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SAFETY INFORMATION j

Quick Reference Guide


GENERAL INFORMATION j
This Quick Reference Guide will HOW TO RIDE THE MOTORCYCLE j
assist you in finding the information
you’re looking for. MAINTENANCE AND ADJUSTMENT j

APPENDIX j

MAINTENANCE RECORD j

A Table of Contents is included after


the Foreword.
Whenever you see the symbols NOTICE
shown below, heed their instructions!
NOTICE is used to address prac-
Always follow safe operating and main-
tices not related to personal in-
tenance practices.
jury.
DANGER
DANGER indicates a hazardous NOTE
situation which, if not avoided, ○NOTE indicates information that may
will result in death or serious in- help or guide you in the operation or
jury. service of the vehicle.

WARNING
WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
NOTICE
THIS PRODUCT HAS BEEN
MANUFACTURED FOR USE IN A
REASONABLE AND PRUDENT
MANNER BY A QUALIFIED OP-
ERATOR AND AS A VEHICLE
ONLY.
Foreword
Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-
torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety and performance.

Please read this Owner’s Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-
tures, capabilities, and limitations. This manual offers many safe riding tips, but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-
cle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-
formation on their Kawasaki Motorcycle, a Service Manual is available for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-
tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.
This manual should be considered a permanent part of the motorcycle and should
remain with the motorcycle when it is sold.

All rights reserved. No part of this publication may be reproduced without our
prior written permission.

This publication includes the latest information available at the time of printing.
However, there may be minor differences between the actual product and illustra-
tions and text in this manual.
All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.


Motorcycle & Engine Company

© 2018 Kawasaki Heavy Industries, Ltd. Apr. 13, 2018. (2)


(Australian model only)

TAMPERING WITH NOISE CONTROL SYSTEM


PROHIBITED
Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any person other than for purposes
of maintenance, repair or replacement, of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while it is in use; and
(b) The use of the vehicle after such device or element of design has been
removed or rendered inoperative by any person.
TABLE OF CONTENTS

SAFETY INFORMATION .................... 10 GENERAL INFORMATION................. 22


Read Owner’s Manual ..................... 10 Specifications ................................... 22
Training ............................................ 10 Serial Number Locations.................. 28
Daily Checks and Periodic Location of Labels ............................ 29
Maintenance ................................. 10 Location of Parts .............................. 38
Loading and Accessories Meter Instruments ............................ 44
Information.................................... 11 Indicators ...................................... 45
Passenger .................................... 12 Speedometer/Tachometer ............ 51
Baggage and Luggage ................. 13 Coolant Temperature Gauge ........ 52
Accessories .................................. 13 Display Setting.............................. 53
Other Load.................................... 14 Clock............................................. 59
If You are Involved in an Accident.... 15 Features ....................................... 60
Safe Operation ................................. 15 Keys ................................................. 63
Carbon Monoxide Hazard............. 15 Ignition Switch/Steering Lock ........... 63
Fueling .......................................... 16 Right Handlebar Switches................ 65
Never Ride with Drugs or Alcohol. 16 Left Handlebar Switches .................. 66
Protective Gear and Clothing ....... 16 Fuel .................................................. 67
Safe Riding Techniques ................ 17 Fuel Requirements ....................... 67
Additional Considerations for High Filling the Tank.............................. 70
Speed Operation ....................... 20 Side Stand ....................................... 73
Seats ................................................ 74 Periodic Maintenance....................... 102
Storage Compartment...................... 78 Engine Oil ........................................ 107
Tie Hooks ......................................... 79 Coolant............................................. 111
Helmet Hooks................................... 79 Air Cleaner ....................................... 113
Helmet Lock (Equipped Models) ...... 80 Throttle Control System ................... 117
Tool Kit ............................................. 81 Idle Speed ........................................ 119
Electric Accessory Connectors ........ 82 Clutch ............................................... 119
Accessory Socket (Equipped Drive Chain ...................................... 121
Models) ......................................... 83 Brakes .............................................. 125
Event Data Recorder........................ 84 Brake Light Switches........................ 128
HOW TO RIDE THE MOTORCYCLE . 86 Suspension System ......................... 130
Break-In ........................................... 86 Front Fork ..................................... 130
Starting the Engine .......................... 87 Rear Shock Absorber ................... 131
Moving Off........................................ 89 Setting Table ................................. 132
Shifting Gears .................................. 89 Wheels ............................................. 133
Braking ............................................. 91 Battery.............................................. 137
Anti-lock Brake System (ABS) ......... 92 Headlight .......................................... 140
Stopping the Engine......................... 94 Fuses ............................................... 141
Stopping the Motorcycle in an General Lubrication.......................... 143
Emergency ................................... 94 Cleaning ........................................... 143
Parking ............................................. 95 General Precautions ..................... 143
MAINTENANCE AND ADJUSTMENT 97 Where to be Careful ..................... 148
Daily Checks .................................... 99 Washing Your Vehicle ................... 148
APPENDIX .......................................... 150 Owner Satisfaction ........................... 158
Storage ............................................ 150 Environmental Protection ................. 160
Troubleshooting Guide..................... 153 MAINTENANCE RECORD ................. 161
10 SAFETY INFORMATION
j SAFETY INFORMATION

Read Owner’s Manual Daily Checks and Periodic


Read this Owner’s Manual care- Maintenance
fully before riding so that you will be It is important to keep your motorcy-
thoroughly familiar with the proper op- cle properly maintained and in safe rid-
eration of your motorcycle’s controls, ing condition. Inspect your motorcy-
its features, capabilities, and limita- cle before every ride and carry out all
tions. This manual offers many safe periodic maintenance. See the Daily
riding tips, but its purpose is not to pro- Checks section and the Periodic Main-
vide instruction in all of the techniques tenance section in the MAINTENANCE
and skills required to ride a motorcycle AND ADJUSTMENT chapter for more
safely. information.

Training WARNING
Kawasaki strongly recommends that Failure to perform these checks
all operators of this vehicle complete a or to correct a problem before
suitable motorcycle rider training pro- operation may result in serious
gram to learn the proper skills and tech- damage or an accident. Always
niques necessary for safe motorcycle perform daily checks before op-
operation. eration.
SAFETY INFORMATION 11
j
To ensure your motorcycle is ser- Loading and Accessories
viced using the latest servicing infor- Information
mation, it is recommended that an
authorized Kawasaki Dealer performs WARNING
the periodic maintenance as directed
in the Owner’s Manual. Incorrect loading, improper in-
If you notice any irregular operat- stallation or use of accessories,
ing condition, have your motorcycle or modification of your motorcy-
thoroughly checked at an authorized cle may result in an unsafe riding
Kawasaki dealer as soon as possible. condition. Before you ride the
motorcycle, make sure it is not
overloaded and that you have
followed these instructions.
Maximum Load
Weight of rider, passenger, baggage,
and accessories must not exceed 180 kg
(397 lb).

With the exception of genuine


Kawasaki Parts and Accessories,
Kawasaki has no control over the
design or application of accessories.
In some cases, improper installation
12 SAFETY INFORMATION
j
or use of accessories, or motorcycle fitting additional accessories. The fol-
modification, will void the motorcycle lowing general guidelines have been
warranty; can negatively affect perfor- prepared to assist you in making your
mance, stability and safety; and can determinations.
even be illegal.
In selecting and using accessories, Passenger
and in loading the motorcycle, you are
personally responsible for your own 1. Never carry more than one passen-
safety and the safety of other persons ger.
involved. 2. The passenger should only sit on the
pillion.
NOTE 3. Any passenger should be thor-
○Kawasaki Parts and Accessories oughly familiar with motorcycle op-
have been specially designed for eration. The passenger can affect
use on Kawasaki motorcycles. We control of the motorcycle by im-
strongly recommend that all parts proper positioning during cornering
and accessories you add to your and sudden movements. It is im-
motorcycle be genuine Kawasaki portant that the passenger sits still
components. while the motorcycle is in motion
Because a motorcycle is sensitive to and not interfere with the operation
changes in weight and aerodynamic of the motorcycle. Do not carry ani-
forces, you must take extreme care in mals on your motorcycle.
carrying cargo, passengers and/or in
SAFETY INFORMATION 13
j
4. Do not carry passengers unless will not move around while you are
passenger footpegs are installed. riding. Recheck baggage security
Instruct any passenger before riding as often as possible (not while the
to keep his or her feet on the pas- motorcycle is in motion) and adjust
senger footpegs and hold on to the as necessary.
operator or seat strap. Do not carry 3. Do not carry heavy or bulky items
a passenger unless he or she is tall on a luggage rack. It is designed
enough to reach the footpegs with for light items, and overloading can
their feet. affect handling due to changes in
weight distribution and aerodynamic
forces.
Baggage and Luggage

1. All baggage should be carried as Accessories


low as possible to reduce the effect
on the motorcycle’s center of grav- 1. Do not install accessories or carry
ity. Baggage weight should also be baggage that impairs the perfor-
distributed equally on both sides of mance of the motorcycle. Make
the motorcycle. Avoid carrying bag- sure that you have not adversely
gage that extends beyond the rear affected any lighting components,
of the motorcycle. road clearance, banking capability
2. Baggage should be securely at- (i.e., lean angle), control operation,
tached. Make sure that the baggage wheel travel, front fork movement,
14 SAFETY INFORMATION
j
or any other aspects of the motor-
cycle’s operation. Other Load
2. Weight attached to the handlebars
or front fork will increase the mass 1. This motorcycle is not intended to
of the steering assembly and can be equipped with a sidecar or to be
result in an unsafe riding condition. used to tow any trailers or other ve-
3. Fairings, windshields, backrests, hicles. Kawasaki does not manu-
and other large items have the ca- facture sidecars or trailers for mo-
pability of adversely affecting stabil- torcycles and cannot predict the ef-
ity and handling of the motorcycle, fects of such accessories on han-
not only due to their weight, but dling or stability, but can only warn
also due to the aerodynamic force that the effects can be adverse and
acting on these surfaces while the that Kawasaki cannot assume re-
motorcycle is in operation. Poorly sponsibility for the results of such
designed or installed items can re- unintended use of the motorcycle.
sult in an unsafe riding condition. 2. Furthermore, any adverse effects on
Lugs are provided on the swingarm motorcycle components caused by
to attach accessory rear stand adap- the use of such accessories will not
tors. Always remove the rear stand be remedied under warranty.
adapters before riding or sitting on
the machine to prevent possible
damage to the muffler or swingarm.
SAFETY INFORMATION 15
j
If You are Involved in an Safe Operation
Accident
The following should be carefully ob-
Make sure of your own safety first. served for safe and effective vehicle
Determine the severity of any injuries operation.
and call for emergency assistance if
needed. Always follow applicable laws Carbon Monoxide Hazard
and regulations if any other person, ve-
hicle or property is involved.
Do not attempt to continue riding DANGER
without first evaluating your motorcy- Exhaust gas contains carbon
cle’s condition. Inspect for fluid leaks, monoxide, a colorless, odor-
check critical nuts and bolts, and check less poisonous gas. Inhaling
the handlebars, control levers, brakes, carbon monoxide can cause
and wheels for damage and proper serious brain injury or death.
function. Ride slowly and cautiously DO NOT run the engine in en-
- your motorcycle may have suffered closed areas. Operate only in a
damage that is not immediately appar- well-ventilated area.
ent. Have your motorcycle thoroughly
checked at a Kawasaki dealer as soon
as possible.
16 SAFETY INFORMATION
j
Fueling Never Ride with Drugs or Alcohol

