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Kawasaki Klx150L Manual

Mar 02, 2018

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    Motorcycle

    Owner's Manua

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    Quick Reference Guide

    This Quick Reference Guide willassist you in finding the informationyou're looking for.

    SAFETY INFOR

    GENERAL INFO

    HOW TO RIDE T

    MAINTENANCE

    APPENDIX

    MAINTENANCE

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    Whenever you see the symbolsshown below, heed their instructions!Always follow safe operating and main-

    tenance practices.

    DANGER

    DANGER indicates a hazardous

    situation which, if not avoided,will result in death or serious in-jury.

    WARNINGWARNING indicates a hazardoussituation which, if not avoided,could result in death or serious

    i j

    NOT

    NOTE indicates inhelp or guide you service of the vehi

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    NOTICE

    THIS PRODUCT HAS BEEN MAN-

    UFACTURED FOR USE IN AREASONABLE AND PRUDENTMANNER BY A QUALIFIED OP-ERATOR AND AS A VEHICLE ON-LY.

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    Foreword

    Congratulations on your purchase of a new Kawasaki motorcytorcycle is the product of Kawasaki's advanced engineering, eand continuous striving for superior reliability, safety and perform

    Please read this Owner's Manual carefully before riding

    thoroughly familiar with the proper operation of your motorcycletures, capabilities, and limitations. This manual offers many safpurpose is not to provide instruction in all the techniques and ska motorcycle safely. Kawasaki strongly recommends that all ophicle enroll in a motorcycle rider training program to attain aware

    and physical requirements necessary for safe motorcycle operat

    To ensure a long, trouble-free life for your motorcycle, give it thmaintenance described in this manual. For those who would likformation on their Kawasaki Motorcycle, a Service Manual is

    h f th i d K ki t l d l Th

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    Keep this Owner's Manual aboard your motorcycle at all tifer to it whenever you need information.

    This manual should be considered a permanent part should remain with the motorcycle when it is sold.

    All rights reserved. No part of this publication may be repror written permission.

    This publication includes the latest information availableHowever, there may be minor differences between the actutions and text in this manual.

    All products are subject to change without prior notice or o

    KAWASAKI HEAVY INDUSTRIES, Motorcycle & Engine Company

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    TABLE OF CONTENTS

    SAFETY INFORMATION ..................... 10

    Read Owner's Manual ....................... 10

    Training .............................................. 10

    Daily Checks and Periodic Mainte-

    nance .............................................. 10Loading and Accessories Information

    11

    Passenger ...................................... 12

    Baggage and Luggage .................. 13

    Accessories ................................... 13Other Load ..................................... 14

    If You are Involved in an Accident ..... 14

    Safe Operation ................................... 15

    Carbon Monoxide Hazard .............. 15

    F li 16

    GENERAL INFORMA

    Specifications ........

    Serial Number Locat

    Location of Labels ..

    Location of Parts ....Meter Instruments ..

    Indicators ...........

    Speedometer/Odo

    Keys .......................

    Ignition Switch/SteerRight Handlebar Sw

    Left Handlebar Switc

    Fuel Tank Cap ........

    Fuel ........................

    F l R i t

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    Rear View Mirror ................................ 51

    HOW TO RIDE THE MOTORCYCLE .. 53

    Break-In ............................................. 53Starting the Engine ............................ 55

    Jump Starting ..................................... 58

    Moving Off .......................................... 60

    Shifting Gears .................................... 61

    Braking ............................................... 62

    Stopping the Engine .......................... 63

    Stopping the Motorcycle in an Emer-

    gency .............................................. 64

    Parking ............................................... 65

    MAINTENANCE AND ADJUSTMENT 67

    Daily Checks ...................................... 69

    Additional Considerations for Off

    Road Operation .............................. 72

    P i di M i t 73

    Clutch .............

    Drive Chain ....

    Brakes ............Brake Light Sw

    Suspension Sy

    Front Fork ..

    Rear Shock A

    Wheels ...........Battery ............

    Headlight ........

    Fuses .............

    General Lubrica

    Cleaning Your M

    General Prec

    Washing You

    APPENDIX .......

    St

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    SAFETY INFORMATION

    Read Owner's Manual

    Read this Owners Manual carefully

    before riding so that you will be thor-oughly familiar with the proper opera-tion of your motorcycles controls, itsfeatures, capabilities, and limitations.This manual offers many safe riding

    tips, but its purpose is not to provide in-struction in all of the techniques andskills required to ride a motorcyclesafely.

    T i i

    techniques necessacycle operation.

    Daily Checks a

    Maintenance

    It is important to cycle properly mainriding condition. Ins

    cycle before every all periodic maintenaChecks section andtenance section in thAND ADJUSTMENT

    10 SAFETY INFORMATION

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    WARNING

    Failure to perform these checksor to correct a problem before op-eration may result in seriousdamage or an accident. Always

    perform daily checks before op-eration.

    To ensure your motorcycle is serv-iced using the latest servicing informa-

    tion, it is recommended that anauthorized Kawasaki Dealer performsthe periodic maintenance as directedin the Owner's Manual.

    If you notice any irregular operating

    diti h t l th

    Loading an

    Information

    Incorrect loastallation or or modificatcycle may resing condition

    motorcycle, overloaded alowed these i

    Maximum Load

    W i ht f id

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    application of accessories. In somecases, improper installation or use of

    accessories, or motorcycle modifica-tion, will void the motorcycle warranty;can negatively affect performance,stability and safety; and can even be il-legal.

    In selecting and using accessories,and in loading the motorcycle, you arepersonally responsible for your ownsafety and the safety of other persons

    involved.NOTE

    Kawasaki Parts and Accessorieshave been specially designed for

    K ki t l W

    forces, you must takcarrying cargo, pas

    fitting additional acclowing general guidprepared to assist ydeterminations.

    Passenger1. Never carry more

    ger.2. The passenger

    the pillion.3. Any passenger

    oughly familiar weration. The pascontrol of the mot

    iti i d

    12 SAFETY INFORMATION

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    4. Do not carry passengers unlesspassenger footpegs are installed.

    Instruct any passenger before rid-ing to keep his or her feet on thepassenger footpegs and hold on tothe operator or seat strap. Do notcarry a passenger unless he or she

    is tall enough to reach the footpegswith their feet.

    Baggage and Luggage

    1. All baggage should be carried aslow as possible to reduce the effecton the motorcycle's center of grav-ity. Baggage weight should also bedistributed equally on both sides of

    h l A id i b

    security as while the m

    and adjust as3. Do not carry

    on a luggagelight items, afect handlin

    weight distriic forces.

    Accessories

    1. Do not instabaggage thaance of the that you hafected any

    d l

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    of the steering assembly and canresult in an unsafe riding condition.

    3. Fairings, windshields, backrests,and other large items have the ca-pability of adversely affecting stabil-ity and handling of the motorcycle,not only due to their weight, but also

    due to the aerodynamic force actingon these surfaces while the motor-cycle is in operation. Poorly de-signed or installed items can resultin an unsafe riding condition.

