KZ650 C1 UserManual

5/26/2018 KZ650 C1 UserManual

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Whenever you see the symbols shown below, heed their instructionsAlways follow safe operating and maintenance practices.lW RNING I his warning symbol identifies special instructions or pro-. cedures which, if not correctly followed, could result inpersonal injury or loss of I fe.

~ ~ l l ~ ~ r ~ u ~ ~ ~ c ~ ~ ~ b ~ l ~ d : ~ ~ i i ~ ~ ~ s ~ ~ ~ ~ ~ l v ~ ~ t r ~ ~ ~ : ~ n ~ e ~ ~ ~ r ~ ~damage to or destruction of equipment.Note indicates points of particular interest for more efficient and

convenient operation.

NOTICETHIS. PRODUCT HAS BEEN MANUFAC-TURED FOR USE IN A REASONABLEAND PRUDENT MANNER BY A QUALI-FIED OPERATOR AND AS A VEHICLEONLY.

FOREWORDWe wish to thank you for choosing this fine Kawasaki Motorcycle. It is the end

product ~ f K a ~ a s ~ ~ i s advanced engineering, exhaustive testing, and continuous strivingfor superior. rehab1hty, safety, and performance. By giving your motorcycle the propercare and maintenance outlined in this manual, you will ensure it a long, trouble-free life.Before starting to ride your motorcycle, please read this manuai thoroughly in order toknow y our motorcycle s capabilities, its limitations, and above all, how to operate itsafely.

In addition to this owner s manual, for those who whould like more detailed information on their Kawasaki Motorcycle, a Shop Manual is now available for purchase fromany Kawasaki Dealer.

_ Due _to i m p r ~ v e m e n t s in design and performance during production, in some cases there may .beminor d1screpanc1es between the actual vehicle and the illustrations and text in this manual.

KAWASAKI HEAVY INDUSTRIES LTD.ENGINE AND MOTORCYCLE GROUP

Kawasaki Heavy Industries, Ltd. 1976


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TABLE 0 F CONTENTSSPECIFICATIONSCONSUMER INFORMATIONSERIAL NUMBER LOCATIONSLOCATION OF PARTSLOCATION OF CAUTION LABELSGENERAL INFORMATIONBrake Lever and Pedal ......... ......... .

Shift Pedal ..................................... .Clutch Lever .................................. .Throttle Grip ...................................Electric Starter ...............................Kick Pedal ......................................Key ................................................Ignition Switch .............................. .Speedometer and Tachome ter ....... .Indicator Lights ............................. .Turn Signal Switch ......................... .Dimmer Switch .............................. .Horn Button .................................. .Hazard Switch ................................. .Headlight Switch ........................... .Engine Stop Switch .... . ......... ........ .Chock Lever ...................................Fuse Box ....................................... .

47

1

1416161718181919222222424252526262727

Fuel Tank ...................................... .Fuel Tank Cap ............................... .Fuel Tap ....................................... .Steering Lock .................................Seat Lock ...................................... .Stands ........................................... .Helmet Hooks ................................Document Container ..................... .Tool Kit .........................................Tools ............................................. .

BREAKING IN ...................................HOW TO RIDE THE MOTORCYCLE

Starting the Engine .........................Moving Off .....................................Shifting.Gears .................................Braking ..........................................Stopping the Engine .......................

28282:2929333133233343435353636

Stopping the Motorcycle inan Emergency ........... ..... ........... 37SAFE OPERATION ............................. 38Safe Riding Technique ..................... 38

Daily Safety Checks ...... ................. 40Additional Considerations forHigh Speed Operation ................ 42

MAINTENANCE AND ADJUSTMENT 43 Disc Brake Fluid ........................ 73Periodic Maintenance Chart ............. 44 Brake Pad Replacement .. ............ 75Engine Oi l ...... ..... ......... ........ ..... ... .. 46 Brake Light Switch Adjustment 7 '.iSpark Plug Maintenance ................... 48 Steering Inspection .... . .... .... . .......... 76Ignition Timing Adjustment ............ 49 Front Fork Maintenance .................. 77

Point Gap Adjustment .... ........... 50 Rear Shock Absorber InspectionTiming Adjustment ..................... 52 and Adjustment ..... .... .. .. .. .. ........ 78Camshaft Chain Adjustment 55 Wheel Inspection ..... ....................... 79Valve Clearance Inspection .............. 56 Wheel Balance .... ............. ......... 79

Air Cleaner Maintenance .................. 58 Rim Runout .............................. 79Throttle Grip Adjustment Tires and Tubes ....... .................. .. 8and Lubrication ......................... 6 Wheel Removal ................................ 82Idling Adjustment ........................... 63 Front Wheel Removal ................. 82Clutch Adjustment and Lubrication 64 Rear Wheel Removal .... . ............. 84

Clutch Adjustment . ................... 64 Battery Maintenance ...... ................. 86Clutch Cable Lubrication ............ 66 Headlight Beam Adjustment ............ 88Drive Chain Maintenance ................. 67 Bulb Rep lacement ........... ................ 90Inspection .................................. 67 Fuel Tap Cleaning ............................ 92Adjustment .......... ................ .... 68 Lubrication ...................................... 94Chain Replacement .................... 70Chain Lubrication ....................... 70 Bolt and Nu_t Tightening .................. 96CLEANING .......................................... 99Brake Adjustment ........................ .. 71 STORAGE ............................................101Front Brake Lever Adjustment .... 71 TROUBLESHOOTING GUIDE .............102Rear Brake Adjustment............... 72 WIRING DIAGRAM Inside back cover

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,,,,,,,,,.,.,,,,,.,,,,.,,,,,,,,,,,,,,,,,,,,,, TABLE 0 F CONTENTSSPECIFICATIONS 4CONSUMER INFORMATION .............. 7SERIAL NUMBER LOCATIONS 10LOCATION OF PARTS ....................... 11LOCATION OF CAUTION LABELS 14GENERAL INFORMATION 16Brake Lever and Pedal ......... ............ 16

Shift Pedal ....................................... 17Clutch Lever .................................... 18Throttle Grip.................................... 18Electric Starter . . . . .. . .... ..... .. .. . . 19Kick Pedal ....................................... 19Key ................................................. 2Ignition Switch ................................ 2Speedometer and Tachometer ......... 21Indicator Lights ............................... 22Turn Signal Swi tch ............... ........ .. 24Dimmer Switch ......................... ...... 24Horn Button ... ................................ 25Hazard Switch ................................. .. 25Headlight Switch ............................. 26Engine Stop Swi tch .... ....... . .... ....... 26Chock Lever . ......... ....... ..... ... ..... . 27Fuse Box ....................... .... .......... 27

Fuel Tank ................. ....................... 28Fuel Tank Cap ................................. 28Fuel Tap ......................................... 2Steering Lock .................................. 29Seat Lock ................. ...................... 29Stands ............................................. 3. Helmet Hooks . . ....... ... . .... . .... . .... 3Document Container ....................... 31Tool Kit ....... ....... ........................ 31Tools ............................................... 32

BREAKING IN .................................... 33HOW TO RIDE THE MOTORCYCLE 34Starting the Engine .......................... 34M.oving Off ...................................... 35Shifting.Gears .................................. 35Braking ........................................... 36Stopping the Engine ........................ 36Stopping the Motorcycle in

an Emergency ..... ............ .......... 37SAFE OPERATION ............................. 38Safe Riding Technique .......... ........... 38Daily Safety Checks ...... ........ ........... 4

Additional Considerations forHigh Speed Opera tion ... . .. .... . ... 42

. MAINTENANCE AND ADJUSTMENT 43Periodic Maintenance Chart ............. 44Engine Oil ........................................ 46Spark Plug Maintenance ................... 48Ignition Timing Adjustment ............ 49Point Gap Adjustment . .. . . .. . ... . 5

Timing Adjustment ..................... 52Camshaft Chain Adjustment............. 55Valve Clearance Inspection .............. 56Air Cleaner Maintenance .................. 58Throttle Grip Adjustment

and.Lubrication .............. . ......... 6Idling Adjustment ........................... 63Clutch Adjustment and Lubrication.. 64Clutch Adjustment ..................... 64Clutch Cable Lubrication ............ 66Drive Chain Maintenance ................. 67Inspection .................................. 67Adjustment .. .. .. .... . .. .. .. .. .. .... . .. . 68Chain Replacement ........ .......... .. 70Chain Lubrication ......... .. . ... .. .... 70Brake Adjustment ............... ........ .. 71Front Brake Lever Adjustment ... 71Rear .Brake Adjust ment.......... ..... 72

Disc Brake Fluid ........................ 73Brake Pad Replacement .............. 75Brake. Light Switch Adjustment ....... 7Steering Inspection .......................... 76Front Fork Maintenance .................. 77Rear Shock Absorber Inspection

and Adjustment ....................... 78Wheel Inspection .............................. 79Wheel Balance . ... .. .. .................. 79Rim Runout .. .... ...... . .. ....... ..... 79Tires and Tubes .... ... ... ... ..... ... ..... 8Wheel Removal .. .. ...... .... . ... ..... ..... . 82Front Wh eel Removal ................. 82Rear Wheel Removal ... ... ... ... . . .... 84Battery Maintenance ........................ 86Headlight Beam Adjustment ............ 88Bulb Replacement ........................... 9Fuel Tap Cleaning .......................... . 92

Lubrication .. .................................... 94Bolt and Nut Tightening .................. 96

CLEANING .......................................... 99STORAGE ............................................101TROUBLESHOOTING GUIDE .............1 2WIRING DIAGRAM Inside back cover

._ 3


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.,,,,,,,,,,,,,,,,,,,.,,,,,, ,,,,,,,,,,,,,,,,,, SP E I FI C T ONS ~

PERFORMANCEMaximum HorsepowerMaximum TorqueMinimum Turning RadiusBraking Distance

DIMENSIONSOveral I LengthOveral I WidthOverall HeightWheelbaseRoad ClearanceDry Weight

