2 ~ 3mm (0.08 ~ 0.12 in). Clutch lever play 2 ~ 3 mm (0.08 ~ 0.12in) Clutch lever operates smoothly. No coolant leekage. Coolant level between level lines (when engine is cold). Properly installed. All lights and horn work. ‘Stops engine. Return to its fully up position by spring tension. Return spring not weak or not damaged. Refer to “Daily Safety Checks” caution label attached to the inside of the left side cover. 56Additional Considerations for High Speed Operation Brakes: The importance of the brakes, especially during high speed cperation, cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss af control. Check to see that the handlebar turns freely but has no play. Tires: High speed operation is hard on tires, and good tires are crucial for riding safety. Examine their overall condition, infiate to the proper pressure, and creck the wheel bal- ance. Fuel: Have sufficient fuel for the high fuel consumption during high speed operation. Engine Oil: To avoid seizure and resulting loss of control, make certain the oil level is at the upper level line. Coolant: To avoid overheating, check that the coolant level is at the upper level line. Electrical Equipment: Make certain that the headlight, tail/brake light, turn signals, horn, etc., all work properly. Miscellaneous: Make certain that all nuts and bolts are tight and that all safety related parts are in good condition. Handling characteristics of a motorcycle at high speeds may vary from those you are ta- miliar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills. 57»»y»yo»ynnnona00» MAINTENANCE AND ADJUSTMENT cacaccacnncccnd The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to kezp the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. If you are in doubt as to any adjustment or vehicle operation, please ask your authorized Kawasaki dealer to check the motorcycle. Please note the Kawasaki cannot assume any responsibility for damage resulting from incorrect maintenance or improper adjustment done by the owner. 58Periodic Maintenance Chart Whichever Emission Related = Frequency comes tirst Car eae e chror oe ~ ° . 80 idle speed--check + —__ fi, l ie | ° . 80 Throttle grip play--check + e ° ° e | 7 [Spark plug-clean and gep + 7 ° ° e [a Valve clearance--check + le ° ° | 2 alr suction valve-check + ° ° . | 73 Ar cleaner element-clean be ° ° - | % Air cleaner element--replace S cleaning . 7 Fuel system-check { ° . . 110 ge ed air cet oo fef [el fas Evaporative emission control system (ch-check , 2 : & i ad Battery electrolyte level-check + | month| « ° ° e | 101 | 59Whichever Non-Emission Related 60 Frequenny neces vel “Odometer Resding km (mi) ¥ PASSES Operation | LR/PW/PS BS oe Every YS Sf S/ Pasa Brake play~check + e ° e | 92 Brake light switch-check + ° ° ° | 94 Brake lining or pad wear~check + oe | 88 Brake fluid level--check + month ° ° ° 30 IK Brake fluid-change 2 years ° 1 Clutch-edjust ~[-lelele e¢ ela | Steering-check + | ef elelele e o|— Drive belt wear~check + ef elelele eo o | 83 | Drive belt tension=check + ° ° ° ° ° e | © | 84 Raglan fastener tightness | . 3 | guy Tire wear-check + __| tele a Engine oil--change year . Oil filter-repiace . . General lubrication—perform e\e Ik Front fork oif-chanoe °Non-Emission Related Whichever Frequency comes first Zh d. MS. ¥ TY, Operation B/E S/S " S/S os /See ee Every ee SOY NS)? © ane IK Swing arm pivot-lubricate | e I e|- lubricate ayers | | 89 Ik Coolant--change 2 years * 7 Radiator hoses, connections Gagn ‘ 3 «le ~check + Ik Steering stem bearing-lubricate | 2 years Ik Master cylinder cup and dust seal-replace ever - Ik Caliper piston seal and dust seal--replace 2 years - Ik Brake cable-replace 2 years = IK Brake hose--replace Ik Fuel hose-replace Should be serviced by an authorized Kawasaki dealer. For higher odometer readings, repeat at the frequency interval established here, Replace, add, adjust, or torque if necessary. (C); California model only 61Engine Oil In order for the engine, transmission, and clutch to function properly, maintain the engine oil at the proper level, and change the oil and oil filter in accordance with the Periodic Maintenance Chart. Not only do dirt and metal particles collect in the oil, but the oil itself loses its lubricative quality if used too long. AWARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may re- sult in engine or transmission seizure, accident, and injury. Oil Level Inspection ©/f the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil 62 Stop the engine, then wait several min- utes until the oil settles. CAUTION Racing the engine before the oil reaches every part can cause engine seizure. @lf the motorcycle has just been used, wait several minutes for all the oil to drain down. @Check the engine oil level through the oil level gauge. With the motorcycle held level, the cil leve should come up between the lines next to the gauge.A. Oil Level Gauge —_C. Lower Level B. Upper Level @/f the oil level is too high, remove the ex- cess oil, using a syringe or some other suitable device ©'f the oil level is too low, add the correct amount of oil through the oil filler open- ing. Use the same type and brand of oil that is already in the engine CAUTION it the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light. If the light stays on when the engine speed is running slightly above the idle speed, stop the engine immediately and find the cause. A. Oil Pressure Warning Light 63Oil and/or Oil Filter Change @Warm up the engine thoroughly, and then stop the engine. @Place an oil pan beneath the engine drain plug, @Remove the engine drain plug. A. Drain Plug @With the motorcycle held level, let the oil completely drain. 