    Other Load

    1. This motorcycle is not intended tobe equipped with a sidecar or to be

    that Kawasaki csponsibility for t

    unintended use o2. Furthermore, an

    on motorcycle coby the use of sucnot be remedied u

    If You are InvoAccident

    Make sure of youDetermine the seveand call for emergneeded. Always folland regulations if an

    14 SAFETY INFORMATION

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    function. Ride slowly and cautiously -your motorcycle may have suffered

    damage that is not immediately appa-rent. Have your motorcycle thoroughlychecked at a Kawasaki dealer as soonas possible.

    Safe Operation

    The following should be carefully ob-served for safe and effective vehicleoperation.

    Carbon Mono

    Exhaust gasmonoxide, a

    poisonous gmonoxide cbrain injury oDo not run thareas. Operat

    tilated area.

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    Fueling

    WARNING

    Gasoline is extremely flammableand can be explosive under cer-

    tain conditions.To avoid a possible fire or explo-sion, turn the ignition switch toOFF. Do not smoke. Make surethe area is well ventilated and

    free from any source of flame orsparks; this includes any appli-ance with a pilot light.

    Protective Gear a

    HelmetKawasaki strongly

    the operator and phelmet even if thisquirement.- Make sure that yo

    rectly and is prope- Choose a motor

    meets the safety

    ble to your countrcycle dealer tonecessary.

    Eye Protection

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    GlovesWear gloves which have suitable

    protection for your hands, especiallyagainst abrasion.

    ClothingWear protective clothing.

    - Wear bright, highly visible clothingthat allows freedom of movement tosuit your riding style.

    - Always wear a long- sleeved jacketand long trousers which are abrasion

    resistant and keep you warm.- Avoid wearing clothes which have

    loose cuffs or other fastenings whichcould interfere with the controls ofyour motorcycle.

    Safe Riding T

    Keep Hands oWhen riding a

    on the handlebafootpegs. Remothe handlebarspegs while ridinyou remove evyou reduce youmotorcycle.

    Look Over YoBefore chang

    your shoulder tclear. Do not rview mirror; yo

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    control, especially when riding in wetconditions or on loose road surfaces,

    when the ability to maneuver will be re-duced.

    Select Correct Gear SpeedsWhen going up steep slopes, shift to

    a lower gear so that there is power tospare rather than overloading the en-gine.

    Use Both Front and Rear Brakes

    When applying the brakes, use boththe front and rear brakes. Applying on-ly one brake for sudden braking maycause the motorcycle to skid and losecontrol.

    Riding in Wet ConRely more on the

    vehicle speed and and rear brakes. Theso be used judiciouding the rear wheacceleration or dece

    Braking performanin wet conditions. Cslow speed and apperal times to help

    them to normal operLubricate the drivweather riding to prerosion.

    Ride Prudently

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    Riding on Rough RoadsExercise caution, slow down, and

    grip the fuel tank with the knees forbetter stability.

    AccelerationWhen quick acceleration is neces-

    sary to pass another vehicle, shift to alower gear to obtain the necessarypower.

    Downshifting

    To avoid engine damage and rearwheel lock-up do not downshift at highrpm.

    Avoid Unnecessary Weaving

    Additional Co

    High Speed O

    Handling cha

    torcycle at hifrom those yat legal highattempt high less you have

    training and skills.Do not operapublic roads.

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    SteeringLooseness in the steering can cause

    loss of control. Check to see that thehandlebars turns freely but has noplay.

    Tires

    High speed operation is hard ontires, and good tires are crucial for saferiding. Examine their overall condition,inflate them to the proper pressure,and check the wheel balance.

    FuelHave sufficient fuel for the high fuel

    consumption during high speed opera-tion.

    Electrical EquipmMake sure that t

    brake light, turn sigwork properly.

    MiscellaneousMake sure that all

    tight and that all sare in good condition

    20 SAFETY INFORMATION

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    GENERAL INFORMATION

    Specifications

    PERFORMANCE

    Maximum Horsepower 8.6 kW (12 PS) at 8 000 r/min (Maximum Torque 11.3 Nm (1.15 kgfm, 100 inlb

    Minimum Turning Radius 2.1 m (82.7 in.)

    DIMENSIONS

    Overall Length 2 080 mm (81.9 in.)

    Overall Width 770 mm (30.3 in.)Overall Height 1 145 mm (45.1 in.)

    Wheelbase 1 340 mm (52.8 in.)

    Road Clearance 300 mm (11.8 in.)Curb Mass 115 kg (253.6 lb)

    G

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    FRAME

    Caster 26.5

    Trail 107 mm (4.21 in.)Tire Size: Front 2.75-21 45P

    Rear 4.10-18 59P

    Rim Size: Front 21 1.60

    Rear 18 1.85Fuel Tank Capacity 7.0 L (1.8 US gal)

    Brake Fluid: Front DOT3 or DOT4

    Rear DOT3 or DOT4

    ELECTRICAL EQUIPMENT

    Battery 12 V 6 AhHeadlight: High Beam 12 V 35 W

    Low Beam 12 V 35 W

    Tail/Brake Light 12V 5 W/21 W

    G

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    Specifications are subject to change without notice, and may country.

    24 GENERAL INFORMATION

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    Serial Number Locations

    The engine and frame serial numbers are used to registeare the only means of identifying your particular machine fmodel type. These serial numbers may be needed by youparts. In the event of theft, the investigating authorities wi

    as well as the model type and any peculiar features of youthem identify it.

    Engine No. Frame No.

    G

    26

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    Location of Labels

    All warning labels which are on yourvehicle are repeated here. Read labelson your vehicle and understand themthoroughly. They contain informationwhich is important for your safety andthe safety of anyone else who may op-erate your vehicle. Therefore, it is veryimportant that all warning labels be onyour vehicle in the locations shown. If

    any label is missing, damaged, orworn, get a replacement from your Ka-wasaki dealer and install it in the cor-rect position.

    1. Brake Fluid (Fro

    26 GENERAL INFORMATION

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    2. Brake Fluid

    3. Battery Po4. Rear Shoc

    G

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    5. Fuel Notice

    6. Important Drive 7. Tire and Load D

    28 GENERAL INFORMATION

    G

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    1)

    2)

    3)

    G

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    4) 5)

    1. Read Owner's M2. Unleaded gasol3. Octane rating of

    43

    30 GENERAL INFORMATION

    G

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    6)

    1. Read Owner's Manual, see page 102. Drive chain slack, see page 94

    7)

    1. Read Owne2. Tire air pre3. Front tire s

    page 1074. Rear tire s

    page 1075. Maximum

    G

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    Location of Parts

    32 GENERAL INFORMATION

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    1. Front Fork 12. Tying Hook (Bo

    G

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    1. License Plate Light 9. Front Brake Light Sw

    34 GENERAL INFORMATION

    G

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    Meter Instruments

    1.Speedometer2.Odometer

    G

    36 GENERAL INFORMATION

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    Indicators

    1. Turn Signal Indicator (Green)2. High Beam Indicator (Blue)

    3. Neutral Indicator (Green)

    36 GENERAL INFORMATION

    G

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    Indicator Initial Operation

    When the ignition switch is turnedon, all indicators go on/off as shown inthe table. If any indicator does not op-erate as shown, have it checked by an

    ON

    ON: When igni: After a few

    : When eng: Goes on.: Goes off.

