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TABLE OF CONTENTS

Specifications .. .. .. . ... .. . .. ... ... .. ... . .. .. . ... .. ... .. . . 6 Fuel Tap ... .. ... ... .. .. . . .. . . . .. . .. . . . ... .. . .. ... .. ... .. ... . 19
Location of Parts .. ... ... .. ... ... .. ... . .. .. . .. . .. ... ... . 9 Fuel Tank Cap ... .. ... . .. .. . .. . . . .. . . .. .. ... ... .. . 20
General Information .. ... .. ... ... .. ... ... .. ... . .. .. . 12 Fuel Tank .. ... ... .. ... .. . . . ... . .. .. . ... .. . .. ... .. ... . 21
Meter Instruments . ... .. ... ... .. ... ... .. ... . .. .. . 12 Stands .. .. ... .. . .. ... ... .. ... ... .. ... . .. .. . .. . .. . .. ... . 22
Speedometer and Tachometer ... .. 13 Tool Kit Compartment/Tool Kit . ... .. . .. ... 24
Water Temperature Gauge . .. .. . .. . .. 13 Break-In . . .. .. . .. . .. ... ... .. ... .. . .. ... .. . .. . .. . . . .. . ... .. .. 25
Indicator Lights .. ... ... .. ... ... .. ... ... .. ... . 14 How to Ride the Motorcycle . . ... ... .. ... ... .. . 26
Key . ... .. ... ... .. . .. ... .. ... . .. .. . ... .. . .. .. . .. ... .. . .. .. 15 Starting the Engine ... .. . .. ... . .. .. . ... .. . .. ... . 26
Ignition Switch/Steering Lock ... .. ... . .. .. . 15 Moving Off . .. .. . .. . .. ... .. ... ... .. ... ... .. ... . . . .. . .. 28
Right Handlebar Switches . ... .. ... ... .. ... . 16 Shifting Gears . . ... .. ... .. . .. ... .. . .. . .. ... . . . .. . .. 29
Engine Stop Switch ... .. ... .. ... ... .. . .. .. 16 Braking . ... ... .. ... . . . .. . .. . . . ... .. ... ... ... ... .. ... .. . 29
Headlight Switch . .. . .. .. . ... .. ... ... .. ... .. 17 Stopping the Engine ... .. ... ... .. . .. ... . .. .. . .. 31
Left Handlebar Switches .. . ... .. ... ... .. ... .. 18 Stopping the Motorcycle
Dimmer Switch . .. ... .. . .. . .. .. . ... .. ... ... .. 18 in an Emergency .. ... .. . .. ... ... ... .. . .. . .. 31
Turn Signal Switch . . . .. . .. .. . ... .. ... ... .. 18 Parking . .. . .. ... ... . . .. . . .. .. . .. .. . .. . .. ... ... ... .. ... . 32
Horn Button ... .. ... .. . .. ... .. . .. . . . .. . ... .. ... 18 Safe Operations .. . .. .. . .. .. . .. ... ... . . . .. .. . ... ... .. . 33
Passing Button ... .. . .. ... .. . .. . .. .. . ... .. ... 18 Daily Safety Checks . .. ... .. ... ... .. ... .. ... ... . 33

SPECIFICATIONS

DIMENSIONS
Overall Length 1,960 mm
Overall Width 715 mm
Overall Height 1,085 mm
Wheelbase 1,320 mm
Road Clearance 130 mm
Dry Weight 115 kg
ENGINE
Type 2-stroke, single cylinder, liquid-cooled, crankcase reed valve
with Super-KIPS (Kawasaki Integrated Power-valve System)
Displacement 148 cc
Bore x Stroke 59 .0 x54.4 mm
Compression Ratio 6.8 :1
Ignition System DC . CDI
Ignition Timing 10° BTDC @ 1,000 rpm
21 ° BTDC @ 5,000 rpm
SPECIFICATIONS

DIMENSIONS
Overall Length 1,960 mm
Overall Width 715 mm
Overall Height 1,085 mm
Wheelbase 1,320 mm
Road Clearance 130 mm
Dry Weight 115 kg
ENGINE
Type 2-stroke, single cylinder, liquid-cooled, crankcase reed valve
with Super-KIPS (Kawasaki Integrated Power-valve System)
Displacement 148 cc
Bore x Stroke 59 .0 x54 .4 mm
Compression Ratio 6 .8 : 1
Ignition System DC . CDI
Ignition Timing 10° BTDC @ 1,000 rpm
21 ° BTDC @ 5,000 rpm

Starting System Primary Kick


Carburetor KEIHIN PWL28
Spark Plug NGK B9ES
Lubrication System Superlube (oil injection)
Engine Oil 2-stroke oil
Engine Oil Capacity 1 .3 L
Coolant Capacity 1 .3 L
TRANSMISION
Transmission Type 6-speed, constant mesh, return shift
Clutch Type Wet, multi disc
Driving system Chain drive
Primary Reduction Ratio 3 .2727 (72/22)
Final Reduction Ratio 2 .7857 (39/14)
Overall Drive Ratio 7 .8737 (Top Gear)
Gear Ratio : 1 st 2 .700 (27/10)
2nd 1 .706 (29/17)
3rd 1 .300 (26/20)
4th 1 .090 (24/22)
5th 0 .952 (20/21)
6th 0 .863 (19/22)
Transmission Oil SE class SAE 10W30 or 10W40
Transmission Oil Capacity 0 .87 L
FRAME
Castor 25°
Trail 89 mm
Tire size : Front 90/90-17 49 S
Rear 100/90-18 56 P
Fuel Tank Capacity 10 .3 L
Engine Oil Capacity (oil tank) 1 .2 L
Brakes : Front - Hydraulic Disc Brake
Rear - Hydraulic Disc Brake

ELECTRICAL EQUIPMENT
Battery 12 V3AH
Headlight 12 V 35/36.5 W
Tail/Brake Light 12V5/18W
Turn Signal Light 12V10W

Specifications subject to change without notice .

