Instrukcja obsługi Kawasaki Vulcan 900 Custom (2018)

Kawasaki Silnik Vulcan 900 Custom (2018)

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Quick Reference Guide GENERAL INFORMATION j
HOW TO RIDE THE MOTORCYCLE j
SAFE OPERATION j
MAINTENANCE AND ADJUSTMENT j
STORAGE j
TROUBLESHOOTING GUIDE j
This Quick Reference Guide will
assist you in finding the information
you’re looking for.
A Table of Contents is included after
the Foreword.
Whenever you see the symbols
shown below, heed their instructions!
Always follow safe operating and main-
tenance practices.
DANGER
DANGER indicates a hazardous
situation which, if not avoided,
will result in death or serious in-
jury.
WARNING
WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
NOTICE
NOTICE is used to address prac-
tices not related to personal in-
jury.
NOTE
NOTE indicates information that may
help or guide you in the operation or
service of the vehicle.
WARNING
Engine exhaust, some of its
constituents, and certain vehi-
cle components contain or emit
chemicals known to the State of
California to cause cancer and
birth defects or other reproduc-
tive harm.
NOTICE
THIS PRODUCT HAS BEEN
MANUFACTURED FOR USE IN A
REASONABLE AND PRUDENT
MANNER BY A QUALIFIED OP-
ERATOR AND AS A VEHICLE
ONLY.
FOREWORD
Congratulations on your purchase of a new Kawasaki Motorcycle. Your new mo-
torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety and performance.
Please read this Owner’s Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-
tures, capabilities, and limitat ions. This m anual offers many safe r iding ti ps, but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-
cle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.
To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-
formation on their Kawasaki Motorcycle, a Service Manual is available for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-
tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.
Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.
This manual should be considered a permanent part of the motorcycle and should
remain with the motorcycle when it is sold.
All rights reserved. No part of this publication may be reproduced without our
prior written permission.
This publication includes the latest information available at the time of printing.
However, there may be minor differences between the actual product and illustra-
tions and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.
Motorcycle & Engine Company
© 2017 Kawasaki Heavy Industries, Ltd. May 17, 2017. (1)
TABLE OF CONTENTS
SPECIFICATIONS............................... 8
SERIAL NUMBER LOCATIONS......... 12
LOCATION OF PARTS ....................... 13
LOCATION OF LABELS..................... 16
LOADING INFORMATION.................. 20
GENERAL INFORMATION ................. 23
Meter Instruments ............................ 23
Speedometer: ............................... 24
Digital Display ............................... 24
Fuel Gauge:.................................. 27
RESET Button/MODE button: ...... 27
Warning/Indicator Lights: .............. 28
Keys ................................................. 29
Ignition Switch .................................. 31
Right Handlebar Switches................ 32
Engine Stop Switch: ..................... 32
Starter Button: .............................. 32
Left Handlebar Switches .................. 33
Dimmer Switch: ............................ 33
Turn Signal Switch:....................... 33
Horn Button: ................................. 33
Brake Lever Adjusters...................... 34
Fuel Tank Cap .................................. 35
Fuel Tank ......................................... 36
Side Stand ....................................... 40
Seat.................................................. 41
Tool Kit Case.................................... 43
Helmet-Hook .................................... 44
Steering Lock ................................... 45
Electric Accessory Connectors ........ 46
BREAK-IN ........................................... 49
HOW TO RIDE THE MOTORCYCLE . 51
Starting the Engine .......................... 51
Moving Off........................................ 54
Shifting Gears .................................. 54
Braking ............................................. 56
Stopping the Engine......................... 57
Stopping the Motorcycle in an
Emergency ................................... 58
Parking ............................................. 59
Catalytic Converter........................... 61
SAFE OPERATION............................. 63
Safe Riding Technique ..................... 63
Daily Checks .................................... 66
Additional Considerations for High
Speed Operation .......................... 69
MAINTENANCE AND ADJUSTMENT 71
Periodic Maintenance Chart............. 76
Engine Oil ........................................ 87
Cooling System................................ 94
Drive Belt.......................................... 101
Spark Plugs...................................... 101
Evaporative Emission Control
System (California model only) .... 102
Valve C learance ......................... ...... 103
Kawasaki Clean Air System............. 103
Air Cleaner ....................................... 104
Throttle Control System ................... 106
Idle Speed ........................................ 108
Clutch............................................... 110
Brakes.............................................. 112
Brake Light Switches........................ 116
Front Fork......................................... 118
Rear Shock Absorber....................... 118
Wheels ............................................. 121
Tires -............................................ 123
Battery.............................................. 127
Headlight Beam................................ 134
Fuses ............................................... 135
General Lubrication.......................... 139
Cleaning........................................... 140
General Precautions ..................... 140
Where to be Careful ..................... 144
Washing Your Vehicle................... 144
Bolt and Nut Tightening.................... 146
STORAGE........................................... 148
TROUBLESHOOTING GUIDE............ 151
YOUR WARRANTY/OWNER
SATISFACTION .............................. 152
Reporting Safety Defects.................. 158
ENVIRONMENTAL PROTECTION..... 159
MAINTENANCE RECORD ................. 160
LABEL INFORMATION ...................... 166
8SPECIFICATIONS
SPECIFICATIONS
PERFORMANCE
Mini mum Turing Radius 3.1 m (12 2 i n.)
DIMENSIONS
Overall Le ngth 2 405 mm (94.7 in.)
Overall Width 895 mm (35.2 in.)
Overall He igh t 1 120 mm (44.1 in.)
Wheelbase 1 645 mm (64.8 i n.)
Road Clearance 140 mm (5.5 in.)
