2009 Kawasaki Kfx450r 2

GENERAL INFORMATION j
Quick Reference Guide

This Quick Reference Guide will assist you in BREAK-IN j
finding the information you’re looking for.
HOW TO RIDE j
SAFE OPERATION j
MAINTENANCE AND ADJUSTMENT j
STORAGE j
TROUBLESHOOTING GUIDE j
A Table of Contents is included after the

Foreword.
Whenever you see the symbols shown below, CAUTION
heed their instructions! Always follow safe operat-
HAZARD
ing and maintenance practices.
Failure to heed CAUTION.
DANGER WHAT CAN HAPPEN
HAZARD CAUTION indicates a hazardous situation
Failure to heed DANGER. which, if not avoided, could result in minor
or moderate injury.
WHAT CAN HAPPEN
DANGER indicates a hazardous situation HOW TO AVOID THE HAZARD
which, if not avoided, will result in death or Read all CAUTIONS in this manual carefully
serious injury. and for your safety be sure to follow their
instructions.
HOW TO AVOID THE DANGER
Read all DANGERS in this manual carefully
and for your safety be sure to follow their NOTICE
instructions. NOTICE is used to address practices not re-
lated to personal injury.
WARNING
HAZARD NOTE
Failure to heed WARNING. This symbol indicates points of particular interest
for more efficient and convenient operation.
WHAT CAN HAPPEN
WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
HOW TO AVOID THE HAZARD

Read all WARNINGS in this manual carefully
and for your safety be sure to follow their
instructions.
IMPORTANT
Off-road vehicle riding is a wonderful sport, and we
hope you will enjoy it to the fullest.
Read this manual carefully and completely before
starting your new Kawasaki. It contains important
safety information.
Never operate an ATV without proper instruction.
Take a training course. Beginners should receive
training from a certified instructor. Contact an au-
thorized ATV dealer or call 1-800-887-2887 to find
out about the training courses nearest you.
Never allow a child under the age of 16 years to
operate this ATV. Use of this ATV by children under
16 years of age can lead to severe injury or death
of the child. Even youths starting at age 16 may
not have the skills, abilities, or judgment needed to
operate this ATV safely.
Therefore youths starting at age 16 should have
adult supervision even after they attend a rider train-
ing course. And parents should never allow contin-
ued use of this ATV if the youth does not have the
abilities and maturity to operate it safely.
Failure to follow the warnings contained in this
manual can result in SERIOUS INJURY or DEATH.
To protect the future of your sport, make sure you
use your vehicle legally, show concern for the envi-
ronment, and respect the rights of other people.
If improperly conducted, the sport has the potential
to cause environmental problems as well as conflicts
with other people. Responsible use of your off-road
vehicle will ensure that these problems and conflicts
do not occur.
SAFE RIDING INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other
vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneu-
vers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures described.
The Owner’s Manual should be kept in the waterproof plastic bag and stored in the storage case provided.
Never operate an ATV without proper instruction. Take a training course. Beginners should receive training
from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the
training courses nearest you.
Never allow a child under age 16 to operate this ATV.
Never carry a passenger on an ATV.
Never operate an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.
Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also
wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV. Alcohol and drugs impair your judgment
and reaction time.
Before starting: put transmission in neutral and check the throttle control for proper operation.
Remember to apply the parking brake before getting off your ATV.
Never operate at excessive speeds. Always go at a speed that is proper for the terrain, visibility and operating
conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow
the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing
terrain conditions when operating the ATV.
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills
necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
Always follow proper procedures for turning as described in this manual. Practice turning at low speeds
before attempting to turn at faster speeds. Do not turn at excessive speed.
Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before
attempting larger hills.
Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully
before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight
forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill
at high speed.
Always follow proper procedures for going down hills and for braking on hills as described in this manual.
Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill
at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side.
Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with
excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn
the ATV around on any hill until you have mastered the turning technique described in this manual on level
ground. Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper
gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special
procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight
uphill. Turn the ATV around and remount, following the procedure described in this manual.
Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as de-
scribed in this manual.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low
speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very
cautious in order to reduce the chance of skidding or sliding out of control.
Never operate an ATV in fast flowing water or in water deeper than that specified in this manual. Remember
that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply
them several times to let friction dry out the linings.
Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe
to proceed in reverse, go slowly.
Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described
in this manual. Type of tire and inflation can affect vehicle handling.
A tire pressure gauge is provided in the tool kit container. Keep it with the vehicle at all times.
Never modify an ATV through improper installation or use of accessories. Installation of accessory items may
affect vehicle handling. Refer to the Loading Information chapter in this manual.
Preserve the environment, ride responsibly and always know and obey laws and regulations governing ATV
operation.
Refueling: Shut engine off and make sure the area is well ventilated and free from any source of flame or
sparks.
Use an antenna flag in hilly terrain and sand dune areas.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800
-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.
FOREWORD
Congratulations on your purchase of a new Kawasaki ATV. It is the result of Kawasaki’s engineering expertise
and a tradition of manufacturing high-quality recreational products.
Please read this Owner’s Manual carefully before starting your new ATV so that you will be thoroughly
familiar with the proper operation of your vehicle’s controls, its features, capabilities, and limitations. This man-
ual offers many safe riding tips, but its purpose is not to provide instruction in all the techniques and skills
required to ride an ATV safely. Kawasaki strongly recommends that all operators of this vehicle enroll in an
ATV rider training program to attain awareness of the mental and physical requirements necessary for safe
ATV operation.
To ensure a long, trouble-free life for your ATV, give it the proper care and maintenance described in this
manual. For those who would like more detailed information on their ATVs, a Service Manual is available for
purchase from any authorized Kawasaki ATV dealer. The Service Manual contains detailed 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 ATV at all times so that you can refer to it whenever you need infor-
mation. This manual should be considered a permanent part of the ATV and should remain with the ATV 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 illustrations and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.

Consumer Products & Machinery Company
© 2008 Kawasaki Heavy Industries, Ltd. Nov. 2008. (4) (D)

TABLE OF CONTENTS
SPECIFICATIONS............................................ 11 HOW TO RIDE ................................................. 45
SERIAL NUMBER LOCATIONS...................... 14 Daily Safety Checks ...................................... 45
LOCATION OF LABELS.................................. 15 Starting the Engine ........................................ 47
LOCATION OF PARTS .................................... 21 Moving Off ..................................................... 48
LOADING INFORMATION............................... 24 Shifting Gears................................................ 49
GENERAL INFORMATION.............................. 26 Braking .......................................................... 50
Indicator Lights .............................................. 26 Stopping the Engine ...................................... 51
Fuel Warning Light: .................................... 26 Parking the ATV............................................. 51
Reverse: ..................................................... 26 Stopping the ATV in an Emergency............... 52
Neutral:....................................................... 26 In case of Vehicle Overturn ........................... 53
Coolant Temperature Warning Light/FI SAFE OPERATION.......................................... 54
Warning Light: ......................................... 26 Read the Owner’s Manual............................. 54
Brake Lever and Pedal.................................. 27 Obey Local Laws ........................................... 54
Parking Brake................................................ 29 Adult Supervision .......................................... 55
Clutch Lever .................................................. 30 Beginning Riders ........................................... 56
Reverse Lock Release Lever ........................ 30 Off-Road Use Only ........................................ 57
Shift Pedal ..................................................... 32 Dress Properly............................................... 58
Fuel Tank ....................................................... 33 Operator Only................................................ 59
Filling the Tank: .......................................... 33 Ride Carefully and with Good Judgement ..... 60
Fuel Requirements: .................................... 34 Never Drink and Drive ................................... 61
Ignition Switch ............................................... 36 Keep Your Feet on the Footboards and
Left Handlebar Switches ............................... 37 Hands on the Handlebars........................... 62
Light/Dimmer Switch: ................................. 37 Before Starting the Engine ............................ 63
Engine Stop Switch: ................................... 37 Use the Parking Brake .................................. 63
Starter Button: ............................................ 38 Modifications and Accessories ...................... 64
Idle Adjusting/Choke Knob ............................ 39 Perform the Daily Safety Checks .................. 65
Throttle Lever ................................................ 39 Tire Air Pressure............................................ 66
Throttle Limiter .............................................. 40 Riding Terrain ................................................ 67
Seat ............................................................... 41 Riding in Reverse .......................................... 69
Storage Case & Tool Kit ................................ 43 Turning the Vehicle........................................ 70
BREAK-IN ........................................................ 44 Climbing Hills................................................. 72
Antenna Flag ................................................. 76 General Lubrication ....................................... 132
Traversing Hillsides ....................................... 76 Cleaning ........................................................ 133
Descending Hills............................................ 77 Bolt and Nut Tightening ................................. 134
Sliding and Skidding...................................... 79 STORAGE........................................................ 136
Riding in Water .............................................. 81 Preparation for Storage ................................. 136
MAINTENANCE AND ADJUSTMENT............. 83 Removal from Storage .................................. 138
EMISSION CONTROL INFORMATION ........ 83 TRANSPORTING THE ATV............................. 139
Periodic Maintenance Chart .......................... 86 TROUBLESHOOTING GUIDE......................... 140
Engine Oil...................................................... 89 OWNER SATISFACTION................................. 142
Cooling System ............................................. 93 ENVIRONMENTAL PROTECTION.................. 143
Radiator and Cooling Fan: ......................... 93 MAINTENANCE RECORD .............................. 144
Coolant: ...................................................... 94
Spark Plug..................................................... 96
Valve Clearance ............................................ 97
Air Cleaner .................................................... 98
Spark Arrester ............................................... 102
Throttle Cable ................................................ 105
Reverse Lock Release Cable ........................ 106
Clutch ............................................................ 107
Drive Chain.................................................... 109
Sprocket Cover.............................................. 113
Idle Adjustment.............................................. 114
Fuel Tank Vent............................................... 116
Brakes ........................................................... 116
Parking Brake ................................................ 120
Brake Light Switch......................................... 121
Wheels .......................................................... 122
Rims: .......................................................... 122
Tires: .......................................................... 122
Joint Boots..................................................... 124
Suspension.................................................... 125
Headlight Beam ............................................. 125
Battery ........................................................... 126
Fuse .............................................................. 130
SPECIFICATIONS 11
SPECIFICATIONS
PERFORMANCE
Maximum Torque 41.9 N·m (4.3 kgf·m, 31 ft·lb) @7 000 r/min (rpm)
Minimum Turning Radius 3.6 m (11.81 ft)
DIMENSIONS
Overall Length 1 806 mm (71.10 in.)
Overall Width 1 170 mm (46.06 in.)
Overall Height 1 064 mm (41.89 in.)
Wheelbase 1 255 mm (49.41 in.)
Tread: Front 972 mm (38.27 in.)
Rear 899 mm (35.39 in.)
Ground Clearance 108 mm (4.25 in.)
Curb Mass 178 kg (392 lb)
ENGINE
Type DOHC, single-cylinder, 4-stroke, liquid-cooled
Displacement 449 cm³ (27.4 cu in.)
Bore × Stroke 96.0 × 62.1 mm (3.78 × 2.44 in.)
Compression Ratio 12.0 : 1
Starting System Electric Starter
Carburetor FI (Keihin 42)
Ignition System Battery & Coil (transistorized ignition)
Ignition Timing (Electronically advanced) 10° (BTDC)/@1 800 r/min (rpm) ∼ 39.5° (BTDC)/@6
000 r/min (rpm)
Spark Plug NGK CPR8EB-9 or CPR9EB-9 (option)
12 SPECIFICATIONS
Lubrication System Forced lubrication (semi-dry sump)

Engine Oil: Type API SF or SG
API SH, SJ, SL, or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 1.35 L (1.43 US qt)
Coolant Capacity 1.4 L (1.48 US qt)
DRIVE TRAIN
Driving System: Chain 2WD
Transmission Type 5-speed return & reverse

Primary Reduction Ratio 2.952
Final Reduction Ratio 2.714
Overall Drive Ratio: Forward Top 8.395
Transmission Gear Ratio: Forward 1st 2.230
2nd 1.800
3rd 1.529
4th 1.278
5th 1.048
Reverse 2.364
Clutch Type: Wet Multi Disc
FRAME
Type Tubular, double cradle
Castor 1.8°
Trail 7.6 mm (0.30 in.)
SPECIFICATIONS 13
Tire Size: Front AT21 × 7-10

Rear AT20 × 10-9
Rim Size: Front 10 × 5.5

Rear 9×8
Brake: Front & Rear Disc (Hydraulic)
Parking Brake Disc (Mechanical)
Fuel Tank Capacity 10 L (2.6 US gal)
ELECTRICAL EQUIPMENT
Battery 12 V 6 Ah
Headlight 12 V 30 W × 2
Tail/Brake Light LED
Specifications subject to change without notice.

14 SERIAL NUMBER LOCATIONS
SERIAL NUMBER LOCATIONS

The frame and engine serial numbers are used to register the vehicle. 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 identify it.
Frame No. Engine No.
A. Frame Number A. Engine Number

B. Shift Pedal
LOCATION OF LABELS 15
LOCATION OF LABELS
All warning labels which are on your ATV are re-
peated here. Read them and understand them thor-
oughly. They contain information which is important
for your safety and the safety of anyone else who
may operate your ATV. Therefore, it is very impor-
tant that all warning labels be on your ATV in the lo-
cations shown. If any label is missing, damaged, or
worn, get a replacement from your Kawasaki dealer
and install it in the correct position.
NOTE
The sample warning labels in this section have
part numbers to help you and your dealer obtain
the correct replacement.
1. General Warning
2. Age Recommendation Warning
3. Tire Pressure & Max. Load Warning
4. Passenger Warning
5. Important Air Cleaner Information
6. Vehicle Emission Control Information
7. Chain Slack Notice
8. Shock Absorber Warning
12. Fuel Information
13. Overturn Notice
14. Important Information
15. Certification Label
16 LOCATION OF LABELS
8. Shock Absorber Warning 9. Specification Label

10. Radiator Cap Danger
11. Battery Danger/Poison
(1) (2)
(3)
(4) (6)
(5) (7)
(8) (10)
(9) (11)
(12) (14)
(13) (15)
LOCATION OF PARTS 21
LOCATION OF PARTS
1. Clutch Lever 7. Reverse Lock Release Lever

2. Parking Brake 8. Fuel Filler Cap
3. Indicator Lights 9. Starter Button
4. Front Brake Reservoir 10. Engine Stop Switch
5. Front Brake Lever 11. Light Switch
6. Throttle Lever
22 LOCATION OF PARTS
12. Radiator
13. Battery
14. Shift Pedal
15. Drive Chain
16. Air Cleaner Box
17. Fuse
18. Coolant Reserve Tank
19. Shock Absorber
LOCATION OF PARTS 23
20. Rear Brake Pedal

21. Spark Plug
22. Fuel Tank
23. Engine Oil Filler Port
24. Muffler
25. Brake Light Switch
24 LOADING INFORMATION
LOADING INFORMATION
Maximum Load WARNING
Weight of rider must not exceed HAZARD
114 kg (250 lb). Overloading this ATV.
WHAT CAN HAPPEN

