99976-1553 en 2 08

70 MAINTENANCE AND ADJUSTMENT
MAINTENANCE AND ADJUSTMENT
The maintenance and adjustments outlined in this chapter must be carried out
and must be done in accordance with the Periodic Maintenance Chart to keep the
motorcycle in good running condition. The initial maintenance is vitally impor-
tant and must not be neglected.
With a basic knowledge of mechanics and the proper use of tools, you should be
able to carry out many of the maintenance items described in this chapter. If you
lack proper experience or doubt your ability, all adjustments, maintenance, and
repair work should be completed by a qualified technician.
Please note that Kawasaki cannot assume any responsibility for damage result-
ing from incorrect or improper adjustment done by the owner.
MAINTENANCE AND ADJUSTMENT 71
Periodic Maintenance Chart

K: Should be serviced by an authorized Kawasaki dealer.
*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions: dusty, wet, muddy,
high speed, or frequent starting/stopping.
1. Periodic Inspection (Engine Related Items)
Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)
1 6 12 18 24 30 36
Operation (Engine Item) Every
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Air cleaner element -
K
clean • • • 95
Valve clearance -
K Every 42 000 km (26 250 mile) 95
inspect
Throttle control system
(play, smooth return, no
drag) - inspect
year • • • • 97
Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)
1 6 12 18 24 30 36
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Engine vacuum
Ksynchronization -
inspect
• • • 100
Idle speed - inspect • • • • 101

Fuel leak (fuel hose and
K
pipe) - inspect
year • • • • –
Fuel hoses damage -

K
inspect
year • • • • –
Fuel hoses installation

K
condition - inspect
year • • • • –
Coolant level - inspect • • • • 89

Coolant leak - inspect year • • • • 87
Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)
1 6 12 18 24 30 36
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Radiator hose damage
- inspect
year • • • • 87
Radiator hoses
installation condition
- inspect
year • • • • 87
Air suction system

K
damage - inspect • • • 94
2. Periodic Inspection (Chassis Related Items)

Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)
Operation (Chassis 1 6 12 18 24 30 36
Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Clutch and drive train:
Clutch operation
(play, engagement,
disengagement) - • • • • 102
inspect
Drive chain lubrication
every 600 km (400 mile) 114
condition - inspect #
Drive chain slack -
every 1 000 km (600 mile) 105
inspect #
Drive chain wear -
inspect # • • • 110
Drive chain guide wear

K
- inspect • • • –
Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)
Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Wheels and tires:
Tire air pressure -
inspect
year • • • 126
Wheels/tires damage -
inspect • • • 127
Tire tread wear,

abnormal wear -
inspect
• • • 127
Wheel bearings
K
damage - inspect
year • • • –
Brake system:
Brake fluid leak -
inspect
year • • • • • • • 115
Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)
Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Brake hoses and pipe
damage - inspect
year • • • • • • • 115
Brake pad wear -

inspect # • • • • • • 115
Brake hose installation

condition - inspect
year • • • • • • • 115
Brake fluid level - 6

inspect months • • • • • • • 116
Brake operation
(effectiveness, play,
drag) - inspect
year • • • • • • • 118
Brake light switch

operation - inspect • • • • • • • 119
Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)
Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Suspensions:
Front forks/rear shock
absorber operation
(damping and smooth • • • 121,122
stroke) - inspect
Front forks/rear shock
absorber oil leak -
inspect
year • • • 121,122
Steering System:
KSteering play - inspect year • • • • –
Steering stem bearings
K
- lubricate
2 years • –
Frequency Whichever
comes See
*Odometer Reading
first Page
km × 1000 ( mile × 1000)
Every
Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Electrical System:
Lights and switches
operation - inspect
year • • • –
Headlight aiming -
inspect
year • • • 135
Side stand switch

operation - inspect
year • • • –
Engine stop switch

operation - inspect
year • • • –
Chassis:
Chassis parts -
lubricate
year • • • –
Bolts and nuts

tightness - inspect • • • • –
3. Periodic Replacement
Frequency Whichever See
comes first *Odometer Reading
Page
km × 1000 ( mile × 1000)
1 12 24 36 48
Change/Replacement Item Every
(0.6) (7.5) (15) (22.5) (30)
Air cleaner element # -
K 2 year 95
replace
Engine oil # - change year • • • • • 83
Oil filter - replace year • • • • • 83
KFuel hoses - replace 4 year • –
KCoolant - change 3 years • 92

Radiator hoses and O-rings
K
- replace
3 years • –
Brake hoses and pipe -

K
replace
4 years • –
Brake fluid (front and rear) -

K
change
2 years • • 118
Frequency Whichever See

comes first *Odometer Reading
Page
km × 1000 ( mile × 1000)
Rubber parts of master

K cylinder and caliper -
replace
4 years • –
KSpark plug - replace • • • • 93

Engine Oil Oil Level Inspection

In order for the engine, transmission,
and clutch to function properly, main-
• If the oil has just been changed, start
the engine and run it for several min-
tain the engine oil at the proper level, utes at idle speed. This fills the oil
and change the oil and replace the oil filter with oil. Stop the engine, then
filter in accordance with the Periodic wait several minutes until the oil set-
Maintenance Chart. Not only do dirt tles.
and metal particles collect in the oil, but
the oil itself loses its lubricative quality NOTICE
if used too long.
Racing the engine before the oil
WARNING reaches every part can cause en-
gine seizure.
Motorcycle operation with insuf-
ficient, deteriorated, or contam-
inated engine oil will cause ac- • Ifwait
the motorcycle has just been used,
several minutes for all the oil to
celerated wear and may result in drain down.
engine or transmission seizure,
accident, and injury. Check the
oil level before each ride and
change the oil according to the
periodic maintenance chart in
the owner’s manual.
• Check the engine oil level through

the oil level gauge. With the motor-
• Ifexcess
the oil level is too high, remove the
oil through the oil filler open-
cycle held level, the oil level should ing using a syringe or some other
come up between the upper and suitable device.
lower level lines next to the gauge. • If the oil level is too low, add the oil
to reach the correct level. Use the
same type and brand of oil that is
already in the engine.
NOTICE
If the engine oil gets extremely
low or if the oil pump does not
function properly or oil pas-
sages are clogged, the oil pres-
sure warning light in the meter
instrument will flash. If this light
A. Oil Level Gauge
B. Upper Level Line remains flashing when the en-
C. Lower Level Line gine speed above idle, stop the
D. Oil Filler Cap engine immediately and have it
serviced.
Failure to do so could cause en-
gine serious damage.
Oil and/or Oil Filter Change

