Kawasaki Klx150L Manual
Transcript of Kawasaki Klx150L Manual
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Motorcycle
Owner's Manua
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Quick Reference Guide
This Quick Reference Guide willassist you in finding the informationyou're looking for.
SAFETY INFOR
GENERAL INFO
HOW TO RIDE T
MAINTENANCE
APPENDIX
MAINTENANCE
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Whenever you see the symbolsshown below, heed their instructions!Always follow safe operating and main-
tenance practices.
DANGER
DANGER indicates a hazardous
situation which, if not avoided,will result in death or serious in-jury.
WARNINGWARNING indicates a hazardoussituation which, if not avoided,could result in death or serious
i j
NOT
NOTE indicates inhelp or guide you service of the vehi
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NOTICE
THIS PRODUCT HAS BEEN MAN-
UFACTURED FOR USE IN AREASONABLE AND PRUDENTMANNER BY A QUALIFIED OP-ERATOR AND AS A VEHICLE ON-LY.
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Foreword
Congratulations on your purchase of a new Kawasaki motorcytorcycle is the product of Kawasaki's advanced engineering, eand continuous striving for superior reliability, safety and perform
Please read this Owner's Manual carefully before riding
thoroughly familiar with the proper operation of your motorcycletures, capabilities, and limitations. This manual offers many safpurpose is not to provide instruction in all the techniques and ska motorcycle safely. Kawasaki strongly recommends that all ophicle enroll in a motorcycle rider training program to attain aware
and physical requirements necessary for safe motorcycle operat
To ensure a long, trouble-free life for your motorcycle, give it thmaintenance described in this manual. For those who would likformation on their Kawasaki Motorcycle, a Service Manual is
h f th i d K ki t l d l Th
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Keep this Owner's Manual aboard your motorcycle at all tifer to it whenever you need information.
This manual should be considered a permanent part should remain with the motorcycle when it is sold.
All rights reserved. No part of this publication may be repror written permission.
This publication includes the latest information availableHowever, there may be minor differences between the actutions and text in this manual.
All products are subject to change without prior notice or o
KAWASAKI HEAVY INDUSTRIES, Motorcycle & Engine Company
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TABLE OF CONTENTS
SAFETY INFORMATION ..................... 10
Read Owner's Manual ....................... 10
Training .............................................. 10
Daily Checks and Periodic Mainte-
nance .............................................. 10Loading and Accessories Information
11
Passenger ...................................... 12
Baggage and Luggage .................. 13
Accessories ................................... 13Other Load ..................................... 14
If You are Involved in an Accident ..... 14
Safe Operation ................................... 15
Carbon Monoxide Hazard .............. 15
F li 16
GENERAL INFORMA
Specifications ........
Serial Number Locat
Location of Labels ..
Location of Parts ....Meter Instruments ..
Indicators ...........
Speedometer/Odo
Keys .......................
Ignition Switch/SteerRight Handlebar Sw
Left Handlebar Switc
Fuel Tank Cap ........
Fuel ........................
F l R i t
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Rear View Mirror ................................ 51
HOW TO RIDE THE MOTORCYCLE .. 53
Break-In ............................................. 53Starting the Engine ............................ 55
Jump Starting ..................................... 58
Moving Off .......................................... 60
Shifting Gears .................................... 61
Braking ............................................... 62
Stopping the Engine .......................... 63
Stopping the Motorcycle in an Emer-
gency .............................................. 64
Parking ............................................... 65
MAINTENANCE AND ADJUSTMENT 67
Daily Checks ...................................... 69
Additional Considerations for Off
Road Operation .............................. 72
P i di M i t 73
Clutch .............
Drive Chain ....
Brakes ............Brake Light Sw
Suspension Sy
Front Fork ..
Rear Shock A
Wheels ...........Battery ............
Headlight ........
Fuses .............
General Lubrica
Cleaning Your M
General Prec
Washing You
APPENDIX .......
St
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SAFETY INFORMATION
Read Owner's Manual
Read this Owners Manual carefully
before riding so that you will be thor-oughly familiar with the proper opera-tion of your motorcycles controls, itsfeatures, capabilities, and limitations.This manual offers many safe riding
tips, but its purpose is not to provide in-struction in all of the techniques andskills required to ride a motorcyclesafely.
T i i
techniques necessacycle operation.
Daily Checks a
Maintenance
It is important to cycle properly mainriding condition. Ins
cycle before every all periodic maintenaChecks section andtenance section in thAND ADJUSTMENT
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WARNING
Failure to perform these checksor to correct a problem before op-eration may result in seriousdamage or an accident. Always
perform daily checks before op-eration.
To ensure your motorcycle is serv-iced using the latest servicing informa-
tion, it is recommended that anauthorized Kawasaki Dealer performsthe periodic maintenance as directedin the Owner's Manual.
If you notice any irregular operating
diti h t l th
Loading an
Information
Incorrect loastallation or or modificatcycle may resing condition
motorcycle, overloaded alowed these i
Maximum Load
W i ht f id
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application of accessories. In somecases, improper installation or use of
accessories, or motorcycle modifica-tion, will void the motorcycle warranty;can negatively affect performance,stability and safety; and can even be il-legal.
In selecting and using accessories,and in loading the motorcycle, you arepersonally responsible for your ownsafety and the safety of other persons
involved.NOTE
Kawasaki Parts and Accessorieshave been specially designed for
K ki t l W
forces, you must takcarrying cargo, pas
fitting additional acclowing general guidprepared to assist ydeterminations.
Passenger1. Never carry more
ger.2. The passenger
the pillion.3. Any passenger
oughly familiar weration. The pascontrol of the mot
iti i d
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4. Do not carry passengers unlesspassenger footpegs are installed.
Instruct any passenger before rid-ing to keep his or her feet on thepassenger footpegs and hold on tothe operator or seat strap. Do notcarry a passenger unless he or she
is tall enough to reach the footpegswith their feet.
Baggage and Luggage
1. All baggage should be carried aslow as possible to reduce the effecton the motorcycle's center of grav-ity. Baggage weight should also bedistributed equally on both sides of
h l A id i b
security as while the m
and adjust as3. Do not carry
on a luggagelight items, afect handlin
weight distriic forces.
Accessories
1. Do not instabaggage thaance of the that you hafected any
d l
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of the steering assembly and canresult in an unsafe riding condition.