LOCATION OF PARTS

1. Clutch Lever 6. Right Handlebar Switches


2. Speedometer 7. Front Brake Lever
3. Tachometer 8 . Throttle Grip
4. Water Temperature Gauge 9. Front Brake Fluid Reservoir
5. Left Handlebar Switches 10 . Ignition Switch
11 . Front Fork 17 . Choke Knob 23 . Radiator
12 . Turn Signal Light 18 . Fuel Tap 24 . Center Stand
13 . Headlight 19 . Rear Shock Absorber 25 . Side Stand
14 . Steering Damper 20 . Engine Oil Tank 26 . Drive Chain
15 . Fuel Tank Cap 21 . Disc
16 . Fuel Tank 22 . Caliper

10

27 . Tail/Brake Light 32 . Battery 37 . Mirror


33 . Coolant Reserve Tank 38 . Rear Brake Light Switch
28 . Muffler
34 . Kick Pedal 39 . Rear Brake Pedal
29 Seat
Tool Kit Case/Tool Kit 35 . Horn 40 . Oil Level Gauge
30 .
31 . Fuse Case 36 . Front Brake Light Switch
GENERAL INFORMATION

Meter Instruments

A. Trip Meter F. Red Zone K. Turn Signal Indicator Light


B. Reset Knob G. Water Temperature Gauge L. Low Fuel Warning Light
C. Odometer H. Engine Oil Level Warning Light M. High Beam Indicator Light
D. Speedometer I. Neutral Indicator Light
E. Tachometer J. Top Gear Indicator Light

12

Speedometer Coolant Temperature Gauge


The speedometer shows the speed of the This gaugeshowsthe temperature of coolant.
vehicle . In the speedometerface are theodometer Ordinarily, the needle should stay within the cool
and trip meter. The odometer shows the total zone . If the needle reaches the "Hot (red)" zone,
distance that the vehicle has been ridden . The stop the engine and check the coolant level in the
trip meter shows the distance traveleed since it reserve tank after the engine cools down .
was last resetto zero . Thetrip meter can be reset
to zero by pushing the reset button .
The tachnometer shows the engine speed in CAUTION
the revolutions per minute (r/min, rpm) . qn the
right side of the tachometer face is a portion Do not let the engine continue running
called the "red zone". Engine r/min (rpm) in the when the gauge needle reaches the
red zone is above maximum recommended "Hot (red)" zone . Prolonged engine
engine speed and is also above the range for operation will result in severe damage
good performance . from overheating.

CAUTION

Engine r/min (rpm) should not be


allowedto enterthe red zone; operation
in thered zone will overstress the engine
and may cause seriousengine damage.

13
Indicator Lights FUEL : The low fuel warning light goes on
whenever the ignition switch is in the ON posi-
HIGH BEAM : When the headlight is on tion with the engine in neutral, and goes off
high beam, the high beam indicator light is lit. when the transmission is in any gear . If the fuel
level gets too low, the light will not go off and will
NEUTRAL: When the transmission is in stay on even in any gear . In this case, add the
neutral, the neutral indicator light is lit. fuel at the earliest opportunity.

TOP : When the transmission is in top (6th)


gear, the top gear indicator light is lit.

ENGINE OIL: The engine oil level warning


light goes on whenever the ignition switch is in
the ON position with the engine in neutral, and
goes off when the transmission is in any gear . If
the engine oil level gets too low, the light will not
go off and will stay on even in any gear . In this
case, add the engines oil as soon as possible .

TURN : When the turn signal switch is turned


to left or right, the turn signal indicator light
flashes on and off.

14

Key Ignition Switch/Steering Lock


This motorcycle hasacombination key, which This is three-position, key-operated switch .
is used for the ignition switch/steering lock and The key can be removed from the switch when
fuel tank cap. it is in the OFF or LOCK position .
Blank keys are available at your Kawasaki
Dealers. Ask your Dealer to make any additional
spare keys you may need, using your original
key as a master.

A. Ignition Switch C. OFF position


B. ON position D. LOCK position

15
Right Handlebar Switches
OFF Engine off. All electrical circuits Engine Stop Switch
off. In addition to the ignition switch, the engine
stop switch must be in the RUN position for the
ON Engine on . All electrical motorcycle to operate.
equipments can be used . (The The engine stop switch is foremergency use.
head, tail and meter lights do If some emergency requires stopping the engine,
not come on if the engine is move the engine stop switch in the OFF position .
not running) .

LOCK Steering locked . Engine off. All NOTE


electrical circuits off.
o Although the engine stop switch stops the
engine, it does not turn off all the electrical
To lock the steering : circuits . Ordinarily, the ignition switch should
1 . Turn the handlebar fully to the left . be used to stop the engine.
2 . With the ignition switch key in the OFF
position, push down and release the key.
3. Turn the key to the LOCK position .
4. Pull the key out.

16

Headlight Switch

OFF The headlight is off with the


switch in the OFF position .

The tail and meter lights come


on if the switch is pushed to the
" position with the ignition switch
in the ON position .

The head, tail, and meter lights


come on if the switch is pushed
A. Engine Stop Switch ON forward to the ON position with
B . Headlight Switch the igniiton switch in the ON
position .

17
Left Handlebar Switches
Dimmer Switch
High or low beam can be selected with
the dimmer switch . When the headlights is
on high beam (HI), the high beam indicator
light is lit.

Turn Signal Switch


When the turn signal switch is turned
to L (left) or R (right), the turn signals flash
on and off.
To stop flashing, push the switch in .
A. Dimmer Switch
Horn Button
B. Turn Signal Switch
When the horn is pushed, the horn sounds .
C. Horn Button
D. Passing Button
Passing Button
When the passing button is pushed, the
headlight high beam (passing beam) comes on
the signal to driver of the vehicles ahead that
you are about to pass him. The passing light
shuts off as soon as the switch is released .

18

Fuel Tap NOTE


The fuel tap has three positions: OFF, ON
and RES (reserve) . If the fuel runs out with the o Since riding distance is limited when on
tap in the ON position, the last 2.1 L of fuel can RES, refuel at the earliest opportunity.
be used by turning the tap to RES position . o Make certain that the fuel tap is turned to ON
(Not RES), after filling up the fuel tank.

AWARNINC,

Practise operating at the fuel tap with


the motorcycle stopped. To prevent
an accident you should be able to
operate the fuel tap while riding with-
out taking your eyes off the road .
Be careful not to touch the hot engine
while operating the fuel tap.

A. Fuel Tap C. OFF position


B. RES position D. ON position

19
Fuel Tank Cap
To open the fuel cap, pull up the key hole
cover. Insert the ignition switch key into the
lock and turn the key to the right .
To close the cap, push it down into place
with the key inserted. The key can be re-
moved by turning it counterclockwise to the
original position .

NOTE

o The tank cap cannot be closed wothout the


key inserted, and the key cnnotbe removed
unless the cap is locked properly. A. Key Hole Cover
o Do not push the cap down with the key, or B. Ignition Switch Key
the cap cannot be locked. C. Fuel Tank Cap

20

Fuel Tank AWARNING


Avoid filling the tank in the rain or where
heavy dust is blowing so that the fuel does not get Gasoline is extremely flammable and
contaminated . can be explosive %nder certain
conditions .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 includes any
appliance with a pilot light. Never fill the
tank so the fuel level rises into the filler
neck. It the tank is overfilled, heat may
cause the fuel to expand and may
overflow through the vents in the tank
cap.
After refueling, make sure the tank cap
1 . Tank Cap 3. Top Level is closed securely .
2. Fuel Tank 4. Filler Neck
If gasoline is spilled on the fuel tank,
wipe it off immediately .