• To change the engine oil and replace
oil filter, the engine oil drain plug
and oil filter must be removed. The
oil change and oil filter replacement
should be done by an authorized
Kawasaki dealer.
A. Oil Pressure Warning Light
A. Drain Plug
WARNING
Motor oil is a toxic substance.
Dispose of used oil properly.
Contact your local authorities
for approved disposal methods
or possible recycling.
• Remove the oil filter cartridge and re-

place it with a new one.
NOTE A. Cartridge
If a torque wrench or required
• Apply a thin film of oil to the packing
Kawasaki special tool is not avail- and tighten the cartridge to the spec-
able, this item should be serviced by ified torque.
a Kawasaki dealer.
• Check the oil level and oil leakage.

Tightening Torque
Engine Oil Drain Plug :
30 N·m (3.0 kgf·m, 22 ft·lb)
Cartridge :
17.5 N·m (1.75 kgf·m, 13 ft·lb)
Recommended Engine Oil

Type: API SG, SH, SJ, SL or SM
A. Packing with JASO MA, MA1 or MA2
• Install the drain plug with its new gas-
ket. Tighten it to the specified torque.
Viscosity: SAE 10W-40
NOTE NOTE
Replace any gaskets with new ones. Do not add any chemical additive to
the oil. Oils fulfilling the above re-
• Fill the engine up to the upper level
line with a good quality engine oil
quirements are fully formulated and
provide adequate lubrication for both
specified in the table. the engine and the clutch.
• Start the engine.
Engine Oil Capacity Although 10W-40 engine oil is the

Capacity : 1.7 L (1.8 US qt) recommended oil for most condi-
tions, the oil viscosity may need to
[when filter is not removed]
be changed to accommodate atmo-
1.9 L (2.0 US qt) spheric conditions in your riding area.
[when filter is removed]
2.4 L (2.5 US qt)
[when engine is completely
dry]
Cooling System NOTICE

Radiator and Cooling Fan - Using high-pressure water, as
Check the radiator fins for obstruc- from a car wash facility, could
tion by insects or mud. Clean off damage the radiator fins and im-
any obstructions with a stream of pair the radiator’s effectiveness.
low-pressure water. Do not obstruct or deflect air-
flow through the radiator by
WARNING installing unauthorized acces-
Keep your hands and clothing sories in front of the radiator or
away from the fan blades at all behind the cooling fan. Inter-
times. ference with the radiator airflow
can lead to overheating and con-
sequent engine damage.
Radiator Hoses -
Check the radiator hoses for leak-
age, cracks or deterioration, and con-
nections for leakage or looseness each
day before riding the motorcycle, and
in accordance with the Periodic Main-
tenance Chart.
Coolant - period of time, the cooling system ac-

Coolant absorbs excessive heat from cumulates rust and scale in the water
the engine and transfers it to the air jacket and radiator. This will clog up
at the radiator. If the coolant level be- the coolant passages, and consider-
comes low, the engine overheats and ably reduce the efficiency of the cooling
may suffer severe damage. Check the system.
coolant level each day before riding the
motorcycle, and in accordance with the WARNING
periodic maintenance chart and replen- Coolant containing corrosion in-
ish coolant if the level is low. Change hitors for alminum engines and
the coolant in accordance with the Pe- radiators include harmful chem-
riodic Maintenance Chart. icals for human body. Drinking
coolant can result in serious in-
Information for Coolant jury or death. Use coolant in ac-
To protect the cooling system (con- cordance with the instractions of
sisting of the aluminum engine and the manufacturer.
radiator) from rust and corrosion, the
use of corrosion and rust inhibitor Soft or distilled water must be used
chemicals in the coolant is essential. If with the antifreeze (see below for an-
coolant containing corrosion and rust tifreeze) in the cooling system.
inhibitor chemicals is not used, over a
NOTICE NOTICE
If hard water is used in the sys- Permanent types of antifreeze on
tem, it causes scale accumula- the market have anti-corrosion
tion in the water passages, and and anti-rust properties. When it
considerably reduces the effi- is diluted excessively, it loses its
ciency of the cooling system. anti-corrosion property. Dilute a
permanent type of antifreeze in
If the lowest ambient temperature en- accordance with the instructions
countered falls below the freezing point of the manufacturer.
of water, use permanent antifreeze in
the coolant to protect the cooling sys- NOTE
tem against engine and radiator freeze
-up, as well as from rust and corrosion. A permanent type of antifreeze is in-
Use a permanent type of antifreeze stalled in the cooling system when
(soft water and ethylene glycol plus cor- shipped. It is colored green and con-
rosion and rust inhibitor chemicals for tains ethylene glycol. It is mixed at
aluminum engines and radiators) in the 50% and has the freezing point of
cooling system. On the mixture ratio –35°C (–31°F).
of coolant, choose the suitable one re-
ferring to the relation between freezing Coolant Level Inspection
point and strength directed on the con- • Situate the motorcycle so that it is
perpendicular to the ground.
tainer.
• Check the coolant level if it is under

the L (Low) level line.
cowl and add coolant into the reserve
tank.
NOTE Coolant Filling

Check the level when the engine is •Remove the upper right inner cowl by
removing the bolt and quick rivet.
cold (room or atmospheric tempera-
ture).
A. Upper Right Inner Cowl