3. Fairings, windshields, backrests,and other large items have the ca-pability of adversely affecting stabil-ity and handling of the motorcycle,not only due to their weight, but also
due to the aerodynamic force actingon these surfaces while the motor-cycle is in operation. Poorly de-signed or installed items can resultin an unsafe riding condition.
Other Load
1. This motorcycle is not intended tobe equipped with a sidecar or to be
that Kawasaki csponsibility for t
unintended use o2. Furthermore, an
on motorcycle coby the use of sucnot be remedied u
If You are InvoAccident
Make sure of youDetermine the seveand call for emergneeded. Always folland regulations if an
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function. Ride slowly and cautiously -your motorcycle may have suffered
damage that is not immediately appa-rent. Have your motorcycle thoroughlychecked at a Kawasaki dealer as soonas possible.
Safe Operation
The following should be carefully ob-served for safe and effective vehicleoperation.
Carbon Mono
Exhaust gasmonoxide, a
poisonous gmonoxide cbrain injury oDo not run thareas. Operat
tilated area.
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Fueling
WARNING
Gasoline is extremely flammableand can be explosive under cer-
tain conditions.To avoid a possible fire or explo-sion, turn the ignition switch toOFF. Do not smoke. Make surethe area is well ventilated and
free from any source of flame orsparks; this includes any appli-ance with a pilot light.
Protective Gear a
HelmetKawasaki strongly
the operator and phelmet even if thisquirement.- Make sure that yo
rectly and is prope- Choose a motor
meets the safety
ble to your countrcycle dealer tonecessary.
Eye Protection
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GlovesWear gloves which have suitable
protection for your hands, especiallyagainst abrasion.
ClothingWear protective clothing.
- Wear bright, highly visible clothingthat allows freedom of movement tosuit your riding style.
- Always wear a long- sleeved jacketand long trousers which are abrasion
resistant and keep you warm.- Avoid wearing clothes which have
loose cuffs or other fastenings whichcould interfere with the controls ofyour motorcycle.
Safe Riding T
Keep Hands oWhen riding a
on the handlebafootpegs. Remothe handlebarspegs while ridinyou remove evyou reduce youmotorcycle.
Look Over YoBefore chang
your shoulder tclear. Do not rview mirror; yo
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control, especially when riding in wetconditions or on loose road surfaces,
when the ability to maneuver will be re-duced.
Select Correct Gear SpeedsWhen going up steep slopes, shift to
a lower gear so that there is power tospare rather than overloading the en-gine.
Use Both Front and Rear Brakes
When applying the brakes, use boththe front and rear brakes. Applying on-ly one brake for sudden braking maycause the motorcycle to skid and losecontrol.
Riding in Wet ConRely more on the
vehicle speed and and rear brakes. Theso be used judiciouding the rear wheacceleration or dece
Braking performanin wet conditions. Cslow speed and apperal times to help
them to normal operLubricate the drivweather riding to prerosion.
Ride Prudently
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Riding on Rough RoadsExercise caution, slow down, and
grip the fuel tank with the knees forbetter stability.
AccelerationWhen quick acceleration is neces-
sary to pass another vehicle, shift to alower gear to obtain the necessarypower.
Downshifting
To avoid engine damage and rearwheel lock-up do not downshift at highrpm.
Avoid Unnecessary Weaving
Additional Co
High Speed O
Handling cha
torcycle at hifrom those yat legal highattempt high less you have
training and skills.Do not operapublic roads.
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SteeringLooseness in the steering can cause
loss of control. Check to see that thehandlebars turns freely but has noplay.
Tires
High speed operation is hard ontires, and good tires are crucial for saferiding. Examine their overall condition,inflate them to the proper pressure,and check the wheel balance.
FuelHave sufficient fuel for the high fuel
consumption during high speed opera-tion.
Electrical EquipmMake sure that t
brake light, turn sigwork properly.
MiscellaneousMake sure that all
tight and that all sare in good condition
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GENERAL INFORMATION
Specifications
PERFORMANCE
Maximum Horsepower 8.6 kW (12 PS) at 8 000 r/min (Maximum Torque 11.3 Nm (1.15 kgfm, 100 inlb
Minimum Turning Radius 2.1 m (82.7 in.)
DIMENSIONS
Overall Length 2 080 mm (81.9 in.)
Overall Width 770 mm (30.3 in.)Overall Height 1 145 mm (45.1 in.)
Wheelbase 1 340 mm (52.8 in.)
Road Clearance 300 mm (11.8 in.)Curb Mass 115 kg (253.6 lb)
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FRAME
Caster 26.5
Trail 107 mm (4.21 in.)Tire Size: Front 2.75-21 45P
Rear 4.10-18 59P
Rim Size: Front 21 1.60
Rear 18 1.85Fuel Tank Capacity 7.0 L (1.8 US gal)
Brake Fluid: Front DOT3 or DOT4
Rear DOT3 or DOT4
ELECTRICAL EQUIPMENT
Battery 12 V 6 AhHeadlight: High Beam 12 V 35 W
Low Beam 12 V 35 W
Tail/Brake Light 12V 5 W/21 W
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Specifications are subject to change without notice, and may country.
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Serial Number Locations
The engine and frame serial numbers are used to registeare the only means of identifying your particular machine fmodel type. These serial numbers may be needed by youparts. In the event of theft, the investigating authorities wi
as well as the model type and any peculiar features of youthem identify it.
Engine No. Frame No.
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Location of Labels
All warning labels which are on yourvehicle are repeated here. Read labelson your vehicle and understand themthoroughly. They contain informationwhich is important for your safety andthe safety of anyone else who may op-erate your vehicle. Therefore, it is veryimportant that all warning labels be onyour vehicle in the locations shown. If
any label is missing, damaged, orworn, get a replacement from your Ka-wasaki dealer and install it in the cor-rect position.
1. Brake Fluid (Fro
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2. Brake Fluid
3. Battery Po4. Rear Shoc
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5. Fuel Notice
6. Important Drive 7. Tire and Load D
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1)
2)
3)
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4) 5)
1. Read Owner's M2. Unleaded gasol3. Octane rating of
43
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6)
1. Read Owner's Manual, see page 102. Drive chain slack, see page 94
7)
1. Read Owne2. Tire air pre3. Front tire s
page 1074. Rear tire s
page 1075. Maximum
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Location of Parts
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1. Front Fork 12. Tying Hook (Bo
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1. License Plate Light 9. Front Brake Light Sw
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Meter Instruments
1.Speedometer2.Odometer
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Indicators
1. Turn Signal Indicator (Green)2. High Beam Indicator (Blue)
3. Neutral Indicator (Green)
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Indicator Initial Operation
When the ignition switch is turnedon, all indicators go on/off as shown inthe table. If any indicator does not op-erate as shown, have it checked by an
ON
ON: When igni: After a few
: When eng: Goes on.: Goes off.