21
Fuel Requirement: Stands
Your Kawasaki engine is designed to use The motorcycle is equipped with two stands :
unleaded gasoline . However, if suitable gaso- a center stand and a side stand.
line is not available then PREMIUM, SUPER or
FOUR-STAR gasoline can be used .

Octane Rating
The octane rating of a gasoline is a measure
of its resistance to detonation or " knocking".
The term commonly used to describe a gaso-
line's octane rating is the Research Octane No .
(RON). Always use a gasoline with an octane
rating equal to, or higher than, Reseach Octane
No . (RON) 91 .

NOTE A. Side Stand

o If "knocking" or "pinging" occurs, use a dif- NOTE


ferent brand of gasoline or higher octane
rating . o When using the side stand, turn the handle-
bar to the left.

22

Whenever the side or center stand is used,


make it a practice to kick the stand fully up
before sitting on the motorcycle .

AWARNING
Forgetting and leaving the side stand
down and riding away could cause an
accident .

To set the motorcycle up on the center


stand, step down firmly on the stand and then lift
the motorcycle up and to the rear using the grab A. Center Stand C. Hand Grip
rail as a handlhold. Don't pull up on the seat to B. Step Down D. Lift up
lift as this will damage the seat .

23
Tool Kit Case
The tool kit case is located in the right side
cover behind the battery.
Store the tool kit with tool kit cases.

Tool Kit
The minor adjustment and replacement of
parts explained in this manual can be performed
with the tool kit.

A. Tool Kit
B. Tool Kit Cases

24

BREAK-IN

The first 1,600 km 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 4,000 r/min (rpm)
800 - 1, 600 km 6,000 r/min (rpm)

NOTE

o When operating on public roadways, keep maximum speed under traffic law limits.

" Do not start moving or race the engine immediately after starting it, even if the engine is already
warm . Run the engine for two or three minutes at idle speed to give the oil a chance to work up
into all the engine parts.
" Do not race the engine while the transmission is in neutral.

In addition to the above, at 1,000 km it is extremely important that the owner have the initial
maintenance service performed by an authorized Kawasaki dealer .

25
HOW TO RIDE THE MOTORCYCLE

Starting The Engine " Turn the ignition switch on .


" Turn the fuel tap on . " Make certain the transmission is in neutral .
" Check that the engine stop switch is in the
RUN position .

A . Ignition Switch
B . ON position
A . Fuel Tap C . Neutral Indicator Light
B . ON position
C . Engine Stop Switch " If the engine is cold, pullout the choke knob
all the way (ON posiition) .

26

A. Choke Knob A. Kick Pedal

NOTE
NOTE

o When the engine is already warm or on hot o If the engine is flooded, kick the engine over
days (higher than 35°C), open the throttle with the throttle fully open until the engine
part way instead of using the choke, and starts .
then start the engine .
" Use the choke as necessary to keep the
engine runing during warm-up .
" Leaving the throttle completely closed, kick
" When the engine is warmed up enough to
the engine over until the engine starts .
idle without using the choke, return the
choke to the off position .
27
NOTE Moving Off
" Check that the side stand is up .
0 If you drive the motorcycle before the en- " Pull in the clutch lever.
gine is warmed up, return the choke to the " Shift into 1 st gear
offposition as soon as you start moving " Open the throttle a little, and start to let out
(20 °C - 35 °C). In cold weather, use the clutch lever very slowly .
choke until you have driven the length of " As the clutch starts to engage, open the
time shown in the table. throttle a little more, giving the engine just
enough fuel to keep it from stalling .
Ambient temperature Choke off after
running for
Below 20° 20 seconds

Below 5°C 40 seconds

CAUTION

Do not let the engine idle longer than


five minutes or engine overheating and
damage may occur. A. Shift Pedal

28

Shifting Gears Braking


" Close the throttle while pulling in the clutch " Close the throttle completely, leaving the
lever. clutch engaged (except when shifting gears)
" Shift into the next higher or lower gear . so that the engine will help slow down the
" Open the throttle part way, while releasing motorcycle.
the clutch lever.the clutch lever. " Shift down one gear at atime so that you are
in 1st gear when you come to a complete
AWARNING stop .
" When stopping, always apply both brakes
When shifting down to a lower gear, do at the same time . Normally the front brake
not shift at such a high speed that the should be applied a little more than the rear .
engine r/min (rpm)jumps excessively . Shift down or fully disengage the clutch as
Not only can this cause engine dam- necessary to keep the engine from stalling .
age, but the rear wheel may skid and " Never lock the brakes, or it will cause the
cause an accident . Downshifting tires to skid . When turning a corner, it is
should be done below 5000 r/min (rpm) better notto brakeat all . Reduce your speed
for each gear . before you get into the corner .
" For emergency braking, disregard
downshifting, and concentrate on applying
the brakes as hard as possible without
skidding .

29
A . Front Brake Lever A. Rear Brake Pedal

30

Stopping the Engine Stoping the Motorcycle in an Emergency


" Close the throttle completely . Your Kawasaki Motorcycle has been
" Shift the transmision into neutral . designed and manufactured to provide you
" Turn the ignition switch off . optimum safety and convenience . However, in
" Support the motorcycle on a firm level surface order to fully benefit from Kawasaki's safety
with the side or center stand . engineering and craftsmanship, it is essential
" Lock the steering . that you, the owner and operator, properly
" Turn the fuel tap to the OFF position . maintain your motorcycle and become thoroughly
familiarwith its operation . Improper maintenance
and insufficient riding skills can create a
dangerous situation know as throttle failure . Two
of most common cause of throttle failure are :
1 . An improperly serviced orcloggedaircleaner
may allowdirtand dustto enterthe carburetor
and stick the throttle open .
2 . During removal of the air cleaner, dirt is
allowed to enter and jam the carburetor .

31
In an emergency situation such as throttle Parking
failure, your motorcycle may be stopped by " Shift the transmission into neutral and turn
disengaging the clutch and applying the brakes . the ignition switch OFF .
Once this stopping procedure is initiated, the " Support the motorcycle on a firm level sur-
engine stop switch may be used to stop the face with the side or center stand.
engine . If the engine stop switch used, turn off
the ignition switch after stopping motorcycle . CAUTION

Do not park a soft steeply inclined


surface or the motorcycle may fall over .

If parking inside a garage or other structure,


be sure it is well ventilated and the motorcy-
cle is not close to any source of flame or
sparks ; this includes any appliance with a
pilot light.
AVVARNING
Gasoline is extremely flammable and
can be explosive under certain
conditions.

" Lock the steering to help prevent theft.

