HE Kawasaki inde: important Safety Infor! ‘mati -Operating Instructions “Maintenance and Storage CONCOURS Motorcycle OWNINE =s) Ya —SAWARNING Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other repro- ductive harm.Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. A Table of Contents is included after the Foreword General a coldur lola} CMLL) the Motorcycle Safe Operation Maintenance and Adjustment Troubleshoo! GuideWhenever you see the symbols shown below, heed their instructions! Always follow safe operating and main- tenance practices. This warning symbol identifies speci instructions or procedures which, if not correctly followed, could result in Personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equip- ment. NOTE OThis note symbol indicates points of particular interest for more efficient and convenient operation. NOTICE THIS PRODUCT HAS BEEN MANU- FACTURED FOR USE IN A REASON- ABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.FOREWORD Congratulations on your purchase of a new Kawasaki Motorcycle. Your new motorcycle 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 motorcyle’s controls, its features, capabilities, and limitations, This manual offers many safe riding tips, but its purpose is not to provide instruction in all the technques and skills required to ride a motorcycle safely. Kawasaki strongly recommends that all operators of this vehicle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for saie 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 information ‘on their Kawasaki Motorzycle, a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer. The Service Manual contains detailed disassembly and maintenance information. Those who plan to do their own work should, of course, be competent mechanics anc 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 illustrations and text in this manual. All products are subject to change without prior notice or obligation. KAWASAKI HEAVY INDUSTRIES, LTD. Consumer Products & Machinery Company © 2004 Kawasaki Heavy Industries, Ltd. Feb. 2004. (1). (S)»omy»mrynynmnnnmnrnmn TABLE OF CONTENTS «cacucneccaanaacane Fuel Tank, : Fuel Ta 12 Stands... 15 ‘Seat Lock AZ Rack and Tying Hooks. 2 20 Document/Tool Kit Container . Specifications | Number Locations .. Mater Instruments... 220 Tool Kit. ‘Speedometer and Tachometer......21 Chain Lock. Fuel Gauge. wot Card Case. Coolant Temperature Gauge.nnn.21 Special Warning on the Use of 2 ing Pockets and Saddlebags .. 23 Fairing Pockets. 24 Saddle Bags Electric Accessory Leads. Helmet Hooks ... Break-In. How to Ride the Motorcycle. Starting the Engine...» indicator Lights... Digital Clock Key Ignition Switch/Steering Lock. Right Handlebar Switches Engine Stop Switch Starter Button ..... Left Handlebar Switches. Dimmer Switch Jump Starting .. Turn Signal Switch Moving Off. Horn Button. Shifting Gears Hazard Switch . Braking .. Brake/Clutch Lever Adjusters..........29 Stopping the Engine. Fuel Tenk Cap... zaStopping the Motorcycle in an Emergency, Parking... Safe Operation. Safe Riding Technique. Daily Safety Checks. Additional Considerati High Speed Operation Maintenance and Adjustment. Periodic Maintenance Chart. Engine Oi Cooling System. Final Gear Case Oil Spark Plugs... Evaporative Emission Control System (California model only ..91 Valve Clearance wi Kawasaki Clean Air System . Air Cleaner we Throttle Gri ‘Choke Lever... Carburetors. Clutch. Brakes......... Brake Light Switches Front Fork Rear Shoc! Wheels... Battery Headlight Beam. Fuses... Fuel System General Lubrication... Cleaning Your Motorcycle . Bolt and Nut Tightening Storage... Troubleshooting Gui le Owner Satisfaction Reporting Safety Defects Environmental Protection Label Information.......2999999999990" DIMENSIONS ‘Overall Length Overall Width Overall Height Wheelbase Road Clearance Dry Weight ENGINE ‘Type Displacement Bore x Stroke Compression Ratio Starting System Cylinder Numbering Method Firing Order Carburetors Ignition System Ignition Timing (Electronically advanced) Spark Plugs SPECIFICATIONS ccaccaaceanmaaanananan 2,290 mm (90.16 in.) 930 mm (36.6 in.) 1,415 mm (55.71 in.) 1,856 mm (61.22 in.) 130 mm (5.12 in.) 270 kg (695 Ib) 270.5 kg (596 Ib) DOHC, 16-valve, 4-cylinder, 4-stroke, liquid-cooled 997 ml (80.8 cu in.) 74.0 x 58.0 mm (2.91 x 2.28 in.) 10.221 Electric starter Left to right, 1-2-3-4 1-2-4-3 Keihin CVK32 x 4 Battery and coil (transistorized ignition) 10° BTDC @1,000 ( 1,200) r/min (rpm) ~ 35° BTDC @3,500 r/min (rpm) NGK DR8EA or ND X24ESR-ULubrication System Engine Oil Type: Capacity = Coolant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Gear Ratio: 1st 2nd 3rd 4th Sth 6th Final Gear Case Oil Final Gear Case Oil Capacity Forced lubrication (wet sump) API SE, SF or SG API SH or SJ with JASO MA SAE 10W-40 3.7 L (3.9 US qt) 3.1 L (3.3 US qt) 6-speed, constant mesh, return shift Wet, multi disc Shaft drive 1.732 (97/56) 2.708 (16/21 x 32/9) 4.530 (Top gear) 3.071 (43/14) 2.055 (37/18) 1.590 (35/22) 1.333 (32/24) 1.183 (30/26) 0.965 (28/29) API GL-5 SAE9O [above 5°C (41°F)] SAEBO [below 5°C (41°F)] 220 mL (0.23 US qt)FRAME Castor 285° Trail 123 mm (4.84 in.) Tire Size’ Front 120/70R18 M/C 59V Tubeless Rear 150/80R16 M/C 71V Tubeless Fuel Tank Capacity 28.5 L (7.53 US gal) ELECTRICAL EQUIPMENT Battery 12V 18 Ah Headlight 12 V 60/55 W Tail/Brake Light 12V 5/21W x2 ; California model Specifications subject to change without notice. 