Curb M ass 277 k g (611 lb)
ENGINE
Type SOHC, V-type 2-cylinder, 4-stroke, liquid-cooled
Displacement 903 cm³ (55.1 cu in.)
Bore × Stroke 88.0 × 74.2 mm (3.5 × 2.9 in.)
Compression Ratio 9.5 : 1
Starting System Electric starter
SPECIFICATIONS 9
Cylinder Numbering Method Front to rear, 1-2
Firing Order 1-2
Fuel System Digital fuel injection system (DFI)
Ignition System Battery and coil (transistorized ignition)
Ignition Timing 3° BTDC @1 000 r/min (rpm)
(Electronically advanced) 39° BTDC @5 400 r/min (rpm)
Spark Plugs NGK CPR7EA-9
Lubrication System Forced lubrication (wet sump)
Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1
or MA2
Viscosity SAE 10W-40
Capacity 3.7 L (3.9 US qt)
Coolant Capacity 2.2 L (2.3 US qt)
TRANSMISSION
Transmission Type 5-speed, constant mesh, return shift
Clutch Type Wet, multi disc
Driving System Belt drive
10 SPECIFICATIONS
Primary Reduction Ratio 2.184 (83/38)
Final Reduction Ratio 2.063 (66/32)
Overall Drive Ratio 4.338 (Top gear)
Gear Ratio 1st 2.786 (39/14)
2nd 1.889 (34/18)
3rd 1.360 (34/25)
4th 1.107 (31/28)
5th 0.963 (26/27)
FRAME
Caster 33.0°
Trail 182 m m (7.2 in.)
Tire Size: Front 80/90-21 M/C 48H
Rear 180/70-15 M/C 76H
Rim Size: Front 21M/C × MT2.15
Rear 15M/C × MT4.50
Fuel Tank Capa cit y 20 L (5.3 US gal)
SPECIFICATIONS 11
ELECTRICAL EQUIPMENT
Battery 12 V 10 Ah (10 HR)
Headlight 12 V 60/55 W
Brake/Tail Li ght 12 V 21/5 W
Specifications are subject to change without notice.
12 SERIAL NUMBER LOCATIONS
SERIAL NUMBER LOCATIONS
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.
Frame No.
A. Frame Number
Engine No.
A. Engine Number
LOCATION OF PARTS 13
LOCATION OF PARTS
1. Clutch Lever
2. Clutch Lever Adjuster
3. Meter Instruments
4. Brake Fluid Reservoir (Front)
5. Brake Lever Adjuster
6. Front Brake Lever
7. Left Handlebar Switches
8. Indicator Lights
9. Fuel Tank Cap
10. Right Handlebar Switches
11. Throttle Grip
14 LOCATION OF PARTS
12. Front Fork
13. Headlight
14. Turn Signal Light
15. Horn
16. Spark Plugs
17. Battery
18. Brake Disc
19. Brake Caliper
20. Wheel
21. Radiator
22. Shift Pedal
23. Oil Level Inspection Window
24. Side Stand Switch
25. Side Stand
26. Fuse Box
27. Coolant Reserve Tank
28. Rear Shock Absorber
29. Belt
30. Belt Pulley
LOCATION OF PARTS 15
31. Tail/Brake Light
32. Seat
33. Tool Kit Case/Tool Kit
34. Air Cleaner Element
35. Fuel Tank
36. Steering Lock
37. Mufflers
38. Idle Speed Adjusting Screw
39. Rear Brake Pedal
40. Rear Brake Light Switch
41. Brake Fluid Reservoir (Rear)
16 LOCATION OF LABELS
LOCATION OF LABELS
All warning labels which are on your
vehicle are repeated here. Read labels
on your vehicle and understand them
thoroughly. They contain information
which is important for your safety and
the safety of anyone else who may op-
erate your vehicle. Therefore, it is very
important that all warning labels be on
your vehicle in the locations shown. If
any label is missing, damaged, or worn,
get a replacement from your Kawasaki
dealer and install it in the correct posi-
tion.
NOTE
The sample warning labels in this
section have part numbers to help
you and your dealer obtain the cor-
rect replacement.
Refer to the actual vehicle label for
model specific data grayed out in the
illustration.
*1. Fuel Level
2. Brake Fluid (Front)
(For further information of label, refer to
the “LABEL INFORMATION” chapter.)
*: only on California model
LOCATION OF LABELS 17
3. Brake Fluid (Rear)
4. Tire and Load Data
5. Battery Position/Danger
(For further information of label, refer to
the LABEL INFORMATION” chapter.)
18 LOCATION OF LABELS
*6. Vacuum Hose Routing Diagram
7. Vehicle Emission Control Information
8. Weight and Manufacture
9. Noise Emission Control Information
(For further information of label, refer to
the “LABEL INFORMATION” chapter.)
*: only on California model
LOCATION OF LABELS 19
10. Radiator Cap Danger
(For further information of label, refer to
the LABEL INFORMATION” chapter.)
20 LOADING INFORMATION
LOADING INFORMATION
WARNING
Incorrect loading, improper in-
stallation or use of accessories,
or modification of your motorcy-
cle may result in an unsafe riding
condition. Before you ride the
motorcycle, make sure it is not
overloaded and that you have
followed these instructions.
With the exception of genuine
Kawasaki Parts and Accessories,
Kawasaki has no control over the
design or application of accessories.
In some cases, improper installation
or use of accessories, or motorcycle
modification, will void the motorcycle
warranty. In selecting and using acces-
sories, and in loading the motorcycle,
you are personally responsible for your
own safety and the safety of other per-
sons involved.
