Versys Manual

Downloaded from www.Manualslib.
com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION j
Quick Reference Guide
HOW TO RIDE THE MOTORCYCLE j
This Quick Reference Guide will SAFE OPERATION j
assist you in finding the information
you’re looking for. MAINTENANCE AND ADJUSTMENT j
STORAGE j
A Table of Contents is included after

the Foreword.

Whenever you see the symbols CAUTION
shown below, heed their instructions!
CAUTION indicates a hazardous
Always follow safe operating and main-
situation which, if not avoided,
tenance practices.
could result in minor or moder-
DANGER ate injury.
DANGER indicates a hazardous

situation which, if not avoided, NOTICE
will result in death or serious in- NOTICE is used to address prac-
jury. tices not related to personal in-
jury.
WARNING
WARNING indicates a hazardous NOTE
situation which, if not avoided, ○This note symbol indicates points of
could result in death or serious particular interest for more efficient
injury. and convenient operation.

(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.

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.

Consumer Products & Machinery Company
© 2009 Kawasaki Heavy Industries, Ltd. Oct. 2009. (1). (M, Ke)

TABLE OF CONTENTS
SPECIFICATIONS............................... 10 Engine Stop Switch ...................... 34

LOCATION OF PARTS ....................... 14 Starter Button ............................... 35
LOADING AND ACCESSORIES Brake/Clutch Lever Adjusters........... 35
INFORMATION ................................ 17 Fuel Tank Cap .................................. 37
GENERAL INFORMATION................. 20 Fuel Tank ......................................... 38
Meter Instruments ............................ 20 Fuel Requirements ....................... 38
Tachometer ................................... 21 Filling the Tank.............................. 40
LCD (Speedometer, Clock, Stand................................................ 42
Odometer, Trip Meter A/B, Fuel Seat.................................................. 43
Gauge) ...................................... 21 Helmet Hooks................................... 45
Warning/Indicator Lights ............... 28 Tool Kit/U-Shaped Lock
Key ................................................... 30 Compartment ................................ 46
Ignition Switch/Steering Lock ........... 31 Rear View Mirror .............................. 47
Left Handlebar Switches .................. 32 Windshield........................................ 48
Dimmer Switch ............................. 33 BREAK-IN ........................................... 51
Turn Signal Switch........................ 33 HOW TO RIDE THE MOTORCYCLE . 53
Horn Button .................................. 33 Starting the Engine .......................... 53
Passing Button ............................. 33 Jump Starting ................................... 55
Hazard Switch .............................. 33 Moving Off........................................ 58
Right Handlebar Switches................ 34 Shifting Gears .................................. 59

Braking ............................................. 60 Valve Clearance ............................... 108
Anti-lock Brake System (ABS) for Kawasaki Clean Air System ............. 109
models equipped with ABS........... 62 Air Cleaner ....................................... 110
ABS Indicator Light ....................... 64 Throttle Control System ................... 111
Stopping the Engine......................... 65 Engine Vacuum Synchronization ..... 114
Stopping the Motorcycle in an Idle Speed ........................................ 114
Emergency ................................... 65 Clutch ............................................... 116
Parking ............................................. 66 Drive Chain ...................................... 119
Catalytic Converter........................... 68 Brakes .............................................. 127
SAFE OPERATION............................. 70 Brake Light Switches........................ 131
Safe Riding Technique ..................... 70 Front Fork......................................... 133
Daily Safety Checks ......................... 73 Rear Shock Absorber....................... 136
Additional Considerations for High Wheels ............................................. 138
Speed Operation .......................... 76 Battery.............................................. 144
MAINTENANCE AND ADJUSTMENT 78 Headlight Beam................................ 149
Periodic Maintenance Chart............. 82 Fuses ............................................... 150
Engine Oil ........................................ 93 Cleaning Your Motorcycle ................ 154
Cooling System ................................ 99 STORAGE........................................... 159
Spark Plugs...................................... 106 ENVIRONMENTAL PROTECTION..... 162
Evaporative Emission Control LOCATION OF LABELS..................... 163
System (Southeast Asia model
only) ............................................. 107

10 SPECIFICATIONS
SPECIFICATIONS
PERFORMANCE
Maximum Horsepower 47 kW (64 PS) @8 000 r/min (rpm)
Maximum Torque 61 N·m (6.2 kgf·m, 45 ft·lb) @6 800 r/min (rpm)
Minimum Turning Radius 2.7 m (8.9 ft)
DIMENSIONS
Overall Length 2 125 mm (83.7 in.)
Overall Width 840 mm (33.1 in.)
Overall Height 1 330 mm (52.4 in.)
Wheelbase 1 415 mm (55.7 in.)
Road Clearance 180 mm (7.1 in.)
Curb Mass:
KLE650C 206 kg (454 lb)
KLE650D 209 kg (461 lb)
ENGINE
Type 4-stroke, DOHC, 2-cylinder, liquid-cooled

SPECIFICATIONS 11
Displacement 649 cm3 (39.6 cu in.)

Bore × Stroke 83.0 × 60.0 mm (3.3 × 2.4 in.)
Compression Ratio 10.6:1
Starting System Electric starter
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
Fuel System FI (Fuel Injection)
Ignition System Battery and coil (transistorized ignition)
Ignition Timing (Electronically 10° BTDC @1 300 r/min (rpm) ∼ 33° BTDC @5 000
advanced) r/min (rpm)
Spark Plugs NGK CR9EIA-9
Lubrication System Forced lubrication (semi-dry sump)
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 2.4 L (2.5 US qt)
Coolant Capacity 1.2 L (1.3 US qt)

12 SPECIFICATIONS
TRANSMISSION
Transmission Type 6-speed, return shift
Clutch Type Wet, multi disc
Driving System Chain drive
Primary Reduction Ratio 2.095 (88/42)
Final Reduction Ratio 3.067 (46/15)
Overall Drive Ratio 5.473 @Top gear
Gear Ratio:
1st 2.438 (39/16)
2nd 1.714 (36/21)
3rd 1.333 (32/24)
4th 1.111 (30/27)
5th 0.966 (28/29)
6th 0.852 (23/27)
FRAME
Caster 25°
Trail 108 mm (4.3 in.)

SPECIFICATIONS 13
Tire Size:
Front 120/70 ZR17 M/C (58W)
Rear 160/60 ZR17 M/C (69W)
Rim Size:
Front 17 × 3.50
Rear 17 × 4.50
Fuel Tank Capacity 19 L (5.0 US gal)
ELECTRICAL EQUIPMENT
Battery 12 V 10 Ah
Headlight:
High Beam 12 V 55 W
Low Beam 12 V 55 W
Tail/Brake Light LED
Even if one of LED (Light Emitting Diode) tail/brake light is not lit, consult with an
authorized Kawasaki dealer.
Specifications are subject to change without notice, and may not apply to every
country.

14 LOCATION OF PARTS
LOCATION OF PARTS
1. Clutch Lever 7. Spring Preload Adjuster (Front Fork)

2. Left Handlebar Switches 8. Rebound Damping Force Adjuster
3. Meter Instruments (Front Fork)
4. Ignition Switch/Steering Lock 9. Right Handlebar Switches
5. Brake Fluid Reservoir (Front) 10. Throttle Grip
6. Front Brake Lever

LOCATION OF PARTS 15
1. Headlight/City Light 7. Seat 12. Brake Disc

2. Turn Signal Light 8. Helmet Holding Hook 13. Brake Caliper
3. Spark Plugs 9. Tool Kit/Storage 14. Front Fork
4. Air Cleaner Compartments 15. Shift Pedal
5. Main Fuse 10. Seat Lock 16. Side Stand
6. Battery 11. Wheel 17. Drive Chain

16 LOCATION OF PARTS
1. License Plate Light 5. Rear Shock Absorber 10. Muffler

2. Tail/Brake Light 6. Spring Preload 11. Rear Brake Light
3. Rebound Damping Adjuster (Rear Shock Switch
Force Adjuster (Rear Absorber) 12. Rear Brake Pedal
Shock Absorber) 7. Fuel Tank 13. Oil Level Gauge
4. Brake Fluid Reservoir 8. Fuel Tank Cap 14. Idle Adjusting Screw
(Rear) 9. Coolant Reserve Tank

LOADING AND ACCESSORIES INFORMATION 17
LOADING AND ACCESSORIES INFORMATION
WARNING warranty, can negatively affect per-

formance, and can even be illegal.
Incorrect loading, improper in-
In selecting and using accessories,
stallation or use of accessories,
and in loading the motorcycle, you are
or modification of your motorcy-
personally responsible for your own
cle may result in an unsafe rid-
safety and the safety of other persons
ing condition. Before you ride
involved.
the motorcycle, make sure that
the motorcycle is not overloaded NOTE
and that you have followed these
instructions.
○Kawasaki Parts and Accessories
have been specially designed for
use on Kawasaki motorcycles. We
With the exception of genuine
strongly recommend that all parts
Kawasaki Parts and Accessories,
and accessories you add to your
Kawasaki has no control over the
motorcycle be genuine Kawasaki
design or application of accessories.
components.
In some cases, improper installation
or use of accessories, or motorcycle Because a motorcycle is sensitive to
modification, will void the motorcycle changes in weight and aerodynamic
forces, you must take extreme care

18 LOADING AND ACCESSORIES INFORMATION
in carrying cargo, passengers and/or 3. All baggage should be carried as

in the fitting of additional accessories. low as possible to reduce the effect
The following general guidelines have on the motorcycle center of gravity.
been prepared to assist you in making Baggage weight should also be dis-
your determinations. tributed equally on both sides of the
1. Any passenger should be thor- motorcycle. Avoid carrying baggage
oughly familiar with motorcycle op- that extends beyond the rear of the
eration. The passenger can affect motorcycle.
control of the motorcycle by im- 4. Baggage should be securely at-
proper positioning during cornering tached. Make sure that the baggage
and sudden movements. It is im- will not move around while you are
portant that the passenger sits still riding. Recheck baggage security
while the motorcycle is in motion as often as possible (not while the
and not interfere with the operation motorcycle is in motion) and adjust
of the motorcycle. Do not carry ani- as necessary.
mals on your motorcycle. 5. Do not carry heavy or bulky items on
2. You should instruct any passenger a luggage rack. They are designed
before riding to keep his or her feet for light items, and overloading can
on the passenger footpegs and hold affect handling due to changes in
on to the operator or seat strap. Do weight distribution and aerodynamic
not carry a passenger unless he or forces.
she is tall enough to reach the foot-
pegs and footpegs are provided.

LOADING AND ACCESSORIES INFORMATION 19
6. Do not install accessories or carry designed or installed items can re-

baggage that impairs the perfor- sult in an unsafe riding condition.
mance of the motorcycle. Make 9. This motorcycle was not intended to
sure that you have not adversely be equipped with a sidecar or to be
affected any lighting components, used to tow any trailers or other ve-
road clearance, banking capability hicles. Kawasaki does not manu-
(i.e., lean angle), control operation, facture sidecars or trailers for mo-
wheel travel, front fork movement, torcycles and cannot predict the ef-
or any other aspects of the motor- fects of such accessories on han-
cycle’s operation. dling or stability, but can only warn
7. Weight attached to the handlebar or that the effects can be adverse and
front fork will increase the mass of that Kawasaki cannot assume re-
the steering assembly and can responsibility for the results of such
sult in an unsafe riding condition. unintended use of the motorcycle.
8. Fairings, windshields, backrests, Furthermore, any adverse effects on
and other large items have the ca- motorcycle components caused by
pability of adversely affecting stabil- the use of such accessories will not
ity and handling of the motorcycle, be remedied under warranty.
not only due to their weight, but Maximum Load
also due to the aerodynamic forces
Weight of rider, passenger, baggage,
acting on these surfaces while the and accessories must not exceed 180 kg
motorcycle is in operation. Poorly (397 lb).

20 GENERAL INFORMATION
GENERAL INFORMATION
Meter Instruments
A. Water Temperature
Warning Indicator Light
B. Oil Pressure Warning
Indicator Light
C. RESET Button
D. Neutral Indicator Light
E. MODE Button
F. High Beam Indicator Light
G. Left Turn Signal Indicator
Light
H. Tachometer
I. Red Zone
J. Right Turn Signal Indicator
Light
K. LCD (Speedometer, Clock,
Odometer, Trip Meter A/B,
Fuel Gauge)
L. FI Indicator Light
M. ABS Indicator Light (model
with ABS)

GENERAL INFORMATION 21
Tachometer NOTICE
The tachometer shows the engine
Engine r/min (rpm) should not
speed in revolutions per minute (r/min,
be allowed to enter the red zone;
rpm). On the right side of the tachome-
operation in the red zone will
ter face is a portion called the “red
overstress the engine and may
zone”. Engine r/min (rpm) in the
cause serious engine damage.
red zone is above maximum recom-
mended engine speed and is also
above the range for good performance. LCD (Speedometer, Clock,
When the ignition key is turned to Odometer, Trip Meter A/B,
“ON”, the tachometer needle momen- Fuel Gauge)
tarily points to the last reading to check The LCD (Liquid Crystal Display) lo-
its operation. If the tachometer nee- cated in the tachometer face is used
dle does not operate correctly, have it to display the Speedometer, Clock,
inspected by an authorized Kawasaki Odometer, Trip Meter A/B, and Fuel
dealer. Gauge. Pushing the MODE button
shifts the display through the follow-
ing four modes: CLOCK, ODO, and
TRIP A/B. When the ignition key is
turned to “ON”, all the LCD segments
are displayed for three seconds, then
the clock or meters operate normally
depending on the mode selected.