Alcohol and drugs impair your judg-


WARNING ment and reaction time. Never con-
Gasoline is extremely flammable sume alcohol or drugs before or while
and can be explosive under cer- riding motorcycles.
tain conditions.
To avoid a possible fire or ex- Protective Gear and Clothing
plosion, turn the ignition switch
off. Do not smoke. Make sure
the area is well ventilated and Helmet
free from any source of flame or Kawasaki strongly recommends both
sparks; this includes any appli- the operator and passenger wear a hel-
ance with a pilot light. met even if this is not a legal require-
ment.
- Make sure that your helmet fits cor-
rectly and is properly fastened.
- Choose a motorcycle helmet that
meets the safety standards appli-
cable to your country. Ask your
motorcycle dealer to advise you if
necessary.
SAFETY INFORMATION 17
j
Eye Protection could interfere with the controls of
Always use eye protection. If your your motorcycle.
helmet does not have a visor installed, - Wear bright, highly visible clothing.
wear goggles.
Boots
Gloves Wear proper protective boots that fit
Wear gloves which have suitable properly and do not interfere with gear
protection for your hands, especially shifting or braking.
against abrasion.
Clothing Safe Riding Techniques
Wear the riding wear which have
protectors for each parts of the body
(chest, shoulders, back, elbows and Keep Hands on Handlebars
knees, etc.) as much as possible, or When riding always keep both hands
wear protectors for them. on the handlebars and both feet on the
- Always wear a long-sleeved jacket footpegs. Removing your hands from
and long trousers which are abrasion the handlebars or feet from the foot-
resistant and keep you warm. pegs while riding can be hazardous. If
- Wear clothing that allows freedom of you remove even one hand or foot, you
movement. reduce your ability to control the motor-
- Avoid wearing clothes which have cycle.
loose cuffs or other fastenings which
18 SAFETY INFORMATION
j
Look Over Your Shoulder Use Both Front and Rear Brakes
Before changing lanes, look over When applying the brakes, use both
your shoulder to make sure the way the front and rear brakes. Applying
is clear. Do not rely solely on the rear only one brake for sudden braking may
view mirror; you may misjudge a vehi- cause the motorcycle to skid and lose
cle’s distance and speed, or you may control.
not see it at all.
Use Engine Brake
Accelerate and Brake Smoothly When going down long slopes, help
In general your actions should be control vehicle speed by closing the
smooth as sudden acceleration, brak- throttle so that the engine can act as an
ing or turning may cause loss of control, auxiliary brake. Use the front and rear
especially when riding in wet conditions brakes for primary braking.
or on loose road surfaces, when the
ability to maneuver will be reduced.
Riding in Wet Conditions
Rely more on the throttle to control
Select Correct Gear Speeds vehicle speed and less on the front and
When going up steep slopes, shift to rear brakes. The throttle should also be
a lower gear so that there is power to used judiciously to avoid skidding the
spare rather than overloading the en- rear wheel from too rapid acceleration
gine. or deceleration.
Braking performance is also reduced
in wet conditions. Carefully ride at a
SAFETY INFORMATION 19
j
slow speed and apply the brakes sev- Acceleration
eral times to help dry and restores them When quick acceleration is neces-
to normal operating performance. sary to pass another vehicle, shift to
Lubricate the drive chain after wet a lower gear to obtain the necessary
-weather riding to prevent rust and cor- power.
rosion.
Downshifting
Ride Prudently To avoid engine damage and rear
Riding at the proper speed and avoid- wheel lock-up do not downshift at high
ing unnecessarily fast acceleration are rpm.
important not only for safety and low
fuel consumption but also for long ve-
Avoid Unnecessary Weaving
Unnecessary weaving jeopardizes
hicle life and quieter operation.
the safety of both the rider and other
Riding on Rough Roads motorists.
Exercise caution, slow down, and
grip the fuel tank with the knees for
better stability.
20 SAFETY INFORMATION
j
see that they are correctly adjusted and
Additional Considerations for functioning properly.
High Speed Operation
Steering
Looseness in the steering can cause
WARNING loss of control. Check to see that the
handlebars turns freely but has no play.
Handling characteristics of a
motorcycle at high speeds may Tires
vary from those you are familiar High speed operation is hard on tires,
with at legal highway speeds. and good tires are crucial for safe rid-
Do not attempt high speed oper- ing. Examine their overall condition, in-
ation unless you have received flate them to the proper pressure, and
sufficient training and have the check the wheel balance.
required skills. Fuel
Do not operate at high speeds on Have sufficient fuel for the high fuel
public roads. consumption during high speed opera-
tion.
Brakes Engine Oil
The importance of the brakes, es- To avoid engine seizure and resulting
pecially during high speed operation, loss of control, make sure that the oil
cannot be overemphasized. Check to level is at the upper level line.
SAFETY INFORMATION 21
j
Coolant Miscellaneous
To avoid overheating, check that the Make sure that all nuts and bolts are
coolant level is at the upper level line. tight and that all safety related parts are
in good condition.
Electrical Equipment
Make sure that the headlight,
tail/brake light, turn signals, horn, etc.,
all work properly.
22 GENERAL INFORMATION
GENERAL INFORMATION
j
Specifications
PERFORMANCE
Maximum Horsepower 33.4 kW (45 PS) @10 000 r/min (rpm)
(CO, IN, MY, PH) 36.0 kW (49 PS) @10 000 r/min (rpm)
Maximum Torque 38.0 N·m (3.9 kgf·m, 28 ft·lb) @8 000 r/min (rpm)
Minimum Turning Radius 2.5 m (8.2 ft)
DIMENSIONS
Overall Length 1 990 mm (78.35 in.)
(IN) 2 020 mm (79.53 in.)
Overall Width 710 mm (28.0 in.)
Overall Height:
EX400G 1 120 mm (44.09 in.)
EX400J 1 150 mm (45.28 in.)
Wheelbase 1 370 mm (53.94 in.)
Road Clearance 140 mm (5.51 in.)
GENERAL INFORMATION 23

Curb Mass: j
EX400G 168 kg (370 lb)
(CO) 166 kg (366 lb)
(IN) 173 kg (381 lb)
(PH) 167 kg (368 lb)
EX400J (IN) 173 kg (381 lb)
(MY) 168 kg (370 lb)
(TH) 169 kg (373 lb)
ENGINE
Type DOHC, 2-cylinder, 4-stroke, liquid-cooled
Displacement 399 cm³ (24.3 cu in.)
Bore × Stroke 70.0 × 51.8 mm (2.76 × 2.04 in.)
Compression Ratio 11.5:1
Starting System Electric starter
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
Fuel System FI (Fuel Injection)
24 GENERAL INFORMATION

Ignition System Battery and coil (transistorized ignition)


j Ignition Timing 10.0° BTDC @1 300 r/min (rpm)  42.0° BTDC @8
(Electronically advanced) 400 r/min (rpm)
(CO, IN, MY, PH) 10.0° BTDC @1 300 r/min (rpm) 
40.9° BTDC @10 000 r/min (rpm)
(SEA-B1/B3, TH) 10.0° BTDC @1 300 r/min (rpm) 
41.9° BTDC @8 400 r/min (rpm)
Spark Plug: Type NGK LMAR9G
Gap 0.7  0.8 mm (0.028  0.031 in.)
Lubrication System Forced lubrication (wet sump)
Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 2.3 L (2.4 US qt)
Coolant Capacity 1.3 L (1.4 US qt)
TRANSMISSION
Transmission Type 6-speed, constant mesh, return shift
Clutch Type Wet, multi disc
Driving System Chain drive
GENERAL INFORMATION 25

Primary Reduction Ratio 2.219 (71/32)


Final Reduction Ratio 2.929 (41/14) j
Overall Drive Ratio 6.738 (Top gear)
Gear Ratio: 1st 2.929 (41/14)
2nd 2.056 (37/18)
3rd 1.619 (34/21)
4th 1.333 (32/24)
5th 1.154 (30/26)
6th 1.037 (28/27)
FRAME
Caster 24.7°
Trail 92 mm (3.6 in.)
Tire Size: Front 110/70R17 M/C 54H
Rear 150/60R17 M/C 66H
Rim Size: Front 17M/C × MT3.00
Rear 17M/C × MT4.00
Fuel Tank Capacity 14 L (3.7 US gal)
26 GENERAL INFORMATION

j Brake Fluid: Front DOT3 or 4


Rear DOT4
ELECTRICAL EQUIPMENT
12 V 8 Ah (10 HR)
Battery
(CO) 12 V 8.6 Ah (10 HR)
Headlight: High Beam LED
Low Beam LED
City Light LED
Brake/Tail Light LED
Turn Signal Light Front 12 V 10 W (RY10W)
Rear 12 V 10 W (WY10W)
License Plate Light 12 V 5 W (W5W)

IN: India model


CO: Colombia model
MY: Malaysia model
PH: Philippines model
SEA-B1: Southeast Asia B1 model
GENERAL INFORMATION 27

SEA-B3: Southeast Asia B3 model


TH: Thailand model j
Even if any one element of LED (Light Emitting Diode) light does not go on, consult
with an authorized Kawasaki dealer.

Specifications are subject to change without notice, and may not apply to every
country.
28 GENERAL INFORMATION

Serial Number Locations


j The engine and frame serial numbers are used to register the motorcycle. They
are the only means of identifying your particular machine from others of the same
model type. These serial numbers may be needed by your dealer when ordering
parts. In the event of theft, the investigating authorities will require both numbers
as well as the model type and any peculiar features of your machine that can help
them identify it.

Engine No. Frame No.

A. Engine Number A. Frame Number


GENERAL INFORMATION 29

Location of Labels
All warning labels which are on your you and your dealer obtain the cor- j
vehicle are repeated here. Read labels rect replacement.
on your vehicle and understand them ○Refer to the actual vehicle label for
thoroughly. They contain information model specific data grayed out in the
which is important for your safety and illustration.
the safety of anyone else who may op-
erate your vehicle. Therefore, it is very
important that all warning labels be on
your vehicle in the locations shown. If
any label is missing, damaged, or worn,
get a replacement from your Kawasaki
dealer and install it in the correct posi-
tion.
NOTE
○The sample warning labels in this
section have part numbers to help 1. Brake Fluid (Front)
30 GENERAL INFORMATION

2. Brake Fluid (Rear)


3. Battery Poison/Danger
4. Rear Shock Absorber Warning
GENERAL INFORMATION 31

5. Radiator Cap Danger


*16. Fuel Level
2
* 7. Helmet Wearing
8. Important Drive Chain Information
9. Tire and Load Data

*1: only on Southeast Asia B1/B3 and


Thailand models
*2: only on Thailand model
32 GENERAL INFORMATION

*310. Noise Test Information


*211. Vehicle Emission Control Information
*412. Vehicle Emission Control Information

*2: only on Thailand model


*3: only on Australia, Malaysia,
Southeast Asia B3 and Thailand
models
4
* : only on Philippines model
GENERAL INFORMATION 33

1) 3)
j

2) 3) only on Colombia model


34 GENERAL INFORMATION

4) 5)
j

6) only on India, Southeast Asia


B1/B3
GENERAL INFORMATION 35

6) only on Thailand model 8)


j

7) only on Thailand model 8) only on Thailand model


36 GENERAL INFORMATION

9) 10) only on Australia model


j

9) only on Thailand model 10) only on Malaysia, Southeast Asia


B3 and Thailand models
GENERAL INFORMATION 37

11) only on Thailand model 12) only on Philippines model


j
38 GENERAL INFORMATION

Location of Parts
j EX400G

1. Rear View Mirrors 6. Left Handlebar Switches


2. Starter Lockout Switch 7. Ignition Switch/Steering Lock
3. Meter Instrument 8. Right Handlebar Switches
4. Brake Fluid Reservoir (Front) 9. Throttle Grip
5. Clutch Lever 10. Front Brake Lever
GENERAL INFORMATION 39

EX400G
j

1. Headlight 7. Spring Preload 12. Drive Chain


2. Turn Signal Lights Adjuster 13. Side Stand
3. Fuel Tank 8. Passenger’s Seat 14. Rear Shock Absorber
4. Air Cleaner 9. Tie Hooks 15. Shift Pedal
5. Fuse Boxes 10. Seat Lock 16. Side Stand Switch
6. Rider’s Seat 11. Chain Adjuster 17. Front Fork
40 GENERAL INFORMATION

EX400G
j

1. License Plate Light 6. Battery 12. Oil Level Inspection


2. Brake/Tail Light 7. Fuel Tank Cap Window
3. Helmet Hooks 8. Spark Plugs 13. Brake Pedal
4. Tool Kit 9. Coolant Reserve Tank 14. Rear Brake Light
5. Brake Fluid Reservoir 10. Brake Discs Switch
(Rear) 11. Brake Calipers 15. Muffler
GENERAL INFORMATION 41

EX400J
j

1. Rear View Mirrors 7. Accessory Socket


2. Starter Lockout Switch 8. Ignition Switch/Steering Lock
3. Meter Instrument 9. Right Handlebar Switches
4. Brake Fluid Reservoir (Front) 10. Throttle Grip
5. Clutch Lever 11. Front Brake Lever
6. Left Handlebar Switches
42 GENERAL INFORMATION

EX400J
j

1. Headlight 8. Pillion Seat Cover 16. Side Stand Switch


2. Turn Signal Lights 9. Tie Hooks 17. Helmet Lock
3. Fuel Tank 10. Seat Lock (Equipped Models)
4. Air Cleaner 11. Chain Adjuster 18. Front Fork
5. Fuse Boxes 12. Drive Chain
6. Rider’s Seat 13. Side Stand
7. Spring Preload 14. Rear Shock Absorber
Adjuster 15. Shift Pedal
GENERAL INFORMATION 43

EX400J
j

1. License Plate Light 6. Battery 12. Oil Level Inspection


2. Brake/Tail Light 7. Fuel Tank Cap Window
3. Helmet Hooks 8. Spark Plugs 13. Brake Pedal
4. Tool Kit 9. Coolant Reserve Tank 14. Rear Brake Light
5. Brake Fluid Reservoir 10. Brake Discs Switch
(Rear) 11. Brake Calipers 15. Muffler
44 GENERAL INFORMATION

Meter Instruments
j 1. Lower Meter Button
2. Upper Meter Button
3. Tachometer
4. Multifunction Meter
5. Gear Position Indicator
6. Fuel Gauge
7. Multifunction Display
- Odometer
- Trip Meter A/B
8. Speedometer
9. Economical Riding Indicator
10. Multifunction Display
- Current Mileage/Average Mileage/Cruising
Range
11. Coolant Temperature Gauge
12. Clock
When the ignition switch is turned on, all LCD
functions are shown for a few seconds, then the
multifunction meter turns to operational mode.
GENERAL INFORMATION 45

Indicators j
1. ABS Indicator (Yellow)
2. Neutral Indicator (Green)
3. High Beam Indicator (Blue)
4. Engine Warning Indicator (Yellow)
5. Left Turn Signal Indicator (Green)
6. Right Turn Signal Indicator (Green)
7. Fuel Level Warning Indicator
8. Battery Warning Indicator
9. Coolant Temperature Warning Indicator
10. Oil Pressure Warning Indicator
11. Warning Indicator (Red)
46 GENERAL INFORMATION

Indicator Initial Operation ON Indicators


j □ □ □
□ □ ■
□ ■ ■
■ ■ ■

ON: When ignition switch is turned on.


: After a few seconds
: When engine starts.
When the ignition switch is turned on, □: Goes on.
all indicators go on/off as shown in the ■: Goes off.
table. If any indicator does not operate *: goes off shorty after the
as shown, have it checked by an autho- motorcycle starts moving.
rized Kawasaki dealer.
GENERAL INFORMATION 47

When Warning Indicators Go On


or Blink j
When warning indicators appear, there could be a problem with vehicle function.
Follow actions in the table after stopping the vehicle in a safe place.
*: The numbers in this column corresponds to reference numbers on page 45.