B. Bolt
A. L (Low) Level Line C. Quick Rivet
B. Right Side Cowl
• Ifcient,
the amount of coolant is insuffi-
remove the upper right inner
NOTE Quick Rivet Installation

The inner cowl uses the quick rivet.
The quick rivet can be removed by
pushing the central pin into the quick
rivets, and when installing it, pull the
central pin fully up first, and then
push into the central pin after insert-
ing it.
Quick Rivet Removal
A. Quick Rivet
B. Center Pin
C. Pull up fully.
D. Push in.
• Remove the cap from the reserve

tank and add coolant through the
filler opening to the F (Full) level line.
A. Quick Rivet
B. Center Pin
C. Push in.
correct mixture ratio by the addition

of antifreeze concentrate as soon as
possible.
NOTICE
If coolant must be added of-
ten, or the reserve tank com-
pletely runs dry, there is proba-
bly leakage in the system. Have
the cooling system inspected
A. Cap
B. Reserve Tank by your authorized Kawasaki
dealer.
• Install the cap.
• Install the upper right inner cowl.
Coolant Change
NOTE Have the coolant changed by an au-
thorized Kawasaki dealer.
In an emergency you can add wa-
ter alone to the coolant reserve tank,
however it must be returned to the
Spark Plugs
The standard spark plug is shown in
the table. The spark plugs should be
replaced in accordance with the Peri-
odic Maintenance Chart.
Spark plug removal should be done
by an authorized Kawasaki dealer.
Spark Plug
Standard Plug NGK CR9EIA-9
0.8 ∼ 0.9 mm
Plug Gap
(0.032 ∼ 0.035 in.) A. Plug Gap
15 N·m
Tightening Torque
(1.5 kgf·m, 11 ft·lb)
Kawasaki Clean Air System the air suction valve is prevented from
The Kawasaki Clean Air System returning. Inspect the air suction valves
(KCA) is a secondary air suction sys- in accordance with the Periodic Main-
tem that helps the exhaust gases to tenance Chart. Also, inspect the air
burn more completely. When the spent suction valves whenever stable idling
fuel charge is released into the ex- cannot be obtained, engine power is
haust system, it is still hot enough to greatly reduced, or there are abnormal
burn. The KCA System allows extra engine noises.
air into the exhaust system so that the Air suction valve removal and inspec-
spent fuel charge can continue to burn. tion should be done by an authorized
This continued burning action tends to Kawasaki dealer.
burn up a great deal of the normally
unburned gases, as well as chang-
ing a significant portion of the carbon
monoxide into carbon dioxide.
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
Valve Clearance Air Cleaner

Valve and valve seat wear decreases A clogged air cleaner restricts the en-
valve clearance, upsetting valve timing. gine’s air intake, increasing fuel con-
sumption, reducing engine power, and
NOTICE causing spark plug fouling.
If valve clearance is left un- The air cleaner element and oil drain
adjusted, wear will eventually must be cleaned in accordance with
cause the valves to remain the Periodic Maintenance Chart by
partly open, which lowers per- an authorized Kawasaki dealer. In
formance, burns the valves and dusty, rainy, or muddy conditions, the
valve seats, and may cause seri- air cleaner element should be ser-
ous engine damage. viced more frequently than the recom-
mended interval.
Valve clearance for each valve
should be checked and adjusted in
accordance with the Periodic Mainte-
nance Chart.
Inspection and adjustment should
be done by an authorized Kawasaki
dealer.
Oil Draining WARNING

• Inspect the drain hose located on the
rear side of the engine to see if any
Oil on tires will make them slip-
pery and can cause an accident
oil or water has run down from the air
and injury. Be sure to install the
cleaner housing.
plug in the drain hose after drain-
ing.
A. Drain Hose
B. Plug
• Ifthethere is any oil in the hose, remove

plug and drain the oil.
Throttle Control System Inspection

Check the throttle grip play in accor-
dance with the Periodic Maintenance
• Check that the throttle grip play is
correct by lightly turning the throttle
Chart, and adjust it if necessary. grip back and forth.
Throttle Grip -
The throttle grip controls the butterfly
valves in the throttle body. If the throt-
tle grip has excessive play due to either
cable stretch or maladjustment, it will
cause a delay in throttle response, es-
pecially at low engine speed. Also, the
throttle valve may not open fully at full
throttle. On the other hand, if the throt-
tle grip has not play, the throttle will be
hard to control, and the idle speed will A. Throttle Grip
B. Throttle Grip Play
be erratic.
Throttle Grip Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
• If there is improper play, adjust it.

Adjustment • Ifjusted
the throttle cable can not be ad-
•Loosen the locknut at the upper end
of the throttle cable and turn the throt-
with the cable adjuster at the
upper end of the throttle cable, use
tle cable adjusting nut in completely the lower end of the throttle cable ad-
so as to give the throttle grip plenty juster located at the front of the fuel
of play. tank.
• Remove the bolt and right side cover.
A. Adjuster
B. Locknut
C. Throttle Cable (Accelerator Cable) A. Bolt
B. Right Side Cover
• Loosen the locknut at the lower end

of the throttle cable and turn the throt-
the return spring. If the throttle grip
does not return properly, check the
tle cable adjusting nut in completely throttle cable routing, grip free play,
so as to give the throttle grip plenty and cable damage.
of play. Tighten the locknut. • With the engine idling, turn the han-
dlebar to each side. If handlebar
movement changes the idle speed,
the throttle cables may be improp-
erly adjusted or in correctly routed,
or they may be damaged. Be sure
to correct any of these conditions be-
fore riding.
WARNING
Operation with an improperly
A. Adjuster
adjusted, incorrectly routed, or
B. Locknut damaged cables could result in
C. Throttle Cable (Decelerator Cable) an unsafe riding condition. Be
sure the control cables are ad-
• Check that the throttle grip moves
smoothly from full open to closed,
justed and routed correctly, and
are free from damage.
and the throttle closes quickly and
completely in all steering positions by
• Fit in the projection and tab into the

holes.
Engine Vacuum Synchronization
Engine vacuum synchronization
• Tighten the bolt. must be checked and adjusted period-
ically in accordance with the Periodic
Maintenance Chart by an authorized
Kawasaki dealer.
NOTE
Poor engine vacuum synchronization
will cause unstable idling, sluggish
throttle response, and reduce engine
power and performance.
A. Right Side Cover