    G

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    *: The numbers in this column corre-sponds to reference numbers on page

    36.Indicators

    *No. Indica-

    tors Status

    1

    When the turn signalswitch is pushed to theleft or right, this indicatorblinks.

    2

    When the headlight is on

    high beam, this indicatorgoes on.

    3

    When the transmission isin neutral, this indicatorgoes on.

    Speedometer/Od

    A. SpeedometerB. Odometer

    Speedometer

    38 GENERAL INFORMATION

    G

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    of 100 meter. This meter cannot be re-set.

    Keys

    This motorcycle has a combinationkey, which is used for the ignition

    switch, steering lock and fuel tank cap.Blank keys are available at your Ka-wasaki dealers. Ask your dealer tomake any additional spare keys youmay need, using your original key as a

    master.

    Ignition Switch/SteeringLock

    A. Ignition Switch/

    B. ON positionC. OFF positionD. LOCK position

    ON Engin

    ment

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    NOTE

    The meter, tail, license plate and city

    lights are on whenever the ignitionkey is in the ONposition. To avoidbattery discharge, always start theengine immediately after turning theignition key to ONposition.

    The headlight is on only while the en-gine is running.

    Steering LockTo lock the steering

    1. Turn the handlebars fully to the left.2. With the ignition key in the OFF

    position, push down the key.3. Turn the ignition key to LOCK po-

    Right Handleb

    A. Engine Stop SwitchB. Starter Button

    G

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    The engine stop switch is for emer-gency use. If required, move the switch

    to the position.NOTE

    Although the engine stop switchstops the engine, it does not turn off

    all the electrical circuits. Ordinarily,the ignition switch should be used tostop the engine.

    Starter Button

    The starter button operates the elec-tric starter when the transmission is inneutral.

    Refer to the Starting the Engine sec-tion in the HOW TO RIDE THE MO-

    Left Handle

    A. Dimmer SwitchB. Turn Signal SwiC. Horn Button

    42 GENERAL INFORMATION

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    Low beam.......( )

    Turn Signal SwitchWhen the turn signal switch is turnedto the left ( ) or right ( ), thecorresponding turn signals blink onand off.

    To stop blinking, push the switch in.

    Horn ButtonWhen the horn button is pushed, the

    horn sounds.

    Fuel Tank Cap

    To open the fuel tank cap, insert theignition key into the fuel tank cap and

    NOT

    The fuel tank cap

    without the key inscannot be removelocked properly.

    Do not push on thcap, or the cap can

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    Fuel

    Fuel Requirement

    Your Kawasaki engine is designed touse only unleaded gasoline with a min-imum octane rating shown below.

    Never use gasoline with an octane rat-ing lower than the minimum specifiedby Kawasaki to prevent severe enginedamage.

    The octane rating of a gasoline is ameasure of its resistance to detonationor knocking. The term commonlyused to describe a gasolines octanerating is the Research Octane Number

    N

    If engine knooccurs, use gasoline of aing. If this cocontinue, it c

    gine damageimportant. Funot meetingspecificationssatisfactory

    ating problemthe use of poommended fered under yo

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    equal to or higher than that shown inthe table.

    Fuel Type Unleaded Gasoline

    Ethanol Content E10 or less

    Minimum OctaneRating

    Research OctaneNumber (RON) 91

    NOTICE

    Do not use any fuel that containsmore ethanol or other oxygen-ates than specified for E10 fuel*in this vehicle. Damage to the en-gine and fuel system, or enginestarting and/or performance

    Filling the Tank

    Avoid filling the twhere heavy dust the fuel does not get

    A. Tank Cap

    G

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    WARNING

    Gasoline is extremely flammableand can be explosive under cer-tain conditions, creating the po-tential for serious burns. Turn theignition switch off. Do not smoke.

    Make sure the area is well venti-lated and free from any source offlame or sparks; this includesany appliance with a pilot light.Never fill the tank completely tothe top. If the tank is filled com-pletely to the top, heat may causethe fuel to expand and overflowthrough the vents in the tank cap.

    N

    Certain ingremay cause page. Be extrafuel during re

    Fuel TapThe fuel tap

    ON, OFF annormal operatio

    to the ONposwith the tap in last 1.6 L (0.42used by turningRESposition.

    46 GENERAL INFORMATION

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    A. Fuel Tap

    B. ON positionC. OFF positionD. RES (Reserve) position

    With the fuel tap in the ONor RESposition fuel flows to carburetor only

    for maintenance anthe motorcycle is sto

    NOTSince riding distan

    on RES, refuel portunity.

    Make sure that thturned to ONposthe fuel tank.

    WAR

    Practice operatinwith the motorcyprevent an accidbe able to opera

    G

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    Side Stand

    The motorcycle is equipped with theside stand.

    A. Side Stand

    stand fully up btorcycle.

    The motorcyside stand swsigned so tha

    start if the trand the side s

    Seat

    Seat Removal

    Remove the bClear the pro

    side cover on

    48 GENERAL INFORMATION

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    A. Bolt (Right Side)

    B. Projection (Right Side)C. Right Side Cover

    A. Bolt (Left Side)

    B. Projection (Left Side)C. Left Side Cover

    Remove the boltfree the seat strap

    Remove the bolt

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    A. Bolt and Washer

    B. Seat StrapC. Bolt (Both Sides)D. Seat

    Seat Installation

    Insert the seat hooks into the stop-

    A. Seat Hooks

    B. StoppersC. Fuel TankD. Frame

    Install the seand tighten th

    50 GENERAL INFORMATION

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    A. Projection (Both Sides)

    B. Grommet (Both Sides)C. Side Cover (Both Sides)

    Tighten the bolt on both sides.

    A. Tying Hooks

    Tool Kit Bag/T

    The tool kit is stobag.

    G

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    A. Tool Kit

    B. Tool Kit Bag

    Rear View Mirror

    Rear View Mirror Adjustment

    the upper heand turn the s

    Tighten the (locknut).

    The upper he

    is left-hand th

    52 GENERAL INFORMATION

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    A. Rear View Mirror

    B. StayC. Rubber BootD. Upper Hexagonal Area (Locknut)E. Lower Hexagonal Area

    HOW TO RI

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    HOW TO RIDE THE MOTORCY

    Break-In

    The first 1 600 km (1 000 miles) that the motorcycle is rithe break-in period. If the motorcycle is not used carefully

    may very well end up with a broken down instead of a after a few thousand kilometers.