10yyy»ynymy»yyyynon SERIAL NUMBER LOCATIONS cacacuccancncnen The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it. A. Frame Number A. Engine Number ah»ynnmoyyym»»»o» oo» LOCATION OF PARTS «aaKnKnndKdKeKennns . Clutch Lever Clutch Fluid Reservoir Meter Instruments Brake Fluid Reservoir (Front) Front Brake Lever Fairing Pocket Left Handlebar Switches Spring Preload Adjuster |. Ignition Switch/Steering Lock Right Handlebar Switches Throttle Grip12 13. 14, 15. 17. 18. 19. 20. 21 22, 23, 24. 25. 26. 27. 28. 29. 30. 31 32. 33. 34. Front Fork Headlight Turn Signal/Running Position Light Spark Plugs Fuel Tap Carburetor Air Cleaner Junction Box (Fuses) Seat Lock Helmet Hook Tying Hook Turn Signal Light Brake Disc Brake Caliper Radiator Idle Adjusting Screw Oil Level Gauge Shift Pedal Side Stand Center Stand Muffler Final Gear Case . Saddlebag 13License Plate Light Tail/Brake Light Rack Brake Fluid Reservoir (Rear) Document/Tool Kit Container Battery Fuel Tank . Fuel Tank Cap Rear Brake Light Switch Air Valve . Rear Shock Absorber Adjusting Stick . Rear Brake Pedal Coolant Reserve Tank Oil Cooler 14yoyoyyyana»»DMD»» LOCATION OF LABELS caaananananKcncacnd . Brake Fluid (Rear) Air Intake Fuel Level Daily Safety Checks . Battery Vent Hose Engine Oil and Oil Filter Vacuum Hose Routing Diagram Tire and Lead Data . Vehicle Emission Control Information . Saddiebag Latch Caution : Saddlebag Loading Information Rack Loading Information : only on California model (For further information of label, refer to the “LABEL INFORMATION’ chapter.) 1 1 1 + B2Se@ 1516 13, Clutch Fluid 14. Break-In Caution 15, Brake Fluid (Front) 16. Radiator Cap 17. Battery Poison/Danger 1B. Noise Emission Control Information For further information of label, refer to the “LABEL INFORMATION’ chapter.)»ormyonnnonan992909099 LOADING INFORMATION «acca nmanmaaaKaed PNWNaIN INC) Incorrect loading, improper instal tion or use of accessories, or modifi- cation of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure that the motorcycle Is not overloaded and that you have these instructions. followed With the exception of genuine Kawa- saki Parts and Accessories, Kawasaki has no control over the design or appli- cation of accessories. In some cases, improper installation or use of accesso- ries, or motorcycle modification, will void the motorcycle warranty. In select- ing and using accessories, and in load- ing the motorcycle, you are personally responsible for your own safety and the safety of other persons involved. NOTE O Kawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accesso- ties you add to your motorcycle be genuine Kawasaki components. Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in the fitting of additional accessories. The following general guidelines have been prepared to assist you in making your determinations. 171. Any passenger should be thoroughly familiar with motorcycle operation. The passenger can affect control of the motorcycle by improper position - ing during comering and sudden movements. It is important that the passenger sit still while the motorcy- cle is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motor- cycle. 2. You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator, seat strap or grab rail. Do not carry a passenger unless he or she is tall enough to reach the fo- otpegs and footpegs are provided. 3. All baggage should be carried as low as possible to reduce the effect on the motorcycle center of gravity. Baggage weight should also be dis- tributed equally on both sides of the motorcycle. Avoid carrying baggage 18 that extends beyond the rear of the motorcycle. . Baggage should be securely at- tached. Make sure that the baggage will not move around while you are riding. Recheck baggage security as often as possible (not while the mo- torcycle is in motion) and adjust as necessary. Do not carry heavy or bulky items on "a luggage rack. They are designed for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces. Do not install accessories or carry ” baggage that impairs the perform- ance of the motorcycle. Make sure that you have not adversely affected any lighting components, road clear- ance, banking capability (i.e. lean angle), control operation, wheel travel, front fork movement, or anyother aspect of the motorcycle’s op- eration. . Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in an unsafe riding condition. Fairings, windshields, backrests, and other large items have the capability of adversely affecting stability and handling of the motorcycle, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly designed or installed items can result in an un- safe riding condition. }. This motorcycle was not intended to be equipped with a sidecar or to be used to tow any trailer or other vehi- cle. Kawasaki does not manufacture sidecars or trailers for motorcycle and cannot predict the effects of such accessories on handling or stability, but can only warn that the effects can be adverse and that Kawasaki cannot assume responsibility for the results of such unintended use of the motorcycle. Furthermore, any ad- verse effects on motorcycle compo- nents caused by the use of such accessories will not be remedied un- der warranty. Maximum Load Weight of rider, passenger, ba gage, and accessories must not e: ceed 200 kg (441 Ib 19»o»»y»nynannnan» GENERAL INFORMATION «ccaccaacacarannd Meter Instruments . Left Turn Signal Indicator Light . Speedometer : Oil Pressure Warning Light gh Beam Indicator : Tachometer ight Turn Signal jicator Light ; Digital Clock + Coolant Temperature Gauge - Red Zone : Trip Meter —Zr 9mm 0 OD > raze : Trip Reset Button M. Odometer “N. Fuel Gauge 20Speedometer and Tachometer The speedometer shows the speed of the vehicle. In the speedometer face are the odometer and trip meter. The odom- eter shows the total distance that the vehicle has been ridden. The trip meter shows the distance traveled since it was last reset to zero. The trip meter can be reset to zero by pushing the reset but- ton. The tachometer shows the engine speed in the revolutions per minute (r/min, rpm). On the right side of the tachometer face is a portion called the "red zone." Engine r/min (rpm) in the red zone is above maximum recom- mended engine speed and is also above the range for good performance. In the tachometer face is the addi- tional trip meter which can be reset to zero by turning the reset button clock- wise. Engine r/min (rpm) should not be al- lowed to enter the red zone; operation in the red zone will overstress the en- gine and may cause serious engine damage. Fuel Gauge The fuel gauge shows the amount of fuel in the fuel tank. When the needle comes near the E (empty) position, re- fuel at the earliest opportunity. Coolant Temperature Gauge This gauge shows the temperature of coolant. Ordinarily, the needle should stay within the white zone. if the nee- dle reaches the "H” line, stop the engine and check the coolant level in the re- serve tank after the engine cools down. 21Do not let the engine continue running when the gauge needle reaches the "H” line. Prolonged engine operation will result in severe damage from overheating. Indicator Lights "7 : The oil pressure warning light goes on whenever the oil pressure is danger- ously low or the ignition key is in the ON position with the engine not run- ning, and goes off when the engine oil pressure is high enough. Refer to the Maintenance and Adjustment chapter for more detailed engine oil information. =D: When the headlight is on high beam, the high beam indicator light is lit N: When the transmission is in neutral, the neutral indicator light is lit. 4®:When the turn signal switch is turned to left or right, the corresponding turn signal indicator light flashes on and off.Digital Clock When the ignition switch is in the “OFF” position, the clock functions with the back-up power supply circuit from the battery. But resetting is required when the battery becomes discharged or is disconnected. To adjust the time follow this proce- dure: 1. Turn the ignition key to the "ON" po- sition 2. Push the "M” button to adjust the minute and the “H” button to adjust the hour. NOTE Pushing the button momentarily ad- vances the hour or minute step by step. Pushing and holding the button advances the hour or minute contin- uously. A. Digital Clock 8. “M” Button C. “H” Button 23This motorcycle has a combination key, which is used for the ignition switch/ steering lock, seat lock, and fuel tank cap. Blank keys are available at your Ka- wasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as @ master, or using the key code on the tag with your keys. Record the code from the tag with your keys here. Participating Kawasaki dealers can use the code to make a new key in the event that your original keys are lost. your key number here. 24 Tag Ignition KeyIgnition Switch/Steering Lock This is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF, LOCK, or P(Park) position. B. LOCK position C. OFF positi OFF Engine off. All electrical circuits off. ON Engine on. All electrical equipment can be used. LOCK | Steering locked. Engine off. All electrical circuits off. P(Park)| Steering locked. Engine off. Tail and license plate lights on. Turn signal cir- cuit on. All other elec- trical circuits cut off. 25NOTE OThe tail, running position, and license plate lights are on whenever the ig- nition key is in the ON position. The headlight goes on when the starter button is released after starting the engine. To avoid battery discharge, always start the engine immediately after turning the ignition key to "ON". O/f you leave the P (Park) position on fora long time (one hour), the battery may become totally discharged. 26 To operate the ignition switch: OFF ON [22> P (Park) Turn the handlebar fully to the 1 left. 2. a. For parking push down the key in the ON position and tum it to P (Park). b. For locking push down the key in the OFF position and turn it to LOCK. LOCKRight Handlebar Switches 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- gency use. If some emergency requires stopping the engine, move the engine stop switch to the "gy" position. NOTE Although the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine. A. Engine Stop Switch B. Starter Button Starter Button The starter button operates the elec- tric starter when pushed with the clutch lever pulled in or the transmission in neutral. Refer to the Starting the Engine sec- tion of the “How to Ride the Motorcy- cle” chapter for starting instructions. 