32

SAFE OPERATION

Daily Safety Checks


Check the following items each day before you ride . The time required is minimal, and habitual
performance of these checks will help ensure you safe, reliable ride .
If any irregularities are found during these checks, refer to the Maintenance and Adjustment
chapter or see your dealer forthe 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.
Engine OII .. ... .. ... .. . .. ... .. . .. ... . . . .. . .. .. . ... . Adequate supply in tank .
Transmission Oil ... ... .. ... ... .. . .. .. . ... .. . .. . Oil level between level lines.
Tires .. . ... .. ... ... .. ... ... .. ... .. . .. ... . . . .. . .. . . . ... . Air pressure (when cold)

Front 200 kPa (2 .0 kg/cmz)

Rear 225 kPa (2 .25 kg/cm')

33
Drive chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slack 30 - 40 mm .
Nuts, bolts, fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check that steering and suspension components, axles,
and all controls are properly tightened or fastened .
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Action smooth but not loose from lock to lock . No binding
of control cables .
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No brake fluid leakage.
Brake pad wear : Lining thickness more than 1 mm left .
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle grip play 2 - 3 mm .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch lever play 2 - 3 mm .
Clutch lever operates smoothly .
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No coolant leakage
Coolant level between level line (when engine is cold) .
Radiator cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Properly installed .
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All lights and horn work .
Engine stop switch . . . . . . . . . . . . . . . . . ., . . . . . . . .  .  . Stop engine .
Side and center stands . . . . . . . . . . . . . . . . . . . . . . . . . Return to their fully up positions by spring tension . Return
springs not weak or not damaged .

34

MAINTENANCE AND ADJUSTMENT

carried out and must be done in


The maintenence and adjustment outlined in chapter are easily
motorcycle in good running condition . The
accordance with Periodic Maintenance Chart to keep the
neglected .
initial maintenance is vitally important and must not be
adjustment or vehicle operation, please ask your authorized Kawasaki
If you are in doubt as to any
Dealer to check the motorcycle .
for damage resulting from incorrect
Please note that Kawasaki cannot assume any responsibility
adjustment done by the owner .
maintenance or improper
Periodic Maintenance Chart

tOdometer Reading km
\ Frequency Whichever »
comes first

00°
Operation + 00° # o
°° o
°° See
Every Page
Idle speed-check t 0 0 0 54
Throttle grip play-check t " " 0 0 50
Oil pump and carburetor
synchronization-check t 0 0 0 52
Spark plug-clean and gap t " 0 " " 0 0 0 45
Air cleaner element-clean t 0 " 0 49
Air cleaner element-replace 5 . cleanings 0 47
Fuel system-check " 0 " 76
K Cylinder head nuts
tightness-check t 0 " " 0 -
Battery electrolyte
level-check t month 0 " 0 72
Brake fluid level-check t month 0 0 0 0 0 0 0 63
K Brake fluid-change 2 years 0 64
Brake light switch-check t " 0 " " 0 0 0 65

36

Frequency Whichever » tOdometer Reading krn

X
comes first

Operation 000 0°0 0°o See


40
Every ` ~5°, Page
Brake pad wear-check t 62
Clutch-adjust " " 0 " 0 0 0 55
K Steering play-check t
Drive chain wear-check t " 0 0 0 0 0 59
Nuts, bolts, fasteners-check t " 0 " 0 -
K KIPS valve cables
operation-check t to 0 -
Tire wear-check t 0 70
Transmission oil-change year 0 41
K General lubrication-perform " 0 -
K Front fork oil-change 0 _
K Swing arm pivot-lubricate 0 -
Coolant - change 2 years 0 45
Radiator hoses, connections
-check t year 0 43
K Steering stem bearing-lubricate 2 years -

37
tOdometer Reading km
Frequency Whichever »
comes first /
i

Operation \ \ \ + o
° See
Every Page
K Caliper piston seal and dust
seal-replace 2 years -
K Master cylinder cup and
dust seal-replace 2 years -
K Brake hose-replace 4 years -
K Fuel hose-replace 4 years -
Drive chain-lubricate Every 300 km 61
Drive chain slack-check Every 800 km 57

K Should be serviced by an authorized Kawasaki Dealer.


" For higher odometer readings, repeat at the frequency interval established here .
t Replace, add, adjust, or torque if necessary .

38

Engine Oil
Do not use ordinary motor oil, transmission
oil, or an inferior grade of oil as a replacementfor
the proper oil. The use of improper oil will lead to
engine trouble.
The engine oil tank is located under the seat .

Adding Oil
" Check the oil level in the engine oil tank .
" Before you run out of oil, add oil. It will take
about 1 .2L.
A. Engine Oil Tank
NOTE B. Engine Oil Tank Cap

o Since mixing different brands of oil deterio- CAUTION


rates the lubricative properties of the oil,
always add oil only of the same brand as is If the engine oil gets extremely low, the
already in the tank. engine oil level warning light will come
on and stay on even in any gear. In this
case, add the engine oil as soon as
possible.

39
Transmission Oil
In order for the transmission and clutch to
function properly, always maintain the transmis-
sion oil at the proper level and change the oil in
accordance with the Periodic Maintenance Chart .

AWARNING

Motorcycle operation with insufficient,


deteriorated, or contaminated transmis-
sion oil will cause accelerated wear and
A . Engine Oil Level Warning Light may result in transmission seizure, ac-
cident, and injury .
CAUTIONS

If the engine is run without the engine Oil Level Inspection


oil, it will be severely damaged . If the oil " To check the oil level, start the engine and
tank is completely dry, add the oil and run it for about two minutes at idle speed .
bleed the air from the oil line by a Then stop the engine and wait two or three
Kawasaki dealer. minutes until oil settles .
" If the motorcycle has just been used, wait
several minutes for all the oil to drain down .

40

Situate the motorcycle so that it is perpen- " If the oil level is too high, remove the excess
dicular to the ground . oil, using a syringe or some other suitable
Checkthe oil level through the oil level gauge . device .
The oil level should come up above the " If the oil level is too low, add of oil through the
center point . oil filler opening . Use the same type and
brand of oil that is already in the engine .

Oil Change
" Warm up the engine thoroughly so that the oil
will pick up any sediment and drain easily .
Then stop the engine .
Place an oil pan beneath the drain plug .
Remove the drain plug at the right engine
cover lower portion .

A . Oil Level Gauge


B. Upper Level
C . Lower Level

41
NOTE

o Replace the damaged gasket with a new


one.

" Pour the good quality motor oil into the en-
gine to 0 .7L .
" Check the oil level (see Oil Level Inspection) .