B. Tab
C. Slots
D. Projection
E. Holes
Idle Speed Adjustment

The idle speed check should be per-
formed in accordance with the Peri-
• Start the engine, and warm it up thor-
oughly.
odic Maintenance Chart or whenever
the idle speed is disturbed.
• Adjust the idle speed by turning the
idle adjusting screw.
Idle Speed
1 250 ∼ 1 350 r/min (rpm)
A. Idle Adjusting Screw
• Open and close the throttle a few

times to make sure that the idle
speed does not change. Readjust if Clutch

necessary. Due to friction plate wear and clutch
• With the engine idling, turn the han-
dlebar to each side. If handlebar
cable stretch over a long period of use,
the clutch operation should be checked
movement changes the idle speed, each day before riding the motorcycle,
the throttle cables may be improperly and in accordance with the Periodic
adjusted or incorrectly routed, or they Maintenance Chart.
may be damaged. Be sure to correct
any of these conditions before riding. WARNING
The engine and exhaust system
WARNING get extremely hot during normal
operation and can cause serious
Operation with damaged cables burns. Never touch a hot engine
could result in an unsafe riding or an exhaust pipe during clutch
condition. Replace damaged adjustment.
control cables before operation.
Inspection
• Check that the clutch lever operates
properly and that the inner cable
slides smoothly. If there is any irreg-
ularity, have the clutch cable checked
by an authorized Kawasaki dealer.
• Check the clutch lever play as shown Adjustment

in the figure. • Loosen the locknut, and turn the
adjuster so that the clutch lever will
Clutch Lever Play
have the proper play.
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
WARNING
Too much cable play can pre-
vent clutch disengagement and
cause an accident resulting in
serious injury or death. When
adjusting the clutch or replac-
ing the cable, be sure the up-
per end of the clutch outer cable
is fully seated in its fitting, or it
could slip into place later, creat-
A. Locknut ing enough cable play to prevent
B. Clutch Lever Play clutch disengagement.
C. Adjuster
If the play is incorrect, adjust the lever

play as follows.
• Ifatitthe
cannot be done, use the adjuster
lower end of the clutch cable
NOTE
by removing the right side cover (see

After the adjustment is made, start
the engine and check that the clutch
the Throttle Control System section). does not slip and that it releases
properly.
For minor corrections, use the ad-
juster at the clutch lever.
A. Adjuster
B. Locknut
C. Clutch Cable
Drive Chain Chain Slack Inspection

The drive chain slack and lubrica-
tion must be checked each day be-
•Set the motorcycle up on its side
stand.
fore riding the motorcycle, and in accor-
dance with the Periodic Maintenance
•Rotate the rear wheel to find the po-
sition where the chain is tightest, and
Chart for safety and to prevent exces- measure the maximum chain slack
sive wear. If the chain becomes badly by pulling up and pushing down the
worn or maladjusted - either too loose chain midway between the engine
or too tight - the chain could jump off sprocket and rear wheel sprocket.
the sprockets or break.
WARNING
A chain that breaks or jumps off
the sprockets could snag on the
engine sprocket or lock the rear
wheel, severely damaging the
motorcycle and causing it to go
out of control. Inspect the chain
for damage and proper adjust-
ment before each ride.
A. Chain Slack
• Ifloose,
the drive chain is too tight or too Adjustment
adjust it so that the chain slack
will be within the standard value.
•Loosen the left and right chain ad-
juster locknuts.
Drive Chain Slack •Remove the cotter pin, and loosen
the rear axle nut.
Standard 25 ∼ 35 mm (1.0 ∼ 1.4 in.)
A. Axle Nut
B. Cotter Pin
C. Adjusting Nut
D. Locknut
• Ifandtheright
chain is too loose, turn in the left
chain adjusting nuts evenly.
• Iflefttheandchainrightis too tight, turn out the

chain adjusting nuts
• To keep the chain and wheel prop-
erly aligned, the wheel alignment in-
evenly. dicator hollow of left wheel alignment
indicator should align with the same
• Turn both chain adjusting nuts evenly
until the drive chain has the correct swingarm mark that the wheel align-
amount of slack. ment indicator hollow of right wheel
alignment indicator aligns with.
A. Marks
B. Indicator
C. Adjusting Nut
D. Locknut
E. Hollow
NOTE Tightening Torque

Wheel alignment can also be Axle Nut:
checked using the straightedge or 108 N·m (11 kgf·m, 80 ft·lb)
string method.
NOTE
WARNING
If a torque wrench is not available,
Misalignment of the wheel will this item should be serviced by a
result in abnormal wear, and may Kawasaki dealer.
result in an unsafe riding con-
dition. Align the rear wheel us- • Rotate the wheel, measure the chain
slack again at the tightest position,
ing the marks on the swingarm
or measuring the distance be- and readjust if necessary.
tween the center of the axle and • Install a new cotter pin through the
rear axle nut and axle, and spread its
swingarm pivot.
ends.
• Tighten both chain adjuster locknuts.
• Tighten the rear axle nut to the spec-
ified torque.
A. Cotter Pin A. Turning Clockwise
NOTE WARNING
When inserting the cotter pin, if the A loose axle nut can lead to an
slots in the nut do not align with
the cotter pin hole in the axle shaft, accident resulting in serious in-
tighten the nut clockwise up to the jury or death. Tighten the axle
next alignment. nut to the proper torque and in-
stall a new cotter pin.
It should be within 30 degree.
Loosen once and tighten again when
the slot goes past the nearest hole. • Check the rear brake (see the Brakes
section).
Wear Inspection
•Remove the chain cover bolts.
A. Bolt
B. Quick Rivet
C. Chain Cover
A. Bolts
NOTE
• Remove the chain cover bolt and
quick rivet to take off the chain guide. The chain cover uses the quick rivet.
The quick rivet can be removed by
pushing the central pin into the quick
rivets, and when installing it, pull the
central pin fully up first, and then
push into the central pin after insert-
ing it.
Quick Rivet Removal Quick Rivet Installation
A. Quick Rivet A. Quick Rivet