Digital Meter
A. Clock
B. Odometer
C. Trip Meter A
D. Trip Meter B
E. Push MODE Button
NOTE
○For safe operation do not press the A. Fuel Gauge
MODE button while riding. B. Speedometer
C. Clock, Trip Meter A/B, Odometer
NOTE
○Do not shift the digital meter display
while riding for safe operation.

mph·km/h Display -
mph·km/h Display can alternate be-
• Display
meter.
the odometer in the digital
tween English and metric modes (mph

and km/h) in the digital meter. Make
• The mph·km/h display shifts by push-
ing the RESET button while the
sure that mph or km/h is correctly dis- MODE button pushed in.
played according to local regulations
before riding.
NOTE
○Do not operate the vehicle with
the digital meter displaying in the
wrong unit (mph or km/h). Shift the
mph·km/h display in the digital meter
as follows.
A. mph·km/h Display

• The mph·km/h display shifts as fol- • Turn the ignition key to “ON”.
lows. • Push
clock.
the MODE button to display the
• Push the RESET button for more

than two seconds. Both the hour and
minute displays start flashing.
A. mph Display
B. km/h Display
C. Push RESET Button with MODE Button in
NOTE
○The data is maintained even if the • Push the RESET button. The hour
display only flashes. Push the
battery is disconnected. MODE button to advance the hours.
Speedometer -
The speedometer shows the speed
of the vehicle in digital value.
Clock -
To adjust the hours and minutes:

• Push the RESET button. The hour

display stops flashing and the minute
step by step. Pushing and hold-
ing the button advance the hour or
display starts flashing. Push the minute continuously.
MODE button to advance the min- ○The clock works normally from the
utes. back-up power while the ignition
switch is turned off.
○When the battery is disconnected,
the clock resets to 1:00 and starts
working again when the battery is
connected.
• Push the RESET button. Both the

hour and minute displays start flash-
Odometer -
The odometer shows the total dis-
ing again. tance the vehicle has been ridden. This
• Push the MODE button. The dis-
plays stop flashing and the clock
meter cannot be reset.
starts working.
NOTE
○Pushing the MODE button momen-
tarily advances the hour or minute

NOTE
○The data is maintained even if the
battery is disconnected.
○When the figures come to 999999,
they are stopped and locked.
Trip Meter -
The trip meters show the distance in
kilometers traveled since they were last
reset to zero.
TRIP A: 0.0 ∼ 999.9
TRIP B: 0.0 ∼ 9999.9
To reset the trip meter:
• Push the MODE button to display the
trip meter A or B.
• Push the RESET button and hold it
in.
• After two seconds, the figure display
turns to 0.0, and then starts counting
when the vehicle is operated. The
meter counts until it is reset.

NOTE in the tank goes down, the segments

○The data is maintained by the back disappear one by one from F (full) to
E (empty). When only the most bot-
-up power if the ignition key is turned
off. tom segment is displayed, 5.0 L (1.3
○When the trip meter is reset while the US gal) of fuel remain. Furthermore,
when the lowest segment and “FUEL”
vehicle is stopped, it starts counting
as soon as the vehicle starts moving. flash in the digital meter, only 3.5 L (0.9
○When the trip meter reaches 999.9 US gal) of fuel remain.
Refuel at the earliest opportunity if
(TRIP A) or 9999.9 (TRIP B) while
running, the meters reset to 0.0 and the most bottom segment of the fuel
continues counting. gauge flashes.
○When the battery is disconnected, When vehicle stands with Side
Stand, Fuel Gauge cannot show the
the meter display resets to 0.0.
amount of fuel in the fuel tank exactly.
Fuel Gauge - Stand upright the vehicle to check the
The fuel in the fuel tank is shown fuel level.
by the number of segments displayed.
When the fuel tank is full, all the seg-
ments are displayed. As the fuel level

: When the headlight is on high

beam, the high beam indicator light
goes on.
: When the turn signal switch is

pushed to the left or right, the cor-
responding turn signal indicator light
flashes.
: The oil pressure warning light

A. Flash goes on whenever the oil pressure is
dangerously low or the ignition key is
NOTE in the ON position with the engine not
running, and goes off when the engine
○When pushing the MODE button
oil pressure is high enough. Refer to
while “FUEL” is displayed, the dis-
play can be shifted to odometer, trip the Maintenance and Adjustment chap-
meter, or clock mode. ter for more detailed engine oil informa-
tion.
Warning/Indicator Lights
: The fuel injection (FI) indicator
: When the transmission is in neu- light goes on when the ignition switch
tral, the neutral indicator light goes on. is turned to “ON” and goes off soon
after ensuring that its circuit functions

properly. The indicator light also goes NOTICE

on whenever the troubles occur in
Do not let the engine continue
digital fuel injection system (DFI). If
running when the warning indi-
the indicator light goes on, have the
cator light flashes. Prolonged
DFI system checked by an authorized
engine operation will result in
Kawasaki dealer. When the indicator
severe damage from overheat-
light flashes, first turn the ignition key
ing.
to “OFF” and then back to “ON”.
: The water temperature warning in-

(For models equipped with ABS)
dicator light goes on whenever the wa-
ter temperature rises to about 119°C : The ABS (Anti-lock Brake Sys-
(246°F) when the motorcycle is in op- tem) indicator light goes on when the
eration. This warns the operator that ignition switch is turned to “ON” and
the water temperature is too high. If the goes off shortly after the motorcycle
warning indicator light goes on, stop starts moving. If the ABS is normal, it
the engine and check the coolant level stays off. If something is wrong with the
in the reserve tank after the engine ABS, the indicator goes on and stays
cools down. on. When the indicator light is on, the
ABS does not function but if the ABS
fails, the conventional brake system will
still work normally.

For more detailed information about Key

ABS, see the Anti-lock Brake System This motorcycle has a combination
(ABS) section in the How to Ride the key, which is used for the ignition
Motorcycle chapter. switch/steering lock, seat lock, and fuel
tank cap.
Blank keys are available at your
Kawasaki dealers. Ask your dealer to
make any additional spare keys you
may need, using your original key as a
master.

Ignition Switch/Steering Lock Engine off. All electrical

OFF
This is a four-position, key-operated circuits off.
switch. The key can be removed from Engine on. All electrical
the switch when it is in the OFF, LOCK, ON
equipment can be used.
or P (Park) position.
Steering locked. Engine
LOCK
off. All electrical circuits off.
Steering locked. Engine
off. License plate, tail,
and city lights on and turn
P (Park)
signals can be used. All
other electrical circuits cut
off.
NOTE
○The city, tail and license plate lights
A. Ignition Switch/Steering Lock are on whenever the ignition key is
B. ON Position
C. OFF Position
in the ON position. One headlight
D. LOCK Position goes on when the starter button is
E. P (Park) Position released after starting the engine. To
avoid battery discharge, always start
the engine immediately after turning
the ignition key to “ON”.

○If you leave the P (Park) position on Left Handlebar Switches

for a long time (one hour), the battery
may become totally discharged.
A. Dimmer Switch
B. Turn Signal Switch
C. Horn Button
D. Passing Button
E. Hazard Switch

Dimmer Switch Horn Button

High or low beam can be selected When the horn button is pushed, the
with the dimmer switch. When the horn sounds.
headlight is on high beam ( ), the
Passing Button
high beam indicator light goes on.
When the passing button is pushed,
High Beam···( ) the headlight high beam (passing
Low Beam···( ) beam) goes on to signal the driver
of the vehicle ahead that you are about
NOTE to pass. The passing light is shut off as
○When the headlight is on high beam, soon as the button is released.
both headlights go on. When the Hazard Switch
headlight is on low beam, only one If an emergency requires you to park
headlight goes on. on the highway shoulder, turn on the
hazard lights to warn other drivers of
Turn Signal Switch your location.
When the turn signal switch is Push in the hazard switch with the
pushed to the left ( ) or right ignition switch in the ON or P (Park)
( ), the corresponding turn sig- position. All the turn signals and turn
nals flash on and off. signal indicator lights will flash on and
To stop flashing, push the switch in. off.

NOTICE Right Handlebar Switches

If you leave the switch on for a
long time, the battery may be-
come totally discharged. So be
careful not to use the hazard
lights for more than 30 minutes.
A. Engine Stop Switch

B. Starter Button
Engine Stop Switch

In addition to the ignition switch,
the engine stop switch must be in
the position for the motorcycle to
operate.

The engine stop switch is for emer- Brake/Clutch Lever Adjusters

gency use. If some emergency re- There is an adjuster on both the
quires stopping the engine, move the brake and clutch levers. Each adjuster
engine stop switch to the position. has 5 positions so that the released
lever position can be adjusted to suit
NOTE the operator’s hands. Push the lever
○Although the engine stop switch forward and turn the adjuster to align
stops the engine, it does not turn off the number with the mark on the lever
all the electrical circuits. Ordinarily, holder.
the ignition switch should be used to The distance from the grip to the re-
stop the engine. leased lever is minimum at Number 5
and maximum at Number 1.
Starter Button
The starter button operates the elec-
tric starter when the transmission is in
neutral.
Refer to the Starting the Engine sec-
tion of the “How to Ride the Motorcycle”
chapter for starting instructions.

A. Adjuster A. Adjuster
B. Mark B. Mark
C. Brake Lever C. Clutch Lever

Fuel Tank Cap

To open the fuel tank cap, pull up the
key hole cover. Insert the ignition key
into the fuel tank cap and turn the key
to the right.
To close the cap, push it down into
place with the key inserted. The key
can be removed by turning it to the left
to the original position.
NOTE
○The fuel tank cap cannot be closed A. Key Hole Cover
B. Ignition Key
without the key inserted, and the key C. Fuel Tank Cap
cannot be removed unless the cap is
locked properly.
○Do not push on the key to close the
cap, or the cap cannot be locked.

Fuel Tank used to describe a gasoline’s octane

Fuel Requirements rating is the Research Octane Number
Your Kawasaki engine is designed (RON).
to use only unleaded gasoline with a
minimum octane rating shown below. NOTICE
Never use gasoline with an octane rat- Do not use leaded gasoline, as
ing lower than the minimum specified this will destroy the catalytic
by Kawasaki to prevent severe engine converter (For further informa-
damage. tion, refer to the “Catalytic Con-
The octane rating of a gasoline is a verter” section in the “How to
measure of its resistance to detona- Ride the Motorcycle” chapter.).
tion or “knocking”. The term commonly

NOTICE Fuel Type and Octane Rating

If engine “knocking” or “ping- (Except for Brazil and Thailand
ing” occurs, use a different Specifications)
brand of gasoline of a higher Use clean, fresh unleaded gasoline
octane rating. If this condition is with an octane rating equal to or higher
allowed to continue, it can lead than that shown in the table.
to severe engine damage. Gaso-
line quality is important. Fuels Fuel Type Unleaded Gasoline
of low quality or not meeting Minimum Octane Research Octane
standard industry specifications Rating Number (RON) 91
may result in unsatisfactory per-
formance. Operating problems
that result from the use of poor (For Brazil Specification)
quality or no recommended fuel Use clean, fresh unleaded gasoline
may not be covered under your with an Antiknock Index equal to or
warranty. higher than that shown in the table.
The Antiknock Index is posted on ser-
vice station pumps. The Antiknock In-
dex is an average of the Research Oc-
tane Number (RON) and the Motor Oc-
tane Number (MON) as shown in the
table.