G
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*: The numbers in this column corre-sponds to reference numbers on page
36.Indicators
*No. Indica-
tors Status
1
When the turn signalswitch is pushed to theleft or right, this indicatorblinks.
2
When the headlight is on
high beam, this indicatorgoes on.
3
When the transmission isin neutral, this indicatorgoes on.
Speedometer/Od
A. SpeedometerB. Odometer
Speedometer
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of 100 meter. This meter cannot be re-set.
Keys
This motorcycle has a combinationkey, which is used for the ignition
switch, steering lock and fuel tank cap.Blank keys are available at your Ka-wasaki dealers. Ask your dealer tomake any additional spare keys youmay need, using your original key as a
master.
Ignition Switch/SteeringLock
A. Ignition Switch/
B. ON positionC. OFF positionD. LOCK position
ON Engin
ment
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NOTE
The meter, tail, license plate and city
lights are on whenever the ignitionkey is in the ONposition. To avoidbattery discharge, always start theengine immediately after turning theignition key to ONposition.
The headlight is on only while the en-gine is running.
Steering LockTo lock the steering
1. Turn the handlebars fully to the left.2. With the ignition key in the OFF
position, push down the key.3. Turn the ignition key to LOCK po-
Right Handleb
A. Engine Stop SwitchB. Starter Button
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The engine stop switch is for emer-gency use. If required, move the switch
to the position.NOTE
Although the engine stop switchstops the engine, it does not turn off
all the electrical circuits. Ordinarily,the ignition switch should be used tostop the engine.
Starter Button
The starter button operates the elec-tric starter when the transmission is inneutral.
Refer to the Starting the Engine sec-tion in the HOW TO RIDE THE MO-
Left Handle
A. Dimmer SwitchB. Turn Signal SwiC. Horn Button
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Low beam.......( )
Turn Signal SwitchWhen the turn signal switch is turnedto the left ( ) or right ( ), thecorresponding turn signals blink onand off.
To stop blinking, push the switch in.
Horn ButtonWhen the horn button is pushed, the
horn sounds.
Fuel Tank Cap
To open the fuel tank cap, insert theignition key into the fuel tank cap and
NOT
The fuel tank cap
without the key inscannot be removelocked properly.
Do not push on thcap, or the cap can
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Fuel
Fuel Requirement
Your Kawasaki engine is designed touse only unleaded gasoline with a min-imum octane rating shown below.
Never use gasoline with an octane rat-ing lower than the minimum specifiedby Kawasaki to prevent severe enginedamage.
The octane rating of a gasoline is ameasure of its resistance to detonationor knocking. The term commonlyused to describe a gasolines octanerating is the Research Octane Number
N
If engine knooccurs, use gasoline of aing. If this cocontinue, it c
gine damageimportant. Funot meetingspecificationssatisfactory
ating problemthe use of poommended fered under yo
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equal to or higher than that shown inthe table.
Fuel Type Unleaded Gasoline
Ethanol Content E10 or less
Minimum OctaneRating
Research OctaneNumber (RON) 91
NOTICE
Do not use any fuel that containsmore ethanol or other oxygen-ates than specified for E10 fuel*in this vehicle. Damage to the en-gine and fuel system, or enginestarting and/or performance
Filling the Tank
Avoid filling the twhere heavy dust the fuel does not get
A. Tank Cap
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WARNING
Gasoline is extremely flammableand can be explosive under cer-tain conditions, creating the po-tential for serious burns. Turn theignition switch off. Do not smoke.
Make sure the area is well venti-lated and free from any source offlame or sparks; this includesany appliance with a pilot light.Never fill the tank completely tothe top. If the tank is filled com-pletely to the top, heat may causethe fuel to expand and overflowthrough the vents in the tank cap.
N
Certain ingremay cause page. Be extrafuel during re
Fuel TapThe fuel tap
ON, OFF annormal operatio
to the ONposwith the tap in last 1.6 L (0.42used by turningRESposition.
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A. Fuel Tap
B. ON positionC. OFF positionD. RES (Reserve) position
With the fuel tap in the ONor RESposition fuel flows to carburetor only
for maintenance anthe motorcycle is sto
NOTSince riding distan
on RES, refuel portunity.
Make sure that thturned to ONposthe fuel tank.
WAR
Practice operatinwith the motorcyprevent an accidbe able to opera
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Side Stand
The motorcycle is equipped with theside stand.
A. Side Stand
stand fully up btorcycle.
The motorcyside stand swsigned so tha
start if the trand the side s
Seat
Seat Removal
Remove the bClear the pro
side cover on
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A. Bolt (Right Side)
B. Projection (Right Side)C. Right Side Cover
A. Bolt (Left Side)
B. Projection (Left Side)C. Left Side Cover
Remove the boltfree the seat strap
Remove the bolt
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A. Bolt and Washer
B. Seat StrapC. Bolt (Both Sides)D. Seat
Seat Installation
Insert the seat hooks into the stop-
A. Seat Hooks
B. StoppersC. Fuel TankD. Frame
Install the seand tighten th
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A. Projection (Both Sides)
B. Grommet (Both Sides)C. Side Cover (Both Sides)
Tighten the bolt on both sides.
A. Tying Hooks
Tool Kit Bag/T
The tool kit is stobag.
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A. Tool Kit
B. Tool Kit Bag
Rear View Mirror
Rear View Mirror Adjustment
the upper heand turn the s
Tighten the (locknut).
The upper he
is left-hand th
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A. Rear View Mirror
B. StayC. Rubber BootD. Upper Hexagonal Area (Locknut)E. Lower Hexagonal Area
HOW TO RI
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HOW TO RIDE THE MOTORCY
Break-In
The first 1 600 km (1 000 miles) that the motorcycle is rithe break-in period. If the motorcycle is not used carefully
may very well end up with a broken down instead of a after a few thousand kilometers.
The following rules should be observed during the break-i
The table shows maximum recommended speed in kbreak-in period.