B. Center Pin B. Center Pin
C. Push in. C. Pull up fully.
D. Push in.
• Stretch the chain taut either by using

the chain adjusters, or by hanging a
10 kg (20 lb) weight on the chain.
• Measure the length of 20 links on
the straight part of the chain from pin
center of the 1st pin to pin center of
the 21st pin. Since the chain may
wear unevenly, take measurements

at several places.
• When installing the chain cover, in-
sert the projections of the chain cover
• If the length exceeds the service limit,
the chain should be replaced.
into the holes.
A. Projection
A. Measure B. Holes
B. Weight C. Chain Cover
Drive Chain 20-Link Length

Service Limit
323 mm (12.7 in.)
WARNING NOTE
For safety, use only the standard Sprocket wear is exaggerated for il-
chain. It is an endless type and lustration. See Service Manual for
should not be cut for installa- wear limits.
tion; have it installed by an au-
• Rotate the rear wheel to inspect the

drive chain for damaged rollers, and
loose pins and links.
• Also inspect the sprockets for un-
evenly or excessively worn teeth,
and damaged teeth.
A. Good Teeth
B. Worn Teeth
C. Damaged Teeth
• Ifdrive
there is any irregularity, have the
chain and/or the sprockets re-
placed by an authorized Kawasaki
dealer.
Lubrication
Lubrication is also necessary after
• Apply oil to the sides of the rollers so
that it will penetrate to the rollers and
riding through rain or on wet roads, or bushings. Apply oil to the O-rings so
any time that the chain appears dry. A that the O-rings will be coated with
heavy oil such as SAE 90 is preferred oil. Wipe off any excess oil.
to a lighter oil because it will stay on the
chain longer and provide better lubrica-
tion.
• Ifusing
the chain is especially dirty, clean it
diesel oil or kerosine and then
apply oil as mentioned above.
Brakes Disc Brake Fluid -

In accordance with the Periodic Main-
Brake Wear Inspection
tenance Chart, inspect the brake fluid
Inspect the brakes for wear. For each
level in both the front and rear brake
front and rear disc brake caliper, if the
fluid reservoirs and change the brake
thickness of either pad is less than
fluid. The brake fluid should also be
1 mm (0.04 in.), replace both pads
changed if it becomes contaminated
in the caliper as a set. Pad replace-
with dirt or water.
ment should be done by an authorized
Kawasaki dealer. Fluid Requirement
Use heavy-duty brake fluid only from
a container marked DOT4.
NOTICE
Do not spill brake fluid onto any
painted surface.
Do not use fluid from a container
that has been left open or that
has been unsealed for a long
time.
A. Lining Thickness Check for fluid leakage around
B. 1 mm (0.04 in.) the fittings.
Check brake hose for damage.
Fluid Level Inspection

• The brake fluid level in the front brake
fluid reservoir must be kept above
the line (lower level line) next to the
gauge and that in the rear brake fluid
reservoir (located under the seat)
must be kept between the upper and
lower level lines (reservoirs held hor-
izontal).
A. Rear Brake Fluid Reservoir

B. Upper Level Line
C. Lower Level Line
A. Front Brake Fluid Reservoir

B. Lower Level Line
• Iflower
the fluid level in either reservoir is
than the lower level line, check
WARNING
Mixing brands and types of
for fluid leaks in the brake lines, and
brake fluid can reduce the brake
fill the reservoir to the upper level
system’s effectiveness and
line. Inside the front brake fluid reser-
voir is a stepped line showing the up-
injury or death. Do not mix two
per level line.
brands of brake fluid. Change
the brake fluid in the brake line
completely if the brake fluid
must be refilled but the type
and brand of the brake fluid that
is already in the reservoir are
unidentified.
A. Front Brake Fluid Reservoir

B. Upper Level Line
NOTE Fluid Change

First, tighten until slight resistance is Have the brake fluid changed by an
felt indicating that the cap is seated authorized Kawasaki dealer.
on the reservoir body; then, tighten
the cap an additional 1/6 turn while Front and Rear Brakes -
holding the brake fluid reservoir Disc and disc pad wear is automat-
body. ically compensated for and has no ef-
fect on the brake lever or pedal action.
So there are no parts that require ad-
justment on the front brakes and rear
brakes.
A. Reservoir
B. Cap
C. Clockwise
D. 1/6 turn
WARNING Brake Light Switches

When either the front or rear brake is
Air in the brake lines diminish
applied, the brake light goes on. The
braking performance and can
front brake light switch requires no ad-
justment, but the rear brake light switch
injury or death. If the brake lever
should be adjusted in accordance with
or pedal feels mushy when it
the Periodic Maintenance Chart.
is applied, there might be air in
the brake lines or the brake may Inspection
be defective. Have the brake • Turn the ignition key to “ON”.
checked immediately by an au-
• The brake light should go on when
the front brake is applied.
• If it does not, ask your authorized
Kawasaki dealer to inspect the front
brake light switch.
• Check the operation of the rear brake Adjustment

light switch by depressing the brake
pedal. The brake light should go on
•To adjust the rear brake light switch,
move the switch up or down by turn-
after the proper pedal travel. ing the switch body.
A. Brake Pedal A. Rear Brake Light Switch

B. Pedal Travel B. Lock Nut
C. Lights sooner
• Iflightit does not, adjust the rear brake
switch.
D. Lights later
Brake Pedal Travel