NOTE
Kawasaki Parts and Accessories
have been specially designed for
use on Kawasaki motorcycles. We
strongly recommend that all parts
and accessories 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
LOADING INFORMATION 21
been prepared to assist you in making
your determinations.
1. Any passenger should be thor-
oughly familiar with motorcycle op-
eration. The passenger can affect
control of the motorcycle by im-
proper positioning during cornering
and sudden movements. It is impor-
tant that the passenger sit still while
the motorcycle is in motion and not
interfere with the operation of the
motorcycle. Do not carry animals
on your motorcycle.
2. You should instruct any passenger
before riding to keep his feet on the
passenger footpegs and hold on to
the operator or seat strap. Do not
carry a passenger unless he or she
is tall enough to reach the footpegs
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 bot h s i des of the
motorcycle. Avoid carrying baggage
that extends beyond the rear of the
motorcycle.
4. 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
motorcycle is in motion) and adjust
as necessary.
5. 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.
6. Do not install accessories or carry
baggage that impairs the perfor-
mance of the motorcycle. Make
sure that you have not adversely
affected any lighting components,
22 LOADING INFORMATION
road clearance, banking capability
(i.e., lean angle), control operation,
wheel travel, front fork movement,
or any other aspect of the motorcy-
cle’s operation.
7. Weight attached to the handlebar or
front fork will increase the mass of
the steering assembly and can re-
sult in an unsafe riding condition.
8. Fairings, windshields, backrests,
and other large items have the ca-
pability of adversely affecting stabil-
ity 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 re-
sult in an unsafe riding condition.
9. This motorcycle was not intended
to be equipped with a sidecar or to
be used to tow any trailer or other
vehicle. Kawasaki does not manu-
facture sidecars or trailers for mo-
torcycles and cannot predict the ef-
fects of such accessories on han-
dling or stability, but can only warn
that the effects can be adverse and
that Kawasaki cannot assume re-
sponsibility for the results of such
unintended use of the motorcycle.
Furthermore, any adverse effects on
motorcycle components caused by
the use of such accessories will not
be remedied under warranty.
Maximum Load
Weight of rider, passenger, baggage,
and accessories must not exceed 180 kg
(397 lb).
GENERAL INFORMATION 23
j
GENERAL INFORMATION
Meter Instruments
A. Speedometer
B. Digital Display
C. Fuel Level Warning
Indicator Light
D. Coolant Temperature
Warning Indicator Light
E. Fuel Gauge
F. Oil Pressure Warning
Indicator Light
G. Fuel Injection Warning
Indicator Light
H. MODE Button
I. RESET Button
J. Neutral Indicator Light
K. Turn Signal Indicator Light
L. High Beam Indicator Lig ht
24 GENERAL INFORMATION
WARNING
For Safety, do not operate the
meter buttons while riding the
motorcycle.
Speedometer:
The speedometer shows the speed
of the vehicle.
Digital Display
The digital display located in the
speedometer face is used to display
the odometer, trip meter, and clock.
Pushing the MODE button shifts the
display through the following three
modes: ODO, TRIP and CLOCK.
When the ignition key is turned to
“ON”, all the segments are displayed
for a few seconds, then the clock or
meters operates normally depending
on the mode selected.
Clock -
To adjust hours and minutes:
Turn the ignition key to “ON”.
Push the MODE button to display the
clock.
Push the RESET button for more
than two seconds. Both the hour and
minute displays start flashing.
Again push the RESET button.
When only the hour display flashes,
push the MODE button to advance
the hours.
GENERAL INFORMATION 25
j
Push the RESET button. The hour
display stops flashing and the minute
display starts flashing. Push the
MODE button to advance the min-
utes.
Push the RESET button. Both the
hour and minute displays start flash-
ing again.
Push the MODE button. The dis-
plays stop flashing and the clock
starts working.
NOTE
Pushing the MODE button momen-
tarily advances the hour or minute
step by step. Pushing and hold-
ing the button advance the hour or
minute continuously.
The clock works normally from the
back-up power while the ignition
switch is turned off.
When the battery is disconnected,
the clock resets to 1:00, and starts
working again when the battery is
connected.
26 GENERAL INFORMATION
Odometer -
The odometer shows the total dis-
tance in kilometers (miles) that the ve-
hicle has been ridden. This meter can-
not be reset.
NOTE
The data is maintained even if the
battery is disconnected.
When the figures come to 999999,
they are stopped and locked.
Trip Meters -
The trip meter shows the distance in
kilometers (miles) traveled since it was
last reset to zero.
To reset a trip meter:
1. Push the MODE button to display
the trip meter.
2. Push the RESET button and hold it
in.
3. After two seconds, the figure display
turns to 0.0, and then starts counting
when the vehicle is operated. The
meter counts until it is next reset.
GENERAL INFORMATION 27
j
NOTE
The data is maintained by the back
-up power if the ignition key is turned
to “OFF”.
When the trip meter reaches 999.9
while riding, the meter resets to 0.0
and continue counting.
When the battery is disconnected,
the meter display resets to 0.0.
Fuel Gauge:
The fuel gauge shows the amount of
fuel in the fuel tank. When the nee-
dle comes near the E (empty) posi-
tion, refuel at the earliest opportunity.
When vehicle stands with side stand,
fuel gauge cannot show the amount of
fuel in the fuel tank exactly. Stand up-
right the vehicle to check the fuel level.
RESET Button/MODE button:
The RESET button is used to re-
set the trip meter and to adjust the
clock. The MODE button is used to
shift through the digital display modes
and to adjust the clock.
28 GENERAL INFORMATION
Warning/Indicator Lights:
N: When the transmission is in neutral,
the neutral indicator light is lit.