Fuel Type Unleaded Gasoline Filling the Tank

Ethanol
Avoid filling the tank in the rain or
E25 where heavy dust is blowing so that the
Content
fuel does not get contaminated.
Antiknock (RON + MON)
Minimum
Octane Index 2
Rating
87
(For Thailand Specification)

Use clean, fresh unleaded gasoline
with an octane rating equal to or higher
than that shown in the table.
Fuel Type Unleaded Gasoline

Ethanol Content E10 or less A. Tank Cap
B. Fuel Tank
Minimum Octane Research Octane C. Top Level
Rating Number (RON) 91 D. Filler Neck

WARNING NOTICE
Gasoline is extremely flammable Southeast Asia and Thailand
and can be explosive under cer- models only:
tain conditions. Turn the igni- Never fill the tank so the fuel
tion key to “OFF”. Do not smoke. level rises into the filler neck. If
Make sure the area is well ven- the tank is overfilled, heat may
tilated and free from any source cause the fuel to expand and
of flame or sparks; this includes flow into the Evaporative Emis-
any appliance with a pilot light. sion Control System resulting in
Never fill the tank so the fuel hard starting and engine hesita-
level rises into the filler neck. If tion and in non compliance with
the tank is overfilled, heat may the emission regulation.
cause the fuel to expand and
overflow through the vents in
the tank cap. NOTICE
After refueling, make sure the Certain ingredients of in gaso-
fuel tank cap is closed securely. line may cause paint fading or
If gasoline is spilled on the fuel damage. Be extra careful not
tank, wipe it off immediately. to spill gasoline or gasoline oxy-
genates blends during refueling.

Stand Whenever the side stand is used,

The motorcycle is equipped with a make it a practice to kick the stand fully
side stand. up before sitting on the motorcycle.
NOTE
○The motorcycle is equipped with a
side stand switch. This switch is de-
signed so that the engine does not
start if the transmission is in gear and
the side stand is down.
A. Side Stand
NOTE
○When using the side stand, turn the
handlebar to the left.

Seat
Seat Removal
Insert the ignition key into the seat
lock, located on the seat cover.
Turn the key clockwise while pulling
on the rear end of the seat.
NOTE
○If there is difficulty removing the seat,
be sure to insert the key all the way
and to push down strongly on the A. Seat
rear end of the seat while turning the B. Seat Lock
key clockwise. C. Ignition Key
D. Insert

Seat Installation
Install the seat in the reverse order of
• Push down the rear part of the seat
until the lock clicks.
removal. • Pull up the rear end of the seat to
• Place the tabs into the matching slot
and receptacles.
make sure it is securely locked.
• Insert the hook at the rear of the seat NOTE

into the lock on the frame. ○If there is difficulty removing the ig-
nition key from the seat lock, turn it
lightly counterclockwise while pulling
it out.
A. Seat
B. Slot
C. Tabs
D. Receptacles
E. Hook
F. Lock

Helmet Hooks WARNING

Helmets can be secured to the mo-
Riding with helmets attached to
torcycle using the helmet hooks located
the hooks could cause an ac-
under the seat.
cident by distracting the oper-
ator or interfering with normal
vehicle operation. Do not ride
the motorcycle with helmets at-
tached to the hooks.
A. Helmet Hooks

Tool Kit/U-Shaped Lock

Compartment
The tool kit is stored under the seat.
The kit contains tools that can be help-
ful in making roadside repairs, adjust-
ments, and some maintenance proce-
dures explained in this manual.
Also, under the seat, there is a lock
strap which can hold a U-shaped lock
(not supplied).
Install the U-shaped part and lock A. Tool Kit
separately and secure them each with B. Strap
its strap. C. U-Shaped Lock (not supplied)

Rear View Mirror NOTICE

Rear View Mirror Adjustment Do not force to tighten and/or
•Adjust the rear view mirror by slightly
moving only the mirror portion of the
loosen the upper hexagonal
area with a pair of spanners
assembly. or wrench. Forcible loosening
•If the rear visibility can not be as-
sured by moving the mirror, turn the
and/or tightening may damage
the upper hexagonal area and/or
stay by hand. the turning mechanism of the
stay.
A. Stay
B. Rear View Mirror

Windshield
The windshield can be adjusted
within 3 positions in height to suit the
rider’s preference. Remove the bolts
on the windshield.
A. Lower Hexagonal Area for Tightening

B. Upper Hexagonal Area
C. Rear View Mirror
A. Windshield
B. Bolts

• Remove the wellnuts and rivets, and

install them in the positions to suit
Windshield Position 1
the rider’s preference. After adjust-

ing, make sure to tighten all four bolts
securely.
A. Windshield
B. Bolts
C. Wellnuts
D. Rivets
A. Wellnuts
B. Rivets

Windshield Position 2 Windshield Position 3
A. Windshield A. Windshield
B. Bolts B. Bolts
C. Wellnuts C. Wellnuts
D. Rivets
NOTE
○Keep the uninstalled rivets in a safe
place.

BREAK-IN 51
BREAK-IN
The first 1 600 km (1 000 miles) that the motorcycle is ridden is designated as the
break-in period. If the motorcycle is not used carefully during this period, you may
very well end up with a “broken down” instead of a “broken in” motorcycle after a
few thousand kilometers.
The following rules should be observed during the break-in period.
• The table shows maximum recommended engine speed during the break-in pe-
riod.
Distance traveled Maximum engine speed
0 ∼ 800 km (0 ∼ 500 miles) 4 000 r/min (rpm)
800 ∼ 1 600 km (500 ∼ 1 000 miles) 6 000 r/min (rpm)
• Do not start moving or race the engine immediately after starting it, even if the
engine is already warm. Run the engine for two or three minutes at idle speed to
give the oil a chance to work up into all the engine parts.
• Do not race the engine while the transmission is in neutral.

52 BREAK-IN
WARNING
New tires are slippery and may cause loss of control and injury.
A break-in period of 160 km (100 miles) is necessary to establish normal
tire traction. During break-in, avoid sudden and maximum braking and
acceleration, and hard cornering.
In addition to the above, at 1 000 km (600 miles) it is extremely important that the
owner have the initial maintenance service performed by an authorized Kawasaki
dealer.

HOW TO RIDE THE MOTORCYCLE 53
HOW TO RIDE THE MOTORCYCLE
Starting the Engine

• Check that the engine stop switch is
in the position.
A. Neutral Indicator Light

B. Ignition Switch
C. ON Position
NOTE
A. Engine Stop Switch
B. Starter Button ○The motorcycle is equipped with a
vehicle-down sensor, which causes
• Turn the ignition key to “ON”. the engine to stop automatically and
• Make
tral.
sure the transmission is in neu- the FI indicator light to flash when the
motorcycle falls down. After righting

54 HOW TO RIDE THE MOTORCYCLE
the motorcycle, first turn the ignition NOTE

key to “OFF” and then back to “ON”
before starting the engine.
○The motorcycle is equipped with a
starter lockout switch. This switch is
• After the meter operation check,
leaving the throttle completely
designed so that the engine does not
closed, push the starter button. the side stand is down. However, the
engine can be started if the clutch
lever is pulled and the side stand is
NOTICE fully up.
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
starter to let it cool and the bat-
tery power recover.
A. Clutch Lever
B. Starter Lockout Switch

NOTICE Jump Starting

If your motorcycle battery is “run
Do not let the engine idle longer
down”, it should be removed and
than five minutes, or engine
charged. If this is not practical, a 12
overheating and damage may
volt booster battery and jumper cables
occur.
may be used to start the engine.

DANGER Connecting Jumper Cables

Battery acid generates hydro- •Remove the seat (see Seat section
in the GENERAL INFORMATION
gen gas which is flammable and
chapter).
explosive under certain con-
ditions. It is present within a •Make sure the ignition key is turned
to “OFF”.
battery at all times, even in a
discharged condition. Keep all •Connect a jumper cable from the
positive (+) terminal of the booster
flames and sparks (cigarettes)
battery to the positive (+) terminal of
away from the battery. Wear eye
the motorcycle battery.
protection when working with a
battery. In the event of battery •Connect another jumper cable from
the negative (–) terminal of the
acid contact with skin, eyes, or
booster battery to your motorcy-
clothing, wash the affected ar-
cle footpeg or other unpainted metal
eas immediately with water for
surface. Do not use the negative (–)
at least 5 minutes. Seek medical
terminal of the battery.
attention.

DANGER
Batteries contain sulfuric acid
that can cause burns and pro-
duce hydrogen gas which is
highly explosive. Do not make
this last connection at the fuel
system or battery. Take care not
to touch the positive and nega-
tive cables together, and do not
lean over the battery when mak-
A. Motorcycle Battery Positive (+) Terminal ing this last connection. Do not
B. From Booster Battery Positive (+) Terminal
C. Footpeg
connect to a frozen battery. It
D. From Booster Battery Negative (–) could explode. Do not reverse
Terminal polarity by connecting positive
(+) to negative (–), or a battery
explosion and serious damage
to the electrical system may oc-
cur.
• Follow the standard engine starting

procedure.

NOTICE Moving Off

Do not operate the starter con- • Check that the side stand is up.
tinuously for more than 5 sec- • Pull in the clutch lever.
onds or the starter will overheat • Shift into 1st gear.
and the battery power will drop • Open the throttle a little, and start to
let out the clutch lever very slowly.
temporarily. Wait 15 seconds
between each operation of the • As the clutch starts to engage, open
the throttle a little more, giving the en-
starter to let it cool and the bat-
gine just enough fuel to keep it from
tery power recover.
stalling.
• After the engine has started, discon-

nect the jumper cables. Disconnect
the negative (–) cable from the mo-
torcycle first.
• Reinstall the removed parts.
A. Shift Pedal

NOTE Shifting Gears

○The motorcycle is equipped with a • Close the throttle while pulling in the
clutch lever.
side stand switch. This switch is de-
signed so that the engine does not • Shift
gear.
into the next higher or lower
the side stand is down.
○When the headlight is on high beam, WARNING
two headlight beams go on, and on
low beam, one headlight goes on. Downshifting to a lower gear at
high speed causes engine rpm
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.
• Open the throttle halfway, while re-

leasing the clutch lever.

NOTE Braking
○The transmission is equipped with a • Close the throttle completely, leav-
ing the clutch engaged (except when
positive neutral finder. When the mo-
torcycle is standing still, the transmis- shifting gears) so that the engine will
sion cannot be shifted past neutral help slow down the motorcycle.
from 1st gear. To use the positive • Shift down one gear at a time so that
you are in 1st gear when you come
neutral finder, shift down to 1st gear,
then lift up on the shift pedal while to a complete stop.
standing still. The transmission will • When stopping, always apply both
brakes at the same time. Normally
shift only into neutral.
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
applying the brakes as hard as pos-
sible without skidding.

• Even in motorcycles equipped with

ABS, braking during cornering may
cause wheel slip. When turning a
corner, it is better to limit braking to
the light application of both brakes
or not to brake at all. Reduce your
speed before you get into the corner.
A. Rear Brake Pedal
A. Front Brake Lever

Anti-lock Brake System (ABS) must take the same care as with mo-
for models equipped with torcycles not equipped with ABS.
ABS
ABS is designed to help prevent
• ABS is not designed to shorten the
braking distance. On loose, uneven
the wheels from locking up when or downhill surfaces, the stopping
hard brakes are applied while running distance of a motorcycle with ABS
straight. The ABS automatically regu- may be longer than that of an equiv-
lates brake force. Intermittently gaining alent motorcycle without ABS. Use
gripping force and braking force helps special caution in such areas.
prevent wheel lock-up and allows sta-
ble steering control while stopping.
• ABS will help prevent wheel lock-up
during straight-up braking, but it can-
Brake control function is identical to not control wheel slip which may be
that of a conventional motorcycle. The caused by braking during cornering.
brake lever is used for the front brake When turning a corner, it is better to
and the brake pedal for the rear brake. limit braking to the light application of
Although the ABS provides stability both brakes or not to brake at all. Re-
while stopping by preventing wheel duce your speed before you get into
lock-up, remember the following char- the corner.
acteristics: • The computers integrated in the ABS
• ABS cannot compensate for adverse
road conditions, misjudgement or im-
compare vehicle speed with wheel
speed. Since non-recommended
proper application of brakes. You tires can affect wheel speed, they

may confuse the computers, which WARNING

can extend braking distance.
Use of non-recommended tires
may cause malfunctioning of
WARNING ABS and can lead to extended
ABS cannot protect the rider braking distance. The rider
from all possible hazards and could have an accident as a re-
is not a substitute for safe rid- sult. Always use recommended
ing practices. Be aware of how standard tires for this motorcy-
the ABS system operates and cle.
its limitations. It is the rider’s
responsibility to ride at appro- NOTE
priate speeds and manner for
weather, road surface and traffic
○When the ABS is functioning, you
may feel a pulsing in the brake lever
conditions. or pedal. This is normal. You need
not suspend applying brakes.
○ABS does not function at the speed
of approx. 5 km/h (3.1 mph) or below.
○ABS does not function if the battery
is discharged.
○ABS indicator light may go on un-
der motorcycle riding condition (ex.
The front or rear wheel races.). In

this case, first turn the ignition key to

“OFF”, and then back to “ON”. ABS
• The light does not go on when the
ignition switch is turned on.
indicator light goes off by this opera-
tion, but if ABS indicator light stays
• The light stays on after the motorcy-
cle starts moving.
on after the motorcycle runs at the
speed of approx. 5 km/h (3.1 mph)
• The light goes on and stays on after
the motorcycle starts moving.
or below, you should have the ABS Remember that the ABS does not
checked by an authorized Kawasaki function when the indicator light is on,
dealer. but if the ABS fails, the conventional
ABS Indicator Light brake system still works normally.
Normally the ABS indicator light goes
on when the ignition switch is turned on
and goes off shortly after the motorcy-
cle starts moving.
If the ABS indicator light shows any of
the following, a fault or faults may have
taken place in the ABS. You should
have the ABS checked by an autho-
rized Kawasaki dealer.

