Operating Instructions 27508 Motorcycle ERS HOAA WARNING Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other repro- ductive harm.GENERAL INFORMATION I HOWTO RIDE THE MOTORCYCLE J This Quick Reference Guide wil [SarE OPERATION ———s«&d assist you in finding the information you're looking for. MAINTENANCE AND ADJUSTMENT J STORAGE I TROUBLESHOOTING GUIDE I Quick Reference Guide A Table of Contents is included after the Foreword.Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and main- tenance practices. This warning symbol identifies special instructions or proce- dures which, if not correctly fol- lowed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or proce- dures which, if not strictly ob- served, could result in damage to or destruction of equipment. NOTE O This note symbol indicates points of particular interest for more efficient and convenient operation. NOTICE THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OP- ERATOR AND AS A VEHICLE ONLY.FOREWORD Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo- forcycle is the product of Kawasaki's advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle's controls, its fea- tures, capabilities, and limitations. This manual offers many safe riding tips, but its purpose is not to provide instruction in all the techniques and skills required to ride a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi- cle enroll in a motorcycle rider training program to attain awareness of the mental and physical 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 in- formation on their Kawasaki Motorcycle, a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer. The Service Manual contains de- tailed disassembly and maintenance information. Those who plan to do their own work should, of course, be competent mechanics and possess the special tools described in the Service Manual. Keep this Owner’s Manual aboard your motorcycle at all times so that you can refer to it whenever you need information.This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold. All rights reserved. No part of this publication may be reproduced without our prior written permission. This publication includes the latest information available at the time of printing. However, there may be minor differences between the actual product and illustra- tions and text in this manual. All products are subject to change without prior notice or obligation. KAWASAKI HEAVY INDUSTRIES, LTD. Consumer Products & Machinery Company © 2005 Kawasaki Heavy Industries, Ltd. June. 2005. (1). (M)TABLE OF CONTENTS SPECIFICATIONS. SERIAL NUMBER LOCATIONS LOCATION OF PARTS... LOCATION OF LABELS LOADING INFORMATION GENERAL INFORMATION Meter Instruments... Speedometer and Tachometer: LCD Display (Clock, Odometer, Warning/Indicator Lights: OY oececssssctneeteneneesee Ignition Switch/Steering Lock. Right Handlebar Switches. Engine Stop Switch: . Starter Button: Left Handlebar Switches . Dimmer Switch: .. Turn Signal Switch: Horn Button: Hazard Swite! Brake/Clutch Lever Adjusters. Fuel Tank Cap. Fuel Tank . Stand.. Seat Lock........ Helmet Hook .... 7 Tool Kit/Storage Compartments Tying Hooks BREAK-IN.. HOW TO RIDE THE MOTORCYCLE : Starting the Engine .. Jump Starting Moving Off ..sccr Shifting Gears .. Braking. Stopping the Engine... Stopping the Motoroycle in an Emergency . 43 43 44 45 | 46 50 51 53 55, 56 S7 59 59 62 65 66 68 69 70Parking... 71 Idle Speed... 115 Catalytic Converter... 72 Clutch “i . 16 SAFE OPERATION... és 73 Drive Chain ... 118 Safe Riding Technique 73 Brakes... 125 Daily Safety Checks. 75 Brake Light Switches. 129 Additional Considerations for High Front Fork. 130 Speed Operation .... Rear Shock Absorbers. 131 MAINTENANCE AND ADJUSTMENT 79 Wheels 134 Periodic Maintenance Chatt.... 84, Battery 3 “ 139 Engine Oil Headlight Beam... 144 Cooling System Fuses 145 Spark Plugs... General Lubrication 148 Evaporative Emission Control Cleaning Your Motorcycle 149 154. . 156 159 . 160 . 162 163 System (California model only’ Kawasaki Clean Air System Valve Clearance Air Cleaner... Bolt and Nut Tightening STORAGE TROUBLESHOOTING GUID! Owner Satisfaction. Throttle Control System Reporting Safety Defects. Choke Lever. ENVIRONMENTAL PROTECTION. Engine Vacuum Synchronization ..... 114 MAINTENANCE RECORD8 SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Dry Weight ENGINE Type Displacement Bore * Stroke Compression Ratio Starting System Cylinder Numbering Method Firing Order Carburetion System SPECIFICATIONS 2.080 mm (81.89 in.) 780 mm (30.7 in.) 1180 mm (46.46 in.) 1.425 mm (66.1 in.) 165 mm (6.5 in.) 199 kg (439 Ib) DOHC, 16-valve, 4-cylinder, 4-stroke, liquid-cooled 748 mL (45.6 cu in.) 68.4 * 60.9 mm (2.7 x 2.00 in.) 13:4 Electric starter Left to right, 1-2-3-4 1-2-4-3 Fi (Fuel Injection System)Ignition System Ignition Timing (Electronically advanced) Spark Plugs Lubrication System Engine Oil Type: Capacity : Coolant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Gear Ratio ist 2nd SPECIFICATIONS 9 Battery and coil (transistorized ignition) 40° BTDC @1 100 r/min (1pm) ~ 37° BTDC @S 800 r/min (rpm) NGK CR9EK or ND U27ETR Forced lubrication (wet sump) API SE, SF or SG ‘API SH or SJ with JASO MA SAE 10W-40 3.8 L (4.0 US qt) 2.9 L (3.1 US qt) 6-speed, retum shift Wet, multi disc Chain drive 41.714 (84/49) 2.867 (43/18) 5.382 (Top gear) 2.571 (36/14) 4.941 (83/17)10 SPECIFICATIONS 3rd 4th Sth 6th FRAME Castor Trail Tire Size: Front Rear Rim Size: Front Rear Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight LED Tail/Brake Light 4.855 (28/18) 1.333 (28/21) 4.200 (24/20) 1.095 (23/21) 25° 407 mm (4.21 in.) 120/70ZR17 M/C (58 W) Tubeless 180/55ZR17 M/C (73 W) Tubeless 17 x 3.50 17 * 5.50 18 L (4.8 US gal) 12V8Ah 12. V 55 W x 2/55 W (Hi/Lo) 12. V 0.5/4.1 W Even if one of LED (Light Emitting Diode) is not lit, consult with an authorized Kawasaki dealer. Specifications subject to change without notice.SERIAL NUMBER LOCATIONS 11 SERIAL NUMBER LOCATIONS 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 investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identity it. Frame No. Engine No. ootaaea_¢ o0I0188 A. Frame Number A. Engine Number12 LOCATION OF PARTS LOCATION OF PARTS TOO 6 4. Clutch Lever 5. Right Handlebar Switches 2, Left Handlebar Switches 6. Front Brake Lever 3. Meter Instruments 7. Throttle Grip 4. Brake Fluid Reservoir (Front) 8. Ignition Switch/Steering LockLOCATION OF PARTS 13 ypoess8 6 9. Wheel 10. Headlight 41. Turn Signal Light 12. Spark Plugs 13. Air Cleaner 44, Coolant Reserve Tank 5. Battery 16. Seat 417. Helmet Hooks 18, Tool Kit/Storage Compartments 49. Tying Hooks 20. Seat Lock 21. Front Fork 22, Brake Disc 23. Brake Caliper 24; Idle Adjusting Screw 25. Side Stand 26. Shift Pedal 27. Drive Chain414 LOCATION OF PARTS Ton.sie 6 28. Tail/Brake Light 29. License Plate Light 30. Brake Fluid Reservoir 34, Main Fuse 32, Fuel Tank 33. Fuel Tank Cap 34, Muffler 35. Rear Brake Light Switch 36. Rear Shock Absorber 37. Rebound Damping Force Adjuster 38. Rear Brake Pedal 39. Oil Level GaugeLOCATION OF LABELS LOCATION OF LABELS 15 ecnneoa 6 reas 4. Break-In Caution *2, Fuel Level 3. Brake Fluid (Front) 4, Brake Fluid (Rear) *: only on California model16 LOCATION OF LABELS Teo2i8as Te 6 5. Daily Safety Checks *6. Vacuum Hose Routing Diagram Oil Filter ion Control Information 9. Noise Emission Control Information 410. Weight and Manufacture *: only on California modelTe2Is78 reo2000822 0 LOCATION OF LABELS 17 41. Tire and Load Data 42. Important Drive Chain Information 43, Battery Poison/Danger48 LOCATION OF LABELS (1) a BREAK-IN CAUTION To. ensure proper vehicle performance, do not exceed the Drealcin limits chown on this tachometer 0500 mie e002 4,000 mm | '500-1,000 mite | foot 800 ton 26.000 mom (2) only on California model CAUTION Never fil tank so fuel level fees into filler neck. If tank is overilled, heat may cause fuel to exoand and flow Into Evaporative Emission Control ‘System resulting in hard starting and engine nestaton, TE05006B TEDSI068 § (3) USE ONLY DOT4 BRAKE FLUID FROM A SEALED CONTAINER. GLEAN FILLER GAP BEFORE REMOVING. —WARNING- ACUTILISER QUE DU FLUIDE DE FREIN DOT4 eosiocsns ¢LOCATION OF LABELS 19 (4) TeomONB S20 LOCATION OF LABELS (5) Handlebar not loose: Clutch lever play: correct, releases: properly. no sl innage Headlight works: Turn signals vork— Kawasaki DAILY SAFETY CHECKS Rear view mirror adjustment Brake lever play correct, fluid uo to upper level Line, No leakage Steering turns freely but has ‘no play Horn vorks No abnorna engine noise No coolant leakages coolant level betve evel lines Engine oil level correct Fuel in tank Throttle grip olay tail erate tight works ‘No abnormal fatust tee 1 signals vi ERE A God cana tien vith proper slack. oil if necessary Tires in good condi tion, veer within service limit, air pressure correct Brake pedal olay correct, ‘Tluid up to upper Level line, no leakage “eocassa §(6) only on California model 3 3 3 VAGUUN HOSE ROUTING DIAGRAW oweer 10 22 ae SH roMt4G wave Foe TaN Inaeeron a TWROTTLE CLEANER neen PURGE) ste kevurw Pox’ ‘CAVISTER, Teoaisian7 © LOCATION OF LABELS 2122 LOCATION OF LABELS (7) ENGINE O/L AND OIL FILTER Engine Gi! Change--mhen filter is not renoved: 3.1 liters(3.3 U8 qt) uhen filter is renoved 4.3 liters (3.5 05 at) Engine Gil Type: APL SE,SF or 80 MPL SW oor Sd vith JASO MA SAE 101-40 See Ovner's Manual for engine oil / filter information and change intervals. Teeats2aus ©LOCATION OF LABELS 23 (8) VEHICLE EWISS1ON CONTROL INFORMATION ENGINE FAWILY CODE WODEL (8) -----~ EXHAUST EMISSION CONTROL SYSTEM DISPLACEMENT TUNE UP_SPEGIFIGATIONS TOHITION TWINS [10 BrOc AT 1100 RPT VOLE SPEED 1100 £ 50 RPM IN NEUTRAL TOLE ATR FUEL [WO ADJUSTMENT WIXTURE SeTTing VALVE CLEARANCE | INTAKE = 0. 