27Left Handlebar Switches Dimmer Switch High or low beam can be selected with the dimmer switct. When the headlight is on high bearn(zO), the high beam indicator light is lit. High Beam ( ZO ) Low Beam ( > ) A. Dimmer Switch B. Turn Signal Switch C. Horn Button D. Hazard Switch 28 Turn Signal Switch When the tum signal switch is turned to the left (©) or right(®), the corre- sponding turn signals flash on and off. To stop flashing, push the switch in Horn Button When the horn button is pushed, the hor sounds. Hazard Switch If an emergency requires you to park on the highway shoulder, turn on the hazard lights to warn other drivers of your location. Push in the hazard switch with the ignition switch in the ON or P(Park) position. All the turn signals and turn signal indicator lights will flash on and off.If you leave the switch on for a long time, the battery may become totally discharged. So be careful not to use the hazard lights for more than 30 mi- nutes. Brake/Clutch Lever Adjusters There is an adjuster on both the brake and clutch levers. Each adjuster has 4 positions so that the released lever posi- tion can be adjusted to suit the operator's hands. Push the lever for- ward and turn the adjuster to align the number with the triangular mark on the lever holder. The distance from the grip to the released lever is minimum at Number 4 and maximum at Number 1. A. Adjuster 29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 OThe fuel tank cap cannot be closed without the key inserted, and the key 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. 30 A. Key Hole Cover B. Ignition Key C. Fuel Tank CapFuel Tank The following octane rating gasoline is recommended in the fuel tank. Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. 1. Tank Cap 2. Fuel Tank 3. Top Level 4. Filler Neck PN TaN Ne) Gasoline is extremely flammable and can be explosive under certain condl- tions. Turn the ignition key to "OFF". Do not smoke. Make sure the area Is lated and free from any of flame or sparks; this in- ny appliance with a pilot light. Never fill the tank so the fuel level rises into the filler neck. If the tank is overfilied, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the fuel tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately. 31CAUTION California models only: Never fill the tank so the fuel level rises into the fil- ler neck. If the tank Is overfilled, heat may cause the fuel to expand and flow into the Evaporative Emission Control System resulting in hard starting and engine hesitation. Fuel Requirements: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 87. The Antiknock Index is posted on ser- vice station pumps in the U.S.A. The octane rating of a gasoline is a measure of its resistance to detonation or “knocking.” The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Cctane Number (MON) as shown in the table. 32 = Octane Rating Method Minimum Rating Antiknock index (RON + MON) 87 2 Research Octane Number (RON) | 91 Mf engine “knocking” or “pinging” oc- curs, use a different brand of gasoline of a higher octane rating. If this condi- tion is allowed to continue it can lead to severe engine damage. Gasoline quality is important. Fuels of low quality or not meeting standard in- dustry specifications may result in un- satisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under your war- ranty.Fuels Containing Oxygenates Gasoline frequently contains oxygen- ates (alcohols and ethers) especially in areas of the U.S. and Canada which are required to sell such reformulated fuels as part of a strategy to reduce exhaust emissions. The types and volume of fuel oxygen- ates approved for use in unleaded gaso- line by the U.S. Environmental Protection Agency include a broad range of alcohols and ethers, but only two components have seen any signif- icant level of commercial use. Gasoline/Alcohol Blends — Gasoline containing up to 10% ethanol (alcohol produced from agricultural products such as corn), also known as “gasohol” is approved for use. Avoid using blends of unleaded gaso- line and methanol (wood alcohol) whe- never possible, and never use “gasohol” containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up to 15% MTBE. NOTE Other oxygenates approved for use in unleaded gasoline include TAME (up to 16.7%) and ETBE (up to 17.2%). Fuel containing these oxygenates can also be used in your Kawasaki. 33Never use gasoline with an octane rat- ing lower than the minimum specified by Kawasaki, Never use “gasohol” with more than 10% ethanol, or more than 5% metha- nol. Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors. Certain ingredients of gasoline may paint fading or damage. Be ex- rreful not to spill gasoline or gas- blends — during ieling. When not operating your Kawa: for 30 to 60 days, mix a fuel stal (such as STA-BIL) with th the fuel tank. Fuel stabilizer additives inhibit oxydation of the fuel which min- imizes gummy deposits. Never store this product with “gaso- hol” in the fuel system. Before stor- age it is recommended that you drain all fuel from the fuel tank and carbure- tors. See the Storage section in this manual. Fuel Tap The fuel tap is an automatic type which shuts off the fuel supply when the engine is stopped in the ON or RES position. A. Fuel Tap C. PRI po B. ON position D. RES positionThe fuel tap has three positions: ON, RES (reserve), and PRI (prime). If the fuel runs out with the tap in the ON po- sition, turn the tap lever to PRI, leave it for a few