Indi-
*No. Status Actions
cators
These indicators go on if the battery voltage is less than
11.0 V or more than 16.0 V. If the voltage is less than 11.0
11 V, charge the battery. If the voltage is more than 16.0
ON
8 V, or if indicators still go on after charging the battery,
have the battery and/or charging system checked by an
authorized Kawasaki dealer.
These indicators go on whenever the oil pressure is
dangerously low or the ignition switch is in the
position with the engine not running. If these indicators
11 go on when the engine speed is above idle, stop the
ON
10 engine immediately and check the engine oil level. If
the amount of engine oil is insufficient, add engine oil.
If the oil level is good, have the engine checked by an
authorized Kawasaki dealer.
48 GENERAL INFORMATION

Indi-
*No. Status Actions
cators
j
These indicators go on whenever the coolant temperature
11 rises to about 115°C (239°F). Refer to the Coolant
ON
9 Temperature Gauge section for more information and
follow instructions in it.
The DFI system has malfunctioned. Have it checked by
4 ON
an authorized Kawasaki dealer.
The ABS has malfunctioned. ABS will not work but
1 ON*1 conventional brakes function. Have the ABS checked by
an authorized Kawasaki dealer.
The lowest segment and fuel level warning indicator
blink in the multifunction display when approximately 2.9
L (0.77 US gal) of usable fuel remains. Refuel at the
Blink
earliest opportunity. If the vehicle is on the side stand, the
7 warning indicator cannot estimate the amount of fuel in
the tank. Stand the vehicle upright to check the fuel level.
The fuel level warning system has malfunctioned. Have
Blink (including the fuel level warning system checked by an authorized
all segments) Kawasaki dealer.
GENERAL INFORMATION 49

*1: ABS indicator may go on: j


○After continuous riding on a rough road.
○When the engine is started with the stand raised and the transmission engaged,
and the rear wheel turns.
○When accelerating so abruptly that the front wheel leaves the ground.
○When the ABS has been subjected to strong electrical interference.
○When tire pressure is abnormal. Adjust tire pressure.
○When a tire different in size from the standard size is being used. Replace with
standard size.
○When the wheel is deformed. Replace the wheel.
If this happens, first turn the ignition switch off, and then back on, and ride the
motorcycle at 10 km/h (6.2 mph) or more. The ABS indicator should then go off. If it
does not, have the ABS checked by an authorized Kawasaki dealer.
50 GENERAL INFORMATION

Other Indicators
j
*No. Indicators Status
2 When the transmission is in neutral, this indicator goes on.

3 When the headlight is on high beam, this indicator goes on.

5 When the turn signal switch is pushed to the left, this indicator blinks.
6 When the turn signal switch is pushed to the right, this indicator blinks.
GENERAL INFORMATION 51

the unit setting (km/h or mph) is cor-


Speedometer/Tachometer rectly displayed before riding. j
Refer to the Unit Setting in the Dis-
play Setting section.
Tachometer
The tachometer shows the engine
speed in revolutions per minute (r/min,
rpm).

NOTICE
Engine speed should not be al-
lowed to enter the red zone; op-
eration in the red zone will over-
A. Tachometer stress the engine and may cause
B. Speedometer
C. Red Zone
serious engine damage.

Speedometer When the ignition switch is turned


The speedometer is digital and can on, the tachometer needle momentar-
be set for km/h or mph. ily sweeps from the minimum to the
The unit setting can be changed ac- maximum reading, then back the mini-
cording to local regulations. Make sure mum reading to check its operation. If
52 GENERAL INFORMATION

the tachometer does not operate cor-


j rectly, have it checked by an authorized
Kawasaki dealer.

Coolant Temperature Gauge

The coolant temperature gauge in-


dicates temperature of the engine
coolant by the number of segments
displayed.
A. Segments
B. H (Hot)
C. C (Cold)

If the coolant temperature rises to


above 115°C (239°F), all segments
go on, and the warning indicator and
coolant temperature warning indicator
go on. This warns the operator that the
coolant temperature is high. Stop the
engine and check the coolant level in
the reserve tank after the engine cools
down. If the amount of the coolant is
GENERAL INFORMATION 53

insufficient, add coolant to the reserve NOTICE


tank. If the coolant level is good, have j
Stop the engine if the warning
the cooling system checked by an au-
indicator and coolant temper-
thorized Kawasaki dealer.
ature warning indicator go on.
Prolonged engine operation will
result in severe engine damage
from overheating.

Display Setting

Multifunction Display

A. Warning Indicator (Red) WARNING


B. Coolant Temperature Warning Indicator
For safety, do not operate the
meter buttons while riding the
motorcycle.

• Push the upper meter button or lower


meter button to select the display
54 GENERAL INFORMATION

modes. The display modes can be NOTE


j shifted in the following order. ○The multifunction display is dis-
played in the unit depending on the
unit mode setting.
GENERAL INFORMATION 55

A. Upper Meter Button


B. Lower Meter Button
C. Flow when pushing upper meter button
D. Flow when pushing lower meter button
56 GENERAL INFORMATION

Odometer
The odometer shows the total dis-
• Push the upper meter button and
hold it in until the display turns to 0.0.
j
tance. This meter cannot be reset.
NOTE
○When the trip meter reaches 9999.9
while riding, the meter resets to 0.0
and continues counting.

Current Mileage
NOTE The current mileage display is re-
○When the figures come to 999999, newed every 4 seconds.
the display is stopped and locked.

Trip Meter

NOTE
○When the ignition switch is turned on,
the numerical value shows “– –.–.”
To reset the trip meter:
After a few seconds of riding the nu-
• Push the upper meter button to select
the trip meter A or B.
merical value is displayed.
GENERAL INFORMATION 57

Average Mileage Cruising Range


This display shows the average fuel This display shows the cruising range j
consumption from the reset. The aver- by numerical value, and indicates the
age mileage display is renewed every cruising range from the remaining fuel
5 seconds. in the fuel tank. This cruising range
display is renewed every 20 seconds.

To reset the average mileage:


• Push the lower meter button and hold
it in until the average mileage values NOTE
resets to “– –. –.” ○The cruising range value is no longer
shown if the fuel level gets too low
NOTE after the fuel level warning indicator
○When the battery is disconnected, starts blinking.
the average mileage resets to “– –.–.” ○To recover the cruising range value
○After resetting the average mileage, display add fuel to at least the level
needed for the fuel level warning in-
the numerical value is not displayed
until the vehicle has travelled 100 m dicators to stop blinking. The cruis-
(328 ft). ing range may still be displayed with
58 GENERAL INFORMATION

a low fuel level, but it will not be ac-


curate until enough fuel is added to
• Push the lower meter button while
pushing the upper meter button to se-
j
stop the fuel level warning indicator lect the meter display units. The dis-
from blinking. play units can be shifted in the follow-
ing order.
Unit Setting

A. Units

• Display the odometer in the multi-


function display.
GENERAL INFORMATION 59

Clock j
To adjust the clock:
• Push the upper and lower meter but-
tons and hold them until both the
hour and minute displays blink.
• Push the lower meter button and hold
it until “12h” or “24h” is appeared on
the display.
• Push the upper meter button to select
“12h” or “24h.”
A. Flow when pushing and holding upper
and lower meter buttons
• Push the lower meter button to select
the hour or minute digits.
B. Flow when pushing lower meter button
C. Flow when pushing upper meter button
D. Flow when pushing and holding lower
• Push the upper meter button to ad-
just the hour or minute digits.
meter button

• To finish the clock adjustment, push


the upper meter button when both the
NOTE
hour and minute digits blink. ○When the battery is disconnected,
the clock is reset to 1:00 (“24h” dis-
play: 13:00) and starts working again
when the battery is connected.
60 GENERAL INFORMATION

WARNING
j Features
Failing to properly observe the
road ahead increases the chance
Economical Riding Indicator of an accident resulting in se-
When riding the motorcycle effi- vere injury or death. Do not con-
ciently, the economical riding indicator centrate on the economical rid-
appears on the multifunction meter to ing indicator by taking your eyes
indicate favorable fuel consumption. off the road; observe using pe-
Monitoring the economical riding indi- ripheral vision.
cator can help the rider maximize fuel
efficiency.
Fuel Gauge
The fuel in the fuel tank is shown by
the number of segments displayed.

A. Economical Riding Indicator


GENERAL INFORMATION 61

level in the tank goes down, the seg-


ments disappear one by one from F j
(full) to E (empty).
○When the fuel level warning indicator
and bottom segment blink, refer to
the “When Warning Indicators Go On
or Blink” of Indicators in this chapter.

Gear Position Indicator


This display shows the correspond-
A. Segments ing gear position when the transmis-
B. F (Full) sion is shifted. As the transmission is
C. E (Empty) shifted, the corresponding gear posi-
tion (1st  6th) is shown in this display.
NOTE When the transmission is in neutral, “N”
○When the fuel tank is full, all the seg- is displayed, and the neutral indicator
ments are displayed. As the fuel goes on.
62 GENERAL INFORMATION

When the transmission is in 1st


1
gear, “1” is displayed.
j
When the transmission is in 2nd
2
gear, “2” is displayed.
When the transmission is in 3rd
3
gear, “3” is displayed.
When the transmission is in 4th
4
gear, “4” is displayed.
When the transmission is in 5th
5
gear, “5” is displayed. A. Neutral Indicator (Green)
When the transmission is in 6th B. Gear Position Indicator
6
gear, “6” is displayed.
NOTE
○If the gear position display in the mul-
tifunction meter blinks “-,” the trans-
mission is not properly shifted to 1st.
Be sure to shift the transmission.
GENERAL INFORMATION 63

Keys
You will need the key number or j
spare key to have a duplicate made.
If all the keys are lost you will need to
replace the ignition switch and all other
locks operated by that key.
Contact your Kawasaki dealer to pur-
chase additional spare keys.

Ignition Switch/Steering
Lock • Engine can be started.
This is a three-position, key-operated
ON
• All electrical equipment can
be used.
switch.
The key can be removed when it is in • Key cannot be removed.
the or position. OFF • Engine off.
• Electrical equipment is off.
• Key can be removed.

• Steering locked.
LOCK
• Electrical equipment is off.
Engine off.
• Key can be removed.

64 GENERAL INFORMATION

For Locking: WARNING


j 1. Turn the handlebars fully to the left.
Turning the ignition switch to
2. Push the key down in the posi-
the position while riding
tion and turn it to .
the motorcycle shuts down the
entire electrical system (head-
light, brake light, turn signal
light, etc.) and the engine will
stop, which could cause an ac-
cident resulting in severe injury
or death. Never operate the
ignition switch while riding the
motorcycle; only operate it when
the motorcycle is at a standstill.

NOTE
○The tail, city and license plate lights
are on whenever the ignition key is
in the position. The headlight
goes on when the starter button is
released after starting the engine.
○Do not leave the ignition switch at the
position for an extended time
GENERAL INFORMATION 65

with the engine stopped, or the bat- MOTORCYCLE chapter for starting
tery may become totally discharged. instructions. j
Engine Stop Switch
To stop the engine in an emergency,
Right Handlebar Switches move the engine stop switch to the
position.
Ordinarily, the engine stop switch
must be in the position for the
motorcycle to operate.
NOTE
○Ordinarily, the ignition switch should
be used to stop the engine.
○Although the engine stop switch
stops the engine, it does not turn off
all the electrical circuits and eventu-
A. Starter Button ally the battery will be discharged.
B. Engine Stop Switch

Starter Button
Refer to the Starting the Engine
section in the HOW TO RIDE THE
66 GENERAL INFORMATION

Left Handlebar Switches NOTE


j ○Do not allow anything to cover the
headlight lens when the headlight is
on. If covered, heat can build up in
the headlight lens causing lens dis-
coloration or melting, as well as dam-
age to the item covering the lens.

Turn Signal Switch


When the turn signal switch is turned
to the left ( ) or right ( ) the cor-
responding turn signal lights and turn
A. Dimmer Switch signal indicator blinks. To cancel the
B. Turn Signal Switch
C. Horn Button turn signal, push the switch in.
D. Passing Button Horn Button
When the horn button is pushed, the
Dimmer Switch horn sounds.
High or low beam can be selected
with the dimmer switch. Passing Button
High beam... (High beam indicator: The high beam turns on only while
see Meter Instruments section) the passing button is pushed.
Low beam...
GENERAL INFORMATION 67

Fuel minimum octane rating shown below.


Never use gasoline with an octane rat- j
WARNING ing lower than the minimum specified
by Kawasaki to prevent severe engine
Gasoline is extremely flammable damage.
and can be explosive under cer- The octane rating of a gasoline is a
tain conditions, creating the po- measure of its resistance to detona-
tential for serious burns. Turn tion or “knocking.” The term commonly
the ignition switch off. used to describe a gasoline’s octane
Do not smoke. rating is the Research Octane Number
Make sure the area is well ven- (RON).
tilated and free from any source
of flame or sparks; this includes NOTICE
any appliance with a pilot light.
Do not use leaded gasoline, as
this will destroy the catalytic
Fuel Requirements converter.