    The following rules should be observed during the break-i

    The table shows maximum recommended speed in kbreak-in period.

    Gear position1st 2nd

    Distance traveled

    54 HOW TO RIDE THE MOTORCYCLE

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    NOTE

    When operating on public roadways, keep maximum speed u

    its.

    Do not start moving or race the engine immediately after staengine is already warm. Run the engine for two or three minutgive the oil a chance to work up into all the engine parts.

    Do not race the engine while the transmission is in neutral.

    WARNING

    New tires are slippery and may cause loss of control and in

    A break-in period of 160 km (100 miles) is necessary to etire traction. During break-in, avoid sudden and maximumceleration, and hard cornering.

    In addition to the above, at 1 000 km (600 miles) it is extremely

    HOW TO RI

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    Starting the Engine

    Turn the fuel tap lever to ON posi-tion.

    A. Engine Stop SwB. Starter Button

    Turn the ignition.

    Make sure tneutral.

    56 HOW TO RIDE THE MOTORCYCLE

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    A. Neutral Indicator (Green)B. Ignition SwitchC. ON position

    If the engine is cold, pull out thechoke lever all the way.

    A. Choke Lever

    NOT

    When the engine on hot days [highF)], do not use th

    l t h l

    HOW TO RI

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    NOTICE

    Do not operate the starter contin-uously for more than 5 seconds,or the starter will overheat andthe battery power will drop tem-porarily. Wait 15 seconds be-

    tween each operation of thestarter to let it cool and the bat-tery power recover.

    NOTEIf the engine is flooded, crank the en-

    gine over with the throttle fully openuntil the engine starts.

    The motorcycle is equipped with a

    clutch lever stand is fully u

    A. Clutch LeverB. Starter Lockout

    When the e

    NOTE lt b t b tt

    58 HOW TO RIDE THE MOTORCYCLE

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    NOTE

    If you drive the motorcycle before

    the engine is warmed up, release thechoke lever as soon as you startmoving.

    If the choke lever is left on too longafter the engine is warm, it will cause

    the spark plug to foul, and poor gasmileage.

    NOTICE

    Do not let the engine idle longerthan five minutes, or engine over-heating and damage may occur.

    volt booster battery may be used to start

    DA

    Battery acid genegas which is flamplosive under cer

    It is present withitimes, even in a ddition. Keep all fla(cigarettes) awaytery. Wear eye pworking with a event of battery askin, eyes, or cloaffected areas im

    Remove the seat (see Seat sectionHOW TO RI

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    Remove the seat (see Seat sectionin the GENERAL INFORMATIONchapter).

    Slide the cap from the positive (+)terminal (see Battery section in theMAINTENANCE AND ADJUST-MENT chapter).

    Connect a jumper cable from thepositive (+) terminal of the boosterbattery to the positive (+) terminal ofthe motorcycle battery.

    NOTICE

    Be careful not to contact thejumper cable slip on the positivebattery terminal to the frame, or it

    A. Motorcycle BattB. From Booster BC. Unpainted MetaD. From Booster B

    nal

    Connect ano

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    DANGER

    Batteries contain sulfuric acidthat can cause burns and pro-duce hydrogen gas which ishighly explosive. Do not makethis last connection at the fuel

    system or battery. Take care notto touch the positive and nega-tive cables together, and do notlean over the battery when mak-ing this last connection. Do not

    connect to a frozen battery. Itcould explode. Do not reverse po-larity by connecting positive (+)to negative (), or a battery explo-sion and serious damage to the

    NOT

    Do not operate thuously for more or the starter withe battery poweporarily. Wait 1

    tween each opstarter to let it cotery power recove

    After the engine hnect the jumper cthe negative () ctorcycle first.

    Install the removed

    Open the throttle a little and start to designed so tHOW TO RI

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    Open the throttle a little, and start tolet out the clutch lever very slowly.

    As the clutch starts to engage, openthe throttle a little more, giving theengine just enough fuel to keep itfrom stalling.

    designed so tstart if the trand the side s

    Shifting Ge

    Close the throclutch lever.

    Shift into thegear.

    Vehicle speed when shi

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    WARNING

    Downshifting at high speed canmake the rear wheel skid andcause an accident resulting in se-vere injury or death, as well ascause the engine to overrev and

    damage it. When shifting down toa lower gear, do not shift at sucha high speed that engine rpmjumps excessively. Downshift atthe vehicle speeds shown in the

    table in this section.

    Open the throttle part way, while re-leasing the clutch lever.

    Vehicle speed when shi

    Shifting down

    5th4th 4th3rd

    3rd2nd

    2nd1st

    Braking

    Close the throttle c

    the clutch engagshifting gears) so help slow down the

    Shift down one geyou are in 1st gea

    necessary to keep the engine from

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    necessary to keep the engine fromstalling.

    Never lock the brakes, or it will causethe tires to skid. When turning a cor-ner, it is better not to brake at all. Re-duce your speed before you get intothe corner.

    For emergency braking, disregarddownshifting, and concentrate on ap-plying the brakes as hard as possiblewithout skidding.

    A. Rear Brake Ped

    Stopping th

    Close the thro Shift the trans

    St i th M t l i2 During removal

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    Stopping the Motorcycle inan Emergency

    Your Kawasaki Motorcycle has beendesigned and manufactured to provideyou optimum safety and convenience.However, in order to fully benefit fromKawasaki's safety engineering andcraftsmanship, 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 adangerous situation known as throttlefailure. Two of the most commoncauses of throttle failure are:

    2. During removal dirt is allowed tocarburetor.

    In an emergencythrottle failure, youstopped by applyindisengaging the clut

    ping procedure is instop switch may beengine. If the engused, turn off the igstopping the motorcy

    P ki

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    Parking

    WARNING

    Operating or parking the vehiclenear flammable materials cancause a fire, and can result inproperty damage or severe per-sonal injury.Do not idle or park your vehicle inan area where tall or dry vegeta-

    tion, or other flammable materialscould come into contact with themuffler or exhaust pipe.

    The engine aget extremelyoperation anburns.Never touch

    haust pipe, oeration or engine.

    Shift the traand turn the igsition.

    Support the level surface w

    If parking inside a garage or other66 HOW TO RIDE THE MOTORCYCLE

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    If parking inside a garage or otherstructure, be sure it is well ventilatedand the motorcycle is not close toany source of flame or sparks; thisincludes any appliance with a pilotlight.

    WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions, creating the po-

    tential for serious burns. Turn theignition switch to OFF. Do notsmoke. Make sure the area is wellventilated and free from anysource of flame or sparks; this in-

    MAINTENANCE AND ADJUST

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    MAINTENANCE AND ADJUST

    The maintenance and adjustments outlined in this chapteaccordance with the Daily Checks and Periodic Maintenacycle in good running condition and to reduce air pollutionance is vitally important and must not be neglected.