ENGINETypeDisplacementBore x StrokeCompression RatioFuelStartingCarburetors

4 SPECIFICATIONS

64 HP @8,500 rpm5.8 kg-m 4 1.9 ft-lbs) @7,000 rpm2.4 m (94.5 in)12 m @5 kph 39.4 t @31 mph)2,170 mm (85.4 in)850 mm (33.5 in)1,175 mm 46.3 in)1,420 mm (55.9 in)145 mm 5.7 in)219 kg 483 lbs)DOHC 4 cylinder, 4-stroke, air-coofed652 cc 39.77 cu in)62 54 mm 2.44 2.13 in)9.5:1Non-leaded gasolineElectric starter and kickMIKUNI VM24SS

Ignition SystemIgnition TimingSpark PlugsLubricationEngine OilEngine Oil Capacity

TRANSMISSIONTypeClutchPrimary Reduction RatioFinal Reduction RatioOverall Drive RatioGear Ratio: 1st

FRAMECastorTrail

2nd3rd4th5th

Battery and coilBTDC 10 @1,600 rpm "'35 @3,200 rpmNGK B7ES, ND W22ES-U, CHAMPION N-4-MCor equivalentForced lubrication (wet sump)SE class SAE 1 OW40, 1OW50, 20W40, or 20W503.5 3.7 us qt)5-speed, const ant mesh, return shiftWet, multi disc2.55 (27/23 x 63/29)2.63 (42/16)5.95 @5th gear)2.33 (35/15)1.63 (31/19)1.27 (28/22)1.04 26/25)0.89 (24/27)63108 ml ' 4.3 in)

SPECIFICATIONS 5


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Tire Size: FrontRearTire Pressure: FrontRearFuel Tank CapacityELECTRICAL EQUIPMENT

BatteryHeadlightTail/Brake LightPosition/Turn Signal LightsTurn Signal LightsMeter LightsNeutral Indicator LightTurn Signal Indicator LightsHigh Beam Indicator LightOil Pressure Warning LightBrake Light Failure Indicator LightHornuses

6 SPECIFICATIONS

3.25H-19 4PR4.00H-18 4PR2.0 kg/cm2 28 psi)2.25 kg/cm2 32 psi)16.8 4.4 US gal)12V 10AH12V 50/35W12V 8/27W12V 8/23W12V 23W12V 3.4W12V 3.4W12V 3.4W12V 3.4W12V 3.4W12V 3.4W12V 2.5A20A Main)10A Head)10A Tail)Specifications subject to change without notice.

ri ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, CONSUMER INFORMATI ON ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,Vehicle Minimum Stopping Distance on Dry Pavement

These figures indicate braking performance that can be met or exceeded by thevehicle to which they apply, without locking the wheels, under different conditionsof loading. The i n f o ~ m t i o n presented represents results obtainable by skilleddrivers under controlled road and vehicle conditions, and the information may notbe correct under other conditions.Description of vehicle to which this table applies: Model KZ650-C1A. Fully Operational Service Brake

Load: LightMaximum 154

5 1 15 2Stopping distance in feet from 6 mph.

Manufac turer: Kawasaki Heavy Industries, Ltd.

CONSUMER INFORMATION 7


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Acceleration and Passing Ability rThese figures indicate passing times and distances that can be met or exceeded by the;vehicle to which they apply, in the situations diagrammed on the riext page.The low-speed pass assumes an initial speed of 20 mph and a limiting speed of 35 mph .The high-speed pass assumes an initial speed of 50 mph and a limiting speed of 80 mph.

Graphic Determination of Passing Timeand Distance

Note: The informat ion presen ted represents results obtainable by skilled drivers:under controlled road and vehicle conditions, and the information may not be correct ....Q)under other conditions.

Description of vehicle to which this table applies. Model KZ650-C1Summary Table:Low-speed passHigh-speed pass 395 feet;953.8 feet; 8.62 seconds9.43 seconds

0

400300200100

0LOW-SPEED

L O W ~ P E E D PASS:

2 4 6 8 9T(seconds)

INITIAL SPEED: 20 MPH LIMITING SPEED: 35 MPH

8 CONSUMER INFORMATION

l.____ OTAL PASSING DISTANCE, FEET _____JI ~ TOTAL PASSING TIME, SECONDS ]

D O } ~~ C ] J n CONSTANT ZO MP D m55

-;.(ooo900

HIGH SPEED PASS:

600c300

0 2 4 6 8T(seconds)

10HIGH-SPEEDINITIAL SPEED 50 MPH LIMITING SPEED: 80 MPH

_ OTAL PASSING DISTANCE. FEETJ . -TOTAL PASSING TIME, SECONDS0 0 : } ~roo'+ 14-100-.iC O N S T N T S O M ~ o

TRUCK

CONSUMER INFORMATION 9


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rI,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, SERIAL NUMBER LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,," ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,The engine and frame serial numbers are used to register the motorcycles They are

the only means of identifying your particular machine from others of the same modeltype These serial numbers may be needed by your dealer when ordering parts Inthe event of theft the investigating autho rities will require both numbers as well asthe model type and any peculiar features of your machine that can help them identify it

1 Engine Number 1 Frame Number

10 SERIAL NUMBER LOCATIONS

1 Clutch Lever2 Dimmer Switch3 Turn Signal Switch4 Starter Loe kout Switch5 Speedometer6 _ Indicator Lights

LOCATION OF PARTS

7 Tachometer8 Brake Fluid Reservoir9 Engine Stop Switch10 Front Brake Lever11 Horn Button

,,,,,,,,,,,,,,,,, ,,,,, , ,, , ,,

12 Hazard Switch13 Ignition Switch14 Starter Button15 Headlight Switch16 Throttle Grip_

LOCATION OF PARTS 11


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17 Disc18 Caliper19 Steering Lock20 Choke Lever21 Shift Pedal22 Fuel Tap

23 Side Stand24 Center Stand25 Seat Lock26 Rear Shock Absorber27 Rear Brake l ight Switch 28 Rear Brake Pedal29 Kick Pedal 30 arburetor31 orn

LOCATION O PARTS 32 LOCATION OF PARTS


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' ' LOCATION 0 F CAUTION LABELS ' ' ' ...r. I- -

1. Engine Oil and Oil Filter2. Battery Vent Hose Routing4 Important Drive Chain lnforh1ation5. Daily Safety Checks

6. Battery Poison/Danger Labelonly on U model) 7 Brake Fluid

3. Tire and Load Data

4 LOCATION OF CAUTION LABELSLOCATION OF CAUTION LABELS 5


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' ' ' ' ' ' GENERAL INFORMATION ' ' ' ' ' ~ ~ i f t Pedal _ .Brake Lever and Pedal The front and rear brakes are hydraulic, The transm1ss1on is a 5-speed, return.The lever on the right side of the disc brake type. The reservoirs must b ~ s h i f t type with neutral halfway between

handlebar operates the _front_ brake, and kept filled. v_vith the disc brake fluid orj1st a n ~ 2nd gears.the foot pedal on the right side operates the brakes will not o p ~ r a t e I A return shift means that to go backthe rear brake. See Pg. 74 for a list of recommended1to 1st gear from h. hWhen stopping always apply both brake fluids and for other importantretu th a ig er gear, you mustb k f rn e way you came shifti b kbrakes at the same time if stopping quick- ra e in ormat1on. _ th h ng acly normally the front brake should be When either the front or rear brake i rToug h ~ f h gears one by one. I s I t t th h. .applied a little mote than the rear. applied, the brake light goes on. Thq . 0 e next 1gher gear. disWhen turning a corner it is .better not front brake employs a pressure s w 1 t c i l n g a g ~ t h ~ clutch (1.e., pull the clutchto brake at all, but if this is unavoidable, which requires no adjust ment, but t h ~ e v e ~ in , lift the shift pedal up as far asuse only the rear brake. rear brake light switch should be a d j u s t e ~ t will go, and then release it. To shiftif necessary. to the next lower gear, disengage the

1 Front Brake Lever

16 GENERAL INFORMATION

~ l u t c _ h push the shift pedal down as far asit will go, and then release it. If theengine is stopped, releasing the clutch

l e v ~ r and rollin9 the motorcycle slightlywhile shifting will help shifting back toneutral.

When the transmission is in neutral, thegreen neutral indicator.light will be lit.

{ ~ E ~ ~ i l l ~ : ~ : i ~ ~ ~ ; i ~ ~ ; : : ~ ~ ~ ~ ~the shift pedal fully. If shifting is donecarelessly, the transmission may jump outof gear, causing overrev damage to theengine.

GENERAL INFORMATION 17


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Clutch LeverThe clutch lever on the left side ofthe hand.lebar disengages the clutch whenpulled in.f the clutch lever develops too muchtravel before it will disengage the clutch;take up the excess play by loosening theknurled locknut, backing out the adjuster,and then tightening the knurled locknut.When this adjustment will no longer takeup lever play, readjust the clutch com-pletely (Pg. 64}.Note: A starter lockout switch is built intothe clutch lever holder. It prevents theelectric starter from operating when theclutch is engaged.

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KeyThis motorcycle has a combinationkey, which is used for the ignition switch,,steering lock, seat lock, and fuel tank cap.

Ignition SwitchThis is a three-positions, key-operatedswitch. The key can be removed from

the switch when it is in the OFF or PARKposition.Note: The motorcycle for Canada isdesigned so that the lights are on whenever the ignition switch is in the ON position. To avoid battery discharge, alwaysstart the engine immediately after turningthe ignition switch to ON.

2 GENERAL INFORMAT ION

OFF Engine off. All electricalcircuits off.Engine on. All electricalON equipment can be used.Engine off. Tail light on.P RK All othercut off.

1 Ignition SwitchA. OFF Position

electrical circuits

B. ON PositionC. PARK Position

Speedometer and TachometerThe speedometer shows the speed ofthe vehicle. In the upper part of thei speedometer face is the trip meter, whichj shows the distance traveled since it waslast reset to zero. The trip meter can bereset to zero by turning the reset wheel.In the lower part of the speedometer face

is the odometer The odometer showsthe total distance that the vehicle hasbeen ridden.

1 Speedometer2. Tachometer 1 3 Red Zone

The tachometer shows the enginespeed in revolutions per minute (rpm).On the right side of the tachometer faceis a portion called the red zone. Engin erpm in the red zone is above maximumrecommended engine speed and is alsoabove the range for good performance.[ E ~ ] ~ ~ : : : : ~ : : ~ ~ ~ : d t ~ : \ ~ ~zone; operation in the red zone will overstress the engine and may cause seriousengine damage.