Gear position1st 2nd
Distance traveled
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NOTE
When operating on public roadways, keep maximum speed u
its.
Do not start moving or race the engine immediately after staengine is already warm. Run the engine for two or three minutgive the oil a chance to work up into all the engine parts.
Do not race the engine while the transmission is in neutral.
WARNING
New tires are slippery and may cause loss of control and in
A break-in period of 160 km (100 miles) is necessary to etire traction. During break-in, avoid sudden and maximumceleration, and hard cornering.
In addition to the above, at 1 000 km (600 miles) it is extremely
HOW TO RI
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Starting the Engine
Turn the fuel tap lever to ON posi-tion.
A. Engine Stop SwB. Starter Button
Turn the ignition.
Make sure tneutral.
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A. Neutral Indicator (Green)B. Ignition SwitchC. ON position
If the engine is cold, pull out thechoke lever all the way.
A. Choke Lever
NOT
When the engine on hot days [highF)], do not use th
l t h l
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NOTICE
Do not operate the starter contin-uously for more than 5 seconds,or the starter will overheat andthe battery power will drop tem-porarily. Wait 15 seconds be-
tween each operation of thestarter to let it cool and the bat-tery power recover.
NOTEIf the engine is flooded, crank the en-
gine over with the throttle fully openuntil the engine starts.
The motorcycle is equipped with a
clutch lever stand is fully u
A. Clutch LeverB. Starter Lockout
When the e
NOTE lt b t b tt
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NOTE
If you drive the motorcycle before
the engine is warmed up, release thechoke lever as soon as you startmoving.
If the choke lever is left on too longafter the engine is warm, it will cause
the spark plug to foul, and poor gasmileage.
NOTICE
Do not let the engine idle longerthan five minutes, or engine over-heating and damage may occur.
volt booster battery may be used to start
DA
Battery acid genegas which is flamplosive under cer
It is present withitimes, even in a ddition. Keep all fla(cigarettes) awaytery. Wear eye pworking with a event of battery askin, eyes, or cloaffected areas im
Remove the seat (see Seat sectionHOW TO RI
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Remove the seat (see Seat sectionin the GENERAL INFORMATIONchapter).
Slide the cap from the positive (+)terminal (see Battery section in theMAINTENANCE AND ADJUST-MENT chapter).
Connect a jumper cable from thepositive (+) terminal of the boosterbattery to the positive (+) terminal ofthe motorcycle battery.
NOTICE
Be careful not to contact thejumper cable slip on the positivebattery terminal to the frame, or it
A. Motorcycle BattB. From Booster BC. Unpainted MetaD. From Booster B
nal
Connect ano
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DANGER
Batteries contain sulfuric acidthat can cause burns and pro-duce hydrogen gas which ishighly explosive. Do not makethis last connection at the fuel
system or battery. Take care notto touch the positive and nega-tive cables together, and do notlean over the battery when mak-ing this last connection. Do not
connect to a frozen battery. Itcould explode. Do not reverse po-larity by connecting positive (+)to negative (), or a battery explo-sion and serious damage to the
NOT
Do not operate thuously for more or the starter withe battery poweporarily. Wait 1
tween each opstarter to let it cotery power recove
After the engine hnect the jumper cthe negative () ctorcycle first.
Install the removed
Open the throttle a little and start to designed so tHOW TO RI
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Open the throttle a little, and start tolet out the clutch lever very slowly.
As the clutch starts to engage, openthe throttle a little more, giving theengine just enough fuel to keep itfrom stalling.
designed so tstart if the trand the side s
Shifting Ge
Close the throclutch lever.
Shift into thegear.
Vehicle speed when shi
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WARNING
Downshifting at high speed canmake the rear wheel skid andcause an accident resulting in se-vere injury or death, as well ascause the engine to overrev and
damage it. When shifting down toa lower gear, do not shift at sucha high speed that engine rpmjumps excessively. Downshift atthe vehicle speeds shown in the
table in this section.
Open the throttle part way, while re-leasing the clutch lever.
Vehicle speed when shi
Shifting down
5th4th 4th3rd
3rd2nd
2nd1st
Braking
Close the throttle c
the clutch engagshifting gears) so help slow down the
Shift down one geyou are in 1st gea
necessary to keep the engine from
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necessary to keep the engine fromstalling.
Never lock the brakes, or it will causethe tires to skid. When turning a cor-ner, it is better not to brake at all. Re-duce your speed before you get intothe corner.
For emergency braking, disregarddownshifting, and concentrate on ap-plying the brakes as hard as possiblewithout skidding.
A. Rear Brake Ped
Stopping th
Close the thro Shift the trans
St i th M t l i2 During removal
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Stopping the Motorcycle inan Emergency
Your Kawasaki Motorcycle has beendesigned and manufactured to provideyou optimum safety and convenience.However, in order to fully benefit fromKawasaki's safety engineering andcraftsmanship, it is essential that you,the owner and operator, properly main-tain your motorcycle and become thor-
oughly familiar with its operation.Improper maintenance can create adangerous situation known as throttlefailure. Two of the most commoncauses of throttle failure are:
2. During removal dirt is allowed tocarburetor.
In an emergencythrottle failure, youstopped by applyindisengaging the clut
ping procedure is instop switch may beengine. If the engused, turn off the igstopping the motorcy
P ki
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Parking
WARNING
Operating or parking the vehiclenear flammable materials cancause a fire, and can result inproperty damage or severe per-sonal injury.Do not idle or park your vehicle inan area where tall or dry vegeta-
tion, or other flammable materialscould come into contact with themuffler or exhaust pipe.
The engine aget extremelyoperation anburns.Never touch
haust pipe, oeration or engine.
Shift the traand turn the igsition.
Support the level surface w
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If parking inside a garage or otherstructure, be sure it is well ventilatedand the motorcycle is not close toany source of flame or sparks; thisincludes any appliance with a pilotlight.
WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions, creating the po-
tential for serious burns. Turn theignition switch to OFF. Do notsmoke. Make sure the area is wellventilated and free from anysource of flame or sparks; this in-
MAINTENANCE AND ADJUST
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MAINTENANCE AND ADJUST
The maintenance and adjustments outlined in this chapteaccordance with the Daily Checks and Periodic Maintenacycle in good running condition and to reduce air pollutionance is vitally important and must not be neglected.
WARNING
Failure to perform these checks or to correct a problemay result in serious damage or an accident. Always pbefore operation.
