Kawasaki ~ A ~ LZX-7 ZX-7R Motorcycle Owner's ManualWhenever you see the symbols shown below, heed their instructions! Always follow safe operating and main- tenance practices. AWARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equip- ment. NOTE OThis note symbol indicates points of particular interest for more efficient and convenient operation. NOTICE THIS PRODUCT HAS BEEN MANU- FACTURED FOR USE IN A REASON- ABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.FOREWORD We wish to thank you for choosing this fine Kawasaki Motorcycle. Your new mo- torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety, and performance. Read this Owner's Manual before riding so you will be thoroughly familiar with the proper operation of your motorcycle's controls, its features, capabilities and limita- tions. This manual offers many safe riding tips, but its purpose is not to provide in- struction in all the techniques and skills required to ride a motorcycle safely. Kawasaki strongly recommends that all operators of this vehicle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle operation. To ensure a long, trouble-free life for your motorcycle, give it the proper care and maintenance described in this manual. For those who would like more detailed infor- mation on their Kawasaki Motorcycle, a Service Manual is available for purchase from any Kawasaki dealer. The Service Manual contains detailed disassembly and mainte- nance information. Due to improvements in design and performance during production, in some cases there may be minor discrepancies between the actual vehicle and the illustrations and text in this manual KAWASAKI HEAVY INDUSTRIES, LTD. CONSUMER PRODUCTS GROUP © Kawasaki Heavy Industries, Ltd.. 1993, 1994 Feb. 1994. (3). (S)mmo» MPMI” TABLE OF CONTENTS «aca aaKcaeKacenene Fuel Tank Cap. Specifications... Fuel Tank.. Consumer Information. Serial Number Locations Location of Parts Location of Labels Loading Information... General Information Meter Instruments. Speedometer and Tachometer Coolant Temperature Gauge Indicator Lights. Key Ignition Switch/Steering Lock... Right Handlebar Switches Engine Stop Switch Starter Button . Tying Hooks Helmet Hook(s) Storage Box. Too! Kit Compartment .. Electric Accessory Leads. Air Cleaner Intake .. Break-In How to Starting the Engine. Jump Starting Left Handlebar Switches. Moving Off.. Dimmer Switch ..... Shifting Gears Turn Signal Switch. Braking...... Stopping the Engine. Stopping the Motorcycle in an Emergency . Horn Button... Brake/Clutch Lever AdjustersParking... Safe Operation. ....... Safe Riding Technique Daily Safety Checks... Additional Considerations for High Speed Operation... Maintenance and Adjustment Periodic Maintenance Chart... ENGINE Oli. esnnrnrenne Cooling System Spark Plugs Valve Clearance Evaporative Emission Control System... Kawasaki Clean Air System. Air Cleaner. , Throttie Grip. Choke Lever. Carburetors Clutch ass Drive Chain. Brakes... - Brake Light Switches Front Fork. Battery Headlight Beam . Fuses, 2421 Fuel System... 122 General besten 123 Cleai 125 Bolt and Nut Tightening... Storage seveecinseh 30 Troubleshooting Guid. sees D2 Reporting Safety Defects... 133 Owner Satisfaction : 2134 Maintenance Record 136Do» MMOMDMMMPHM MPD” GPECIFICATIONS CKaKcceeeeeaememecee «eee (* ZX750M only) DIMENSIONS Overall Length 2,085 mm (82.09 in.) Overall Width 730 mm (28.7 in.) Overall Height 1,140 mm (44.88 in.) Wheelbase: 1,430 mm (56.30 in.) Road Clearance 100 mm (3.94 in.) Dry Weight 205 kg (452 Ib) 205.5 kg (453 Ib) * 200 kg (441 Ib) 200.5 kg (442 Ib) ENGINE Type DOHC, 16-valve, 4-cylinder, 4-stroke, liquid-cooled Displacement 749 mL (45.7 cu in.) Bore x Stroke 71.0 x 47,3 mm (2.80 x 1.86 in.) Compression Ratio 11551 Starting System Electric starter Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Carburetors Keihin CVKD38 x 4 * Keihin FVKD3S9 x 4 Ignition System Battery and coil (transistorized ignition)Ignition Timing (Electronically advanced) Spark Plugs Lubrication System Engine Oil Engine Oil Capacity Coolant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Retio Gear Ratio: Ist 2nd 3rd 4th Sth 6th 10° BTDC @1,100 [ 5° BTDC @1,300] r/min (rpm) ~ 50° BTDC @7,000 r/min (rpm) NGK CR9E or ND U27ESR-N Forced lubrication (wet sump) SE, SF or SG class SAE 10W40, 10W50, 20W40, or 20W50 4.0 L (4.2 US qt) 2.8L (3.0 US qt) 6-speed, constant mesh, return shift Wet, multi disc Chain drive 1.784 (93/53) 2.750 (44/16) * 2.562 (41/16) 5.324 (Top gear) * 6.396 (Top gear) 2.857 (40/14) + 2.375 (38/16) 2,055 (37/18) —* 1.894 (36/19) 1.650 (33/20) = 1.619 (34/21) 1,391 (32/23) = 1.409 (31/22) 1.222 (33/27) * 1.291 (31/24) 1.103 (32/28) * 1.200 (30/25)FRAME Castor 24.5° Trail 95 mm (3.74 in.) Tire Size: Front 120/70ZR17 Tubeless Rear 180/552R17 Tubeless Fuel Tank Capacity 18 L (4.8 US gal) 17 L (4.5 US gal) ELECTRICAL EQUIPMENT Battery 12.V 10 Ah *12V8Ah Headlight 12 V 60/55 W x2 Tail/Brake Light 12V 8/27 Wx2 : California model Specifications subject 10 change without notice.»o»pmmymrrm»»” CONSUMER INFORMATION «Kacacancacnncnc Vehicle Minimum Stopping Distance on Dry Pavement These figures indicate braking performance that can be met or exceeded by the vehicle to which they apply, without locking the wheels, under different condi- tions of loading. The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions. Description of vehicle to which this table applies: Model ZX750-L2/M2 A. Fully Operational Service Brake Load: Light XX 152 Maximum RON WSS 0 50 100 150 