Your Kawasaki engine is designed


to use only unleaded gasoline with a
68 GENERAL INFORMATION

NOTICE Fuel Type and Octane Rating


j If engine “knocking” or “ping- (Except for Australia, Colombia,
ing” occurs, use a different India, Philippines and Thailand
brand of gasoline of a higher Specifications)
octane rating. If this condition is Use clean, fresh unleaded gasoline
allowed to continue, it can lead with an octane rating equal to or higher
to severe engine damage. Gaso- than that shown in the table.
line quality is important. Fuels
of low quality or not meeting Fuel Type Unleaded Gasoline
standard industry specifications Minimum Octane Research Octane
may result in unsatisfactory per- Rating Number (RON) 91
formance. Operating problems
that result from the use of poor
quality or no recommended fuel NOTICE
may not be covered under your Do not use any fuel with an
warranty. ethanol in this vehicle. It has
not been tested and certified for
use with such fuels. Damage
to the engine and fuel system,
or engine starting and/or per-
formance problems may result
from the use of improper fuel.
GENERAL INFORMATION 69

(For Australia, India, Philippines and NOTICE


Thailand Specifications) j
Do not use any fuel that con-
Use clean, fresh unleaded gasoline
tains more ethanol or other oxy-
with an ethanol volume content not
genates than specified for E10
more than 10% and an octane rating
fuel* in this vehicle. Damage
equal to or higher than that shown in
to the engine and fuel system,
the table.
or engine starting and/or per-
Fuel Type Unleaded Gasoline
formance problems may result
from the use of improper fuel.
Ethanol Content E10 or less
Minimum Octane Research Octane *E10 means fuel containing up to
Rating Number (RON) 91 10% ethanol.
(For Colombia Specifications)
Use clean, fresh unleaded gasoline.
The Antiknock Index is posted on ser-
vice station pumps. The octane rating
of a gasoline is a measure of its resis-
tance to detonation or “knocking.” The
Antiknock Index is an average of the
Research Octane Number (RON) and
the Motor Octane Number (MON) as
shown in the table.
70 GENERAL INFORMATION

Fuel Type Unleaded Gasoline *E10 means fuel containing up to 10%


j Ethanol Content E10 or less
ethanol.
Antiknock Index 87 or more
Filling the Tank
NOTICE Avoid filling the tank in the rain or
where heavy dust is blowing so that the
Do not use any fuel that con-
fuel does not get contaminated.
tains more ethanol or other oxy-
genates than specified for E10
fuel* in this vehicle. Damage
to the engine and fuel system,
or engine starting and/or per-
formance problems may result
from the use of improper fuel.
GENERAL INFORMATION 71

WARNING NOTICE
Gasoline is extremely flammable Australia, India, Southeast Asia j
and can be explosive under cer- B1/B3 and Thailand models only:
tain conditions, creating the po- Never fill the tank so the fuel
tential for serious burns. Turn level rises into the filler neck. If
the ignition switch off. Do not the tank is overfilled, heat may
smoke. cause the fuel to expand and
Make sure the area is well ven- flow into the Evaporative Emis-
tilated and free from any source sion Control System resulting in
of flame or sparks; this includes hard starting, engine hesitation
any appliance with a pilot light. and non-compliance with the
Never fill the tank completely to emission regulation.
the top.
If the tank is filled completely to • Lift the key hole cover.
the top, heat may cause the fuel
to expand and overflow through
• tank cap.
Insert the ignition key into the fuel

the vents in the tank cap.


After refueling, make sure the
• Turn the key clockwise while pushing
down the fuel tank cap.
tank cap is closed securely. If
gasoline is spilled on the fuel
tank, wipe it off immediately.
72 GENERAL INFORMATION

A. Key Hole Cover A. Tank Cap


B. Ignition Key B. Fuel Tank
C. Fuel Tank Cap C. Top Level
D. Bottom of Filler Neck (Maximum Fuel
• Open the fuel tank cap. Level)
• Add fuel.
NOTE
○Do not exceed the maximum fuel
level as shown.

• Push the fuel tank cap down into


place with the key inserted.
GENERAL INFORMATION 73

• The key can be removed by turning


counterclockwise to the original po-
cannot be removed unless the cap is
locked properly. j
sition. ○Do not push on the key to close the
• Close the key hole cover. cap, or the cap cannot be locked.

NOTICE
Side Stand
Never fill the tank completely to
the top. Always kick the stand fully up before
If the tank is filled completely to moving the motorcycle. The engine will
the top, heat may cause the fuel stop automatically if the motorcycle is in
to expand and overflow through gear and the clutch is released with the
the vents in the tank cap. side stand down.
After refueling, make sure the NOTE
tank cap is closed securely.
If gasoline is spilled on the fuel ○When using the side stand, turn the
handlebars to the left.
tank, wipe it off immediately.
○Make sure the side stand is down se-
curely before leaving the motorcycle.
NOTE ○Do not sit on the motorcycle while it
○The fuel tank cap cannot be closed is on its side stand.
without the key inserted, and the key
74 GENERAL INFORMATION

Seats
j The seats can be removed by in order
of the passenger’s seat then the rider’s
seat.
Passenger’s Seat Removal
• Insert
lock.
the ignition key into the seat

• Lift the front part of the passenger’s


seat upward while turning the key
clockwise. A. Ignition Key
• Remove the passenger’s seat for-
ward.
B. Passenger’s Seat

• Remove the ignition key. Passenger’s Seat Installation


• Insert the hooks at the rear of the
passenger’s seat into the slots of the
frame.
• Insert the seat lock projection at the
front of the passenger’s seat into the
latch hole.
• Push down the front part of the pas-
senger’s seat until the lock clicks.
GENERAL INFORMATION 75

(For pillion seat cover equipped mod-


els) j
NOTE
○Do not carry any passenger when the
pillion seat cover is installed on the
motorcycle.

Pillion Seat Cover Removal


• Insert
lock.
the ignition key into the seat
A. Hooks
B.
C.
Slots
Seat Lock Projection
• Lift the front part of the pillion seat
cover upward while turning the key
D. Latch Hole clockwise.

• Pull up the front and rear ends of the • Remove the pillion seat cover back-
ward.
passenger’s seat to make sure they
are securely locked. • Remove the ignition key.
76 GENERAL INFORMATION

A. Ignition Key A. Slot


B. Pillion Seat Cover B. Hook
C. Seat Lock Projection
D. Latch Hole
Pillion Seat Cover Installation
• Insert the slot at the rear of the pil-
lion seat cover into the hook on the
• Pull up the front and rear ends of the
pillion seat cover to make sure they
bracket. are securely locked.
• Insert the seat lock projection at the
front of the pillion seat cover into the Rider’s Seat Removal
latch hole. • Remove the passenger’s seat (see
• Push down the front part of the pillion
seat cover until the lock clicks.
Passenger’s Seat Removal).
GENERAL INFORMATION 77

• Lift the rear part of the rider’s seat up-


ward while pulling the seat lock cable
• Insert the seat latch at the rear part
of the rider’s seat into the latch hole j
backward. of the frame.
• Remove the rider’s seat backward. • Push down the rear part of the rider’s
seat until the lock clicks.

A. Seat Lock Cable


B. Rider’s Seat A. Hooks
B. Fuel Tank Bracket
Rider’s Seat Installation C. Seat Latch
D. Latch Hole
• Insert the hooks at the front of the
rider’s seat under the fuel tank
bracket.
• Pull up the front and rear ends of the
rider’s seat to make sure they are
securely locked.
78 GENERAL INFORMATION

• Install the passenger’s seat


Passenger’s Seat Installation).
(see
j

Storage Compartment
The storage compartment are lo-
cated under the passenger’s seat.
• Pull the tab to open the compartment
cover.

A. Compartment Cover
B. Tab
C. Pull
D. Open
GENERAL INFORMATION 79

A. Storage Compartment A. Tie Hooks

Tie Hooks Helmet Hooks


When securing light loads to the seat, The helmets can be secured to the
use the tie hooks. motorcycle using the helmet hooks lo-
cated under the passenger’s seat.
80 GENERAL INFORMATION

Helmet Lock (Equipped


j Models)
The helmet lock is located to the left
of the motorcycle.
To unlock the helmet lock
• Insert the ignition key into the helmet
lock and turning it clockwise.

To lock the helmet lock


A. Helmet Hooks • Turn
wise.
the ignition key counterclock-

WARNING • Remove the ignition key.


Riding with helmets attached to
the hooks could cause an ac-
cident by distracting the oper-
ator or interfering with normal
vehicle operation. Do not ride
the motorcycle with helmets at-
tached to the hooks.
GENERAL INFORMATION 81

Tool Kit
The tool kit is located under the j
rider’s seat.
Keep the tool kit in the original place.
Hold the tool kit with the band securely.

A. Helmet Lock
B. Ignition Key

WARNING
Riding with a helmet attached to
the lock could cause an accident A. Tool Kit
by distracting the operator or in- B. Band
terfering with normal vehicle op-
eration. Do not ride the motorcy-
cle with a helmet attached to the
lock.
82 GENERAL INFORMATION

Electric Accessory
j Connectors
The electric power of the battery can
be used through the electric accessory
connectors.
NOTE
○The electrical accessory connection
to the connectors should be done by
an authorized Kawasaki dealer.
A. Accessory Connectors (Under Upper
Accessory Connector
Inner Fairing)
Location Polarity Wire Color
Under Upper (+) White/Black
Inner Fairing (–) Black/Yellow
Under Com- (+) White/Black
partment
Cover (–) Black/Yellow
Maximum Current: 1.9 A
GENERAL INFORMATION 83

Accessory Socket
(Equipped Models) j
The electric power of the battery can
be used through the accessory socket.
Observe and follow the notes listed be-
low.

A. Accessory Connectors (Under


Compartment Cover)

NOTICE
This accessory circuit has 5 A
fuse for the connectors. Always
install a fuse 5 A or less for the A. Accessory Socket
circuit. Do not connect more
than 25 W of load to this acces-
sory circuit or the battery may
become discharge, even with the
engine running.
84 GENERAL INFORMATION

NOTICE Event Data Recorder


j If using an accessory in the In common with many other ve-
socket, unless it has a water- hicle manufacturers, Kawasaki has
proof connection, do not oper- equipped this motorcycle with an event
ate this motorcycle in the rain or data recorder (EDR). The purpose of
wash it. Always put the cap on this device is to record data that assists
the socket when the accessory with understanding of how some of the
is not used. vehicle’s systems were performing
during a short period of time immedi-
ately before and during an accident or
NOTICE similar event involving minor damage.
This accessory circuit has 5 A Due to accident variables, all vehicle
fuse for the socket and connec- performance data may not be stored
tors. Always install a fuse 5 A on the EDR.
or less for the circuit. Do not NOTE
connect more than 25 W of load
to this accessory circuit or the ○During normal riding, data is
battery may become discharge, recorded but not saved unless the
even with the engine running. vehicle is involved in an accident
event.
○At no time other than in the event of
an accident or similar event involving
GENERAL INFORMATION 85

minor damage is it possible for EDR vehicle speed, engine crankshaft rota-
data to be stored for retrieval. tional speed and throttle opening, etc. j
○Depending on the type of accident This data can help provide a better
event, it is possible that the EDR may understanding for both the rider and the
not record some or all of the data, manufacturer of how the vehicle was
or it may not record if the EDR is performing at the time of an accident or
damaged. near accident-like situation.
○This device does not collect or store To access information on an EDR,
personal data or information (e.g. special equipment and access to the
name, gender, age). EDR is required. Kawasaki will not
share EDR information without obtain-
The EDR in this vehicle is designed to
ing your consent, unless required by
record only data that is relevant to the
government authorities, or acting pur-
vehicle’s running condition at the time
suant to lawful authority.
of an accident like, but not limited to,
86 HOW TO RIDE THE MOTORCYCLE
HOW TO RIDE THE MOTORCYCLE

Break-In Distance traveled


Maximum engine
j speed
The first 1 600 km (1 000 mile) that
the motorcycle is ridden is designated 0  800 km (0 
4 000 r/min (rpm)
as the break-in period. If the motorcy- 500 mile)
cle is not used carefully during this pe- 800  1 600 km
6 000 r/min (rpm)
riod, you may very well end up with a (500  1 000 mile)
“broken down” instead of a “broken in”
motorcycle after a few thousand kilo-
NOTE
meters.
The following rules should be ob- ○When operating on public roadways,
served during the break-in period. keep maximum speed under traffic
• The table shows maximum recom-
mended engine speed during the
law limits.

break-in period. • Do not start moving or race the en-


gine immediately after starting it,
even if the engine is already warm.
Run the engine for two or three min-
utes at idle speed to give the oil a
chance to work up into all the engine
parts.
HOW TO RIDE THE MOTORCYCLE 87

• Do not race the engine while


transmission is in neutral.
the Starting the Engine
• Check
in the
that the engine stop switch is
position.
WARNING j
New tires are slippery and may
cause loss of control and injury.
A break-in period of 160 km (100
miles) is necessary to estab-
lish normal tire traction. During
break-in, avoid sudden and max-
imum braking and acceleration,
and hard cornering.

In addition to the above, at 1 000


km (600 mile) it is extremely important A. Engine Stop Switch
that the owner has the initial mainte- B. Starter Button
nance service performed by an autho-
rized Kawasaki dealer. • Turn the ignition key to position.
• tral.
Make sure the transmission is in neu-
88 HOW TO RIDE THE MOTORCYCLE

• Without holding the throttle grip, push


the starter button to start the engine.

j NOTICE
Do not operate the starter con-
tinuously for more than 5 sec-
onds, or the starter will overheat
and the battery power will drop
temporarily. Wait 15 seconds
between each operation of the
A. Neutral Indicator (Green)
B. Ignition Switch
starter to let it cool and the bat-
C. Position tery power recover.

NOTE NOTE
○The motorcycle is equipped with a ○The motorcycle is equipped with a
vehicle-down sensor which causes starter lockout switch. This switch is
the engine to stop automatically if the designed so that the engine does not
motorcycle falls down. After right- start if the transmission is in gear and
ing the motorcycle, first turn the ig- the side stand is down. However, the
nition key to and then back to engine can be started if the clutch
before starting the engine.
HOW TO RIDE THE MOTORCYCLE 89

lever is pulled and the side stand is Moving Off


fully up.
• Check that the side stand is up.
• Pull in the clutch lever.
j
• Shift into 1st gear.
• let outthe
Open throttle a little, and start to
the clutch lever very slowly.
• As the clutch starts to engage, open
the throttle a little more, giving the en-
gine just enough fuel to keep it from
stalling.