: When the headlight is on high
beam, the high beam indicator light is
lit.
: When the turn signal switch is
pushed to left or right, the turn signal
indicator light flashes on and off.
: The oil pressure warning indica-
tor light goes on whenever the oil pres-
sure is dangerously low or the ignition
switch is in the ON position with the en-
gine not running, and goes off when the
engine oil pressure is high enough. Re-
fer to the Maintenance and Adjustment
chapter for more detailed engine oil in-
formation.
: The warning indicator light goes
on whenever the coolant temperature
rises to 120°C (248°F) o r higher when
the motorcycle is in operation. If it
stays on, stop the e ngine and check the
coolant level in the reserve tank after
the engine cools down.
FI: The fuel injection (FI) warning in-
dicator light goes on when the ignition
key is turned to “ON” and goes off soon
after ensuring that its circuit functions
properly. The warning indicator light
also goes on whenever the troubles oc-
cur in digital fuel injection system (DFI).
If the warning indicator light comes on,
have the D FI system check ed by an au-
thorized Kawasaki dealer.
GENERAL INFORMATION 29
j
: The fuel level warning indicator
light goes on when approximately 4.0 L
(1.0 US gal) of usable fuel remains. Re-
fuel at the earliest opportunity when the
fuel level warning indicator light comes
on with the engine running. When ve-
hicle stands with side stand, fuel level
warning indicator light cannot show the
amount of fuel in the fuel tank exactly.
Stand upright the vehicle to check the
fuel level.
Keys
This motorcycle has a combination
key, which is used for the ignition
switch, steering lock, and fuel tank
cap. Included with the key is a k ey
number, which is stamped on the sep-
arate plate. Record the key number in
the space provided and store the num-
ber in a safe place. If your keys came
with a p late, store it in a safe place as
well.
30 GENERAL INFORMATION
A. Ignition Key
B. Tag
C. Key Number
Write your key number here.
In the event you lose your keys, you
will need the key number to have a du-
plicate made. If you cannot locate your
key number, contact the dealer where
you purchased your Kawasaki motor-
cycle. I t’s possible the dealer may hav e
the number in its records. If the key
number is lost completely, you will need
to replace the ignition switch and all
other locks operated by that key.
Contact your Kawasaki dealer to pur-
chase additional spare k eys either u s-
ing your original key as a master or us-
ing the key code on the tag or your key.
Store one key at home and keep an-
other spare in your wallet or riding gear,
in case the original is lost.
GENERAL INFORMATION 31
j
Ignition Switch
The ignition switch is located at
the left side behind the rear cylinder.
This is a three-position, key-operated
switch. The key can be removed from
the switch when it is in the OFF or P
(Park) position.
A. Ignition Switch
B. OFF
C. ON
D. P (Park)
OFF
Engine off. All electrical
circuits off.
ON Engine on. All electrical
equipment can be used.
P (Park)
Engine off. Taillight and
licence plate light on. All other
electrical circuits cut off.
NOTE
Tail and, license plate lights are on
whenever the ignition switch is in the
ON position. The headlight goes on
when the s tarter button is releas ed
after starting the engine. To avoid
battery discharge, always start the
engine immediately after turning the
ignition ke y to ON.
If you leave the motorcycle in the P
(Park) position or in the ON position
without the motorcycle running for a
long time (one hour), the battery may
become totally discharged.
32 GENERAL INFORMATION
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 required, move the en-
gine stop switch to the position.
NOTE
Although the engine stop switch
stops the engine, it does not t urn off
all the electrical circuits. Ordinarily,
the ignition switch should be used to
stop the engine.
Starter Button:
The starter button operates the elec-
tric starter when the transmission is in
neutral.
Refer to the Starting the Engine sec-
tion of the “How to Ride the Motorcycle
chapter for starting instructions.
A. Engine Stop Switch
B. Starter Button
GENERAL INFORMATION 33
j
Left Handlebar Switches
Dimmer Switch:
High or low beam can be selected
with the dimmer switch. When the
headlight is on high beam ( ), the
high beam indicator light is lit.
High beam.......( )
Low beam.......( )
NOTE
Do not allow anything to cover the
headlight lens when the headlight is
on. If covered, heat can build up in
the headlight lens causing lens d is-
coloration or melting, as well as dam-
age to the item covering the lens.
Turn Signal Switch:
When the turn s ignal switch is turned
to the left ( ) or right ( ), the
corresponding turn signals flash on and
off.
To stop flashing, push the switch in.
Horn Button:
When the horn button is pushed, the
block horn sounds.
A. Dimmer Switch
B. Turn Signal Switch
C. Horn Button
34 GENERAL INFORMATION
Brake Lever Adjusters
There is an adjuster on the brake
lever. The adjuster has 5 positions so
that the released lever position can be
adjusted to suit the operators hands.
Push the lever forward and turn the ad-
juster to align the number with the ar-
row mark on the lever holder. The dis-
tance from the grip to the released lever
is minimum at Number 5 and maximum
at Number 1. A. Adjuster
B. Arrow Mark
GENERAL INFORMATION 35
j
Fuel Tank Cap
To open the fuel tank cap, 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 b e removed by turning it to the left
to the original position. Close the key
hole cover.
NOTE
The 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 o r the cap cannot be locked.
A. Ignition Key
B. Fuel Tank Cap
C. Key Hole Cover
36 GENERAL INFORMATION
Fuel Tank
Avoid filling the tank in the rain or
where heavy dust is blowing so that the
fuel does not get contaminated.