    WARNING

    Failure to perform these checks or to correct a problemay result in serious damage or an accident. Always pbefore operation.

    With a basic knowledge of mechanics and the proper useable to carry out many of the maintenance items describelack proper experience or doubt your ability, all adjustmentspair work should be completed by a qualified technician

    68 MAINTENANCE AND ADJUSTMENT

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    DANGER

    Exhaust gas contains carbon monoxide, a colorless, odogas. Inhaling carbon monoxide can cause serious brain DO NOT run the engine in enclosed areas. Operate only in area.

    NOTE

    If a torque wrench is not available, the maintenance items wcific torque value should be serviced by an authorized Kawasa

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    Daily Checks

    Check the following items each day before you ride. The tand habitual performance of these checks will help ensure y

    If any irregularities are found during these checks, refer AND ADJUSTMENT chapter or see your dealer for the actio

    motorcycle to a safe operating condition.

    Operation

    Fuel

    Adequate supply in tank, no leaks

    Engine oil

    Oil level in the operating range (grid area) on the dipstick

    Tires

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    Operation

    Bolts, nuts and fastenersCheck for loose and/or missing bolts, nuts and fasteners

    Steering

    Action smooth but not loose from lock to lock

    No binding of control cables

    Brakes

    Brake pad wear

    Brake fluid level

    No brake fluid leakage

    Throttle

    Throttle grip free play

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    Operation

    Engine stop switchStops engine

    Side stand

    Return to its fully up position by spring tension

    Return spring not weak or not damaged

    Rear view mirrors

    Rear view sight

    72 MAINTENANCE AND ADJUSTMENT

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    Additional Considerations for Off Road Opera

    Brakes:The importance of reliable brakes is obvious. Check tcorrectly adjusted and functioning properly.

    Steering:Looseness in the steering can cause loss of controlthe handlebars turns freely but has no play.

    Tires: Due to the extra stress to the tires on rough roads, btheir overall condition, and inflate to the proper pressure.Drive Chain:When not adjusted properly, the severe stress o

    cause damage to the sprockets and cause the chain to be thrchain slack and alignment, and lubricate if necessary.

    Fuel:Have sufficient fuel for the high fuel consumption on rougEngine Oil:To avoid engine seizure and resulting loss of cont

    the oil level is at the operating range (grid area) on the dipstick.Miscellaneous: Check to see that the electrical equipment is

    erly, all nuts and bolts are tight, and all safety related parts are in

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    Periodic Maintenance

    *A: Service at number of years shown or indicated odometer reever comes first.

    *B: For higher odometer readings, repeat at the frequency inter*C: Service more frequently when operating in severe condition

    speed, or frequent starting/stopping.

    : Inspection : Dealer Inspectio

    : Change or Replace : Dealer Change

    : Lubrication : Dealer Lubricati

    Items

    year(*A)

    Odome 1 000 k

    1(0 6)

    6(3 8) (

    Odometer R

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    Items

    year

    (*A)

    Odometer R 1 000 km (

    1(0.6)

    6(3.8)

    12(7.6)

    Choke operation :1

    Fuel system :1

    Fuel hose :5

    Valve clearance

    Air suction system

    Clutch operation (play, engagement,disengagement)

    Engine oil and oil filter (*C) :1

    Tire air pressure :1

    Odome

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    Items

    year

    (*A)

    Odome 1 000 k

    1(0.6)

    6(3.8) (

    Drive chain slack (*C) : every

    Drive chain wear (*C)

    Drive chain guide wear

    Brake system :1

    Brake operation (effectiveness, play,no drag) :1

    Brake fluid level :0.5

    Brake fluid (front and rear) :2

    Odometer R

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    Items

    year

    (*A)

    1 000 km (

    1(0.6)

    6(3.8)

    12(7.6)

    Suspension system :1

    Lubrication of rear suspension

    Steering play :1

    Steering stem bearings :2

    Electrical system :1

    Spark plug

    Chassis parts :1

    Condition of bolts nuts and fasteners

    E i Oil

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    Engine Oil

    Oil Level Inspection

    If the engine is cold, start the engineand run it for several minutes at idlespeed.

    Stop the engine, then wait severalminutes until the oil settles.

    NOTICE

    Racing the engine before the oilreaches every part can cause en-gine seizure.

    With the motorcycle held level, un-

    A. Oil Filler Cap/Di

    N

    Be careful noforeign mategine

    between upper and lower level linesth di ti k

    same type and brad i th i

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    on the dipstick.

    A. Oil Filler Cap/DipstickB. Upper Level LineC. Lower Level LineD. O-ring

    ready in the engin

    NOTDo not pinch the O

    ling the dipstick on

    When the O-ring c

    oil filler neck, instaoil filler neck corrstall the dipstick.

    Oil and/or Oil Filter C

    Warm up the engithen stop it.Remove the dipstiPlace an oil pan be Remove the eng

    WARNING If the oil filtemove the oil f

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    WARNING

    Engine oil is a toxic substance.Dispose of used oil properly.Contact your local authorities forapproved disposal methods orpossible recycling.

    move the oil fa new one as

    Remove the filter cover an

    A Oil Filt C

    Be sure to install the filter with thegrommet facing inside

    Install the spring s80 MAINTENANCE AND ADJUSTMENT

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    grommet facing inside.

    A. GrommetB. Oil Filter

    NOTICE

    A. O-ringB. Spring

    Install the oil filtearrow mark faces

    NOTE

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    Replace the gasket with a new one.

    Tightening Torque

    Oil Filter Cover Bolts:

    5.2 Nm (0.53 kgfm, 46 inlb)

    Engine Oil Drain Plug:

    18 Nm (1.8 kgfm, 13 ftlb)

    NOTE

    If a torque wrench is not available,

    this item should be serviced by anauthorized Kawasaki dealer.

    Pour in the specified type andamount of oil.

    Do not add an

    the oil. Oils quirements aprovide adequthe engine an

    Engine Oil Capacit

    1.13 L (1.19 US q

    [when filter is not

    1.15 L (1.22 US q

    [when filter is rem

    Although 10Wrecommended the oil viscoschanged to acco

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    Start the engine.

    Check the oil level and oil leakage.

    Spark Plug

    Spark Plug Replacement

    C f ll ll th k l

    A. Spark Plug CapB. Spark Plug

    Unscrew the spaspark plug wrencsupplied tool kit (Tool Kit section in

    make sure stalled

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    A. Spark Plug WrenchB. Wrench

    NOTE

    Spark plug installation is performedin the reverse order of removal.

    stalled.

    Check the hig

    damaged, or c

    Spark Plug

    StandardPlug

    NG

    Plug Gap 0.6

    (0.

    Tightening Torque

    Spark Plug:

    13 Nm (1.3 kg

    Remove the left sisection in the GEN

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    A. 0.6 ~ 0.7 mm (0.024 ~ 0.028 in.)

    Air Cleaner

    Air Cleaner Element Replacement

    NOTE

    section in the GENTION chapter).