200 Stopping distance in feet from 60 mph. Manufacturer: Kawasaki Heavy Industries, Ltd.»yyyypyyoyon oo SERIAL NUMBER LOCATIONS «aKcaaacannqacnnk The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identity Frame No. Engine No. A. Engine Number»ooammmnyyymmy mmm» LOCATION OF PARTS EMM EEE MEE Clutch Lever Clutch Fluid Reservoir Meter Instruments Brake Fluid Reservoir (Front) Front Biake Lever Left Handiebar Switches Spring Preload Adjuster Rebound Damping Force Adjuster Ignition Switch/Steering Lock Right Handlebar Switches Throttle Grip. Front Fork Headlight Turn Signal Light Spark Plugs . Air Cleaner Fuel Tap Storage Box . Battery ). Seat Lock Helmet Hook Too! Kit Compartment Tying Hooks Brake Disc . Brake Caliper . Oil Filter . Side Stand . Shift Pedal Drive Chain ZX750LZX750L, Tail/Brake Light Passengers Seat Coolant Reserve Tank Brake Fluid Reservoir (Rear) Ridor's Seat Junction Box (Fuses) . Carburetors Fuol Tank Cap . Fuel Tank . Muffler |. Roar Brake Light Switch . Rear Shock Absorber Rebound Damping Force Adjuster . Rear Brake Pedal . Idle Adjusting Screw . Oil Level Gauge . Oil Cooler Radiztor 132X750M 1. Compression Damping Force Adjuster 2. Pad Lock 3. Helmet Hook 142Xx750M»»mmymmmrmmnrmmm nnn” LOCATION OF LABELS «Kcacaimaaacacaccnd o—- 1. Engine Oil and Oil Filter **2. Fuel Level **3. Vacuum Hose Routing Diagram 4. Daily Safety Checks *5. Vehicle Emission Control Information (on California model) 6. Brake Fluid (Rear) *7. Vehicle Emission Control Information 8. Tire and Load Data 9. Important Drive Chain information : only on US model only on California model 1610, Clutch Fluid “11, Break-In Caution 12. Brake Fluid (Front) *13, Noise Emission Cortrol Information 14, Battery Poison/Danger ‘only on US model 17»mymmnmmmynymyyyyy LOADING INFORMATION cacccaacaacceeeeee Fela Un ced Incorrect loading, improper installa- tion or use of accessories, or modifi- cation of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure that the motorcycle is not overloaded (refer to page 113 for maximum load information) and that you have fol- lowed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. In some cases, improper installation or use of ac- cessories, or motorcycle modification, will void the motorcycle warranty. In selecting and using accessories, and in loading the motorcycle, you are per- sonally responsible for your own safety and the safety of other persons involved. 18 NOTE OKawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accesso- ries you add to your motorcycle be genuine Kawasaki components, Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in the fitting of additional accessories. The following general guidelines have been prepared to assist you in making your determinations.ds Any passenger should be thoroughly familiar with motorcycle operation. The passenger can affect control of the motorcycle by improper position- ing during cornering and sudden movements. It is important that the passenger sit still while the motorcy- cle is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motor- cycle. You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator, seat strap or grab rail. Do not carry a passenger unless he or she is tall enough to reach the footpegs and footpegs are provided. All baggage should be carried as low as possible to reduce the effect on the motorcycle center of gravity. Baggage weight should also be dis- tributed equally on both sides of the motorcycle. Avoid carrying baggage that extends beyond the rear of the motorcycle. Baggage should be securely at- tached. Make sure that the baggage will not move around while you are riding. Recheck baggage security as often as possible {not while the mo- torcycle is in motion) and adjust as necessary. Do not carry heavy or bulky items on "a luggage rack. They are designed for light items, ard overloading can affect handling due to changes in weight distribution and aerodynamic forces. Do not install accessories or carry baggage that impairs the perform- ance of the motorcycle. Make sure that you have not adversely affected any lighting components, road clear- ance, banking capability (i.e., lean angle), contro! operation, wheel travel, front fork movement, or any 1920 other aspect of the motorcycle’s op. eration, Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in an unsafe riding condition Fairings, windshields, backrests, and other large items have the capability of adversely affecting stability and handling of the motorcycle, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly designed or installed items can result in an un- safe riding condition . This motorcycle was not intended to be equipped with a sidecar or to be used to tow any trailer or other vehi- cle. Kawasaki does not manufacture sidecars or trailers and cannot pre- dict the effects of such accessories on handling or stability, but can only warn that the effects can be adverse and that Kawasaki cannot assume responsibility for the results of such unintended use of the motorcycle. Furthermore, any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty.»»»»mmynyMmyyyyyyy GENERAL INFORMATION Meter Instruments meN = On m comp MRM MEEK Speedometer Tachometer Red Zone Coolant Temperature Gauge High Beam Indicator Light Neutral Indicator Light Turn Signal Indicator ight Oil Pressure Warning Light - Trip Meter : Trip Reset Knob - Odometer 21Speedometer and Tachometer The speedometer shows the speed of the vehicle. In the speedometer face are the odometer and trip