A. Tank Cap
B. Fuel Tank
C. Top Level
D. Filler Neck
WARNING
Gasoline is extremely flammable
and can be explosive under cer-
tain conditions, creating the po-
tential for serious burns. Turn
the ignition switch to OFF”. Do
not smoke. Make sure the area
is well ventilated and free from
any source of flame or sparks;
this includes any appliance with
a pilot light. Never fill the tank
completely to the top. If the tank
is fi lled completely to the top,
heat may cause the fuel to ex-
pand and overflow through the
vents in the tank cap. After re-
fueling, make sure the tank cap
is closed securely. If gasoline is
spilled on the fuel tank, wipe it
off immediately.
GENERAL INFORMATION 37
j
NOTICE
California models only: Never
fill the tank so the fuel level rises
into the filler neck. If the tank is
overfilled, heat may cause the
fuel to expand and flow into the
Evaporative Emission Control
System resulting in hard start-
ing and engine hesitation and
in compliance with the emission
regulation.
Fuel Requirement:
Fuel Type
Use clean, fresh unleaded gasoline
with a minimum Antiknock Index of 87.
The Antiknock Index is posted on ser-
vice station pumps. The octane rating
of a gasoline is a measure of its resis-
tance to detonation or “knocking”. The
Antiknock Index is an average of the
Research Octane Number (RON) and
the Motor Octane Number (MON) as
shown in the table.
Minimum
Octane Rating Method Rating
(RON + MON)
Antiknock
Index 287
38 GENERAL INFORMATION
NOTICE
If engine “knocking” or ping-
ing” occurs, use a different
brand of gasoline of a higher
octane rating. If this condition is
allowed to continue it can lead
to severe engine damage.
Gasoline quality is important.
Fuels of low quality or not meet-
ing standard industry specifi-
cations may result in unsatis-
factory performance. Operating
problems that result from the
use of poor quality or nonrecom-
mended fuel may not be covered
under your warranty.
Fuels Containing Oxygenates
Gasoline frequently contains oxy-
genates (alcohols and ethers) espe-
cially in areas of the U.S. and Canada
which are required to sell such refor-
mulated fuels as part of a strategy to
reduce exhaust emissions.
The types and volume of fuel oxy-
genates approved for use in unleaded
gasoline 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 (alco-
hol produced from agricultural products
such as corn), also known as “gasohol”
is approved for use.
GENERAL INFORMATION 39
j
NOTICE
Avoid using blends of unleaded
gasoline and methanol (wood
alcohol) whenever possible, and
never use gasohol” contain-
ing more than 5% methanol.
Fuel system damage and perfor-
mance problems may result.
Gasoline/Ether Blends - The most
common ether is methyl tertiary butyl
ether (MTBE). You may use gasoline
containing up to 15% M TBE.
NOTE
Other oxygenates approved for use
in unleaded gasoline include TAME
(up to 16.7%) and ETBE (up to
17.2%). Fuel containing these oxy-
genates can also be used in your
Kawasaki.
NOTICE
Never use gasoline with an oc-
tane rating lower than the mini-
mum specified by Kawasaki.
Never use “gasohol” with more
than 10% ethanol, or more than
5% methanol. Gasoline con-
taining methanol must also be
blended with cosolvents and
corrosion inhibitors.
Certain ingredients of gasoline
may cause paint fading or dam-
age. Be extra careful not to spill
gasoline or gasoline oxygenate
blends during refueling.
When not operating your
Kawasaki for 30 to 60 days, mix a
fuel stabilizer (such as STA-BIL)
with the gasoline in the fuel tank.
Fuel stabilizer additives inhibit
oxidation of the fuel which mini-
mizes gummy deposits.
40 GENERAL INFORMATION
NOTICE
Never store this product with
“gasohol” in the fuel system.
Before storage it is recom-
mended that you drain all fuel
from the fuel system. See the
Storage section in this manual.
Side Stand
The motorcycle is equipped with a
side stand.
A. Side Stand
NOTE
When using the side stand, turn the
handlebar to the left.
Do not sit on the motorcycle while it is
on its side stand. Always kick the stand
fully up before sitting on the motorcycle.
GENERAL INFORMATION 41
j
NOTE
The motorcycle is equipped with a
side stand switch. This switch is de-
signed so that the engine does not
start if the transmission is in gear and
the side stand is down.
Seat
Seat Removal
To remove the seat, insert the ignition
key into the seat lock, and turn the
key to the right.
A. Seat Lock
B. Turn Key to Right
Pull the seat to the rear.
42 GENERAL INFORMATION
Seat Installation
To install the seat, insert the tab of
the front on the s eat into the slot on
the frame.
Insert the projections of the middle on
the seat into the holes on the frame.
Push down the middle on the seat.
A. Tab
B. Slot
C. Projections
D. Holes
Pull the front and rear ends of the
seat to make sure they are securely
locked.
GENERAL INFORMATION 43
j
Tool Kit Case
The tool kit case is located under the
seat. The kit contains tools that can
be helpful in making roadside repairs,
adjustments, and some maintenance
procedures explained in this manual.
Keep the tool k it in this case.
Remove the seat.
Open the tool kit case cover b y
pulling the knob.
A. Tool Kit Case
B. Tool Kit
44 GENERAL INFORMATION
Helmet-Hook
Helmet can be secured to the motor-
cycle using the helmet-hook. The hel-
met hook is located under the seat.
WARNING
Riding with helmet attached to
the hook could cause an acci-
dent by distracting the operator
or interfering with normal vehi-
cle operation. Do not ride the
motorcycle with helmet attached
to the hook.
A. Helmet-Hook
GENERAL INFORMATION 45
j
Steering Lock
The motorcycle is equipped with the
steering lock at the right side of the
head pipe.