10 mm (0.4 in.)
NOTICE Front Fork

The front fork operation and oil leak-
To avoid damaging the electrical
age should be checked in accordance
connections inside the switch,
with the Periodic Maintenance Chart.
be sure that the switch body
does not turn during adjustment. Front Fork Inspection
• Holding the brake lever, pump the
front fork up and down by several
times for inspection of smooth stroke.
• Visually inspect the front fork for oil
leakage, scoring or scratches on the
outer surface of the inner tube.
• Ifshould
any doubt about the front fork, it
be done by an authorized
Rear Shock Absorbers
The rear shock absorber operation
Kawasaki dealer. and oil leakage should be checked in
accordance with the Periodic Mainte-
nance Chart.
Rear Shock Absorber Inspection

•Press down on the seat several times
to check if the rear shock absorber
stroke is smooth.
•Visually inspect the rear shock ab-
sorber for oil leakage.
A. Inner Tube
• Ifsorber,
any doubt about the rear shock ab-
it should be done by an au-
Spring Preload Adjustment
The spring preload adjuster on the
thorized Kawasaki dealer. rear shock absorber has 7 positions.
A. Rear Shock Absorber A. Spring Preload Adjuster

B. Wrench
The rear shock absorber can be ad-
justed by changing the spring preload • Inble,accordance with the following ta-
turn the preload adjuster with the
and rebound damping force for various
riding and loading conditions. wrench from the tool kit.
Position 1 2 3 4 5 6 7
Spring Action Stronger ——
The standard setting position for an Wheels

average-build rider of 68 kg (150 lb) Tubeless tires are installed on the
with no passenger and no accessories wheels of this motorcycle. The indica-
is No. 4. tions of TUBELESS on the tire side wall
and the rim show that the tire and rim
are specially designed for tubeless use.
A. TUBELESS Mark
WARNING
Installing a tube inside a tube-
less-type tire can create exces-
sive heat build up that can dam-
age the tube and cause rapid
deflation. The tires, rims, and
air valves on this motorcycle are
designed only for tubeless type
wheels. The recommended stan-
dard tires, rims, and air valves
A. TUBELESS Mark must be used for replacement.
The tire and rim form a leakproof unit Do not install tube-type tires on
by making airtight contacts at the tire tubeless rims. The beads may
chamfers and the rim flanges instead not seat properly on the rim
of using an inner tube. causing tire deflation. Do not
install a tube inside a tubeless
tire. Excessive heat build-up
may damage the tube causing
tire deflation.
Tires - Tire pressure is affected by changes

in ambient temperature and altitude,
Payload and Tire Pressure
and so the tire pressure should be
Failure to maintain proper inflation
checked and adjusted when your rid-
pressures or observe payload limits for
ing involves wide variations in tem-
your tires may adversely affect han-
perature or altitude.
dling and performance of your motorcy-
cle and can result in loss of control. The
maximum recommended load in addi-
tion to vehicle weight is 180 kg (397 lb),
including rider, passenger, baggage,
and accessories.
• Remove the air valve cap.
• Check the tire pressure often, using
an accurate gauge.
• Make sure to install the air valve cap
securely.
NOTE A. Tire Pressure Gauge
Measure the tire pressure when the Tire Air Pressure (when cold)
tires are cold (that is, when the mo- Front 225 kPa (2.25 kgf/cm², 32 psi)
torcycle has not been ridden more
than a mile during the past 3 hours). Rear 250 kPa (2.50 kgf/cm², 36 psi)
Tire Wear, Damage Minimum Tread Depth

As the tire tread wears down, the tire Front — 1 mm (0.04 in.)
becomes more susceptible to puncture
Under 130 km/h
and failure. An accepted estimate is Rear 2 mm (0.08 in.)
(80 mph)
that 90% of all tire failures occur during
the last 10% of tread life (90 % worn). Over 130 km/h
3 mm (0.12 in.)
So it is false economy and unsafe to (80 mph)
use the tires until they are bald.
• In accordance with the Periodic
Maintenance Chart, measure the
depth of the tread with a depth
gauge, and replace any tire that
has worn down to the minimum al-
lowable tread depth.
A. Tire Depth Gauge
• Visually inspect the tire for cracks

and cuts, replacing the tire in case of
bad damage. Swelling or high spots
indicate internal damage, requiring WARNING

tire replacement.
Tires that have been punctured
• Remove any imbedded stones or
other foreign particles from the tread.
and repaired do not have the
same capabilities as undam-
NOTE aged tires and can suddenly fail,
Most countries may have their own causing an accident resulting
in serious injury or death. Re-
regulations requiring a minimum tire
tread depth; be sure to follow them. place damaged tires as soon as
Have the wheel balance inspected possible. To ensure safe han-
dling and stability, use only the
whenever a new tire is installed.
recommended standard tires for
replacement, inflated to the stan-
dard pressure. If it is necessary
to ride on a repaired tire, do not
exceed 100 km/h (60 mph) until
the tire is replaced.
NOTE
When operating on public roadways,
keep maximum speed under traffic
law limits.
Standard Tire (Tubeless) WARNING

Size: 120/70ZR17 M/C (58W) New tires are slippery and may
Front BRIDGESTONE cause loss of control and injury.
“BT021F J”
A break-in period of 160 km (100
Size: 160/60ZR17 M/C (69W) miles) is necessary to estab-
Rear BRIDGESTONE lish normal tire traction. During
“BT021R J” break-in, avoid sudden and max-
imum braking and acceleration,
WARNING and hard cornering.
Mixing tire brands and types can

adversely affect handling and
injury or death. Always use the
same manufacturer’s tires on
both front and rear wheels.
Battery Due to their internal composition,

The battery installed in this motorcy- batteries continually self discharge.
cle is a sealed type, so it is not nec- The discharge rate depends on the
essary to check the battery electrolyte type of battery and ambient temper-
level or add distilled water. ature. As temperatures rise, so does
The sealing strip should not be pulled the discharge rate. Every 15°C (27°F)
off once the specified electrolyte has doubles the rate.
been installed in the battery for initial Electrical accessories, such as digi-
service. tal clocks and computer memory, also
However, in order to maximize bat- draw current from the battery even
tery life and ensure that it will provide when the key is switched off. Combine
the power needed to start the motor- such “key-off” draws with hot temper-
cycle you must properly maintain the ature, and a battery can go from fully
battery’s charge. When used regularly, charged to completely discharged in a
the charging system in the motorcycle matter of days.
helps keep the battery fully charged. If
your motorcycle is only used occasion-
ally or for short periods of time, the bat-
tery is more likely to discharge.
Self-discharge Current Drain