meter. The odometer shows the total distance that the vehicle has been ridden. The trip meter shows the distance traveled since it was last reset to zero. The trip meter can be reset to zero by turing the reset knob counterclockwise. The tachometer shows the engine speed in the revolutions per minute (r/min, rpm). On the right side of the tachometer face is a portion called the "red zone.” Engine r/min (rpm) in the ted zone is above maximum recom- mended engine speed and is also above the range for good performance. CAUTION Engine rimin (rpm) should not be al- lowed to enter the red zone; operation in the red zone will overstress the en- gine and may cause serious engine Coolant Temperature Gauge This gauge shows the temperature of coolant. Ordinarily, the needle should stay within the scaled zone. If the nee- dle reaches the red zone (marked "H"), stop the engine and check the coolant level in the reserve tank after the engine cools down.CAUTION Do not jet the engine continue running when the gauge needle reaches the red zone. Prolonged engine operation will result in severe damage from overheating. Indicator Lights OIL: The oil pressure warning light goes on whenever the oil pressure is dangerously low or the ignition switch is in the ON position with the engine not running, and goes off when the en- gine oil pressure is high enough. Refer to the Maintenance and Adjustment chapter for more detailed engine oil in- formation. TURN: When the turn signal switch is turned to left or right, the turn signal in- dicator light flashes on and off. NEUTRAL: When the transmission is in neutral, the neutral indicator light is lit. HIGH BEAM: When the headlight is on high beam, the high beam indicator light is lit 23ey This motorcycle has a combination key, which is used for the ignition switch/ steering lock, seat lock, and fuel tank cap. Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a mas- ter. 24 Ignition Switch/Steering Lock This is @ four-position, key-operated switch. The key can be removed from the switch when it is ir the OFF, LOCK, or P(PARK) position. A. Ignition Switch/Steering Lock B. ON position C. OFF po: D. LOCK posOFF Engine off. All electrical circuits off ON Engine on. All electrical equipment can be used. Lock | Steering locked. Engine off. All electrical circuits off. Steering locked. Engine off. Tail and license plate lights on. All other elec- trical circuits cut off. P (Park) NOTE ©The tail and license plate lights are on whenever the ignition switch is in the ON position. The headlight goes on when the starter button is released af- ter starting the engine. To avoid bat- tery discharge, always start the engine immediately after turning the ignition switch to ON. Of you leave the PARK position on for a fong time (one hour), the battery may become totally discharged. To lock the steering: 1. Turn the handlebar fully to the left. 2. With the ignition switch key in the OFF position, push down and re- lease the key. 3. Turn the key to LOCK or P (Park) position. 4. Pull the key out. 25Right Handlebar Switches Engine Stop Switch In addition to the ignition switch, the engine stop switch must be in the RUN position for the motorcycle to operate. The engine stop switch is for emer- gency use. If some emergency requires stopping the engine, move the engine stop switch to the OFF position. NOTE OAlthough the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine. 26 A. Engine Stop Switch B. Starter Button Starter Button The starter button operates the elec- tric starter when pushed with the clutch lever pulled in or the transmission in neutral Refer to the Starting the Engine sec- tion of the “How to Ride the Motorcy- cle” chapter for starting instructions.Left Handlebar Switches Dimmer Switch High or low beam can be selected with the dimmer switch. When the headlight is on high beam (HI), the high beam indicator light is lit C. Horn Button A, Dimmer Switch Turn Signal Switch Turn Signal Switch When the turn signal switch is turned to L (left) or R (right), the correspond- ing turn signals flash on and off. To stop flashing, push the switch in. Horn Button When the horn button is pushed, the hor sounds. 27Brake/Clutch Lever Adjusters There is an adjuster on both the brake and clutch levers. Each adjuster has 4 positions so that the released lever posi- tion can be adjusted to suit the operator's hands. Push the lever for- ward and turn the adjuster to align the number with the triangular mark on the lever holder. The distance from the grip to the released lever is minimum at Number 4 and maximum at Number 1. 28 Fuel Tank Cap To open the fuel tank cap, pull up the key hole cover. Insert the ignition switch key into the jock and turn the key to the right To close the cap, push it down into place with the key inserted. The key can be removed by turning it counterclock- wise to the original position NOTE OThe tank cap cannot be closed with- out the key inserted, and the key can- not be removed unless the cap is locked properly. ©Do not push the cep down with the key, or the cap cannot be locked.Fuel Tank The following octane rating gasoline is recommended in the fuel tank. Avoid © filling the tank in the rain or where / heavy dust is blowing so that the fuel does not get contaminated. A. Key Hole Cover C. Fuel Tank Cap B, Ignition Switch Key 1. Tank Cap 3. Top Level 2, Fuel Tank 4. Filler Neck 29NAN eF Gasoline is extremely flammable and can be explosive under certain condi- tions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this in- cludes any appliance with a pilot light. Never fill the tank so the fuel level rises into the filler neck. If the tank Is overfilled, heat may cause the fuel to expand and overllow through the vents in the tank cap. Alter refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately. 