To lock the steering:
1. Tu rn the handlebar to the left.
2. Insert the ignition key.
3. Turn the key half a turn to the left.
4. Pull the key out.
NOTE
If the steering is hard to lock, turn the
handlebar slightly to the left or the
right.
When unlocking the steering lock,
turn the handlebar slightly to the
right.
WARNING
Attempting to ride with the steer-
ing locked could cause an acci-
dent. Unlock the steering before
starting the engine.
A. Steering Lock
46 GENERAL INFORMATION
Electric Accessory Connectors
The electric power of the battery can
be used through the electric acces-
sory connectors regardless of ignition
switch position. Observe and follow
the notes listed below.
Electr ic Access ory Connectors
Location Polarity Wire Color
(+) White/Blue
Under Rider’s
Seat (–) Black/Yellow
(+) White/Blue
Under Fuel
Tank (–) Black/Yellow
Maximum Current: 10 A
A. Electric Accessory Connectors
When using the electric accessory
connectors under the fuel tank, the
electric accessory connection to the
connectors shou ld be done by an au-
thorized Kawasaki dealer.
GENERAL INFORMATION 47
j
NOTICE
This accessory circuit has elec-
trical accessory circuit (10 A
fuse) for the connectors. Al-
ways install a fuse 10 A or less
for the circuit. Do not connect
more than 70 W of load to this
accessory circuit or the battery
may become discharge, even
with the engine running.
WARNING
Take care not to pinch any wire
between the seat and the frame
or between other parts to avoid
a short circuit.
Rear View Mirror
Rear View Mirror Adjustment
Adjust the rear v iew m i rror by slightly
moving only the mirror portion of the
assembly.
If the rear visibility can not be as-
sured by moving the mirror, loosen
the upper hexagonal area and turn
the stay by hand.
Tightening Torque
Lowing Hexagonal A rea:
30 m (3.1 k gf·m, 22 ft·lb)
Upper Hexagonal Are a:
18 m (1.8 k gf·m, 13 ft·lb)
NOTE
The upper hexagonal area (locknut)
has left hand threads.
48 GENERAL INFORMATION
A. Stay
B. Rear View Mirror
A. Lower Hexagonal Area for Tightening
B. Upper Hexagonal Area
C. Rear View Mirror
NOTE
If a torque wrench is not available,
this item should be serviced by a
Kawasaki dealer.
BREAK-IN 49
BREAK-IN
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 speed in km/h (mph) during the break
-in period.
km/h (mph)
Gear position
Distance traveled 1st 2nd 3rd 4th 5th
0800 km (0 500 mi) 32 (20) 50 (30) 65 (40) 80 (50) 95 (60)
800 1 600 km (500 1 000 mi)40 (25) 65 (40) 90 (55) 100 (70) 130 (80)
NOTE
When operating on public roadways, keep maximum speed under traffic law lim-
its.
50 BREAK-IN
Do not start moving or race the engine immediately after starting it, even if the
engine is already warm. Run the engine for two or three minutes at idle speed to
give the oil a chance to work up into all the engine parts.
Do not race the engine while the transmission is in neutral.
WARNING
New tires are slippery and may cause loss of control and injury.
A break-in period of 160 km (100 mi) is necessary to establish normal
tire traction. During break-in, avoid sudden and maximum braking and
acceleration, and hard cornering.
In addition to the above, at 1 000 km (600 mi) it is extremely important that the
owner has the initial maintenance service performed by an authorized Kawasaki
dealer.
HOW TO RIDE THE MOTORCYCLE 51
HOW TO RIDE THE MOTORCYCLE
Starting the Engine
Check that the engine stop switch is
in the position.
A. Engine Stop Switch
B. Starter Button
Turn the ignition key to ON.
A. Ignition Switch
B. ON Position
52 HOW TO RIDE THE MOTORCYCLE
Make sure the transmission is in neu-
tral.
A. Neutral Indicator Light
NOTE
While the engine is cold, the fast idle
system automatically raises the en-
gine idling speed. At this time, the
fuel injection warning indicator light
may go on if you operate the throt-
tle grip unnecessarily.
The motorcycle is equipped with a
vehicle-down sensor, which causes
the engine to stop automatically
when the motorcycle falls down. Af-
ter righting the motorcycle, first turn
the ignition key to “OFF” and then
back to “ON ” before starting the e n-
gine.
Without holding the throttle grip, push
the s tarter button to start the engine.
NOTICE
Do not operate the starter con-
tinuously for more than 5 sec-
onds, or the starter will overheat
and the battery power will drop
temporarily. Wait 15 seconds
between each operation of the
starter to let it cool and the bat-
tery power recover.
HOW TO RIDE THE MOTORCYCLE 53
NOTE
The motorcycle is equipped with a
starter lockout switch. This switch is
designed so that the engine does not
start if the transmission is in gear and
the side stand is down. However, the
engine can be started if the clutch
lever is pulled and the side stand is
fully up.
A. Clutch Lever
B. Starter Lockout Switch
NOTICE
Do not let the engine idle longer
than five minutes, or engine
overheating and damage may
occur.
54 HOW TO RIDE THE MOTORCYCLE
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 c l utch starts to engage, open
the throttle a little more, giving the en-
gine just enough fuel to keep it from
stalling.
NOTE
The motorcycle is equipped with a
side stand switch. This switch is de-
signed so that the engine does not
start if the transmission is in gear and
the side stand is down.
Shifting Gears
Close the throttle while pulling in the
clutch lever.
Shift into the next higher or lower
gear.
A. Shift Pedal
Open the throttle part way, while re-
leasing the clutch lever.
For smooth riding, shift up or down
when the motorcycle is operated the
speeds shown in the table below.