Approx. Number of Days Days form Days form
From 100% Charged to 100% 100%
Discharging
100% discharged charged to charged to
Ampere
Temperature 50% 100%
Lead Lead
Discharged Discharged
-Antimony -Calcium
7 mA 60 Days 119 Days
Battery Battery
40°C (104°F) 100 Days 300 Days
25°C (77°F) 200 Days 600 Days
0°C (32°F) 550 Days 950 Days
In extremely cold weather the fluid in

an inadequately charged battery can
easily freeze, which can crack the case
and buckle the plates. A fully charged
battery can withstand sub-freezing
temperatures with no damage.
Battery Sulfation
A common cause of battery failure is
sulfation.
Sulfation occurs when the battery is If you will not be using the motorcy-
left in a discharged condition for an ex- cle for longer than two weeks, the
tended time. Sulfate is a normal by battery should be charged using an
product of the chemical reactions within appropriate charger. Do not use an au-
a battery. But when continuous dis- tomotive-type quick charger that may
charge allows the sulfate to crystallize overcharge the battery and damage it.
in the cells, the battery plates become
Kawasaki-recommended chargers
permanently damaged and will not hold
are:
a charge. Battery failure due to sulfa-
OptiMate
tion is not warrantable.
Yuasa 1.5 Amp Automatic charger
Battery Maintenance Battery Mate 150-9
It is the owner’s responsibility to keep If the above chargers are not avail-
the battery fully charged. Failure to do able, use equivalent one.
so can lead to battery failure and leave For more details, ask your Kawasaki
you stranded. dealer.
If you are riding your vehicle infre-
quently, inspect the battery voltage Battery Charging
weekly using a voltmeter. If it drops
below 12.8 volts, the battery should be
•Remove the battery from the motor-
cycle (see Battery Removal).
charged using an appropriate charger
(check with your Kawasaki dealer).
•Attach the leads from the charger
and charge the battery at a rate that
is 1/10th of the battery capacity. For
example, the charging rate for a 10 Battery Removal

Ah battery would be 1.0 ampere. • Remove the seat.
• The charger will keep the battery fully
charged until you are ready to re-
install the battery in the motorcycle
(see Battery Installation).
NOTICE
Never remove the sealing strip,
or the battery can be damaged.
Do not install a conventional
battery in this motorcycle, or the
electrical system cannot work A. (+) Terminal
properly. B. (–) Terminal
NOTE
• Disconnect the cables from the bat-
tery, first from the (–) terminal and
If you charge the sealed battery, then the (+) terminal.
never fail to observe the instructions • Take the battery out of the case.
shown in the label on the battery. • Clean the battery using a solution of
baking soda and water. Be sure that
the wire connections are clean.
Battery Installation • Cover the (+) terminal with its protec-

•Place the battery in the battery case. tive cap.
•Connect the capped cable to the (+)
terminal, and then connect the black
• Reinstall the parts removed .
cable to the (–) terminal.
NOTE
Install the battery in the reverse order
of the Battery Removal.
NOTICE
Installing the (–) cable to the (+)
terminal of the battery or the (+)
cable to the (–) terminal of the
battery can seriously damage
the electrical system.
• Put a light coat of grease on the ter-

minals to prevent corrosion.
Headlight Beam Vertical Adjustment

The headlight beam is adjustable ver-
Horizontal Adjustment
tically. If adjusted too low, neither low
The headlight beam is adjustable
nor high beam will illuminate the road
horizontally. If not properly adjusted
far enough ahead. If adjusted too high,
horizontally, the beam will point to one
the high beam will fail to illuminate the
side rather than straight ahead.
road close ahead, and the low beam
• Turn the horizontal adjuster clock-
wise or counterclockwise until the
will blind oncoming drivers.
beam points straight ahead. • Turn the vertical adjuster clockwise
or counterclockwise to adjust its ver-
tical angle.
A. Horizontal Adjuster
A. Vertical Adjuster
NOTE Fuses
On high beam, the brightest point Fuses are arranged in the fuse box
should be slightly below horizontal located under the seat. The main fuse
with the motorcycle on its wheels and is mounted on the starter relay behind
the rider seated. Adjust the headlight the right side cover. If a fuse fails dur-
to the proper angle according to local ing operation, inspect the electrical sys-
regulations. tem to determine the cause, and then
replace it with a new fuse of proper am-
perage.
A. Fuse Box
B. Fuses
C. Spare Parts
• Remove the main fuse cover by re-

moving the bolt.
A. Main Fuse
B. Spare Fuse
A. Main Fuse Cover

B. Bolt
WARNING Cleaning Your Motorcycle

Substituting fuses can cause General Precautions
wiring to overheat, catch fire Frequent and proper care of your
and/or fail. Do not use any sub- Kawasaki motorcycle will enhance
stitute for the standard fuse. its appearance, optimize overall per-
Replace the blown fuse with a formance, and extend its useful life.
new one of the correct capacity, Covering your motorcycle with a high
as specified on the junction box quality, breathable motorcycle cover
and main fuse. will help protect its finish from harmful
UV rays, pollutants, and reduce the
amount of dust reaching its surfaces.
• Be sure the engine and exhaust are
cool before washing.
• Avoid applying degreaser to seals,
brake pads, and tires.
• Always use non-abrasive wax and
cleaner/polisher.
• Avoid all harsh chemicals, solvents,
detergents, and household cleaning
products such as ammonia-based
A. Normal
window cleaners.
B. Failed
• Gasoline, brake fluid, and coolant Washing Your Motorcycle