1 Trip Meter 3 Reset Wheel2 Odometer



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Indicator LightsThere are six indicator lights on theswitch panel.1. Neutral Indicator Light2. High Beam Indicator Light3. Oil Pressure Warning Light4. Brake Light Failure Indicator Light5. Left Turn Signal Indicator Light6. Right Turn Signal Indicator Light

NEUTRALHIGH BEAM

OIL

When the gears are n neutral, the green indicator light s lit.When the headlight s on high beam, the blue indicator light s lit.The red oil pressure warning light goes on whenever the ignitionswitch s n the O position with the engine not running, and goes offwhen the engine oil has reached sufficient pressure. (Refer to themaintenance and adjustment section for detailed information.)


STOPLAMP

L-TURNR-TURN

The indicator light labeled STOP LAMP , located on the switch panel,s used to detect brake light failure.If the brake light s functioning properly, the brake light failure indicatorlight goes on whenever one or both brakes are applied, and goes offwhenever the brake or brakes are released.If the brake light s not functioning properly, the light will still go onwhenever one or both brakes are applied; however, when neither brakes applied, the light will flash on and off indicating that the brake light

circuit or the brake light itself s faulty.If the indicator light does not go on when a brake s applied, one of thebrake switches, the indicator light switch inside the left side cover, orthe indicator light itself s not functioning properly, or the groundcircuit s interrupted.When the turn signal switch s turned on left, the orange left turn signalindicator light flashes on and off.When the turn signal switch s turned on right, the orange right turnsignal indicator light flashes on and off.



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Turn Signal SwitchThe turn signals are operated by turn

signal switch located on the Ieft side ofthe handlebar.When the switch is operated one ofthe turn signal indicator lights flashes onand off together with the turn signals.L ......... LeftR ........ Right

1 Turn Signal SwitchA Left B. Right


Dimmer SwitchHigh or low beam can be selected with

the dimmer switch. When the headlight ison high beam a blue indicator light in theswitch panel lights.H . ........High BeamLO ......... Low Beam

1 Dimmer SwitchA High Beam B. Low Beam

r o r n Button :1 The horn is operated by t1he horn

button located on the left side of thehandlebar.If the horn does not operate properlycheck that the battery is good and thatthe horn is mounted securely with noth-ing touching it. f the horn itself is atfault, it should be adjusted, repaired, orreplaced immediately.

1. Horn Button

Hazard Switchf an emergency requires you to park

on the highway shoulder, turn on thehazard switch to warm other drivers ofyour location.Push the hazard switch with the ig-nition switch ON, or with the ignitionswitch on PARK position if you leave themotorcycle for a while, then al I the turnsignals will flash on and off.[ ~ ~ ~ @ ] ~ i i ' c ~ u k ~ ~ v ~ n ~ r ~ a ~ ~ ~ :time, the battery might be totally dis-charged. So be careful not to use it formore than 30 minutes.



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Headlight Switchnot on Canadian model

The headlight switch has two positions:OFF and ONOFF

O

The headlight is off with theswitch in the OFF position.The head, tail, meter, and posi-tion lights come on if the switchis pushed forward to the ON po-sition with the ignition switchin the ON position.


Engine Stop SwitchIn addition to the ignition switch, theengine stop switch must be in the RUNposition for the motorcycle to operate.The engine stop switch is for emergen-cy use. If some emergency requiresstopping the engine, flick the engine stopswitch to either of the OFF positions.Note: Although the engine stop switchstops the engine, it does not turn off all :the electrical circuits. Ordinarily, theignition switch should be used to stop theengine.

1. Engine Stop Switch

Choke LeverTo provide a rich starting mixturewhen the engine is cold, there is a chokelever on the left side of the engine.Pull it all the way up and leave it upuntil the engine is warm. As the enginebecomes warm and engine rpm increases,push down the choke lever gradually sothat engine speed stays below 2;500 rpm.Once the engine has sufficiently warm-ed up and before moving off, return thechoke lever all the way back down.Note: If the choke lever is left pulled up

too long after the engine is warm, it willcause ~ p r k plug fouling and poor fueleconomy.

1 . Choke Lever

Fuse BoxThe fuse box is located inside the rightside cover, and it contains three fuses andtwo sapre fuses. If a fuse blows duringoperation, inspect the electrical system todetermine the cause, and then replace thefuse.

[ ~ E ~ T I ~ ~ ~ } ; ~ ~ ~ : t ~ ~ ~ = ~ J f s ~ ~ ~ t i t u t eReplace the fuse with one of the correctcapacity, as specified in the fuse box foreach circuit.

1. 20A Fuse 3. Spar:e Fuses2. 10A Fuses



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Fuel TankNon-leaded gasoline should be used inthe fuel tank. Avoid filling the tank inthe rain or where heavy dust is blowingso that the fuel does not get contaminated.

[ ~ [ f I ~ ~ : ~ : : ~ t ~ ~ ~ = ~ o t = ~ k A ~ ~ ~ ~gasoline expands in a warm tank, it mayoverflow from the vents in the tank cap.Always put in gasoline with the ignitionswitch key turned off, and the motorcycle away from any source of sparks.

Fuel Tank CapTo open the fuel tank cap: insert theignition switch key into the cap, turn thekey to the right, and open the cap. Thefuel tank cap is locked when pushed backinto place.28 GENERAL INFORMATION

Fuel TapThe fuel tap has three positions: OFF,

ON, and RES reserve). If the fuel runsout with the tap in the ON position, thelast 2.4 liters 0.63 US gal) of fuel canbe used by turning the tap to RES.Note:Since riding distance is limitedwhen on RES, refuel at the earliest opportunity.Make certain that the fuel tap is turnedto ON Not RES), after filling up the fueltank.

1. Fuel Tank Cap B. RES Position .2. FuelTap C. ON PositionA. OFF Position

neering ock To help prevent theft, the handle- ........_.can be locked in the full right potion. To lock the steering:1. Turn the handlebar to the right.2. Insert the ignition switch key.3. Turn the key to the left.4. Push the key in, and turn it to theright.5. Pull the key out.IWARNING I Unlock the steering be fore.. ... starting the engine. Attempting to drive with the steering lockedcould cause an accident.


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StandsThe motorcycle is equipped with twostands: a center stand and a side stand.Whenever the side stand is used, makeit a firm practice to kick the stand fullyup before sitting on the motorcycle.IWARNING 1 Forgetting and leaving

.. . the side stand down whileriding could cause an accident.When using the side stand, have thehandlebar turned to the left, - , ,A. Lift here


To set the motorcycle up on the centerstand, step down firmly on the stand andthen lift the motorcycle up and to the rearusing the grab rail s ahandhold. Don tpull up on the seat to lift it s this willonly damage the seat.

Helmet HooksThe rider s hel met can b ~ secured to the motorcycle using the helmet hookslocated under the seat.

1. Helmet Hooks

ocument ContainerA receptacle for the owner s manuald any papers or documents that should

f be kept with the motorcycle is locatedon the bottom of the seat.

1. Document Container

Tool KitThe tool kit is located under the seatbehind the battery. The minor adjustments and replacement of parts explainedin this manual can be performed withthese tools.~ ] ~ : o i d : ~ ~ ~ o b : ~ : i ~ : ~ ~Don t overfill the tool case, or thebattery may be damaged.

1 Tool Kit



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Tools

C 0 0 0 0 0 0I IiII'0 0 @@ @@ @


1. Spark Plug Wrench2. Pliers3. 27 mm Axle Wrench4. Open End Wrench

22mm5. Open End Wrench14 x 17 mm

6. Open End Wrench12x13mm7. Open End Wrench8 x 10 mm8. Tool Case

9. Screwdriver Grip10. Slot Bit11. Phillips Bit 212. Phillips Bit 313. Screwdriver T-handle14. Thick ness Gauge0.35mm

15. Wrench Extender16. Hook Wrench

,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,, RE KING IN ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,The first 1,600 km (1,000 mi) that the motorcycle is ridden is designated as the break-inperiod. If the motorcycle is not used carefully during this period, you may very well endup with a broken down instead of a broken in motorcycle after a few thousandkilometers.The following rules should be observed during the break-in period.

The table shows maximum recommended engine rpm during the break-in period.Distance traveled Maximum engine rpm0 '800 km (0 '500 mi) 4,000 rpm800 '1,600 km (500 '1,000 mi) 6,000 rpm

Do not start moving or race the engine immediately after starting it, even if the engine isalready warm. Run the engine for two or three minutes at 950 ' 1,050 rpm to give theoil a chance to work up into all the engine parts.

Do not race the engine while the gears are in neutral.The slow riding nettessary during the break-in period may cause carbon to build up onthe spark plugs and foul them. If inspection of the spark plugs shows this to be thecase, replace the standard .NGK 87ES, ND W22ES..lJ, or CHAMPION N-4-MC with NGKB6ES, ND W20ES-U, or CHAMPION N-5-MC for the duration of the break-in period.

In addition to the above, the owner should take the motorcycle to an authorizedKawasaki Dealer for initial maintenance service at soo km (500 mi).

BREAKING IN 33


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. HOW TO RIDE THE MOTORCYCLE .Starting the EngineCheck that the steering is unlocked.Turn the fuel tap on.Turn the engine stop switch to RUN.Turn the ignition switch on.Make certain the gears are in neutral.The green neutral indicator light shouldbe lit.If the engine is cold pull up the chokelever leaving the throttle completelyclosed.Push the starter. button with the clutchlever pulled in or kick the engine overuntil the engine starts . Warm it up atl ss than 2 500 rpm.When the engine is warm enough to idlewithout use of the choke lever pushdown the choke lever.Note: oWhen the engine is already warmor on hot days open the throttle partway instead of using the chok e lever andthen start the engine.

4 HOW TO RIDE THE MOTORCYCLE

1. Neutral Indicator Light 2. Choke Lever

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 on the clutch lever very slowly.As the clutch starts to engage open the throttle a little more giving the engine justenough fuel to keep it from stalling.