HOW TO RIDE THE MOTORCYCLE 55
WARNING
Downshifting at high speed can
make the rear wheel skid and
cause an accident resulting in
severe injury or death, as well
as cause the engine to overrev
and damage it. When shifting
down to a lower gear, do not
shift at such a high speed that
engine rpm jumps excessively.
Downshift at the vehicle speeds
shown in the table in this sec-
tion.
NOTE
The transmission is equipped with a
positive neutral finder. When the mo-
torcycle is standing still, the transmis-
sion cannot be shifted past neutral
from 1st gear. To use the positive
neutral finder, shift down to 1st gear,
then lift up on the shift pedal while
standing still. The transmission will
shift only into neutral.
Vehicle speed when shifting
Shifting up km/h (mph) Shifting down km/h (mph)
1st 2nd 20 (12) 5th 4th 40 (25)
2nd 3rd 30 (19) 4th 3rd 30 (19)
3rd 4th 40 (25) 3rd 2nd 20 (12)
4th 5th50 (31) 2nd 1st 15 (9)
56 HOW TO RIDE THE MOTORCYCLE
Braking
Close the throttle completely, leav-
ing 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 lit-
tle more than the rear. Shift down or
fully disengage the clutch as neces-
sary to keep the engine from stalling.
Never lock the brakes, or it will cause
the tires to skid. When turning a cor-
ner, it is better not to brake at all. Re-
duce your speed before you get into
the corner.
For emergency braking, disregard
downshifting, and concentrate on
applying the brakes as hard as pos-
sible without skidding.
A. Front Brake Lever
HOW TO RIDE THE MOTORCYCLE 57
A. Rear Brake Pedal
Stopping the Engine
Close the throttle completely.
Shift the transmission into neutral.
Turn the ignition key to “OFF”.
Support the motorcycle on a firm,
level surface with the side stand.
Lock the steering.
58 HOW TO RIDE THE MOTORCYCLE
Stopping the Motorcycle in an
Emergency
Your Kawasaki Motorcycle has been
designed and manufactured to pro-
vide you optimum safety and conve-
nience. However, in order to fully ben-
efit from Kawasaki’s safety engineering
and craftsmanship, it is essential that
you, the owner and operator, properly
maintain your motorcycle and become
thoroughly familiar with its operation.
Improper maintenance can create a
dangerous situation known as throttle
failure.
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 throttle body and stick
the throttle open.
2. During removal of the air cleaner,
dirt is allowed to enter and jam t he
throttle body.
In an emergency situation such as
throttle failure, your vehicle may be
stopped by applying the brakes and
disengaging the clutch. Once this
stopping procedure is initiated, the en-
gine stop switch may be used to stop
the engine. If the engine stop switch is
used, turn off the ignition switch after
stopping the motorcycle.
HOW TO RIDE THE MOTORCYCLE 59
Parking
WARNING
Operating or parking the vehi-
cle near flammable materials can
cause a fire, and can result in
property damage or severe per-
sonal injury.
Do not idle or park your vehicle
in an area where tall or dry veg-
etation, or other flammable ma-
terials could come into contact
with the muffler or exhaust pipe.
WARNING
The engine and exhaust system
get extremely hot during normal
operation and can cause serious
burns.
Never touch a hot engine, ex-
haust pipe, or muffler during op-
eration or after stopping the en-
gine.
Shift the transmission into neutral
and turn the ignition key to “OFF”.
Support the motorcycle on a firm,
level surface with the side stand.
NOTICE
Do not park on a soft or steeply
inclined surface, or the motorcy-
cle may fall over.
60 HOW TO RIDE THE MOTORCYCLE
If parking inside a garage or other
structure, be sure it is well v entilated
and the motorcycle is not close to
any source of flame or sparks; this
includes any appliance with a pilot
light.
WARNING
Gasoline is extremely flammable
and can be explosive under cer-
tain conditions, creating the po-
tential for serious burns. Turn
the ignition switch to “OFF”. Do
not smoke. Make sure the area is
well ventilated and free from any
source of flame or sparks; this
includes any appliance with a pi-
lot light.
Lock the steering to help prevent
theft.
NOTE
When stopping near traffic at night,
you can leave the taillight, licence
plate light on for greater visibility by
turning the ignition key to the P (Park)
position.
Do not leave the ignition switch at P
position too long, or the battery will
discharge.
HOW TO RIDE THE MOTORCYCLE 61
Catalytic Converter
This motorcycle is equipped with
a catalytic converter in the exhaust
system. Rhodium, Platinum, and/or
palladium converter reacts with carbon
monoxide, hydorocarbons and nitro-
gen oxides to convert them into carbon
dioxide, water, and nitrogen resulting
in much cleaner exhaust gases to be
discharged into the atmosphere.
For proper operation of the catalytic
converter, the following cautions must
be observed.
WARNING
Operating or parking the vehi-
cle near flammable materials can
cause a fire, and can result in
property damage or severe per-
sonal injury.
Do not idle or park your vehicle
in an area where tall or dry veg-
etation, or other flammable ma-
terials could come into contact
with the muffler or exhaust pipe.
WARNING
The engine and exhaust system
get extremely hot during normal
operation and can cause serious
burns.
Never touch a hot engine, ex-
haust pipe, or muffler during op-
eration or after stopping the en-
gine.
SAFE OPERATION 63
SAFE OPERATION
Safe Riding Technique
The points given below are applicable for everyday motorcycle use and should
be carefully observed for safe and e ffective vehicle operation.
For safety, eye protection and a
helmet are strongly recommended.