With a basic knowledge of mechanics and the proper useable to carry out many of the maintenance items describelack proper experience or doubt your ability, all adjustmentspair work should be completed by a qualified technician
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DANGER
Exhaust gas contains carbon monoxide, a colorless, odogas. Inhaling carbon monoxide can cause serious brain DO NOT run the engine in enclosed areas. Operate only in area.
NOTE
If a torque wrench is not available, the maintenance items wcific torque value should be serviced by an authorized Kawasa
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Daily Checks
Check the following items each day before you ride. The tand habitual performance of these checks will help ensure y
If any irregularities are found during these checks, refer AND ADJUSTMENT chapter or see your dealer for the actio
motorcycle to a safe operating condition.
Operation
Fuel
Adequate supply in tank, no leaks
Engine oil
Oil level in the operating range (grid area) on the dipstick
Tires
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Operation
Bolts, nuts and fastenersCheck for loose and/or missing bolts, nuts and fasteners
Steering
Action smooth but not loose from lock to lock
No binding of control cables
Brakes
Brake pad wear
Brake fluid level
No brake fluid leakage
Throttle
Throttle grip free play
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Operation
Engine stop switchStops engine
Side stand
Return to its fully up position by spring tension
Return spring not weak or not damaged
Rear view mirrors
Rear view sight
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Additional Considerations for Off Road Opera
Brakes:The importance of reliable brakes is obvious. Check tcorrectly adjusted and functioning properly.
Steering:Looseness in the steering can cause loss of controlthe handlebars turns freely but has no play.
Tires: Due to the extra stress to the tires on rough roads, btheir overall condition, and inflate to the proper pressure.Drive Chain:When not adjusted properly, the severe stress o
cause damage to the sprockets and cause the chain to be thrchain slack and alignment, and lubricate if necessary.
Fuel:Have sufficient fuel for the high fuel consumption on rougEngine Oil:To avoid engine seizure and resulting loss of cont
the oil level is at the operating range (grid area) on the dipstick.Miscellaneous: Check to see that the electrical equipment is
erly, all nuts and bolts are tight, and all safety related parts are in
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Periodic Maintenance
*A: Service at number of years shown or indicated odometer reever comes first.
*B: For higher odometer readings, repeat at the frequency inter*C: Service more frequently when operating in severe condition
speed, or frequent starting/stopping.
: Inspection : Dealer Inspectio
: Change or Replace : Dealer Change
: Lubrication : Dealer Lubricati
Items
year(*A)
Odome 1 000 k
1(0 6)
6(3 8) (
Odometer R
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Items
year
(*A)
Odometer R 1 000 km (
1(0.6)
6(3.8)
12(7.6)
Choke operation :1
Fuel system :1
Fuel hose :5
Valve clearance
Air suction system
Clutch operation (play, engagement,disengagement)
Engine oil and oil filter (*C) :1
Tire air pressure :1
Odome
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Items
year
(*A)
Odome 1 000 k
1(0.6)
6(3.8) (
Drive chain slack (*C) : every
Drive chain wear (*C)
Drive chain guide wear
Brake system :1
Brake operation (effectiveness, play,no drag) :1
Brake fluid level :0.5
Brake fluid (front and rear) :2
Odometer R
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Items
year
(*A)
1 000 km (
1(0.6)
6(3.8)
12(7.6)
Suspension system :1
Lubrication of rear suspension
Steering play :1
Steering stem bearings :2
Electrical system :1
Spark plug
Chassis parts :1
Condition of bolts nuts and fasteners
E i Oil
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Engine Oil
Oil Level Inspection
If the engine is cold, start the engineand run it for several minutes at idlespeed.
Stop the engine, then wait severalminutes until the oil settles.
NOTICE
Racing the engine before the oilreaches every part can cause en-gine seizure.
With the motorcycle held level, un-
A. Oil Filler Cap/Di
N
Be careful noforeign mategine
between upper and lower level linesth di ti k
same type and brad i th i
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on the dipstick.
A. Oil Filler Cap/DipstickB. Upper Level LineC. Lower Level LineD. O-ring
ready in the engin
NOTDo not pinch the O
ling the dipstick on
When the O-ring c
oil filler neck, instaoil filler neck corrstall the dipstick.
Oil and/or Oil Filter C
Warm up the engithen stop it.Remove the dipstiPlace an oil pan be Remove the eng
WARNING If the oil filtemove the oil f
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WARNING
Engine oil is a toxic substance.Dispose of used oil properly.Contact your local authorities forapproved disposal methods orpossible recycling.
move the oil fa new one as
Remove the filter cover an
A Oil Filt C
Be sure to install the filter with thegrommet facing inside
Install the spring s80 MAINTENANCE AND ADJUSTMENT
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grommet facing inside.
A. GrommetB. Oil Filter
NOTICE
A. O-ringB. Spring
Install the oil filtearrow mark faces
NOTE
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Replace the gasket with a new one.
Tightening Torque
Oil Filter Cover Bolts:
5.2 Nm (0.53 kgfm, 46 inlb)
Engine Oil Drain Plug:
18 Nm (1.8 kgfm, 13 ftlb)
NOTE
If a torque wrench is not available,
this item should be serviced by anauthorized Kawasaki dealer.
Pour in the specified type andamount of oil.
Do not add an
the oil. Oils quirements aprovide adequthe engine an
Engine Oil Capacit
1.13 L (1.19 US q
[when filter is not
1.15 L (1.22 US q
[when filter is rem
Although 10Wrecommended the oil viscoschanged to acco
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Start the engine.
Check the oil level and oil leakage.
Spark Plug
Spark Plug Replacement
C f ll ll th k l
A. Spark Plug CapB. Spark Plug
Unscrew the spaspark plug wrencsupplied tool kit (Tool Kit section in
make sure stalled
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A. Spark Plug WrenchB. Wrench
NOTE
Spark plug installation is performedin the reverse order of removal.
stalled.
Check the hig
damaged, or c
Spark Plug
StandardPlug
NG
Plug Gap 0.6
(0.
Tightening Torque
Spark Plug:
13 Nm (1.3 kg
Remove the left sisection in the GEN
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A. 0.6 ~ 0.7 mm (0.024 ~ 0.028 in.)
Air Cleaner
Air Cleaner Element Replacement
NOTE
section in the GENTION chapter).
Remove the air cleer bolts and air cleer.