Stopping the Engine Stopping the Motorcycle in an

• Close the throttle completely. Emergency
• Shift the transmission into neutral. Your Kawasaki Motorcycle has been
• Turn the ignition key to “OFF”. designed and manufactured to pro-
• Support the motorcycle on a firm,
level surface with the side stand.
vide you optimum safety and conve-
nience. However, in order to fully ben-
• Lock the steering. efit from Kawasaki’s safety engineering
and craftsmanship, it is essential that
NOTE you, the owner and operator, properly
○The motorcycle is equipped with a maintain your motorcycle and become
vehicle-down sensor, which causes thoroughly familiar with its operation.
the engine to stop automatically and Improper maintenance can create a
the FI indicator light to flash when the dangerous situation known as throt-
motorcycle falls down. After righting tle failure. Two of the most common
the motorcycle, first turn the ignition causes of throttle failure are:
key to “OFF” and then back to “ON” 1. An improperly serviced or clogged
before starting the engine. air cleaner may allow dirt and dust
to enter the throttle body and stick
the throttle open.
2. During removal of the air cleaner,
dirt is allowed to enter and jam the
fuel injection system.

In an emergency situation such as Parking

throttle failure, your vehicle may be
stopped by applying the brakes and
• Shift the transmission into neutral
and turn the ignition key to “OFF”.
disengaging the clutch. Once this
stopping procedure is initiated, the en-
• Support the motorcycle on a firm,
level surface with the side stand.
gine stop switch may be used to stop
the engine. If the engine stop switch is NOTICE
used, turn off the ignition switch after
stopping the motorcycle. Do not park on a soft or steeply
inclined surface, or the motorcy-
cle may fall over.
• Ifstructure,
parking inside a garage or other
be sure it is well ventilated
and the motorcycle is not close to
any source of flame or sparks; this
includes any appliance with a pilot
light.

WARNING WARNING
The muffler and exhaust pipe Gasoline is extremely flammable
are very hot while the engine is and can be explosive under cer-
running and just after the engine tain conditions, creating the po-
stops. This can ignite a fire, re- tential for serious burns. Turn
sulting in property damage or the ignition switch “OFF”. Do
severe personal injury. not smoke. Make sure the area is
Do not idle or park your vehi- well-ventilated and free from any
cle in an area where flammable source of flame or sparks; this
materials such as grasses or dry includes any appliance with a pi-
leaves may contact with muffler lot light.
or exhaust pipe. Never fill the tank completely
to the top. If the tank is filled
completely to the top, heat may
cause the fuel to expand and
overflow through the vents in
the tank cap. After refueling,
make sure the tank cap is closed
securely.
If gasoline is spilled on the fuel
tank, wipe it off immediately.

• Lock the steering to prevent theft. Catalytic Converter

This motorcycle is equipped with
NOTE a catalytic converter in the exhaust
○When stopping near traffic at night, system. Platinum and rhodium in the
you can leave the taillight on for converter react with carbon monox-
greater visibility by turning the igni- ide, hydrocarbons and nitrogen oxides
tion key to the P (Park) position. to convert them into carbon dioxide,
○Do not leave the ignition switch at P water, nitrogen and oxygen resulting
(Park) position too long, or the bat- in much cleaner exhaust gases to be
tery will discharge. discharged into the atmosphere.
For proper operation of the catalytic
converter, the following cautions must
be observed.

WARNING • Use only unleaded gasoline. Never

use leaded gasoline. Leaded gaso-
The muffler and exhaust pipe
line significantly reduces the capabil-
are very hot while the engine is
ity of the catalytic converter.
running and just after the engine
stops. This can ignite a fire, re- • Do not operate the vehicle with the
engine or any one cylinder misfiring.
sulting in property damage or
Under these conditions unburned
severe personal injury.
air/fuel mixture flowing out of engine
Do not idle or park your vehi-
excessively accelerates reaction in
cle in an area where flammable
the converter allowing the converter
materials such as grasses or dry
to overheat and become damaged
leaves may contact with muffler
when the engine is hot, or reduces
or exhaust pipe.
converter performance when the en-
gine is cold.

70 SAFE OPERATION
SAFE OPERATION
Safe Riding Technique

The points given below are applicable for everyday motorcycle use and should
be carefully observed for safe and effective vehicle operation.
For safety, eye protection and a When riding always keep both
helmet are strongly recommended. hands on the handlebars and both
You should be aware of and verify feet on the footpegs. Removing
the applicable safety regulations in your hands from the handlebars or
force prior to riding your motorcy- feet from the footpegs while riding
cle. Gloves and suitable footwear can be hazardous. If you remove
should also be used for added pro- even one hand or foot, you can
tection in case of a mishap. reduce your ability to control the
motorcycle.
A motorcycle does not provide
the impact protection of an auto- Before changing lanes, look over
mobile, so defensive riding in addi- your shoulder to make sure the way
tion to wearing protective apparel is clear. Do not rely solely on the
is extremely important. Do not let rear view mirror; you may misjudge
protective apparel give you a false a vehicle’s distance and speed, or
sense of security. you may not see it at all.

SAFE OPERATION 71
In general your actions should When going down long slopes,

be smooth as sudden acceleration, control vehicle speed by closing
braking or turning may cause loss the throttle. Use the front and rear
of control, especially when riding in brakes for auxiliary braking.
wet conditions or on loose roadway
surfaces, when the ability to maneu- In wet conditions, rely more on the
ver will be reduced. throttle to control vehicle speed and
less on the front and rear brakes.
When going up steep slopes, shift The throttle should also be used ju-
to a lower gear so that there is plenty diciously to avoid skidding the rear
of power to spare rather than over- wheel from too rapid acceleration or
loading the engine. deceleration.
When applying the brakes, use Riding at the proper rate of speed
both the front and rear brakes. Ap- and avoiding unnecessarily fast ac-
plying only one brake for sudden celeration are important not only for
braking may cause the motorcycle safety and low fuel consumption but
to skid and lose control. also for long vehicle life and quieter
operation.
On rough roads, exercise caution,

slow down, and grip the fuel tank
with the knees for better stability.

72 SAFE OPERATION
When quick acceleration is neces- Avoiding unnecessary weaving is

sary as in passing, shift to a lower important to the safety of both the
gear to obtain the necessary power. rider and other motorists.
Do not downshift at too high an

r/min (rpm) to avoid damage to the
engine from overrevving.

SAFE OPERATION 73
Daily Safety Checks

Check the following items each day before you ride. The time required is minimal,
and habitual performance of these checks will help ensure you 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 motor-
cycle to a safe operating condition.
WARNING
Failure to perform these checks before operation may result in serious
damage or an accident. Always perform daily safety checks before oper-
ation.
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.

74 SAFE OPERATION
Fuel ............................. Adequate supply in tank, no leaks.

Engine Oil ................... Oil level between level lines.
Tires ............................ Air pressure (when cold):
Front 225 kPa (2.25 kgf/cm², 32 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
Install the air valve cap.
Drive Chain ................. Slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.)
Lubricate the drive chain if dry.
Nuts, Bolts, Fasteners Check that steering and suspension components, axles,
and all controls are properly tightened or fastened.
Steering ...................... Action smooth but not loose from lock to lock.
No binding of control cables.
Brakes ........................ Brake pad wear: Lining thickness more than 1 mm (0.04
in.) left.
No brake fluid leakage.
Throttle ....................... Throttle grip play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).
Clutch ......................... Clutch lever play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).
Clutch lever operates smoothly.
Coolant ....................... No coolant leakage.
Coolant level between level lines (when engine is cold).

SAFE OPERATION 75
Electrical Equipment ... All lights (Headlight, City Light, Tail/Brake Lights, Turn Sig-
nal Lights, License Plate Light, Warning/Indicator Lights)
and 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.
Refer to the “Daily Safety Checks” caution label attached on the rear fender rear.

76 SAFE OPERATION
Additional Considerations for High Speed Operation

Brakes: The importance of the brakes, especially during high speed operation,
cannot be overemphasized. Check to see that they are correctly adjusted and func-
tioning properly.
Steering: Looseness in the steering can cause loss of control. Check to see that
the handlebar turns freely but has no play.
Tires: High speed operation is hard on tires, and good tires are crucial for riding
safety. Examine their overall condition, inflate them to the proper pressure, and
check the wheel balance.
Fuel: Have sufficient fuel for the high fuel consumption during high speed oper-
ation.
Engine Oil: To avoid engine seizure and resulting loss of control, make sure that
the oil level is at the upper level line.
Coolant: To avoid overheating, check that the coolant level is at the upper level
line.
Electrical Equipment: Make sure that the headlight, tail/brake light, turn signal
lights, license plate light, horn, etc., all work properly.
Miscellaneous: Make sure that all nuts and bolts are tight and that all safety
related parts are in good condition.

SAFE OPERATION 77
WARNING
Handling characteristics of a motorcycle at high speeds may vary from
those you are familiar with at legal highway speeds. Do not attempt high
speed operation unless you have received sufficient training and have the
required skills.

78 MAINTENANCE AND ADJUSTMENT
MAINTENANCE AND ADJUSTMENT
The maintenance and adjustments outlined in this chapter must be carried out in
accordance with the Periodic Maintenance Chart to keep the motorcycle in good
running condition. The initial maintenance is vitally important and must not be
neglected.
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 done by the owner.

MAINTENANCE AND ADJUSTMENT 79
EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated
crankcase emission (1) and exhaust emission (2) control systems in compliance
with applicable regulations of the United States Environmental Protection Agency.
Additionally, Kawasaki has incorporated an evaporative emission control system
(3) in compliance with applicable regulations of the United States Environmental
Protection Agency.
1. Crankcase Emission Control System

This system eliminates the release of crankcase vapors into the atmosphere.
Instead, the vapors are routed through an oil separator to the intake side of the
engine. While the engine is operating, the vapors are drawn into the combustion
chamber, where they are burned along with the fuel and air supplied by the fuel
injection system.
2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere
by the exhaust of this motorcycle. The fuel, ignition and exhaust systems of this
motorcycle have been carefully designed and constructed to ensure an efficient
engine with low exhaust pollutant levels. The exhaust system of this model motor-
cycle includes a catalytic converter system.

3. Evaporative Emission Control System

The evaporative emission control system for this vehicle consists of low perme-
ation fuel hoses and a fuel tank.
3. Evaporative Emission Control System (Southeast Asia)

Vapors caused by fuel evaporation in the fuel system are not vented into the
atmosphere. Instead, fuel vapors are routed into the running engine to be burned,
or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor
separator and returned to the fuel tank.
High Altitude Performance Adjustment Information

High altitude adjustment is not required.

MAINTENANCE AND WARRANTY

Proper maintenance is necessary to ensure that your motorcycle will continue to
have low emission levels. This Owner’s Manual contains those maintenance rec-
ommendations for your motorcycle. Those items identified by the Periodic Mainte-
nance Chart are necessary to ensure compliance with the applicable standards.
As the owner of this motorcycle, you have the responsibility to make sure that
the recommended maintenance is carried out according to the instructions in this
Owner’s Manual at your own expense.
The Kawasaki Limited Emission Control System Warranty requires that you re-
turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty.
Please read the warranty carefully, and keep it valid by complying with the owner’s
obligations it contains.