15-0.24 WN (0. 0059-0. 0084 IM (ENGINE COLD) | EXHAUST : 0, 22-0.31 WM (0, 0087-0, 0122 IN, SPARK PLUG GROEK (HGK) SPARK PLUG GAP : 0.7-0.0 IM U27ETR (DENSO) (0. 028-0.032 IN) FUEL GASOLINE WITH RESEARCH OOTANE HO. (RON) 91 WIM. ENGINE O1L SERVICE RATING = APT SE. SF OR SG APL SHOR Sd WITH JASO MA VISCOSITY : SAE 108-40 SEE THE OWWER’ § MANUAL FOR ENGINE OIL INFORMATION. THIS VEHICLE CONFORUS TO USEPA REGULATIONS ne APPLICABLE TO bts WODEL YEAR NEW MOTORCYCLES KAWASAKI HEAVY INDUSTRIES, LTD. Tevs20s678 ¢24 LOCATION OF LABELS (8) only on California model VEHICLE EWISS( CH CONTROL INFOREAT OH EXHAUST EMISS(ON CONTROL SYSTER DISPLACEMENT ~ TUNE UP SPECIFICATIONS TemITrON TATKG [10 BVOC AT 1100 BP THLE SPEED Tie 4 50 RPE IW NEVTEAL [PRLe ATR. Enero sovosrienr VALVE OLEACANCE [INTIME = 0. 18-0.24 WT (0.008-0.009 TH) (ENGINE COLE) | EXHAUST; 0.22-0.91 WN (0,008-0.012 10) TURK PLU GREK (WGK) SPARK PLUG GAP. 0.1-0.8 1 UPTETR (DENSE) (w.078-0. 032 1H) FUEL GASLINE LTH RESEARCH OCTANE NO. (BON) 91 41M, TRETNE OTT FEVIGE RATING “APT St, SF OF SE APL SH'OR SJ VITH ASO A WISOSITY < SAE 10R-40 SEE THE OWUER" S NAMUAL FOR ENSINE OL LAFORWATION, HTS VENTOLE CHATORNS. TY USEPA AD TALIFORT REGULATIONS APPLICABLE To DOXXK]NODEL YEAR LER voToRorcLes AND 1S. CERTIFIED 10. 1- 28/40 M0 EN6IRE FAMILY EXHAUST E-E EMISS10W STANDARD GAL FORNIA EAUASLL HEAVY CHOUSTRLES, LTD Teoazoasz9(9) WoTOReVeLe NOISE EWISEION toaTROL IKE TIS XK12 MOTOREYCLE MEETS EFA YO/SE Euissiow REOUIAENENTS BY THE FEDELAL TEST PROCEDITE. NODIFIGATIONS WHICH CAUSE THIS KoTOREYCLE To EXGEED FEDERAL KOISE STLEOAADS ALE PROHIBITED EY FEOERIL LAW. SEE ONNER'S MANGAL HODEL SPECIFIC SODE:xXHXKILI22% SEE TENIGLE IDENTIFICATION NONBER CH STEERING READ HOUSE LIWIT/CLOS ING RPM: L2SUX/XKKKIIX Teosaesane ¢ (11) The stat at ang etc tire nate, ame to Ue Cit eaace Me Lie vith lle nate tee, LOCATION OF LABELS 25 ro, ay KIWASINY HEAVT INDUSTRIES, LUD Wis YEW) CLE cOvFOR ALL APPLICAOLE FEDERUL HITOR YENLULE FETT SUMMOAEDS 1M EFFECT AN THE DATE AUUPADTURE SHOTY ABIVE.SVaR 126 LE ne 6 7s. WM ora ace (ae) nt si br Ht TIRE, J171/08053.50 RIL, AT 96 FSI. COLD AMR 2°56) UBS. ATE 1S6/552R1 74/0 738)” TIRE, UITIOxEyS.50-RIM, AT 42 FSI, COLD, wage ea TEosaazans ¢ uotor veut tis fs anocrele etldMcoewisafe Theat ae the Unde Nir Mita Me ibn prcste sec Tic wresurtCol___[ Sgt Wao Toe utes Tie) Tiina Tear oT gy oll gD 1 mn(0, 041) tod ye re ex 1 ATT EL LAWALL] Teoas786 826 LOCATION OF LABELS (12) ( INPORTANT DRIVE CHAIN INFORMATION Te prevent te the the drive chain nail be properly auleteined. tl Tubricstad avery 500 adjusted as often as necessary to Keep ehain elack st about 25~A5ea(1.0~1.6in] neasa Between sprockets on the lover chain run ith the sotereycle on the side stand. The standard chain is as Eruna ECS20NVAL th estinated 5 ite of 15400~4500040(0400~28000ni), depending on the severity of ese Sad the frequency cf lubrication and adjustment, For safety replace the chzin with enly the etandare chain any tine it wears to over 323a0(12.Tin), measared over a 20-Lix ul led etraight vith M4N(Q0isf 201H) of tension. See the reeszeopne ©LOCATION OF LABELS 27 (13) A '@ = a | S=—_ | FLUSH EYES VWeS ' & | (“== | IMMEDIATELY SHIELD! ' SULFURIC | WITH WATER EYES | NO !ACID GET EXPLOSIVE 'e SPARKS. | CAN CAUSE MEDICAL GASES CaN Cause |! * FLAMES ' BLINDNESS OR BLINDNESS OR INJURY: e SMOKING | SEVERE BURNS. (a OMe as enh emne sa) INU.S.A., YUASA INC. By, QOGAGA 3 Te091 15828 LOADING INFORMATION A WARNING Incorrect loading, improper in- stallation or use of accessories, or modification of your motorcy- cle may result in an unsafe rid- Before you ride ing condition. the motorcycle, make sure that the motorcycle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. In some cases, improper installation or use of accessories, or motorcycle modification, will void the motorcycle LOADING INFORMATION warranty. In selecting and using acces- sories, 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 components. Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in the fitting of additional accessories.The following general guidelines have been prepared to assist you in making your determinations. 4. Any passenger should be thor- oughly familiar with motorcycle op- eration. The passenger can affect control of the motorcycle by im- proper positioning during cornering and sudden movements. It is impor- tant that the passenger sit still while the motorcycle is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motorcycle. 2. You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator, seat strap or grab rail. Do not carry a passenger unless he or she is tall enough to reach the footpegs and footpegs are provided. LOADING INFORMATION 29 3. All baggage should be carried as low as possible to reduce the effect on the motorcycle center of gravity. Baggage weight should also be dis- tributed equally on both sides of the motorcycle. Avoid carrying baggage that extends beyond the rear of the motorcycle. 4. Baggage should be securely at- tached. Make sure that the baggage will not move around while you are riding. Recheck baggage security as often as possible (not while the motorcycle is in motion) and adjust as necessary. 5. Do not carry heavy or bulky items on a luggage rack. They are designed for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces.30 LOADING INFORMATION 6. Do not install accessories or carry baggage that impairs the perfor- mance of the motorcycle. Make sure that you have not adversely affected any lighting components, road clearance, banking capability (ie., lean angle), control operation, wheel travel, front fork movement, or any other aspect of the motorcy- cle’s operation. 7. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can re- sult in an unsafe riding condition. 8. Fairings, windshields, backrests, and other large items have the ca- pability of adversely affecting stabil- ity and handling of the motorcycle, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly designed or installed items can re- sult 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. Kawaseki does not manu- facture sidecars or trailers for mo- torcycles and cannot predict the ef- fects of such accessories on han- dling or stability, but can only warn that the effects can be adverse and that Kawasaki cannot assume re- sponsibility for the results of such unintended use of the motorcycle. Furthermore, any adverse effects on motorcycle components caused by the use of such accessories will not be remedied uncer warranty. Maximum Load Weight of rider, passenger, baggage, and accessories must not exceed 180 kg (397 Ib).GENERAL INFORMATION 34 GENERAL INFORMATION Meter Instruments A. Speedometer B. Left Turn Signal indicator Light ©. Tachometer D. Red Zone E. Right Turn Signal Indicator Light F. High Beam Indicator Light G. Neutral Indicator Light H. Oil Pressure Warning Light 1. RESET Button J. Fl Indicator Light (LED) K. Fuel Level Gauge L. MODE Button M. Coolant Temperature Warning Light (LED) N. LCD Display (Clock, Trip Meter AJB, Odomoter) yao2002827 632 GENERAL INFORMATION i Speedometer and Tachometer: The speedometer shows the speed of the vehicle. The tachometer shows the engine speed in revolutions per minute (r/min, rpm). On the right side of the tachome- ter face is a portion called the “red zone”. Engine r/min (rpm) in the red zone is above maximum recom- mended engine speed and is also above the range for good performance. When the ignition key is turned to “ON’, the speedometer and tachome- ter needles momentarily point to their last readings to check their opera- tion. If the speedometer and tachome- ter needles do not operate correctly, have them inspected by an authorized Kawasaki dealer. CAUTION Engine r/min (rpm) should not be allowed to enter the red zone; operation in the red zone will overstress the engine and may cause serious engine damage. LCD Display (Clock, Odometer, Trip Meters): The speedometer face contains the LCD (Liquid Crystal Display). Push- ing the “MODE” button, shifts the dis- play through the following four modes-: in the order of Clock, Odometer, Trip Meter A/B. When the ignition key is turned to "ON’, all the LCD segments are displayed for three seconds, then the clock or meters depending on the mode selected, will operate normally on the mode selected.GENERAL INFORMATION 33 QO ® wheat @l>[G) >) |g om ~L © od. ¢ USF ED score * leek e Push the “RESET” button. The E eter i C. Trip meter A hour display only flashes. Push D. Trip meter B E. Push MODE Button NOTE OFor safe operation do not press the "MODE" Button while riding. Clock = To adjust the hours and minutes: e Turn the ignition key to “ON”. e Push the “MODE” button to display the clock. Push the “RESET” button for more than two seconds. Both the hour and minute displays start flashing. the “MODE” button to advance the hours. “1 §2F vue Teoz02ss71 6 @ Push the “RESET” button. The hour display stops flashing and the minute display starts flashing. Push the “MODE” button to advance the min- utes.34 GENERAL INFORMATION ale “ted oat e Push the “RESET” button. Both the hour and minute displays start flash- ing again. e Push the “MODE” button. The dis- plays stop flashing and the clock starts working. NOTE Pushing the “MODE” button momen- tarily advances the hour or minute step by step. Pushing and hold- ing the button advance the hour or minute continuously. OThe clock works normally from the back-up power while the ignition switch is turned off. rao2020021 9 OWhen the battery is disconnected, the clock resets to 1:00 and starts working again when the battery is connected. Odometer - The odometer shows the total dis- tance in kilometers or miles that the ve- hicle has been ridden. This meter can- not be reset. 8156 NOTE ©The data is maintained even if the battery is disconnected OWhen the figures come to 999999, they are stopped and locked. reosesenzt oTrip Meters - The trip meters show the distance in kilometers traveled since they were last reset to zero. TRIP A: 0.0 - 999.9 TRIP B: 0.0 - 9999.9 To reset a trip meter: 4. Push the MODE button to display trip meter A or B. 2. Push the RESET button and hold it in. 3. After two seconds, the figure display turns to 0.0, and then starts counting when the vehicle is operated. The meter counts until it is next reset. GENERAL INFORMATION 35 NOTE O The data is maintained by the back -up power if the ignition key is turned off. © When the trip meter is reset while the vehicle is stopped, it starts counting as soon as the vehicle starts moving. OWhen the figures come to 999.9 (TRIP A) or 9999.9 (TRIP B) while the vehicle is running, they turn back to 0.0 and start counting again. OWhen the battery is disconnected, the meter display resets to 0.0.36 GENERAL INFORMATION TRIP A e5.3 t nr Ut Teozosaar4 ¢ Fuel Gauge: The fuel in the fuel tank is shown by the number of segments displayed. When the fuel tank is full, all the seg- ments are displayed. As the fuel level in the tank goes down, the segments disappear one by one from F (full) to E (empty). When only the most left seg- ment is displayed, 5.0 L (1.3 US gal) of fuel remain. Furthermore, when the left most segment of the fuel gauge and the fuel level warning symbol (7) flash in the LCD, only 4.0 L (1.1 US gal) of fuel remain. If this occurs, refuel at the ear- liest opportunity.reozo9sez2 ¢ A. Flash Warning/indicator Lights: N: When the transmission is in neutral, the neutral indicator light is lit. => : When the headlight is on high beam, the high beam indicator light is lit. GENERAL INFORMATION 37 @® : When the turn signal switch is pushed to the left or right, the cor- responding turn signal indicator light flashes. sea: The oil pressure warning light goes on whenever the oil pressure is dangerously low or the ignition key 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 chap- ter for more detailed engine oil informa- tion. Fl: The fuel injection (Fl) indicator light goes on when the ignition key is turned to “ON” and goes off soon after en- suring that its circuit functions properly. The indicator light also goes on when- ever the troubles occur in digital fuel injection system (DF). If the indicator light comes on, have the DF! system38 GENERAL INFORMATION Gi checked by an authorized Kawasaki CAUTION dealer, When the indicator light flashes, : : ea ty EA Do not let the engine continue first turn the ignition key to “OFF” and running when the warning light then baciste"OR's goes on. Prolonged engine op- eration will result in severe dam- a: The coolant temperature warn- age from overheating. ing light (LED) goes on whenever the coolant temperature rises to 115°C (239°F) when the motorcycle is in op- eration. When the coolant temperature tises to 120°C (248°F), the warning light starts flashing. This warns the operator that the coolant temperature is too high. If the warning light flashes, stop the engine and check the coolant level in the reserve tank after the en- gine cools down:Key This motorcycle has a combination key, which is used for the ignition switch/steering lock, seat lock, and fuel tank cap. 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, or using the key code on the tag with your keys. Record the code from the tag with your keys here. Participating Kawasaki dealers can use the code to make a new key in the event that your original keys are lost. Write your key number here. GENERAL INFORMATION 39 Ignition Key Key Number Teosouzs24 ©40 GENERAL INFORMATION Ignition Switch/Steering Lock This is a four-position, key-operated switch. The key can be removed from the switch when itis in the OFF, LOCK, or P (Park) position. Teoso07Bz2 ¢ A. Ignition Switch/Steering Lock B. ON position €. OFF position D. LOCK position E. P (Park) position OFF [Engine off. All electrical circuits off. Engine on. All electrical ON equipment can be used. Steering locked. Engine off. LOCK | | Ail electrical circuits off. Steering locked. Engine off. Tail light, city light and P (Park) | license plate light on and tum signals can be used. All other electrical circuits cut off. NOTE O The city, tail, and license plate lights are on whenever the ignition key is in the ON position. One headlight goes on when the starter button is released after starting the engine. To avoid battery discharge, always start the engine immediately after turning the ignition key to “ON”Olf you leave the P (Park) position on for a long time (one hour), the battery may become totally discharged. Jo operate the ignition Switch: orf <——> on > Pier) 1. Turn the handlebar fully te the eft. 2. alFor parking puch down the key in the OM position and turn it to P(Park) Lock b.Fer locking push down the key in the OFF position and ture it te Lock. oosnoreze & GENERAL INFORMATION 41 Right Handlebar Switches Engine Stop Switch: In addition to the ignition switch, the engine stop switch must be in the © position for the motorcycle to operate. The engine stop switch is for emer- gency use. If some emergency re- quires stopping the engine, move the engine stop switch to the * position NOTE OAlthough the engine stop switch stops the engine, it does not turn off all the elecirical circuits. Ordinarily, the ignition switch should be used to stop the engine.42. GENERAL INFORMATION ToONZ1B 6 A. Engine Stop Switch B. Starter Button Starter Button: The starter button operates the elec- tric starter when the transmission is in neutral. Refer to the Starting the Engine sec- tion of the “How to Ride the Motorcycle” chapter for starting instructions. Left Handlebar Switches Dimmer Switch: High or low beam can be selected with the dimmer switch. When the headlight is on high beam ( =D ), the high beam indicator light is lit. High beam.......( #0) Low beam......( © ) NOTE When the headlight is on high beam, both head lights are lit. When the headlight is on low beam, only one headlight is lit.———— © © Teale 6 A. Dimmer Switch B. Turn Signal Switch C. Horn Button D. Hazard Switch Turn Signal Switch: When the turn signal switch is turned to the left( @ ) or right ( ), the corresponding turn signals flash on and off. To stop flashing, push the switch in. GENERAL INFORMATION 43 Horn Button: When the horn button is pushed, the horn sounds. Hazard Switch: If an emergency requires you to park on the highway shoulder, turn on the hazard lights to warn other drivers of your location. Push in the hazard switch with the ignition switch in the ON or P (Park) position. Alll the turn signals and turn signal indicator lights will flash on and off. CAUTION If you leave the switch on for a long time, the battery may be- come totally discharged. So be careful not to use the hazard lights for more than 30 minutes.44 GENERAL INFORMATION Brake/Clutch Lever Adjusters There is an adjuster on both the brake and clutch levers. Each adjuster has 5 positions so that the released lever position can be adjusted to suit the operator's hands. Push the lever forward and turn the adjuster to align the number with the arrow mark on the lever holder. The distance from the grip to the released lever is minimum at Number 5 and maximum at Number 1 61000586 A. Adjuster B. MarkFuel Tank Cap To open the fuel tank cap, pull up the key hole cover. Insert the ignition key into the fuel tank cap 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 to the left to the original position. NOTE ©The fuel tank cap cannot be closed without the key inserted, and the key cannot be removed unless the cap is locked properly. ©Do not push on the key to close the cap, or the cap cannot be locked. GENERAL INFORMATION 45 vao0ee 6 A. Key Hole Cover B. Ignition Key C. Fuel Tank Cap46 GENERAL INFORMATION Fuel Tank The following octane rating gasoline is recommended in the fuel tank. Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. Fercozaz2 © A Tank Cap B. Fuol Tank C. Top Level D. Filler Neck A. WARNING Gasoline is extremely flammable and can be explosive under cer- tain conditions. Turn the igni- tion key to “OFF”, Do not smoke. Make sure the area is well ven- tilated and free from any source of flame or sparks; this includes any appliance with a pilot light. 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 overflow through the vents in the tank cap. After refueling, make sure the fuel tank cap is closed securely. If 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 System resulting in hard start- ing and engine hesitation. Fuel Requirement: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 87 The Antiknock Index is posted on ser- vice station pumps. The octane rating GENERAL INFORMATION 47 of a gasoline is a measure of its resis- tance to detonation or “knocking.” The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON) as shown in the table. 5 Minimum Octane Rating Method Rating Antiknock (RON + MON) ———_| 7 Index 2 Research Octane Number a (RON)48 GENERAL INFORMATION CAUTION If engine “knocking” or “ping- ing” occurs, use a different brand of gasoline of a higher octane rating. If this condition is allowed to continue it can lead to severe engine damage. Gasoline quality is important. Fuels of low quality or not meet- ing standard industry specifi- cations may result in unsatis- factory performance. Operating problems that result from the use of poor quality or nonrecom- mended fuel may not be covered under your warranty. Fuels Containing Oxygenates Gasoline frequently contains oxy- genates (alcohols and ethers) espe- cially in areas of the U.S. and Canada which are required to sell such refor- mulated fuels as part of a strategy to reduce exhaust emissions. The types and volume of fuel oxy- genates approved for use in unleaded gasoline by the U.S. Environmental Protection Agency include a broad range of alcohols and ethers, but only two components have seen any signif- icant level of commercial use. Gasoline/Alcohol Blends - Gasoline containing up to 10% ethanol (alco- hol produced from agricultural products such as corn), also known as “gasohol” is approved for use.GENERAL INFORMATION 49 CAUTION CAUTION Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever possible, and never use “gasohol” contain- ing more than 5% methanol. Fuel system damage and perfor- mance problems may result. Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up to 15% MTBE. NOTE Other oxygenates approved for use in unleaded gasoline include TAME (up to 16.7%) and ETBE (up to 17.2%). Fuel containing these oxy- genates can also be used in your Kawasaki. Never use gasoline with an oc- tane rating lower than the mini- mum specified by Kawasaki. Never use “gasohol” with more than 10% ethanol, or more than 5% methanol. Gasoline con- taining methanol must also be blended with solvents and cor- Certain ingredients of gasoline may cause paint fading or dam- age. Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling. When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA-BIL) with the gasoline in the fuel tank. Fuel stabilizer additives inhibit oxidation of the fuel which mini- mizes gummy deposits.50 GENERAL INFORMATION CAUTION Never store this product with “gasohol” in the fuel system. Before storage it is recom- mended that you drain all fuel from the fuel system. See the Storage section in this manual. Stand The motorcycle is equipped with a side stand. revo ¢ A, Side Stand NOTE OWhen using the side stand, turn the handlebar to the left.Whenever the side stand is used, make it a practice to kick the stand fully up before sitting on the motorcycle. NOTE OThe motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine does not start if the transmission is in gear and the side stand is down. GENERAL INFORMATION 51 Seat Lock Seat Removal Insert the ignition key into the seat lock, located under the rear cowling. Turn the key clockwise while pulling on the rear end of the seat. NOTE Olf there is difficulty removing the seat, be sure to insert the key all the way, and to push down strongly on the rear end of the seat while turning the key clockwise.52 GENERAL INFORMATION Tare 6 A. Seat B. Seat Lock C. Ignition Key D. Insert Seat Installation Place the tabs into the matching slot and receptacles. A. Seat B. Slot C. Tab D. Respectable E. Hook F. Lock e Insert the hook at the rear of the seat into the lock on the frame. Push down the rear part of the seat until the lock clicks. e Pull up the rear end of the seat to make sure they are securely locked.@ If there is difficulty removing the ig- nition key from the seat lock, turn it lightly counterclockwise while pulling it out. GENERAL INFORMATION 53 Helmet Hook A helmet can be secured to the mo- torcycle using the helmet hook. The helmet hook can be unlocked by insert- ing the ignition switch key into the lock and turning it clockwise. To lock the helmet hook, insert the open end of the hook into the socket. y NOTGNINes Do not ride the motorcycle with a helmet attached to the hook/ca- ble. The helmet could cause an accident by distracting the op- erator or interfering with normal vehicle operation.54 GENERAL INFORMATION we21013e 6 we2ionse 6 A. Helmet Hook A. Helmet-Holding Cable B. Lock c. Key A helmet can be secured to the mo- torcycle using the helmet-holding ca- ble located under the seat.Tool Kit/Storage Compartments The tool kit/storage compartments are located under the seat. Store the tool kit in the compart- ment provided at the front. The kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual. Use the main compartment to keep the owner's manual, any papers or documents that should be kept with the motorcycle. GENERAL INFORMATION 55 15190105 6 A. Main Compartment: B. Tool Kit56 GENERAL INFORMATION | Tying Hooks ‘When tying up light loads to the seat, use the tying hooks located on the left and right sides of the rear fairing. rego A. Tying HookBREAK-IN 57 BREAK-IN 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. e The table shows maximum recommended engine speed during the break-in pe- riod. Distance traveled Maximum engine speed (0 ~ 800 km (0 ~ 500 mi) 4 000 r/min (rpm) ‘800 ~ 1 600 km (00 ~ 1 000 mi) 6 000 r/min (rpm) e 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.58 BREAKIN A WARNING New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. During break-in, avoid sudden and maximum braking and acceleration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner have the initial maintenance service performed by a competent mechanic following the procedures in the Service Manual.Starting the Engine © Check that the engine stop switch is in the © position. e Turn the ignition key to “ON”. e Make sure the transmission is in neu- tral HOW TO RIDE THE MOTORCYCLE 59 HOW TO RIDE THE MOTORCYCLE A. Engine Stop Switch B. Starter Button C. Neutral Indicator Light D. Ignition Switch E. ON position NOTE OThe motorcycle is equipped with a vehicle-down sensor, which causes the engine to stop automatically and60 HOW TO RIDE THE MOTORCYCLE the Fi indicator light to flash when the ] motorcycle falls down. After righting the motorcycle, first turn the ignition key fo “OFF” and then back to “ON” before starting the engine. © If the engine is cold, pull the choke lever alll the way, NOTE OWhen the engine is already warm or on hot days [35°C (95°F) or more], * Choke Lever close the throttle completely anddo — e Leaving the throttle completely not use the choke for starting the en- closed, push the starter button. gine. 11020228 6CAUTION Do not operate the starter con- tinuously for more than 5 sec- onds, or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the bat- tery power recover. NOTE ©The motorcycle is equipped with a starter lockout switch. This switch is designed so that the engine does not start if the transmission is in gear and the side stand is down. However, the engine can be started if the clutch lever is pulled and the side