64 @if the oil filter is to be changed, remove the cartridge and replace it with a new one. A. Cartridge @ Apply a thin film of oil on the gasket and tighten the cartridge to the specified torque,A. Gasket @install the engine drain plug with its gasket. Tighten it to the specified torque. NOTE O Replace the damaged gasket with a new one. @Fill the engine up to the upper level with good quality motor oil specified in the table, @Check the oil level. @Start the engine and check for oil leakage. Tightening Torque Engine Drain Plug: 29 N-m (3.0 kg-m, 22 ft-lb) Cartridge: 15 ~ 20N-m (15 ~ 20kg-m, 11.0 ~ 14.5 ft-lb) 65Engine Oil Grade: SE or SF class Viscosity: SAE 10W40, 10W5O, 20W40, or 20W50 Capacity: 2.8 L (3.0 US qt) [when filter is not removed] 3.0 L (3.2 US qt) [when filter is removed] 66 Cooling System Radiator and Cooling Fan Check the radiator fins for obstruction by insects or mud. Clean off any ob: structions with a stream of low-pressure water. CGN Ne] The cooling fan turns on automatically, even with the ignition switch off. Keep your hands and clothing away from the fan blades at all times.CAUTION Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator’s effective ness. Do not obstruct or deflect airflow through the radiator by installing unauthorized accessories in front of the radiator or be- hind the cooling fan. Interference with the radiator airflow can lead to overheat- ing and consequent engine damage. Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radi- ator. If the coolant level becomes low, the engine overheats and may suffer severe damage. Check the coolant level each day before riding the motorcycle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart. Information for Coolant To protect the cooling system (consist- ing of the aluminum engine and radiator) from rust and corrosion, the use of corro- sion and rust inhibitor chemicals in the coolant is essential, If coolant containing corrosion and rust inhibitor chemicals is not used, over a period of time, the cooling system accumulates rust and scale in the water jacket and radiator. This will clog up the coolant passages, and considerably re- duce the efficiency of the cooling system. Daas Use coolant containing corrosion inhibitors made specifically for alumi- num engines and radiators in accord- ance with the instructions of the manufacturer. Chemicals are harmful to the human body. 67Soft or distilled water must be used with the antifreeze (seo below for anti- freeze) in the cooling system. CAUTION it hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. If the lowest ambient temperature en- countered falls below the freezing point of water, use permanent antifreeze in the coolant to protect the cooling system against engine and radiator freeze-up, as well as from rust and corrosion. Use a permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) in the cooling sys- tem. On the mixture ratio of coolant, choose the suitable one referring to the re- 68 lation between freezing point and strength directed on the container. CAUTION Permanent types of antifreeze o: market have anti-corrosion and anti-rust properties. When it is diluted exces- sively, it loses its anti-corrosion prop- erty. Dilute a permanent type of antifreeze in accordance with the in- structions of manufacturer. NOTE OA permanent type of antifreeze is in- stalled in the cooling system when shipped. It is colored green, contains a 50% solution of ethylene glycol, and has the freezing point of -35°C (—37°F).Coolant Level Inspection @Situate the motorcycle so that it is per- pendicular to the ground (on its side stand). @Check the coolant level through the coolant level gauge in the right front side cover. The coolant level should be be- tween the FULL and LOW marks. NOTE Check the level when the engine is cold (room or atmospheric temperature). Ee A. Right Front Side Cover B. FULL Mark Cc. LOW Mark @ If the amount of coclant is insufficient, remove the right front side cover, un- ‘screw the cap from the reserve tank, and add coolant through the filler opening to the FULL mark. Install the cap and cover. 69CAUTION If coolant must be added often, or the re- serve tank completely runs dry, there is probably leakage in the system. Have the cooling system inspected by your au- thorized Kawasaki dealer. Coolant Change Have the coolant changed by an au- A. Reserve Tank —C. Full Mark thorized Kawasaki dealer. B. Cap D. Low Mark NOTE Oln an emergency you can add water alone to the coolant reserve tank, how- ever jt must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible 70Spark Plugs The standard spark plug is shown in the table. The spark plugs should be taken out periodically in accordance with the Peri- odie Maintenance Chart for cleaning, in- spection, and resetting of the plug gap. Maintenance If the plug is oily or has carbon built up on it, have it cleaned, preferably in a sand-blasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other suitable tool Measure the gap with a wire-type thick- ness gauge, and adjust the gap if incorrect by bending the outer electrode. If the spark plug electrodes are corroded or dam- aged, or if the insulator is cracked, replace the plug. Use the standard plug. 1 06 - 0.7mm } (0.024 — 0.028 in| nSpark Plug Hotter Spark Plug Standard NGK D9EA or NGK D8EA or ND X24ES-U Plug ND X27ES-U © NGK DR8ES-L or ND X24ESR-U ONGK DRBES or @ : Canadian model ND X27ESR-U Plug 0.6 ~ 0.7mm Gap (0.024 ~ 0.028 in) Tightening | 14.N-m Torque (1.4. kg-m, 10.0 ft-Ib) © : Canadian model CAUTION For cold weather and/or low speed rid- ing, a hotter spark plug shown in the ta- ble may be used for quicker warm-ups and more efficient engine operation. However, for normal temperatures and/or high speed use, the standard spark plug must be used to prevent en- gine damage. 72Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. CAUTION It valve clearance is left unadjusted, the wear will eventually cause the valves to remain partly open; which lowers per- formance, burns the valves and valve seats, and may cause serious engine damage. Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Maintenance Chart. Inspection and adjustment should be done only by a competent mechanic fol- lowing the instructions in the Service Manual Kawasaki Clean Air System The Kawasaki Clean Air Systom (KCA) is @ secondary air suction system that helps the exhaust gases to burn more com- pletely. When the spent fuel charge is re- leased into the exhaust system, it is still hot enough to bum. The KCA System allows extra air into the exhaust system so that the spent fuel charge can continue to burn: This continued burning action tends to burn up a great deal of the normally un- burned gases, as well as changing a signif- icant portion of the poisonous carbon monoxide into harmless carbon dioxide. 73Air Suction Valves: The air suction valve is essentially a check valve which allows fresh air to flow only from the air cleaner into the exhaust port. Any air that has passed the air suction valve is prevented from retuming Inspect the air suction valves in accord- ance with the Periodic Maintenance Chart. Also, inspect the air suction valves when- ever stable idling cannot be obtained, en- gine power is greatly reduced, or there are abnormal engine noises. Air suction valve removal and in- spection should be done only by a compe- tent mechanic following the instructions in the Service Manual. 74 Evaporative Emission Control System (California model only) This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjust- ments are required, a thorough visual in- spection must be made at the intervals specified by the Periodic Maintenance Chart. Inspection @Check that the hoses are securely con- nected. @Replace any kinked, deteriorated, or damaged hoses.VACUUM HOSE ROUTING DIAGRAM vacuum SWITCH VALVE CARBURETOR WHITE CONNECTS 2 RETURN PUMP, Air Cleaner A clogged air cleaner restricts the engine's air intake, increasing fuel con- sumption, reducing engine power, and causing spark plug fouling. ‘The air cleaner element must be cleaned and replaced in accordance with the Peri- odic Maintenance Chart. In dusty areas. the element should be cleaned more fre- quently than the recommended interval. After riding through rain or on muddy roads, the element should be cleaned im- mediately. The element should be re- placed if it is damaged. 76Element Removal @ Remove the right side cover. @Unscrew the bolts from the air cleaner cap and remove the cap from air cleaner housing. A. Bolts B. Air Cleaner Cap @Pull out the element from the housing, 76 A. Element Push a clean, lint-free towel into the air cleaner housing to keep ditt or other for- eign material from enteing. @ inspect the element material and sponge gasket for damage. If any part of the e!- ement is damaged, the element must be replaced.AWARNING If dirt or dust is allowed to pass through into the carburetors, the throttle may be- come stuck, possibly causing accident. CAUTION Wf dirt gets through into the engine, ex- cessive engine wear and possibly en- gine damage will occur. NOTE ©Flement installation is performed in the reverse order of removal. Element Cleaning @Clean the element in a bath of a high flash-point solvent. © Dry the element with compressed air or by squeeze it. @ After cleaning, saturate the element with SE class SAE 30 motor oil, squeeze out the excess, then wiap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element. AWARNING Clean the element in a well ventilated area, and take care that there are no spatks or flame anywhere near the working area; this includes any appli- ance with a pilot lighl, Do not use gaso- line or a low flash-point solvent to clean the element. A fire or explosion could result. 7Throttle Grip The throttle grip controls the throttle valves. If the throttle grip has excessive play due to either cable stretch or maladjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle valves may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Check the throt- tle grip play periodically in accordance with the Periodic Maintenance Chart, and adjust the play if necessary. Inspection @Check that there is 2 ~ 3 mm (0.08 ~ 0.12 in) throttle grip play when lightly turning the throttle grip back and forth. ©1f there is improper play, adjust it. 78 A. Throttle Grip B. 2 ~ 3mm (0.08 ~ 0.12 in) Adjustment @Loosen the locknuts, and screw both throttle cable adjusters in completely at the upper end of the throttle cables so as to give the throttle grip plenty of play. @Turn out the decelerator cable adjuster until there is no play when the throttle grip is completely closed. Tighten the locknut.A. Accelerator Cable C. Adjusters B, Decelerator Cable D. Locknuts ®Turn the accelerator cable adjuster until 2 ~ 3mm (0.08 ~ 0.12 in) of throttle grip play is obtained. Tighten the locknut. NOTE Off the throttle cables cannot be adjusted by using the cable adjusters at the upper end of the throttie cables, have them ad- justed by a competent mechanic follow- ing the instructions in the Service Manual. 79