NOTE
A. Clutch Lever
○The motorcycle is equipped with a
B. Starter Lockout Switch side stand switch. This switch is de-
signed so that the engine does not
start if the transmission is in gear and
NOTICE the side stand is down.
Do not let the engine idle longer
than 5 minutes, or engine over- Shifting Gears
heating and damage may occur.
• Close the throttle while pulling in the
clutch lever.
90 HOW TO RIDE THE MOTORCYCLE

• Shift
gear.
into the next higher or lower WARNING
Downshifting to a lower gear at
high speed causes engine rpm
j to increase excessively, poten-
tially damaging the engine and
it may also cause the rear wheel
to skid and cause an accident.
Downshifting should be done
below 5 000 rpm for each gear.

NOTE
○The transmission is equipped with a
A. Shift Pedal positive neutral finder. When the mo-
torcycle is standing still, the transmis-
• Open the throttle part way, while re-
leasing the clutch lever. sion cannot be shifted past neutral
from 1st gear. To use the positive
neutral finder, shift down to 1st gear,
then lift up on the shift pedal while
standing still. The transmission will
shift only into neutral.
HOW TO RIDE THE MOTORCYCLE 91

Braking applying the brakes as hard as pos-


sible without skidding.
• Close the throttle completely, leav-
ing the clutch engaged (except when • Even in motorcycles equipped with
ABS, braking during cornering may j
shifting gears) so that the engine will cause wheel slip. When turning a
help slow down the motorcycle. corner, it is better to limit braking to
• Shift down one gear at a time so that
you are in 1st gear when you come
the light application of both brakes
or not to brake at all. Reduce your
to a complete stop. speed before you get into the corner.
• When stopping, always apply both
brakes at the same time. Normally
the front brake should be applied a lit-
tle more than the rear. Shift down or
fully disengage the clutch as neces-
sary to keep the engine from stalling.
• Never lock the brakes, or it will cause
the tires to skid. When turning a cor-
ner, it is better not to brake at all. Re-
duce your speed before you get into
the corner.
• For emergency braking, disregard
downshifting, and concentrate on A. Front Brake Lever
92 HOW TO RIDE THE MOTORCYCLE

prevent wheel lock-up and allows sta-


ble steering control while stopping.
Brake control function is identical to
j that of a conventional motorcycle. The
brake lever is used for the front brake
and the brake pedal for the rear brake.
Although the ABS provides stability
while stopping by preventing wheel
lock-up, remember the following char-
acteristics:
A. Rear Brake Pedal • To apply the brake effectively, use
the front brake lever and rear brake
pedal simultaneously in the same
Anti-lock Brake System manner as conventional motorcycle
(ABS) brake system.
ABS is designed to help prevent • ABS cannot compensate for adverse
road conditions, misjudgment or im-
the wheels from locking up when the proper application of brakes. You
brakes are applied hard while running must take the same care as with mo-
straight. The ABS automatically regu- torcycles not equipped with ABS.
lates brake force. Intermittently gaining
gripping force and braking force helps • ABS is not designed to shorten the
braking distance. On loose, uneven
or downhill surfaces, the stopping
HOW TO RIDE THE MOTORCYCLE 93

distance of a motorcycle with ABS WARNING


may be longer than that of an equiv-
ABS cannot protect the rider
alent motorcycle without ABS. Use
from all possible hazards and
special caution in such areas. j
is not a substitute for safe rid-
• ABS will help prevent wheel lock-up
when braking in a straight line, but it
ing practices. Be aware of how
the ABS system operates and
cannot control wheel slip which may
its limitations. It is the rider’s
be caused by braking during corner-
responsibility to ride at appro-
ing. When turning a corner, it is bet-
priate speeds and manner for
ter to limit braking to the light appli-
weather, road surface and traffic
cation of both brakes or not to brake
conditions.
at all. Reduce your speed before you
get into the corner.
• Same as conventional brake system, • The computers integrated in the ABS
compare vehicle speed with wheel
an excessive sudden braking may speed. Since non-recommended
cause wheel lock up that makes it tires can affect wheel speed, they
harder to control a motorcycle. may confuse the computers, which
• During braking, ABS will not prevent
the rear wheel lifting.
can extend braking distance.
94 HOW TO RIDE THE MOTORCYCLE

WARNING the “Battery Maintenance” section in


the MAINTENANCE AND ADJUST-
Use of non-recommended tires
MENT chapter.
may cause malfunctioning of
j ABS and can lead to extended
braking distance. The rider Stopping the Engine
could have an accident as a re-
sult. Always use recommended • Close the throttle completely.
standard tires for this motorcy- • Turn the transmission
Shift the into neutral.
cle. • Support the motorcycle on. a firm,
ignition key to
• level surface with the side stand.
NOTE
○When the ABS is functioning, you • Lock the steering.
may feel a pulsing in the brake lever
or pedal. This is normal. You need Stopping the Motorcycle in
not suspend applying brakes. an Emergency
○ABS does not function at speeds of Your Kawasaki Motorcycle has been
approx. 10 km/h (6.2 mph) or below. designed and manufactured to pro-
○ABS does not function if the battery vide you optimum safety and conve-
is discharged. When riding with an nience. However, in order to fully ben-
insufficiently charged battery, ABS efit from Kawasaki’s safety engineering
may not function. Keep the bat- and craftsmanship, it is essential that
tery in good condition according to
HOW TO RIDE THE MOTORCYCLE 95

you, the owner and operator, properly the engine. If the engine stop switch is
maintain your motorcycle and become used, turn off the ignition switch after
thoroughly familiar with its operation. stopping the motorcycle.
Improper maintenance can create a j
dangerous situation known as throt- Parking
tle failure. Two of the most common
causes of throttle failure are:
1. An improperly serviced or clogged WARNING
air cleaner may allow dirt and dust Operating or parking the vehi-
to enter the throttle body and stick cle near flammable materials can
the throttle open. cause a fire, and can result in
2. During removal of the air cleaner, property damage or severe per-
dirt is allowed to enter and jam the sonal injury.
fuel injection system. Do not idle or park your vehicle
in an area where tall or dry veg-
In an emergency situation such as
etation, or other flammable ma-
throttle failure, your vehicle may be
terials could come into contact
stopped by applying the brakes and
with the muffler or exhaust pipe.
disengaging the clutch. Once this
stopping procedure is initiated, the en-
gine stop switch may be used to stop
96 HOW TO RIDE THE MOTORCYCLE

WARNING and the motorcycle is not close to


any source of flame or sparks; this
The engine and exhaust system
includes any appliance with a pilot
get extremely hot during normal
j light.
operation and can cause serious
burns.
Never touch a hot engine, ex- WARNING
haust pipe, or muffler during op- Gasoline is extremely flammable
eration or after stopping the en- and can be explosive under cer-
gine. tain conditions, creating the po-
tential for serious burns. Turn
• Shift the transmission into neutral
and turn the ignition key to .
the ignition switch off. Do not
smoke. Make sure the area is
• Support the motorcycle on a firm,
level surface with the side stand.
well ventilated and free from any
source of flame or sparks; this
includes any appliance with a pi-
NOTICE lot light.
Do not park on a soft or steeply
inclined surface, or the motorcy- • Lock
theft.
the steering to help prevent
cle may fall over.

• Ifstructure,
parking inside a garage or other
be sure it is well ventilated
MAINTENANCE AND ADJUSTMENT 97
MAINTENANCE AND ADJUSTMENT
The maintenance and adjustments outlined in this chapter must be carried out in
accordance with the Daily Checks and Periodic Maintenance to keep the motorcy-
cle in good running condition and to reduce air pollution. The initial maintenance
is vitally important and must not be neglected. j

WARNING
Failure to perform these checks or to correct a problem before opera-
tion may result in serious damage or an accident. Always perform daily
checks before operation.

With a basic knowledge of mechanics and the proper use of tools, you should be
able to carry out many of the maintenance items described in this chapter. If you
lack proper experience or doubt your ability, all adjustments, maintenance, and
repair work should be completed by a qualified technician.
Please note that Kawasaki cannot assume any responsibility for damage result-
ing from incorrect or improper adjustment made by the owner.
98 MAINTENANCE AND ADJUSTMENT

DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous
gas. Inhaling carbon monoxide can cause serious brain injury or
death. DO NOT run the engine in enclosed areas. Operate only in a
well-ventilated area.
j

WARNING
The cooling fan spins at high speed and can cause serious injuries. Keep
your hands and clothing away from the cooling fan blades at all times.

NOTE
○If a torque wrench is not available, the maintenance items which require a specific
torque value should be serviced by an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT 99

Daily Checks
Check the following items each day before you ride. The time required is minimal,
and habitual performance of these checks will help ensure you a safe, reliable ride.
If any irregularities are found during these checks, refer to the MAINTENANCE
AND ADJUSTMENT chapter or see your dealer for the action required to return the
motorcycle to a safe operating condition. j

See
Operation
Page
Fuel
Adequate supply in tank, no leaks –
Engine oil
Oil level between level lines 107
Tires
Air pressure (when cold), install the air valve cap 133
Tire wear 134
Drive chain
Slack 121
Lubricate if dry 121
100 MAINTENANCE AND ADJUSTMENT

See
Operation
Page
Bolts, nuts and fasteners
Check for loose and/or missing bolts, nuts and fasteners –
Steering
j
Action smooth but not loose from lock to lock –
No binding of control cables –
Brakes
Brake pad wear 127
Brake fluid level 126
No brake fluid leakage –
Throttle
Throttle grip free play 117
Clutch
Clutch lever free play 119
Clutch lever operates smoothly –
Coolant
No coolant leakage –
MAINTENANCE AND ADJUSTMENT 101

See
Operation
Page
Coolant level between level lines (when engine is cold) 111
Electrical equipment
All lights (head, city, brake/tail, turn signal, license plate, warning/indicator) and – j
horn work
Engine stop switch
Stops 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 –
102 MAINTENANCE AND ADJUSTMENT

Periodic Maintenance
*A: Service at number of years shown or indicated odometer reading intervals,
whichever comes first.
*B: For higher odometer readings, repeat at the frequency interval established here.
j *C: Service more frequently when operating in severe conditions: dusty, wet, muddy,
high speed, or frequent starting/stopping.
*D: Australia, India, Southeast Asia B1/B3 and Thailand models only

: Inspection : Dealer Inspection

: Change or Replace : Dealer Change or Replace

: Lubrication : Dealer Lubrication


MAINTENANCE AND ADJUSTMENT 103

Odometer Reading (*B)


year × 1 000 km (× 1 000 mile) See
(*A) 1 6 12 18 24 Page
Items (0.6) (3.8) (7.6) (11.4) (15.2)
Air cleaner element (*C) 113
j
Idle speed 119
Throttle control system (play, smooth
:1 117
return, no drag)
Engine vacuum synchronization –

Fuel system :1 –

Fuel filter –

Fuel hose :5 –

Evaporative emission control system –


(*D)
Coolant level 111

Cooling system :1 –
104 MAINTENANCE AND ADJUSTMENT

Odometer Reading (*B)


year × 1 000 km (× 1 000 mile) See
(*A) 1 6 12 18 24 Page
Items (0.6) (3.8) (7.6) (11.4) (15.2)

j Coolant, water hose and O-ring : every 36 000 km –


:3
(22 500 mile)

Valve clearance : every 42 000 km –


(26 250 mile)
Air suction system –

Clutch operation (play, engagement,


119
disengagement)
Engine oil (*C) and oil filter :1 108

Tire air pressure :1 133

Wheel and tire :1 134

Wheel bearing damage :1 –

Drive chain lubrication condition (*C) : every 600 km (400 mile) 121
MAINTENANCE AND ADJUSTMENT 105

Odometer Reading (*B)


year × 1 000 km (× 1 000 mile) See
(*A) 1 6 12 18 24 Page
Items (0.6) (3.8) (7.6) (11.4) (15.2)

Drive chain slack (*C) : every 1 000 km 121 j


(600 mile)
Drive chain wear (*C) –

Drive chain guide wear –

Brake system :1 –

Brake operation (effectiveness, play, –


no drag) :1

Brake fluid level :1 126

Brake fluid (front and rear) :2 –

Brake hose :4 –

Rubber parts of brake master cylinder : every 48 000 km –


and caliper :4
(30 000 mile)
106 MAINTENANCE AND ADJUSTMENT

Odometer Reading (*B)


year × 1 000 km (× 1 000 mile) See
(*A) 1 6 12 18 24 Page
Items (0.6) (3.8) (7.6) (11.4) (15.2)
Brake pad wear (*C) 127
j
Brake light switch operation 128

Suspension system :1 –

Lubrication of rear suspension –

Steering play :1 –

Steering stem bearing :2 –

Electrical system :1 –

Spark plug –

Chassis parts :1 –

Condition of bolts, nuts and fasteners –


MAINTENANCE AND ADJUSTMENT 107

Engine Oil
Oil Level Inspection
• Ifandtherunengine is cold, start the engine
it for several minutes at idle
speed. j
• Stop the engine, then wait several
minutes until the oil settles.