    Remove the air cleer bolts and air cleer.

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    A. Wing BoltB. Washer

    C. Air Cleaner Element

    Stuff a clean, lint-free towel into theair cleaner duct so no dirt is allowedto enter the carburetor.

    If dirt or dusthrough intothrottle may sibly causingto keep the

    during cleani

    N

    If dirt gets tgine, excesspossibly engcur.

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    A. FrameB. Air Cleaner Element

    Replace the air cleaner element witha new one.

    Install the frame into the new ele-ment.

    A. Apply grease.

    Install the elementighten the wing boInstall the air cleanTighten the air cle

    er bolts to the spec

    Air Cleaner Element Cleaning

    NOTERemove the a

    Air Cleaner E

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    NOTE

    In dusty areas, the element shouldbe cleaned more frequently than therecommended interval.

    After riding through rain or on mud-dily roads, the element should be

    cleaned immediately.

    WARNING

    Gasoline and low flash-point sol-vents can be flammable and/orexplosive and cause severeburns. Clean the element in awell-ventilated area, and take

    Air Cleaner E

    Separate thecleaner elemeement Replac

    Clean the eleflash-point sobrush.

    Squeeze it dnot twist the the element c

    Check all the

    visible damagIf any of the pdamaged, rep

    After cleaningwith a high-q

    WARNING

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    Gasoline and low flash-point sol-vents are extremely flammableand may explode, causing severeburns. Do not use gasoline or alow flash-point solvent to clean

    the element. Clean the element ina well-ventilated area. Be surethere are no sparks or flame inthe work area, including any ap-pliance with a pilot light.

    Oil Draining

    Inspect the drain caps located at thebottom of the air cleaner housing to

    A. Drain Caps

    If there is any oilcap and drain the

    WAR

    Throttle Control System

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    Throttle GripThrottle Grip Free Play Inspection

    Check that the throttle grip movessmoothly from full open to close, andthe throttle closes quickly and com-

    pletely by the return spring in allsteering positions.

    If the throttle grip does not returnproperly, have the throttle controlsystem checked by an authorized

    Kawasaki dealer. Check the throttle grip free play by

    turning back and forth.

    A. Throttle GripB. Throttle Grip Fr

    Throttle Grip Free

    2 ~ 3 mm (0.08

    If there is imp

    Tighten the locknut. movement changthe throttle cables

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    A. LocknutB. Throttle CableC. Accelerator Cable Adjuster

    If the throttle cable cannot be ad-j t d ith th dj t t th

    adjusted or inco

    they may be damcorrect any of thefore riding.

    WAROperation with justed, incorrecdamaged cable cunsafe riding conthe control cablerouted correctly, damage.

    that is necessary to enable easy start-ing when the engine is cold.

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    g gIf starting difficulty or rich fuel mixture

    trouble occurs, inspect the choke lever,and adjust it if necessary.

    Choke Lever Inspection

    Check that the choke lever returns

    properly and that the inner cableslides smoothly. If there is any irregu-larity, have the choke cable checkedby an authorized Kawasaki dealer. A. Choke Lever

    Idle Speed

    Idle Speed Adjus

    Start the engi

    Idle Speed

    1 400 50 r/min (rpm)

    adjusted or incothey may be dam

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    ( p )

    A. Idle Adjusting Screw

    Open and close the throttle a fewtimes to make sure that the idle

    y ycorrect any of the

    fore riding.

    WAR

    Operation with a

    could result in acondition. Replacontrol cable befo

    Clutch

    Clutch Operation Insp

    Check that the clu

    Clutch Lever Free Play

    2 ~ 3 mm (0.08 ~ 0.12 in.) Turn the adju

    lever will ha

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    ( )

    A. AdjusterB. LocknutC. Clutch Lever Free Play

    If the pla is incorrect adj st the le

    play.

    Tighten the lo

    Excess clutc

    prevent clutand cause aserious injuryjusting the cthe upper enis fully seatedit doesn't slipcreate excess

    NOTE

    After the adjustment is made, start

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    After the adjustment is made, startthe engine and check that the clutchdoes not slip and that it releasesproperly.

    Drive Chain

    Drive Chain Lubrication

    Lubrication is necessary after ridingthrough rain or on wet roads, or anytime that the chain appears dry.

    If the chain is especially dirty, clean itusing a cleaner for chains following theinstructions supplied by the chaincleaner manufacturer.

    A l l b i t t th id f th

    Wipe off any lubrthe tire surface.

    Drive Chain Slack Ins

    Raise the rear wheClean the chain if

    chain midway between the swingarmpivot and rear axle.

    Drive Chain Slac

    Remove the aR th

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    A. Chain SlackB. Swingarm Pivot

    If the drive chain is too tight or too

    Remove the the rear axle n

    Loosen the ljuster locknut

    standard chain slack. To keep thechain and wheel properly aligned,th t h th i ht h l li

    NOT

    Wheel alignmen

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    the notch on the right wheel align-

    ment indicator should align with thesame swingarm mark that the left in-dicator notch align with.

    gchecked using thstring method.

    WAR

    Misalignment of tsult in abnormalresult in an unsation. Align the rethe marks on th

    measuring the dithe center of the arm pivot.

    Ti ht b th h i

    NOTE

    If a torque wrench is not available, When inserti

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    q ,this item should be serviced by anauthorized Kawasaki dealer.

    Rotate the wheel, measure the chainslack again at the tightest position,and readjust if necessary.

    Insert a new cotter pin through theaxle, and spread its ends.

    slots in the ncotter pin holeen the nut cloalignment.

    It should be w

    Loosen once the slot goes p

    WARNING WAR

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    A loose axle nut can lead to an

    accident resulting in serious in-jury or death. Tighten the axle nutto the proper torque and install anew cotter pin.

    Check the rear brake (see Brakessection in this chapter).

    Install the axle cap.

    BrakesIf you feel there is something wrong

    when applying the brakes, have thebrake system checked by an author

    Air in the brake

    braking performcause an accidenjury or death. If thpedal feels mushplied, there mighbrake lines or thdefective. Havechecked immediathorized Kawasak

    Brake Fluid Level Ins

    With the front brheld horizontal, th

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    A. Front Brake Fluid ReservoirB. Lower Level Line

    With the rear brake fluid reservoirheld horizontal, the brake fluid levelmust be kept between the upper andlower level lines.

    A. Rear Brake FluiB. Upper Level Lin

    C. Lower Level Lin

    If the fluid lever level line ifluid is leaking

    thickness of either pad lining is lessthan 1 mm (0.04 in.), replace both padsin the caliper as a set Pad replace

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    in the caliper as a set. Pad replace-

    ment should be done by an authorizedKawasaki dealer.

    A. Front Brake Pads

    A. Rear Brake PadsB. Lining Thickness

    C. 1 mm (0.04 in.)

    Brake Light Sw

    B k Li h S i h I

    If it does not, ask your authorizedKawasaki dealer to inspect the frontbrake light switch

    Brake Pedal Trave

    10 mm (0.39 in.)