WARNING Could cause changes in vehicle handling
HAZARD which could lead to an accident.
Operating this ATV with improper modifica-
tions. HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for
WHAT CAN HAPPEN this ATV.
Improper installation of accessories or mod-
ification of this vehicle may cause changes With the exception of genuine Kawasaki Parts and
in handling which could lead to an accident. Accessories, Kawasaki has no control over the de-
sign or application of accessories. In some cases,
HOW TO AVOID THE HAZARD improper installation or use of accessories, or vehi-
Never modify this ATV through improper in- cle modifications, will void the vehicle warranty. In
stallation or use of accessories. All parts and selecting and using accessories, and in loading the
accessories added to this vehicle should be vehicle, you are personally responsible for your own
genuine Kawasaki or equivalent components safety and the safety of other persons involved.
designed for use on this ATV and should be NOTE
installed and used according to instructions.
If you have questions, consult an authorized
Kawasaki Parts and Accessories have been spe-
cially designed for use on Kawasaki vehicles.
ATV dealer. We strongly recommend that all parts and ac-
cessories you add to your vehicle be genuine
Kawasaki components.
LOADING INFORMATION 25
Because an all terrain vehicle is sensitive to in-

creases in weight, changes in weight distribution,
and aerodynamic forces, you must take extreme
care in the fitting of accessories. The following
general guidelines have been prepared to help you
make your determinations.
• Do not install accessories that impairs the perfor-

mance of the vehicle. Make sure that you have
not adversely affected any lighting component,
ground clearance, brake or control operation,
wheel movement, or any other aspect of the vehi-
cle’s operation.
• Weight attached to the handlebar will increase the
mass of the steering assembly and can result in
an unsafe riding condition.
• Windshields, trunk boxes, and other large items
have the capability of adversely affecting stability
and handling of the vehicle, because of their
weight and the aerodynamic forces acting on
these surfaces while the vehicle is in operation.
Poorly designed or installed items can result in an
unsafe riding condition.
26 GENERAL INFORMATION
j
GENERAL INFORMATION
Fill the fuel as soon as possible because there is
Indicator Lights no reserve tank in this vehicle (see the Fuel Tank
section).
The indicator lights are mounted at the middle of
Reverse:
the handlebars.
When the transmission is in reverse gear, the re-
verse indicator light is lit.
Neutral:
When the transmission is in neutral, the neutral
indicator light is lit.
Coolant Temperature Warning Light/FI Warning
Light:
Engine Coolant Overheating
The coolant temperature warning light goes on
whenever the coolant temperature rises too high
while the vehicle is in operation. If it stays on, stop
the engine and check the following items after the
engine cools down.
A. Fuel Warning Light
B. Reverse Indicator Light • Radiator grill
C. Neutral Indicator Light • Coolant level and its quality
D. Coolant Temperature Warning Light/FI Warning
Light
• Cooling fan
Refer to the TROUBLESHOOTING chapter and
Cooling System section in the MAINTENANCE AND
Fuel Warning Light: ADJUSTMENT chapter for more details.
The fuel warning light goes on when the remaining
fuel in the tank has become 2 litters (0.5 US gal).
GENERAL INFORMATION 27
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NOTICE
Do not let the engine continue running with
Brake Lever and Pedal
a warning light on. Prolonged engine oper-
The lever on the right side of the handlebars oper-
ation can result in engine damage from over
ates the front brake.
-heating.
FI System Failure
This warning light also functions as FI warning
light. If the light still stays on after the trouble sources
for the cooling system are removed, there is a pos-
sibility of ECU malfunction or other reasons. See an
authorized Kawasaki dealer for services.
A. Brake Lever
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The foot pedal on the right side operates the rear WARNING
brake.
HAZARD
Stalling, rolling backwards or improperly dis-
mounting while climbing a hill.
WHAT CAN HAPPEN

Could result in ATV overturning.

Use low gearing and maintain steady speed
when climbing a hill.
If you lose all forward speed:
Keep weight uphill.
Apply the brakes.
Lock parking brake, after you are stopped.
If you begin rolling backwards:
A. Brake Pedal Keep weight uphill.
Never apply the rear brake while rolling back
wards.
Apply the front brake.
When fully stopped, apply rear brake as well,
and then lock parking brake.
Dismount on uphill side or to a side if pointed
straight uphill.
Turn the ATV around and remount, following
the procedure described in the Safe Opera-
tion chapter.
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Parking Brake
The rear brake is used as the parking brake.
When the parking brake lever is flipped to the
”PARK ON” position, the parking brake is on. To
release the parking brake, flip the lever to the “PARK
OFF” side.
A. “ON” Position
B. “OFF” Position
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Clutch Lever Reverse Lock Release Lever
The clutch lever on the left side of the handlebar This vehicle is equipped with a reverse gear.
disengages the clutch when pulled in. Always pull in The reverse lock release lever is mounted on the
the clutch lever before starting the engine. right side of the handlebars. You need to push this
If the clutch lever has too much free paly, it may not lever to shift into reverse gear.
properly disengage the clutch. Refer to the MAINTE-
NANCE AND ADJUSTMENT chapter for the clutch In order to shift into reverse, follow the procedure:
adjustment procedure. 1. Start the engine following the procedure in the
“Starting the Engine” section.
2. Make certain the vehicle is completely stopped,
the transmission is in neutral, and the engine is
idling.
3. Pull in the clutch lever and shift into the first
gear.
4. Push the reverse lock release lever and press
down the shift pedal into reverse gear.
5. Release the reverse lock release lever and shift
pedal.
6. The vehicle can now be operated in reverse.
To shift out of reverse, follow this procedure:

1. Stop the vehicle completely.
2. Pull in the clutch and lift the shift pedal up to the
A. Clutch Lever
first gear.
j
WARNING
HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN

You could hit an obstacle or person behind
you, resulting in serious injury or death.

When you select reverse gear, make sure
there are no obstacles or people behind you.
When it is safe to proceed, go slowly.
A. Reverse Lock Release Lever
WARNING
HAZARD
Shifting into 1st gear while moving in re-
verse.
WHAT CAN HAPPEN

Can cause the vehicle to stop suddenly and
go forward. This can lift the front wheels off
the ground and cause the operator to lose
control. Or the vehicle can tip over back-
wards causing an accident.

Never operate the shift pedal to change gears
while the vehicle is moving in reverse.
j
To shift to the next lower gear, disengage the
Shift Pedal clutch, press the shift pedal down as far as it will go,
engage the clutch gently, and then release the shift
The transmission is a 5-speed return shift type with pedal.
reverse. Neutral is located between first gear and Before shifting into reverse, engage 1st gear.
second gear as shown. Then with the clutch lever pulled, push the reverse
lock release lever and press down the shift pedal
into reverse gear. Release the reverse lock release
lever and shift pedal. Refer to the "Reverse Lock
Release Lever" section for detailed instructions.
If the engine is stopped, releasing the clutch lever
and rolling the vehicle slightly while shifting will help
shifting back to neutral.
WARNING
HAZARD
Shifting into the reverse gear from the first
gear and vice versa while moving.
WHAT CAN HAPPEN

A. Shift Pedal Shifting the gears while the vehicle is mov-
ing can cause abrupt changes in speed and
A "return shift" means to go back to first gear from direction resulting in loss of control and ac-
a higher gear, you must shift back through the gears cident with severe personal injury or death.
one by one. The same is true when upshifting: each
gear must be engaged before the next higher gear HOW TO AVOID THE HAZARD
may be selected. Do not shift the gears while the vehicle is
To engage first gear from neutral, pull in the clutch moving. Stop the vehicle to shift the trans-
lever and press down on the shift pedal, gently re- mission.
lease the clutch lever, then release the shift pedal.
To shift to the next higher gear, pull in the clutch
lever, lift the shift pedal with your toe, gently release
the clutch lever, and then release the shift pedal.
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WARNING
HAZARD
Fuel Tank
Inattentive operation in “R” (Reverse). Back-
ing up without looking where you are going. Filling the Tank:
Only use gasoline with the recommended octane
WHAT CAN HAPPEN rating (See next page.) Avoid filling the tank in the
Inattentive operation in “R” (Reverse) could rain or where heavy dust is blowing so that the fuel
cause you to hit a person or obstacle behind does not get contaminated.
you, resulting in severe personal injury or Never fill the tank completely to the top. As the
death. fuel expands in a warm tank, it may overflow from
the vent hose. After refueling, make sure the filler
HOW TO AVOID THE HAZARD cap is closed securely.
Before shifting into “R” (Reverse), make sure
there are no people or obstacles behind you,
and then proceed at a safe speed. Always
look where you are going, whether forward
or in reverse.
NOTICE
When changing gears, press firmly on the
shift pedal to ensure complete, positive shift-
ing. Careless, incomplete shifts can cause
the transmission to jump out of gear and lead
to engine damage.
A. Filler Cap
B. Vent Hose
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WARNING
HAZARD
Refueling without following proper precau-
tions.
WHAT CAN HAPPEN

Gasoline is extremely flammable and can be
explosive under certain conditions.
A fire or explosion can cause severe injury
or death.

When refueling, do not smoke. Turn the igni-
tion key to “OFF”. Make sure the area is well
A. Fuel Tank
B. Filler Neck
ventilated and free from any source of flame
C. Top Level or sparks; this includes any appliance with a
pilot light.
Never fill the tank completely to the top! Heat
may cause the fuel to expand and overflow
through the vent in the tank cap.
After refueling, make sure the fuel tank cap
is closed securely.
If gasoline is spilled on the rear fender wipe
it off immediately.
Fuel Requirements:
Fuel Type
Use clean, fresh unleaded gasoline with a mini-
mum Antiknock Index of 91. The Antiknock Index is
posted on service station pumps in the U.S.A. The
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octane rating of a gasoline is a measure of its re- Canada which are required to sell such reformu-
sistance to detonation or “Knocking.” The Antiknock lated fuels as part of a strategy to reduce exhaust
Index is an average of the Research Octane Num- emissions.
ber (RON) and the Motor Octane Number (MON) as The types and volume of fuel oxygenates ap-
shown in the table below. proved for use in unleaded gasoline by the U.S.
Minimum Environmental Protection Agency include a broad
Octane Rating Method range of alcohols and ethers, but only two compo-
Rating nents have seen any significant level of commercial
(RON + MON) use.
Antiknock Index 91 Gasoline/Alcohol Blends-Gasoline containing up
2
to 10% ethanol (alcohol produced from agricultural
products such as corn), also known as “gasohol” is
NOTICE approved for use.
If engine “knocking” or “pinging” occurs, NOTICE
use a different brand of gasoline of a higher
octane rating. If this condition is allowed to Avoid using blends of unleaded gasoline and
continue it can lead to severe engine dam- methanol (wood alcohol) whenever possible,
age. and never use “gasohol” containing more
Gasoline quality is important. Fuels of low than 5% methanol. Fuel system damage and
quality or not meeting standard industry performance problems may result.
specifications may result in unsatisfactory
performance. Operating problems that result Gasoline/Ether Blends– The most common ether
from the use of poor quality or nonrecom- is methyl tertiary butyl ether (MTBE). You may use
mended fuel may not be covered under your gasoline containing up to 15% MTBE.
warranty. NOTE
Other oxygenates approved for use in unleaded
Fuels Containing Oxygenates gasoline include TAME (up to 16.7%) and ETBE
Gasoline frequently contains oxygenates (alco- (up to 17.2%). Fuel containing these oxygenates
hols and ethers) especially in areas of the U.S. and can also be used in your Kawasaki.
j
NOTICE
Never use gasoline with an octane rat-
Ignition Switch
ing lower than the minimum specified by
The ignition switch is located on the right front
Kawasaki.
fender. It is a 2-position, key-operated switch. The
Never use “gasohol” with more than 10%
key can be removed only when in the “OFF” position.
ethanol, or more than 5% methanol. Gaso-
The lights, ignition, and electric starter will operate
line containing methanol must also be
only when the key is in the “ON” position. Remove
blended with cosolvents and corrosion
the key to prevent unauthorized vehicle use.
inhibitors.
Certain ingredients of gasoline may cause
paint fading or damage. 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 minimizes gummy deposits.
Never store this product with “gasohol” in
the fuel system. Before storage it is recom-
mended that you drain all fuel from the fuel
tank and carburetors. See the Storage sec-
tion in this manual.
A. Ignition Switch
B. “ON” position
C. “OFF” position
Blank keys are available at your Kawasaki dealer.
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
j
make a new key in the event that your original keys
are lost. Left Handlebar Switches
NOTE
Only blank keys are available. Light/Dimmer Switch:
The switch positions are identified on the housing.
Headlight and taillight come on by turning the switch
to “LO” (low beam) or “HI” (high beam) with the ig-
Write your key number here. nition key in the “ON” position. Select high or low
beam as necessary.
A. Key
B. Key Number A. Light/Dimmer Switch
C. Key Cap B. Starter Button
C. Engine Stop Switch
Engine Stop Switch:

In addition to the ignition switch, the engine stop
switch must be in the “RUN” position for the engine
to operate. If some emergency requires stopping
j
the engine, shift the engine stop switch to the “OFF” NOTE
position. For the electric starter to operate, the engine stop
Although the engine stop switch stops the engine, switch must be set to the “RUN” position, the ig-
it does not turn off all the electrical circuits. If the nition switch must be turned to the “ON” position,
engine stop switch is used, be sure to turn off the and the clutch must be pulled in, if the shift control
ignition switch after stopping the vehicle. is in a position other than “N” (neutral).
A. Engine Stop Button

B. “RUN” position
C. “OFF” position
Starter Button:
Refer to the “Starting the Engine” section of the
“How to Ride” chapter for starting instructions.
j
Idle Adjusting/Choke Knob Throttle Lever
This vehicle is equipped with an idle adjust- The throttle lever is located on the right side of the
ing/choke knob which operates as a choke knob in handlebars. Pushing the lever forward increases en-
addition to the idle adjuster. gine speed. When released, spring pressure returns
the lever to the rear. Always check that the throttle
lever returns normally before starting the engine. In
addition, there must be adequate throttle cable play.
Refer to the MAINTENANCE AND ADJUSTMENT
chapter for the throttle cable adjustment procedure.
A. Idle Adjusting/Choke Knob

B. Engine Cylinder (left side)
• When starting in cold condition, refer to the Start-

ing the Engine section of the HOW TO RIDE chap-
ter.
A. Throttle Lever
• For adjusting the engine idling speed, refer to the
MAINTENANCE AND ADJUSTMENT chapter.
B. Throttle Limitter
j
WARNING
Throttle Limiter HAZARD
Operating this ATV at excessive speeds.
The vehicle is equipped with a throttle limiter to
decrease maximum engine power for an unskilled
WHAT CAN HAPPEN
rider. The limiter functions by restricting the moving
Increases your chances of losing control of
distance of the throttle lever.
the ATV, which can result in an accident.
WARNING
HAZARD Always go at a speed that is proper for the
Operating this ATV without proper instruc- terrain, visibility and operating conditions,
tion. and your experience.
WHAT CAN HAPPEN Loosen the lockout and turn the screw in or out.
The risk of an accident is greatly increased if Turning in decreases the maximum engine power,
the operator does not know how to operate turning out increases the maximum engine power.
the ATV properly in different situations and
on different types of terrain.