Shifting GearsClose the throttle while pulling in the clutch lever at the same time.Shift into the next higher or lower gear.Open the throttle part way and release the clutch lever.j W RNING I When shifting down to a lower gear do not shift at such a h igh speed..._ .;...that the engine is suddenly jerked into high rpm or into the red zone.Not only can this cause engine damage but the rear wheel may skid and cause anaccident. Downshifting should be done below 6 000 rpm for each gear.

HOW TO RIDE THE MOTORCYCLE 35


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BrakingClose 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 finally in 1st gear just when you get

Stopping the Motorcycle in an EmergencyYour Kawasaki Motorcycle has been designed and manufactured to provide you

optimum safety and convenience. However, in order to fully benefit from Kawasaki'ssafety engineering and craftsmanship, it is essential that you the owner and operatorcompletely stopped. / properly maintain your motorcycle and become thoroughly familiar with its operation.When stopping, always apply both brakes at the same time if stopping quickly; normallythe front brake should be applied a little more than the rear. Downshift or fully dis-engage the clutch s necessary to keep the engine from stalling or to stop more quickly.

Never lock the brakes and cause the tires to skid. When turning a corner it is better notto brake at all, but if this is unavoidable, use only the rear brake. .I

For emergency braking, disregard downshifti ng, and concentrate on applying the brakes rs .hard s possible without skidding.

Stopping the EngineClose the throttle completely.Shift the gears into neutral.Turn the ignition switch off, or if only stopping for a short time (less than one hour)

on the road at night, turn it to PARKClose the fuel tap.Lock the steering.

36 OW TO RIDE THE MOTORCYCLE

Improper maintenance and insufficient riding skills can create a dangerous situationknown as throttle failure. Two of the most common causes of throttle failure are:1. During removal of the air cleaner by the owner, dirt is allowed to enter and jama carburetor.2. A novice may forget which direction the throttle rotates; then jerk the throttlewide open thinking he has shut it off; panic when the machine accelerates suddenlyinstead of slowing down; and freeze , holding the throttle wide open.Kawasaki has provided an engine stop switch or button on ll its motorcycles whichmay be used to safely stop your motorcycle in an emergency. Alternatively, your motor-

cycle may be stopped by applying the brakes and disengaging the clutch. But if theengine stop switch is used, turn off the ignition switch after stopping the motorcycle.

OW TO RIDE THE MOTORCYCLE 37


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S FE OP R T ONSafe Riding Technique

The points given elow are applicable for everyday motorcycle use and should be care-fully observed for s fe and effective vehicle operation.

For safety eye protection and a hel-met are strongly recommende d. Glovesand suitable footwear should also beused for added protection in case of amishap.

When going up steep slopes shift toa lower gear so that there is plenty ofpower to spare rather than overload theengine.

When applying the brakes use boththe front and rear brakes. Applyingonly one brake for sudden braking maycause the motorcycle to skid and losecont ot

When going down long slopes c ontrolvehicle speed by closing the throttle. Usethe front and rear brakes for auxiliarybraking.

38 SAFE OPERATION

On rainy days rely more on thethrottle to control vehicle speed and lesson the front and rear brakes. Thethrottle should also be used judiciouslyto avoid skidding the rear wheel fromtoo rapid acceleration or deceleration.

Riding at the prr Jer rate of speedand avoiding unnecessarily fast acceleration are important not only for safetyand low fuel consumption but also forlong vehicle life and quieter operation.

On rough roads exercise caution reduce speed and grip the fuel tank withthe knees when necessary for betterstability.

When quick acceleration is necessarys in passing shift to a lower gear toobtain the necessary power.

Do not downshift at too high an rpmto v o i damage to the engine from over-revving.

Avoiding unnecessary weaving is im-portant to the safety of both the riderand other motorists.

SAFE OPERATION 39


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Daily Safety Checksn order to ride more enjcyably and more safely, the daily safety checks should never

be neglected. Since engine trouble or a severe accident may be prevented through carry-ing out these simple checks and correcting any trouble, make it a habit each day beforeriding to check the following:Gasoline ........... ............. ....... Gasoline in tankEngine oil ......... ............ ....... Oil level correct Pg. 46)Tires .................................... Check for wear, cracks, and other damage Pg. 80)

Air pressure: front 2.00 kg/cm2 (28 psi)rear 225 kg/cm2 (32 psi)

Drive chain .......................... Check overall condition; chain slack 20 ;._ 30 mm (0.8' 1.2 in); oil as necessary Pg. 67)

Battery ................................ Electrolyte level above the lower level mark Pg. 86)Nuts and bolts ..................... Tighten any loose nuts and bolts Pg. 96)Front brake ......................... Brake lever play is 3 .... 5 mm (0.12 .... 2 in); fluid up to

level line; no damage to brake line or fittings Pg. 71)

40 SAFE OPERATION

Clutch ...............................Rear Brake ........................Throttle grip .....................Steering .........................Front fork ........................

Rear shock absorbers ........Electrical equipment ........Engine ..............................

Clutch lever play about 2 .... 3 mm (0.08 ..._ 0.12 in); releasesproperly, no slippage Pg. 64)Brake pedal play 8 ..._ 10 mm (0.32 '0A0 in); fluid up to levelline; brake light functioning properly Pg. 72, 75Throttle grip play 2' '3 mm (0.08 '0.12 in) Pg. 60)Check that the steering turns freely but has no play Pg. 76)When pushing down on the handlebar with the front brakefully applied, the front fork functions properly; no oilleakage Pg. 77)Function properly, no oil leakage Pg. 78)Check that the headlight, tail/brake light, turn signals, andhorn work.No abnormal engine noise

f any irregularities are found during the above checks, refer to the Maintenance andAdjustment Section to make the corrections necessary for safe operation.

SAFE OPERATION 41


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Additional Considerations for High Speed OperationBrakes

Steering

Tires

Spark Plugs

GasolineEngine OilElectrical EquipmentMiscellaneous

42 SAFE OPERATION

The importance of the brakes especially during high speedoperation cannot be overemphasized. .Check to see thatthey are correctly adjusted and functioning properly.Looseness in the steering can cause loss of control. Checkto see that the handlebar turns freely but has no play.High speed operation is hard on tires and good tires arecrucial for riding safet y. Examine their overall conditioninflate to the proper pressure and check the wheel balance.The standard plug is NGK B7ES ND W22ES-U or CHAMPIONN4-MC but for prolonged high speed operation use the .nextcolder heat range spark plug NGK BSES ND W24ES-U orCHAMPION N-3-MC.Have sufficient fuel for high fuel consumption during highspeed operation.To avoid seizure and resulting loss of control make certainthe oil level is at the upper level mark.Make certain that the headlight tail/brake light turn signalshorn etc. all work properly.Make certain that all nuts and bolts are tight and that allsafety related parts are in good condition.

' ' ' ' ' ' MAINTENANCE AND ADJUSTMENT ;

The maintenance and adjustments outlined in this section are easily carried out andmust be done in accordance with the Periodic Maintenance Chart to keep the motorcyclein good running condition. Some of these are so important that you should make ahabit of checking them frequently or daily as in the case of the daily safety checks.

f you are in doubt as to the adjustment or vehicle operation please ask your author-ized Kawasaki Dealer to check the motorcycle.Please note that Kawasaki can not assume any responsibility for damage resulting fromincorrect maintenance or improper adjustment done by the owner.

MAINTENANCE AND ADJUSTMENT 43


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....

Periodic Maintenance ChartAfter After Every Every After After Every EveryFrequency initial initial subsequent subsequent Page initial initial subsequent subsequent Page

Operation 800 km 5,000 km 5,000 km 10,000 km Reference 800km 5,000 km 5,000 km 10,000 km Reference500 mi) 3,000 mi) 3,000 mil 6,000 mi) n 500mi) 3,000 mil 3,000 mil 6,000 mi)Check, adjust brakes 7 Clean air cleaner element 59Check brake fluid level 73 Perform general lubrication 94Check, adjust clutch 64 Change engine oil Every subsequent 3,000 km (2,00Q mil 47Check, adjust carburetors 63 . Change oil filter element Every subsequent 6,000 km 4,000 mil 47Check rim runout 79 Lubricate drive chain Every 300 km 200 mi) 70Clean fuel system 9 Check, adjust drive chain Every 800 km 500 mi) 67Clean, set spark plug gaps 48 Chan.ge air cleaner element **Every 10,000 km 6,000 mi) or after 60Check tire pressure and 80 cleaning 5 timestread wear Check brake wear Every 10,000 km 6,000 mil 75Adjust camshaft chain 55 *Change front fork oil Every 10,000 km 6,000 mi) 77Check, adjust points, timing 49 Lubricate timing advancer Every 10,000 km 6,000 mi) -Check valve clearance 56 Change brake fluid **Every year or 10,000 km 6,000 mil 73*Check steering play 76 *Regrease wheel bearings **Every 2 years or 20,000 km (12,000 mil -Tighten bolts and nuts 96 *Regrease speedometer gear box **Every 2 years or 20,000 km (12,000 mi J - 67 *Regrease brake camshaft **Every 2 years or 20,000 km 12,000 mil iCheck drive chain wear -*Lubricate steering stem bearings **Every 2 years or 20,000 km 12,000 mi) -

*Should be serviced by an authorized Kawasaki Dealer.**Whichever occurs first.

MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT 5 i

r

..

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Engine OilIn order for the engine, transmission,and clutch to function properly, maintain

the engine oil at the proper level, andchange the oil in accordance with theperiodic maintenance chart.Motorcycle operation with

insufficient, deteriorated,or contaminated engine oil will causeaccelerated wear and may result in engineor transmission seizure.Oil LevelSituate the motorcycle so that it isperpendicular to the ground (on its cen-

ter stand).If the oil has just been changed, startthe engine and run it for several minutesat idle speed. This fills the oil filterwith oil. Then wait several minutesuntil the oil settles.ifl] p ~ d ~ ~ engine at idleleast until the6 MAINTENANCE ND ADJUSTMENT

oil pressure warning light turns off.Racing the engine befQl e the oil reachesevery part can cause the engine seizure.If the motorcycle has just been used,wait several minutes for all the oil to

drain down.Check the engine oil level through theoil level gauge in the lower right side

of the engine. With the motorcycleheld ievel or on the center stand, the oillevel should come up between the linesnext to the gauge.