NOTICE
A. Oil Level Inspection Window
Racing the engine before the oil B. Oil Filler Cap
reaches every part can cause en- C. Upper Level Line
gine seizure. D. Lower Level Line

• Check the engine oil level through • Ifexcess


the oil level is too high, remove the
oil through the oil filler open-
the oil level inspection window. With
ing using a syringe or some other
the motorcycle held level, the oil level
suitable device.
should come up between the upper
and lower level lines next to the oil • If the oil level is too low, add oil to
reach the correct level. Use the
level inspection window.
same type and brand of oil that is
already in the engine.
108 MAINTENANCE AND ADJUSTMENT

Oil and/or Oil Filter Change


• Warm up the engine thoroughly, and
then stop it.
• Place an oil pan beneath the engine.
• gasket. the engine oil drain bolt and
Remove
j

WARNING
Engine oil is a toxic substance.
Dispose of used oil properly.
A. Engine Oil Drain Bolt
Contact your local authorities B. Gasket
for approved disposal methods
or possible recycling. • Let the oil completely drain with
the motorcycle perpendicular to the
ground.
• If the oil filter is to be replaced, re-
move the oil filter and replace it with
a new one.
MAINTENANCE AND ADJUSTMENT 109

NOTE
○If a torque wrench or required
Kawasaki special tool is not avail-
able, this item should be serviced by
an authorized Kawasaki dealer.
j

A. Gasket

• Install the drain bolt with a new gas-


ket. Tighten it to the specified torque.

NOTE
A. Oil Filter ○Replace the gasket with a new one.
• Apply a thin film of oil to the gasket
and tighten the oil filter to the speci-
fied torque.
110 MAINTENANCE AND ADJUSTMENT

Tightening Torque Engine Oil Capacity


Oil Filter: 1.6 L (1.7 US qt)
17.5 N·m (1.78 kgf·m, 12.9 ft·lb) [when filter is not removed]
Engine Oil Drain Bolt: 2.0 L (2.1 US qt)
30 N·m (3.1 kgf·m, 22 ft·lb)
j [when filter is removed]
• Fill the engine up to the upper level
line with a good quality engine oil Although 10W-40 engine oil is the
specified in the table. recommended oil for most condi-
tions, the oil viscosity may need to
Recommended Engine Oil
be changed to accommodate atmo-
Type: spheric conditions in your riding area.
API SG, SH, SJ, SL or SM with JASO
MA, MA1 or MA2 rating
Viscosity:
SAE 10W-40

NOTE
○Do not add any chemical additive to
the oil. Oils fulfilling the above re-
quirements are fully formulated and
provide adequate lubrication for both
the engine and the clutch.
MAINTENANCE AND ADJUSTMENT 111

• Start the engine.


• Check the oil level and oil leakage.

Coolant
Coolant Level Inspection j
• Position the motorcycle so that it is
perpendicular to the ground.
• Check the coolant level through the
coolant level gauge on the reserve
tank located in right middle fairing. A. F (Full) Level Line
The coolant level should be between B. L (Low) Level Line
C. Reserve Tank
the F (Full) and L (Low) level lines.
NOTE
○Check the level when the engine is
cold (room or atmospheric tempera-
ture).

• Ifcient,
the amount of coolant is insuffi-
add coolant into the reserve
tank.
112 MAINTENANCE AND ADJUSTMENT

Coolant Filling however it must be returned to the


• Remove the cap from the reserve
tank and add coolant through the
correct mixture ratio by the addition
of antifreeze concentrate as soon as
filler opening to the F (Full) level line. possible.

j NOTICE
If coolant must be added of-
ten, or the reserve tank com-
pletely runs dry, there is proba-
bly leakage in the system. Have
the cooling system inspected
by your authorized Kawasaki
dealer.

A. Reserve Tank Cap Coolant Change


Have the coolant changed by an au-
NOTE thorized Kawasaki dealer.
○In an emergency you can add wa-
ter alone to the coolant reserve tank,
MAINTENANCE AND ADJUSTMENT 113

Coolant Requirement NOTICE


If hard water is used in the sys-
WARNING tem, it causes scale accumula-
Coolant containing corrosion in- tion in the water passages, and
hibitors for aluminum engines considerably reduces the effi-
and radiators include harm- ciency of the cooling system. j
ful chemicals for human body.
Drinking coolant can result in
serious injury or death. Use NOTE
coolant in accordance with the ○A permanent type of antifreeze is in-
instructions of the manufacturer. stalled in the cooling system when
shipped. It is mixed at 50% and has
Use a permanent type of antifreeze the freezing point of –35°C (–31°F).
(soft water and ethylene glycol plus cor-
rosion and rust inhibitor chemicals for
aluminum engines and radiators) in the Air Cleaner
cooling system. On the mixture ratio This motorcycle’s air cleaner element
of coolant, choose the suitable one re- consists of a wet paper filter. Replace-
ferring to the relation between freezing ment of the air cleaner element should
point and strength directed on the con- be done by an authorized Kawasaki
tainer. dealer.
114 MAINTENANCE AND ADJUSTMENT

Oil Draining
• Remove the rider’s seat (see Seats
section in the GENERAL INFORMA-
TION chapter).
• Remove the bolt and washer.
j • Remove the bolt.
• Pull the left side cover outward to
clear the projections and tabs.
• Remove the left side cover.

A. Bolt and Washer


B. Bolt
C. Projections
D. Tabs
E. Left Side Cover

• Remove
bracket.
the fuse box from the
MAINTENANCE AND ADJUSTMENT 115

A. Fuse Box A. Transparent Drain Cap


B. Clamp
• Inspect the transparent drain cap lo-
cated the left lower end of the air • Ifremove
there is any oil in the drain cap,
cleaner housing to see if any oil has the clamp and drain cap, and
run down. drain the oil.
116 MAINTENANCE AND ADJUSTMENT

WARNING • Insert the projections of the left side


cover into the grommets.
Oil on tires will make them slip-
pery and can cause an accident
and injury. Be sure to install the
drain cap to the air cleaner hous-
j ing after draining.

• Install the fuse box to the bracket.

A. Tabs
B. Slots
C. Projections
D. Grommets
E. Left Side Cover

• Tighten the bolt.


A. Fuse Box • Tighten the bolt with washer.
• Insert the tabs of the left side cover
into the slots.
MAINTENANCE AND ADJUSTMENT 117

completely by the return spring in all


steering positions.
• If the throttle grip does not return
properly, have the throttle control
system checked by an authorized
Kawasaki dealer. j
• Check the throttle grip free play by
turning back and forth.

A. Bolt
B. Bolt and Washer

• Install the removed parts.


Throttle Control System
Throttle Grip
Throttle Grip Free Play Inspection A. Throttle Grip
• Check that the throttle grip moves
smoothly from full open to close,
B. Throttle Grip Free Play

and the throttle closes quickly and


118 MAINTENANCE AND ADJUSTMENT

Throttle Grip Free Play


2  3 mm (0.08  0.12 in.)

• If there is improper play, adjust it.


j Throttle Grip Free Play Adjustment
• Loosen the locknut, and turn the
adjuster until the proper amount of
throttle grip play is obtained.
• Tighten the locknut.
A. Locknut
B. Adjuster
C. Throttle Cable (Accelerator Cable)

• Ifjusted
the throttle cables cannot be ad-
with the adjuster at the upper
end of the throttle cable, further ad-
justment of the throttle cables should
be done by an authorized Kawasaki
dealer.
• With the engine idling, turn the han-
dlebars to each side. If handlebars
movement changes the idle speed,
MAINTENANCE AND ADJUSTMENT 119

the throttle cables may be improperly speed is disturbed, inspection of the


adjusted or incorrectly routed, or they idle speed control should be done by
may be damaged. Be sure to correct an authorized Kawasaki dealer.
any of these conditions before idling.
NOTE

WARNING
○While the engine is cold, the fast idle j
system automatically raises the en-
Operation with improperly ad- gine idle speed.
justed, incorrectly routed, or Idle Speed
damaged cables could result in
an unsafe riding condition. Be 1 300 ±50 r/min (rpm)
sure the control cables are ad-
justed and routed correctly, and
are free from damage. Clutch
Clutch Operation Inspection

Idle Speed
• Check that the clutch lever operates
properly and that the inner cable
slides smoothly. If there is any irreg-
The idle speed inspection should be ularity, have the clutch cable checked
performed in accordance with the Peri- by an authorized Kawasaki dealer.
odic Maintenance chart.
This motorcycle is equipped with the • Check the clutch lever free play.
Idle Speed Control System. If the idle
120 MAINTENANCE AND ADJUSTMENT

Clutch Lever Free Play Clutch Lever Free Play Adjustment


2  3 mm (0.08  0.12 in.) • Loosen the locknut, and turn the
adjuster so that the clutch lever will
have the specified free play.

j WARNING
Excess clutch lever free play
could prevent clutch disengage-
ment and cause a crash result-
ing in serious injury or death.
When adjusting the clutch lever
free play, be sure the upper end
of the clutch outer cable is fully
A. Adjuster seated in its fitting so that it
B. Locknut doesn’t slip into place later and
C. Clutch Lever Free Play
create excessive free play.
• Ifclutch
the free play is incorrect, adjust the
lever free play as follows. • Tighten the locknut.
• cable adjusted
If it cannot be done, have the clutch
by an authorized
Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT 121

NOTE coated with lubricant. Wipe off any


○After the adjustment is made, start excess lubricant.
the engine and check that the clutch
does not slip and that it releases
properly.
j
Drive Chain
Drive Chain Lubrication
Lubrication is necessary after riding
through rain or on wet roads, or any
time that the chain appears dry.
Use a lubricant for sealed chains to
prevent deterioration of chain seals. If • Wipe off any lubricant that gets on the
tire surface.
the chain is especially dirty, clean it
using a cleaner for sealed chains fol- Drive Chain Slack Inspection
lowing the instructions supplied by the
chain cleaner manufacturer. • Set
stand.
the motorcycle up on its side

• Apply lubricant to the sides of the


rollers so that it will penetrate to the • Clean the chain if it is dirty, and lubri-
cate it if it appears dry.
rollers and bushings. Apply lubricant
to the seals so that the seals will be • Rotate the rear wheel to find the po-
sition where the chain is tightest, and
122 MAINTENANCE AND ADJUSTMENT

measure the maximum chain slack Drive Chain Slack Adjustment


by pulling up and pushing down the
chain midway between the engine
• Loosen the left and right chain ad-
juster locknuts.
sprocket and rear wheel sprocket. • Remove the cotter pin, and loosen
the axle nut.
j

A. Chain Slack
A. Axle Nut
• Ifloose,
the drive chain is too tight or too
adjust it so that the chain slack
B.
C.
Cotter Pin
Adjuster
is within the standard value. D. Locknut

Drive Chain Slack • Iflefttheandchain is too loose, turn in the


right chain adjusters evenly.
Standard: 20  30 mm (0.8  1.2 in.)
MAINTENANCE AND ADJUSTMENT 123

• Iflefttheandchain is too tight, turn out the


right chain adjusters evenly.
• Turn both chain adjusters evenly
until the drive chain has the correct
amount of slack. To keep the chain
and wheel properly aligned, the left j
wheel alignment indicator should
align with the same swingarm mark
that the right wheel alignment indica-
tor aligns with.
A. Marks
B. Wheel Alignment Indicator
C. Adjuster
D. Locknut

NOTE
○Wheel alignment can also be
checked using the straightedge or
string method.
124 MAINTENANCE AND ADJUSTMENT

WARNING • Rotate the wheel, measure the chain


slack again at the tightest position,
Misalignment of the wheel will
and readjust if necessary.
result in abnormal wear, and may
result in an unsafe riding con- • Install a new cotter pin through the
axle nut and axle, and spread its
dition. Align the rear wheel us-
j ends.
ing the marks on the swingarm
or measuring the distance be-
tween the center of the axle and
swingarm pivot.

• Tighten both chain adjuster locknuts.


• torque. the axle nut to the specified
Tighten

Tightening Torque
Axle Nut:
98 N·m (10 kgf·m, 72 ft·lb)
A. Cotter Pin

NOTE NOTE
○If a torque wrench is not available, ○When inserting the cotter pin, if the
this item should be serviced by an slots in the nut do not align with
authorized Kawasaki dealer. the cotter pin hole in the axle shaft,
MAINTENANCE AND ADJUSTMENT 125

tighten the nut clockwise up to the WARNING


next alignment.
○It should be within 30 degrees. A loose axle nut can lead to an
○Loosen once and tighten again when accident resulting in serious in-
jury or death. Tighten the axle
the slot goes past the nearest hole.
nut to the proper torque and in-
stall a new cotter pin. j

• Check the rear brake (see Brakes


section).

Brakes
If you feel there is something wrong
when applying the brakes, have the
brake system checked by an autho-
rized Kawasaki dealer immediately.
A. Turn Clockwise
126 MAINTENANCE AND ADJUSTMENT

WARNING
Air in the brake lines diminish
braking performance and can
cause an accident resulting in
injury or death. If the brake lever
j or pedal feels mushy when it
is applied, there might be air in
the brake lines or the brake may
be defective. Have the brake
checked immediately by an au-
thorized Kawasaki dealer. A. Front Brake Fluid Reservoir
B. Lower Level Line

Brake Fluid Level Inspection • With the rear brake fluid reservoir
• With the front brake fluid reservoir
held horizontal, the brake fluid level
held horizontal, the brake fluid level
must be kept between the upper and
must be above the lower level line. lower level lines.
MAINTENANCE AND ADJUSTMENT 127

thickness of either pad lining is less


than below table, replace both pads
in the caliper as a set. Pad replace-
ment should be done by an authorized
Kawasaki dealer.
Lining Thickness Service Limit j
Front 1.0 mm (0.04 in.)
Rear 1.5 mm (0.06 in.)

A. Rear Brake Fluid Reservoir


B. Upper Level Line
C. Lower Level Line

• Iflower
the fluid level is lower than the
level line it may indicate that
the fluid is leaking. In this case, have
the brake system inspected by an au-
thorized Kawasaki dealer.