Periodic Maintenance Chart

1. Periodic Inspection (Engine Related Items)
Frequency Whichever
comes first *Odometer Reading
km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
K
Air cleaner
element - clean • • • 110
Valve clearance
K every 42 000 km (26 250 mile) 108
- inspect
Throttle control
system (play,
smooth return,
no drag) -
year • • • • 111
inspect
Engine vacuum
K synchronization
- inspect
• • • 114
Idle speed -
inspect • • • • 114

Frequency Whichever
km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Fuel leak (fuel
K hose and pipe) -
inspect
year • • • • –
Fuel hoses
K damage -
inspect
year • • • • –
Fuel hoses
K
installation
condition -
year • • • • –
inspect
Coolant level -
inspect • • • • 102
Coolant leak -
inspect
year • • • • 99

Frequency Whichever
km × 1 000 (mile × 1 000) See
Page
Operation 1 6 12 18 24 30 36
Every
(Engine Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Radiator hose
damage -
inspect
year • • • • 99
Radiator hoses
installation
condition -
year • • • • 99
inspect
Evaporative
emission
control system
- function • • • • • • • 107
(Southeast Asia
model only)
Air suction
K system damage
- inspect
• • • 109

2. Periodic Inspection (Chassis Related Items)

Frequency Whichever
km × 1 000 (mile × 1 000)
See
Page
Operation
1 6 12 18 24 30 36
(Chassis Every
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Items)
Clutch and drive train:
Clutch
operation (play,
engagement,
disengagement)
• • • • 116
- inspect
Drive chain
lubrication
every 600 km (400 mile) 126
condition -
inspect #
Drive chain
every 1 000 km (600 mile) 119
slack - inspect #
Drive chain
wear - inspect # • • • 124

Frequency Whichever
km × 1 000 (mile × 1 000)
See
Page
Operation
1 6 12 18 24 30 36
(Chassis Every
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Items)
Drive chain
K guide wear -
inspect
• • • –
Wheels and tires:

Tire air pressure
- inspect
year • • • 140
Wheels/tires
damage -
inspect
• • • 141
Tire tread wear,

abnormal wear -
inspect
• • • 141
Wheel bearings
K damage -
inspect
year • • • –

Frequency Whichever
km × 1 000 (mile × 1 000)
See
Page
Operation
1 6 12 18 24 30 36
(Chassis Every
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Items)
Brake system:
Brake fluid leak
- inspect
year • • • • • • • 127
Brake hoses
damage -
inspect
year • • • • • • • 127
Brake pad wear

- inspect # • • • • • • 127
Brake hose
installation
condition -
year • • • • • • • 127
inspect
Brake fluid level
- inspect
6 months • • • • • • • 128

Frequency Whichever
km × 1 000 (mile × 1 000)
See
Page
Operation
1 6 12 18 24 30 36
(Chassis Every
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Items)
Brake operation
(effectiveness,
play, drag) -
year • • • • • • • 130
inspect
Brake light
switch operation
- inspect
• • • • • • • 131
Suspensions:
Front forks/rear
shock absorber
operation
(damping and • • • 133,
136
smooth stroke) -
inspect

Frequency Whichever
km × 1 000 (mile × 1 000)
See
Page
Operation
1 6 12 18 24 30 36
(Chassis Every
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Items)
Front forks/rear
shock absorber
oil leak - inspect
year • • • 133,
136
Steering system:
K
Steering play -
inspect
year • • • • –
Steering stem
K bearings -
lubricate
2 years • –
Electrical system:
Lights and
switches
operation -
year • • • –
inspect

Frequency Whichever
km × 1 000 (mile × 1 000)
See
Page
Operation
1 6 12 18 24 30 36
(Chassis Every
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Items)
Headlight
aiming - inspect
year • • • 149
Side stand
switch operation
- inspect
year • • • –
Engine stop
switch operation
- inspect
year • • • –
Chassis:
K
Chassis parts -
lubricate
year • • • –
Bolts and nuts

K tightness -
inspect
• • • • –

3. Periodic Replacement
Frequency Whichever
km × 1 000 (mile × 1 000) See
Page
1 12 24 36 48
Every
Change/Replacement Items (0.6) (7.5) (15) (22.5) (30)
K Air cleaner element # - replace 2 years 110
Engine oil # - change year • • • • • 95
Oil filter - replace year • • • • • 95
K Fuel hoses - replace 4 years • –
K Coolant - change 3 years • 106
K
Radiator hoses and O-rings -
replace
3 years • –
K Brake hoses - replace 4 years • –
K
Brake fluid (front and rear) -
change
2 years • • 130
K
Rubber parts of master
cylinder and caliper - replace
4 years • –

Frequency Whichever
km × 1 000 (mile × 1 000) See
Page
1 12 24 36 48
Every
Change/Replacement Items (0.6) (7.5) (15) (22.5) (30)
K Spark plug - replace • • • • 106
K
Vehicle-down sensor mounting
dampers - replace
4 years • –
K: Should be serviced by an authorized Kawasaki dealer.

*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions: dusty, wet, muddy,
high speed, or frequent starting/stopping.

Engine Oil Oil Level Inspection

In order for the engine, transmission,
and clutch to function properly, main-
• If the oil has just been changed, start
the engine and run it for several min-
tain the engine oil at the proper level, utes at idle speed. This fills the oil
and change the oil and replace the oil filter with oil. Stop the engine, then
filter in accordance with the Periodic wait several minutes until the oil set-
Maintenance Chart. Not only do dirt tles.
and metal particles collect in the oil, but
the oil itself loses its lubricative quality NOTICE
if used too long.
Racing the engine before the oil
WARNING reaches every part can cause en-
gine seizure.
Motorcycle operation with insuf-
ficient, deteriorated, or contam-
inated engine oil will cause ac-
celerated wear and may result in
engine or transmission seizure,
accident, and injury. Check the
oil level before each ride and
change the oil according to the
periodic maintenance chart in
the Owner’s Manual.

• Ifwait
the motorcycle has just been used,
several minutes for all the oil to
• Ifexcess
the oil level is too high, remove the
oil through the oil filler open-
drain down. ing using a syringe or some other
• Check the engine oil level through suitable device.
the oil level gauge. With the motor-
cycle held level, the oil level should
• If the oil level is too low, add the oil
to reach the correct level. Use the
come up between the upper and same type and brand of oil that is
lower level lines next to the gauge. already in the engine.
NOTICE
If the engine oil gets extremely
low or if the oil pump does not
function properly or oil pas-
sages are clogged, the oil pres-
sure warning indicator light
will go on. If it stays on when
the engine speed is above idle,
stop the engine immediately and
have it serviced. Failure to do
A. Oil Level Gauge
B. Upper Level Line so could cause serious engine
C. Lower Level Line damage.
D. Oil Filler Cap

Oil and/or Oil Filter Change

• Warm up the engine thoroughly, and
then stop it.
• Place an oil pan beneath the engine.
• Remove the engine oil drain bolt.
A. Oil Pressure Warning Indicator Light
A. Drain Bolt
• Let the oil completely drain with

the motorcycle perpendicular to the
ground.

WARNING
Motor oil is a toxic substance.
Dispose of used oil properly.
Contact your local authorities
for approved disposal methods
or possible recycling.
• Remove the oil filter and replace it

with a new one.
NOTE A. Oil Filter

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

• Apply a thin film of engine oil to the NOTE

packing and tighten the oil filter to the
specified torque.
○Replace the gasket with a new one.
Tightening Torque
Tightening Torque
Engine Oil Drain Bolt:
Oil Filter: 30 N·m (3.1 kgf·m, 22 ft·lb)
17.5 N·m (1.8 kgf·m, 13 ft·lb)
• Fill the engine up to the upper level

line with a good quality engine oil
specified in the table.
Recommended Engine Oil
Type:
API SG, SH, SJ, SL or SM with JASO
MA, MA1 or MA2
Viscosity:
SAE 10W-40
NOTE
A. Packing
○Do not add any chemical additive to
• Install the drain bolt with its new gas-
ket. Tighten it to the specified torque.
the oil. Oils fulfilling the above re-
quirements are fully formulated and

provide adequate lubrication for both Although 10W-40 engine oil is the
the engine and the clutch. recommended oil for most condi-
Engine Oil Capacity
tions, the oil viscosity may need to
be changed to accommodate atmo-
Capacity: spheric conditions in your riding area.
1.7 L (1.8 US qt) (when filter is not
removed)
1.9 L (2.0 US qt) (when filter is
removed)
2.4 L (2.5 US qt) (when engine is
completely dry)
• Start the engine.

• Check the oil level and oil leakage.

Cooling System NOTICE

Radiator and Cooling Fan - Using high-pressure water, as
Check the radiator fins for obstruc- from a car wash facility, could
tion by insects or mud. Clean off damage the radiator fins and im-
any obstructions with a stream of pair the radiator’s effectiveness.
low-pressure water. Do not obstruct or deflect air-
flow through the radiator by
WARNING installing unauthorized acces-
The cooling fan spins at high sories in front of the radiator or
speed and can cause serious behind the cooling fan. Inter-
injuries. Keep your hands and ference with the radiator airflow
clothing away from the cooling can lead to overheating and con-
fan blades at all times. sequent engine damage.
Radiator Hoses -
Check the radiator hoses for leakage,
cracks or deterioration, and connec-
tions for leakage, or looseness each
day before riding the motorcycle, and
in accordance with the Periodic Main-
tenance Chart.

Coolant - period of time, the cooling system ac-

Coolant absorbs excessive heat from cumulates rust and scale in the water
the engine and transfers it to the air jacket and radiator. This will clog up
at the radiator. If the coolant level be- the coolant passages, and consider-
comes low, the engine overheats and ably reduce the efficiency of the cooling
may suffer severe damage. Check the system.
coolant level each day before riding the
motorcycle, and in accordance with the WARNING
periodic maintenance chart and replen- Coolant containing corrosion
ish coolant if the level is low. Change inhibitors for alminum engines
the coolant in accordance with the Pe- and radiators include harmful
riodic Maintenance Chart. chemicals for human body.
Information for Coolant Drinking coolant can result in
To protect the cooling system (con- serious injury or death. Use
sisting of the aluminum engine and coolant in accordance with the
radiator) from rust and corrosion, the instractions of the manufacturer.
use of corrosion and rust inhibitor
chemicals in the coolant is essential. If Soft or distilled water must be used
coolant containing corrosion and rust with the antifreeze (see below for an-
inhibitor chemicals is not used, over a tifreeze) in the cooling system.

NOTICE NOTICE
If hard water is used in the sys- Permanent types of antifreeze on
tem, it causes scale accumula- the market have anti-corrosion
tion in the water passages, and and anti-rust properties. When it
considerably reduces the effi- is diluted excessively, it loses its
ciency of the cooling system. anti-corrosion property. Dilute a
permanent type of antifreeze in
If the lowest ambient temperature en- accordance with the instructions
countered falls below the freezing point of the manufacturer.
of water, use permanent antifreeze in
the coolant to protect the cooling sys- NOTE
tem against engine and radiator freeze
-up, as well as from rust and corrosion. ○A permanent type of antifreeze is in-
Use a permanent type of antifreeze stalled in the cooling system when
(soft water and ethylene glycol plus cor- shipped. It is colored green and con-
rosion and rust inhibitor chemicals for tains ethylene glycol. It is mixed at
aluminum engines and radiators) in the 50% and has the freezing point of
cooling system. On the mixture ratio –35°C (–31°F).
of coolant, choose the suitable one re-
ferring to the relation between freezing
point and strength directed on the con-
tainer.

Coolant Level Inspection NOTE

•Situate the motorcycle so that it is
perpendicular to the ground.
○Check the level when the engine is
cold (room or atmospheric tempera-
•Check the coolant level through the
coolant level gauge on the reserve
ture).
tank located to the right of the engine. • Ifcient,
the amount of coolant is insuffi-
remove the right middle fair-
The coolant level should be between
the F (Full) and L (Low) level lines. ing and add coolant into the reserve
tank.
A. F (Full) Level Line

B. L (Low) Level Line
C. Right Middle Fairing

Coolant Filling • Remove the bolts.

•Remove the seat (see Seat section
• Clear the projections from the grom-
mets, and remove the right middle
chapter). fairing forward.
•Remove the screw.
•Clear the projections from the grom-
mets, and remove the right side
cover backward.
A. Right Middle Fairing

B. Bolts
C. Projections and Grommets
A. Right Side Cover

B. Screw

• Remove the cap from the reserve

tank and add coolant through the
however, it must be returned to the
correct mixture ratio by the addition
filler opening to the F (Full) level line. of antifreeze concentrate as soon as
possible.
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.
B.
C.
Reserve Tank
Cap
F (Full) Level Line
• Install the cap.
D. L (Low) Level Line
NOTE
○In an emergency you can add wa-
ter alone to the coolant reserve tank,

• Install the right middle fairing as fol- • Install the right side cover as follows.
lows. • Fit the projections to the slots.
• Fit the projections to the slots. • Fit the projections to the grommets.
• Fit the projections to the grommets. • Tighten the screw.
• Tighten the bolts. • Install the seat (see Seat section
chapter).
A. Right Middle Fairing

B. Projections
C. Slots
A. Right Side Cover
D. Grommets
B. Projections
C. Slots
D. Grommets

Coolant Change Spark Plugs

Have the coolant changed by an au- The standard spark plug is shown in
thorized Kawasaki dealer. the table. The spark plugs should be
replaced in accordance with the Peri-
odic Maintenance Chart.
Spark plug removal should be done
by an authorized Kawasaki dealer.
Spark Plug
Standard Plug NGK CR9EIA-9
0.8 ∼ 0.9 mm
Plug Gap
(0.031 ∼ 0.035 in.)
15 N·m
Tightening Torque
(1.5 kgf·m, 11 ft·lb)

Evaporative Emission Control

System (Southeast Asia
model only)
This system routes fuel vapors from
the fuel system into the running engine
or stores the vapors in a canister when
the engine is stopped. Although no ad-
justments are required, a thorough vi-
sual inspection must be made at the in-
tervals specified by the Periodic Main-
A. 0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.) tenance Chart.
Inspection
• Check that the hoses are securely
connected.
• Replace any kinked, deteriorated, or
damaged hoses.