30 CAUTION California models only: Never fill the tank so the fuel level rises into the filler neck. If the tank is overtilled, heat may cause the {uel to expand and flow into the Evaporative Emission Control System resulting in hard start- ing and engine hesitation. Fuel Requirement: Octane Rating The octane rating of a gasoline is a measure of its resistance to detonation or “knocking.” Use a gasoline with an octane rating equal to or higher than that shown in the table bolowOctane Rating Method Minimum Rating (RON + MON) Antiknock Index —————— 87 2 Research Octane No. (RON) at The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON) The Antiknock Index is posted on ser- vice station pumps in the U.S.A. Re- search Octane Number is a commonly used term describing a gasoline’s octane rating. NOTE O/f "knocking" or "pinging" occurs, use a different brand of gasoline or higher octane rating. Gasoline and Aleohol Blends Blends of gasoline and alcohol called "gasohol” can be used on an occasional basis, however continued use is not re- commended. Switch back immediately to gasoline which does not contain al- cohol if you experienc any operating ir- regularities. Any deterioration of fuel system components or degradation of performance resulting from the use of gasohol will not be covered by Kawasaki’s Limited Warranty, Emissions Warranties, or Good Times. Protection Plan. If you decide to use gasohol, be sure to follow these simple cautions: 31CAUTION Never use gasohol with an octane rat- ing lower than the minimum octane rating specified by Kawasaki for this product. Never use gasohol containing more than 10% ethanol (grain alcohol). Never use gasohol containing more than 5% methanol (wood alcohol). Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors. Never use gasohol for extended peri- ods and never store this product with gasohol in the fuel system. Gasoline containing alcohol can cause paint damage. Be extra careful not to Spill gasohol during refueling. 32 Fuel Tap The fuel tap has three positions: OFF, ON, and RES (reserve). For normal op- eration turn the tap to the ON position. If the fuel runs out with the tap in the ON position, the last 5.0 L (1.3 US gal) of fuel can be used by turning the fuel tap to the RES position A. Fuel Tap B. RES position D. ON positionWith the fuel tap in the ON or RES position fuel flows to carburetors only when the engine is started or is running, and fuel supply is shut off when the en- gine is stopped. Turn the fuel tap to the OFF position when the fuel tank is removed for main- tenance and adjustments or the motor cycle is stored for a long time. NOTE OSince riding distance is limited when on RES, refuel at the earliest opportu- nity. OMeke certain that the fuel tap is turned to ON (Not RES) after filling up the fuel tank. When the carburetor is completely empty, it takes about 30 seconds for the engine to start. CAUTION Do not operate the starter contin- uously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. CSN) Practice operating the fuel tap with the motorcycle stopped. To prevent an accident you should be able to operate the fuel tap while riding without taking your eyes off the road. 33Stand Whenever the side stand is used, The motorcycle is equipped with the make it a practice to kick the stand fully side stand. up before sitting on the motorcycle. NOTE ©The motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine stops if the clutch is engaged with the trans- mission in gear when the side stand has been left down. A. Side Stand NOTE OQWhen using the side stand, turn the handlebar to the left. 34Seat Lock ZX750L: To open the seat, first remove the passenger's seat by inserting the ignition switch key into the seat lock, turning the key to the left, pulling up on the rear of the seat, and pulling the seat forward. ‘A. Possenger’s Seat ©. Ignition Switch Key B. Seat Lock Then remove the rider's seat by pull- ing the release bar to the rear and pull- ing the seat up and to the rear. 8. Release Bar A. Rider's Seat 35ZX750M: Then pull the release bar forward and To open the seat, first remove the pull the seat up and to the rear. backrest pad by inserting the ignition switch key into the pad lock and turning the key to the right. = A. Backrest Pad C. Ignition Switch Key B. Lock 36Rear Fairing The rear fairing can be removed for the brake fluid and coolant refilling and air cleaner element and spark plug main- tenance. Both models have a three-piece rear fairing. Remove the fairing mounting screws shown and do the same on the other side. (2x750M) A. Rear Fairing (ZX750L) A. Rear Fairing B. ScrewsTying Hooks (ZX750L only) When tying up light loads to the seat, use the tying hooks on the left and right grab handles. A. Tying Hooks B. Handle 38 Helmet Hook(s) Helmet(s) can be secured to the mo- torcycle using the helmet hooks located under the passenger's seat on the ZX750L or the helmet hook at the left side on the ZX750M. The helmet hook of the ZX750M can be locked and unlocked with the ig- nition switch key. AWARNING Do not ride the motorcycie with helmet(s) attached to the hook(s). The helmet(s) could cause an accident by distracting the operator or interfering with normal vehicle operation.