Brake Pad Wear Inspection


Inspect the brakes for wear. For each A. Front Brake Pads
B. Lining Thickness
front and rear disc brake caliper, if the C. Service Limit
128 MAINTENANCE AND ADJUSTMENT

• IfKawasaki
it does not, ask your authorized
dealer to inspect the front
brake light switch.
• Check the operation of the rear brake
light switch by depressing the brake
j pedal. The brake light should go on
after the proper pedal travel.

A. Rear Brake Pads


B. Lining Thickness
C. Service Limit

Brake Light Switches


Brake Light Switch Inspection
• Turn the ignition switch on.
A. Brake Pedal
• The brake light should go on when
the front brake is applied.
B. 10 mm (0.39 in.)

• Ifthetherearlightbrake
does not come on, adjust
light switch.
MAINTENANCE AND ADJUSTMENT 129

Brake Pedal Travel • To adjust the rear brake light switch,


move the switch up or down by turn-
10 mm (0.39 in.)
ing the adjusting nut.
Brake Light Switch Adjustment
• Remove the right front footpeg
bracket bolts. j
• Pull
ward.
the footpeg bracket a little bit out-

A. Rear Brake Light Switch


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

A. Right Front Footpeg Bracket Bolts


B. Right Front Footpeg Bracket
130 MAINTENANCE AND ADJUSTMENT

NOTICE Suspension System


To avoid damaging the electrical
connections inside the switch, Front Fork
be sure that the switch body
does not turn during adjustment.
j NOTICE
• Install the right front footpeg bracket. After riding on the normal road,
• Tighten the right front footpeg
bracket bolts to the specified torque.
the unpaved road and in the
rainy weather, clean off any dirt
Tightening Torque (grit, mud or insect etc.) that
Front Footpeg Bracket Bolts: stuck to inner tube before it
25 N·m (2.5 kgf·m, 18 ft·lb)
hardens. If the motorcycle keeps
running with the dirt stuck to the
inner tube, the oil seal will be
NOTE damaged and it causes the oil
○If a torque wrench is not available, leak.
this item should be serviced by an
authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT 131

Rear Shock Absorber

Spring Preload Adjustment


The spring preload adjuster on the
rear shock absorber has 5 positions. j
Standard
2nd position

• Inturnaccordance with the setting table,


the preload adjuster with the A. Spring Preload Adjuster
B. Wrench
wrench from the tool kit.
132 MAINTENANCE AND ADJUSTMENT

Setting Table
Rear Shock Absorber Spring Preload Setting
Softest setting Hardest setting
Standard
j limit limit
Adjuster Position 1st 2nd 5th
Spring Action Weak ←→ Strong
Setting Soft ←→ Hard
Load Light ←→ Heavy
Road Good ←→ Bad
Speed Low ←→ High
MAINTENANCE AND ADJUSTMENT 133

Wheels
Tire Pressure Inspection
• Remove the air valve cap.
• an accuratetiregauge.
Check the pressure often, using
j
• Make sure to install the air valve cap
securely.

NOTE
○Measure the tire pressure when the A. Tire Pressure Gauge
tires are cold (that is, when the mo-
torcycle has not been ridden more Tire Air Pressure (when cold)
than 1.6 km (1 mile) during the past Front 200 kPa (2.00 kgf/cm², 28 psi)
3 hours). Rear 225 kPa (2.25 kgf/cm², 32 psi)
○Tire pressure is affected by changes
in ambient temperature and altitude,
and so the tire pressure should be Tire Wear, Damage
checked and adjusted when your rid- As the tire tread wears down, the tire
ing involves wide variations in tem- becomes more susceptible to puncture
perature or altitude. and failure. An accepted estimate is
that 90% of all tire failures occur during
the last 10% of tread life (90% worn).
134 MAINTENANCE AND ADJUSTMENT

So it is false economy and unsafe to Minimum Tread Depth


use the tires until they are bald. Front — 1 mm (0.04 in.)
Tire Wear Inspection Under 130 km/h
2 mm (0.08 in.)
• Measure the depth of the tread with
a depth gauge, and replace any tire Rear
(80 mph)

j Over 130 km/h


that has worn down to the minimum 3 mm (0.12 in.)
(80 mph)
allowable tread depth.
• Visually inspect the tire for cracks
and cuts, replacing the tire in case of
bad damage. Swelling or high spots
indicate internal damage, requiring
tire replacement.

A. Tire Depth Gauge


MAINTENANCE AND ADJUSTMENT 135

WARNING
Tires that have been punctured
and repaired do not have the
same capabilities as undam-
aged tires and can suddenly fail,
causing an accident resulting j
in serious injury or death. Re-
place damaged tires as soon as
possible. To ensure safe han-
dling and stability, use only the
A. Crack or Cut recommended standard tires for
B. Nail
C. Swelling or High Spot
replacement, inflated to the stan-
D. Stone dard pressure. If it is necessary
to ride on a repaired tire, do not
• Remove any imbedded stones or
other foreign particles from the tread.
exceed 100 km/h (60 mph) until
the tire is replaced.
NOTE
NOTE
○Have the wheel balance inspected
whenever a new tire is installed. ○Most countries may have their own
regulations requiring a minimum tire
tread depth; be sure to follow them.
136 MAINTENANCE AND ADJUSTMENT

○When operating on public roadways, WARNING


keep maximum speed under traffic
Mixing tire brands and types can
law limits.
adversely affect handling and
Standard Tire cause an accident resulting in
Make, Type: injury or death. Always use the
j DUNLOP, SPORTMAX, GPR same manufacturer’s tires on
Front -300F N both front and rear wheels.
Size:
110/70R17 M/C 54H
Make, Type: WARNING
DUNLOP, SPORTMAX, GPR New tires are slippery and may
Rear -300 N cause loss of control and injury.
Size: A break-in period of 160 km (100
150/60R17 M/C 66H miles) is necessary to estab-
lish normal tire traction. During
break-in, avoid sudden and max-
imum braking and acceleration,
and hard cornering.
MAINTENANCE AND ADJUSTMENT 137

Battery Battery Maintenance


It is the owner’s responsibility to keep
The battery installed in this motorcy- the battery fully charged. Failure to do
cle is a sealed type, so it is not nec- so can lead to battery failure and leave
essary to check the battery electrolyte you stranded.
level or add distilled water. If you are riding your vehicle infre- j
NOTICE quently, inspect the battery voltage
weekly using a voltmeter. If it drops
Never remove the sealing strip, below 12.6 volts/12.8 volts (YTZ10S),
or the battery can be damaged. the battery should be charged using an
Do not install a conventional appropriate charger (check with your
battery in this motorcycle, or the Kawasaki dealer). If you will not be us-
electrical system cannot work ing the motorcycle for longer than two
properly. weeks, the battery should be charged
using an appropriate charger. Do not
(exept Colombia model) use an automotive-type quick charger
Make Siam Furukawa that may overcharge the battery and
Type FTX9-BS
damage it.
NOTE
(only on Colombia model)
Make Yuasa Battery
○Leaving the battery connected
causes the electrical components
Type YTZ10S
138 MAINTENANCE AND ADJUSTMENT

(clock etc.) to make the battery dis-


charged, resulting the over discharge
• The charger will keep the battery fully
charged until you are ready to re-
of the battery. In this case, the repair install the battery in the motorcycle
or replacement of the battery is not (see Battery Installation).
included in the warranty. If you do
j not drive for four weeks or more, dis-
connect the battery from the vehicle.
DANGER
Kawasaki-recommended chargers are: • Battery acid generates hydro-
gen gas which is flammable
Battery Mate 150-9 and explosive under certain
OptiMate 4 conditions. It is present within
Yuasa MB-2040/2060 a battery at all times, even in a
Christie C10122S
discharged condition. Keep all
flames and sparks (cigarettes)
If the above chargers are not avail-
away from the battery.
able, use equivalent one.
For more details, ask your Kawasaki • Wear eye protection when
working with a battery. In the
dealer.
event of battery acid contact
Battery Charging with skin, eyes, or clothing,
• Charge the battery following the in-
structions of your battery charger.
wash the affected areas imme-
diately with water for at least
five minutes. Seek medical at-
tention.
MAINTENANCE AND ADJUSTMENT 139

Battery Removal
• Make sure the ignition switch is
turned off.
• Remove the rider’s seat (see Seats
section in the GENERAL INFORMA-
TION chapter). j
• Remove the bolt and bracket.
• Disconnect the negative (–) cable
from the (–) terminal.
• Slide the red cap from the positive (+)
terminal. A. Bolt
• Disconnect the positive (+) cable
from the (+) terminal.
B.
C.
Bracket
Red Cap and (+) Terminal
D. (–) Terminal

• Take
case.
the battery out of the battery

• Clean the battery using a solution of


baking soda and water. Be sure that
the cable connections are clean.

Battery Installation
• Place the battery on the battery case.
140 MAINTENANCE AND ADJUSTMENT

• Connect the positive (+) cable to the


(+) terminal, and then connect the
Horizontal Adjustment
The headlight beam is adjustable
negative (–) cable to the (–) terminal. horizontally. If not properly adjusted
horizontally, the beam will point to one
NOTICE side rather than straight ahead.
j
Installing the negative (–) cable • Turn the horizontal adjuster in or out
until the beam points straight ahead.
to the (+) terminal of the battery
or the positive (+) cable to the (–)
terminal of the battery can seri-
ously damage the electrical sys-
tem.

• Put a light coat of grease on the ter-


minals to prevent corrosion.
• Cover
cap.
the (+) terminal with the red

• Install the removed parts.


A. Vertical Adjusters
B. Horizontal Adjusters
Headlight
Headlight aiming should be done by
an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT 141

Vertical Adjustment
The headlight beam is adjustable ver-
tically. 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 j
road close ahead, and the low beam
will blind oncoming drivers.
• Turn the vertical adjuster in or out to
adjust the headlight vertically.

NOTE
Fuses
○On high beam, the brightest point
Fuses are arranged in the fuse boxes
should be slightly below horizontal
with the motorcycle on its wheels and located behind the left side cover. The
the rider seated. Adjust the headlight main fuse is located under the fuel tank.
to the proper angle according to local If a fuse fails during operation, inspect
regulations. the electrical system to determine the
cause, and then replace it with a new
fuse of proper amperage.
If the fuse fails repeatedly, there is
something wrong with the electrical
142 MAINTENANCE AND ADJUSTMENT

system. Have the motorcycle checked WARNING


by an authorized Kawasaki dealer.
Substituting fuses can cause
The main fuse removal should be
wiring to overheat, catch fire
done by an authorized Kawasaki
and/or fail. Do not use any sub-
dealer.
stitute for the standard fuse.
j Replace the blown fuse with a
new one of the correct capacity,
as specified on the fuse boxes
and main fuse.

A. Fuse Boxes
B. Main Fuse

A. Normal
B. Failed
MAINTENANCE AND ADJUSTMENT 143

General Lubrication Apply grease to the following


Lubricate the points shown below, points
with either engine oil or regular grease, • (K) Clutch Inner Cable Upper End
in accordance with the Periodic Main- • (K) Throttle Inner Cable Upper Ends
tenance Chart or whenever the vehicle
(K): Should be serviced by an authorized j
has been operated under wet or rainy
Kawasaki dealer.
conditions.
Before lubricating each part, clean off
any rusty spots with rust remover and NOTE
wipe off any grease, oil, dirt, or grime. ○After connecting the cables, adjust
them.
Apply motor oil to the following
pivots
• Side Stand Cleaning
• Clutch Lever
• Rear Brake Pedal
Front Brake Lever
• General Precautions
Lubricate the following cables Frequent and proper care of your ve-
with a pressure cable luber hicle will enhance its appearance, opti-
• (K) Clutch Inner Cable mize overall performance, and extend
• (K) Throttle Inner Cables its useful life. Covering your vehicle
with a high quality, breathable vehicle
144 MAINTENANCE AND ADJUSTMENT

cover will help protect its finish from WARNING


harmful UV rays, pollutants, and re-
Build-up of debris or flammable
duce the amount of dust reaching its
material in and around the vehi-
surfaces.
cle chassis, engine, and exhaust
can cause mechanical problems
j and increase the risk of fire.
When operating the vehicle in
conditions that allow debris or
flammable material to collect in
and around the vehicle, inspect
the engine, electrical component
and exhaust areas frequently. If
debris or flammable materials
have collected, park the vehi-
cle outside and stop the engine.
Allow the engine to cool, then
remove any collected debris. Do
not park or store the vehicle in
an enclosed space prior to in-
specting for build-up of debris
or flammable materials.
MAINTENANCE AND ADJUSTMENT 145

• Be sure the engine and exhaust are


cool before washing.
• Take care when washing the head-
light lens and other plastic parts as
• When washing the vehicle, always
use a mild neutral detergent and wa-
they can easily be scratched.

ter. NOTE
• Avoid applying all harsh chemi- ○After riding in an area where the j
cals, solvents, degreaser, oil re- roads are salted or near the ocean,
mover, electrical contact cleaner, immediately wash your vehicle with
and household cleaning products cold water. Do not use warm water
such as ammonia-based window as it accelerates the chemical reac-
cleaners. They will damage or de- tion of the salt. After drying, apply
teriorate painted parts, plastic parts, a corrosion protection spray on all
rubber parts and other synthetic metal and chrome surfaces to pre-
parts including covers and headlight vent corrosion.
lens. ○Condensation may form on the inside
• Avoid applying degreaser to seals,
brake pads, and tires.
of the headlight lens after riding in
the rain, washing the vehicle or hu-
• Gasoline, brake fluid, and coolant
will damage the finish of painted and
mid weather. To remove the mois-
ture, start the engine and turn on the
plastic surfaces: wash them off im- headlight. Gradually the condensa-
mediately. tion on the inside of the lens will clear
• Avoid wire brushes, steel wool, and
all other abrasive pads or brushes.
off.
146 MAINTENANCE AND ADJUSTMENT