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A. Wing BoltB. Washer
C. Air Cleaner Element
Stuff a clean, lint-free towel into theair cleaner duct so no dirt is allowedto enter the carburetor.
If dirt or dusthrough intothrottle may sibly causingto keep the
during cleani
N
If dirt gets tgine, excesspossibly engcur.
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A. FrameB. Air Cleaner Element
Replace the air cleaner element witha new one.
Install the frame into the new ele-ment.
A. Apply grease.
Install the elementighten the wing boInstall the air cleanTighten the air cle
er bolts to the spec
Air Cleaner Element Cleaning
NOTERemove the a
Air Cleaner E
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NOTE
In dusty areas, the element shouldbe cleaned more frequently than therecommended interval.
After riding through rain or on mud-dily roads, the element should be
cleaned immediately.
WARNING
Gasoline and low flash-point sol-vents can be flammable and/orexplosive and cause severeburns. Clean the element in awell-ventilated area, and take
Air Cleaner E
Separate thecleaner elemeement Replac
Clean the eleflash-point sobrush.
Squeeze it dnot twist the the element c
Check all the
visible damagIf any of the pdamaged, rep
After cleaningwith a high-q
WARNING
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Gasoline and low flash-point sol-vents are extremely flammableand may explode, causing severeburns. Do not use gasoline or alow flash-point solvent to clean
the element. Clean the element ina well-ventilated area. Be surethere are no sparks or flame inthe work area, including any ap-pliance with a pilot light.
Oil Draining
Inspect the drain caps located at thebottom of the air cleaner housing to
A. Drain Caps
If there is any oilcap and drain the
WAR
Throttle Control System
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Throttle GripThrottle Grip Free Play Inspection
Check that the throttle grip movessmoothly from full open to close, andthe throttle closes quickly and com-
pletely by the return spring in allsteering positions.
If the throttle grip does not returnproperly, have the throttle controlsystem checked by an authorized
Kawasaki dealer. Check the throttle grip free play by
turning back and forth.
A. Throttle GripB. Throttle Grip Fr
Throttle Grip Free
2 ~ 3 mm (0.08
If there is imp
Tighten the locknut. movement changthe throttle cables
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A. LocknutB. Throttle CableC. Accelerator Cable Adjuster
If the throttle cable cannot be ad-j t d ith th dj t t th
adjusted or inco
they may be damcorrect any of thefore riding.
WAROperation with justed, incorrecdamaged cable cunsafe riding conthe control cablerouted correctly, damage.
that is necessary to enable easy start-ing when the engine is cold.
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g gIf starting difficulty or rich fuel mixture
trouble occurs, inspect the choke lever,and adjust it if necessary.
Choke Lever Inspection
Check that the choke lever returns
properly and that the inner cableslides smoothly. If there is any irregu-larity, have the choke cable checkedby an authorized Kawasaki dealer. A. Choke Lever
Idle Speed
Idle Speed Adjus
Start the engi
Idle Speed
1 400 50 r/min (rpm)
adjusted or incothey may be dam
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( p )
A. Idle Adjusting Screw
Open and close the throttle a fewtimes to make sure that the idle
y ycorrect any of the
fore riding.
WAR
Operation with a
could result in acondition. Replacontrol cable befo
Clutch
Clutch Operation Insp
Check that the clu
Clutch Lever Free Play
2 ~ 3 mm (0.08 ~ 0.12 in.) Turn the adju
lever will ha
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( )
A. AdjusterB. LocknutC. Clutch Lever Free Play
If the pla is incorrect adj st the le
play.
Tighten the lo
Excess clutc
prevent clutand cause aserious injuryjusting the cthe upper enis fully seatedit doesn't slipcreate excess
NOTE
After the adjustment is made, start
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After the adjustment is made, startthe engine and check that the clutchdoes not slip and that it releasesproperly.
Drive Chain
Drive Chain Lubrication
Lubrication is necessary after ridingthrough rain or on wet roads, or anytime that the chain appears dry.
If the chain is especially dirty, clean itusing a cleaner for chains following theinstructions supplied by the chaincleaner manufacturer.
A l l b i t t th id f th
Wipe off any lubrthe tire surface.
Drive Chain Slack Ins
Raise the rear wheClean the chain if
chain midway between the swingarmpivot and rear axle.
Drive Chain Slac
Remove the aR th
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A. Chain SlackB. Swingarm Pivot
If the drive chain is too tight or too
Remove the the rear axle n
Loosen the ljuster locknut
standard chain slack. To keep thechain and wheel properly aligned,th t h th i ht h l li
NOT
Wheel alignmen
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the notch on the right wheel align-
ment indicator should align with thesame swingarm mark that the left in-dicator notch align with.
gchecked using thstring method.
WAR
Misalignment of tsult in abnormalresult in an unsation. Align the rethe marks on th
measuring the dithe center of the arm pivot.
Ti ht b th h i
NOTE
If a torque wrench is not available, When inserti
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q ,this item should be serviced by anauthorized Kawasaki dealer.
Rotate the wheel, measure the chainslack again at the tightest position,and readjust if necessary.
Insert a new cotter pin through theaxle, and spread its ends.
slots in the ncotter pin holeen the nut cloalignment.
It should be w
Loosen once the slot goes p
WARNING WAR
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A loose axle nut can lead to an
accident resulting in serious in-jury or death. Tighten the axle nutto the proper torque and install anew cotter pin.
Check the rear brake (see Brakessection in this chapter).
Install the axle cap.
BrakesIf you feel there is something wrong
when applying the brakes, have thebrake system checked by an author
Air in the brake
braking performcause an accidenjury or death. If thpedal feels mushplied, there mighbrake lines or thdefective. Havechecked immediathorized Kawasak
Brake Fluid Level Ins
With the front brheld horizontal, th
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A. Front Brake Fluid ReservoirB. Lower Level Line
With the rear brake fluid reservoirheld horizontal, the brake fluid levelmust be kept between the upper andlower level lines.
A. Rear Brake FluiB. Upper Level Lin
C. Lower Level Lin
If the fluid lever level line ifluid is leaking
thickness of either pad lining is lessthan 1 mm (0.04 in.), replace both padsin the caliper as a set Pad replace
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in the caliper as a set. Pad replace-
ment should be done by an authorizedKawasaki dealer.
A. Front Brake Pads
A. Rear Brake PadsB. Lining Thickness
C. 1 mm (0.04 in.)
Brake Light Sw
B k Li h S i h I
If it does not, ask your authorizedKawasaki dealer to inspect the frontbrake light switch
Brake Pedal Trave
10 mm (0.39 in.)