1 . Upper Level2. Lower Level 3. Oil Level Gauge

If the oil level is too high, remove theexcess oil, using a syringe or some othersuitable device.

If the amount of oil is insufficient, addthe correct amount of oil through theoil filler opening. Fill, using the sametype and make of oil that is already inthe engine.

Engine Oil and Oil Filter ChangeThe engine oil should be changed peri-odically to ensure long engine life. Notonly do dirt and metal filings collect inthe oil, but the oil itself loses its lubrica-tive quality if used too long.

The oil and oil filter must be changedperiodically (Pg. 45 .To change the oil and filter1 Warm the engine up thoroughly.2. Position the vehicle off its side standso that it is fully perpendicular to theground.

3. Remove the drain plug. If the oilfilter is to be changed, remove the oilfilter mounting bolt, and drop out theoil filter.

1. Drain Plug 2. Oil Filter Mounting Bolt

1. Oil f .ilter

MAINTENANC E AND ADJUSTMENT 7


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4. With the drain plug and oil filter backin place, fill the engine up to the upperlevel with S class S E 10W40, 10W50,20W40, or 20W50 motor oil. It willtake about 3.5 liters (3.7 US qt) whenthe oil filter is changed. When the oilfilter is not changed, a refill takesabout 3.0 liters (3.2 US qt).Note: Check for o ring damage.

When installing the oil filter, make surethe O ring is in place.

1. 0 ring

48 MAINTENANCE ND ADJUSTMENT

Spark Plug MaintenanceThe standard spark plug is a NGK B7ES

ND W22ES-U or CH MPION N-4-MC. Itshould have a 0.7 '0 .8 mm (0.028 '0.032in) gap, and be tightened to 2.8 kg-m(20 ft-lbs) of torque.

MaintenanceThe spark plugs should be taken outperiodically for cleaning and to reset thegaps Pg. 44). If either plug is oily or has

carbon built up on it, have it cleaned,preferably in a sand-blasting device, andthen clean off any abrasive particles.The plug may also be cleaned usingsolvent and a wire brush or other suitabletool. Measure the gap with a thicknessgauge, and adjust the gap if incorrect bybending the outer electrode.Heat Range

To find out whether the right temperature plugs are being used, pull them outand examine the ceramic insulator aroundthe center electrode. f the ceramic is alight brown color, the spark plugs arecorrectly matched to engine temperature.f the ceramic is burned white, the plugs

should be replaced with the next coldertype, NGK BSES ND W24ES-U orCH MPION N-3-MC. f the ceramic isblack, the plugs should be replaced withthe next- hotter type, NGK B6ES NDW20ES-U or CH MPION N-5-MC.

Ignition Timing Adjustme.ntIncorrect ignition timing can causepoor performance, knocking, overheating,and serious engine damage. Periodic ad

justment will be necessary to compensatefor wear of parts, and the ignition timingmust be checked whenever ignition relatedparts have been d i s a s ~ e m b l e d or replaced.Correct ignition timing is achieved byfirst obtaining the correct contact breakerpoint gaps this can also be achieved byadjusting the dwell angles to the specified

a m o u n ~ and then- changing the positionof the adjusting plates. Often the first. step returns the timing very close to thecorrect original setting . Once the timinghas been adjusted, it may be checked foraccuracy by the use of a strobe light.There are two sets of contact breakerpoints, the left set marked 1 4 firesspark plugs 1 and 4 simultaneously, andthe right set marked 2 3 fires plugs



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2 and 3 1ao 0 later. The gap for each setof points must be adjusted separately.

1. Contact Breaker Points u1 42. Contact Breaker Points u2 3Note:Spark plugs and cylinders are numbered consecutively, starting from the left.There are two F marks on the timingadvancer, which can be viewed throughthe inspection window by turning thecrankshaft. One is marked 1 4 and theother one is marked 2 3 . After the gap

.50 MAINTENANCE AND ADJUSTMENT

is adjusted for both sets of points, timingmust be adjusted for each F mark.

Point Gap AdjustmentRemove the contact breaker cover.Clean the points with clean paper or

cloth, using an oil-free solvent. A business card soaked in trichloroethylenecan be used to remove traces of oil. Torepair light damage, use emery cloth or

an oilstone. If the points are badlyworn down or damaged, or if the springis weak, replace the contact breaker.

Lubricate the point cam oil felt sparinglywith suitable point cam lubricant. Donot overlubricate. Replace the oil felt.if it is worn.

1. Oil FeltUsing a 17 mm wrench on the crankshaft,turn the engine clockwise until the contact breaker points are at their widestopening

Measure the size of the point gap with athickness gauge. The prope r gap is 0.3' 0 .4 mm (0.012 '0.016 in).

1. Thickness GaugeIf the gap is incorrect, loosen the contact breaker base screws (2) just enoughto allow the base to move. Open thepoints using a slot screwdriver on thecontact breaker base pry point, and insert a thickness gauge of 0.35 mm (0.014in between the points. Tighten the contact breaker base screws (2), and remove



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the thickness gauge. Again turn thecrankshaft, and recheck the point gap.

1. Pry Points2. Contact Breaker Base ScrewsCheck and adjust the other contactbreaker point gap, following the stepsabove.Timing AdjustmentTurn t ~ e ignition-switch off .-Turn-the engine s t o p ~ s w i t h o f f


Turn the crankshaft so that the F markon the timing advancer is aligned withthe timing mark.

Timing Mark 2. F markSet an ohmmeter to the R x 1 range and

connect it across the appropriate set ofpoints, one lead to the wire coming fromthe points (or to the spring leaf), andthe other ohmmeter lead to chassisground (engine, frame, contact breakermou_nting, etc .)._ Make sure that bothleads are securely connect ed.

1. OhmmeterLoosen the adjusting plate screws 2)and turn the adjusting plate using ascrewdriver in the pry points so thatthe contact s are just opening. Theohmmeter needle will flicker just whenthe points begin to open ''?r ~ ~ o s e .

1. Pry Points

If the adjusting plate will not travel farenough to allow correct timing adjustment, loosen the mounting plate s r ~ w s3) and turn the mounting plate toprovide more room for adjustment.

1. Mounting Plate ScrewsTurning the crankshaft clockwise, check

to see if the F mark is aligned withthe timing mark when the needle'jumps.If not, readjust.

Tighten all the screws that were loosened.Repeat the steps above using the other

F mark.MAINTENANCE ND ADJUSTMENT 53


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Disconnect the ohmmeter leads, andturn the engine stop switch back to theRUN position.

Connect a strobe light lead to the sparkplug lead numbered 4 in order to checkthe ignition timing for the 1 and 4cylinders under operating condition.

Start the engine, and direct the light atthe timing mark. At idle speed thetiming mark and the F mark on thetiming advancer must be aligned forcorrect low rpm ignition timing. At

54 MAINTENANCE AND ADJUSTMENT

3 000 .. 3.400 rpm, the timing mark andthe lines on the timing advancer mustbe aligned for correct. high rpm ignitiontiming. If both low and high rpm ig-nition timing are incorrect, adjust thetiming as just explained. If either lowor high rpm ignition timing is correctbut the other is not, ask your dealerto check the engine.

1. Timing Mark 3. Lines2. F markNext, move the strobe light lead to thespark plug lead numbered 3 ", and check

the ignition timing for cylinders 2 and3 .

Install the contact breaker cover.

Camshaft Chain AdjustmentTo keep the chain from makingnoise, periodic adjustment is necessary inaccordance with the Periodic MaintenanceChart (Pg. 44).

C a ~ s h a f t chain and c h a ~ nguide wear cause the :chamto devj lop slack, which will cause noiseand may result in engine damage.However, if the adjustment fails tokeep the chain from making noise, thecamshaft chain or chain guides have probably worn past their service limits andwill need to be replaced.

IW RNING I Take care not to touch the...._ cylinder or exhaust pipeswhen they are hot to prevent a burn.Remove the contact breaker cover.Using a 17 mm wrench, turn the crank-shaft clockwise about two turns, andset the corner near" the 2 and 3 Tmark on the, timing advancer so that italigns with the mark on the right enginecover.


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Loosen the chain tensioner locknut andbolt. {With the b olt loose, a spring inside takes up slack automatically).

l Adjusting Bolt 2. Locknut.Tighten the bolt and then its locknut.

Valve Clearance InspectionValve and valve seat wear decreasesvalve clearance, upsetting valve timing.


vG .

f A : ~ J ll f n a ~ s ~ e e ~ ~ n e ~ ~ ~ ~ ~eventually cause the. valves to remainpartly open, which lowers performance,burns the valves and valve seats, and maycause serious engine damage.Valve clearance for each valve shouldbe checked and, if incorrect, adjusted inaccordance with the Periodic MaintenanceChart {Pg. 44) and any time that clearancemay have been affected by disassembly.Inspection should be performed periodically and requires no special tools.Adjustment, however, involves camshaftremoval and re-timing and should be doneonly by a Kawasaki Dealer or by followingthe instructions in the Shop Manual.Note: Valve clearance must be checkedwhen the engine is cold.To check the valve clearanceRemove the fuel tank.

Remove the spark plug caps from allplugs.Remove the ignition coils.

1. Ignition CoilRemove the cylinder head cover bolts{24), and lift the cover off the cylinderhead and out of the way.Remove the contact breaker cover.To check the e x h ~ s t camshaft valves,use a 17 mm wrench on. the crankshaftto turn the crankshaft so that the line

adjoining the Ex mark on the exhaustcamshaft sprocket is pointing to thefront aligned with the cylinder headsurface.

1. Line 2. Exhaust Camshaft SprocketInsert a thickness gauge between the camand the valve lifter, and measure the twovalves { 1 and 3) for which there isclearance. The correct clearance is 0.08

' '. '0.18 ~ {0.003 '0.007 in).



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1. T h i ~ k n e s s GaugeTurn the crankshaft until the Ex t . rked line is pointing to the rear al :t,,: edwith the cylinder head surface (

tion), and measure the other two v.( 2 and #4).To check the inlet camshaft valves, .n

the crankshaft so that the inlet camshaftsprocket arrow adjoining the T mark ispointing to the rear aligned whh thecylinder head surface, and measure the

- - two valves ( 5 and #7) for which thereis clearance.