Radiator Matte Paint Parts


Clean off any obstructions with a
stream of low-pressure water.
• When washing the vehicle, always
use a mild neutral detergent and wa-
ter, or cleaners for matte paint.
NOTICE • The matte paint effect may be lost
j Using high-pressure water, as when the paint is excessively rubbed.
from a car wash facility, could • If any doubt, consult an authorized
Kawasaki dealer.
damage the radiator fins and
impair the radiator’s effective-
ness. Do not obstruct or deflect Plastic Parts
airflow through the radiator by After washing, use a soft cloth to
installing unauthorized acces- gently dry plastic parts. When dry,
sories in front of the radiator or treat the headlight lens and other non-
behind the cooling fan. Inter- painted plastic parts with an approved
ference with the radiator airflow plastic cleaner/polisher product.
can lead to overheating and con-
sequent engine damage.
MAINTENANCE AND ADJUSTMENT 147

NOTICE should be washed with a mild neu-


tral detergent and finished with a spray
Plastic parts may deteriorate
polish. Aluminum wheels, both painted
and break if they come in con-
and unpainted can be cleaned with
tact with chemical substances
special non-acid based wheel spray
or household cleaning products
cleaners. j
such as gasoline, brake fluid,
window cleaners, thread-locking Leather, Vinyl, and Rubber
agents, or other harsh chemi- If your vehicle has leather acces-
cals. If a plastic part comes in sories, special care must be taken.
contact with any harsh chemical Use a leather cleaner/treatment to
substance, wash it off immedi- clean and care for leather accessories.
ately with water and a mild neu- Washing leather parts with detergent
tral detergent, and then inspect and water will damage them, shorten-
for damage. Avoid using abra- ing their life.
sive pads or brushes to clean Vinyl parts should be washed with the
plastic parts, as they will dam- rest of the vehicle, then treated with a
age the part’s finish. vinyl treatment.
The sidewalls of tires and other rub-
ber components should be treated with
Chrome and Aluminum
a rubber protectant to help prolong their
Chrome and uncoated aluminum
useful life.
parts can be treated with a chrome/alu-
minum polish. Coated aluminum
148 MAINTENANCE AND ADJUSTMENT

NOTICE
Where to be Careful
Coin operated, high pressure
spray washers are not recom-
Avoid spraying water with any great
mended. Water may be forced
force near the following places.
into bearings and other compo-
j • Disc brake master cylinder and
caliper.
nents causing eventual failure
from rust and corrosion. Some
• Under the rider’s seat, left side cover
and fuel tank - if water gets into the
soaps are highly alkaline and
may leave a residue or cause
fuse box or battery, it can ground out
spotting.
the spark. When this happens the
vehicle will not operate properly and
the affected parts must be wiped dry. NOTE
○Abrasive cleanser or high pressure
washer will damage the surface fin-
ish on the bodywork.

Washing Your Vehicle

• Before washing, precautions must be


taken to keep water off the following
parts.
MAINTENANCE AND ADJUSTMENT 149

Muffler rear opening - cover with a detergent can damage parts of your
plastic bag. vehicle).
Ignition switch - cover the keyhole • Remove the plastic bag and tape.
with tape. • Use a soft cloth to dry your vehicle.
• Rinse your vehicle with cold water
from a garden hose to remove any
As you dry, inspect your vehicle for
chips and scratches. Do not let the j
loose dirt. water air dry as this can damage the
• Mix a mild neutral detergent (de- painted surfaces.
signed for motorcycles or automo-
biles) and water in a bucket. Use
• Carefully ride your vehicle at a slow
speed and apply the brakes several
a soft cloth or sponge to wash your times. This helps dry the brakes
vehicle. and restores them to normal operat-
• After washing, rinse your vehicle
thoroughly with clean water to re-
ing performance.

move any residue (residue from the


150 APPENDIX
APPENDIX

Storage
Whenever your motorcycle will not be in use for a long period, proper storage is
essential.
It consists of checking and replacing missing or worn parts; lubricating parts to
j ensure that they do not corrode and, in general, preparing the motorcycle so that
when the time comes to use it again, it will be in top condition.
See your authorized Kawasaki dealer for this service or do the following.
Preparation for Storage
Make sure the area is well ventilated and free from any source of flame.

DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous
gas. Inhaling carbon monoxide can cause serious brain injury or
death. DO NOT run the engine in enclosed areas. Operate only in a
well-ventilated area.
APPENDIX 151

WARNING
Gasoline is extremely flammable and can be explosive under certain con-
ditions, creating the potential for serious burns.

• Turn the ignition switch off.


• Make sure
Do not smoke.
• this includestheany
area is well ventilated and free from any source of flame or sparks;
appliance with a pilot light. j

WARNING
Gasoline is a toxic substance. Dispose of gasoline properly. Contact your
local authorities for approved disposal methods.

• Clean the entire vehicle thoroughly.


• engine oil.engine
Run the for about five minutes to warm the oil, shut it off, and drain the
(see Engine Oil section in the MAINTENANCE AND ADJUSTMENT
chapter)
152 APPENDIX

WARNING
Engine oil is a toxic substance. Dispose of used oil properly. Contact
your local authorities for approved disposal methods or possible recy-
cling.

• Put in fresh engine oil.


j • Removethethefuelspark
Empty from the fuel tank using a pump or syphon.
• spark plugs cannotplugs and add fogging oil into the combustion chambers. If the
be removed, take the motorcycle to an authorized Kawasaki
dealer.
• Set the motorcycle on a stand so that both wheels are raised off the ground. (If
this cannot be done, put boards under the front and rear wheels to keep damp-
ness away from the tire rubber.)
• 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 it where it will not be exposed to direct sunlight,
moisture, or freezing temperatures. During storage it should be given a slow
charge (one ampere or less) about once a month. Keep the battery well charged
especially during cold weather.
• Tie plastic bag over the muffler to prevent moisture from entering.
• Put a cover over the motorcycle to keep dust and dirt from collecting on it.
APPENDIX 153

Preparation after Storage


• Remove the plastic bag from the muffler.
• Fill the fuel battery
Charge the if necessary and install the battery in the motorcycle.
• Check all thetank with fresh fuel.
• Lubricate the points listed in the Daily Checks section.
• pivots, bolts, and nuts.

j
Troubleshooting Guide
If a Problem Occurs
Performing daily checks and periodic maintenance prevents unexpected troubles
from occurring. In case of a breakdown, take emergency measures and contact
your Kawasaki dealer to request repair. For safety, inspection and maintenance
should be done within your knowledge and ability. If you are not confident in com-
pleting an inspection or maintenance, ask an authorized Kawasaki dealer to do the
work.
154 APPENDIX

WARNING
• When carrying out an inspection, follow the precautions below.
• Secure a place where you can work in safety without obstructing traffic
around you. Do not carry out any inspection unless it is safe.
• Support the motorcycle on a firm, level surface with the stand.
• The engine and muffler will become hot during operation. To avoid
burns etc., do not touch the hot engine or muffler just after the engine
j has stopped.
• Exhaust gas contains harmful substances such as carbon monoxide.
Do not run the engine in an enclosed garage or poorly ventilated area.
• Wait until the engine cools down before carrying out inspection and
maintenance or replenishing fuel. Make sure the area is well ventilated
and free from any source of flame or sparks. Do not place any appliance
with a pilot light nearby.
• If a test ride is needed, ride in a safe area and pay close attention to
traffic around you.

When any warning indicators go on or blink, have the motorcycle inspected by


an authorized Kawasaki dealer immediately.
If the Engine Does Not Start
When the engine turns over but the engine does not start, inspect as follows.
APPENDIX 155

• Check the fuel level in the fuel tank. If only a small quantity of fuel remains in
the bottom, replenish the fuel tank. (Fuel in the tank cannot be completely con-
sumed.)
• Leaving the motorcycle unused for a long time may cause fuel in the tank to
deteriorate. In that case, ask an authorized Kawasaki dealer for inspection.
• When the engine warning indicator on the meter goes on and stays on, there may
be a problem with the fuel injection system. Ask an authorized Kawasaki dealer
for inspection and maintenance. j
• The motorcycle is equipped with a vehicle-down sensor which stops the engine
automatically when the motorcycle falls down. When the starter button is pressed
after the motorcycle has fallen down, the engine does not start. To start the en-
gine, switch the ignition key to the position and then back to the position.
If the engine will not start after completing the above inspection and maintenance,
there may be something wrong with another system such as the ignition system.
Ask an authorized Kawasaki dealer for inspection and maintenance.

When the starter motor does not rotate, inspect as follows.


• Check the position of the engine stop switch. Push the engine stop switch in the
position if it is in the position.
• Make sure that the gear position is in the neutral position. If not, shift the trans-
mission into neutral.
156 APPENDIX

• Inspect the fuse condition. If any fuse has blown, replace it with a new one of the
same amperage.

WARNING
Substituting fuses can cause wiring to overheat, catch fire and/or fail. Use
only standard fuses of the correct capacity and specifications.
j
• Check the battery cable connections etc. (see page 139). If necessary, tighten
the connecting bolts to securely connect them.
• Inor case of slow blinking of the turn signal lights, low volume of the horn sound,
when you press the starter button and hear a click but the starter motor does
not rotate, battery charging status is not good. Refresh the battery’s charge (see
page 138) and check if the starter motor rotates.
• Even after a refresh charge, if the starter motor stops rotating the engine properly,
the battery may have deteriorated. Have the battery inspected by an authorized
Kawasaki dealer.
If the starter motor will not start after completing the above inspection and mainte-
nance, there may be something wrong with another part such as the starter motor.
Ask an authorized Kawasaki dealer for inspection and maintenance.
APPENDIX 157

If the Engine Stalls or Runs Poorly


• Check the fuel level in the fuel tank. If only a small quantity of fuel remains,
replenish the fuel tank. (Fuel in the tank cannot be completely consumed.)
• Raise the side stand fully up before starting the engine. (If you try to move off
with the side stand is still down, the engine will stop.)
• Make
page 68).
sure that correct fuel is used. If not, replace the fuel the correct type (see

• Due to too much play in the clutch lever, the clutch may not disengage. If there
is any problem, adjust the clutch lever free play correctly.
j

• Inor case of slow blinking of the turn signal lights, low volume of the horn sound,
when you press the starter button and hear a click but the starter motor does
not rotate, the battery is discharged. Check the connections of the battery termi-
nals for looseness (see page 139). If necessary, tighten the bolts to remove the
looseness. If the above methods cannot solve the problems, ask an authorized
Kawasaki dealer for inspection and maintenance.
• If the warning indicator goes on and coolant temperature warning indicator is dis-
played, the engine may have overheated. Check the coolant level in the reserve
tank after the engine cools down. If the coolant quantity is less than the lower
level, replenish the coolant or soft water up to the upper level (see page 111). Ask
an authorized Kawasaki dealer to identify the cause of the overheat immediately.
• When the engine warning indicator on the meter goes on and stays on, there
is something wrong with the fuel injection system. Ask an authorized Kawasaki
dealer for inspection and maintenance.
158 APPENDIX

If the engine stalls after completing the above inspection and maintenance, there
may be something wrong with other system. Ask an authorized Kawasaki dealer
for inspection and maintenance.

Owner Satisfaction
(For Products Sold in Australia Only)
j Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki
Motors Pty., Ltd. If you have a problem concerning warranty or service, please take
the following action:

Contact the owner and/or service manager of your authorized Kawasaki dealer.
Fully explain your problem and ask for assistance in resolving the situation. The
OWNER of the dealership is an independent business person and is concerned
with your satisfaction and your future business. For this reason the owner is in the
best position to assist you. Also, all warranty and service matters are handled and
resolved through the authorized Kawasaki dealer network.
APPENDIX 159

If you are unsatisfied after working with your Kawasaki dealer and feel you still
require further assistance, WRITE to the address below. Please be certain to pro-
vide the model, product identification number, mileage or hours of use, accessories,
dates that events occurred and what action has been taken by both you and your
dealer. Include the name and address of the dealership. To assist us in resolving
your inquiry, please include copies of related receipts and any other pertinent infor-
mation including the names of the dealership personnel with whom you have been
working in the resolution of your problem. j
Upon receipt of your WRITTEN correspondence we will contact the dealership and
work with them in resolving your problem.

In order to provide a permanent record, all warranty and service resolutions take
place only through WRITTEN correspondence.
160 APPENDIX

Please send your correspondence to:

Customer Relations:
Technical Services Department
KAWASAKI MOTORS Pty., Ltd.
LOCKED BAG 802,
ERMINGTON. NSW. 1700.
j A.C.N. 002 840 315.
E-mail: info@Kawasaki.com.au

Environmental Protection
To help preserve the environment, properly discard used batteries, tires, oils and
fluids, or other vehicle components that you might dispose of in the future. Con-
sult your authorized Kawasaki dealer or local environmental waste agency for their
proper disposal procedure. This also applies to disposal of the entire vehicle at the
end of its life.
MAINTENANCE RECORD 161
MAINTENANCE RECORD

Owner Name.......................................................................................
Address ..............................................................................................
Phone Number ...................................................................................
Engine Number ..................................................................................
Vehicle Number..................................................................................
Key Code ............................................................................................ j
Selling Dealer Name ..........................................................................
Phone Number ...................................................................................
Warranty Start Date ...........................................................................
Note: Keep this information and a spare key in a secure location.

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading
162 MAINTENANCE RECORD

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

j
MAINTENANCE RECORD 163

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

j
164 MAINTENANCE RECORD

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

j
MAINTENANCE RECORD 165

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading

j
166 MAINTENANCE RECORD

Odometer
Date Maintenance Performed Dealer Name Dealer Address
Reading