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brake light switch.
Check the operation of the rearbrake light switch by depressing thebrake pedal. The brake light shouldgo on after the proper pedal travel.
Brake Light Swit
To adjust the move the swiing the adjust
NOTICE
To avoid damaging the electrical
NOT
Sticking muds o
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To avoid damaging the electrical
connections inside the switch, besure that the switch body doesnot turn during adjustment.
Suspension System
Front Fork
The front fork operation and oil leak-age should be checked in accordancewith the Periodic Maintenance Chart.
After riding through muddy or dustyroads, the front inner tube should be
Sticking muds o
sliding surface ocould damage tleading to an oil sliding surface aft
Front Fork Inspection
Holding the brakefront fork up and dto inspect smooth
Tuck up the fork bo Visually inspect tleakage, scoring oouter surface of th
N
Sticking mud
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A. Inner TubeB. Fork Boot (Both Sides)
Rear Shock Absorber
The rear shock absorber operationand oil leakage should be checked in
Sticking mud
sliding surfaabsorber couseal, leadingthe sliding ride.
Rear Shock Absorber Inspection
Press down on the seat severaltimes to inspect the stroke
for various riding ations.
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times to inspect the stroke.
Visually inspect the rear shock ab-sorber for oil leakage. If there is any doubt about the rear
shock absorber, it should be done byan authorized Kawasaki dealer.
Spring Preload Adjus
The spring adjustshock absorber can
If the spring actiotoo stiff, have it adju
ized Kawasaki deale
Wheels
Tire Air Pressure Insp
Remove the air vaCheck the tire air ing an accurate ga
Make sure to instasecurely
more than a mile during the past 3hours).
Tire air pressure is affected by
Tire Air Pressure (
Front 150 k
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Tire air pressure is affected by
changes in ambient temperature andaltitude, and so the tire air pressureshould be checked and adjustedwhen your riding involves wide varia-tions in temperature or altitude.
Rear 150 k
Tire Wear, DamAs the tire tre
becomes more
and failure. Anthat 90% of all tthe last 10% ofSo it is false ecuse the tires unt
Tire Wear Inspec
Measure the a depth gaugthat has worn
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A. Tire Depth Gauge
Minimum Tread Depth
Front 2 mm (0.08 in.)
Rear 2 mm (0.08 in.)
Visually inspect the tire for cracks
A. Crack or CutB. Nail
C. Swelling or High SpoD. Stone
Remove any imbother foreign partic
WARNING
Tires that have been punctured
When operatikeep maximulaw limits
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Tires that have been punctured
and repaired do not have thesame capabilities as undamagedtires and can suddenly fail, caus-ing an accident resulting in seri-ous injury or death. Replacedamaged tires as soon as possi-ble. To ensure safe handling andstability, use only the recom-mended standard tires for re-
placement, inflated to thestandard pressure. If it is neces-sary to ride on a repaired tire, donot exceed 100 km/h (60 mph) un-til the tire is replaced
law limits.
Standard Tire
Front
Make, TyIRC, G
Size:2.75-2
Rear
Make, TyIRC, G
Size:4.10-1
Mixing tire bradversely af
WARNING
New tires are slippery and may
NOT
Never remove th
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New tires are slippery and may
cause loss of control and injury.A break-in period of 160 km (100miles) is necessary to establishnormal tire traction. Duringbreak-in, avoid sudden and maxi-mum braking and acceleration,and hard cornering.
BatteryThe battery installed in this motor-
cycle is a sealed type, so it is not nec-essary to check the battery electrolyte
Never remove th
or the battery canDo not install a cotery in this motelectrical systemproperly.
Make Furuka
Type FTX7L
Battery MaintenaIt is the owner's re
the battery fully chaso can lead to batter
(check with your Kawasaki dealer). Ifyou will not be using the motorcycle forlonger than two weeks, the battery
If the above cable, use equiva
For more deta
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o ge t a t o ee s, t e batte y
should be charged using an appropri-ate charger. Do not use an automotive-type quick charger that may over-charge the battery and damage it.
NOTELeaving the battery connected
causes the electrical components tomake the battery discharged, result-ing the over discharge of the battery.
In this case, the repair or replace-ment of the battery is not included inthe warranty. If you do not drive forfour weeks or more, disconnect the
o o e deta
dealer.Battery Charging
Charge the bstructions of y
The charger fully chargedreinstall the b(see Battery I
DANGER
Battery acid generates hydrogen
Remove the seatin the GENERAchapter).
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Battery acid generates hydrogen
gas which is flammable and ex-plosive under certain conditions.It is present within a battery at alltimes, even in a discharged con-dition. Keep all flames and sparks(cigarettes) away from the bat-tery. Wear eye protection whenworking with a battery. In theevent of battery acid contact with
skin, eyes, or clothing, wash theaffected areas immediately withwater for at least five minutes.Seek medical attention.
p )
Remove the bolts
A. BoltsB Battery Holder
Remove the battery. Connect the minal, and theto the () term
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A. CapB. () TerminalC. (+) TerminalD. Battery
Clean the battery using a solution of
( )
N
Installing theterminal of th
cable to thebattery can selectrical sys
Put a light cominals to prev
Cover the (+) Install the rem
Vertical Adjustment
The headlight beam is adjustablevertically. If adjusted too low, neither
NOT
On high beam, tshould be slightly
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low nor high beam will illuminate theroad far enough ahead. If adjusted toohigh, the high beam will fail to illumi-nate the road close ahead, and the lowbeam will blind oncoming drivers.
Turn the vertical adjuster in or out toadjust the headlight vertically.
should be slightly
with the motorcyand the rider seheadlight to the pring to local regulat
Fuses
The main fuse and spare fuse are lo-
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The main fuse and spare fuse are lo
cated under the seat. If a fuse fails dur-ing operation, inspect the electricalsystem to determine the cause, andthen replace it with a new fuse of prop-er amperage.
If the fuse fails repeatedly, there issomething wrong with the electricalsystem. Have the motorcycle checkedby an authorized Kawasaki dealer.
The main fuse removal should bedone by an authorized Kawasaki deal-er.