1. Arrow 2. Inlet Camshaft SprocketTurn the crankshaft until the T marked

arrow is pointing to the front alignedwith the cylinder head surface { rotation), and measure the other two valves( 6 and 8).

Air Cleaner MaintenanceA clogged air cleaner restricts theengine s air intake , increasing gas co n

sumption, reducing engine power, andcausing spark plug f o u l i n ~

Air Cleaner Element CleaningThe air cleaner element must be cleaned periodically {Pg. 45). In dusty areas,the element should be cleaned more fre

quently than the recommended interval.After riding through rain or on muddyroads, the element should be cleanedimmediately.ELEMENT REMOVALUnlock and lift up the seat.Remove the fuel tank.

1. Fuel Tank

Remove the air cleaner cap and pull outthe element.

1 ement 2. Air Cleaner CapELErJIENT CLEANINGCkan the element in a bath of a highfie ih-point solvent.

~ .:ter the element is clean, dry it with_compressed air or by shaking it.r ~ ~ ~ ~ ~ OClean the element iri:al . E ~ ~ ~ } E : J well-ventilated area, andtake ample care that there are no sparksor flame anywhere near the working area .

M INTEN NCE ND ADJUSTMENT 59


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oBecause of the danger of highly flammable liquids, do not use gasoline or a lowflash-point solvent to clean the element.OA break in the element material or damage to the sponge gasket will allow dirtand dust to pass through into the carburetors and eventually damage the engine.If any part of the element is damaged, theelement must be replaced.ODon t oil the element or carburetion willbe upset.Element ReplacementThe element should be changed periodically (Pg. 45), or if it is damaged.

Throttle Grip Adjustmentand LubricationThere are two throttle cables, theaccelerator cable for opening the throttle

valves and decelerator cable for closingthem. If the cables are too loose from


either cable stretch or maladjustment, theexcessive play in the throttle grip willcause a delay in throttle response, especially at low rpm. Also, the throttlevalves may not open fullv at full throttle.

1. Accelerator Cable 2. Decelerator CableOn the other hand, if the cables are tootight, the throttle will be hard to control,and the idle speed will be erratic.To check the throttle cable adjustmentCheck that there is ' 3 mm (o.oa '

0.12 in) grip play.

Push the throttle grip completely closed.At this time there should be no clearance between the cable bracket and thestopper.

1. Cable Bracket 2. StopperIf one of the above checks shows it

to be maladjusted, adjust the throttlecable as follows:Loosen the locknuts, and screw BOTH

throttle cable adjusting nuts in fullyat the upper end ofcthethrottlecables'

so as to give the throttle grip plenty ofplay.

1. Locknuts 2. Adjusting NutsTurn out the DECELERATOR cableadjusting nut until there is no clearance

between the cable bracket and the stopper when the throttle grip is completelyclosed.Turn the ACCELERATOR cable adjusting nut until 2 3 mm (0.08 '0.12 in) of

throttle grip play is obtained. Tightenthe locknuts.



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Note: If the throttle cables can not beadjusted by using the cable adjusting nutsat the upper end of the throttle cablesuse the cable adjuster at 1;he lower end ofthe throttle cables. Do not forget tosecurely tighten the adjuster mountingnuts.

LubricationIn order to keep the throttle grip turn-ing properly and throttle cables slidingsmoothly they should be lubricatedperiodically in the following manner.

Remove the engine stop switch housingscrews.Remove the throttle cable tips fromtheir catch in the throttle grip and takeoff the throttle grip.Wipe the old grease from the grip po-sition on the handlebar and apply alight coat of grease in its place.


VQ _

Turn the handlebar to the left.Fill the compartment in the lower halfof the housing with oil and wait untilthe oil has seeped in between the innerand outer cables.

Install the engine stop switch housing.Tighten the screws securely.Note: After throttle grip assembly checkthat the throttle grip turns properly andthat the inner cables slide smoothly.Idling AdjustmentStart the engine and warm it up for

5 minutes.

Adjust idle speed to 950 .... 1 050 rpmby turning the idle adjusting screw.

1. Idle Adjusting ScrewOpen and close the throttle a few times

to make sure that the idle speed doesnot change. Readjust if necessary.

Note: With the engine idling turn thehandlebar to each side. If handlebarmovement changes idle speed the throt-tle cables may be improperly adjusted orincorrectly routed or they may be dam-aged.



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IW RN 1 I Operation with improperly.. .- - - - a d j u s t e d , incorrectly rout-ed, or damaged cables could result in anunsafe idling condition.

Clutch Adjustment and LubricationDue to friction plates wearing andclutch cable stretching over a long periodof use, the clutch must be adjusted pe-riodically Pg. 44).IW RNING I To avoid a serious b u ~ n

.. . never touch a hot engmeor exhaust pipe during clutch adjustment.To adjust the clutchLoosen the locknut at the middle of the

clutch cable, and turn the adjusting nutto give the cable plenty of play.


Loosen_ the knurled locknut just enoughso that the adjuster will turn freely, andthen turn the adjuster to make a 5 .. 6mm 0.2 ' 0.24 in) gap between theadjuster and knurled locknut.

1. Locknut 3. Knurled Locknut2. Adjusting Nut 4. AdjusterRemove the clutch adjusting cover andgasket.Loosen the locknut, and back out theclutch adjusting screw 3 or 4 turns until

the screw turns without drag.

1. Clutch Adjusting Cover2. Locknut 3. Clutch Adjusting ScrewTurn the adjusting screw in until itbecomes hard to turn. This is the pointwhere the clutch is just starting torelease.Back out the adjusting screw turn

from that point, and tighten the locknutwithout changing the adjusting screwposition.Take up all the cable play with theadjusting nut at the middle of the cable,and then tighten the locknut.

Make sure the lower end of the clutchouter cable is properly fitted into thehole in the engine sprocket cover.

I W RNING : f the c ~ l e is not fu_lly1- - - - eated m the engmesprocket cover hole, it could slip intoplace later and the clutch would notdisengage.Turn the adjuster at the clutch leverso that the clutch lever wi have 2 '3mm (0.08 '0.12 in) of play, and tighten

the knurled locknut.

1. Adjuster 2. Knurled Locknut



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Install the clutch adjusting cover andgasket.Clutch Cable Lubri cationThe exposed portions of the innercable should be lubricated in the following manner.CABLE UPPER END REMOVALRemove the clutch adjusting cover.Loosen the locknut, and back out theclutch adjusting screw 3 or 4 turns.

1 Clutch Adjusting Cover 3 Adjusting Screw2 Locknut


Loosen the knurled locknut at the clutchlever, and screw the adjuster fully in.Line up the slots in the clutch leverholder, knurled locknut, and adjuster.

1 Adjuster 3 Lever Holder2 Knurled Locknut 4 Clutch LeverFree the inner cable from the lever.CABLE LUBRICATION

The most satisfactory way is to allowthe oil to seep in between the inner and

outer cable by forming some sort of reservoir to hold the oil. Lubricat e the cableas shown.

1 Inner Cable 2. Outer CableAfter lubricating the clutch cable, wipe

off spilled oil.Note: After connecting the upper end ofthe clutch cable, adjust the clutch Pg.64 .

Drive Chain MaintenanceThe drive chain must be kept properlyadjusted for safety and to prevent excessive wear. f the chain becomes badlyworn or maladjusted - either too loose

or too tight - the chain could jump offthe sprocket or break.I W RNING I A jumped or broken h ~ i n.... . could snag on the engmesprocket or lock the rear wheel, severelydamaging the motorcycle and causing itto go out of control.

InspectionWith the motorcycle resting on thecenter stand, the chain should have a

20...., 30 mm 0.8...., 1.2 in) slack measuredmidway between the sprockets. Rotatethe rear wheel around to find the placewhere the chain is tightest because it



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wears unevenly). If there is less than 5mm 0.6 in) or more than 35 mm 1.4 in)slack, the chain should be readjusted.

n addition to checking the slack,rotate the rear wheel to inspect the drivechain and sprockets for damaged rollers,loose pins and links, unevenly or excessively worn teeth, and damaged teeth.

f there is any irregularity, have thedrive chain and/or the sprockets repalcedby an authorized Kawasaki Dealer.


SPROCKETS

Adjustment

'

Worn Tooth(Engine Sprocket)>a

Direction of rotation

Remove the cotter pin, and loosen thenut at the rear end of the torque I nk.

Loosen the left and right chain adjusterlock nuts.Remove the axle cotter pin, and loosenthe axle nut.

1. Chain Adjuster Locknut 3. Cotter Pin2. Adjusting Bolt 4. Axle NutIf the chain is too tight, back out theleft and right chain adjusting bolts evenly, and kick the wheel forward until thechain is too loose.Turn the left and right chain adjustingbolts evenly until the drive chain has the

correct amount of slack. To keep thechain and wheel aligned, the notch onthe left chain adjuster should align withthe same swing arm mark that the rightchain adjuster notch aligns with.

1. Marks 2. NotchIW RNING I Misalignment of the wheel.. . will result in abnormal wearand may resul t in an unsafe ridi 1g condition.Tighten the axle nut to 12 kg-m 87ft-lbs) of torque.



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Rotate the wheel, measure the verticalmovement again at the tightest position,and readjust if necessary.Insert a new cotter pin through the axle

nut and axle, and spread its ends.Tighten the torque link rear nut inserta new cotter ptn.IWARNING I If the axle and torque.link.,. nuts are not securely tight-ened and the cotter pins are not installed,an unsafe riding condition may result.

Chain ReplacementCheck chain wear by first stretching

the chain tight [adjust it taut or hang a10 kg 20 lb) weigh t on it] and thenmeasure the length of 20 links. If thedistance from the center of the s_t pinto the center of the 21st pin is more than323 mm 12.7 in) , the chain should bereplaced.