(2X750L) “— (2X750M) A. Helmet Hooks A. Ignition Switch Key B. Helmet Hook 39Storage Box Under the rider’s seat is 2 storage box. Use the box to keep the owner's manual and any papers or documents that should be kept with the motorcycle. A. Storage Box 40 Tool Kit Compartment The tool kit companment is located under the passenger's seat on the ZX750L or behind the seat on the ZX750M. For access to the compart- ment of the ZX750M ramove the back- rest pad with the ignition switch key (see Seat Lock section). Store the tool kit in the compartment. The minor adjustments and replacement of parts explained in this manual can be performed with the tools in the kit.(2X750L) (ZX750M) A. Tool Kit A. Tool Kit CFElectric Accessory Leads The electric power of the battery can be used through the electric accessory leads regardless of ignition switch posi- tion. Observe and follow the notes listed below. Electric Accessory Leads Location | Polarity | Lead Color Under Rider's] (+) _| White/Blue Seat (-) [Yellow/Black Maximum Current: 10A 42 A. Accessory Leads CAUTION Whenever you leave the motorcycle, stop using the electric accessories. Be careful not to discharge the battery totally. For example, if a current of 10 amperes is continuously taken out with the engine stopped, even an originally-tully-charged battery may become totally discharged in about 20 minutes.AWARNING Take care not to pinch any lead be- tween the seat and the frame or be- tween other parts to avoid a short circuit. Air Cleaner Intake The air cleaner intake allows air to enter the air cleaner, then the carburetors. Never allow anything to re- strict the flow of air into the air cleaner. A restricted air cleaner will reduce per- formance and increase exhaust emis- sions. 43Y99>90D9D999I9999999 9999999999 9I999999999M BREAK-IN Ce MEEK EME The first 1,600 km (1,000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down” instead of a “broken in” motorcycle after a few thousand kilometers. The following rules should be observed during the break-in period. @The table shows maximum recommended engine speed during the break-in period. Distance traveled Maximum engine speed 0 ~ 800 km (0 ~ 500 mi) 4,000 r/min (rpm) 800 ~ 1,600 km (500 ~ 1,000 mi) | 6,000 r/min (rpm) | ©Do not start moving or race the engine immediately aiter starting it, even if the en- gine is already warm. Run the engine for two or three minutes at idle speed to give the oil a chance to work up into all the engine parts. @Do not race the engine while the transmission is in neutral In addition to the above, at 800 km (500 mi) it is extremely important that the owner have the initial maintenance service performed by a competent mechanic fol- lowing the procedures in the Service Manual. 44»»»»mmnyonnyn HOW TO RIDE THE MOTORCYCLE «Kcannncainnnd Starting the Engine @Turn the fuel tap to the ON position. B. Starter Button E. ON posi C. Neutral Indicator Light @If the engine is cold, pull the choke @Check that the engine stop switch is lever all the way. in the RUN position. Turn the ignition switch on. Make certain the transmission is in neutral or the clutch is disengaged 45NOTE OWhen the engine is already warm or on hot days [higher than 35°C (95°F), open the throttle part way in- Stead of using the choke, and then start the engine. A. Choke Lever @Leaving the throttle completely closed, push the starter button with the clutch lever pulled in until the engine starts. 46 CAUTION Do not operate the starter contin- uously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. NOTE Olf the engine is flooded, crank the en- gine over with the throttle fully open until the engine starts. ©The motorcycle is equipped with @ starter lockout switch. This switch prevents the electric starter from oper- ating when the clutch is engaged and the transmission is not in neutral.A. Clutch Lever | B. Starter Lockout Switch Gradually return the choke toward the off position a little at a time as neces- sary to keep the engine speed below 2,500 ¢/min (rom) during warm-up. @When the engine is warmed up enough to idle without using the choke, return the choke to the off po: sition. NOTE Olf you drive the motorcycle before the engine is warmed up, return the choke to the off position as soon as you start moving. CAUTION Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. 2X750M only: NOTE OWhen the engine is stopped, do not operate the throtile The accelerator pumps will flood the engine resulting in starting difficulty. OAfter the engine has started, do not repeatedly operate the throttle at an idle. The acceleratcr pumps may foul the spark plugs with excess fuel. 47Jump Starting If your motorcycle battery is “run down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. AWARNING Battery acid generates hydrogen gas which is flammable and explosive un- der certain conditions. It is present within a battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away {rom the battery. Wear eye protection when working with a battery. In the event of battery acid contact with skin, eyes, or clothing, wash the affected areas im- mediately with water for at least five minutes. Seek medical attention. Connecting Jumper Cables @Remove the seat and take out the storage box, 48 @Make sure the turned "OFF." @Connect a jumper cable from the posi- tive (+) terminal of the booster bat- tery to the positive (+) terminal of the motoreycle battery. ignition switch is A. Motorcycle Battery Positive (+) Terminal B. To