seconds, and then turn it to RES. The last 6.5 L (1.72 US gal) of fuel can be used by turning the fuel tap lever to RES. The PRI position bypasses the auto- matic control and is useful for priming the engine after running out of gas, or for completely draining the tank. NOTE Since riding distance is limited when on RES, refuel at the earliest opportu- nity. OMbke certain that the fuel tap lever is turned to ON (Not RES) after filling up the fuel tank. OTo start a cold engine after the motor- cycle has been stored for a long time, first turn the tap lever to PRI, leave it for a moment, and return it to ON. ENN Incl Practice operating the fuel tap with the motorcycle stopped. To prevent an accident you should be able to operate the fuel tap while riding without taking your eyes off the road. Be careful not to touch the hot engine while operating the fuel tap. Do not leave the fuel tap in the PRI (prime) position while riding or park- ing the motorcycle. The engine may become flooded or fue! may spill onto the ground and create a fire hazard, if the vehicle falls over. 35Stands The motorcycle is equipped with two stands: a center stand and a side stand. a, NOTE When using the side stand, turn the handlebar to the left. Whenever the side stand or center stand is used, make it a practice to kick the stand fully up before sitting on the motorcycle. 36 NOTE OThe motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine stops if the clutch is engaged with the trans- mission in gear when the side stand is left down. To set the motorcycle up on the cen- ter stand, step down firmly on the stand, and then lift the motorcycle up and to the rear using the grab rail as a hand- hold. Don’t pull up on the seat to lift as this will damage the seat.Seat Lock To remove the seat, insert the ignition key into the seat lock, turn the key to the right, and pull up on the rear of the cane seat. The seat is locked when pushed back into place. ® A. Center Stand C. Grab Rail B. Step down. D. Lift up. Pe ' A. Seat Lock —_B. Ignition Key 37Rack and Tying Hooks When tying light loads to the rack, first remove the seat and unbolt the rack cover. Then pull up the hooks on both sides of the tail/brake light. The rack cover can be stored on the front section of the rear fender. Be sure to bolt the cover securely. (CAUTION Do not carry more than 5 kg (11 Ib) load on the rack. 38 A. Cover B. BoltA. Rack B. Tying Hooks Document/Tool Kit Container The document/too! kit container is located under the seat. Use it to keep the owner's manual and any papers or documents that should be kept with the motorcycle. A. Document/Tool Kit Container B. Tool Ki 39Tool Kit The tool kit is stored in the document/tool kit container. The minor adjustments and replacement of parts explained in this manual can be per- formed with the tools in the kit. 40 Chain Lock The chain lock is stored in the same place as the tool kit. Route the chain through the wheel and around the front forks, then lock it to prevent the wheel from rotating for anti-theft protection when parking. FG Do not ride the motorcycle with the chain installed. Forgetting and start- ing could cause an accident.A. Chain Lock B. Key Card Case This case is inside the left side cover. Use it to carry a business card, insur- ance policy numbers, etc. A. Left Side Cover B. Card Case a4Special Warning on the Use of Fair- ing Pockets and Saddlebags When preparing to rida this motorcy- cle, always check the saddlebags for se- cure mounting in their respective brackets. Be certain the saddlebag latches fully engage their brackets by at- tempting to pull them from the brackets. Make sure the saddiebag lids and fairing pockets are securely latched 42 PGA} The sudden detachment or loss of a saddlebag or the sudden opening of one of the lids could distract or alarm the motorcycle rider, and the conse- quent loss of attention to road and traf- tic conditions could cause loss of control and rious accident. Also the sudden change of vehicle balance resulting from the loss of a saddlebag could cause loss of contro! and a seri- ous accident. A dislodged saddiebag could phys- cally obstruct the motorcycle’s path, or interfere in the path of a following motorcycle or other vehicle. This could cause a loss of control by one of the motorcycle riders or another vehi- cle driver with a consequent accident. Keep both saddlebag lids securely latched when riding. A piece of cloth- Ing or other object could fall into the rear wheel which could result in rear wheel lockup and consequent skidding and loss of control.PAW AGA Ce} Make certain the fairing pockets tightly closed, so as to prevent a loos object from interfering with the steer- ing mechanism, vehicle controls, or the rider's attention to road and traffic ore, or attach objects in the area between the movable parts of the steering mechanism (including handlebar, front fork, etc.) and the fixed parts of the chi (including fairing, fuel tank, frat object which lodg mechanism could cause loss of con- trol and a serious accident. Fairing Pockets To open each fairing pocket lid, insert the ignition key into the lock, turn the key clockwise, and pull up the lid. The lid can be removed by sliding it to the rear. To close the lid, turn the key counterclockwise and pull it out. CAUTION Do not carry loads of more than 0.5 kg (1 Ib) in each of the fairing