Tightening Torque

Engine Drain Plug :


A . Drain Plug
2 .0 kg/m (14 .5 ft/Ib)

With the motorcycle perpendicular to the


ground, let the oil completely drain . Transmission Oil
After the oil has completely drained, install
the drain plug with its gasket . Proper torque Grade : SE class
for it is shown in the table . Viscosity: SAE 10W30 or 10W40
Capacity : 0 .87 L
(Overhaul)

42

Coolant
excessive heat from the
Cooling system Coolant absorbs radiator . If
it to the air at the
Radiator engine and transfers over-
for obstruction by low, the engine
Check the radiator fins obstructions with a the coolant level becomes damage . Check the
off any severe
insects or mud . Clean heats and may suffer
water . each day before riding the motorcy -
low-pressure coolant level
stream of coolant if the level is low .
cle, and replenish accordance with the Peri-
CAUTION Change the coolant in
Chart .
odic Maintenance
water, as from a
Using high - pressure
could damage the NOTE
car wash facility, the radiator's
radiator fins and impair antifreeze is installed in
effectiveness . o A permanent type of
deflect airflow when shipped. It is colored
Do not obstruct or installing unau- the cooling system
glycol. It is mixed at
through the radiator by green, contains ethylene freezing point of -
in front of the ra- 50% solution and has
the
thorized accessories
with the radiator 0 F) .
diator . Interferance 350C (-31
overheating and con-
airflow can lead to
.
sequent engine damage Coolant Level Inspection perpen-
motorcycle so that it is
" Situate the center stand) .
(on its
Radiator Hoses dicular to the ground
for cracks or dete-
Check the radiator hoses looseness in ac-
for
rioration, and connections Maintenance chart .
with the Periodic
cordance
43
" Check the coolant level through the coolant " If the amount of coolant is insufficient, re-
level gauge on the reserve tank . The coolant move the front right side cover, take off the
level should be between the upper and lower cap from the reserve tank and add coolant
level lines . through the filler opening to the upper level
line .
NOTE

o Check the level when the engine is cold


(room or atmospheric temperature).

A . Cap B. Reserve Tank

" Install the removed parts .

A . Reserve Tank C . Lower Levei Line


B . Upper Level Line

44

NOTE Spark Plug


The standard spark plug is shown in the
0 In an emergency you can add water alone to table . The spark plug should be taken out peri-
the coolant reserve tank, however it must be odically in accordance with the Periodic Mainte-
returned to the correct mixture ratio by the nance Chart for cleaning, inspection, and reset-
addition of antifreeze concentrate as soon as ting of the plug gap .
possible.
Maintenance
If the plug is oily or has carbon built up on it,
have it cleaned, preferably in a sand-blasting
If coolant must be added often, or the device, and then clean off any abrassive parti
reserve tank completely runs dry, there cles . The plug may also be cleaned using a high
is probably leakage in the system . Have flash-point solvent and a wire brush or other
the cooling system inspected by your suitable tool . Measure the gap with a wire-type
authorised Kawasaki Dealer. thickness gauge, and adjust the gap if incorrect
by bending the outer electrode . If the spark plug
electrodes are corroded or damaged, or if the
Coolant Change insulator is cracked, replace the plug . Use the
Have the coolant changed by an authorized standard plug .
Kawasaki dealer .

45
CAUTIONS

For cold weather and/or low speed


riding, a hotter spark plug shown in
the table maybe used for quickerwarm-
ups and more efficient engine opera-
tion . However, for normal tempera-
tures and/or high speed use, the stand-
ard spark plug must be used to pre-
vent engine damage.

Spark Plug Hotter Spark Plug

Standard NGK BP9ES


Plug

Plug Gap 0 .7 - 0 .8 mm

Tightening 27 N-m
Torque (2 .8 kg-m)

46

Air Cleaner
A clogged air cleaner restricts the engine's
air intake, increasing fuel consumption, reducing
engine power, and causing spark plug fouling .
The air cleanerelement must be cleaned and
replaced in accordance with the Periodic Mainte-
nance Chart . In dusty areas, the element should
be cleaned more frequently than the recom-
mended interval .
After riding through rain or on muddy roads,
the element should be cleaned immediately . The
element should be replaced if it is damaged .
A . Fuel Tap C. Bolt
B . Fuel Tank
Element Removal
" Remove the front left and front right side
" Disconnect the leads under the fuel tank .
covers .
" Remove the fuel tank .
" Remove the seat .
" Unscrew the air cleaner housing cap screws,
" Turn the fuel tap to the OFF position .
and take out the air cleaner housing cap .
" Take off the fuel hose from the fuel tap .
" Remove the fuel tank mounting bolt.

47
A . Air Cleaner Housing Cap A . Element
B . Screws
Put a clean, lint-free towel into the air cleaner
" Remove the element housing to keep dirt or other foreign material
from entering .
Inspect the element material for damage . If
any part of the element is damaged, the
element must be replaced .

48

AWARNING " Dry the element with compressed air or


squeeze it .
If dirt or dust is allowed to pass through " After cleaning, saturate the element with 2-
into the carburetor, the throttle may stroke racing oil orhigh-qualityfoam-air-filter
become stuck, possibly causing acci- oil, squeeze out the excess oil, then wrap it in
dent. a clean rag and squeeze it as dry as possible .
Be careful not to tear the element .
CAUTION

If dirt gets through into the engine, AWARNING


excessive engine wear and possibly
Clean the element in a well ventilated,
engine damage will occur .
area, and take care that there are no
sparks or flame anywhere near the work-
ing area ; this includes any appliance
NOTE
with a pilot light . Do not use gasoline or
o Element installation is performed in the re- a low flash-point solvent to clean the
verse order of removal. element . A fire or explosion could re-
o When installing the air cleaner housing cap, sult.
fit it in the housing properly.

Element Cleaning
" Clean the element in a bath of a high flash-
point solvent .

49
Throttle Control Cable " Check that the safety clip at the lower end of
The throttle control cable is actually an as- the carburetor cable is in place .
sembly of three cables : the throttle cable, the " Check the throttle cable play . When lightly
carburetor cable, and the oil pump cable . The turning the throttle grip, the grip should have
throttle cable runs from the throttle grip to the 2-3 mm of play . If the throttle cable has
cable assembly junction where it connects to improper play, adjust it .
both the carburetor cable which leads to the
carburetor, and the oil pump cable which leads to
the oil pump .
Cable stretch will cause delayed engine re-
sponse and upset the oil pump synchronization,
necessitating periodic adjustment. To compen-
sate for cable stretch, adjust the throttle cable
and the oil pump cable in accordance with the
Periodic Maintenance Chart .

Throttle Cable :
Inspection
" Check to see that the outer cable ends of the
throttle and carburetor cables are fully seated A . Throttle Grip B. 2-3 mm
in each cable adjuster .

50

Adjustment NOTE
" Loosen the locknut on the upper end of the
throttle cable, and turn the adjuster until the o If the throttle grip play cannot be adjusted
proper amount of throttle grip play is ob- with the adjuster at the throttle cable, use the
tained . Tighten the locknut . carburetor cable adjuster at the carburetor .
After completion of the adjustment, tighten
the locknut.

A . Adjuster B . Locknut
A . Carburetor Cable C .Locknut
B . Adjuster D .Safety Clip

" Check the oil pump cable .