Valve Clearance
Valve and valve seat wear decreases
valve clearance, upsetting valve timing.
NOTICE
If valve clearance is left un-
adjusted, wear will eventually
cause the valves to remain
partly open; which lowers per-
formance, burns the valves and
valve seats, and may cause seri-
ous engine damage.
Valve clearance for each valve

should be checked and adjusted in
accordance with the Periodic Mainte-
nance Chart.
Inspection and adjustment should
be done by an authorized Kawasaki
dealer.

Kawasaki Clean Air System the air suction valve is prevented from
The Kawasaki Clean Air System returning. Inspect the air suction valve
(KCA) is a secondary air suction sys- in accordance with the Periodic Main-
tem that helps the exhaust gases to tenance Chart. Also, inspect the air
burn more completely. When the spent suction valve whenever stable idling
fuel charge is released into the ex- cannot be obtained, engine power is
haust system, it is still hot enough to greatly reduced, or there are abnormal
burn. The KCA System allows extra engine noises.
air into the exhaust system so that the Air suction valve removal and inspec-
spent fuel charge can continue to burn. tion should be done by an authorized
This continued burning action tends to Kawasaki dealer.
burn up a great deal of the normally
unburned gases, as well as chang-
ing a significant portion of the carbon
monoxide into carbon dioxide.
Air Suction Valve -
The air suction valve is essentially a
check valve which allows fresh air to
flow only from the air cleaner into the
exhaust port. Any air that has passed

Air Cleaner Oil Draining

A clogged air cleaner restricts the en-
gine’s air intake, increasing fuel con-
• Inspect the drain hose located on the
rear side of the engine to see if any
sumption, reducing engine power, and oil or water has run down from the air
causing spark plug fouling. cleaner housing.
The air cleaner element must be
cleaned in accordance with the Pe-
riodic Maintenance Chart. In dusty,
rainy, or muddy conditions, the air
cleaner element should be serviced
more frequently than the recom-
mended interval by an authorized
Kawasaki dealer.
A. Drain Hose
B. Plug
• Ifthethere is any oil in the hose, remove

plug from the lower end of the
drain hose and drain the oil.

WARNING Throttle Control System

Check the throttle grip play in accor-
Oil on tires will make them slip-
dance with the Periodic Maintenance
pery and can cause an accident
Chart, and adjust it if necessary.
and injury. Be sure to install the
plug in the drain hose after drain- Throttle Grip -
ing. The throttle grip controls the butterfly
valves in the throttle body. If the throt-
tle grip has excessive play due to either
cable stretch or maladjustment, it will
cause a delay in throttle response, es-
pecially at low engine speed. Also, the
throttle valve may not open fully at full
throttle. On the other hand, if the throt-
tle grip has not play, the throttle will be
hard to control, and the idle speed will
be erratic.

Inspection Adjustment
• Check that the throttle grip play is
correct by lightly turning the throttle
•Loosen the locknut at the upper end
of the throttle cable, and turn the
grip back and forth. throttle cable adjuster in completely
so as to give the throttle grip plenty
of play.
A. Throttle Grip
B. Throttle Grip Play
Throttle Grip Play A. Locknut
B. Adjuster
2 ∼ 3 mm (0.08 ∼ 0.12 in.) C. Throttle Cable (Accelerator Cable)
• If there is improper play, adjust it.

• Ifjusted
the throttle grip play cannot be ad-
with the accelerator cable ad-
• Turn out the accelerator cable ad-
juster until a play of 2 ∼ 3 mm (0.08
juster at the throttle grip, use the de- ∼ 0.12 in.) is obtained at the throttle
celerator cable adjuster located un- grip.
der the fuel tank. • Tighten the locknut.
• Turn out the decelerator cable adjust-
ing nut until there is no play when the
• With the engine idling, turn the han-
dlebar to each side. If handlebar
throttle grip is completely closed. movement changes the idle speed,
• Tighten the locknut. the throttle cables may be improperly
adjusted or incorrectly routed, or they
may be damages. Be sure to correct
any of these conditions before idling.
WARNING
Operation with improperly ad-
justed, incorrectly routed, or
damaged cable could result in
an unsafe riding condition. Be
sure the control cable is ad-
A. Adjuster
justed and routed correctly, and
B. Locknut is free from damage.
C. Throttle Cable (Decelerator Cable)

Engine Vacuum Synchronization Idle Speed

Engine vacuum synchronization The idle speed check should be per-
must be checked and adjusted period- formed in accordance with the Peri-
ically in accordance with the Periodic odic Maintenance Chart or whenever
Maintenance Chart by an authorized the idle speed is disturbed.
Kawasaki dealer.
Adjustment
NOTE •Start the engine, and warm it up thor-
○Poor engine vacuum synchronization oughly.
will cause unstable idling, sluggish •Adjust the idle speed by turning the
idle adjusting screw.
throttle response, and reduce engine
power and performance. Idle Speed
1 250 ∼ 1 350 r/min (rpm)

adjusted or incorrectly routed, or they

may be damaged. Be sure to correct
any of these conditions before riding.
WARNING
Operation with damaged cables
could result in an unsafe riding
condition. Replace damaged
control cables before operation.
A. Idle Adjusting Screw
• Open and close the throttle a few

times to make sure that the idle
speed does not change. Readjust if
necessary.
• With the engine idling, turn the han-
dlebar to each side. If handlebar
movement changes the idle speed,
the throttle cables may be improperly

Clutch
Due to friction plate wear and clutch
• Check the clutch lever play as shown
in the figure.
cable stretch over a long period of use,
the clutch operation should be checked
each day before riding the motorcycle,
and in accordance with the Periodic
Maintenance Chart.
Inspection
• Check that the clutch lever operates
properly and that the inner cable
slides smoothly. If there is any irreg-
ularity, have the clutch cable checked
by an authorized Kawasaki dealer.
A. Locknut
B. Clutch Lever Play
C. Adjuster
Clutch Lever Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
If the play is incorrect, adjust the lever

play as follows.

Adjustment • Loosen the locknut, and turn the

adjuster so that the clutch lever will
WARNING have the proper play.
Excess clutch cable play could • If it cannot be done, use the nuts at
the lower end of the clutch cable.
prevent clutch disengagement
and cause a crash resulting in
serious injury or death. When
adjusting the clutch cable, be
sure the upper end of the outer
cable is fully seated in its fitting
so that it doesn’t slip into place
later and create excessive cable
play.
A. Nuts
B. Clutch Cable

WARNING DANGER
To avoid a serious burn, never Exhaust gas contains carbon
touch a hot engine or an exhaust monoxide, a colorless, odor-
pipe during clutch adjustment. less poisonous gas. Inhaling
carbon monoxide can cause
serious brain injury or death.
NOTE
DO NOT run the engine in en-
○After the adjustment is made, start closed areas. Operate only in a
the engine and check that the clutch well-ventilated area.
does not slip and releases properly.
○For minor corrections, use the ad-
juster at the clutch lever.

Drive Chain Chain Slack Inspection

The drive chain slack and lubrica-
tion must be checked each day be-
•Set the motorcycle up on its side
stand.
fore riding the motorcycle, and in accor-
dance with the Periodic Maintenance
•Rotate the rear wheel to find the po-
sition where the chain is tightest, and
Chart for safety and to prevent exces- measure the maximum chain slack
sive wear. If the chain becomes badly by pulling up and pushing down the
worn or maladjusted - either too loose chain midway between the engine
or too tight - the chain could jump off sprocket and rear wheel sprocket.
the sprockets or break.
WARNING
A chain that breaks or jumps off
the sprockets could snag on the
engine sprocket or lock the rear
wheel, severely damaging the
motorcycle and causing it to go
out of control. Inspect the chain
for damage and proper adjust-
ment before each ride.
A. Chain Slack

• Ifloose,
the drive chain is too tight or too Chain Slack Adjustment
adjust it so that the chain slack
will be within the standard value.
•Remove the cotter pin, and loosen
the rear axle nut.
Drive Chain Slack •Loosen the left and right chain ad-
juster locknuts.
Standard 25 ∼ 35 mm (1.0 ∼ 1.4 in.)
A. Rear Axle Nut

B. Cotter Pin
C. Adjuster
D. Locknut
• Iflefttheandchain is too loose, turn out the

right chain adjusters evenly.

• Ifandtheright
chain is too tight, turn in the left
chain adjusters evenly.
• Turn out both chain adjusters evenly
until the drive chain has the cor-
rect amount of slack. To keep the
chain and wheel properly aligned,
the notch on the left wheel alignment
indicator should align with the same
swingarm mark that the right indica-
tor notch aligns with.
A. Marks
B. Notch
C. Indicator
D. Adjuster
E. Locknut
NOTE
○Wheel alignment can also be
checked using the straightedge or
string method.

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
rear axle nut and axle, and spread its
dition. Align the rear wheel us-
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.

• Tighten the rear axle nut to the spec-
ified torque.
Tightening Torque
Rear Axle Nut:
108 N·m (11.0 kgf·m, 80 ft·lb)
A. Cotter Pin
NOTE
○If a torque wrench is not available,
this item should be serviced by a
Kawasaki dealer.

NOTE WARNING
○When inserting the cotter pin, if the A loose axle nut can lead to an
slots in the nut do not align with accident resulting in serious in-
the cotter pin hole in the axle shaft, jury or death. Tighten the axle
tighten the nut clockwise up to the nut to the proper torque and in-
next alignment. stall a new cotter pin.
○It should be within 30 degree.
○Loosen once and tighten again when • Check the rear brake (see Brakes
the slot goes past the nearest hole. section).
A. Turning Clockwise

Wear Inspection center of the 1st pin to the pin center

•Remove the bolts to take off the chain
cover.
of the 21st pin. Since the chain may
wear unevenly, take measurements
at several places.
• Ifthethechain
length exceeds the service limit,
should be replaced.
A. Chain Cover
B. Bolts
• Stretch the chain taut either by using

the chain adjusters, or by hanging a A. Measure
10 kg (20 lb) weight on the chain. B. Weight
• Measure the length of 20 links on the
straight part of the chain from the pin

Drive Chain 20-Link Length NOTE

Service Limit 319 mm (12.56 in.)
○Sprocket wear is exaggerated for il-
lustration. See Service Manual for
wear limits.
WARNING
For safety, use only the standard
chain. It is an endless type and
should not be cut for installa-
tion; have it installed by an au-
thorized Kawasaki dealer.
• Rotate the rear wheel to inspect the

drive chain for damaged rollers, and
loose pins and links.
• Also inspect the sprockets for un-
evenly or excessively worn teeth, A. Good Teeth
B. Worn Teeth
and damaged teeth. C. Damaged Teeth
• Ifdrive
there is any irregularity, have the
chain and/or the sprockets re-
placed by an authorized Kawasaki
dealer.

Lubrication
Lubrication is also necessary after
• Apply oil to the sides of the rollers so
that it will penetrate to the rollers and
riding through rain or on wet roads, or bushings. Apply oil to the O-rings so
any time that the chain appears dry. A that the O-rings will be coated with
heavy oil such as SAE 90 is preferred oil. Wipe off any excess oil.
to a lighter oil because it will stay on the
chain longer and provide better lubrica-
tion.
• Ifusing
the chain is especially dirty, clean it
diesel oil or kerosine and then
apply oil as described above.

Brakes Disc Brake Fluid -

In accordance with the Periodic Main-
Brake Wear Inspection
tenance Chart, inspect the brake fluid
Inspect the brakes for wear. For each
level in both the front and rear brake
front and rear disc brake caliper, if the
fluid reservoirs and change the brake
thickness of either pad is less than
fluid. The brake fluid should also be
1 mm (0.04 in.), replace both pads
changed if it becomes contaminated
in the caliper as a set. Pad replace-
with dirt or water.
ment should be done by an authorized
Kawasaki dealer. Fluid Requirement
Use heavy-duty brake fluid only from
a container marked DOT4.
NOTICE
Do not spill brake fluid onto any
painted surface.
Do not use fluid from a container
that has been left open or that
has been unsealed for a long
time.
A. Lining Thickness Check for fluid leakage around
B. 1 mm (0.04 in.) the fittings.
Check brake hose for damage.

Fluid Level Inspection

• The brake fluid level in the front brake
fluid reservoir must be kept above
the line (lower level line) next to the
gauge and that in the rear brake fluid
reservoir (located under the seat)
must be kept between the upper and
lower level lines (reservoirs held hor-
izontal).
A. Rear Brake Fluid Reservoir

B. Upper Level Line
C. Lower Level Line
A. Front Brake Fluid Reservoir

B. Lower Level Line

• Iflower
the fluid level in either reservoir is
than the lower level line, check
WARNING
Mixing brands and types of
for fluid leaks in the brake lines, and
brake fluid can reduce the brake
fill the reservoir to the upper level
system’s effectiveness and
line. Inside the front brake fluid reser-
cause an accident resulting in
voir is a stepped line showing the up-
injury or death. Do not mix two
per level line.
brands of brake fluid. Change
the brake fluid in the brake line
completely if the brake fluid
must be refilled but the type
and brand of the brake fluid that
is already in the reservoir are
unidentified.
NOTE
○First, tighten until slight resistance is
felt indicating that the cap is seated
A. Front Brake Fluid Reservoir on the reservoir body, then tighten
B. Upper Level Line the cap an additional 1/6 turn while
holding the brake fluid reservoir
body.