Beginning and inexperienced operators
should complete a certified training course
offered by The ATV Safety Institute (ASI).
They should then regularly practice the
skills learned in the course and the oper-
ating techniques described in the Owner’s
Manual.
For more information about the training
course, contact an authorized ATV dealer or
call:
1-800-887-2887.
j
Seat
To remove the seat, push the latch lever located at
the left rear end of the vehicle and lift the seat up.
A. Locknut
B. Screw
C. Throttle Lever
NOTICE
If the throttle limiter is adjusted, verify the A. Latch Lever
changes in throttle in an open, non-traffic
area.
Never try to adjust the limiter by racing the
engine in neutral or in gear with brake on, or
the engine may be damaged.
j
To attach the seat, insert the front and center Make sure the rear projections of the seat enter
hooks of the seat into the front stopper and the into the dampers.
center slot and slide it all the way forward pushing
the seat end.
A. Seat
B. Rear Projections
A. Seat C. Dampers
B. Front Hook D. Latch Pin
C. Front Stopper
D. Center Hook
E. Center Slot
j
Push down on the rear of the seat to lock it.
Pull up the rear end of the seat to make sure it is Storage Case & Tool Kit
securely locked.
The storage case is located under the seat. Keep
this Owner’s Manual in the storage case. Here is
where you will find a tool kit.
The minor adjustments and replacement of parts
explained in this manual can be performed with the
tools in the kit.
A. Seat
B. Push.
A. Storage Case
B. Tool Kit
44 BREAK-IN
BREAK-IN
j The first 10 hours (100 km, 60 mi) of vehicle op-
eration is designated as the break-in period. Do not
exceed ½ throttle during break-in period. If the vehi-
cle is not used carefully during this period, you may
end up with a “broken down” instead of “broken in”
vehicle.
Break-in Period Maximum Throttle Position
First 10 hours
1/2 Throttle
(100 km, 60 mi)
NOTE
Do not start moving or race the engine immedi-
ately after starting it, even if the engine is already
warm.
Do not race the engine while the transmission is
in neutral.
It is important to perform the initial service after the
first 10 hours (100 km, 60 mi) of operation as de-
scribed in this manual and the service manual for
this vehicle. See the Periodic Maintenance Chart
in the MAINTENANCE AND ADJUSTMENT chap-
ter.
HOW TO RIDE 45
HOW TO RIDE
DANGER
Daily Safety Checks HAZARD
Running the engine without ventilation.
Check the following items each day before you j
ride. The time required is minimal, and habitual per- WHAT CAN HAPPEN
formance of these checks will help ensure you a Breathing exhaust gas leads to carbon
safe, reliable ride. monoxide poisoning, asphyxiation, and
If any irregularities are found during these checks, death. Exhaust gases contain carbon
refer to the MAINTENANCE AND ADJUSTMENT monoxide; a colorless, odorless, poisonous
chapter, see your dealer, or refer to the Service Man- gas.
ual for the action required to return the vehicle to a
safe operating condition. HOW TO AVOID THE HAZARD
Do not start or run the engine in a closed area
WARNING such as a garage.
HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN

Increases the possibility of an accident or
equipment damage.

Always inspect your ATV each time you use
it to make sure the ATV is in safe operating
condition.
Always follow the inspection and mainte-
nance procedures and schedules described
in the Owner’s Manual.
46 HOW TO RIDE
Fuel .................................................. Enough fuel in tank, no leaks.
Engine Oil ........................................ Oil level between “H” (High) and “L” (Low) lines, no leaks.
Coolant ............................................ Coolant level between level lines (when engine is cold), no leaks.
Tires ................................................. Air Pressure (when cold):
Front: 30 kPa (0.30 kgf/cm², 4.3 psi)
Rear: 27 kPa (0.27 kgf/cm², 3.6 psi)
j Check for cuts, cracks, damage, or excessive wear.
Check for any imbedded stones or other foreign particles in tread.
Drive Chain ...................................... Slack should be 40 ∼ 50 mm (1.57 ∼ 1.97 in.)
Lubricate chain.
Air Cleaner Element ........................ Check for dirt; clean or replace as required.
Nuts, Bolts, Fasteners ..................... Check that steering and suspension components, axles, and all controls
are properly fastened.
Steering ........................................... Action smooth but not loose from lock to lock.
Control cables must not bind.
Check for braking effectiveness (while test running).
Brakes ............................................. No brake fluid leakage.
Parking brake: Stops vehicle completely. Outer cable slack within 2 mm
(0.08 in.)
Throttle ............................................ Throttle lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).
Throttle lever snaps back to idle position when released.
Clutch .............................................. Clutch lever free play 5 ∼ 10 mm (0.2 ∼ 0.4 in.)
Clutch lever operates smoothly.
Reverse Lock Release Lever .......... Release lever free play 1 ∼ 2 mm (0.04 ∼ 0.08 in.)
Lights ............................................... Headlight and taillight/brake light work.
Engine Stop Switch ......................... Stops engine.
Protective Clothing .......................... The operator must wear a helmet and eye protection plus suitable pro-
tective clothing, such as boots, gloves, long trousers, and a long-sleeved
shirt or jacket.
HOW TO RIDE 47
has warmed, push the idle adjusting/choke knob

Starting the Engine back.
Idle Adjusting/Choke Knob

DANGER
HAZARD j
WHAT CAN HAPPEN

Breathing exhaust gas leads to carbon
monoxide poisoning, asphyxiation, and
death. Exhaust gases contain carbon
monoxide; a colorless, odorless, poisonous
gas.

such as a garage.
Pushed (closed) Pulled (open)
• Check that the engine stop switch is in the “RUN”
position.
condition condition
• Turn the ignition key to “ON”.

• Put thetheshiftparking
Apply brake. NOTE
• neutral indicator lighttheshould
lever in “N” (Neutral) position. The
be lit.
The engine has a protection mode that prevents
the engine from starting when the throttle is open.
NOTE Leave the throttle closed while starting.
If the clutch lever is pulled, it is possible to start in Do not leave the idle adjusting/choke knob pulled
longer than necessary, or it will cause poor fuel
any shift position. economy. When the engine is already warm or the
• When the engine is cold (same as outside temper-
ature), pull the idle adjusting/choke knob. Keep
weather is hot (35°C, 95°F or more) , do not use
the idle adjusting/choke knob. Leave the throttle
the throttle completely closed. When the engine closed.
48 HOW TO RIDE
• Push
starts.
the starter button. Repeat until the engine
Moving Off
NOTICE • Make sure the transmission is in neutral.
Do not operate the electric starter continu- • Releasethethefrontparking
Apply and rear brakes.
j ously for more than 5 seconds. The starter • With the clutch lever brake.
will overheat and the battery power will drop • shift pedal with your toe pulled in, press down on the
to engage 1st gear.
temporarily. Wait 15 seconds between each
operation of the starter to let it cool and the • Gently release the clutch lever while gradually in-
Release the brakes.
battery power recover. • creasing engine speed by pushing forward on the
Do not let the engine idle longer than five
minutes or engine overheating and damage throttle lever as the clutch engages.
may occur. NOTE
Practice starting and stopping (using the brakes)
until you are familiar with the controls.
HOW TO RIDE 49
NOTICE
Shifting Gears When shifting down to a lower gear, do not
shift at such a high speed that the engine
• Release the throttle and pull in the clutch lever at
the same time.
speed jumps excessively. This could cause
engine damage.
• Shift to the next higher or lower gear by pulling up
once or pushing down once on the shift pedal. j
• Push the throttle lever forward part way to in-
crease engine speed while gently releasing the
clutch lever.
• Release the shift pedal.
WARNING
HAZARD
Downshifting at high speeds.
WHAT CAN HAPPEN

Can cause the rear wheels to slide and the
operator to lose balance. The operator may
lose control of the vehicle and have an acci-
dent.

Slow down before shifting down to a lower
gear. Try to match vehicle speed with the cor-
responding engine speed of the lower gear
before completing the shift.
50 HOW TO RIDE
WARNING
Braking HAZARD
Stalling, rolling backwards or improperly dis-
• Close the throttle completely. Leave the clutch
engaged (except when shifting gears) so that the
engine will help slow down the vehicle.
j WHAT CAN HAPPEN
• Shift down one gear at a time so you are in 1st
gear when you come to complete stop.
• Under most conditions stop by pulling in the front

brake lever and pressing down the rear brake
pedal. Shift down or fully disengage the clutch as
necessary to keep the engine from stalling.
• For emergency braking disregard downshifting,
and concentrate on applying the brakes as hard
Keep weight uphill.
Apply the brakes.
as possible. Lock parking brake, after you are stopped.
• To stop while riding in reverse, close the throttle
completely, leaving the clutch engaged so that the If you begin rolling backwards:
engine will help slow down the vehicle, and grad- Keep weight uphill.
Never apply the rear brake while rolling back
ually apply the brakes. Sudden application of the
wards.
rear brake can cause the front end of the vehicle Apply the front brake.
to lift off the ground. Fully disengage the clutch as When fully stopped, apply rear brake as well,
necessary to keep the engine from stalling. and then lock parking brake.
• Refer to the Climbing Hills section in the SAFE
OPERATION chapter for the braking and riding Dismount on uphill side or to a side if pointed
techniques you must use when climbing hills. straight uphill.
the procedure described in the Safe Opera-
tion chapter.
HOW TO RIDE 51
Stopping the Engine Parking the ATV
• Close the throttle completely. • Stop the vehicle on a level surface.

• Apply thetransmission
Put the into the “N” (Neutral) position.
WARNING
• from rolling.
parking brake to help prevent the vehicle
j
HAZARD
• Turn the ignition key to “OFF”. Parking on a steep incline.
NOTE
WHAT CAN HAPPEN
This ATV is equipped with a vehicle-down sen-
May result in the vehicle overturning or
sor, which causes the engine to stop automatically
when the ATV is tilted excessively or tipped over. rolling down the hill and causing an acci-
If this sensor is activated, first recover the ATV dent.
and turn the ignition key to “OFF” and then back
to “ON” before starting the engine. HOW TO AVOID THE HAZARD
Do not park on steep inclines. If you must
park on a hill, place the vehicle diagonally
so that it never faces uphill, downhill or side-
ways. Set the parking brake securely.
• When the engine has stopped, shift the transmis-

sion into 1st gear. Apply the parking brake to help
prevent the vehicle from rolling.
• Remove
use.
the ignition key to prevent unauthorized
• Ifsure
parking inside a garage or other structure, be
it is well ventilated and the vehicle is not close
to any source of flame or sparks; this includes any
appliance with a pilot light.
52 HOW TO RIDE
WARNING
HAZARD
Stopping the ATV in an Emergency
Parking near an appliance with a pilot light.
Your Kawasaki vehicle has been designed and
Parking in a structure without ventilation.
manufactured to provide you optimum safety and
convenience. However, in order to fully benefit from
j WHAT CAN HAPPEN
Kawasaki’s safety engineering and craftsmanship, it
Gasoline is extremely flammable and can be
is essential that you, the owner and operator, prop-
explosive under certain conditions.
erly maintain your vehicle and become thoroughly
familiar with its operation. Improper maintenance
or death.
can create a dangerous situation known as throttle
failure. Two of the most common causes of throttle
failure are:
Park the vehicle in a well ventilated area away
from any source of flame or sparks. This in-
1. An improperly serviced or clogged air cleaner
cludes any appliance with a pilot light.
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 throttle body.
In an emergency situation such as throttle failure,
your vehicle may be stopped by applying the brakes
and shifting the engine stop switch to the “OFF” po-
sition. If the engine stop switch is used, turn off the
ignition switch after stopping the vehicle.
HOW TO RIDE 53
NOTE
In case of Vehicle Overturn This ATV is equipped with a vehicle-down sen-
sor, which causes the engine to stop automatically
If the vehicle is overturned, engine oil can flow when the ATV is tilted excessively or tipped over.
from the engine into the intake tract and air cleaner If this sensor is activated, first recover the ATV
housing resulting in lack of lubrication and possible and turn the ignition key to “OFF” and then back
engine damage. To avoid engine damage caused j
to “ON” before starting the engine.
by vehicle’s overturn, operate the vehicle at a slow
speed until the engine oil level can be inspected and
have the vehicle inspected by a dealer.
54 SAFE OPERATION
SAFE OPERATION
Knowing and following these rules for safe riding
will increase your enjoyment of your new Kawasaki Obey Local Laws
ATV and help avert serious injury or death. Refer
also to page in front of “Foreword” for “Safe Riding Know and obey all laws and regulations governing
Information.” the use of off-road vehicles in your riding area. Re-
spect private property; do not ride there without the
j Read the Owner’s Manual express written permission of the owner. Always try
to preserve nature and the environment.
Read and understand this Owner’s Manual, and
carry it with you when you ride. This is especially
important for younger riders and beginners. Refer
to this Owner’s Manual if you have any questions.
SAFE OPERATION 55
that requires them to reach to put their feet on

Adult Supervision the footboards and their hands on the handlebars.
Study this manual with your child to be sure he
This vehicle is not a toy. It is an off-road motor or she fully understands all of the special safety
vehicle. Use by children under 16 years of age is instructions.
not recommended.
WARNING
HAZARD
Failure to follow the age recommendations
j
for this ATV.
Failure to supervise children 16 years of age
and older.
WHAT CAN HAPPEN

Use of this ATV by children under 16 years of
age can lead to severe injury or death of the
child.
Even though a child may be within the age
group for which this ATV is recommended,
he or she may not have the skills, abilities, or
Youths starting at age 16 should have adult super- judgement needed to operate the ATV safely
vision even after they attend a rider training course. and may be involved in a serious accident.
Parents must ensure that their child has the skills,
abilities and judgement required to operate the ATV HOW TO AVOID THE HAZARD
safely. A child under 16 should never operate this
Youngsters must continue to develop their riding ATV. Youths starting at age 16 should have
skills and use proper riding techniques. Parents adult supervision even after they attend a
need to monitor their child’s progress and make cer- rider training course.
tain their child avoids unsafe situations. Never allow continued use of this ATV by a
Always equip your child with proper protective child if he or she does not have the abilities
gear. It is important that your child rides an appro- and maturity to operate it safely.
priate sized ATV. Never put your child on a vehicle
56 SAFE OPERATION
WARNING
Beginning Riders HAZARD
Operating this ATV without proper instruc-
Beginning riders should practice braking and turn-
tion.
ing in an open, off-road area away from other riders.
The terrain should be flat and free of obstacles with a
WHAT CAN HAPPEN
loose or hard dirt surface, but not a mixture of both.
The risk of an accident is greatly increased if
Do not ride on pavement. ATV’s are designed for
the operator does not know how to operate
off-road use only.
j the ATV properly in different situations and
on different types of terrain.

Beginning and inexperienced operators
should complete a certified training course
offered by The ATV Safety Institute (ASI).
They should then regularly practice the
skills learned in the course and the oper-
ating techniques described in the Owner’s
Manual.
For more information about the training
course, contact an authorized ATV dealer or
call:
1-800-887-2887.
SAFE OPERATION 57
Off-Road Use Only

This vehicle is designed for off-road use only. Op-
eration on public streets, roads, and highways is not
recommended and is not safe.
ATV tires are not designed to operate on paved or
concrete surfaces. The tires will not slip as neces-
sary which may seriously affect control of the vehi-
cle. j
WARNING
HAZARD
Operating this ATV on paved surfaces, in-
cluding sidewalks, paths. parking lots, drive- By operating on a public road you take the risk that
ways, and streets. you could collide with another vehicle. Also, in many
states use on public streets is illegal.
WHAT CAN HAPPEN
ATV tires are designed for off-road use. WARNING
Paved surfaces may seriously affect han- HAZARD
dling and control of the ATV, and may cause Operating this ATV on public streets, roads
the vehicle to go out of control. or highways.
HOW TO AVOID THE HAZARD WHAT CAN HAPPEN
Avoid operating the ATV on pavement when- You can collide with another vehicle.
ever possible. If you must ride on a paved
surface, go slowly and do not make sudden HOW TO AVOID THE HAZARD
turns or stops. Never operate this ATV on any public street,
road or highway, even a dirt or gravel one.
In many states it is illegal to operate ATVs on
pubic streets, roads and highways.
58 SAFE OPERATION
Dress Properly
Always wear an approved helmet, eye protec-
tion, and protective clothing. The proper clothing
can make riding more comfortable and reduce the
chance of injury If you take a spill. Long pants will
also protect your legs from the hot exhaust system.
j
SAFE OPERATION 59
WARNING
HAZARD
Operator Only
Operating this ATV without wearing an ap-
This vehicle is designed to carry only the operator.
proved motorcycle helmet, eye protection
It does not have a seat strap, passenger’s grab rail,
and protective clothing.
dual seat, or footpegs for a passenger. The long seat
is needed for the operator to maintain vehicle control
WHAT CAN HAPPEN
by shifting his or her body weight. A passenger inter-
Operating without an approved motorcycle
feres with the operator’s ability to control the vehicle
helmet increases your chances of a severe j
which can cause harm to the operator. Also, a pas-
head injury or death in the event of an acci-
senger will impair the steering response of the vehi-
dent.
cle by shifting weight from the front wheels, causing
Operating without eye protection can result
loss of control which may cause an accident. And
in an accident and increases your chances
without secure seating, a passenger may lose his or
of a severe injury in the event of an accident.
her balance and fall off the vehicle. Never carry a
Operating without protective clothing in-
passenger. Never ride as a passenger.
creases your chances of severe injury in the
event of an accident.