pockets.Saddlebags Saddlebags are provided at both sides of the rear wheel to carry baggage NOTE Olf the holder rails are removed from the motorcycle, install the covers pro- vided in the saddlebag to fill the re- cesses. A. Holder Rail B. CoverTo remove the saddlebag: Swing open the key hole cover of the latch on the front of the saddlebag and insert the saddlebag key into the key hole, then unlock by turning the key counterclockwise. Pull open the latch and remove the saddlebag by pulling it upward. ©. Latch D. Saddlebag A. Key Hole Cover B. Saddlebag Key To install the saddlebag: Hook the saddlebag upper ends onto the holder rail and push the saddlebag down. Hook the latch end onto the bracket and push the latch back se- curely, then lock it by turning the sad- dlebag key clockwise. A. Holder Rai B. Bracket 45Udlebag lid: latch on the upper side ag in the same way as val, then swing open the To close the saddlebag lid: Close the lid and push the latches back securely, then lock them. Do not carry loads of more than 10 kg (22 Ib) in each saddiebag. Distribute loads equally on both sides to minimize imbalance. Read the "Loading Information” chap- ter before loading.Electric Accessory Leads The electric power of the battery can be used through the electric accessory leads regardless of ignition switch posi tion. Observe and follow the notes listed below. Electric Accessory Leads Location Polarity| Lead Color Under (4) | White/Biue Seat (-)_|_ Black/Yellow Under Left (+) | White/Biue Fairing Pocket | (-) | Black/Yellow Maximum Current: 104 aed Take care not to pinch any lead be- tween other parts to avoid a short cir- cuit. Whenever you leave the motorcycle, stop using the electric accessori Be careful not to discharge the battery totally. For example, if a current of 20 amperes is continuously taken out with the engine stopped, even an orl- ginally-fully-charged battery may be- come totally discharged in about 20 minutes. A. Accessory Leads 47A. Accessory Leads 48 Helmet Hooks Helmets can be secured to the motor- cycle using the helmet hooks. The helmet hook can be unlocked by inserting the ignition key into the lock, and turning the key to the right. PEN} Do not ride the motorcycle with hel- mets attached to the hooks. The hel- mets could cause an accident by distracting the operator or interfering with normal vehicle operation.A. Helmet Hook A. Helmet Hook 499999992099999 ]N}I3P9IHNWNWD BREAK =IN KKM MMMM EMME The first 1,600 km (1,000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a "broken down” instead of a “broken in” motorcycle after a few thousand kilometers. The following rules should be observed during the break-in period. @The table shows maximum recommended engine speed during the break-in period. Maximum engine speed 4,000 r/min (rpm) 6,000 r/min (rpm) Distance traveled 0 ~ 800 km (0 ~ 500 mi) 800 ~ 1,600 km (500 ~ 1,000 mi) @Do not start moving or race the engine immediately after starting it, even if the en- gine 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. 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 cor- nering.In addition to the above, at 800 km (500 mi) it is extremely important that the owner have the initial maintenance service performed by a competent mechanic fol- lowing the procedures in the Service Manual. 51»»nmnnnennnvnn HOW TO RIDE THE MOTORCYCLE «aacacncacacug Starting the Engine @If the engine is cold, pull the choke @Check that the engine stop switch is lever all the wey. in the "C)" position @Turn the ignition key to “ON”, NOTE @Make certain the wansmission iS 19 Gwhen the engine is already warm or ‘on hot days [35°C (95°F) or more], open the throttle part way instead of using the choke, and then start the engine. A. Engine Stop Switch B. Starter Button C. Neutral Indicator Light D. Ignition Switch E. ON position A. Choke Lever 52@Leaving the throttle completely closed, push the starter button. CAUTION Do not operate the starter contin- uously for more than 5 seconds 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 battery Pol OV. NOTE Of the engine is flooded, crank the en- gine over with the throttle fully open until the engine starts. OThe motorcycle is equipped with a starter lockout switch. This switch prevents the electric starter from oper- ating when the clutch is engaged and the transmission is not in neutral. A, Clutch Lever B. Starter Lockout Switch @Gradually return the choke lever back a little at a time as necessary to keep the engine speed below 2,500 r/min (rpm) during warm-up. @When the engine is warmed up enough to idle without using the choke, return the choke lever alll the way back. 53NOTE O/f you drive the motoreycle before the engine is warmed up, return the choke to the off position as soon as you start moving. Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. 