will damage the finish of painted and
plastic surfaces: wash them off im-
•Rinse your bike with cold water from
a garden hose to remove any loose
mediately. dirt.
• Avoid wire brushes, steel wool, and
all other abrasive pads or brushes.
•Mix a mild neutral detergent (de-
signed for motorcycles or automo-
• Use care when washing the wind-
shield, headlight cover, and other
biles) and water in bucket. Use
a soft cloth or sponge to wash your
plastic parts as they can easily be motorcycle. If needed, use a mild de-
scratched. greaser to remove any oil or grease
• Avoid using pressure washers; wa- build up.
ter can penetrate seals and electrical
components and damage your mo-
•After washing, rinse your motorcy-
cle thoroughly with clean water to re-
torcycle. move any residue (residue from the
• Avoid spraying water in delicate
areas such as in air intakes, fuel
detergent can damage parts of your
motorcycle).
system, brake components, electri-
cal components, muffler outlets, and
•Use a soft cloth to dry your motorcy-
cle. As you dry, inspect your motor-
fuel tank openings. cycle for chips and scratches. Do not
let the water air dry as this can dam-
age the painted surfaces.
• Start the engine and let it idle for sev-

eral minutes. The heat from the en-
rain or washing the motorcycle. To
remove the moisture, start the engine
gine will help dry moist areas. and turn on the headlight. Gradually
• Carefully ride your motorcycle at a
slow speed and apply the brakes
the condensation on the inside of the
lens will clear off.
several times. This helps dry the
brakes and restores them to normal Painted Surfaces
operating performance. After washing your motorcycle, coat
• Lubricate the drive chain to prevent
rusting.
painted surfaces, both metal and plas-
tic, with a commercially available mo-
torcycle/automotive wax. Wax should
NOTE be applied once every three months or
After riding in an area where the as conditions require. Avoid surfaces
roads are salted or near the ocean, with “satin” or “flat” finishes. Always
immediately wash your motorcycle use non-abrasive products and apply
with cold water. Do not use warm them according to the instructions on
water as it accelerates the chemical the container.
reaction of the salt. After drying, Windshield and Other Plastic Parts
apply a corrosion protection spray After washing use a soft cloth to gen-
on all metal and chrome surfaces to tly dry plastic parts. When dry, treat
prevent corrosion. the windshield, headlight lens, and
Condensation may form on the inside other non-painted plastic parts with
of the headlight lens after riding in the
an approved plastic cleaner/polisher Chrome and Aluminum

product. Chrome and uncoated aluminum
parts can be treated with a chrome/alu-
NOTICE minum polish. Coated aluminum
Plastic parts may deteriorate should be washed with a mild neu-
and break if they come in con- tral detergent and finished with a spray
tact with chemical substances polish. Aluminum wheels, both painted
or household cleaning products and unpainted can be cleaned with
such as gasoline, brake fluid, special non-acid based wheel spray
window cleaners, thread-locking cleaners.
agents, or other harsh chemi- Leather, Vinyl, and Rubber
cals. If a plastic part comes in If your motorcycle has leather ac-
contact with any harsh chemical cessories, special care must be taken.
substance, wash it off immedi- Use a leather cleaner/treatment to
ately with water and a mild neu- clean and care for leather accessories.
tral detergent, and then inspect Washing leather parts with detergent
for damage. Avoid using abra- and water will damage them, shorten-
sive pads or brushes to clean ing their life.
plastic parts, as they will dam- Vinyl parts should be washed with the
age the part’s finish. rest of the motorcycle, then treated with
a vinyl treatment.
The sidewalls of tires and other rub- WARNING

ber components should be treated with
Rubber protectants can be slip-
a rubber protectant to help prolong their
pery and, if used on the tread
useful life.
area, cause loss of traction re-
sulting in accident causing in-
jury or death. Do not apply rub-
ber protectant to any tread area.

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70 MAINTENANCE AND ADJUSTMENT

MAINTENANCE AND ADJUSTMENT

Periodic Maintenance Chart

Idle speed - inspect • • • • 101

Fuel hoses damage -

Fuel hoses installation

Coolant level - inspect • • • • 89

Air suction system

2. Periodic Inspection (Chassis Related Items)

Drive chain guide wear

Tire tread wear,

Brake pad wear -

Brake hose installation

Brake fluid level - 6

Brake light switch

Side stand switch

Engine stop switch

Bolts and nuts

KCoolant - change 3 years • 92

Brake hoses and pipe -

Brake fluid (front and rear) -

Frequency Whichever See

Rubber parts of master

KSpark plug - replace • • • • 93

Engine Oil Oil Level Inspection

• Check the engine oil level through

Oil and/or Oil Filter Change

A. Oil Pressure Warning Light

• Remove the oil filter cartridge and re-

• Check the oil level and oil leakage.

Recommended Engine Oil

Engine Oil Capacity Although 10W-40 engine oil is the

Cooling System NOTICE

Coolant - period of time, the cooling system ac-

• Check the coolant level if it is under

NOTE Coolant Filling

A. Upper Right Inner Cowl

NOTE Quick Rivet Installation

• Remove the cap from the reserve

correct mixture ratio by the addition

Valve Clearance Air Cleaner

Oil Draining WARNING

• Ifthethere is any oil in the hose, remove

Throttle Control System Inspection

• If there is improper play, adjust it.

• Loosen the locknut at the lower end

• Fit in the projection and tab into the

A. Right Side Cover

Idle Speed Adjustment

A. Idle Adjusting Screw

• Open and close the throttle a few

speed does not change. Readjust if Clutch

• Check the clutch lever play as shown Adjustment

If the play is incorrect, adjust the lever

by removing the right side cover (see

Drive Chain Chain Slack Inspection

• Iflefttheandchainrightis too tight, turn out the

NOTE Tightening Torque

A. Cotter Pin A. Turning Clockwise

Quick Rivet Removal Quick Rivet Installation

A. Quick Rivet A. Quick Rivet

• Stretch the chain taut either by using