stand is fully up. HOW TO RIDE THE MOTORCYCLE 61 iozors6 6 A. Clutch Lever B. Starter Lockout Switch e Gradually return the choke lever back a little at a time as necessary to keep the engine speed below 2 500 r/min (rpm) during warm-up. e@ When the engine is warmed up enough to idle without using the62 HOWTO RIDE THE MOTORCYCLE choke, return the choke lever all the ] way back. NOTE O/f you drive the motorcycle before the engine is warmed up, return the choke lever all the way back as soon as you start moving. CAUTION Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. Jump Starting If your motorcycle battery is “run 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A WARNING Battery acid generates hydro- gen gas which is flammable and explosive under certain con- ditions. It is present within a 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 battery. In the event of battery acid contact with skin, eyes, or clothing, wash the affected ar- eas immediately with water for at least five minutes. Seek medical attention. Connecting Jumper Cables @ Remove the seat. e Make sure the ignition key is turned to OFF. HOW TO RIDE THE MOTORCYCLE 63 e Connect a jumper cable from the positive (+) terminal of the booster battery to the positive (+) terminal of the motorcycle battery. T0s0168_ 6 A. Motorcycle Battery Positive (+) Terminal B. From Booster Battery Positive (+) Terminal C. Footpeg D. From Booster Battery Negative (-) Terminal e Connect another jumper cable from the negative (-) terminal of the64 HOW TO RIDE THE MOTORCYCLE booster battery to your motorcy- cle footpeg or other unpainted metal surface. Do not use the negative (-) terminal of the battery. A WARNING Do not make this last connec- tion at the fuel system or battery. Take care that you do not touch the positive and negative 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 con- necting positive (+) to negative (-) or a battery explosion and serious damage to the electrical system may occur. @ Follow the standard engine starting procedure. CAUTION Do not operate the starter con- tinuously for more than 5 sec- onds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the bat- tery power recover. After the engine has started, discon- nect the jumper cables. Disconnect the negative (-) cable from the mo- torcycle first. @ Reinstall the parts removed.Moving Off @ Check that the side stand is up. Pull in the clutch lever. @ Shift into 1st gear. e 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 en- gine just enough fuel to keep it from IS g rey. A. Shift Pedal cl HOW TO RIDE THE MOTORCYCLE 65 NOTE OThe motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine does not start if the transmission is in gear and the side stand is down. OWhen the headlight is on high beam, two headlight beams are lit, and on low beam, the one side of the head- lights is lit.66 HOW TO RIDE THE MOTORCYCLE Shifting Gears Close the throttle while pulling in the clutch lever. @ Shift into the next higher or lower gear. For smooth riding, each gear position should cover the proper rate of speed shown in the table. PNAS) When shifting down to a lower gear, do not shift at such a high speed that the engine r/min (rpm) jumps excessively. Not only can this cause engine dam- age, but the rear wheel may skid and cause an accident. Down- shifting should be done below 5 000 r/min (rpm) for each gear. © Open the throttle part way, while re- leasing the clutch lever. NOTE © The transmission is equipped with a positive neutral finder. When the mo- torcycle is standing still, the transmis- sion cannot be shifted past neutral from 1st gear. 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 neuiral.HOW TO RIDE THE MOTORCYCLE 67 Vehicle speed when shifting Shifting up kmih (mph) Shifting down km/h (mph) ist > 2nd 45 (9) 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 15 (9) 5th — 6th 55 (34) 2nd — ist 15 (9)68 HOW TO RIDE THE MOTORCYCLE Braking © Close the throttle completely, leav- ing 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. e When stopping, always apply both brakes at the same time. Normally the front brake should be applied a lit- tle more than the rear. Shift down or fully disengage the clutch as neces- sary to keep the engine from stalling. @ Never lock the brakes, or it will cause the tires to skid. When turning a cor- ner, itis better not to brake at all. Re- duce your speed before you get into the corner. e For emergency braking, disregard downshifting, and concentrate on applying the brakes as hard as pos- sible without skidding. Tiosoxes 6 A. Front Brake LeverCAUTION In order to protect the emission control parts, do not turn off the ignition switch when the motor- cycle is in motion. Fios0188 6 A, Rear Brake Pedal HOW TO RIDE THE MOTORCYCLE 69 Stopping the Engine @ Close the throttle completely. Shift the transmission into neutral. @ Turn the ignition key to “OFF”. e Support the motorcycle on a firm, level surface with the side stand. e Lock the steering. NOTE OThe motorcycle is equipped with a vehicle-down sensor, which causes the engine to stop automatically and the fuel injection indicator light to flash when the motorcycle falls down. After righting the motorcycle, first turn the ignition key to “OFF” and then back to “ON” before starting the engine.70 HOW TO RIDE THE MOTORCYCLE Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to pro- vide you optimum safety and conve- nience. However, in order to fully ben- efit 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 maintenance can create a dangerous situation known as throt- tle failure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust to enter the throttle body and stick the throttle open 2. During removal of the air cleaner, dirt is allowed to enter and jam the fuel injection system. In an emergency situation such as throttle failure, your vehicle may be stopped by applying the brakes and disengaging the clutch. Once this stopping procedure is initiated, the en- gine stop switch may be used to stop the engine. If the engine stop switch is used, turn off the ignition switch after stopping the motorcycle.Parking © Shift the transmission into neutral and turn the ignition key to “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 motorcy- cle may fall over. e If parking inside a garage or other structure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this includes any appliance with a pilot light. HOW TO RIDE THE MOTORCYCLE 71 7 AAS Gasoline is extremely flammable and can be explosive under cer- tain conditions. e@ Lock the steering to help prevent theft. NOTE OWhen stopping near traffic at night, you can leave the taillight on for greater visibility by turning the igni- tion key to the P (park) position. ODo not leave the ignition switch at P position too long, or the battery will discharge.72 HOW TO RIDE THE MOTORCYCLE Catalytic Converter This motorcycle is equipped with a catalytic converter in the exhaust system. Platinum and radium in the converter react with harmful carbon monoxide and hydrocarbons to con- vert them into harmless carbon dioxide and water resulting in much cleaner exhaust gases to be discharged into the atmosphere. For proper operation of the catalytic converter, the following cautions must be observed. @ This model's muffler and exhaust gas are hotter than usual because of the chemical reaction that takes place in the catalytic converter. Although the muffler is made of double tubing to reduce heat transfer the temperature on the muffler surface is very hot. @ Use only unleaded gasoline. Never use leaded gasoline. Leaded gaso- line significantly reduces the capabil- ity of the catalytic converter. © Do not coast the vehicle with the igni- tion switch and/or engine stop switch off. Do not attempt to start the en- gine by rolling the vehicle if the bat- tery is discharged. Do not operate the vehicle with the engine or any one cylinder misfiring. Under these conditions unburned air/fuel mixture flowing out of engine excessively ac- celerates reaction in the converter al- lowing the converter to overheat and become damaged when the engine is hot, or reduces converter perfor- mance when the engine is cold.Safe Riding Technique SAFE OPERATION 73 SAFE OPERATION The points given below are applicable for everyday motorcycle use and should be carefully 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 over- loading 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74 SAFE OPERATION the throttle. Use the front and rear brakes for auxiliary braking. On rainy days, rely more on the throttle to control vehicle speed and less on the front and rear brakes. The throttle should also be used ju- diciously to avoid skidding the rear wheel from too rapid acceleration or deceleration. Riding at the proper rate of speed and avoiding unnecessarily fast ac- celeration are important not only for safety and low fuel consumption but also for long vehicle life and quieter operation. When riding in wet conditions or on loose roadway surfaces, the abil- ity to maneuver will be reduced. All of your actions should be smooth under these conditions. Sudden ac- celeration, braking or turning may cause loss of control. On rough roads, exercise caution, slow down, and grip the fuel tank with the knees for better stability. When quick acceleration is neces- sary as in passing, shift to a 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.SAFE OPERATION 75 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 Adjustment chapter or see your dealer for the action required to return the motor- cycle ta a safe operating condition. WANTS) Failure to perform these checks every day before you ride may result in serious damage or a severe accident. Fuel .. Adequate supply in tank, no leaks. il level between level lines. Tires .. Air pressure (when cold): Front [UP t© 180 kg (397 Ib) | 250 kPa (2.50 kg/em?, 36 vat Load psi) Rear [UP 10 180 kg (997 tb) | 290 kPa (2.90 kglem?, 42 Load psi) Install the air valve cap. .. Slack 25 ~ 35 mm (1.0 ~ 1.4 in.) Drive chain ...76 SAFE OPERATION Nuts, bolts, fasteners .. Check that steering and suspension components, axles, and all controls are properly tightened or fastened. Steering ........ . Action smooth but not loose from lock to lock. No binding of control cables. Brakes ..... . Brake pad wear: Lining thickness more than 1 mm (0.04 in.) left. No brake fluid leakage. Throtile grip play 2 ~ 3 mm (0.08 ~ 0.12 in.). Clutch lever play 2 ~ 3 mm (0.08 ~ 0.12in.). Clutch lever operates smoothly. . No coolant leakage Coolant level between level lines (when engine is cold). Electrical equipment ... All lights and horn work. Engine stop switch ...... Stops engine Side stand ........ . Returns to its fully up position by spring tension. Returns spring not weak or not damaged. Throttle Clutch Coolant .... Refer to the “Daily Safety Checks” caution label attached to the bottom of the seat.SAFE OPERATION 77 Additional Considerations for High Speed Operation Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and func- tioning properly. Steering: Looseness in the steering can cause loss of 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, inflate them to the proper pressure, and check the wheel balance. Fuel: Have sufficient fuel for the high fuel consumption during high speed oper- ation. Engine Oil: To avoid engine seizure and resulting loss of control, make sure that 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 sure that the headlight, tail/brake light, turn signals, horn, etc., all work properly. Miscellaneous: Make sure that all nuts and bolts are tight and that all safety related parts are in good condition.78 SAFE OPERATION Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills.MAINTENANCE AND ADJUSTMENT 79 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.80 MAINTENANCE AND ADJUSTMENT EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicle sold in California 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 chamber, where they are burned along with the fuel and air supplied by the fuel injection system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The exhaust system of this model mo- torcycle includes a catalytic converter system.MAINTENANCE AND ADJUSTMENT 81 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, orstored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. High Altitude Performance Adjustment Information High Altitude adjustment is not required. MAINTENANCE AND WARRANTY Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels. This Owner’s Manual contains those maintenance rec- ommendations for your motorcycle. Those items identified by the Periodic Mainte- nance Chart are necessary to ensure compliance with the applicable standards. ‘As the owner of this motorcycle, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. The Kawasaki Limited Emission Control System Warranty requires that you re- turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty. Please read the warranty carefully, and keep it valid by complying with the owner's obligations it contains.82 MAINTENANCE AND ADJUSTMENT You should keep a maintenance record for your motorcycle. To assist you in keeping this record, we have provided space on pages 164 through 170 of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, bills, etc., as verification of this maintenance.MAINTENANCE AND ADJUSTMENT 83 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, re- pair, or replacement, 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 after such device or element of design has been removed or rendered 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 compliance with Federal regulations. Removal of the muffler(s) or any internal 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.84 MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart 4. Periodic Inspection (Engine Related Items) Frequency | Whichever See comes, *Odometer Reading first => km * 1000 ( mile x 1000) | °@9° . 4 6 12 18 24 30 36 Operation (Engine Item) Every | vo.gy | (ay | (7-5) | (12) | (15) | (20) | 24) Air cleaner element - clean ° e | 108 ) Valve clearance - inspect (e) ° 108 Throttle control system (play, smooth return, no year| @ ° e e | 110 drag) - inspect (e) Choke operation - inspect | year | © e ° ° | 13 Engine vacuum synchronization - inspect (2) Idle speed - inspect (e) ° ° e ° | 115MAINTENANCE AND ADJUSTMENT 85 Frequency | Whichever comes Odometer Reading noe 7 > km x 1000 ( mile x 1000) | "29 : 1] 6 | 12] 18 | 24 | 30 | 36 Operation (Engine Items) every | oe) | cay | crs) | 12 | (18) | 20 | ea) Fuel teak (fuel hose and | year | e ° el - pipe) - inspect Fuel hoses damage - - Rae year | © ° ° ° Fuel hoses installation - K condition - inspect ea) ° ° ° Coolant level - inspect ° ° ° e | 102 Coolant leak - inspect year | © ° ° e | 104 Radietor hose damage- | vear | @ x ‘ «| 99 inspect Radiator hoses installation | year |e ° ° a ee condition - inspect86 MAINTENANCE AND ADJUSTMENT Frequency | Whichever See cone *Odometer Reading a »> km x 1000 ( mile x 1000) | P29 4 | 6 | 12 | 18 | 24 | 30] 36 Operation (Engine Items) Every | io.ey | ce) | 7-3) | (12) | (18) | (20) | (24) Air suction system damage ° ° | 407 - inspect (e) Evaporative emission control system - function e|e]e]| ee} e | e | 106 (California mode! only) (e)MAINTENANCE AND ADJUSTMENT 87 2. Periodic Inspection (Chassis Related Items) Frequency | Whichover comes “Odometer Reading | °° ; »> km x 1000 ( mile x 1000) | °#9° Operation (Chassis tems) | ever | ey | Gy fey | ae | aay | eo) lea (0.6) | (4) | (7-5) | (42) | (15) | (20) | (24) Clutch and drive train: Clutch operation (play, engagement, ° ° ° © | 116 disengagement) - inspect Drive chain lubrication Condition - inspect # every 600 km (400 mile) 124 Drive chain slack - inspect # every 1 000 km (600 mile) 118 Drive chain wear - inspect # e e © | 122 Drive chain guide wear - ‘* ° el - inspect Wheels and tires: Tire air pressure - inspect | year e ° e | 13588 MAINTENANCE AND ADJUSTMENT Frequency | Whichovor See ia *Odometer Reading . »> fem » 1000 mile = 1000) | P29 1 | 6 | 12 | 18 | 24] 30 | 36 Operation (Chassis Items) every | oe | a |r| a2 | ca) | eo) | ea) Wheels/tires damage - peels ° ° © | 136 Tire tread wear, abnormal 7. ‘ ele wear - inspect Wheel bearings damage - | yagp ° ° «| - inspect Brake system: Brake fluid leak-inspect | year] e | e | © | e | © | o | o | 126 Brake hoses damage - inspect yer| e | e | e]e|e|e| eo | 126 Brake pad wear - inspect # elele|e|e| ois Brake hose installation condition - inspect year | 2 * ° ? ° 2 e | eeMAINTENANCE AND ADJUSTMENT 89 Frequency | Whichever See comes “Odometer Reading v > km x 1000 ( mile x 1000) | P29 . 