Always wear an approved motorcycle helmet
that fits property.
You should also wear:
eye protection (goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
60 SAFE OPERATION
WARNING
HAZARD
Ride Carefully and with Good
Carrying a passenger on this ATV.
Judgement
We want you to enjoy your riding experiences, so
WHAT CAN HAPPEN
ride carefully and safely. Exercise good judgement.
Passengers affect balance and steering and
Avoid wheelies and jumps. Also, don’t ride at exces-
increase risk of losing control.
sive speeds, too fast for conditions, or faster than
Carrying a passenger could cause an acci-
your skill level. Riding too fast and trying unsafe
j dent, resulting in harm to you and/or your
stunts can cause you to lose control of the vehicle
passenger.
and have an accident. Practice basic maneuvers so
you can ride confidently and safely.
Never carry a passenger. The long seat is to
allow the operator to shift position as needed
during operation. It is not for carrying pas-
sengers.
SAFE OPERATION 61
WARNING
HAZARD
Never Drink and Drive
Attempting wheelies, jumps, and other
Alcohol and drugs impair your judgement and slow
stunts.
your reactions. Even drugs prescribed by a physi-
cian can be dangerous. Check with your doctor.
WHAT CAN HAPPEN
Increases the chance of an accident, includ- WARNING
ing an overturn.
HAZARD j
HOW TO AVOID THE HAZARD Operating this ATV after consuming alcohol
Never attempt stunts, such as wheelies or or drugs.
jumps. Don’t try to show off.
WHAT CAN HAPPEN
Could seriously affect your judgement.
WARNING Could cause you to react more slowly.
HAZARD Could affect your balance and perception.
Operating this ATV at excessive speeds. Could result in an accident.
WHAT CAN HAPPEN HOW TO AVOID THE HAZARD

Increases your chances of losing control of Never consume alcohol or drugs before or
the ATV, which can result in an accident. while driving this ATV.

Always go at a speed that is proper for the
terrain, visibility and operating conditions,
and your experience.
62 SAFE OPERATION
WARNING
Keep Your Feet on the Footboards and HAZARD
Hands on the Handlebars Removing hands from handlebars or feet
from footboards during operation.
Always ride with your feet on the footboards. If
your feet touch the ground while you are moving, you
WHAT CAN HAPPEN
could be injured. It is possible to have the rear wheel
Removing even one hand or foot can reduce
run over your foot.
your ability to control the ATV or could cause
If you have a lot of motorcycle experience, your
j you to lose your balance and fall off of the
natural reaction to the vehicle tipping or skidding
ATV. If you remove a foot from a footboard,
may be to put a foot down. This is a reaction you
your foot or leg may come into contact with
must “unlearn”.
the rear wheels, which could injure you or
Also, removing your feet from the footboards and
cause an accident.
removing your hands from the handlebars can cause
you to lose your balance and fall off the ATV. Keep
your hands and feet on the ATV always.
Always keep both hands on the handlebars
and both feet on the footboards of your ATV
during operation.
SAFE OPERATION 63
Before Starting the Engine Use the Parking Brake

Three “musts” before starting the engine are: Always apply the parking brake before getting off
1) Set the parking brake, your vehicle. If it should roll, it might be damaged or
2) Put the transmission in neutral, cause injury.
NOTE
The engine can be started in any shift position if
the clutch is pulled. However, it is recommended j
to shift into neutral before starting the engine.
3) Check the throttle for proper operation. It should
snap closed when released with the handlebars
in any position.
64 SAFE OPERATION
WARNING
Modifications and Accessories HAZARD
Operating this ATV with improper modifica-
Installation of accessories may affect the handling
tions.
of your ATV. See the Loading Information chapter of
this manual for more detailed information. Kawasaki
WHAT CAN HAPPEN
does not recommend that you modify your ATV in
Improper installation of accessories or mod-
any way. Unauthorized modifications may produce
ification of this vehicle may cause changes
dangerous handling conditions or adversely affect
j in handling which in some situations could
vehicle reliability.
lead to an accident.

Never modify this ATV through improper in-
stallation or use of accessories. All parts and
accessories added to this vehicle should be
genuine Kawasaki or equivalent components
designed for use on this ATV and should be
installed and used according to instructions.
If you have questions, consult an authorized
ATV dealer.
SAFE OPERATION 65
WARNING
Perform the Daily Safety Checks HAZARD
Failure to inspect the ATV before operating.
Refer to the Daily Safety Checks section for a list
Failure to properly maintain the ATV.
of items to check each day before you ride. Habit-
ual performance of these checks will help to insure a
WHAT CAN HAPPEN
safer, more reliable ride. Be sure that any irregulari-
Increases the possibility of an accident or
ties found during these checks are corrected before
equipment damage.
riding.
j
Always inspect your ATV each time you use
it to make sure the ATV is in safe operating
condition.
Always follow the inspection and mainte-
nance procedures and schedules described
in the Owner’s Manual.
66 SAFE OPERATION
WARNING
Tire Air Pressure HAZARD
Operating this ATV with improper tires, or
This vehicle is equipped with low pressure tires.
with improper or uneven tire pressure.
Tire inflation and type can affect the vehicle’s han-
dling characteristics. Check the tire pressure fre-
WHAT CAN HAPPEN
quently, using the tire gauge in the tool kit. Use only
Use of improper tires on this ATV, or opera-
the recommended tires for replacement.
tion of this ATV with improper or uneven tire
j pressure, may cause loss of control, increas-
ing your risk of an accident.

Always use the size and type tires specified
in the Owner’s Manual for this vehicle.
Always maintain proper tire pressure as de-
scribed in the Owner’s Manual.
SAFE OPERATION 67
WARNING
Riding Terrain HAZARD
Failure to use extra care when operating this
Before riding in a new area be sure to check for
ATV on unfamiliar terrain.
hidden obstacles or hazards. Keep your speed
down until you know the area well. You must know
WHAT CAN HAPPEN
the land you intend to ride on and be familiar with
You can come upon hidden rocks, bumps, or
your machine and its handling characteristics to
holes, without enough time to react.
have a safe and enjoyable riding experience. Use
Could result in the ATV overturning or going j
existing trails and stay away from excessively rough,
out of control.
slippery or loose terrain. Don’t attempt to ride over
large obstacles. Hazardous conditions such as
these can cause loss of control and an accident. Be
Go slowly and be extra careful when operat-
cautious when visibility is limited; you may not be
ing on unfamiliar terrain.
able to see obstacles in your path.
Always be alert to changing terrain condi-
tions when operating the ATV.
If you must ride over a small obstacle, approach it

slowly. As the vehicle goes up and over the obstacle,
shift your weight to stay centered over the vehicle.
Use careful throttle control. Stand up if necessary to
maintain your balance.
68 SAFE OPERATION
WARNING WARNING
HAZARD HAZARD
Improperly operating over obstacles. Failure to use extra care when operating on
excessively rough, slippery or loose terrain.
WHAT CAN HAPPEN
Could cause loss of control or a collision. WHAT CAN HAPPEN
Could cause the ATV to overturn. Could cause loss of traction or vehicle con-
trol, which could result in an accident, in-
j HOW TO AVOID THE HAZARD cluding an overturn.
Before operating in a new area, check for ob-
stacles. HOW TO AVOID THE HAZARD
Never attempt to ride over large obstacles, Do not operate on excessively rough, slip-
such as large rocks or fallen trees. pery or loose terrain until you have learned
When you go over obstacles, always fol- and practiced the skills necessary to control
low proper procedures as described in the the ATV on such terrain.
Owner’s Manual. Always be especially cautious on these
kinds of terrain.
SAFE OPERATION 69
WARNING
Riding in Reverse HAZARD
Shifting into 1st gear while moving in re-
Start the engine following the procedure in the
verse.
"Starting the Engine" section. Before shifting into re-
verse, engage 1st gear. Then with the clutch lever
WHAT CAN HAPPEN
pulled in push the reverse lock release lever and
Can cause the vehicle to stop suddenly and
press down the shift pedal into reverse gear. Re-
go forward.
lease the reverse lock release lever and shift pedal.
This can lift the front wheels off the ground j
Refer to the "Reverse Lock Release Lever" section.
and cause the operator to lose control. Or
Turn around and look behind you before backing
the vehicle can tip over backwards causing
up to be sure there are no obstacles or people in your
an accident.
way. Gently release the clutch lever while gradually
increasing engine speed by pushing forward on the
throttle lever as the clutch engages, and begin back-
Never operate the shift pedal to change gears
ing up cautiously.
while the vehicle is in reverse.
To stop while riding in reverse, close the throttle
completely, leaving the clutch engaged so that the
engine will help slow down the vehicle, and gradually WARNING
apply the brakes. Sudden application of the rear
HAZARD
brake can cause the front end of the vehicle to lift off
Going too fast in “R” (Reverse).
the ground. Fully disengage the clutch as necessary
to keep the engine from stalling.
WHAT CAN HAPPEN
Going too fast in “R” (Reverse) can cause a
loss of control and accident resulting in se-
vere personal injury or death.

Always maintain safe speeds. Use the Re-
verse Power Assist Switch only if additional
power is needed.
70 SAFE OPERATION
WARNING
HAZARD
Turning the Vehicle
Inattentive operation in “R” (Reverse). Back-
The new rider must learn this turning technique to
ing up without looking where you are going.
make turns smoothly and quickly. Slide forward on
the seat, and turn the handlebar in the direction of
WHAT CAN HAPPEN
the turn. Lean your body to the inside of the turn
Inattentive operation in “R” (Reverse) could
while shifting your body weight onto the footboard
cause you to hit a person or obstacle behind
on the outside of the turn.
j you, resulting in severe personal injury or
death. WARNING
HOW TO AVOID THE HAZARD HAZARD
Before shifting into “R” (Reverse), make sure Turning improperly.
there are no people or obstacles behind you,
and then proceed at a safe speed. Always WHAT CAN HAPPEN
look where you are going, whether forward ATV could go out of control, causing a colli-
or in reverse. sion or overturn.
Remember: HOW TO AVOID THE HAZARD

Look behind you before backing up. Always follow proper procedures for turning
Open the throttle gradually. as described in this section.
To stop, gradually apply the brakes. Practice turning at low speeds before at-
tempting to turn at faster speeds.
Do not turn at excessive speed.
Practice turning at low speed in a large, open prac-

tice area. Slow down before entering a turn and
use the throttle to maintain an even speed through
the turn. When the turn is completed, straighten the
handlebar and reposition your weight.
Since both rear wheels of this ATV turn at the same
speed, the inside wheel gives up traction (or “slips”)
on the ground during a turn. Sliding forward on the
SAFE OPERATION 71
seat and shifting body weight onto the outside foot- WARNING
board, helps the rear wheels turn easier and improve
HAZARD
front wheel steering.
Removing hands from handlebars or feet
from footboards during operation.
WHAT CAN HAPPEN

Removing even one hand or foot can reduce
your ability to control the ATV or could cause
you to lose your balance and fall off of the j
ATV. If you remove a foot from a footboard,
your foot or leg may come into contact with
the rear wheels, which could injure you or
cause an accident.

Always keep both hands on the handlebars
and both feet on the footboards of your ATV
during operation.
The type of riding terrain has a large effect on turn-

ing. On loose surfaces the inside rear wheel will slip
easily and the vehicle can be turned sharply. On
hard surfaces the inside rear wheel will not slip as
easily, and the vehicle’s turning radius will increase.
Thus you must allow more room to complete your
turn.
If the vehicle starts to tip in a turn, lean more to

the inside of the turn. It may be necessary to reduce
your speed and straighten out if possible. Don’t put
your foot down; keep both feet on the footboards.
72 SAFE OPERATION
Remember:
Slow down before entering the turn. Climbing Hills
Sit forward on the seat.
Lean into the turn. Do not attempt to climb hills or steep inclines un-
Put your weight on the outer footboard. til you have mastered the controls and basic riding
Maintain an even speed through the turn. techniques of this vehicle. Then practice hill climbing
techniques on gentle slopes first before you gradu-
ate to steeper hills.
j WARNING
HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN

Could cause loss of control or cause ATV to
overturn.

Always follow proper procedures for climb-
ing hills as described in the Owner’s Manual.
Always check the terrain carefully before you
start up any hill.
Never climb hills with excessively slippery or
loose surfaces.
Shift your weight forward.
Never open the throttle suddenly or make
sudden gear changes. The ATV could flip
over backwards.
Never go over the top of any hill at high
speed. An obstacle, a sharp drop, or another
vehicle or person could be on the other side
of the hill.
SAFE OPERATION 73
Don’t attempt to climb hills that are too steep for WARNING
the ATV or for your abilities. When climbing a hill,
HAZARD
lean forward to keep the front wheels from lifting. On
Operating on excessively steep hills.
steeper hills you may need to stand and lean forward
for even more weight transfer. The front wheels must
WHAT CAN HAPPEN
be kept on the ground so you can steer and also to
The vehicle can overturn more easily on ex-
prevent the possibility of tipping over backwards.
tremely steep hills than on level surfaces or
small hills.
j
Never operate the ATV on hills too steep for
the ATV or for your abilities.
Practice on smaller hills before attempting
larger hills.
Avoid hills with slippery sides that will cause you

to lose traction. Do not climb hills where you can-
not see far enough ahead. If you cannot see what
is on the other side of the crest of a hill, slow down
until you can get a clear view. Speed up before as-
cending the hill. If the vehicle doesn’t have enough
power to reach the top of a hill and starts to lose
forward momentum, turn around and ride downhill if
you have enough space.
74 SAFE OPERATION
WARNING rear end of the ATV uphill as far as possible. Re-

mount the ATV from the uphill side if it is not facing
HAZARD
straight downhill. then, while keeping as much of
Improperly turning on hills.
your weight as possible on the uphill side, turn the
handlebars downhill. Release the parking brake and
WHAT CAN HAPPEN
ride downhill.
overturn.
j HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any
hill until you have mastered the turning tech-
nique as described in this manual on level
ground. Be very careful when turning on any
hill.
Rear brake application will brake the downhill
wheels when climbing hills and so will front brake
application when descending hills.
If the vehicle stalls on a hill, apply the brakes be-
fore the vehicle starts to roll backwards. If the vehi-
cle should start to roll backwards on a hill, dismount
to the side immediately or apply the front brake grad-
ually. You may tip the vehicle over backwards if you
apply the rear brake suddenly after the vehicle starts
to roll backwards, or if you try to apply power while
rolling backwards. If you are stopped on a hillside,
apply the parking brake and carefully dismount on
the uphill side of the vehicle (so it cannot roll over
onto you). To turn the machine around, drag the
SAFE OPERATION 75
WARNING Remember:
HAZARD Some hills are too steep. Use common sense.
Stalling, rolling backwards or improperly dis- Never ride past your limit of visibility. If you can’t
see what is on the other side of the crest of a hill,
slow down until you can get a clear view.
WHAT CAN HAPPEN Don’t let the vehicle roll backward. If it does, avoid
sudden braking and use only the front brake.
If you get stuck on a hill, set the parking brake and
dismount on the uphill side.
HOW TO AVOID THE HAZARD j
Keep weight uphill.
Apply the brakes.
Lock parking brake, after you are stopped.
If you begin rolling backwards:
Keep weight uphill.
Never apply either front or rear brakes
suddenly while rolling backwards.
Apply both front and rear brakes gradually.
When fully stopped, lock parking brake.
Dismount on uphill side or to a side if pointed
straight uphill.
the procedure described in this manual.
76 SAFE OPERATION
Antenna Flag Traversing Hillsides