A. Main FuseB. Spare Fuse
Substituting fing to overhe
Before lubricatingoff any rusty spots and wipe off any g
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A. NormalB. Failed
General Lubrication
Lubricate the points shown below,
grime.Apply motor oil to
pivots
Side Stand
Clutch LeverFront Brake LeverRear Brake Pedal
Lubricate the follo
with a pressure(K)Choke Inner C(K)Clutch Inner C(K)Throttle Inner C
After connecthem.
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Apply grease to the following
points(K)Choke Inner Cable Upper End(K)Clutch Inner Cable Upper End(K)Throttle Inner Cable Upper Ends
them.
Cleaning Y
General Prec
Frequent andwasaki motorcypearance, performance, a
Covering your quality, breathawill help protecUV rays, polluamo nt of d st
WARNING
Build-up of debris or flammable
Be sure the engincool before washin
Avoid applying d
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p
material in and around the ve-hicle chassis, engine, and ex-haust can cause mechanicalproblems and increase the risk offire.
When operating the vehicle inconditions that allow debris orflammable material to collect inand around the vehicle, inspectthe engine, electrical componentand exhaust areas frequently. Ifdebris or flammable materialshave collected, park the vehicleoutside and stop the engine Al-
brake pads, and tiAvoid all harsh ch
detergents, and hproducts such awindow cleaners.
Gasoline and brakthe finish of paintefaces: wash them
Avoid wire brusheall other abrasive p
Use care when wlight lens and oththey can easily be
Avoid using press
components, muffler outlet, and fueltank openings.
not let the wadamage the p
Start the engi
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Washing Your MotorcycleRinse your motorcycle with cold
water from a garden hose to removeany loose dirt.
Mix a mild neutral detergent (de-signed for motorcycles or automo-biles) and water in a bucket. Use asoft cloth or sponge to wash yourmotorcycle. If needed, use a mild de-
greaser to remove any oil or greasebuild up.
After washing, rinse your motorcyclethoroughly with clean water to re-move any residue (residue from the
eral minutes.gine will help
Carefully rideslow speed several times
brakes and reoperating per
Lubricate therusting.
After riding iroads are salimmediately
Condensation may form on the in-side of the headlight lens after ridingin the rain, washing the motorcycle
headlight lens and plastic parts with ancleaner/polisher prod
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or humid weather. To remove themoisture, start the engine and turnon the headlight. Gradually the con-densation on the inside of the lenswill clear off.
Semi-gloss FinishTo clean the semi-gloss finish;
When washing the motorcycle, al-ways use a mild neutral detergentand water.
The semi-gloss finish effect may belost when the finish is excessivelyrubbed
NOT
Plastic parts maybreak if they comchemical substa
hold cleaning prgasoline, brake cleaners, thread-or other harsh
plastic part comeany harsh chemwash it off imwater and a mildgent and then in
Chrome and AluminumChrome and uncoated aluminum
parts can be treated with a chrome/alu-
The sidewallsber componentsa rubber prote
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minum polish. Coated aluminumshould be washed with a mild neutraldetergent and finished with a spraypolish. Aluminum wheels, both paintedand unpainted can be cleaned with
special non-acid based wheel spraycleaners.
Leather, Vinyl, and RubberIf your motorcycle has leather acces-
sories, special care must be taken.Use a leather cleaner/treatment toclean and care for leather accessories.Washing leather parts with detergent
their useful life.
Rubber protepery and, if area, cause sulting in accor death. Doprotectant to
APPENDIX
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Storage
Preparation for Storage
Clean the entire vehicle thoroughly.Run the engine for about five minutes to warm the oil, shut it of
gine oil.
WARNING
Engine oil is a toxic substance. Dispose of used oil properlocal authorities for approved disposal methods or possib
Put in fresh engine oil. Empty the fuel from the fuel tank by the pump or siphon
WARNING
Gasoline is extremely flammable and can be explosiv
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ditions, creating the potential for serious burns. TurnDo not smoke. Make sure the area is well ventilatedsource of flame or sparks; this includes any applianGasoline is a toxic substance. Dispose of gasoline prlocal authorities for approved disposal methods.
Remove the spark plug and spray fogging oil directly intengine over several times with the starter button to coat ththe spark plug.
WARNING
An air/oil mist may be forcibly ejected from the spark pget into your eyes Do not lean over the engine when
Set the motorcycle on a box or stand so that both wheelsground. (If this cannot be done, put boards under the front akeep dampness away from the tire rubber.)
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Spray oil on all unpainted metal surfaces to prevent rusting. Arubber parts or in the brakes.Lubricate the drive chain and all the cables.Remove the battery, and store it where it will not be exposed
moisture, or freezing temperatures. During storage it shou
charge (one ampere or less) about once a month. Keep the baespecially during cold weather.
Tie plastic bag over the muffler to prevent moisture from enteriPut a cover over the motorcycle to keep dust and dirt from coll
Preparation after StorageRemove the plastic bag from the muffler.Install the battery in the motorcycle and charge the battery if neFill the fuel tank with fuel.
Ch k ll th i t li t d i th D il Ch k ti
Troubleshooting Guide
Engine Does Not Start
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Starter Motor Won't Turn
Engine stop switch offTransmission not in neutralFuse blownBattery cables do not make good electrical contact with baBattery dischargedEngine Cranks, But Won't Start
No fuel in tankFuel line clogged
Fuel broken downChoke is not used when engine is coldEngine floodedSpark plug not in good contact
Clutch does not properly disengageWhile Riding
Choke is used too long after moving off
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No fuel in tankFuel tap is turned offFuel tank air vent is obstructedOverheatingBattery discharged
Environmental Protection
To help preserve the environment, properly discard used batte
fluids, or other vehicle components that you might dispose of in your authorized Kawasaki dealer or local environmental wastproper disposal procedure. This also applies to disposal of the eend of its life.
MAINTENANCE RECORD
MA
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Owner Name .......................................................................Address ...............................................................................
Phone Number ....................................................................
Engine Number ...................................................................
Vehicle Number ..................................................................
Key Code .............................................................................
Selling Dealer Name ...........................................................
Phone Number ....................................................................Warranty Start Date ............................................................
Note:Keep this information and a spare key in a secure lo
Date Odometer
Reading Maintenance Performed Dealer Name
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Date Odometer
Reading Maintenance Performed Dealer Name
MA
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Date Odometer
Reading Maintenance Performed Dealer Name
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Date Odometer
Reading Maintenance Performed Dealer Name
MA
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Date Odometer
Reading Maintenance Performed Dealer Name
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