41 6 12 18 24 30 36 Operation (Chassis items) | Evory | (a ey | (ay | (7-5) | (42) | (48) | (20) | (24) Brake fluid level inspect | em @ | @ | © | @ | © | e | © | 126 Brake operation (effectiveness, play, drag)- | year | @ e e e e e e | 128 inspect Brake light switch operation e e e e e e © | 129 = inspect Suspensions: Front forks/rear shock absorber operation * ‘ we fees (damping and smooth stroke) - inspect Front forks/rear shock i ° absorber oil leak - inspect | “7 * @ | rs0n3190 MAINTENANCE AND ADJUSTMENT Frequency | Whichever comes *Odometer Reading Eau y »> km x 1000 { mile x 1000) | P49 7 | 6 | 12] 18 | 24 | 30 | 36 Operation (Chassis Items) ever | aoe) | cay | 7s) | (12) | (05) | (20) | 24) Uni-trak rocker arm ° ° el - ‘operation - inspect Unitrak tie rods operation - ° ° ol. inspect Steering System: KSteoring play - inspect year] © ° ° ° Steering stem bearings - 2 ° _ lubricate years Electrical System: Lights and switches year ° ; ol - operation - inspect Headlight aiming - inspect. | year ° ° © | 144MAINTENANCE AND ADJUSTMENT 94 Frequency | Whichever See eomes: *Ocometer Reading 7 > km % 4000 { mile x 1000) | P#9° t 6 12 18 24 30 36 Operation (Chassis Items) eve | coe) | cay | es)| c1ay | (45) | (20) | (24) Side stand switch operation _ - inspect year e e a Engine stop switch operation | year ° ° ol - - inspect Chassis: KChassis parts - lubricate | year ° ° el Bolts and nuts tightness - inspect ° ° ° 2 ‘15492 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency| Whichever comes first *Odometer Reading > km x 1000 { mile x 1000)| gee Page ChangeiReptacement Item every | ia a aa ay ay oi Air cleaner element # (2) ° 108 Engine oil # year ° e |] e}|e|e | Oil filter year e e e e ° 96 K Fuel hoses 4 year e | - K Coolant 3 years e 104 K Radiator hoses and O-rings 3 years e = KBrake hoses 4 years eo | - K Brake fluid (front and rear) 2 years e e | 128 Soe of master cylinder 4 years m7 _ Spark plug (2) e |e |e | © | to4MAINTENANCE AND ADJUSTMENT 93 K: Should be serviced by an authorized Kawasaki dealer. ## Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent staring/stopping. *: For higher odometer readings, repeat at the frequency interval established here. (e): Emission Related Item94 MAINTENANCE AND ADJUSTMENT Engine Oil In order for the engine, transmission, and clutch to function properly, main- tain the engine oil at the proper level, and change the oil and replace the 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. A WARNING Motorcycle operation with insuf- ficient, deteriorated, or contami- nated engine oil will cause accel- erated wear and may result in en- gine or transmission seizure, ac- cident, and injury. Oil Level Inspection @ If the oil has just been changed, start the engine and run it for several min- utes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil set- tles. CAUTION Racing the engine before the oil reaches every part can cause en- gine seizure. @ If 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 motor- cycle held level, the oil level should come up between the upper and lower level lines next to the gauge.® © ke = SHY & —o OS e pop Oil Level Gauge Upper Level Line Lower Level Line Oil Filler Cap If the oil level is too high, remove the excess oil through the oil filler open- ing using a syringe or some other suitable device. 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. MAINTENANCE AND ADJUSTMENT 95 CAUTION 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 will light. If this light stays on when the en- gine speed is above 1 300 r/min (rpm), stop the engine immedi- ately and find the cause. A. Oil Pressure Warning Light96 MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change e Warm up the engine thoroughly, and then stop it. e Place an oil pan beneath the engine. @ Remove the engine oil drain plug. —_ M4 Teea0298_6 A. Drain Plug eLet the oil completely drain with the motorcycle perpendicular to the ground. Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. e Remove the oil filter cartridge and re- place it with a new one. NOTE Olf a torque wrench or required Kawasaki special tool is not avail- able, this item should be serviced by a Kawasaki dealer.MAINTENANCE AND ADJUSTMENT 97 Ho10308 6 owas A. Cartridge A. Packing e Apply a thin film of oil to the packing e Install the drain plug with a new gas- and tighten the cartridge to the spec- ket. Tighten it to the specified torque. ified torque. NOTE OReplace any gaskets with new ones. Fill the engine up to the upper level line with a good quality engine oil specified in the table. @ Start the engine. © Check the oil level and oil leakage.98 MAINTENANCE AND ADJUSTMENT Tightening Torque Engine Oil Drain Plug : 29 N-m (3.0 kgfm, 21 ft-lb) Cartridge : 34 N-m (3.2 kgfm, 23 ft-lb) Although 10W-40 engine oil is the recommended oil for most condi- tions, the oil viscosity may need to be changed to accommodate atmo- spheric conditions in your riding area. [when filter is removed] 3.8 L (4.0 US gt) [when engine is completely ary] Recommended Engine Oil SHE “70-50 Type: API SE, SF or SG SAE 20-40 API SH or SJ with JASO MA SKE TOW-50 Viscosity: SAE 10W-40 SAE TON-20) Engine Oil Capacity SAE to 30 Capacity: 3.1 L (3.3 US qt) bow [when filler is not removed] The 3.3 L (3.5 US qt) Teoacessze ¢Cooling System Radiator and Cooling Fan - Check the radiator fins for obstruc- tion by insects or mud. Clean off any obstructions with a stream of low-pressure water. A WARNING The cooling fan turns on auto- matically, even with the ignition switch off. Keep your hands and clothing away from the fan blades at all times. MAINTENANCE AND ADJUSTMENT 99 CAUTION Using high-pressure water, as from a car wash facility, could damage the radiator fins and im- pair the radiator’s effectiveness. Do not obstruct or deflect air- flow through the radiator by installing unauthorized acces- sories in front of the radiator or behind the cooling fan. Inter- ference with the radiator airflow can lead to overheating and con- sequent engine damage. Radiator Hoses - Check the radiator hoses for leakage, cracks or deterioration, and connec- tions for leakage, or looseness each day before riding the motorcycle, and in accordance with the Periodic Main- tenance Chart.100 MAINTENANCE AND ADJUSTMENT Coolant - Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level be- comes low, the engine overheats and may suffer severe damage. Check the coolant level each day before riding the motorcycle, and in accordance with the periodic maintenance chart, 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 (con- sisting of the aluminum engine and radiator) from rust and corrosion, the use of corrosion 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 ac- cumulates rust and scale in the water jacket and radiator. This will clog up the coolant passages, and consider- ably reduce the efficiency of the cooling system. A WARNING Use coolant containing corro- sion inhibitors made specifically for aluminum engines and ra- diators in accordance with the instructions of the manufacturer. Chemicals are harmful to the hu- man body. Soft or distilled water must be used with the antifreeze (see below for an- tifreeze) in the cooling system.MAINTENANCE AND ADJUSTMENT 101 CAUTION CAUTION If hard water is used in the sys- tem, it causes scale accumula- tion in the water passages, and considerably reduces the effi- ciency 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 sys- tem 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 cor- rosion and rust inhibitor chemicals for aluminum engines and radiators) in the cooling system. On the mixture ratio of coolant, choose the suitable one re- ferring to the relation between freezing point and strength directed on the con- tainer. Permanent types of antifreeze on the market have anti-corrosion and anti-rust properties. When it is diluted excessively, it loses its anti-corrosion property. Dilute a permanent type of antifreeze in accordance with the instructions of the manufacturer, NOTE OA permanent type of antifreeze is in- stalled in the cooling system when shipped. It is colored green and con- tains ethylene glycol. It is mixed at 50% and has the freezing point of -35°C (-31°F).102 MAINTENANCE AND ADJUSTMENT Coolant Level Inspection e Situate the motorcycle so that it is perpendicular to the ground. e Check the coolant level through the coolant level inspection window on the left side cover. Kooi 6 A. Left Side Cover B. Inspection Window © The coolant level should be between the F (Full) and L (Low) level lines. NOTE OCheck the level when the engine is cold (room or atmospheric tempera- ture). THOME 6 A. F (Full) Level Line B. L (Low) Level Line C. Left Side Cover If the amount of coolant is insuffi- cient, remove the left side cover and add coolant into the reserve tank.MAINTENANCE AND ADJUSTMENT 104 CAUTION CAUTION If hard water is used in the sys- tem, it causes scale accumula- tion in the water passages, and considerably reduces the effi- ciency 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 sys- tem 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 cor- rosion and rust inhibitor chemicals for aluminum engines and radiators) in the cooling system. On the mixture ratio of coolant, choose the suitable one re- ferting to the relation between freezing point and strength directed on the con- tainer. Permanent types of antifreeze on the market have anti-corrosion and anti-rust properties. When it is diluted excessively, it loses its anti-corrosion property. Dilute a permanent type of antifreeze in accordance with the instructions of the manufacturer. NOTE OA permanent type of antifreeze is in- stalled in the cooling system when shipped. It is colored green and con- tains ethylene glycol. It is mixed at 50% and has the freezing point of -35°C (-31°F).102 MAINTENANCE AND ADJUSTMENT Coolant Level Inspection e Situate the motorcycle so that it is perpendicular to the ground. @ Check the coolant level through the coolant level inspection window on | the left side cover. A. Left Side Cover B. Inspection Window The coolant level should be between the F (Full) and L (Low) level lines. NOTE OCheck the level when the engine is cold (room or atmospheric tempera- ture). ® TxONONEB A.F (Full) Level Line B. L (Low) Level Line C. Left Side Cover © lf the amount of coolant is insuffi- cient, remove the left side cover and add coolant into the reserve tank.Coolant Filling e Remove the left side cover by remov- ing the bolt. eH 6 A. Left Side Cover B. Bolt e Remove the cap from the reserve tank and add coolant through the filler opening to the F (Full) level line. MAINTENANCE AND ADJUSTMENT 103 To . A. Reserve Tank B. F (Full) Level Line C.L (Low) Level Line D. Gap e Install the cap and the parts re- moved, NOTE Oln an emergency you can add wa- ter alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition404 MAINTENANCE AND ADJUSTMENT of antifreeze concentrate as soon as possible. CAUTION 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 by your authorized Kawasaki dealer. Coolant Change Have the coolant changed by an au- thorized Kawasaki dealer. 