In hilly country, use an antenna flag so others can When riding across the side of a hill, keep your
see you coming from the other side of a hill or sand body weight toward the top of the hill. Avoid hills with
dune. Take extra care when approaching blind hill slippery sides that will cause you to lose traction.
tops and corners. Also avoid traversing hillsides covered with rocks or
other obstacles which may cause you to lose your
balance or tip over.
j If the vehicle begins to tip, steer downhill if possible
to regain control. If you discover that the vehicle is
in danger of rolling over, dismount on the uphill side.
SAFE OPERATION 77
WARNING
HAZARD
Descending Hills
Improperly crossing hills.
Slow down or stop at the top of a hill so you can
pick a safe path for descent where you can clearly
WHAT CAN HAPPEN
see far enough ahead to avoid any obstacles.
overturn. WARNING
HOW TO AVOID THE HAZARD HAZARD j
Avoid crossing the side of a steep hill if pos- Going down a hill improperly.
sible.
When crossing the side of a hill: WHAT CAN HAPPEN
Always follow proper procedures as de- Could cause loss of control or cause ATV to
scribed in this manual. overturn.
Avoid hills with excessively slippery or loose
surfaces. HOW TO AVOID THE HAZARD
Shift your weight to the uphill side of the ATV. Always follow proper procedures for going
down hills as described in this manual. Note:
a special technique is required when braking
as you go down a hill.
Always check the terrain carefully before you
start down any hill.
Shift your weight backward.
Never go down a hill at high speed.
Avoid going down a hill at an angle that
would cause the vehicle to lean sharply to
one side. Go straight down the hill where
possible.
78 SAFE OPERATION
WARNING
HAZARD
Applying brakes improperly.
WHAT CAN HAPPEN

Could cause ATV to overturn.

j Apply both front and rear breaks gradually.
Be careful if the surface is loose; the tires may skid

and braking effectiveness will be reduced.
Turning while descending a slope must be done
very carefully and gradually to avoid tipping the ve-
Normally you should descend straight down a hill, hicle over.
since riding at an angle could cause the vehicle to The rider should keep his feet on the footboards
lean to one side and possibly tip over. Shift into a and transfer his weight to the rear of the vehicle, and
low gear before beginning your descent. Sit back on the uphill side of the vehicle.
on the seat and brace yourself by straightening your
arms. Hold your speed down by keeping the throttle
closed. Apply the brakes as necessary. Avoid sud-
den application of the front brake; it could cause the
vehicle to overturn.
SAFE OPERATION 79
Remember:
Stop and look for obstacles before descending a Sliding and Skidding
hill.
Go straight downhill. On slippery or loose surfaces, special care is
Shift your weight to the rear. required. Sliding may be hazardous because the
Go slowly. wheels may suddenly regain traction and cause
Avoid excessive use front brake. the vehicle to tip or overturn and have an accident.
If you must turn, do so carefully and gradually, Therefore, never ride “over your head” when you
keeping your weight toward the top of the hill. are unprepared for the riding surface.
Often you can correct a skid by turning the wheels j
in the direction of the skid and placing additional
body weight on the front wheels. Do not apply heavy
braking force or accelerate when skidding, since this
may cause you to lose control altogether.
Learn to safely control skidding or sliding by prac-
ticing at low speeds and on level, smooth terrain.
80 SAFE OPERATION
WARNING Remember:
HAZARD Be especially careful on very slippery and very
high traction surfaces.
Skidding or sliding improperly.
Steer in the direction of the skid.
WHAT CAN HAPPEN Don’t ride on public streets, roads, or highways.
You may lose control of this ATV.
You may also regain traction unexpectedly,
which may cause the ATV to overturn.
j
Learn to safely control skidding or sliding
by practicing at low speeds and on level,
smooth terrain.
On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to
reduce the chance of skidding or sliding out
of control.
Use caution and maintain low speeds to avoid un-
controlled skidding on areas covered with clay, mud,
ice, or snow. These conditions are particularly haz-
ardous when descending a hill or making a turn. Re-
member that this vehicle is not allowed on public
streets, roads, or highways.
On loose or slippery surfaces you may be able to
improve steering control by moving forward on the
seat. This puts more of your weight over the front
wheels.
SAFE OPERATION 81
Riding in Water
Choose a location to enter and exit the water
where the banks are not too steep or slippery.
Check the water before entering for rocks, holes or
other obstacles which may cause you to overturn or
become stuck or submerged.
Observe the following rules for operating the vehi-
cle in water: j
Never operate the vehicle in rivers or streams
where the water is flowing quickly. Such operation
could lead to an accident if the vehicle loses traction
and is swept into the current.
Never operate the vehicle in deep water. The A. Axle
maximum fording depth is up to the axle in quiet
(slow-moving) water. Vehicle operation in deeper
water may be unpredictable and hazardous, and
could lead to an accident.
82 SAFE OPERATION
WARNING wheel bearings may lose their lubricant and require

replacement. Check the engine oil: a milky appear-
HAZARD
ance indicate that water has entered.
Operating this ATV through deep or fast flow-
Remove the drain plug at the bottom of the engine
ing water.
and check for water inside.
Wash the vehicle in fresh water if it is exposed to
WHAT CAN HAPPEN
salt water or operated in muddy conditions.
Tires may float, causing loss of traction and
Wet brakes provide little or no efficiency and could
loss of control, which could lead to an acci-
lead to an accident and injury. After operation in
j dent.
water, always apply the brakes long enough for the
friction to dry the pads. Also, brakes that get wet
may wear out faster. Check for brake wear more
Never operate this ATV in fast flowing water
frequently if the vehicle is used in water.
or in water deeper than the bottom edge of
the axle caps. Remember:
Remember that wet brakes may have re- Don’t ride in fast flowing water.
duced stopping ability. Test your brakes Stay out of water deeper than the lower end of the
after leaving water. If necessary, apply them axle cap.
several times to let friction dry out the pads. Dry out the brakes.
Check the air cleaner for water.
After the vehicle is operated in water, check the Check the engine oil for water.
air cleaner. After prolonged exposure to water, the
MAINTENANCE AND ADJUSTMENT 83
MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Periodic
Maintenance Chart to keep the vehicle in good running condition. The initial maintenance is vitally important
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 resulting from incorrect or improper adjustment done by the owner.
EMISSION CONTROL INFORMATION j

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and ex-
haust 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 evapora-
tive emission control system (3) in compliance with applicable regulations of the United States Environmental
Protection Agency.
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 vehicle.
The fuel, ignition and exhaust systems of this vehicle have been carefully designed and constructed to ensure
an efficient engine with low exhaust pollutant levels.
3. Evaporative Emission Control System
The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel
tank.
84 MAINTENANCE AND ADJUSTMENT
High Altitude Performance Adjustment Information
High Altitude adjustment is not required.
MAINTENANCE
Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels. This
Owner’s Manual contains maintenance operations recommended for your vehicle. Maintenance operations
necessary to ensure compliance with the applicable emission standards are noted in the Periodic Maintenance
Chart. As the owner of this vehicle, you have the responsibility to make sure that the recommended mainte-
nance is carried out according to the instructions in this Owner’s Manual at your own expense.
You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided
space at the end of this manual where an authorized Kawasaki dealer, or someone equally competent, can
j record the maintenance. You should also retain copies of maintenance work orders, receipts, etc., as verifica-
tion of this maintenance.
Warranty
This vehicle is designed, built, and equipped in compliance with applicable regulations of the United States
Environmental Protection Agency (EPA) and California Air Resources Board (CARB) at the time of sale. The
EPA and CARB require that your vehicle comply with certain emissions regulations during a portion of its useful
life and is free from defects in material and workmanship which could cause the vehicle to fail to conform with
applicable regulations. Please read your Kawasaki Limited Emission Control Systems Warranty delivered with
this Owner’s Manual carefully and keep it valid by complying with the owner’s obligations it contains. To ob-
tain warranty service, the Kawasaki Limited Emission Control Systems Warranty requires that you return your
vehicle to an authorized Kawasaki dealer for remedy under warranty.
TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED:

Federal regulations and California State law prohibit the following acts or the causing thereof: (1) the removal
or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purposes of emission 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:
Do not tamper with the original emission related parts:
•Throttle body or internal parts •
Fuel pump/Fuel injector
•Spark plug •
Air cleaner element
•Magneto ignition system •
Electronic control unit (ECU)
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, repair, 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.
j
Among those acts presumed to constitute tampering are the acts listed below:
• Replacement of the original exhaust system or •
Removal of the air cleaner housing or its cover.
muffler with a component not in compliance with
Federal regulations.
•
Modifications to the muffler or air intake system
by cutting, drilling, or other means if such modifi-
•Removal of the muffler or any internal portion of cations result in increased noise levels.
the muffler. •
Modifications to the air cleaner element
Periodic Maintenance Chart

In addition to the following items, always perform the Daily Safety Checks listed in the HOW TO RIDE chapter.
• = Clean, adjust, lubricate, replace parts as necessary.

D = Service to be performed by an authorized Kawasaki dealer or someone equally competent.
= Emission related parts.
FREQUENCY First
Regular Service
Service
Every 90 days
j After 10 Every 10 Every 30 of vehicle use or Every
hrs. or days or days or 1,700 km (1 100 year of
100 km 200 km 600 km ml) whichever use
(60 mi) of (120 mi) (360 mi) comes first
use of use of use
OPERATION
ENGINE
Air cleaner-service* • •
Throttle lever play-inspect • •
First 1 700 km (1 100 mi);
Valve clearance-inspect*
thereafter every 3 400 km (2 200 mi)
Idle speed-inspect
•
Reverse lock release lever play - inspect
• •
Engine oil-change*
• •
Oil filter-replace*
• •
FREQUENCY First
Regular Service
Service
Every 90 days
After 10 Every 10 Every 30 of vehicle use or Every
use of use of use
OPERATION
Spark plug-clean and gap D D j

Spark arrester-clean
Fuel hoses and connections-inspect D
•
Fuel hose-replace 4 years (D)
Radiator-clean*
Radiator hoses and connections-inspect*
• • D
Coolant-change* 2 years (D)
Clutch operation (play, disengagement,
engagement) - inspect • •
CHASSIS
Joint boots-inspect *
Brake hose-replace
•4 years (D)•
Brake light switch-inspect*
Brake pad wear-inspect *
•
D
•
D
Brake fluid level-inspect
Brake fluid-change
• • D
FREQUENCY First
Regular Service
Service
Every 90 days
After 10 Every 10 Every 30 of vehicle use or Every
use of use of use
OPERATION
j Brake hoses and connections-inspect D

Master cylinder piston assembly and dust
2 years (D)
seal-replace
Brake caliper piston seal and dust
2 years (D)
seal-replace
Tire wear-inspect *
Steering-inspect D
• D
General lubrication*
•
Bolts and nuts-tighten
• •
Drive chain lubrication condition-inspect*
•
Drive chain slack-inspect*
•
Drive chain wear-inspect*
•
Drive chain guide wear-inspect*
•
* Service more frequently when operated in mud, dust, or other harsh riding conditions.
NOTICE
Engine Oil Racing the engine before the oil reaches ev-
ery part can cause engine seizure.
In order for the engine, transmission and clutch
Operation with insufficient, deteriorated, or
to function properly, maintain the engine oil at the
contaminated engine oil will cause acceler-
proper level, and change the oil and oil filter period-
ated engine wear.
ically.
Not only do dirt and metal particles collect in the
oil, but the oil itself loses its lubricative quality if used Oil Level Inspection
too long. • Ifa the oil has just been changed, let the vehicle sit
few minutes allowing the oil to settle.
WARNING • Start the engine and run it for several minutes at
idle speed. Do not run the engine at high en- j
HAZARD
Engine or transmission seizure. gine speed.
• Stop the engine and wait several minutes for the
oil to settle.
WHAT CAN HAPPEN
Can lock the rear wheels causing an accident • Check the engine oil level with the vehicle level
through the oil level inspection window on the
and injury.
lower right side of the engine. The oil level should
HOW TO AVOID THE HAZARD come up between the high and low level lines at
Do not operate this vehicle with insufficient, the window.
deteriorated, or contaminated engine oil. • If the oil level is too high, remove the excess oil
using a syringe or other suitable device.
Because of the semi-dry sump lubrication system, • If the oil level is too low, add the correct amount
of oil through the oil filler opening. Use oil of the
the engine oil level indicated on the oil level inspec-
tion window will fluctuate depending on the vehi- same type and brand as those of the one that is
cle’s position and engine speed when the engine’s already in the engine.
shut off. To ensure a proper reading of the engine NOTE
oil level, follow the Oil Level Inspection procedures
closely.
If no oil appears in the oil level inspection window,
shake the vehicle vigorously to see if oil level is
visible. If no oil appears, remove drain plugs to
empty any oil that may be in the transmission and
crankcase, reinstall the drain plugs and refill with Oil and/or Oil Filter Change
the specified amount of oil. The engine oil and/or oil filter should be changed
periodically to ensure long engine life.
• Warm up the engine thoroughly so that the oil will
pick up any sediment and drain easily.
• Stop the engine, and place a container beneath it.
• Remove the oil filler cap.
• Remove the oil drain plugs and drain the oil.
A. Oil Level Inspection Window

B. High Level Line
C. Low Level Line
D. Oil Filler Cap
A. Drain Plug (M6)

B. Drain Plug (M12)
WARNING • When the oil filter is replaced, remove the oil filter
cover and take off the cover with O-ring.
HAZARD
Improper disposal of used motor oil.
WHAT CAN HAPPEN

Used motor oil is a toxic substance, which
can pollute the environment.

Contact your local authorities for approved
disposal methods and follow those methods
at all times. j
A. Oil Filter Cover

B. Bolts
NOTICE
Be careful not to allow any dirt or foreign ma-
terials to enter the engine.
• Replace the oil filter element with a new one. • After the oil has completely drained out, install the
drain plugs with their new gaskets. Proper torque
for them is shown in the table.
Engine Oil Drain Plugs Tightening Torque
Drain Plug (M6) 7.0 N·m (0.7 kgf·m, 5.2 ft·lb)
Drain Plug (M12) 15 N·m (1.5 kgf·m, 11 ft·lb)
NOTE
Replace any gaskets or O-ring with new ones.
j • Fill the engine up to the high level line with good
quality engine oil specified in the table.
• Install the oil filler cap.
• Start the engine.
A. Oil Filter Element
B. Grommet
• Check the oil level and oil leakage.
Engine Oil
• Apply oil to the grommet. Grade: API SF or SG
• Install the oil filter element with the grommet to-
ward the oil filter cover.
API SH, SJ, SL, or SM with JASO
MA, MA1 or MA2
NOTICE Viscosity: SAE 10W-40
Inside-Out installation stops oil flow, causing Capacity: 1.15 L (1.22 US qt)
engine seizure. [when filter is not removed]
• Install the oil filter cover with grease applied to a

new O-ring and tighten its bolts to the specified
1.20 L (1.27 US qt)
[when filter is removed]
torque.
1.35 L (1.43 US qt)
Oil Filter Cover
[when engine is completely dry]
9.8 N·m (1.0 kgf·m, 87 in·lb)
NOTE
Do not add any chemical additive to the oil. Oils Cooling System
fulfilling the above requirements are fully formu-
lated and provide adequate lubrication for both the Radiator and Cooling Fan:
engine and the clutch.
Although 10W-40 engine oil is the recommended WARNING
oil for most conditions, the oil viscosity may need Do not touch the radiator when it is hot, nor
to be changed to accommodate atmospheric condi- open the radiator cap. Hot coolant inside will
tions in your riding area. cause you severe burns.
Check and clean the grille and radiator fins for ob-
struction by insects or mud in accordance with the j
Periodic Maintenance Chart. In dusty areas, the ra-
diator should be cleaned more frequently than the
recommended interval.
WARNING
HAZARD
The cooling fan turns on automatically, even
with the ignition switch off.
WHAT CAN HAPPEN

Can cause injury to your hands if you touch
the turning fan.