So there are no parts that require ad-

justment on the front and rear brakes.
WARNING
Air in the brake lines diminish
braking performance and can
injury or death. If the brake lever
or pedal feels mushy when it
is applied, there might be air in
A. Reservoir the brake lines or the brake may
B. Cap be defective. Have the brake
C. Clockwise
D. 1/6 turn
checked immediately by an au-
Fluid Change
Have the brake fluid changed by an
authorized Kawasaki dealer.
Front and Rear Brakes -
Disc and disc pad wear is automat-
ically compensated for and has no ef-
fect on the brake lever or pedal action.

Brake Light Switches

When either the front or rear brake is
• Check the operation of the rear brake
light switch by depressing the brake
applied, the brake light goes on. The pedal. The brake light should go on
front brake light switch requires no ad- after the proper pedal travel.
justment, but the rear brake light switch
should be adjusted in accordance with
the Periodic Maintenance Chart.
Inspection
• Turn the ignition key to “ON”.
• The brake light should go on when
the front brake is applied.
• If it does not, ask an authorized
Kawasaki dealer to inspect the front
brake light switch.
A. Brake Pedal
B. 10 mm (0.39 in.)
• Iflightit does not, adjust the rear brake

switch.
Brake Pedal Travel
10 mm (0.39 in.)

Adjustment • To adjust the rear brake light switch,

•Disconnect the connector. move the switch up or down by turn-
ing the switch body.
A. Connector
A. Rear Brake Light Switch
B. Adjusting Nut
C. Lights sooner
D. Lights later
• Connect the connector.

Front Fork
The front fork operation and oil leak-
age should be checked in accordance
with the Periodic Maintenance Chart.
Front Fork Inspection
• Holding the brake lever, pump the
front fork up and down by several
times to inspect smooth stroke.
• Visually inspect the front fork for oil
leakage, scoring or scratches on the
outer surface of the inner tube. A. Inner Tube
• If there is any doubt about the front

fork, it should be checked by an au-

On the top of each front fork leg is Spring Preload Adjustment

a spring preload adjuster and on the
spring preload adjuster of the right
•Turn the spring preload adjuster into
the nut to increase spring force and
front fork leg is a rebound damping out to decrease spring force. The
force adjuster so that the spring force adjusting range is as follows.
and damping force can be adjusted Adjusting Range
for different riding and loading condi-
15 turns out*
tions. Weaker spring force and damp-
ing force are for comfortable riding, *: Counterclockwise from the fully
but they should be increased for high seated position
speed riding or riding on rough roads.
Rebound Damping Force Adjustment
•Turn the rebound damping force
adjuster all the way into the spring
preload adjuster with a screwdriver.
This makes the damping force great-
est.
•Turn out the adjuster to decrease
damping force.
A. Spring Preload Adjuster

B. Rebound Damping Force Adjuster

Spring Preload
7 turns out*
Adjuster
Rebound
Damping Force 1 3/4 turns out*
Adjuster
*: Counterclockwise from the fully

seated position
NOTICE
A. Screwdriver Do not force to turn the rebound
B. Rebound Damping Force Adjuster damping force adjuster from the
The standard setting positions of the fully seated position, as the ad-
spring preload adjuster and rebound justing mechanism may be dam-
damping force adjuster for an average aged.
-build rider of 68 kg (150 lb) with no pas-
senger and no accessories are as fol-
lows:

Rear Shock Absorber

The rear shock absorber operation
• Ifshock
there is any doubt about the rear
absorber, it should be checked
and oil leakage should be checked in by an authorized Kawasaki dealer.
accordance with the Periodic Mainte-
nance Chart.
Rear Shock Absorber Inspection
•Press down on the seat several times
to inspect the stroke.
•Visually inspect the rear shock ab-
sorber for oil leakage.
A. Rear Shock Absorber
The rear shock absorber can be ad-

justed by changing the spring preload
and rebound damping force for various
riding and loading conditions.
Spring Preload Adjustment
The spring preload adjuster on the
rear shock absorber has 7 positions.

NOTICE
Be careful not to damage the
motorcycle parts when adjust-
ing the spring preload.
Rebound Damping Force Adjustment

The rebound damping force adjuster
is located at the lower end of the rear
shock absorber.
A. Spring Preload Adjuster
B. Wrench
• Inble,accordance with the following ta-

turn the preload adjuster with the
wrench from the tool kit.
Position 1 2 3 4 5 6 7
Spring Action Stronger ——→
The standard setting position for an

average-build rider of 68 kg (150 lb) A. Rebound Damping Force Adjuster
with no passenger and no accessories
is No. 5.

• Turn the rebound damping force ad-

juster towards the H mark to make
Wheels
Tubeless tires are installed on the
the damping force greatest. wheels of this motorcycle. The indica-
• Turn the adjuster towards the S mark
to decrease damping force.
tions of TUBELESS on the tire side wall
and the rim show that the tire and rim
The standard setting position of the are specially designed for tubeless use.
rebound damping force adjuster for an
average-build rider of 68 kg (150 lb)
with no passenger and no accessories
is as follows:
Rebound Damping
5 clicks*
Force Adjuster
*: out from the fully seated position
A. TUBELESS Mark

WARNING
Installing a tube inside a tube-
less-type tire can create exces-
sive heat build up that can dam-
age the tube and cause rapid
deflation. The tires, rims, and
air valves on this motorcycle are
designed only for tubeless type
wheels. The recommended stan-
dard tires, rims, and air valves
A. TUBELESS Mark must be used for replacement.
The tire and rim form a leakproof unit Do not install tube-type tires on
by making airtight contacts at the tire tubeless rims. The beads may
chamfers and the rim flanges instead not seat properly on the rim
of using an inner tube. causing tire deflation. Do not
install a tube inside a tubeless
tire. Excessive heat build-up
may damage the tube causing
tire deflation.

Tires - ○Tire pressure is affected by changes

in ambient temperature and altitude,
Payload and Tire Pressure
and so the tire pressure should be
Failure to maintain proper inflation
checked and adjusted when your rid-
pressures or observe payload limits for
ing involves wide variations in tem-
your tires may adversely affect han-
perature or altitude.
dling and performance of your motorcy-
cle and can result in loss of control. The
maximum recommended load in addi-
tion to vehicle weight is 180 kg (397 lb),
including rider, passenger, baggage,
and accessories.
• Remove the air valve cap.
• Check the tire pressure often, using
an accurate gauge.
• Make sure to install the air valve cap
securely.
NOTE A. Tire Pressure Gauge
○Measure the tire pressure when the Tire Air Pressure (when cold)
tires are cold (that is, when the mo- Front 225 kPa (2.25 kgf/cm², 32 psi)
torcycle has not been ridden more
Rear 250 kPa (2.50 kgf/cm², 36 psi)
than a mile during the past 3 hours).

Tire Wear, Damage

As the tire tread wears down, the tire
• InMaintenance
accordance with
Chart,
the Periodic
measure the
becomes more susceptible to puncture depth of the tread with a depth
and failure. An accepted estimate is gauge, and replace any tire that
that 90% of all tire failures occur during has worn down to the minimum al-
the last 10% of tread life (90% worn). lowable tread depth.
So it is false economy and unsafe to
use the tires until they are bald.
A. Tire Depth Gauge

Minimum Tread Depth WARNING

— 1 mm Tires that have been punctured
Front
(0.04 in.) and repaired do not have the
Under 130 km/h 2 mm same capabilities as undam-
(80 mph) (0.08 in.) aged tires and can suddenly fail,
Rear
Over 130 km/h 3 mm causing an accident resulting
(80 mph) (0.12 in.) in serious injury or death. Re-
place damaged tires as soon as
• Visually inspect the tire for cracks
and cuts, replacing the tire in case of
possible. To ensure safe han-
dling and stability, use only the
bad damage. Swelling or high spots recommended standard tires for
indicate internal damage, requiring replacement, inflated to the stan-
tire replacement. dard pressure. If it is necessary
• Remove any imbedded stones or
other foreign particles from the tread.
to ride on a repaired tire, do not
exceed 100 km/h (60 mph) until
the tire is replaced.
NOTE
○Have the wheel balance inspected
NOTE
whenever a new tire is installed.
○Most countries may have their own
regulations requiring a minimum tire
tread depth; be sure to follow them.

○When operating on public roadways, Replacement Tire (Tubeless) KLE650C

keep maximum speed under traffic Model only
law limits. Make, Type:
Standard Tire (Tubeless) PIRELLI, SCORPION
Front SYNC FRONT
Make, Type: Size:
DUNLOP, SPORTMAX 120/70 ZR17 M/C (58W)
Front RADIAL D221FAG
Size: Make, Type:
120/70 ZR17 M/C (58W) PIRELLI, SCORPION
Rear SYNC RADIAL
Make, Type: Size:
DUNLOP, SPORTMAX D221G 160/60 ZR17 M/C (69W)
Rear
Size:
160/60 ZR17 M/C (69W)
WARNING
Mixing tire brands and types can
adversely affect handling and
injury or death. Always use the
same manufacturer’s tires on
both front and rear wheels.

WARNING Battery
The battery installed in this motorcy-
New tires are slippery and may
cle is a sealed type, so it is not nec-
cause loss of control and injury.
essary to check the battery electrolyte
A break-in period of 160 km (100
level or add distilled water.
miles) is necessary to estab-
The sealing strip should not be pulled
lish normal tire traction. During
off once the specified electrolyte has
break-in, avoid sudden and max-
been installed in the battery for initial
imum braking and acceleration,
service.
and hard cornering.
However, in order to maximize bat-
tery life and ensure that it will provide
the power needed to start the motor-
cycle you must properly maintain the
battery’s charge. When used regularly,
the charging system in the motorcycle
helps keep the battery fully charged. If
your motorcycle is only used occasion-
ally or for short periods of time, the bat-
tery is more likely to discharge.
Due to their internal composition,
batteries continually self discharge.
The discharge rate depends on the

type of battery and ambient temper- Self-discharge

ature. As temperature rises, so does Approx. number of days
the discharge rate. Every 15°C (27°F) from 100% charged to
doubles the rate. 100% discharged
Electrical accessories, such as digi- Tempera-
ture Lead Lead
tal clocks and computer memory, also
-Antimony -Calcium
draw current from the battery even
when the key is switched off. Due to Battery Battery
a combination of such “key-off” draws 40°C
and hot temperature, a battery can go 100 Days 300 Days
(104°F)
from fully charged to completely dis-
25°C (77°F) 200 Days 600 Days
charged in a matter of days.
0°C (32°F) 550 Days 950 Days

Current Drain Sulfation occurs when the battery is

Days from Days from
left in a discharged condition for an ex-
100% 100% tended time. Sulfate is a normal by
Discharging product of the chemical reactions within
charged charged
Ampere a battery. But when continuous dis-
to 50% to 100%
discharged discharged charge allows the sulfate to crystallize
7 mA 60 Days 119 Days in the cells, the battery plates become
permanently damaged and will not hold
10 mA 42 Days 83 Days a charge. Battery failure due to sulfa-
15 mA 28 Days 56 Days tion is not warrantable.
20 mA 21 Days 42 Days Battery Maintenance -
30 mA 14 Days 28 Days It is the owner’s responsibility to keep
the battery fully charged. Failure to do
In extremely cold weather the fluid in so can lead to battery failure and leave
an inadequately charged battery can you stranded.
easily freeze, which can crack the case If you are riding your vehicle infre-
and buckle the plates. A fully charged quently, inspect the battery voltage
battery can withstand sub-freezing weekly using a voltmeter. If it drops
temperature with no damage. below 12.8 volts, the battery should be
charged using an appropriate charger
Battery Sulfation - (check with a Kawasaki dealer). If
A common cause of battery failure is
sulfation.

you will not be using the motorcy- capacity. For example, the charging
cle for longer than two weeks, the rate for a 10 Ah battery would be 1.0
battery should be charged using an ampere.
appropriate charger. Do not use an au-
tomotive-type quick charger that may
• The charger will keep the battery fully
charged until you are ready to re-
overcharge the battery and damage it. install the battery in the motorcycle
(see Battery Installation).
Kawasaki-recommended chargers
are:
OptiMate ΙΙΙ NOTICE
Yuasa 1.5 Amp Automatic charger Never remove the sealing strip,
Battery Mate 150-9 or the battery can be damaged.
Do not install a conventional
If the above chargers are not avail- battery in this motorcycle, or the
able, use equivalent one. electrical system cannot work
For more details, ask a Kawasaki properly.
dealer.
Battery Charging - NOTE
•Remove the battery from the motor-
cycle (see Battery Removal).
○If you charge the sealed battery,
never fail to observe the instructions
•Attach the leads from the charger to
the battery and charge the battery at
shown in the label on the battery.
a rate that is 1/10th of the battery

Battery Removal • Clean the battery using a solution of

•Remove the seat (see Seat section
baking soda and water. Be sure that
the cable connections are clean.
chapter).
•Slide the red cap. Battery Installation
•Disconnect the cables from the bat-
tery, first from the (–) terminal and
•Place the battery in the rear fender
front.
then the (+) terminal. •Connect the (+) cable to the (+) ter-
minal, and then connect the (–) cable
to the (–) terminal.
NOTICE
Installing the (–) cable to the (+)
terminal of the battery or the (+)
cable to the (–) terminal of the
battery can seriously damaged
the electrical system.
A. Red Cap ((+) Terminal) • Put a light coat of grease on the ter-
minals to prevent corrosion.
B. (–) Terminal
• Cover the red cap.
• Take the battery out. • Reinstall the removed parts.