70 M INTEN NCE AND DJUSTMENT

1. WeightIWARNING F o r safety, use only the... .- - - - s t a n d a r d chain: ENUMAEK530SH-T 2 0, 102 links. This is an end-less type and should not be cut forinstallation; have it installed by aKawasaki Dealer.Chain Lubrication

To minimize chain wear, the drivechain should be lubricated periodicallyPg. 45). It shoul d also be oiled afterriding through rain or c:in wet roads, afterwashing the motorcycle, or any othertime the chain appears dry.

Use a heavy oil such as SAE 90 weightgear oil to lubricate the chain. A lighteroil is still better than no oil at all, but aheavier oil will stay on the chain longerand provide better lubrication. Apply oilto the sides of the rollers and O rings.Wipe off any excess oil.

1. Pin 3. Roller2 Links 4. 0 ringBrake Adjustment

This motorcycle brake system ishydraulic disc type on both the front andrear wheels.

Disc and disc pad wear is automaticallycompensated for and has no affect onbrake lever or brake pedal action.However, the brake lever or pedal mayoccasionally require adjustment due towear inside the lever or pedal assemblyitself, or in case of disassembly.Front Brake Lever AdjustmentStraighten the part of the washer thatis bent over the side of the adjustingbolt locknut.

1. Washer 3. Adjusting Bolt2 Locknut

M INTEN NCE AND DJUSTMENT 7


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Loosen the locknut, turn the adjustingbolt a fraction of a turn so that thelever has 3 5 mm (0.12 ' 0.20 in play,and tighten the locknut.

Bend back part of the washer over theside of the locknut.Rear Brake AdjustmentRear brake adjustment consists of twoseparate adjustments: brake pedal positionand brake pedal play.


BRAKE PEDAL POSITIONWhen the brake pedal s n its rest posi-

tion, it should be 20 '30 mm (0.8 '1.2in lower than the top of the right foot-peg.If it s too low; loosen the locknut, turn

the brake pedal adjusting bolt to obtainthe correct pedal position, and thentighten the locknut.

1 Push ~ d 3 Adjusting Bolt2 Locknut 4 Rear Brake Pedal

If it s too high; first loosen the locknuts,and shorten the push rod to give thebrake pedal plenty of play. Then adjustthe brake pedal position.

1 Joint 2 Sleeve 3 LocknutsNote: When ti ghtening the locknuts, makecertain the sleeve s properly fitted on thejoint.BRAKE PEDAL PLAYThe brake pedal should have 8 10 mm

(0.32 '0.40 in of free play from the rest

position before the push rod contactsthe master cylinder piston.

To adjust play, loosen the locknuts andturn the push rod.

1 Push Rod 2 Rear Brake PedalCheck the rear brake light switch.Check for brake drag.Check braking effectiveness.Disc Brake Fluid

The disc brake fluid reservoirs must befilled up to the level line with one of the



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recomme nded brake fluids. Fill the bothreservoirs up to the upper level line. Ifnone of the recommended brake fluidsare available, use extra heavy-duty brakefluid only from a container markedD.O.T.3.

1 . Upper Level 2. lower Level


Recommended Disc Brake FluidAtlas Extra Heavy DutyShell Super Heavy DutyTexaco Super Heavy DutyWagner Lockheed Heavy DutyCastrol Girling-GreenCastrol GT LMA)Castro Disc Brake Fluid

The fluid should be changed periodically (Pg. 45 . It should also be changedif it becomes contaminated with dirt orwater.

ODo not spi I brake fluidonto any painted surface.

ooo not mix two brands of fluid.ooo not use fluid from a container thathas been left unsealed or that has beenopen for a long time.OCheck for fluid leakage around thefittings.OCheck for brake hose damage.

Brake Pad Replace mentThe brake pads must be replaced when

they are worn down through the red line.

A. Front1. Red LineNote: Disc brake maintenance (exce ptfor adding fluid, adjusting hand leverplay, brake pedal position, and brakepedal play) should be performed onlyby a Kawasaki Dealer.I W RN 1NG I f the brake lever or pedal.. . feels mushy when it is applied, there might be air in the brake lines

or the brake may be defective. Since isdangerous to operate the motorcycleunder such conditions, have the brakechecked immediately.Brake Light Switch Adjustment

The front brake light switch is a pressure switch and is not adjustable. If itdoes not turn on the brake light with lightpressure on the brake lever, the switchmust be replaced and the brake lines bledafterward.

1. Front Brake Light Switch



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The rear brake light switch must turnon the brake light after about 15 mm 0.6in of brake pedal movement. Adjust itby loosening the two mounting nuts,moving the switch up or down andtightening the mounting nuts whenthe switch is properly positioned.

1. Rear Brake Light Switch A. Lights sooner2. Mounting Nuts B. Lights later~ ~ T ~ ~ ~ t r ~ ~ ~ l i ~ o ~ ~ ~ ~ s ~ ~ i ~the switch, be sure that the switch bodydoes not turn during adjustment.


Steering InspectionFor safety, the steering should alwaysbe kept adjusted so that the handlebarwill turn freely but have no play.If the steering is too tight, it will bedifficult to turn the handlebar quickly,

the motorcycle may pull to one side, andthe steering stem bearings may becomedamaged. If the steering is too loose, thehandlebar will vibrate and the motorcyclewiil be unstable and difficult to steer in astraight line.

.To check the steering adjustment, firstplace a stand or block under the engine sothat the front wheel is raised off theground. Push the handlebar lightly toeither side; if it continues moving underits own momentum the steering is nottoo tight. Squatting in front of themotorcycle, grasp the lower ends of thefront fork at the axle, and push and pullthe fork end back and forth; if play isfelt, the steering is too loose.

Note: Since the steering adjustment issensitive and crucial for safe operation,have it performed only by an authorizedKawasaki Dealer.

Front Fork MaintenanceInspectionPushing down on the handlebar withthe front brake fully applied, check thatthe front fork functions properly. Checkthe dust seals for damage, and look forany signs of oil leakage.

A. Push downIn case of improperly functioning-shock absorbers, dust seal damage, or oilleakage; consult your authorized KawasakiDealer.

MaintenanceDirt or sand that has worked its waypast a dust seal will eventually damagethe oil seal causing oil leakage. Periodi-cally, slide up the dust seals and clean outany dirt or sand. Be careful not to

MAINTENANCE ND ADJUSTMENT 77


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damage either the oil seal or the innertube surface.

Dust SealSince the front fork oil deteriorateswith use, have the oil in both tubeschanged periodically by your authorizedKawasaki Deale r Pg. 45).

Rear Shock Absorber I s p ~ t i o nand AdjustmentInspection

Since the rear shock absorbers aresealed units and can not be disassembled,


only external checks of operation arenecessary.Check that the rear shock absorbersfunction properly and that there is no oilleakage and no mounting bushing damage.Make sure that the mounting fastenersare tight.

n case any irregularity is found duringinspection, consult your authorizedKawasaki Dealer.Adjustment

The rear sho ck abso rbers have .5 po-sitions so that the springs can be adjustedfor different road and loading conditions.

1 Hook Wrench

f the spring action feels too soft ortoo stiff, adjust it in accordance with thefollowing table:

Position 2 3 4 5Spring Action Stronger >lW RN G I If the rear s ~ o k absorbers... . are not ad1usted equally,handling may be impa_ired.

; Wheel InspectionWheel BalanceAn u nbalan ced wheel will cause thevehicle to vibrate or the steering to wob-ble, especially at high speeds. Sincewb_eelbalance greatly affects motorcycle safety,

have the wheels inspected by a KawasakiDealer whenever abnormal handling isexperi enced during riding. Also, havethe wheel balance inspected whenever anew tire is fitted.Rim RunoutThe wheels are manufactured to veryhigh standards of accuracy and trueness,and should remain within manufacturingtolerances for runout. The rim runoutshould be check ed periodically Pg. 44),or whenever the wheel have been subject-ed to severe impact.

The rim axial runout should be under3 mm 0.12 in), and the rim radial runoutshould be under 2 mm 0.08 in). f eitherrunout exceeds the servicP limit, it shouldbe replaced, since adjustment is not pos-sible.Note: f necessary, ask your authorizedKawasaki Dealer for inspection.



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Tires and TubesRemember that tire pressure is affectedby change in ambient temperature andaltitude, and so the tire pressure should bechecked and adjusted when your ridinginvolves wide variations in temperature oraltitude.Proper tire inflation pressure is essen-tial for safety, comfort, and economy.

Wears unevenlyWears unevenlySlips on pavement

Abnormally high or low tire air pressurehas a bad effect on stability and handling.Underinflation could result in tire failuredue to flexing, and overinflation couldresult in tire failure due to the decreased


ability of the tire to cushion shock. Im-proper inflation will also cause the tiretreads to wear unevenly, with most wearalong the outside of the treads when thetire is underinflated, and along the centerof the tread when the tire is overinflated.Use an accurate tire pressure gauge oftenand measure the tire pressure when thetires are cold that is, when the motor-cycle has not been ridden more than amile during the past 3 hours .

.-; .1. Tire Pressure augeNear the end of useful life, the tiresbecome increasingly vulnerable to punc-ture or blowout. An accepted fact is that

90 per cent of all tire failures occur duringthe last 10 per cent of tread life 90 percent worn . So it is false economy andunsafe to use the tires until they are bald.Tread wear limits are specified in thismanual to give you a guide for decidingwhen the tires should be replaced. naddition, a visible check of tread wearshould be made frequently.Replace any tire that has worn downto the minimum allowable tread depth.

n the event of a flat tire resultingfrom a punctured tube, replace the tubeonly with a Kawasaki replacement tube.Air Pressure (Cold) Size

Repair of the tube is not recommended,but if undertaken, it must be done withextreme care to prevent a subsequent flattire, and possible loss of control.

Make Minimum TreadType Depth

Front 2.00 kg/cm2 28 psi) 3.25H-19 4PR DUNLOP F6B 1 mm 0.04 nilor equivalentUp to 97.5 kg 2.25 kg/cm2 DUNLOP Normal 2mm215 lbs) load 32 psi) 4.00H-18 4PR K87 MARKUM Speed 0.08 in)Rear 2.50 kg/cm2 Over 3 mmOver 97.5 kg or equivalent215 lbs) load 36 psi) 80 MPH 0.12 in)



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Wheel RemovalFront Wheel RemovalDisconnect the lower end of the speedometer cable with pliers.Remove one of the front brake calipers,and put it out of the way.Loosen the front axle clamp nuts 4)

but do not remove them. Then loosenthe front axle nuts (2).

i1. Speedometer Cable 3. xle Clamp NutsAxle NutRemo.ve the front axle clamp nuts, lock.. washers, and clamps.