51
Oil Pump Cable : " Check to see that the outer cable end of the
Inspection oil pump cable is fully seated in the cable
Warm up the engine, and check the engine adjuster.
idling (See the Carburetor section) . " Check to see that the tang on the oil pump
Check the throttle cable . lever is bent to hold the oil pump inner cable .
Unscrew the engine sprocket cover bolts and " Turn the throttle grip fully, and check to see
remove the engine sprocket cover. if the synchronization mark on the pump
Unscrew the oil pump cover screws, and lever aligns with the mark on the lever stop .
remove the oil pump cover.
NOTE

o The pump lever has two marks on it. One is


the synchronization mark which is used to
check the oil pump synchronization, and the
other is the idle mark which is to used during
oil pump synchronization.

" The synchronization mark and the lever stop


mark should be aligned . If they do not line up,
adjust the oil pump cable as follows .

A . Oil Pump .Cover B . Screws

52

A . Mark on Lever Stop A . Oil Pump Cable C. Locknut


B . Idle Mark B . Adjuster u,,,
C . Synchronization Mark
0 Tighten the locknuts, an;I check the pump
Adjustment synchronization . Readjust if necessary .
" Loosen the oil pump cable adjuster lock nuts,
and turn the adjuster to synchronize the
pump with the carburetor.

53
Carburetor " Start the engine, and warm it up throughly.
The following procedure covers the idle ad- " Adjust the idle speed to 1200-1400 r/min
justment, which should be performed in accord- (rpm) by turning the idle adjusting screw .
ance with the Periodic Maintenance Chart or " Open and close the throttle a few times to
whenever the idle speed is disturbed . make sure that the idle speed does not
change . Readjust if necessary .
Adjustment " With the engine idling, turn the handlebar to
" First turn in the air screw until it seats lightly, each side . If handlebar movement changes
and back it out 1 1/4 turns . the idle speed, the throttle cable may be
improperly adjusted or incorrectly routed, or
it may be damaged . Be sure to correct any of
these conditions before riding .

AWARNING

Operation with improperly adjusted,


incorrectly routed, or a damaged cable
could result in an unsafe riding condi-
tion .

54

Clutch
Due to friction plate wear and clutch cable
stretch over a long period of use, the clutch must
be adjusted in accordance with the Periodic
Maintenance Chart .

To avoid a serious burn, never touch a


hotengine orexhaust pipeduring clutch
adjustment.

A . Clutch Lever C . Locknut


B . 2-3 mm D. Adjuster
Inspection
" Check that the clutch lever has 2-3 mm of
If it does not, adjust the lever play as follows.
play as shown in the figure .

Adjustment
" Loosen the locknut at the clutch lever.
" Turn the adjuster so that the clutch lever will
have 2-3 mm of play .

55
AWARNING

Be sure the upper end of the clutch


outer cable is fully seated in its fitting,
or it could slip into place later, creating
enough cable play to prevent clutch
disengagement, resulting in a hazard-
ous riding condition .

Tighten the locknut .


If it cannot be done, use the nut at the lower A . Nuts B . Clutch Cable
end of the cable so that the clutch lever has
2-3 mm of play .
NOTE

o After adjustment is made, start the engine


and check that the clutch does not slip and
that it releases properly .

56

Drive Chain
The drive chain must be checked, adjusted,
and lubricated in accordance with the Periodic
Maintenance Chart for safety and to prevent
excessive wear . If the chain becomes badly
worn or maladjusted - either too loose ortoo tight
- the chain could jump off the sprockets or break.

AWARNING

A chain that breaks or jumps off the


sprockets could snag on the engine
sprocket or lock the ;rear wheel, se- A . 30 - 40 mm
verely damaging the motorcycle and
causing it to go out of control . " If the drive chain is too tight or too loose,
adjust it so that the chain slack will be within
the standard value .
Slack Inspection
" Set the motorcycle with its center stand . Drive Chain Slack
" Rotate the rear wheel to find the position Standard 30-35 mm
where the chain is tightest, and meassure the
vertical movement midway between the Too loose more than 40 mm
sprockets . Too tight I less than 30 m m

57
Adjustment
" Loosen the rear torque link nut .

CAUTION

Do not forget to loosen the torque link


nut .

A . Marks D . Cotter Pin


B . Notch E . Adjusting Nut
C . Axle Nut F . Locknut

" If the chain is too tight, back out the left and
right chain adjusting nuts evenly, and kick the
wheel forward until the chain is too loose .
" Turn both chain adjusting nuts evenly until
A . Torque Link Nut the drive chain has the correct amount of
slack . To keep the chain and wheel properly
" Loosen the left and right chain adjuster aligned, the notch on the left chain adjuster
locknuts . should align with the same swing arm mark
" Remove the cotter pin, and loosen the axle that the right chain adjuster notch aligns with .
nut . 58

NOTE " Rotate the wheel, measure the chain slack


again at the tightest position, and readjust if
o Wheel alignment can also be checked using necessary.
the straightedge or string method. Insert a new cotter pin through the axle shaft,
and spread its ends .
AWARNING Tighten the rear torque link nut to the speci-
fied torque .
Misalignment of the wheel will result in
abnormal wear, and may result in an
AWARNING
unsafe riding condition .

If the axle nut or torque link nut is not


" Tighten both chain adjuster locknuts . securely tighten or the cotter pin is not
" Tighten the axle nut to the specified torque. installed, an unsafe riding condition
may result .
Tightening Torque

Axle Nut 64 N-m


" Check the rear brake (see the Brakes sec-
6 .5 kg-m
tion) .
Torque Link 16 N-m
Nut (1 .6 kg-m) Wear Inspection
" Stretch the chain taut either by using the
chain adjusters, or by hanging a 10 kg weight
on the chain

59
Measure the length of 20 links on the straight Drive Chain 20-Link Length
part of the chain from pin center of the 1 st pin
to pin center of the 21 st pin . Since the chain Service Limit : 323 mm (12.7 in)
may wear unevenly, take measurements at
several places . AWARNING
If the length exceeds the service limit, the
chain should be replaced . For safety, use only the standard chain .
Have it installed by an authorized
Kawasaki dealer .

Rotate the rear wheel to inspect the drive


chain for damaged rollers, and loose pins
and links .
Also inspect the sprockets for unevenly or
excessively worn teeth, and damaged teeth .

NOTE

A . Weight B . Measure o Sprocket wearis exaggerated forillustration .


See Service Manual for wear limits.

60

" Apply oil to the sides of the rollers so


that it will
penetrate to the rollers and bushings .
Wipe
off any excess oil .

Dvect'on o! rotauon

" If there is any irregularity, have the


drive
chain and/or the sprockets replaced
by an
authorized Kawasaki dealer .