Booster Battery Positive (+) Terminal C. Unpainted Metal Surface D. To Booster Battery Negative (-) Terminal @Connect another jumper cable from the negative (-) terminal of the booster battery to your motorcyclerear brake pedal or other unpainted metal surface. Do not use the nega- tive (-) terminal of the battery. AWARNING Do not make this last connection at the carburetor or battery. Take care that you do not touch the positive and neg- ative cables together, and do not lean over the battery when making this last connection. Do not jump start a frozen battery. It could explode. Do not reverse polarity by connecting positive (+) to negative (—) or a bat- tery explosion and serious damage to the electrical system may occur. @Follow the standard engine starting procedure. CAUTION Do not operate the starter contin- uously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. @After the engine starts, disconnect the jumper cables. Disconnect the nega- tive (~) cable from the motorcycle first. @ install the removed parts. 49Moving Off @Check that the side stand is up. @Pull in the clutch lever. @Shift into 1st gear. @Open the throttle a little, and start to let out the clutch lever very slowly. @As the clutch starts to engage, open the throttle a little more, giving the engine just enough fuel to keep it from stalling. A. Shift Pedal 50 NOTE OThe motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine stops if the clutch is engaged with the trans- mission in gear when the side stand has been left down.Shifting Gears @Close the throttle while pulling in the clutch lever. @Shift into the next higher or lower gear. For smooth riding, shift up or down when the motorcycle is oper- ated at the speed shown in the table. Vehicle speed when shifting AWARNING When shifting down to a lower gear, do not shift at such a high speed that the engine r/min (rpm) jumps exces- sively. Not only can this cause engine damage, but the rear whee! may skid and cause an accident. Downshifting should be done below 5,000 rimin (rpm) for each gear. Shifting up_|_km/h(mph) [Shifting down] km/h(mph) 1st > and 15(9) 6th > 5th | 30(19) 2nd > 3rd 25(15) Sth > 4th 25(15) 3rd > 4th 35(21) 4th > 3rd 20(12) 4th > Sth 45(27) 3rd — 2nd 15(9) 5th > 6th 56(34) 2nd > 1st 16(9) 51@Open the throttle part way, while re- leasing the clutch lever. NOTE OThe transmission is equipped with a positive neutral finder. When the mo- torcycle is standing still, the trans- mission cannot be shifted past neutral from 1st gear. To use the positive neutral finder, shift down to 1st gear, then lift up on the shift pedal while standing still. The transmission will shift only into neutral. 52 Braking @Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. @Shift down one gear at a time so that you are in 1st gear when you come to 2 complete stop. @When stopping, always apply both brakes at the same time. Normally the front brake should be applied a little more than the rear. Shift down or fully disengage the clutch as neces- sary to keep the engine from stalling. @ Never lock the brakes, or it will cause the tires to skid. When turning a cor- ner, it is better not to brake at all. Re- duce your speed befcre you get into the corner, @For emergency braking, disregard downshifting, and concentrate on ap- plying the brakes as hard as possible without skidding.trol parts, do not turn off the ignition switch when the motorcycle is in mo- tion. A, Front Brake Lever ‘A. Rear Brake Pedal 53Stopping the Engine @Close the throttle completely. @ Shift the transmission into neutral. Turn the ignition switch off. eSupport the motorcycle on a firm, level surface with the side stand. @ Lock the steering. Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to provide you optimum safety and convenience. However, in order to fully benefit from Kawasaki's safety engineering and craftsmanship, it is essential that you, the owner and operator, properly main- tain your motorcycle and become thor- oughly familiar with its operation. Improper maintenance can create a dan- gerous situation known as throttle fail- ure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust to enter the carburetor and stick the throttle open. 2. During removal of the air cleaner, dirt is allowed to enter and jam the car- buretor. In an emergency situation such as throttle failure, your vehicle may be stopped by applying the brakes and dis- engaging the clutch, Once this stop-ping procedure is initiated, the engine stop switch may be used to stop the en- gine, If the engine stop switch is used, turn off the ignition switch after stop- ping the motorcycle. Parking @Shift the transmission into neutral and turn the ignition switch off. @Support the motorcycle on a firm, level surface with the side stand. CAUTION Do not park on a soft or steeply in- clined surface or the motorcycle may fall over. @lf parking inside 2 garage or other structure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this in- cludes any appliance with a pilot light. AWARNING Gasoline is extremely flammable and can be explosive under certain condi- tions, 55@Lock the steering to help prevent theft. NOTE When stopping near traffic at night, you can leave the taillight on for greater visibility by turning the ig- nition switch to the P (Park) position. Do not leave the switch at P position too long. or the battery will discharge. 