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    brake light switch.

    Check the operation of the rearbrake light switch by depressing thebrake pedal. The brake light shouldgo on after the proper pedal travel.

    Brake Light Swit

    To adjust the move the swiing the adjust

    NOTICE

    To avoid damaging the electrical

    NOT

    Sticking muds o

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    To avoid damaging the electrical

    connections inside the switch, besure that the switch body doesnot turn during adjustment.

    Suspension System

    Front Fork

    The front fork operation and oil leak-age should be checked in accordancewith the Periodic Maintenance Chart.

    After riding through muddy or dustyroads, the front inner tube should be

    Sticking muds o

    sliding surface ocould damage tleading to an oil sliding surface aft

    Front Fork Inspection

    Holding the brakefront fork up and dto inspect smooth

    Tuck up the fork bo Visually inspect tleakage, scoring oouter surface of th

    N

    Sticking mud

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    A. Inner TubeB. Fork Boot (Both Sides)

    Rear Shock Absorber

    The rear shock absorber operationand oil leakage should be checked in

    Sticking mud

    sliding surfaabsorber couseal, leadingthe sliding ride.

    Rear Shock Absorber Inspection

    Press down on the seat severaltimes to inspect the stroke

    for various riding ations.

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    times to inspect the stroke.

    Visually inspect the rear shock ab-sorber for oil leakage. If there is any doubt about the rear

    shock absorber, it should be done byan authorized Kawasaki dealer.

    Spring Preload Adjus

    The spring adjustshock absorber can

    If the spring actiotoo stiff, have it adju

    ized Kawasaki deale

    Wheels

    Tire Air Pressure Insp

    Remove the air vaCheck the tire air ing an accurate ga

    Make sure to instasecurely

    more than a mile during the past 3hours).

    Tire air pressure is affected by

    Tire Air Pressure (

    Front 150 k

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    Tire air pressure is affected by

    changes in ambient temperature andaltitude, and so the tire air pressureshould be checked and adjustedwhen your riding involves wide varia-tions in temperature or altitude.

    Rear 150 k

    Tire Wear, DamAs the tire tre

    becomes more

    and failure. Anthat 90% of all tthe last 10% ofSo it is false ecuse the tires unt

    Tire Wear Inspec

    Measure the a depth gaugthat has worn

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    A. Tire Depth Gauge

    Minimum Tread Depth

    Front 2 mm (0.08 in.)

    Rear 2 mm (0.08 in.)

    Visually inspect the tire for cracks

    A. Crack or CutB. Nail

    C. Swelling or High SpoD. Stone

    Remove any imbother foreign partic

    WARNING

    Tires that have been punctured

    When operatikeep maximulaw limits

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    Tires that have been punctured

    and repaired do not have thesame capabilities as undamagedtires and can suddenly fail, caus-ing an accident resulting in seri-ous injury or death. Replacedamaged tires as soon as possi-ble. To ensure safe handling andstability, use only the recom-mended standard tires for re-

    placement, inflated to thestandard pressure. If it is neces-sary to ride on a repaired tire, donot exceed 100 km/h (60 mph) un-til the tire is replaced

    law limits.

    Standard Tire

    Front

    Make, TyIRC, G

    Size:2.75-2

    Rear

    Make, TyIRC, G

    Size:4.10-1

    Mixing tire bradversely af

    WARNING

    New tires are slippery and may

    NOT

    Never remove th

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    New tires are slippery and may

    cause loss of control and injury.A break-in period of 160 km (100miles) is necessary to establishnormal tire traction. Duringbreak-in, avoid sudden and maxi-mum braking and acceleration,and hard cornering.

    BatteryThe battery installed in this motor-

    cycle is a sealed type, so it is not nec-essary to check the battery electrolyte

    Never remove th

    or the battery canDo not install a cotery in this motelectrical systemproperly.

    Make Furuka

    Type FTX7L

    Battery MaintenaIt is the owner's re

    the battery fully chaso can lead to batter

    (check with your Kawasaki dealer). Ifyou will not be using the motorcycle forlonger than two weeks, the battery

    If the above cable, use equiva

    For more deta

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    o ge t a t o ee s, t e batte y

    should be charged using an appropri-ate charger. Do not use an automotive-type quick charger that may over-charge the battery and damage it.

    NOTELeaving the battery connected

    causes the electrical components tomake the battery discharged, result-ing the over discharge of the battery.

    In this case, the repair or replace-ment of the battery is not included inthe warranty. If you do not drive forfour weeks or more, disconnect the

    o o e deta

    dealer.Battery Charging

    Charge the bstructions of y

    The charger fully chargedreinstall the b(see Battery I

    DANGER

    Battery acid generates hydrogen

    Remove the seatin the GENERAchapter).

    110 MAINTENANCE AND ADJUSTMENT

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    Battery acid generates hydrogen

    gas which is flammable and ex-plosive under certain conditions.It is present within a battery at alltimes, even in a discharged con-dition. Keep all flames and sparks(cigarettes) away from the bat-tery. Wear eye protection whenworking with a battery. In theevent of battery acid contact with

    skin, eyes, or clothing, wash theaffected areas immediately withwater for at least five minutes.Seek medical attention.

    p )

    Remove the bolts

    A. BoltsB Battery Holder

    Remove the battery. Connect the minal, and theto the () term

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    A. CapB. () TerminalC. (+) TerminalD. Battery

    Clean the battery using a solution of

    ( )

    N

    Installing theterminal of th

    cable to thebattery can selectrical sys

    Put a light cominals to prev

    Cover the (+) Install the rem

    Vertical Adjustment

    The headlight beam is adjustablevertically. If adjusted too low, neither

    NOT

    On high beam, tshould be slightly

    112 MAINTENANCE AND ADJUSTMENT

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    low nor high beam will illuminate theroad far enough ahead. If adjusted toohigh, the high beam will fail to illumi-nate the road close ahead, and the lowbeam will blind oncoming drivers.

    Turn the vertical adjuster in or out toadjust the headlight vertically.

    should be slightly

    with the motorcyand the rider seheadlight to the pring to local regulat

    Fuses

    The main fuse and spare fuse are lo-

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    The main fuse and spare fuse are lo

    cated under the seat. If a fuse fails dur-ing operation, inspect the electricalsystem to determine the cause, andthen replace it with a new fuse of prop-er amperage.

    If the fuse fails repeatedly, there issomething wrong with the electricalsystem. Have the motorcycle checkedby an authorized Kawasaki dealer.

    The main fuse removal should bedone by an authorized Kawasaki deal-er.

    A. Main FuseB. Spare Fuse

    Substituting fing to overhe

    Before lubricatingoff any rusty spots and wipe off any g

    114 MAINTENANCE AND ADJUSTMENT

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    A. NormalB. Failed

    General Lubrication

    Lubricate the points shown below,

    grime.Apply motor oil to

    pivots

    Side Stand

    Clutch LeverFront Brake LeverRear Brake Pedal

    Lubricate the follo

    with a pressure(K)Choke Inner C(K)Clutch Inner C(K)Throttle Inner C

    After connecthem.