Keep your hands and clothing away from the
fan blades at all times.
Coolant:
Coolant absorbs heat from the engine and trans-
fers it to the air at the radiator. If the coolant level
becomes low, the engine overheats and may suffer
damage. Check the coolant level each day before
operating the vehicle, and replenish coolant if the
level is low. Change the coolant in accordance with
the Periodic Maintenance Chart.
Coolant Level Inspection
• Situate the vehicle on level ground.
j
• gauge on coolant
Check the level through the coolant level
the reserve tank. The coolant level
should be between the “F” (Full) and “L” (Low)
A. Grille marks.
B. Coolant Reserve Tank NOTE
• Clean the grille and radiator fins of any obstruc-
tions with a stream of low-pressure water.
Check the level when the engine is cold (room or
atmospheric temperature).
• If insects or mud can not be completely removed,
it should be cleaned by an authorized Kawasaki
dealer.
NOTICE
Using high-pressure water, as from a car
wash facility, could damage the radiator fins
and impair the radiator’s effectiveness.
Do not obstruct or deflect airflow through
the radiator by installing unauthorized ac-
cessories in front of the radiator or behind
the cooling fan. Interference with the ra-
diator airflow can lead to overheating and
consequent engine damage.
NOTE
In an emergency you can add water alone to the
coolant reserve tank, however it must be returned
to the correct mixture ratio by the addition of an-
tifreeze concentrate as soon as possible.
A permanent type of antifreeze is installed in the
cooling system when shipped. It is colored green
and contains ethylene glycol. It is mixed at 50%
and has the freezing point of –35°C (–31°F).
NOTICE
If coolant must be added often, or the reserve j
tank completely runs dry, there is probably
A. Reserve Tank leakage in the system. Have the cooling sys-
B. Cap tem inspected by your authorized Kawasaki
C. “F” (Full) Mark dealer.
D. “L” (Low) Mark
• Ifcapthefrom
amount of coolant is insufficient, unscrew the
the reserve tank and add coolant through
Coolant Change
Have the coolant changed by an authorized
the filler opening to the “F” (Full) mark. Install the Kawasaki dealer.
cap.
Recommended Coolant Solution
Water 50%: Coolant 50% (1 : 1)
Recommended Coolant:
Permanent type coolant (ethylene glycol plus
corrosion and rust inhibitor chemicals for
aluminum engines and radiator).
Spark Plug
The standard spark plug is shown in the table. The
spark plug should be taken out in accordance with
the Periodic Maintenance Chart for cleaning, inspec-
tion, and resetting of the plug gap.
Maintenance
If the plug is oily or has carbon build-up, have it
cleaned, preferably in a sand-blasting device, and
then clean off any abrasive particles. The plug may
j also be cleaned using a high flash-point solvent and
a wire brush or other suitable tool. Measure the gap
with a wire-type thickness gauge, and adjust the gap
A. Spark Plug
if incorrect by bending the outer electrode. If the B. Fuel Tank
spark plug electrode is corroded or damaged, or if
the insulator is cracked, replace the plug. Use the
standard plug.
NOTE
Since the spark plug is located just below the fuel
tank, you need to remove the fuel tank to gain ac-
cess for maintaining the spark plug.
Ask your authorized dealer to have the plug ser-
viced in accordance with the Maintenance Chart.
Spark Plug
Standard Plug NGK CPR8EB-9 or CPR9EB-9 Valve Clearance
Solid Post Type Valve and valve seat wear decrease valve clear-
Plug Gap 0.8 ∼ 0.9 mm (0.032 ∼ 0.035 in.) ance, upsetting valve timing.
Tightening NOTICE
13 N·m (1.3 kgf·m, 9.4 ft·lb)
Torque
If valve clearance is left unadjusted, wear will
eventually cause the valves to remain par-
Spark Plug Fitting tially open, which lowers performance, burns
• Insert the plug into the plug hole. the valves and valve seats, and may cause
• Tighten the plug to the specified torque. serious engine damage. j
• to make sure itplug
Put the spark cap in place and pull up lightly
is securely in place. Valve clearance for each valve should be checked
and adjusted in accordance with the Periodic Main-
tenance Chart.
Inspection and adjustment should be done by an
authorized Kawasaki dealer.
Valve Clearance (Engine Cold)
INTAKE 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.)
EXHAUST 0.17 ∼ 0.22 mm (0.007 ∼ 0.009 in.)
Element Cleaning
Air Cleaner • Remove the seat.
A clogged air cleaner restricts the engine’s air in-
take, increases fuel consumption, reduces engine
power, and causes spark plug fouling.
WARNING
HAZARD
A clogged air cleaner.
j WHAT CAN HAPPEN

May allow dirt and dust to enter the throttle
body and stick the throttle open. This could
cause an accident.
HOW TO AVOID THE HAZARD A. Mud Guard Plate

Clean the air cleaner regularly and according B. Air Cleaner Cover
to the instructions in this section. C. Snaps
• Remove the mud guard plate.

NOTICE NOTE
A clogged air cleaner may allow dirt and dust This mud guard plate prevents splashed mud from
to enter the engine causing excessive wear entering into the air cleaner. Be sure to install it
and possibly engine damage. after the air cleaner maintenance.
The air cleaner element must be cleaned in ac- • Pull

cover.
up the snaps and remove the air cleaner
cordance with the Periodic Maintenance Chart. In
dusty areas, the element should be cleaned more • Pull the air cleaner element up and take it out of
the air cleaner housing.
frequently than the recommended interval. After rid-
ing through rain or on muddy roads, the element
should be cleaned immediately.
WARNING
HAZARD
Dirt or dust allowed into the throttle body.
WHAT CAN HAPPEN

Can cause the throttle to stick open. This
could cause an accident.

Be sure to cover the air cleaner opening to
the throttle body after removing the element.
Clean the air cleaner case as described in j
this section.
A. Element
B. Air Cleaner Housing NOTICE
Check inside the inlet tract for dirt. If dirt is present, If dirt gets through into the engine, exces-
clean the intake tract thoroughly. You may also need sive engine wear and possibly engine dam-
to replace the air filter element. age will occur.
• Wrap a clean, lint-free towel over the inlet tract to
keep dirt or other foreign material from entering.
• Wipe out the inside of the air cleaner housing with
a clean damp towel.
• Remove the element frame to clean the element

in a bath of biodegradable foam air filter cleaner
using a soft bristle brush.
WARNING
HAZARD
Cleaning the air cleaner element with gaso-
line or low flash-point solvent.
WHAT CAN HAPPEN

Gasoline or low flash-point solvents are ex-
j tremely flammable and can be explosive un-
der certain conditions.
A. Seal or death.
B. Element Frame
C. Element
D. Washer HOW TO AVOID THE HAZARD
E. Fitting Bolt Use a high flash-point solvent to clean the air
cleaner element. Never use gasoline or low
NOTE flash-point solvents.
Clean the element in a well-ventilated area
This air cleaner has been treated with a free from any source of flame or sparks; this
biodegradable foam air cleaner oil. It is recom- includes any appliance with a pilot light.
mended to clean and re-oil using biodegradable
foam air filter cleaner and oil.
However, if you use petroleum-based foam air fil- • Squeeze it dry in a clean towel. Do not wring the
element or blow it dry; the element can be dam-
ter oil, be sure to remove the biodegradable foam aged.
air filter oil completely.
Mixing the two kinds of oil may form a gluey white • Inspect the element for damage. If it is torn, punc-
tured, or hardened, replace it.
substance, though it does not affect the efficiency
of the cleaner. NOTE
Replace the element after cleaning it five times or
if it is damaged.
• After cleaning, saturate the element with a

biodegradable foam air filter oil, squeeze out
the excess, then wrap it in a clean rag and
squeeze it as dry as possible. Be careful not to
tear the element.
• Remove the towel from the inlet tract.
• Install the element in the air cleaner housing to
avoid the edges of the element from turning over.
Clamp the air cleaner housing cover securely.
• Install the mud guard plate and the seat.
NOTE
The element is sealed at its front end with the air j
cleaner housing. The sealing efficiency of the el-
ement may deteriorate if the edges of the element A. Drain Cap
are turned over during installation. B. Air Cleaner Housing
Also be sure to install the seal between the ele-
ment and the air cleaner housing.
Dust, Oil and/or Water Inspection

• Remove the drain cap on the bottom of the air
cleaner housing to expel dust, oil and/or water ac-
cumulated inside.
Spark Arrester Cleaning
Spark Arrester
WARNING
This vehicle is equipped with a spark arrester ap- HAZARD
proved for off-road use by the U.S. Forest Service. It Hot muffler.
must be properly maintained to ensure its efficiency.
In accordance with the Periodic Maintenance Chart, WHAT CAN HAPPEN
clean the spark arrester. Can burn your hands.
WARNING HOW TO AVOID THE HAZARD
HAZARD Wear gloves while cleaning the spark ar-
j Incorrectly installed spark arrester. rester. The engine must be running during
this procedure.
WHAT CAN HAPPEN
Can emit sparks which can cause a fire. • Remove the rear cap of the muffler.
Be sure the spark arrester and muffler are
installed securely.
• Remove the spark arrester and clean in a bath of

high-flash point solvent and if necessary use a fine
wire brush to gently remove any particles in the
screen.
A. Muffler
B. Rear Cap
C. Bolts
D. Spark Arrester
A. Spark Arrester
• Instartanthe
open area away from combustible materials,
engine with the transmission in neutral.
WARNING • Stop the engine.

HAZARD • Reinstallthethespark
Install arrester in place.
Cleaning the spark arrester near combustible • rear end cap.
materials.
WHAT CAN HAPPEN

Can cause a fire resulting in burns.

Never run the engine with the spark arrester
disassembled near combustible materials.
j Hot carbon particles are emitted during the
cleaning procedure.
• Raise and lower engine speed while tapping on

the muffler with a rubber mallet until carbon parti-
cles are purged from the muffler.
DANGER
HAZARD
WHAT CAN HAPPEN

monoxide poisoning, asphyxiation, and
gas.

such as a garage.
Throttle Cable
There must be free play in the throttle mechanism.
Measure the distance the throttle lever moves before
the engine begins to pick up speed. Free play should
be 2 ∼ 3 mm (0.08 ∼ 0.12 in.).
A. Adjuster
B. Locknut
If the free play cannot be set by adjusting the upper
cable adjuster, use the adjuster at the lower end of
the throttle cable. This adjustment however should
be done by an authorized Kawasaki dealer.
A. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Adjustment
• Slide the rubber cover off of the adjuster at the
throttle case.
• Loosen the locknut and turn the throttle cable up-
per adjuster to obtain the specified free play.
• Tighten the locknut and reinstall the rubber cover.
Adjustment
Reverse Lock Release Cable • Loosen
cable.
the locknut on the reverse lock release
There must be free play in the reverse lock release

system. Determine the amount of the release cable
• Turn the adjuster until the cable has the proper
amount of play.
play at the release lever. Push the lever until resis-
tance is felt; the amount of the lever is equivalent to
• Tighten the locknut after adjustment.
that of cable play.
The proper amount of play is about 1 ∼ 2 mm (0.04
∼ 0.08 in. ) at the release lever. Adjust the release
cable if there is too much or too little play.
j
A. Adjuster
B. Locknut
C. Reverse Lock Release Lever
D. Release cable
A. Reverse Lock Release Lever

B. 1 ∼ 2 mm (0.04 ∼ 0.08 in. )
Clutch
Due to friction plate wear and clutch cable stretch
over a long period of use, the clutch must be ad-
justed in accordance with the Periodic Maintenance
Chart.
WARNING
HAZARD
Malfunctioning controls.
WHAT CAN HAPPEN

j
Can result in an unsafe riding condition and
cause an accident. A. Clutch Lever
B. 5 ∼ 10 mm (0.2 ∼ 0.4 in.)
HOW TO AVOID THE HAZARD If the play is incorrect, adjust the lever play as fol-
Be sure the control cable is properly ad- lows.
justed and correctly routed. Replace the
cable if it is damaged. Adjustment
• Turn the knurled adjuster so that the clutch lever
will have 5 ∼ 10 mm (0.2 ∼ 0.4 in.) of free play.
Inspection
• Check that the clutch lever has 5 ∼ 10 mm (0.2 ∼
0.4 in.) of free play as shown.
A. Knurled Adjuster A. Knurled Adjuster

B. Adjusting Nut B. Rubber Cover (removed)
C. Locknut C. Turning-out distance of knurled adjuster
Be careful that the knurled adjuster has its limit
in turning out, or the outer cable may come off the WARNING
adjuster. HAZARD
Remove the rubber cover and make sure periodi- Clutch outer cable not fully seated in ad-
cally if the knurled adjuster still has allowance to turn juster.
out.
WHAT CAN HAPPEN
Can slip out of the place and create exces-
sive cable play. This could prevent clutch
disengagement resulting in a hazardous rid-
ing condition.

Check that the clutch outer cable is seated in
the adjuster.
If the knurled adjuster at the clutch lever has

reached its limit, use the adjusting nut next to the Drive Chain
knurled adjuster as follows.
• Turn in the knurled adjuster all the way. The drive chain must be checked, adjusted, and
• Loosen the locknut of the adjusting nut and turn
the adjusting nut so that the clutch lever play be-
lubricated in accordance with the Periodic Mainte-
nance Chart for safety and to prevent excessive
comes 5 ∼ 10 mm (0.2 ∼ 0.4 in.). wear. If the chain becomes badly worn or malad-
justed – either too loose or too tight – the chain
NOTE could jump off the sprockets or break.
After the adjustment is made, start the engine and
check that the clutch does not slip and that it re- WARNING
leases properly.
HAZARD j
A chain that breaks or jumps off the sprock-
ets.
WHAT CAN HAPPEN

Can snag on the engine sprocket and lock
the rear wheels. This can cause the vehicle
to go out of control.

Inspect and service the chain regularly and
according to the instructions in this section.
Chain Slack Inspection

• Stop the engine.
WARNING
HAZARD
Trying to measure chain slack when the en-
gine is running or the rear wheels are turning.
WHAT CAN HAPPEN

Your hands can get caught in the chain and
be severely injured.

Before inspecting chain slack, stop the en-
j gine and apply the parking brake.
• Check the amount of chain slack with your finger

by firmly pulling up the chain. There should be 40 A. 40 ∼ 50 mm
∼ 50 mm (1.6 ∼ 2.0 in.) of slack. If there is less
than 40 mm (1.6 in.) or more than 50 mm (2.0 in.) Chain Slack Adjustment
of slack, adjust the chain slack. • Loosen the clamp bolts at the end of the swingarm.
• shaft housing
Put the wrench provided in the tool kit to the axle
and turn it forward or rearward until
the drive chain has the correct amount of chain
slack.
A. Axle Shaft Housing Tightening Torque

B. Clamp Bolts
C. Wrench Clamp Bolts: 32 N·m (3.3 kgf·m, 24 ft·b)
NOTICE WARNING
Do not overtighten the chain. Overtighten- HAZARD
ing will cause accelerated wear to engine and Loose swingarm clamp bolts.
drive line components.
WHAT CAN HAPPEN
• Tighten the clamp bolts to the specified torque fol-
lowing the order shown in the illustration.
Can cause the rear brake to fail or the drive
chain to become loose and jump off the
sprockets. Brake failure, or lock up of the
rear wheels from a jammed chain can cause
a serious accident.