54 Jump Starting If your motorcycle battery is “run down,” it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. Na ed Battery acid generates hydrogen gas which is flammable and explosive un- der certain conditions. It is present within a battery at all time: tes) away from the battery. Wear eye protection when working with a battery. In the event of battery acid contact with skin, ey clothing, wash the affected mediately with water for minutes. Seek medical attention.Connecting Jumper Cables @Remove the left side cover. @ Make sure the ignition key is turned to “OFF.” Connect a jumper cable from the posi- tive (+) terminal of the booster bat- tery to the positive (+) battery cable at the starter relay terminal. A. Positive (+) Starter Relay Terminal 8. From Booster Battery Positive (+) Terminal C. Unpainted Metal Surface D. From Booster Battery Negative (-) Terminal @Connect another jumper cable from the negative (—) terminal of the booster battery to your motorcycle rear brake pedal or other unpainted metal surface. Do not use the nega- tive (—) terminal of the battery. AWARNING Do not make this last connection at the carburetor or battery. Take care that you do not touch the positive and neg- ative cables together, and do not lean over the battery when making this last connection. Do not jump start a frozen battery. It could explode. Do not reverse polarity by connecting positive (+) to negative (—), or a bat- tery explosion and serious damage to the electrical system may occur. @Follow the standard engine starting procedure. 55Do not operate the starter contin- uously for more than 5 seconds 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 battery power recover. @After the engine has started, discon- nect the jumper cables. Disconnect the negative (-) cable from the mo- torcycle first. @ install the removed parts 56 Moving Off Check that the side stand is up. @Pull in the clutch lever. @Shift into 1st gear. @Open the throttle a little, and start to let out the clutch lever very slowly. @As the clutch starts to engage, open the throttle a little more, giving the engine just enough fuel to keep it from stalling. . Shift PedalNOTE OThe motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine stops if the clutch is engaged with the trans- mission in gear when the side stand is left down. Shifting Gears @Close the throttle while pulling in the clutch lever. @Shift into the next higher or lower gear. For smooth riding, each gear position should cover the proper rate of speed shown in the table. 57AAWARNING When shifting down to a lower g do not shift at such a high sj the engine 1 sively. Not only can this cause engine damage, but the rear wheel may skid and cause an accident. Downshifting jould be done below 5,000 r/min (rpm) for each ge: Vehicle speed when shifting Shifting up_|_km/h(mph) [Shifting down, km/h(mph) Ast > 2nd 15(9) 6th > 5th 30(19) 2nd + 3rd 25(15) Sth > 4th 25(15) 3rd — 4th 35(21) 4th > 3rd 20(12) 4th + Sth 45(27) 3rd > 2nd 15(9) 5th > 6th 55(34) | 2nd — 1st 58 15(9)@Open the throttle part way, while re- leasing the clutch lever. NOTE ©The transmission is equipped with a positive neutral finder. When the mo- torcycle is standing still, the trans- mission cannot be shifted past neutral from 1st gear. To use the positive neutral finder, shift down to 1st gear. then lift up on the shift pedal while standing still. The transmission will shift only into neutral. Braking @Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. @Shift down one gear at a time so that you are in 1st gear when you come to a complete stop. @When stopping, always apply both brakes at the same time. Normally the front brake should be applied a little 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 ap- plying the brakes as hard as possible without skidding.In order to protect the emission con- trol parts, do not turn off the ignition ‘switch when the motorcycle is in mo- tion. A. Rear Brake Pedal A. Front Brake LeverStopping the Engine @Close the throttle completely. @Shift the transmission into neutral. ‘urn the ignition key to "OFF". @Support the motorcycle on a firm, level surface with the side or center stand, @Lock the steering. Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to provide you optimum safety and convenience. However, in order to fully benefit from Kawasaki's safety engineering and craftsmanship, it is essential that you, the owner and operator, properly main- tain your motorcycle and become thor- oughly familiar with its operation. Improper maintenance can create a dan- gerous situation known as throttle fail- ure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust to enter the carburetor and stick the throttle open. 2. During removal of the air cleaner, dirt is allowed to enter and jam the car- buretor. In an emergency situation such as throttle failure, your vehicle may be stopped by applying the brakes and dis- engaging the clutch. Once this stop- 61ping procedure is initiated, the engine ‘stop switch may be used to stop the en- gine. If the engine stop switch is used, turn off the ignition switch after stop- ping the motorcycle. 62 Parking @Shift the transmission into neutral and turn the ignition key to “OFF”, @Support the motorcycle on a firm, level surface with the side or center stand. Do not park on a soft or steeply in- clined surtace or the motorcycle may fall over. @if parking inside a garage or other structure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this in- cludes any appliance with a pilot light. AAWARNING Gasoline is extremely flammable and can be explosive under certain condi- tions.@Lock the steering to help prevent theft. NOTE OWhen stopping near traffic at night. you can leave the taillight on for greater visibility by turning the ig- nition key to the P (Park) position. Do not leave the ignition switch at P position too long, or the battery will discharge. 