Lubrication " If the chain is especially dirty, clean


it using
Lubrication is also necessary after riding diesel oil or kerosine and then apply
through rain or on wet roads, or anytime oil as
that the mentioned above .
chain appears dry. A heavy oil such
as SAE 90 is
preferred to a lighter oil because it will stay
on the
chain longer and provide better
lubrication .

61
Brakes Disc Brake Fluid :
Brake Wear Inspection In accordance with the Periodic Maintenance
In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in the reser-
Chart, inspect the brakes for wear . For each front voirs and change the brake fluid . The brake fluid
and rear disc brake caliper, if the thickness of should also be changed if it becomes contami-
either pad is less than 1 mm, replace both bads nated with dirt or water.
in the caliper as a set. Pad replacement should
be done by an authorized Kawasaki dealer. Fluid Requirement
Recommended fluids are given in the table .
If none of the recommended brake fluids are
available, use extra heavy-duty brake fluid only
from a container marked D.O .T . 3 or D .O .T .4 .

Recommended Disc Brake Fluid


(D .O .T .3)

Atlas Extra Heavy Duty


Shell Super Heavy Duty
Texaco Super Heavy Duty
Wagner Lockheed Heavy Duty
Castrol Girling-Universal
Castrol GT (LMA)
Castrol Disc Brake Fluid

62

(D .0 .T .4) Fluid Level Inspection


0 The brake fluid level in the front and rear
Castrol Girling-Universal reservoirs must be kept between the upper
Castrol GT (LMA) and lower level lines (reservoirs held hori-
Castrol Disc Brake Fluid zontal) .
Check Shock Premium Heavy Duty

NOTE

o Brake fluid of D .O. T.3 is installed in the brake


system when shipped.

Do not spill brake fluid onto any painted


surface .
Do not use fluid from a container that A . Front Reservoir
has been left open or that has been B . Upper Level Line
unsealed for a long time. C . Lower Level Line
Check for fluid leakage around the fit-
tings .
Check for brake hose damage .

63
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CAUTION

To avoid damaging the electrical con-


nections inside the switch, be sure that
the switch body does not turn during
adjustment .

Adjustment
" To adjust the rear brake light switch, move
the switch up or down by turning the adjusting
nut .

A. Rear Brake Light Switch


B. Adjusting Nut
C. Lights sonner
D. Lights later

66

Stable Steering System " Turn the adjuster clockwise for heavy
Adjustment steering handling condition, and the opposite
The stable steering system has 7 adjustable way for light steering handling condition .
way to rebound damping and to assure a smooth
and well controlled ride

A. Adjuster B. Mark

Stable Steering System


AWARNING
If the steering handling condition feels too
light or too heavy, adjust it in accordance with Do not adjust the stable steering
the following table . system while riding .
LIGHTER <---- ----> HEAVIER
ANTI-CLOCKWISE CLOCKWISE
67
Rear Shock Absorber Position 1 2 3 4 5
Spring Adjustment
The spring adjustingsleeve on the rear shock Spring Action - Stronger
absorber has 5 positions so that the spring can
be adjusted for different road and loading condi- Remove the front left side cover.
tions . Using the hookwrench and wrench bar (own-
er's tool), turn the adjusting sleeve clock-
wise .

A. Adjusting Sleeve

If the spring action feels too soft or too stiff, A. Hook Wrench B. Wrench Bar
adjust it in accordance with the following table.

68

Wheels
AWARNING
Tires :
To avoid an injury, be careful not to hit Payload and Tire Pressure
your hand against the frame or other Failureto maintain properinflating pressures
parts when adjusting the rear shock or observe payload limits for your tires may
absorber . adversely affect handling and performance of
your motorcycle and can result in loss of control.
The maximum recommended load in addition to
vehicle weight is 150 kg, including rider, passen-
ger, baggage, and accessories .

" Check the tire pressure often, using an accu-


rate gauge.

Tire Air Pressure (when cold)

Front 200 kPa (2 .00 kg/cmz)

Rear 225 kPa (2 .25 kg/cmz)

69
NOTE Tire Wear, Damage
As the tire tread wears down, the tire becomes
0 Measure the tire pressure when the tires are more susceptible to puncture and failure. An
cold (that is, when the motorcycle has not accepted estimate is that 90% of all tire failures
been ridden more than a mile during the past occur during the last 10% of tread life (90%
3 hours). worn) . So it is false economy and unsafe to use
0 Tire pressure is affected by changes in ambi- the tires until they are bald .
ent temperature and altitude, and so the tire " In accordance with the Periodic Maintenance
pressure should be checked and adjusted Chart ; measure the depth of the tread with a
when your riding involves wide variations in depth gauge, and replace any tire that has
temperature or altitude. worn down to the minimum allowable tread
depth .

Minimum Tread Depth

Front 1 mm

Rear 2 mm

A . Tire Pressure Gauge


70

AWARNING

To ensure safe handling and stability,


use only the recommended standard
tires for replacement, inflated to the
standard pressure.

Standard Tire

Front 90/90 - 17 49S


A . Tire Depth Gauge IRC NF45

" Visually inspect the tire for cracks and cuts, Rear 100/90 - 18 56P
replacing the tire in case of bad damage . IRC NR55
Swelling or high spots indicate internal dam-
age, requiring tire replacement .
" Remove any imbedded stones or other for-
eign particles from the tread .

NOTE

o Have the wheel balance inspected whenever


a new tire is installed.
71
Battery
Battery Electrolyte Level Inspection
The battery electrolyte level must be kept
between the upper and lower level lines . Check
the electrolyte level in each cell in accordance
with the Periodic Maintenence Chart .
" Remove the battery from the motorcycle
(see Battery Removal)
" Check that the electrolyte level in each cell
is between the upper and lower level lines .
" If the electrolyte level is low in any cell, fill
with distilled water as follows . A. Battery C . (-) Terminal
" Remove the battery filler caps and fill with B. (+) Terminal D . Battery Band
distilled water until the electrolyte level in
each cell reaches the upper level line . Battery Removal
" Remove the both side covers and fuel tank .
CAUTION " Remove the fuel tank bracket .
" Unhook the rubber band and battery cover.
Add only distilled water to the battery .
Ordinary tap water is not a substitute
for distilled water and will shorten the
life of the battery

72

Battery Installation
" Putthe battery in the batterycase, and route
the battery vent hose as shown on the
caution label .
" Put a light coat of grease on the terminals to
prevent corrosion .

A. Fuel Tank Bracket


B. Mounting Bolts
C. Rubber Band
D. Battery Cover

" Disconnect the leads from the battery, first


from the (-) terminal and then the (+) termi-
nal . A . Grease
" Take the battery out of the case .
" Clean the battery using a solution of baking
soda and water. Be sure that the lead con-
nections are clean .