Use a jack under the engine or othersuitable means to lift the front of themotorcycle. Drop the front wheel outof the forks, and remove it.

Insert the wood wedge [5 '6 mm (0.2'0.24 in) thick] between the disc brakepads. This prevents them from beingmoved out of their proper position,should the brake lever be squeezed accidentally.

lnstal lationRemove the wedges from between thedisc brake pads.Position the front wheel in its place.between the front fork t ubes, and slowlylower the front fork tube bottom ends

onto the front axle.Mount the front axle clamps, and tighten the nuts loosely. The arrow at the

bottom of the clamp must point to thefront.

speedometer gear housing sothat it points to the two o clock position.Be sure that the small projection on thegear housing does not catch on the lowerpart of the left tube.

Tighten the axle nuts to 8 kg-m 58ft-lbs) of torque, and position the speedometer housing by turning it counterclockwise until i t stops.Tighten first the front axle clamp nutand then the rear nut to 1.9 kg-m (14ft-lbs) of torque. There will be a gapat the rear of the clamp after tightening.

IW RNING I If the clamps are installed.,. incorrectly or improperlytightened, the clamps and/or the studscould fail, resulting in loss of control.



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Mount the brake caliper, and tighten themounting bolts to 4 kg m 29 ft-lbs) oftorque.

Connect the lower end of the speedometer cable with pliers.

Rear Wheel RemovalPut the motorcycle up on its centerstand.Remove the cotter pin, nut, and bolt

at the rear end of the torque link.

1. Torque Link Nut 2. Cotter Pin


Remove the chain guard.Remove the axle cotter pin, and loosenthe axle nut.Loosen the left and right chain adjusterlocknuts, fully loosen both chain adjusting bolts, and then push the wheel forward so that the chain can be easilyremoved from the rear sprocket.

1. Cotter Pin 3. Locknut2. Axle Nut 4. Adjusting BoltRemove the bolts 2) and take out thechain adjuster stoppers 2).

1. Bolt 2. Chain Adjuster StopperRemove the drive chain from the rearsprocket, and hang it to the left side

of the swing arm.

1. Drive Chain 2. Rear Sprocket

Remove the rear wheel together withthe rear caliper by pulling them towardthe rear.

Remove the axle nut, and pull out theaxle.

Free the caliper out of the disc, andinsert a wood wedge [7 ' 8 mm (0.28'0.32 in) thick] between the disc brakepads. This prevents them from beingmoved out of their proper positionshould the brake pedal be pushed accidentally.

Take out the rear wheel.

InstallationRemove the wedge from between the

brake pads.Put the caliper on the disc so that thedisc is between the pads.

MAINTENANCE. AND ADJUSTMENT 8


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Run the axle through the right chainadjuster, rear caliper holder, collar, rearhub, coupling sleeve, coupling, couplingcollar, and left chain adjuster. Thens r ~ w on the axle nut.

1. Chain Adjuster 4. Collar2. Coupling Collar 5. Caliper Holder3. CouplingPut the rear wheel into the swing armend.Fit the drive chain onto the rear sprocket.


I1

Fit the chain adjuster stoppers, andtighten the bolts.Fit the rear caliper into the torque linkend and insert the bolt through themfrom left to right. Tighten the torquelink nut loosely.Adjust the drive chain Pg. 68).Install the chain cover.

Battery MaintenanceBattery Electrolyte Level

Keep the electrolyte level between thelower and upper level marks. When itgets low, remove the battery filler capsand fili_/>with distilled water until theelectrolyte level in each cell reaches theupper level mark.

: Upper Level 3. Filler Cap2. Lower. Levelrrm ll ~ ~ b ~ r ~ ~ s t ~ ; i ~ ~ e ~ ~ ~water is not a substitute for distilledwater and will shorten the life of the

,battery.Battery Removal and InstallationBattery removal is necessary when thebatter y elect rolyte specific gravity readingis below 1.200, indicating the need forbattery recharging.

a. Unlock the seat, swing the seat open,remove the battery band, and disconnect first the ground -) negativecable connection and then the positive(+)cable.

1. - Terminal 3. Battery Vent Hose2. Terminalb. Battery installation is performed in thereverse order of removal. Make sure

that the battery case rubber dampersare properly in place, and pay particular attention to the battery venthose routing. Connect the ~ p p e dlead to the positive +) terminal,



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cover it with its protective cap, andthen connect the black lead to thenegative -) terminal.

E ~ ~ I [ q ~ : : ~ w : ; ; m r ~ ~ : : o ~ ~ ~ c ~ : :for charging it. If the battery is chargedwhile still installed, battery electrolytemay spill and corrode the frame or otherparts of the motorcycle.Because the battery gives off an explosivegas mixture of hydrogen and oxygen,keep any sparks or open flame away fromthe battery during charging.Route the battery vent hose as shown inthe caution label.Make sure the battery vent hose end iskept away from the chain. Electrolytefrom the battery vent hose can corrodeand dangerously weaken the chain.Do not let the battery vent hose get folded or pinched, and route it away from theexhaust system.


- - - ___ :;:;...;-_., - ----::;:. ..... ' _ -

Keep the battery terminals clean, andput a light coat of grease on them toprevent corrosion.

Headlight Beam AdjustmentThe headlight beam is adjustable inboth the horizontal and vertical directions. It should be aimed straight ahead,

with the brightest spot slightly belowhorizontal on high beam. The properangle is 0.4 degrees down . Th is is a 50mm (2 in drop at 7.6 m (25 ft}, measured from the center of the headlight,with the motorcycle on its wheels andthe rider seated. If not properly adjustedhorizontally, the beam will point to oneside rather than straight ahead. If adjusted too low vertically, neither low nor

high beam will illuminate the road farenough ahead. If adjusted too highvertically, high beam will fail to illuminate the road close ahead, and low beamwill blind oncoming drivers.

7.6 m 25 ftsb mm li--------- '- '- '- - '------. . . f(2 in) Heigt1t of lieadlight center 0.4___j___

Center of brightest Spot

Horizontal AdjustmentTurn the small screw on the headlightrim in or out until the beam pointsstraight ahead. Turning the adjustingscrew clockwise makes the headlightbeam point to the left.

1 Adjusting ScrewVertical Adjustme ntRemove the two screws from the lowerside of the headlight housing, and drop

out the headlight unit.

1. Mounting Screw



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Loosen the headlight housing mountingnuts and adjust the headlight vertically.

1 Mounting NutTighten the headlight housing mounting

nuts and mount the headlight unit.

Bulb ReplacementWhen exchanging bul bs be sure that

the replacement is the proper bulb.


- - - ~ - 'The proper bulbs are as follows.

H L Sealed Beam Unit : 12V 50/35WTurn Signal Light Bulb : 12V 23WPosition/Turn Signal Light Bulb : 12V 8/23WTail/Brake Light Bulb : 12V 8/27WHeadlight Sealed Beam Unit ReplacementRemove the two mounting screws and

drop out the headlight unit.

1 Mounting ScrewTake out the headlight socket.

Remove the horizontal adjusting screwand two sealed beam unit retainingscrews.

1 Headlight Socket 3 Adjusting Screw2 Retaining ScrewPull the sealed beam unit from the rim.Note: oWhen ins talling the new sealedbeam unit be sure that the TOP markis facing up.oAfter replacement is made adjust thebeam horizontally by turning the adjusting screw.

Turn Signal Light andTail/Brake Light Bulb ReplacementRemove the lens press the bulb n ~wards twist it to the left and pull it out

1 Tail/Brake Light Bulb



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Note: When installing a lens, tighten thescrews uniformly, but not too tightly, inorder to avoid damaging the lens.

Fuel Tap CleaningAccumulation of water or sediment in

the fuel tank and tap will restrict the flowof fuel and cause the carburetors tomalfunction. The fuel tap should becleaned out periodically in the followingmanner Pg. 44):Turn the fuel tap lever to OFF, and unscrew the sediment cup from the bottom

of the fuel tap. The gasket and filter aremounted on the fuel tap. Being carefulnot to damage the gasket and filter,remove the filter using a screwdriver.


1. Sediment Cup

1. Sediment Cup2. Gasket

3. Filter

Using a piece of cloth, wipe out theinside of the fuel tap, wash the cup andfilter in a high flash-point solvent andthen reassemble.Note: Off water has accumulated in the

sediment cup, water may also have accumulated in the float bowls. In this casehave the carburetors checked by yourauthorized Kawasaki Dealer.OAfter washing, check the gasket andfilter. Replace if damaged.oMake sure the sediment cup is tight.Turn the fuel tap lever a few times to theRES position, and check for leaks. If

fuel leaks from the sediment cup, the gasket may be damaged. Visually inspec tthe gasket and replace it if necessary.IW RNING : oClean the fuel tap in a._ , . ---- wel l -vent i la ted area, andtake ample care that there are no sparksor flame anywhere near the working area.ONever clean out the fuel tank or tapwhen the engine is still warm.

OWipe any fuel off the engine beforestarting it.



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Lubricationn order to get maximum service life from all parts and to keep the motorcyclerunning safely it must be kept properly lubricated.

Using SAE 30 motor oil lubricate the points indicated whenever they are dry afterriding through rain or after washing the motorcycle.After several thousand kilometers of service in addition to the points shown here

other parts should be inspected and lubricated by a Kawasaki Dealer.

94, MAINTENANCE AND ADJUSTMENTEvery 10,000 km 6,000 mi



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- olt and ut Tightening

Every day before riding check without fail the tightness of the bolts and riuts listedhere. Also check to see that each cotter pin s in place and in good condition

1 Front Fender MountingBolts2 Stem Clamp Bolts3 Handlebar Clamp Bolts4 Clutch Lever Holder Bolt5 Stem Head Bolts6. Front xle Clamp Nuts7. Caliper Mounting Bolts8. Muffler Moun

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KZ650 C1 UserManual