63Domomo»»nn»»n»n»DyM” SAFE OPERATION «aaaaaKaKnanKceKcacnne 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 helmet are strongly recom- mended, Gloves and suitable footwear should also be used for added protection in case of a mishap. the impact protection of an auto- so defensive riding in ad- to wearing protective apparel is extremely important. Do not let protective apparel give you a false sense of security. Before changing lanes, look over your shoulder to make sure the way is clear. Do not rely solely on the rear view mirror; you may misjudge a vehicle’s dis- tance and speed, or you may not see it at all. When going up steep slopes, shift to a lower gear so that there is plenty of power to spa: than overloading the en- When applying the brakes. use both the front and rear brakes. Applying only one brake for sud- den braking may cause the mo- torcycle to skid and lose control. When going down long slopes, control vehicle speed by closing the throttle, Use the front and rear brakes for auxiliary braking.On rainy days, rely more on the throttle to control vehicle speed and less on the front and rear brakes. The throttle should also be used judiciously to avoid skidding the rear wheel from too rapid acceleration or deceler- ation. Riding at the proper rate of speed and avi 1g unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for long vehicle life and quieter operation. When riding in wet conditions or on loose roadway surfaces, the ability to maneuver will be re- duced. All of your actions should be smooth under these condi tions. Sudden ace ing or turning may cau: control. On rough roads, exercise cau- tion, slow down, and grip the fuel tank with the knees for bet- ter stability. When quick acceleration is necessary as in passing, shift to a lower gear to obtain the nec- essary power. Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrewving. Avoiding unnecessary weaving is important to the safety of both the rider and other motorists.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 motorcycle to a safe operating condition. Failure to perform these checks every day before you ride may result in serious damage or a severe accident. Fuel .. i Adequate supply in tank, no leaks. Engine oil .. Qil level between level lines. Tires... Air pressure (when cold) Front | 250 kPa (2.50 kgf/cm’, 36 psi) Rear | 290 kPa (2.90 kgf/cm’, 42 psi) Install the air valve cap.Nuts, bolts, fasteners.......... Check that steering and suspension components, axles, and all controls are properly tightened or fastened. SteeFIAY ..csesseeesseusseneeree Action smooth but not loose from lock to lock. No bind- ing 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 . No clutch fluid leakage. Coolant No coolant leakage. Coolant level between level lines (when engine is cold). No oil leakage. All lights and horn work. Stops engine. Return to their fully up positions by spring tension Return springs not weak or not damaged. Final Gear Case Electrical equipm Engine stop switch. Side and center stand Refer to the “Daily Safety Checks” caution label attached to the back of the right side cover. 67Additional Considerations for High Speed Operation Handling characteristics of a motorcycle at high speeds may vary from those you are I highway speeds. Do not attempt high speed operation unless you have received sutficient training and have the required si Brakes: The importance of the brakes, especially during high speed operation, can- not 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 safe- ty. Examine their overall condition, inflate to the proper pressure, and check the wheel balance. Spark Plugs: For demanding operation such as racing, install spark plugs with one heat colder range NGK DR9EA or ND X27ESR-U. Fuel: Have sufficient fuel for high fuel consumption during high speed operation. Engine Oil: To avoid engine seizure and resulting loss of control, make certain 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.Final Gear Case Oil: To avoid seizure and resulting loss of control, make certain the oil level is correct. Electrical Equipment: Make certain that the headlight, tail/brake light, turn signals, hom, etc., all work properly. Miscellaneous: Make certain that all nuts and bolts are tight and that all safety re- lated parts are in good condition.»»»nono»yyyny MAINTENANCE AND ADJUSTMENT cacacacacacnd The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motor- cycle in good running condition. The initial maintenance is vitally important and must not be neglected. If you are in doubt as to eny adjustment or vehicle operation, please ask your au- thorized Kawasaki dealer to check the motorcycle. Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect maintenance or improper adjustment done by the owner. 70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 and California Air Resources Board. Additionally, Kawasaki has incor- porated an evaporative emission control system (3) in compliance with applica- ble regulations of the California Air Resources Board on vehicle sold in California only. 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 sup- plied by the carburetors. - Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmos- phere by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure en effi- cient engine with low exhaust pollutant levels. 71