73
Putthebattery cover on the battery, and hook Headlight Beam
the rubber band . Horizontal Adjustment
Connectthe white/red lead to the (+) terminal, The headlight beam is adjustable horizontally .
and then connectthe blackyellow lead to the If not properly adjusted horizontally, the beam
(-) terminal . will point the one side rather than straight ahead.
Install the parts removed.

CAUTION

Make sure the battery vent hose is kept


away from the drive system and ex-
haust system . Battery electrolyte can
corrode and dangerously weaken the
drive system . Do not let the vent hose
become folded, pinched, or melted by
the exhaust system . An unvented A. Horizontal Adjuster B . Vertical Adjuster
batterywill not keep a charge and it may
crack from built-up gas pressure.

74

" Turn the adjuster in or out with the screw-


driver until the beam points straight a head .

Vertical Adjustment
The headlight beam is adjustable vertically,
If adjusted too low, neither low nor high beam
will illuminate the road far enough ahead. If
adjusted too high, the high beam will fail to
illuminate the road close ahead, and the low
beam will blind oncoming drivers .

Put a Phillips screwdriver into the vertical Fuse


adjuster guide. The fuse case is located on the battery
Turn the adjuster in or out with the screw- cover. If a fuse fails during operation, inspect
driver to adjust the headlight vertically .
the electrical system to determine the cause,
and then replace it with a new fuse of proper
NOTE amperage .
0 On high beam, the brightest point should be AWARNING
slightly below horizontal with the motorcy-
cle on its wheels and the rider seated. Do notuse any substitute forthe stand-
Adjust the headlight to the proper angle ard fuse .
according to local regulations.

75
o Replace the blown fuse with anew one of AWARNING
the correct capacity, as specified on the
fuse case . 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 includes any ap-
pliance with a pilot light . Make sure the
engine is cold before working . Wipe
any fuel off the engine before starting
it .

Inspection
" Turn the fuel tap to the "OFF" position .
" Unscrew the sediment cup from the bottom
Fuel System of the fuel tap, and check to see if water or
Accumulation of moisture or sediment in the dirt gas accumulated in the sediment cup .
fuel system will restrict the flow of fuel and
cause carburetor mal Iuction . The system should
be checked in accordance with the Periodic
Maintenence Chart .

76

A . Sediment Cup
A. Sediment Cup C. Filter
B . Gasket
" Being careful not to damage the gasket and
filter, remove them out of the fuel tap using
Using a piece of cloth, wipe out the inside of
a thin screwdriver .
the fuel tap, wash the cup and filter in a high
flash-point solvent .
If water has accumulated in the sediment
cup, holding a container under the fuel tap,
open the fuel tap until only fuel comes out,
then off the tuel tap .
Visually inspect the gasket and filter . Re-
place them with new ones if they are dam-
aged .
77
" Rear opening of the muffler ; Cover with a Preparation for Washing
plastic beg secured with a rubber band . Before washing, precautions must be taken
to keep water off the following places :
NOTE " Rear opening of the muffler ; Cover with a
plastic beg secured with a rubber band .
o Turn the fuel tap lever to the RES position, " Clutch and brake levers, switch housings on
and check for fuel leaks .
the handlebar ; Cover with plastic bags .
o If any water or dirt apears during the above
" Ignition switch ; Cover the keyhole with tape .
operation, have the fuel system checked by
" Air cleaner intake ; Close up the intake with
an authorized Kawasaki Dealer. tape, or stuff with rags .

Cleaning
Where to be Careful
For the prolonged life of your motorcycle,
Avoid spraying water with any great force
wash it down immediately after it has been
near the following places :
splashed with seawater or exposed to sea " Speedometer and tachometer .
breeze ; operated on rainy days, rough roads, or
" Disc brake master cylinders and calipers .
in dusty areas ; or operated on roads on which
salt has been scattered for ice removal .

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" Under the fuel tank ; If water gets into the After Washing
ignition coil or into the spark plug cap, the " Remove the plastic bags and tape, and
spark will jump through the water and be clean the air cleaner intake .
grounded out . When this happens, the mo- " Lubricate the pivots, nuts, and bolts .
torcycle will not start and the affected parts " Test the brakes before motorcycle opera-
must be wiped dry tion .
" Front and rear hubs " Start the engine and run it for 5 miniutes .
" Steering pivot (steering stem head pipe)
" Swing arm pivot AWARNING

NOTE Never wax or lubricates the brake disc .


Loss of braking and accident could
o Coin operated, high pressure spray wash- result. Clean the disc with an oilless
ers are not recommended. The water may solvent such as trichloroethylene or
be forced into bearings and other compo- acetone . Observe the solvent manu-
nents causing eventual failure from rust and facturer's warnings .
corrosion . Some of the soaps which are
highly alkaline leave a residue or cause
spotting.

79
t

STORAGE

Preparation for Storage :


" Clean the entire vehicle thoroughly .
screw at the
" Empty the fuel from the fuel tank, and empty the carburetor by unscrewing the drain
long time, the fuel will break down and could clog the carburetor) .
float bowl . (If left in for a
around to
" Remove the empty fuel tank, pour about 250 mL of motor oil into the tank, roll the tank
coat the inner surfaces thoroughly, and pour out the excess oil .

Gasoline isextremely flammable and can beexplosive undercertain conditions . Turn the
free from
ignition switch OFF . Do not smoke . Make sure the area is well ventilated and
appliance with a pilot light .
any source of flame or sparks ; this includes any

Kick the
" Remove the spark plug and put several drops of SE class SAE 30 oil into the cylinder .
cylinder wall with oil, and install the spark plug .
engine over slowly a few times to coat the
" Reduce tire pressure by about 20% .
this cannot
" Set the motorcycle on a box or stand so that both wheels are raised off the ground . (If
rear wheels to keep dampness away from the tire rubber .)
be done, put boards under the front and

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" Spray oil on all unpainted metal surfaces to prevent rusting . Avoid getting oil on rubber parts or
in the brakes .
" Lubricate the drive chain and all the cables .
" Remove the battery, and store itwhere it will not be exposed to direct sunlight, moisture, orfreezing
temperatures . During storage it should be given a slow charge (one ampere or less) about once
a month . Keep the battery well charged during cold weather so that the electrolyte does not freeze
and crack open the battery . The more discharged the battery becomes, the more easily it freezes .
" Tie a plastic bag over the exhaust pipe to prevent moisture from entering .
" Put a cover over the motorcycle to keep dust and dirt from collecting on it .

Preparation for after Storage :


" Removed plastic bag from exhaust.
" Check the electrolyte level in the battery, charge the battery if necessary, and install it in the
motorcycle . Be careful that the battery vent hose is not pinched and that it is routed away from
the chain .
" Make sure the spark plug is tight .
" Check the engine oil .
" Fill the fuel tank with fuel .
" Check all the points listed in the Daily Safety Checks section .
" Lubricate the pivots, nuts, and bolts .

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