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 NGK CRSEK or Plug ND U27ETR 07 0.8mm Plug Gap (0.028 ~ 0.032 in.) Tightening 73 Nem Torque (4.3 kfm, 10 feb)Txos01822 © MAINTENANCE AND ADJUSTMENT 105 Hotter Spark Plug NGK CR8EK or ND U24ETR A, Plug Gap CAUTION For cold weather and/or low speed riding, a hotter spark plug shown in the table may be used for quicker warm-ups and more efficient engine operation. How- ever, for normal temperatures and/or high speed use, the stan- dard spark plug must be used to prevent engine damage.4106 MAINTENANCE AND ADJUSTMENT 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 ad- justments are required, a thorough vi- sual inspection must be made at the in- tervals specified by the Periodic Main- tenance Chart. Inspection @ Check that the hoses are securely connected. @ Replace any kinked, deteriorated, or damaged hoses. x 2 3 VACUUM HOSE ROUTING DIASRAW AIR surronins FUEL TAM, vue rwuecroe Te were LEAR rerun Pour couneor 10 52 teen ceunae) CANISTER wire Te0a1 51007 ©Kawasaki Clean Air System The Kawasaki Clean Air System (KCA) is a secondary air suction sys- tem that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the ex- haust system, it is still hot enough to burn. 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 unburned gases, as well as changing a significant portion of the poisonous carbon monoxide into harmless 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 MAINTENANCE AND ADJUSTMENT 107 exhaust port. Any air that has passed the air suction valve is prevented from returning. Inspect the air suction valves in accordance with the Periodic Main- tenance Chart. Also, inspect the air suction valves whenever stable idling cannot be obtained, engine power is greatly reduced, or there are abnormal engine noises. Air suction valve removal and inspec- tion should be done only by a compe- ‘tent mechanic following the instructions in the Service Manual108 MAINTENANCE AND ADJUSTMENT Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. CAUTION If valve clearance is left un- adjusted, wear will eventually cause the valves to remain partly open, which lowers per- formance, burns the valves and valve seats, and may cause seri- ous engine damage. Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Mainte- nance Chart. Inspection and adjustment should be done only by a competent mechanic following the instructions in the Service Manual. Air Cleaner Aclogged air cleaner restricts the en- gine’s air intake, increasing fuel con- sumption, reducing engine power, and causing spark plug fouling The air cleaner element must be cleaned in accordance with the Pe- tiodic Maintenance Chart. In dusty, rainy, or muddy conditions, the air cleaner element should be serviced more frequently than the recom- mended interval by a competent me- chanic following the instructions in the Service Manual Oil Draining e Inspect the drain hose located on the rear side of the engine to see if any oil or water has run down from the air cleaner housing.MAINTENANCE AND ADJUSTMENT 109 NAVAN el Be sure fo install the plug in the drain hose after draining. Oil on tires will make them slippery and can cause an accident and in- jury. Te100268 6 A. Drain Hose B. Plug If there are any oil in the reservoir, remove the plug from the lower end of the drain hose and drain the oil.110 MAINTENANCE AND ADJUSTMENT Throttle Control System Check the throttle grip play, in accor- dance with the Periodic Maintenance Chart, and adjust the throttle grip play if necessary. Throttle Grip - The throttle grip controls the butterfly valves in the throttle body. If the throt- tle grip has excessive play due to ei- ther cable stretch or maladjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle valve 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. Inspection Check that there is the proper throt- tle grip play when lightly turning the throttle grip back and forth TWHa7B 8 A. Throttle Grip B. Throttle Grip Play Throttle Grip Play 2~3 mm (0.08 ~ 0.12 in.) @ If there is improper play, adjust it.Adjustment e Loosen the locknut near the throttle grip, and turn the cable adjuster un- til the proper throttle grip play is ob- tained. Tighten the locknut against the cable adjuster. TK110158_ 8 A, Locknut B. Adjuster C. Throttle Cable (Accelerator Cable) MAINTENANCE AND ADJUSTMENT 114 e If the throttle cables cannot be ad- justed with the cable adjuster at the throttle grip, use the cable adjusters located at the front of the fuel tank. e Loosen the locknut at the throttle grip and turn in the adjuster fully. © Tighten the locknut. e Loosen the locknuts above the en- gine, and screw both throttle cable adjusters in fully so as to give the throtile grip plenty of play. e Turn out the decelerator cable adjust- ing nut until there is no play when the throttle grip is completely closed. Tighten the locknut. e Turn out the decelerator cable ad- juster until 2 ~ 3 mm (0.08 ~ 0.12 in.) of throttle grip play is obtained. Tighten the locknut.412, MAINTENANCE AND ADJUSTMENT THIN005B 8 A. Adjusters B. Locknuts G. Decelerator Cable D. Accelerator Cable @ Check that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and com- pletely in all steering positions by the retum spring. If the throttle grip does not return properly, check the throttle cable routing, grip free play, and ca- ble damage. @ 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. A WARNING Operation with an improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe ri ing condition.Choke Lever When the choke lever is pulled, the fuel injection system provides a rich starting mixture that is necessary to en- able easy starting when the engine is cold. Check the choke lever operation and play in accordance with the Periodic Maintenance chart and adjust it if nec- essary. Inspection @ Check that the choke lever returns properly and that the inner cable slides smoothly. If there is any ir- regularity, have the choke cable checked only by a competent me- chanic following the instructions in the Service Manual. ® Push the choke lever back all the way. @ Determine the amount of choke ca- ble play at the choke lever. Pull the MAINTENANCE AND ADJUSTMENT 113 choke lever till just before the cam moves the link lever; the amount of choke lever travel is the amount of cable play. reo 6 A. Link Lever B. Cam e The choke lever play is measured at the bottom of the choke lever. If there is loo much or too little play, have the choke cable adjusted only by a414 MAINTENANCE AND ADJUSTMENT competent mechanic following the in- structions in the Service Manual. Check Lever Play 0 ~ 0.5 mm (0 ~ 0.02 in.) TK120178 6 A. Choke Lever B. Choke Lever Play Engine Vacuum Synchronization Engine vacuum — synchronization must be checked and adjusted period- ically in accordance with the Periodic Maintenance Chart by a competent mechanic following the instructions in the Service Manual. NOTE OPoor engine vacuum synchronization will cause unstable idling, sluggish throitle response, and reduce engine power and performance.Idle Speed The idle speed check should be per- formed in accordance with the Peri- odic Maintenance Chart or whenever the idle speed is disturbed. Adjustment e Start the engine, and warm it up thor- oughly. ® Adjust the idle speed by turing the idle adjusting screw. Idle Speed 1050 ~ 1 150 rmin (rpm) MAINTENANCE AND ADJUSTMENT 115 rei10see 6 A. Idle Adjusting Screw © Open and close the throttle a few times to make sure that the idle speed does not change. Readjust if necessary. © With the engine idling, turn the han- dlebar to each side. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or they may be damaged. Be sure to correct any of these conditions before riding.