Headlight Beam Vertical Adjustment

The headlight beam is adjustable ver-
Horizontal Adjustment
tically. If adjusted too low, neither low
The headlight beam is adjustable
nor high beam will illuminate the road
horizontally. If not properly adjusted
far enough ahead. If adjusted too high,
horizontally, the beam will point to one
the high beam will fail to illuminate the
side rather than straight ahead.
road close ahead, and the low beam
• Turn the horizontal adjuster clock-
wise or counterclockwise until the
will blind oncoming drivers.
beam points straight ahead. • Turn the vertical adjuster clockwise
or counterclockwise to adjust its ver-
tical angle.
A. Horizontal Adjuster
A. Vertical Adjuster

NOTE Fuses
○On high beam, the brightest point Fuses are arranged in the fuse box
located under the seat. The main fuse
should be slightly below horizontal
with the motorcycle on its wheels and is mounted on the starter relay behind
the rider seated. Adjust the headlight the left side cover. If a fuse fails during
to the proper angle according to local operation, inspect the electrical system
regulations. to determine the cause, and then re-
place it with a new fuse of proper am-
perage.
A. Fuse Box
B. Fuses
C. Spare Parts

• Remove the bolt. • Remove the cover by removing the

• Clear the projections from the grom-
mets, and remove the left frame
bolt.
cover upward.
A. Cover
B. Bolt
A. Left Frame Cover
B. Bolt

• Disconnect the connector. • Install the left frame cover as follows.

• Fit the projection to the slot.
• Fit the projections to the grommets.
• Tighten the bolt.
A. Main Fuse
B. Spare Fuse
C. Connector
A. Left Frame Cover

B. Projections
C. Slot
D. Grommets

WARNING
Substituting fuses can cause
wiring to overheat, catch fire
and/or fail. Do not use any sub-
stitute for the standard fuse.
Replace the blown fuse with a
new one of the correct capacity,
as specified on the fuse box and
main fuse.
A. Normal
B. Failed

Cleaning Your Motorcycle • Gasoline, brake fluid, and coolant

will damage the finish of painted and
General Precautions
plastic surfaces: wash them off im-
Frequent and proper care of your
mediately.
Kawasaki motorcycle will enhance
its appearance, optimize overall per- • Avoid wire brushes, steel wool, and
all other abrasive pads or brushes.
formance, and extend its useful life.
Covering your motorcycle with a high • Use care when washing the wind-
shield, headlight cover, and other
quality, breathable motorcycle cover
plastic parts as they can easily be
will help protect its finish from harmful
scratched.
UV rays, pollutants, and reduce the
amount of dust reaching its surfaces. • Avoid using pressure washers; wa-
ter can penetrate seals and electrical
• Be sure the engine and exhaust are
cool before washing.
components and damage your mo-
torcycle.
• Avoid applying degreaser to seals,
brake pads, and tires. • Avoid spraying water in delicate
areas such as in air intakes, fuel
• Always use non-abrasive wax and
cleaner/polisher.
system, brake components, electri-
cal components, muffler outlets, and
• Avoid all harsh chemicals, solvents,
detergents, and household cleaning
fuel tank openings.
products such as ammonia-based
window cleaners.

Washing Your Motorcycle • After cleaning your motorcycle,

•Rinse your bike with cold water from
a garden hose to remove any loose
check the rubber boot covering the
shift pedal ball joint for correct instal-
dirt. lation. Be sure the sealing lip of the
•Mix a mild neutral detergent (de-
signed for motorcycles or automo-
rubber boot fits into the groove of the
ball joint.
biles) and water in a bucket. Use
a soft cloth or sponge to wash your
motorcycle. If needed, use a mild de-
greaser to remove any oil or grease
which build up.
•After washing, rinse your motorcy-
cle thoroughly with clean water to re-
move any residue (residue from the
detergent can damage parts of your
motorcycle).
•Use a soft cloth to dry your motorcy-
cle. As you dry, inspect your motor- A. Rubber Boot
cycle for chips and scratches. Do not
let the water air dry as this can dam-
age the painted surfaces.

• Ifa the boot is damaged, replace it with

new one. If the boot is not posi-
several times. This helps the brakes
dry and restores its normal operating
tioned in the groove correctly, place performance.
it in the correct position. • Lubricate the drive chain to prevent
rusting.
NOTE
○After riding in an area where the
roads are salted or near the ocean,
immediately wash your motorcycle
with cold water. Do not use warm
water as it accelerates the chemical
reaction of the salt. After drying,
apply a corrosion protection spray
on all metal and chrome surfaces to
A. Not correct position prevent corrosion.
B. Correct position ○Condensation may form on the inside
• Start the engine and let it idle for sev-
eral minutes. The heat from the en-
of the headlight lens after riding in the
rain, washing the motorcycle or hu-
gine will help dry moist areas. mid weather. To remove the mois-
• Carefully ride your motorcycle at a
slow speed and apply the brakes
ture, start the engine and turn on the

headlight. Gradually the condensa- an approved plastic cleaner/polisher

tion on the inside of the lens will clear product.
off.
NOTICE
Painted Surfaces Plastic parts may deteriorate
After washing your motorcycle, coat and break if they come in con-
painted surfaces, both metal and plas- tact with chemical substances
tic, with a commercially available mo- or household cleaning products
torcycle/automotive wax. Wax should such as gasoline, brake fluid,
be applied once every three months or window cleaners, thread-locking
as conditions require. Avoid surfaces agents, or other harsh chemi-
with “satin” or “flat” finishes. Always cals. If a plastic part comes in
use non-abrasive products and apply contact with any harsh chemical
them according to the instructions on substance, wash it off immedi-
the container. ately with water and a mild neu-
Windshield and Other Plastic Parts tral detergent, and then inspect
After washing use a soft cloth to gen- for damage. Avoid using abra-
tly dry plastic parts. When dry, treat sive pads or brushes to clean
the windshield, headlight lens, and plastic parts, as they will dam-
other non-painted plastic parts with age the part’s finish.

Chrome and Aluminum Vinyl parts should be washed with the

Chrome and uncoated aluminum rest of the motorcycle, then treated with
parts can be treated with a chrome/alu- a vinyl treatment.
minum polish. Coated aluminum The sidewalls of tires and other rub-
should be washed with a mild neu- ber components should be treated with
tral detergent and finished with a spray a rubber protectant to help prolong their
polish. Aluminum wheels, both painted useful life.
and unpainted can be cleaned with
special non-acid based wheel spray WARNING
cleaners. Rubber protectants can be slip-
Leather, Vinyl, and Rubber pery and, if used on the tread
If your motorcycle has leather ac- area, cause loss of traction re-
cessories, special care must be taken. sulting in accident causing in-
Use a leather cleaner/treatment to jury or death. Do not apply rub-
clean and care for leather accessories. ber protectant to any tread area.
Washing leather parts with detergent
and water will damage them, shorten-
ing their life.

STORAGE 159
STORAGE
Preparation for Storage

• Clean the entire vehicle thoroughly.
• Run the engine for about five minutes to warm the oil, shut it off, and drain the
engine oil.
WARNING
Motorcycle oil is a toxic substance. Dispose of used oil properly. Con-
tact your local authorities for approved disposal methods or possible re-
cycling.
• Put in fresh engine oil.

• Empty the fuel from the fuel tank by the pump or siphon.

160 STORAGE
WARNING
Gasoline is extremely flammable and can be explosive under certain con-
ditions, creating the potential for serious burns. Turn the ignition key to
“OFF”. Do not smoke. Make sure the area is well-ventilated and free from
any source of flame or sparks; this includes any appliance with a pilot
light. Gasoline is a toxic substance. Dispose of gasoline properly. Con-
tact your local authorities for approved disposal methods.
• Empty the fuel system by running the engine at idle speed until the engine stalls
(If left in for a long time, the fuel will break down and could clog the fuel system.).
• Reduce tire pressure by about 20%.
• Set the motorcycle on a box or 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 bags over the muffler to prevent moisture from entering.

STORAGE 161
• Put a cover over the motorcycle to keep dust and dirt from accumulating on it.
Preparation after Storage
• Remove the plastic bags from the muffler.
• Install the battery in the motorcycle and charge the battery if necessary.
• Fill the fuel tank with fuel.
• Check all the points listed in the Daily Safety Checks section.
• Lubricate the pivots, bolts, and nuts.

162 ENVIRONMENTAL PROTECTION
ENVIRONMENTAL PROTECTION
To protect our environment, properly discard used batteries, tires, engine oil, or
other vehicle components that you might dispose of in the future. Consult your
authorized Kawasaki dealer or local environmental waste agency for their proper
disposal procedures.

LOCATION OF LABELS 163
LOCATION OF LABELS
*1. Unleaded Gasoline

**2. Fuel Level
3. Brake Fluid (Front)
4. Brake Fluid (Rear)
*: Except for Brazil, Southeast
Asia, Malaysia and Australia
models
**: only on Southeast Asia model

164 LOCATION OF LABELS
5. Daily Safety Checks

6. Tire and Load Data
7. Important Drive Chain Informa-
tion
*8. Noise Emission Control Informa-
tion
9. Battery Poison/Danger
*: only on Australia model

*10. Vacuum Hose Routing Diagram

*: only on Southeast Asia model

(1) Except for Brazil, Southeast Asia, (3)

Malaysia and Australia models
(2) only on Southeast Asia model

(4)

(5)

(6)
(7)

(8) only on Australia model

(9)

(10) only on Southeast Asia model


Versys Manual

Uploaded by

Copyright:

Available Formats

Versys Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Versys Manual

Uploaded by

Copyright:

Available Formats

Downloaded from www.Manualslib.

com manuals search engine

A Table of Contents is included after

Downloaded from www.Manualslib.com manuals search engine

DANGER indicates a hazardous

Downloaded from www.Manualslib.com manuals search engine

TAMPERING WITH NOISE CONTROL SYSTEM

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Downloaded from www.Manualslib.com manuals search engine

SPECIFICATIONS............................... 10 Engine Stop Switch ...................... 34

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Displacement 649 cm3 (39.6 cu in.)

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

1. Clutch Lever 7. Spring Preload Adjuster (Front Fork)

Downloaded from www.Manualslib.com manuals search engine

1. Headlight/City Light 7. Seat 12. Brake Disc

Downloaded from www.Manualslib.com manuals search engine

1. License Plate Light 5. Rear Shock Absorber 10. Muffler

Downloaded from www.Manualslib.com manuals search engine

WARNING warranty, can negatively affect per-

Downloaded from www.Manualslib.com manuals search engine

in carrying cargo, passengers and/or 3. All baggage should be carried as

Downloaded from www.Manualslib.com manuals search engine

6. Do not install accessories or carry designed or installed items can re-

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

tween English and metric modes (mph

Downloaded from www.Manualslib.com manuals search engine

• Push the RESET button for more

Downloaded from www.Manualslib.com manuals search engine

• Push the RESET button. The hour

• Push the RESET button. Both the

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

NOTE in the tank goes down, the segments

Downloaded from www.Manualslib.com manuals search engine

: When the headlight is on high

: When the turn signal switch is

: The oil pressure warning light

Downloaded from www.Manualslib.com manuals search engine

properly. The indicator light also goes NOTICE

: The water temperature warning in-

Downloaded from www.Manualslib.com manuals search engine

For more detailed information about Key

Downloaded from www.Manualslib.com manuals search engine

Ignition Switch/Steering Lock Engine off. All electrical

Downloaded from www.Manualslib.com manuals search engine

○If you leave the P (Park) position on Left Handlebar Switches

Downloaded from www.Manualslib.com manuals search engine

Dimmer Switch Horn Button