56vevomoa20y099>99999399999999999999990999 GAFE OPERATION cecanenaem eae eeeeee Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation, For safety. eye protection and a helmet are strongly recom- mended. Gloves and suitable footwear should also be used for added protection in case of a hap. A motorcycle does not provide the impact protection of an auto- mobile, so defensive riding in ad- dition to wearing protective apparel is extremely important. Do not let protective apparel give you a false sense of security. Before changing lanes, look over your shoulder to make sure the way is clear. Do not rely solely on the rear view mirror you may misjudge a vehicle's tance and speed. or you may not see it at all. When going up steep slopes. shift to a lower gear so that there is plenty of power to spare rather than overloading the en- gine. When applying the brakes, use both the front and rear brakes. Applying only one brake for sud- den braking may cause the mo- toreycle to skid and lose control. When going down ‘ong slopes, control vehicle speed by closing the throttle. Use the front and rear brakes for auxiliary braking. 57On rainy days, rely more on the throttle to control vehicle speed and less on the front and rear brakes. The throttle should also be used judiciously to avoid skidding the rear wheel from too rapid acceleration or deceler- ation. Riding at the proper rate of speed and avoiding unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for long vehicle life and quieter operation. When riding in wet conditions or on loose roadway surfaces, the ability to maneuver will be re- duced. All of your actions should be smooth under these condi- tions. Sudden acceleration, brak- ing or turning may cause loss of control. 58 On rough roads, exercise cau- tion, slow down, and grip the fuel tank with the knees for bet- ter stability. When quick acceleration is necessary as in passing, shift to a lower gear to obtain the neces- sary power. Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrevving. Avoiding unnecessary weaving is important to the safety of both the rider and other motorists.Safety Checks Check the following items each day before you ride. The time required is minimal and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motorcycle to a safe operating condition. Failure to perform these checks every day before you ride may result in serious damage or a severe accident. Fuel .. Adequate supply in tank, no leaks. Oil level between level lines Air pressure (when cold): For tires except for Michelin tires: Front_| 250 kPa (2.5 kg/cm?, 36 psi) Rear 290 kPa (2.9 kg/cm?, 41 psi) For Michelin tires: Front | 230 kPa (2.3 kg/cm?, 33 psi) Rear 250 kPa (2.5 kg/cm?, 36 psi) 59Drive chain Nuts, bolts, fasteners .. Steering .. Brakes... Throttle ..... Clutch ... Coolant Radiator cep..... Electrical equipment. Engine stop switch Side stand oc... Slack 10 ~ 15 mm (0.4 ~ 0.6 in.). Check that steering and suspension components, axles, and all controls are properly tightened or fastened. Action smooth but not loose from lock to lock. No bind- ing of control cables. Brake pad wear: Lining thickness more than 1 mm (0.04 in.) left No brake fluid leakage. Throttle grip play 2 ~ 3 mm (0.08 ~ 0.12 in.). No clutch fluid leakage. No coolant leakage. Coolant level between level lines (when engine is cold). Properly installed. All lights and horn work. Stops engine. Returns to its fully up position by spring tension. Return spring not weak or not damaged Refer to the “Daily Safety Checks” caution label attached to the bottom of the seat. 60Additional Considerations for High Speed Operation Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play. Tires: High speed operation is hard on tires, and good tires are crucial for riding safety. Examine their overall condition, inflate to the proper pressure, and check the wheel balance. Fuel: Have sufficient fuel for high consumption during high speed operation. Engine Oil: To avoid seizure and resulting loss of control, make certain that the oil level is at the upper level line. Coolant: To avoid overheating, check that the coolant level is at the upper level line Electrical Equipment: Make certain that the headlight, tail/brake light, turn signals, hom, etc., all work properly. Miscellaneous: Make certain that all nuts and bolts are tight and that all safety related parts are in good condition. Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills. 61pyyypayyyyoo? MAINTENANCE AND ADJUSTMENT KKannnKanancnd The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motor- cycle in good running condition. The initial maintenance is vitally important and must not be neglected. If you are in doubt as to any adjustment or vehicle operation, please ask your au- thorized Kawasaki dealer to check the motorcycle. Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect maintenance or improper adjustment done by the owner. 62EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incor- porated an evaporative emission control system (3) in compliance with applica- ble regulations of the California Air Resources Board on vehicle sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into the combustion chamber, where they are burned along with the fuel and air sup- plied by the carburetors. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmos- phere by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an effi- cient engine with low exhaust pollutant levels. 