Be sure to tighten the swingarm clamp bolts
to the specified torque.
Wear Inspection WARNING
• Stretch the chain taut either by using the chain
adjusters, or by hanging a 10 kg (22 lb) weight on
HAZARD
Chain failure.
the chain.
• Measure the length of 20 links on the straight part
of the chain from pin center of the 1st pin to pin
WHAT CAN HAPPEN
Can lock the rear wheels and cause an acci-
center of the 21st pin. Since the chain may wear
dent.
unevenly, take measurements at several places.
• If the length exceeds the service limit, the chain
should be replaced.
Use only a genuine Kawasaki replacement
chain installed by an authorized Kawasaki
j dealer.
• Rotate the rear wheels to inspect the drive chain

for damaged rollers, and loose pins and links.
• Also inspect the sprockets for unevenly or exces-
sively worn and/or damaged teeth.
NOTE
Sprocket wear is exaggerated for illustration. See
Service Manual for wear limits.
A. Measure
B. Weight
Drive Chain 20-Link Length

Service Limit: 324 mm (12.8 in.)
• Ifand/or
there is any irregularity, have the drive chain
the sprockets replaced by an authorized Sprocket Cover
Kawasaki dealer.
Do not operate this vehicle without the sprocket
Lubrication cover installed and in good condition.
• Support the rear of the vehicle on a stable stand
with both rear wheels off the ground. Turn the
wheels slowly while oiling the chain.
WARNING
• Use a heavy oil, such as SAE90 gear oil, to lubri-
cate the chain. Make sure the oil penetrates the
HAZARD
Missing sprocket cover.
side plates of the chain.
WHAT CAN HAPPEN
Can cause the rider’s clothing or body to be- j
come entangled in the chain and sprocket.

Never operate the vehicle with the sprocket
cover missing.
Idle Adjustment
Idle adjustment is done with the idle adjust-
ing/choke knob.
A. Sprocket Cover
B. Engine Sprocket
A. Idle Adjusting/Choke knob

B. Engine Cylinder (left side)
Adjustment The idle adjusting/choke knob also functions as

the choke knob. When adjusting the idle, be sure
WARNING to have the knob fully pushed-in. With the knob
HAZARD pulled-out, you cannot adjust the idling.
Hot engine.
WARNING
WHAT CAN HAPPEN
HAZARD
Can burn your hands.
Failure to maintain the control cable.
WHAT CAN HAPPEN
Never touch a hot engine during idle adjust-
Can result in control malfunction and an ac-
ment. j
cident. Without proper maintenance the ca-
ble can become frayed, kinked, pinched, and
• Adjust the idle speed to the specified speed by
turning the idle adjusting/choke knob. damaged so that it can break or jam.
• With the engine idling, turn the knob counterclock-
wise to raise the idling speed and clockwise to re- HOW TO AVOID THE HAZARD
duce it. Be sure the control cable is properly ad-
justed and correctly routed. Replace the
• Open and close the throttle a few times to make
sure that the idle speed does not change. Read- cable if it is damaged.
just if necessary.
Specified Idle Speed: 1 800 ±100 rpm
NOTE
With the engine idling, turn the handlebar to each
side. If handlebar movement changes idle speed,
the throttle cable may be incorrectly routed, im-
properly adjusted, or it may be damaged.
Fuel Tank Vent Brakes

The fuel tank vent hose must be routed as speci- Disc and brake pad wear is automatically compen-
fied. sated for and has no effect on the brake lever or
The engine may stall or lose power if the fuel tank pedal action. There are no parts that require adjust-
vent is plugged or if the vent hose is pinched. Inspect ment on the brakes except brake lever position.
the vent hose before riding and whenever the engine
seems to lose power. If the fuel tank is full but the WARNING
engine feels as if it is running out of fuel, check the HAZARD
vent and vent hose. Air in brake line.
j
WHAT CAN HAPPEN
Can make the brake feel mushy or soft. This
may cause reduced braking performance or
brake failure and result in an accident.

If brake lever travel is excessive or the brake
feels mushy, have an authorized Kawasaki
dealer inspect it immediately.
Brake Wear Inspection

In accordance with the Periodic Maintenance
Chart, inspect the brakes for wear. For each disc
A. Fuel Tank Vent Hose
B. Fuel Tank Cap brake calipers, if the thickness of either pad is less
than 1 mm (0.04 in.), replace both pads in the caliper
as a set. Pad wear inspection and pad replacement
should be done by an authorized Kawasaki dealer.
WARNING
HAZARD
Contaminated brake fluid.
WHAT CAN HAPPEN

Can reduce braking performance or cause
brake failure, resulting in an accident.

Do not use brake fluid from a container that
has been left open or that has been unsealed
for a long time. The fluid will absorb moisture j
and may be contaminated with dust and dirt.
A. Pad Thickness
B. 1 mm (0.04 in.) WARNING
Disc Brake Fluid HAZARD
In accordance with the Periodic Maintenance Damaged or leaking brake hoses and fittings.
Chart, inspect the brake fluid level in the front brake
fluid reservoir and change the brake fluid. The WHAT CAN HAPPEN
brake fluid should also be changed if it becomes Can cause brake failure resulting in an acci-
contaminated with dirt or water. dent.
Fluid Requirement HOW TO AVOID THE HAZARD

Use extra heavy-duty brake fluid only from a con- Inspect brake fluid level regularly.
tainer marked DOT4. Replace any damaged or leaking brake
hoses and fittings.
NOTICE Maintain the brake system in accordance
Do not spill brake fluid onto any painted sur- with the Periodic Maintenance Chart.
face. It will damage the paint. If brake fluid is
spilled, wash it off immediately with water.
Fluid Level Inspection
• The brake fluid levels in the brake fluid reservoirs
must be kept above the lower level line (reservoir
held horizontal).
A. Rear Reservoir
B. Lower Level Line
• Iflinethewith
level is low, fill the reservoir to the upper level
the same type and brand of fluid that is
A. Front Reservoir already in the reservoir. Inside the reservoir is a
B. Lower Level Line stepped line showing the upper level line.
Fluid Change
Have the brake fluid changed by an authorized
Kawasaki dealer.
A. Front Reservoir
B. Upper Level Line
A. Rear Reservoir
B. Upper Level Line
Parking Brake
• Ifcable
it moves more than 2 mm (0.08 in.), adjust the
tension as follows.
The parking brake needs proper tension on the

cable to hold the vehicle from rolling while parked.
In accordance with the Periodic Maintenance Chart,
check the cable tension as follows.
A. Adjusting nut
B. Locknut
• Release the locknut and turn the adjusting nut until

movement becomes less than 2 mm (0.08 in.).
A. Parking Brake Lever • Tighten the locknut.
B. Parking Brake Outer Cable NOTE
C. Rubber Cover (Removed)
D. Check movement here.
Make sure the parking brake lever flips to either
position without difficulties.
• Pull and remove the rubber cover.
• Flip the brake lever to the “PARK OFF” position.
• Holding the outer cable, pull it and check if the
cable adjuster end moves more than 2 mm( 0.08
in.).
Brake Light Switch

• Ifbulb
the light does not turn on as above, check the
and if necessary, adjust the brake light switch.
Only the switch at the rear brake pedal can be

Adjustment
adjusted. • To adjust the brake light switch (located near the
brake pedal), move the switch forward or rearward
When the brake pedal is depressed, the brake light
by turning the adjusting nut.
goes on. The brake light switch should be inspected
in accordance with the Periodic Maintenance Chart. NOTICE
The brake light switch of the front brake lever can-
not be adjusted. To avoid damaging the electrical connec-
tions inside the switch, be sure that the
Inspection switch body does not turn during adjust-
• Turn the ignition switch to the “ON” position. ment. j
• go on aftertheabout
Depress brake pedal. The brake light should
10 mm (0.4 in.) of pedal travel.
A. Brake Light Switch

A. Brake Pedal B. Adjusting Nut
B. 10 mm (0.4 in.) C. Lights later.
D. Lights sooner.
NOTE
Wheels Tires are an important part of the suspension on
your ATV. Tire construction characteristics and
Rims: tire inflation pressure can greatly influence vehicle
handling. Kawasaki recommends that you always
The rims are a drop-center, tubeless tire design.
replace tires with standard replacement tires as
Take care not to damage the sealing surfaces of the
shown here. It is also very important to have
tire or rim when removing or installing tires. Note that
tires of the same type and size, and at the same
the rims, like automotive rims, are not symmetrical
inflation pressure, on one axle.
and should be installed in one direction only. All
wheels must be installed so that the valve stems are Installation of non-standard tires, or use of differ-
ent tires on one axle, can change the handling of
on the outside of the vehicle.
the vehicle and possibly result in a loss of control.
j
Tires: Installation of tubeless tires on rims requires com-
The front and rear tires are directional knobby pressed air and is normally recommended as a
tubeless tires. When replacing tires, check the dealer service operation. However, a tube can be
valve stems and cores for damage. Take care not inserted into the tire by the operator as an emer-
to damage the tire sealing surfaces of the rims. Be gency repair.
certain the directional arrows on the tires indicate
rolling forward. Maximum Tire Air Pressure for Seating Beads
Standard Tires Front and Rear 250 kPa (2.5 kgf/cm², 36 psi)
AT21 × 7R10
Front Payload and Tire Pressure
KT391 T/L
Failure to maintain proper inflation pressures for
AT20 × 10R9 your tires may adversely affect handling and perfor-
Rear
KT396 T/L mance of your vehicle and can result in loss of con-
trol.
Tire Air Pressure (when cold) Use the tire pressure gauge in the tool kit to accu-
rately set tire pressure.
Front 30 kPa (0.3 kgf/cm², 4.4 psi)
Rear 27 kPa (0.27 kgf/cm², 3.9 psi)
WARNING • InChart,
accordance with the Periodic Maintenance
measure the depth of the tread with a
HAZARD
depth gauge, and replace any tire that has worn
Unequal tire pressure.
down to the minimum allowable tread depth.
WHAT CAN HAPPEN
Can cause difficult and unpredictable steer-
ing resulting in an accident.

Inflate the tires to the correct air pressure.
WARNING j
HAZARD
Operating this ATV with improper tires, or
with improper tire pressure.
WHAT CAN HAPPEN

Use of improper tires on this ATV, or opera- A. Tire Depth Gauge
tion of this ATV with improper tire pressure,
may cause loss of control, increasing your Minimum Tread Depth
risk of an accident. Front Tire 3 mm (0.12 in.)
Rear Tire 3 mm (0.12 in.)
Always use the size and type tires specified
Tightening Torque
in the Owner’s Manual for this vehicle.
Always maintain proper tire pressure as de- Wheel Nut 79 N·m (8.1 kgf·m, 58 ft·lb)
scribed in this Owner’s Manual.
• Visually inspect the tire for cracks and cuts, replac-
ing the tire in case of bad damage. Swelling or
Tire Wear, Damage high spots indicate internal damage, requiring tire
As tire tread wears down, tires become more sus- replacement.
ceptible to puncture and failure.
• Remove any imbedded stones or other foreign

particles from the tread. Joint Boots
In accordance with the Periodic Maintenance
Chart, inspect the joint boots on the front suspen-
sion arms (4 pieces), and tie rod ends (4 pieces), for
cracks, holes, damage or deterioration. If there is
any indication of these troubles in one of them, have
the joint boot replaced by an authorized Kawasaki
dealer.
A. Joint Boots
B. Tie Rod
Suspension Headlight Beam

The front and rear shock absorbers can be ad- The headlight beams can be adjusted vertically.
justed by changing the spring preload for various rid-
ing and loading conditions. If the spring action feels
• Turn the adjusting screw on each headlight rim in
or out to adjust the headlight vertically.
too soft or too stiff, have it adjusted by an authorized
Kawasaki dealer.
A. Headlight
B. Adjusting Screw
A. Front Shock Absorbers
B. Rear Shock Absorber
Battery
The battery is located below the radiator.
DANGER
HAZARD
Batteries contain sulfuric acid.
Batteries produce hydrogen gas.
WHAT CAN HAPPEN

j Sulfuric acid can cause burns.
Hydrogen gas can cause an explosion.
HOW TO AVOID THE HAZARD A. Battery Cover

B. Radiator
Read and understand the battery safety la-
bel.
(see Location of Label chapter). Battery Removal
• Remove the battery cover.
• Put a light coat of grease on the terminals to pre-

vent corrosion.
• Cover the (+) terminal with its protective cap.
• Reinstall the battery cover.
WARNING
HAZARD
Loose battery cables.
WHAT CAN HAPPEN

Can create sparks which can cause a fire or
explosion resulting in injury or death. j
A. Battery Case Make sure the battery terminal screws are
B. (+) Terminal
tightened securely and the covers are in-
C. (–) Terminal
stalled over the terminals.
• Disconnect the cables from the battery, first from
the (–) terminal and then the (+) terminal.
NOTICE
• Remove the battery from its case.
• and water.battery
Clean the using a solution of baking soda
Be sure that the lead connections are
Do not reverse the battery connections, or
damage to the regulator/rectifier unit will re-
clean. sult.
• Perform a visual inspection. Inspect for defective
or cracked case and cover, and loose or damaged Battery Characteristics
terminal posts or cables. Replace battery and/or The battery installed in this vehicle is a sealed
cables immediately if any damage is found. type, and the sealing strip should not be removed
Battery Installation at any time after the specified electrolyte has been
• Put the battery in place. installed in the battery for initial service. It is not nec-
• Securely connect the cable with protective cap to
the (+) terminal, and then securely connect the
essary to check the battery electrolyte level or add
distilled water.
black cable to the (–) terminal.
However, in order to maximize battery life and en- Self-discharge
sure that it will provide the power needed to start
your vehicle you must properly maintain the battery’s Approx. Number of Days
charge. When used regularly, the charging system From 100% Charged to 100%
in your vehicle helps keep the battery fully charged. Temperature discharged
If your vehicle is only used occasionally or for short Lead-Antimony Lead-Calcium
periods of time, the battery is more likely to dis-
charge. Battery Battery
Due to their internal composition, batteries contin- 40°C (104°F) 100 Days 300 Days
ually self discharge. The discharge rate depends 25°C (77°F) 200 Days 600 Days
on the type of battery and ambient temperature. As
temperatures rise, so does the discharge rate. Ev- 0°C (32°F) 550 Days 950 Days
j ery 15°C (27°F) doubles the rate.
Electrical accessories, such as digital clocks and Current Drain (Y50-N18L-A)
computer memory, also draw current from the bat- Days from
tery even when the key is switched off. Combine Days from 100%
Discharg- 100% Charged
such “key-off” draws with hot temperature, and a Charged to 50%
ing Ampere to 100%
battery can go from fully charged to completely dis- Discharged
Discharged
charged in a matter of days. 7 mA 60 Days 119 Days
10 mA 42 Days 83 Days
In extremely cold weather the fluid in an inade-

quately charged battery can easily freeze, which
can crack the case and buckle the plates. A fully
charged battery can withstand sub-freezing temper-
atures with no damage.
Battery Sulfation
A common cause of battery failure is sulfation.
Sulfation occurs when the battery is left in a dis- For more details, ask your Kawasaki dealer.
charged condition for an extended time. Sulfate is a
Battery Charging
normal by product of the chemical reactions within a
battery. But when continuous discharge allows the •Remove the battery from the vehicle (see Battery
Removal).
sulfate to crystallize in the cells, the battery plates
become permanently damaged and will not hold a •Attach the leads from the charger and charge the
battery at a rate that is 1/10th of the battery ca-
charge. Battery failure due to sulfation is not war-
pacity. For example, the charging rate for a 10 Ah
rantable.
battery would be 1.0 ampere.
Battery Maintenance
It is the owner’s responsibility to keep the battery
•The charger will keep the battery fully charged un-
til you are ready to reinstall the battery in the vehi-
fully charged. Failure to do so can lead to battery cle (see Battery Installation).
failure and leave you stranded. j
If you are riding your vehicle infrequently, inspect NOTICE
the battery voltage weekly using a voltmeter. If Never remove the sealing strip, or the battery
it drops below 12.6 volts, the battery should be can be damaged.
charged using an appropriate charger (check with Do not install a conventional battery on this
your Kawasaki dealer or visit buykawasaki.com) vehicle, or the electrical system cannot work
at a rate of 1/10th of the battery capacity. If you properly.
will not be using your vehicle for longer than two
weeks, the battery should be charged using an
appropriate charger. Do not use an automotive-type NOTE
quick charger that may overcharge the battery and If you charge the sealed battery, never fail to ob-
damage it. serve the instructions shown on the label on the
Kawasaki-recommended chargers are: battery.
OptiMate
Yuasa 1.5 Amp Automatic charger
Battery Mate 150–9
If the above chargers are not available, use equiv-
alent one.
WARNING
HAZARD
Fuse
Handling battery parts that contain lead and
The main fuse and the fuses for the radiator fan
lead compounds
and fuel pump are located in the front part of the ve-
hicle, and spare fuses are next to them. If the elec-
WHAT CAN HAPPEN
trical systems do not function, inspect the fuse. Be-
Could cause health problem.
fore replacing the fuse, check the wiring harness and
electrical equipment for bare wires or other possible
causes.
Wash hands after handling battery.
NOTICE
j
The standard fuses are 30 A (main fuse), and
10 A (radiator fan and fuel pump). Do not use
a fuse of a higher capacity, or damage to the
electrical system could result.
• Remove the front cover.