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    Apply grease to the following

    points(K)Choke Inner Cable Upper End(K)Clutch Inner Cable Upper End(K)Throttle Inner Cable Upper Ends

    them.

    Cleaning Y

    General Prec

    Frequent andwasaki motorcypearance, performance, a

    Covering your quality, breathawill help protecUV rays, polluamo nt of d st

    WARNING

    Build-up of debris or flammable

    Be sure the engincool before washin

    Avoid applying d

    116 MAINTENANCE AND ADJUSTMENT

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    p

    material in and around the ve-hicle chassis, engine, and ex-haust can cause mechanicalproblems and increase the risk offire.

    When operating the vehicle inconditions that allow debris orflammable material to collect inand around the vehicle, inspectthe engine, electrical componentand exhaust areas frequently. Ifdebris or flammable materialshave collected, park the vehicleoutside and stop the engine Al-

    brake pads, and tiAvoid all harsh ch

    detergents, and hproducts such awindow cleaners.

    Gasoline and brakthe finish of paintefaces: wash them

    Avoid wire brusheall other abrasive p

    Use care when wlight lens and oththey can easily be

    Avoid using press

    components, muffler outlet, and fueltank openings.

    not let the wadamage the p

    Start the engi

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    Washing Your MotorcycleRinse your motorcycle with cold

    water from a garden hose to removeany loose dirt.

    Mix a mild neutral detergent (de-signed for motorcycles or automo-biles) and water in a bucket. Use asoft cloth or sponge to wash yourmotorcycle. If needed, use a mild de-

    greaser to remove any oil or greasebuild up.

    After washing, rinse your motorcyclethoroughly with clean water to re-move any residue (residue from the

    eral minutes.gine will help

    Carefully rideslow speed several times

    brakes and reoperating per

    Lubricate therusting.

    After riding iroads are salimmediately

    Condensation may form on the in-side of the headlight lens after ridingin the rain, washing the motorcycle

    headlight lens and plastic parts with ancleaner/polisher prod

    118 MAINTENANCE AND ADJUSTMENT

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    or humid weather. To remove themoisture, start the engine and turnon the headlight. Gradually the con-densation on the inside of the lenswill clear off.

    Semi-gloss FinishTo clean the semi-gloss finish;

    When washing the motorcycle, al-ways use a mild neutral detergentand water.

    The semi-gloss finish effect may belost when the finish is excessivelyrubbed

    NOT

    Plastic parts maybreak if they comchemical substa

    hold cleaning prgasoline, brake cleaners, thread-or other harsh

    plastic part comeany harsh chemwash it off imwater and a mildgent and then in

    Chrome and AluminumChrome and uncoated aluminum

    parts can be treated with a chrome/alu-

    The sidewallsber componentsa rubber prote

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    minum polish. Coated aluminumshould be washed with a mild neutraldetergent and finished with a spraypolish. Aluminum wheels, both paintedand unpainted can be cleaned with

    special non-acid based wheel spraycleaners.

    Leather, Vinyl, and RubberIf your motorcycle has leather acces-

    sories, special care must be taken.Use a leather cleaner/treatment toclean and care for leather accessories.Washing leather parts with detergent

    their useful life.

    Rubber protepery and, if area, cause sulting in accor death. Doprotectant to

    APPENDIX

    120 APPENDIX

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    Storage

    Preparation for Storage

    Clean the entire vehicle thoroughly.Run the engine for about five minutes to warm the oil, shut it of

    gine oil.

    WARNING

    Engine oil is a toxic substance. Dispose of used oil properlocal authorities for approved disposal methods or possib

    Put in fresh engine oil. Empty the fuel from the fuel tank by the pump or siphon

    WARNING

    Gasoline is extremely flammable and can be explosiv

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    ditions, creating the potential for serious burns. TurnDo not smoke. Make sure the area is well ventilatedsource of flame or sparks; this includes any applianGasoline is a toxic substance. Dispose of gasoline prlocal authorities for approved disposal methods.

    Remove the spark plug and spray fogging oil directly intengine over several times with the starter button to coat ththe spark plug.

    WARNING

    An air/oil mist may be forcibly ejected from the spark pget into your eyes Do not lean over the engine when

    Set the motorcycle on a box or stand so that both wheelsground. (If this cannot be done, put boards under the front akeep dampness away from the tire rubber.)

    122 APPENDIX

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    Spray oil on all unpainted metal surfaces to prevent rusting. Arubber parts or in the brakes.Lubricate the drive chain and all the cables.Remove the battery, and store it where it will not be exposed

    moisture, or freezing temperatures. During storage it shou

    charge (one ampere or less) about once a month. Keep the baespecially during cold weather.

    Tie plastic bag over the muffler to prevent moisture from enteriPut a cover over the motorcycle to keep dust and dirt from coll

    Preparation after StorageRemove the plastic bag from the muffler.Install the battery in the motorcycle and charge the battery if neFill the fuel tank with fuel.

    Ch k ll th i t li t d i th D il Ch k ti

    Troubleshooting Guide

    Engine Does Not Start

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    Starter Motor Won't Turn

    Engine stop switch offTransmission not in neutralFuse blownBattery cables do not make good electrical contact with baBattery dischargedEngine Cranks, But Won't Start

    No fuel in tankFuel line clogged

    Fuel broken downChoke is not used when engine is coldEngine floodedSpark plug not in good contact

    Clutch does not properly disengageWhile Riding

    Choke is used too long after moving off

    124 APPENDIX

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    No fuel in tankFuel tap is turned offFuel tank air vent is obstructedOverheatingBattery discharged

    Environmental Protection

    To help preserve the environment, properly discard used batte

    fluids, or other vehicle components that you might dispose of in your authorized Kawasaki dealer or local environmental wastproper disposal procedure. This also applies to disposal of the eend of its life.

    MAINTENANCE RECORD

    MA

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    Owner Name .......................................................................Address ...............................................................................

    Phone Number ....................................................................

    Engine Number ...................................................................

    Vehicle Number ..................................................................

    Key Code .............................................................................

    Selling Dealer Name ...........................................................

    Phone Number ....................................................................Warranty Start Date ............................................................

    Note:Keep this information and a spare key in a secure lo

    Date Odometer

    Reading Maintenance Performed Dealer Name

    126 MAINTENANCE RECORD

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    Date Odometer

    Reading Maintenance Performed Dealer Name

    MA

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    Date Odometer

    Reading Maintenance Performed Dealer Name

    128 MAINTENANCE RECORD

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    Date Odometer

    Reading Maintenance Performed Dealer Name

    MA

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    Date Odometer

    Reading Maintenance Performed Dealer Name

    130 MAINTENANCE RECORD

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