6364 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of vehicles operated above 4,000 feet, Kawasaki recommends the following Environmental Protection Agency (EPA) approved modification. NOTE © When properly performed, these specified modifications only are not consid- ered to be emissions system "tampering" and vehicle performance is generally unchanged as a result. Installation Instructions: High altitude adjustment requires replacement of certain carburetor compo- nents. Installation of these optional parts may be performed by an authorized Kawasaki dealer, or the consumer, following repair recommendations specified in the appropriate Kawasaki Service Manual.MAINTENANCE AND WARRANTY Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels. This Owner's Manual contains those maintenance recommendations for your motorcycle. Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards. As the owner of this motorcycle, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. The Kawasaki Limited Emission Contro| System Warranty requires that you return your motorcycle to an authorized Kawasaki dealer for remedy under war- ranty. Please read the warranty carefully, and keep it valid by complying with the owner's obligations it contains. You should keep a maintenance record for your motorcycle. To assist you in keeping this record, we have provided space on pages 136 through 140 of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, bills, etc., as verification of this maintenance. 65TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal jaw prohibits the following acts or the causing thereof: (1) the re- moval or rendering inoperative by any person other than for purposes of mainte- nance, 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. Among those acts presumed to constitute tampering are the acts listed below: Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. Removal of the muffler(s) or any intemal portion of the muffler(s). Removal of the air box or air box cover. Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels. 66Periodic Maintenance Chart Whichever 7 Frequency lssntae i ‘Odometer Reading km (mi) ‘© ¥ eg beked bs heoeake S88 eS/2s S PVPS Shee Operation every |/ 9/ °e/ *e INOS /oce Carburetor synchronization elwlslelelwelel as -check + Idle speed=check | e|elele|elele| ss " Throttle grip play~check + ° e ° ° 89 8 sperle plug-sleen andl gent elelele Leela E|__Vaive clearance-check ° ° . © | 83 § | Air suction valve--check + . e |e ele! e!| as 2 Air cleaner element-clean e ° e o | 86 a Air cleaner element-replace 5 cleanings e 86 Fuel system-check e | ° e | 122 Evaporative emission control . system (c)--check + fsTe ye) Se] ee K Brake light switch-check | eilelel,elele|e |i Brake pad wear-check + | e ° ° e ° ° 101 Brake/clutch fluid fevel-check + month| @ e e ° e ° 2 |102,9% 67TWiichever 2 ™ 5 Frequency — comes first So tomeres Rea ¥y $9 Ss bsb9/boR9 Operation ae S/F S/se0 Every S/Page K Brake/clutch fluid-change | 2 years - { * 04,9! K Steering-check + ele elele | - Drive chain wear-check + ele tele e | 99 | bt, els trent tightness ; 7 | 7 be | 128 Tire wear -cheek + oe) efelel| «lis Engine ail-change veor | ® Le . * | 70 | Oil filter-reptace — [ jpte « e | 70 __General lubrication-periorm _* 8 . . ° ° 123 K Front fork oil~change i i el - [Swing arm pivor, uni-rak I | | Pe | | linkage --lubricate | ¥ + * 7 K Coolant-chenge a 2 years | rs ed ee ec) Regieice how connections year . . a » 75 K Steering stem bearing-lubricate | 2 years * =Whichever Frequency AS Operation K Fuel filter-replace IK Brake/clutch master cylinder cup |, ] and dust seal-replace vee z fiper piston seal and dust & Jk Clutch slave cylinder piston seal |) _ z -replace eas g |K Brake hose/clutch hose and pine é replace A.vtark - ‘2 IK Fuel hose-replace 4 years = 2 |_ Drive chain-tubricate Every 300 km (200 mi) 100 Drive chain slack~check + Every 600 km (500 mi) 86 K : Should be serviced by an authorized Kawasaki dealer. * : For higher odometer readings, repeat at the frequency interval established here. 1 + Replace, add, adjust, or torque if necessary. (c): California model only 69Engine Oil In order for the engine, transmission, and clutch to function properly, main- tain the engine oil at the proper level, and change the oil and oil filter in ac- cordance with the Periodic Maintenance Chart. Not only do dirt and metal parti- cles collect in the oil, but the oil itself loses its lubricative quality if used too long. Naa NEF Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. 70 Oil Level Inspection @If the oil has just been changed, start the engine and run it for several min- Utes at idle speed. This fills the oil fil- ter with oil. Stop the engine, then wait several minutes until the oil set- tles. CAUTION Racing the engine before the oil re- aches every part can cause engine seizure. @\f the motorcycle has just been used, wait several minutes for all the oil to drain down @Check the engine oil level through the oil level gauge. With the motorcycle held level, the oil level should come up between the lines next to the gauge.A. Oil Level Gauge C. Lower Level Line B. Upper Level Line D. Oil Filler Cap @ If the oil level is too high, remove the excess oil, using a syringe or other suitable device, through the oil filler opening. @/f the oil level is too low, add the cor- rect amount of oil. Use the same type and brand of oil that is already in the engine. CAUTION If the engine oil gets extremely low or If the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the engine speed is above 1,300 r/min (rpm), stop the engine immediately and find the cause. 20 4 a A. Oil Pressure Warning Light 71