• Radiator and fuel pump fuses are stowed in the
vinyl bag, open it to take out the fuse cases.
A. Front Cover A. Radiator Fuse

B. Screws B. Fuel Pump Fuse
C. Main Fuse
• Pull
fuse.
and remove the fuse case to inspect each D. Vinyl Bag
NOTE
General Lubrication After connecting the cables, adjust them.
Lubricate the points shown below, with either mo-
tor oil or regular grease, in accordance with the Peri-
odic Maintenance Chart or whenever the vehicle has
been operated under wet or rainy conditions, and es-
pecially after using a high-pressure spray washer.
Before lubricating each part, clean off any rusty
spots with rust remover and wipe off any grease, oil,
dirt, or grime.
j NOTE
A few drops of oil are effective in keeping bolts
and nuts from rusting and sticking. This makes re-
moval easier. Badly rusted nuts, bolts, etc., should
be replaced with new ones.
Apply motor oil to the following pivots:
Brake Lever
Brake Pedal
Reverse Lock Release Lever
Clutch Lever
Parking Brake Lever
Apply grease to the following points:
Throttle Inner Cable Upper End
Clutch Inner Cable Upper End
Lubricate the following cables with a pressure
cable luber
Clutch Inner Cable
Throttle Inner Cable
Cleaning
• Swingarm pivot
NOTE
For the prolonged life of your vehicle, wash it down Coin operated, high pressure spray washers are
immediately after it has been splashed with seawa- not recommended. The water may be forced into
ter or exposed to the sea breeze, or operated on bearings and other components causing eventual
rainy days, rough terrain, or in dusty areas. failure from rust and corrosion. Some of the soaps
which are highly alkaline leave a residue or cause
Preparations for Washing spotting.
Before washing, these precautions must be taken
to keep water off the following parts. After Washing
• Muffler rear opening – cover with a plastic bag
secured with a rubber band. • Remove all plastic bags from the muffler and the
handlebars, take the tape off the ignition switch, j
• Brake and clutch levers, switch case, throttle case
– cover with plastic bags.
and open the air cleaner intake.
• Ignition switch – cover the keyhole with tape. • Lubricate the points listed in the General Lubrica-
tion section.
• Air cleaner intake – close opening with tape, or
stuff in rags. • Test the brakes before operation.
• Start the engine and run it for 5 minutes.
Where to be Careful
Avoid spraying water with any great force near the WARNING
following places. HAZARD
• Disc brake master cylinder and caliper. Wax, oil, or grease on brake discs.
• Under the fuel tank – if water gets into the spark
plug cap, the spark will jump through the water and WHAT CAN HAPPEN
be grounded out. When this happens, the vehicle Can cause loss of braking and an accident.
will not start and the affected parts must be wiped
dry. HOW TO AVOID THE HAZARD
• Fuses and other electric equipment under the front
cover
Clean the brake discs with an oilless solvent
such as trichloroethylene or acetone. Ob-
• Front wheel hub and rear axle shaft housing serve the solvent manufacturer’s warnings.
• Steering pivot
Bolt and Nut Tightening

Every day before riding, check the tightness of the nuts and bolts listed here. Please refer to the Service
Manual or ask your authorized dealer for the torque values.
1. Front Shock Absorber 6. Stem Bracket Bolts 12. Stem Bearing Bracket Bolts
Mounting Bolts and Nuts 7. Garb Rail Bolts 13. Suspension Arm Pivot Bolts
2. Handlebar Clamp Bolts 8. Caliper Mounting Bolts 14. Engine Mounting Bolts and
3. Clutch Lever Pivot Nut 9. Steering Knuckle Pivot Nuts Nuts
4. Clutch Lever Holder Screws 10. Hub Nut 15. Shift Pedal Bolt
5. Left Switch Housing Screws 11. Wheel Nuts 16. Footpeg Mounting Bolt
17. Chain Adjuster Clamp Bolts 22. Brake Lever Pivot Nut
18. Muffler Mounting Bolts 23. Brake Pedal Bolt
19. Rear Shock Absorber Mounting Bolts and Nuts 24. Swing Arm Pivot Nuts
20. Exhaust Pipe Holder Nuts 25. Rear Frame Bolts and Nuts
21. Throttle Case Screws
136 STORAGE
STORAGE
Preparation for Storage

• Empty the fuel tank.
WARNING
• Clean the entire vehicle thoroughly. HAZARD
• Run the engine for about five minutes to warm the
oil, shut it off and drain the engine oil.
Draining the fuel system without following
proper precautions.
WARNING WHAT CAN HAPPEN
HAZARD Gasoline is extremely flammable and can be
Improper disposal of used motor oil. explosive under certain conditions.
WHAT CAN HAPPEN or death.
j Used motor oil is a toxic substance, which
can pollute the environment. HOW TO AVOID THE HAZARD
When working on the fuel system, do not
HOW TO AVOID THE HAZARD smoke. Turn the ignition key to “OFF”. Make
Contact your local authorities for approved sure the area is well ventilated and free from
disposal methods and follow those methods any source of flame or sparks; this includes
at all times. any appliance with a pilot light.
If gasoline is spilled, wipe it up immediately.
• Put in fresh engine oil.
STORAGE 137
WARNING WARNING
HAZARD HAZARD
Improper disposal of gasoline. An air/oil mist may be forcibly ejected from
the spark plug hole.
WHAT CAN HAPPEN
Gasoline is a toxic substance, which can pol- WHAT CAN HAPPEN
lute the environment. The air/oil mist could get into your eyes, and
cause severe discomfort or eye injury if not
HOW TO AVOID THE HAZARD removed immediately.
Contact your local authorities for approved
disposal methods and follow those methods HOW TO AVOID THE HAZARD
at all times. Do not lean over the engine when perform-
ing this procedure. If you do get some air/oil
• Remove the spark plug and spray fogging oil,
such as Kawasaki K-Kare Fogging Oil (P/N
mist in your eyes, wash your eyes immedi-
ately with liberal amounts of clean, fresh wa- j
K61030-002), directly into the cylinder. Turn the ter. Consult a physician as soon as possible.
engine over several times with the starter button
to coat the cylinder walls. Install the spark plug.
• Put boards under the front and rear wheels to keep
dampness away from the tire rubber.
NOTE
Ask an authorized dealer for this service since the • Spray oil on all unpainted metal surfaces to pre-
vent rusting. Avoid getting oil on rubber parts or in
fuel tank needs to be removed as an access. the brakes.
• Lubricate all the cables.
• Remove the battery, and store it where it will not
be exposed to direct sunlight, moisture, or freezing
temperatures. During storage it should be given a
slow charge (one ampere or less) about once a
month.
138 STORAGE
NOTICE
Keep the battery well charged during cold
Removal from Storage
weather so that the electrolyte does not
freeze and crack open the battery. The more DANGER
discharged a battery becomes, the more
easily it freezes. HAZARD
• Tie a plastic bag over the muffler to prevent mois-
ture from entering. WHAT CAN HAPPEN
• Put a cover over the vehicle to keep dust and dirt
from collecting on it. monoxide poisoning, asphyxiation, and
gas.
j HOW TO AVOID THE HAZARD
such as a garage.
• Remove the plastic bag from the muffler.

• vehicle. battery if necessary, and install it in the
Charge the
• Fill the fuel tank with fuel.

• Checks”allsection.
Check the points listed in the “Daily Safety
• Lubricate the points listed in the “General Lubrica-

tion” section.
TRANSPORTING THE ATV 139
TRANSPORTING THE ATV

Note the following points for transporting the vehi-
cle.
• Check that the vent hose for the fuel tank is prop-
erly routed.
WARNING
HAZARD
Transporting this ATV tipped up on its rear
A. Filler Cap end.
B. Fuel Tank Vent Hose
WHAT CAN HAPPEN
• Always
ing.
position the vehicle level when transport-
Can cause gasoline to leak from the fuel tank
causing a fire hazard.

Never tip this vehicle up on end for transport-
ing.
140 TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Starter Motor Not Rotating • Engine overheated
• Engine stop switch “OFF” Too much idling or low speed running (not
• Fuse failed enough air flow)
• Battery leads do not make good electrical contact
with battery terminals.
Wrong spark plug
Radiator clogged
• Battery discharged Coolant level too low
Coolant deteriorated
Engine Cranks, But Won’t Start Cooling fan malfunction
• No fuel in tank Engine oil low
• Fuel filter clogged (on pump)
• Fuel pump malfunction No Power
• Water in fuel • Engine overheated
Too much idling or low speed running (not
• Idle adjusting knob is not used when engine is cold
• Air filter clogged or inlet blocked enough air flow)
Wrong spark plug
• Engine flooded
Radiator clogged
j • Fuel tank vent clogged or hose kinked
Coolant level too low
• Spark plug wire not connected on spark plug
Coolant deteriorated
• Valve clearance incorrect
Cooling fan malfunction
• Spark plug dirty
Engine oil low
• Ignition key not turned off first when vehicle tipped
over and vehicle-down sensor activated • Compression leakage
Valve clearance insufficient
Engine Stops • Clutch slipping
Clutch cable misadjusted
• No fuel in tank
• Water in fuel • Clutch doesn’t disengage properly
• Fuel filter clogged (on pump) • Fuel filter clogged
• Fuel pump malfunction • Air filter clogged or inlet blocked
• Air filter clogged or inlet blocked • Spark plug dirty or worn
• Fuel tank vent clogged • Idle adjusting knob left on
• Transmission in too high a gear
TROUBLESHOOTING GUIDE 141
• Engine oil incorrect

• Water in fuel
j
142 OWNER SATISFACTION
OWNER SATISFACTION
(For Products Sold in the Continental United States of America Only)

Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Corp., U.S.A. If
you have a problem concerning warranty or service, please take the following action:
Contact the owner and/or service manager of your authorized Kawasaki dealer. Fully explain your problem
and ask for assistance in resolving the situation. The OWNER of the dealership is concerned with your sat-
isfaction and your future business. For this reason the owner is in the best position to assist you. Also, all
warranty and service matters are handled and resolved through the authorized Kawasaki dealer network.
If you are unsatisfied after working with your Kawasaki dealer and feel you still require further assistance,
write to the address below. Please be certain to provide the model, product identification number, mileage or
hours of use, accessories, dates that events occurred and what action has been taken by both you and your
dealer. Include the name and address of the dealership. To assist us in resolving your inquiry, please include
copies of related receipts and any other pertinent information including the names of the dealership personnel
with whom you have been working in the resolution of your problem.
Upon receipt of your correspondence we will contact the dealership and work with them in resolving your
problem.
In order to provide a permanent record, all warranty and service resolutions take place only through written
correspondence.
Please send your correspondence to:. CONSUMER RELATIONS

KAWASAKI MOTORS CORP., U.S.A.
P.O. Box 25252
SANTA ANA, CA. 92799-5252
(949) 460–5688
ENVIRONMENTAL PROTECTION 143
ENVIRONMENTAL PROTECTION
To protect our environment, properly discard used tire, engine oil, or other vehicle components that you might
dispose of in the future.
Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal proce-
dure.
144 MAINTENANCE RECORD
MAINTENANCE RECORD
Owner Name...................................................................................................................................
Address ..........................................................................................................................................
Phone Number ...............................................................................................................................
Engine Number ..............................................................................................................................
Vehicle Number..............................................................................................................................
Selling Dealer Name ......................................................................................................................
Address ..........................................................................................................................................
Phone Number ...............................................................................................................................
Warranty Start Date .......................................................................................................................

Note: Keep this information and a spare key in a secure location.
Date Traveled Distance Maintenance Performed Dealer Name Dealer Address

MAINTENANCE RECORD 145


MAINTENANCE RECORD 147


2009 Kawasaki Kfx450r 2

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GENERAL INFORMATION j

Quick Reference Guide

MAINTENANCE AND ADJUSTMENT j

A Table of Contents is included after the

HOW TO AVOID THE HAZARD

KAWASAKI HEAVY INDUSTRIES, LTD.

© 2008 Kawasaki Heavy Industries, Ltd. Nov. 2008. (4) (D)

Lubrication System Forced lubrication (semi-dry sump)

Transmission Type 5-speed return & reverse

Tire Size: Front AT21 × 7-10

Rim Size: Front 10 × 5.5

Specifications subject to change without notice.

SERIAL NUMBER LOCATIONS

Frame No. Engine No.

A. Frame Number A. Engine Number

8. Shock Absorber Warning 9. Specification Label

1. Clutch Lever 7. Reverse Lock Release Lever

20. Rear Brake Pedal

WHAT CAN HAPPEN

Because an all terrain vehicle is sensitive to in-

• Do not install accessories that impairs the perfor-

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

To shift out of reverse, follow this procedure:

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

A. Reverse Lock Release Lever

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

WHAT CAN HAPPEN

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Engine Stop Switch:

A. Engine Stop Button

A. Idle Adjusting/Choke Knob

• When starting in cold condition, refer to the Start-

HOW TO AVOID THE HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

has warmed, push the idle adjusting/choke knob

Idle Adjusting/Choke Knob

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

• Turn the ignition key to “ON”.

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

• Under most conditions stop by pulling in the front

Stopping the Engine Parking the ATV

• Close the throttle completely. • Stop the vehicle on a level surface.

• When the engine has stopped, shift the transmis-

that requires them to reach to put their feet on

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Off-Road Use Only

HOW TO AVOID THE HAZARD

WHAT CAN HAPPEN HOW TO AVOID THE HAZARD

HOW TO AVOID THE HAZARD

Before Starting the Engine Use the Parking Brake

HOW TO AVOID THE HAZARD

HOW TO AVOID THE HAZARD

If you must ride over a small obstacle, approach it

HOW TO AVOID THE HAZARD

Remember: HOW TO AVOID THE HAZARD