You should be aware of and verify
the applicable safety regulations in
force prior to riding your motorcy-
cle. Gloves and suitable footwear
should also be used for added pro-
tection in case of a mishap.
A motorcycle does not provide
the impact protection of an auto-
mobile, so defensive riding in addi-
tion to wearing protective apparel
is extremely important. Do not let
protective apparel give you a false
sense of security.
Wear the riding wear which have
protectors for each parts of the body
(chest, shoulders, back, elbows and
knees, etc.) as much as possible, or
wear protectors for them.
-Always wear a long-sleeved jacket
and long trousers which are abra-
sion resistant and keep you warm.
-Wear clothing that allows freedom
of movement.
-Avoid wearing clothes which have
loose cuffs or other fastenings
which could interfere with the
controls of your motorcycle.
-Wear bright, highly visible cloth-
ing.
64 SAFE OPERATION
When riding always keep both
hands on the handlebars and both
feet on the footpegs. Removing
your hands from the handlebars or
feet from the footpegs while riding
can be hazardous. If you remove
even one hand or foot, you can
reduce your ability to control the
motorcycle.
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 vehicles distance and speed, or
you may not see it at all.
In general your actions should
be smooth as sudden acceleration,
braking or turning may cause loss
of control, especially when riding in
wet conditions or on loose roadway
surfaces, when the ability to maneu-
ver will be reduced.
When going up steep slopes, shift
to a lower gear so that there is plenty
of power to spare rather than over-
loading the engine.
When applying the brakes, use
both the front and rear brakes. Ap-
plying only one brake for sudden
braking may cause the motorcycle
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.
In wet conditions, rely more on the
throttle to control vehicle speed and
less on the front and rear brakes.
The throttle should also be u sed ju-
diciously to avoid skidding the rear
SAFE OPERATION 65
wheel from too rapid acceleration or
deceleration.
Riding at the proper rate of speed
and avoiding unnecessarily fast ac-
celeration are important not only for
safety and low fuel consumption but
also for long vehicle life and quieter
operation.
On rough roads, exercise caution,
slow down, and grip the fuel tank
with the knees for better stability.
When quick acceleration is neces-
sary as in passing, shift to a lower
gear to obtain the necessary power.
Do not downshift at too high an
r/min (rpm) to avoid damage to the
engine from overrevving.
Av oiding unnecessary weaving is
important to the safety of both the
rider and other motorists.
66 SAFE OPERATION
Daily Checks
Check the following items each day before you ride. The time required is minimal,
and habitual performance of these checks will help ensure you a safe, reliable ride.
If any irregularities are found during these checks, refer to the Maintenance and
Adjustment chapter or see your dealer for the action required to return the motor-
cycle to a safe operating condition.
WARNING
Failure to perform these checks before operation may result in serious
damage or an accident. Always perform daily checks before operation.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous
gas.
Inhaling carbon monoxide can cause serious brain injury or death.
Do not run the engine in enclosed areas. Operate only in a well-ventilated
area.
Fuel ............................. Adequate supply in tank, no leaks.
Engine oil .................... Oil level between level lines.
Tires ............................ Air pressure (when cold):
SAFE OPERATION 67
Front Up to 180 kg (397 lb)
Load
280 kPa (2.80 kgf/cm², 40 psi)
Rear Up to 97.5 kg (215 lb)
Load 200 kPa (2.00 kgf/cm², 28 psi)
97.5  180 kg
(215  397 lb) Load 225 kPa (2.25 kgf/cm², 32 psi)
Install the air valve cap.
Nuts, bolts, fasteners .. Check that steering and suspension components, axles,
and all controls are properly tightened or fastened.
Steering ...................... Action smooth but not loose from lock to lock.
No binding of control cables.
Brakes ........................ Brake pad wear: Lining thickness more than 1 mm (0.04
in.) left.
No brake fluid leakage.
Throttle ....................... Throttle grip play 2  3 mm (0.08  0.12 in.).
Clutch ......................... Clutch lever play 2  3 mm (0.08  0.12 in.).
Clutch lever operates smoothly.
Coolant ....................... No coolant leakage.
Coolant level between level lines (when engine is cold).
Electrical equipment ... All lights (Headlight, Tail/Brake Lights, Tu rn Signal Lights
Warning/Indicator Lights) and horn work.
Engine stop switch ...... Stops engine.
68 SAFE OPERATION
Side stand ................... Returns to its fully up position by spring tension.
Return spring not weak or not damaged.
SAFE OPERATION 69
Additional Considerations for High Speed Operation
WARNING
Handling characteristics of a motorcycle at high speeds may vary from
those you are familiar with at legal highway speeds. Do not attempt high
speed operation unless you have received sufficient training and have the
required skills.
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
safety. Examine their overall condition, inflate them to the proper pressure, and
check the wheel balance.
Fuel: Have sufficient fuel for the high fuel consumption during high speed opera-
tion.
Spark Plugs: For demanding operation such as racing, install spark plugs with
one heat colder range NGK CPR8EA-9.
Engine Oil: To avoid engine seizure and resulting loss of control, make sure that
the oil level is at the upper level line.
70 SAFE OPERATION
Coolant:To avoid overheating, check that the coolant level is at the upper level line.
Electrical Equipment: Make sure that the headlight, tail/brake light, turn signals,
horn, etc., all work properly.
Miscellaneous: Make sure that all nuts and bolts are tight and that all safety related
parts are in good condition.
MAINTENANCE AND ADJUSTMENT 71
MAINTENANCE AND ADJUSTMENT
The maintenance and adjustments outlined in this chapter must be carried out
and must be done in accordance with the Periodic Maintenance Chart to keep the
motorcycle in good running condition. The initial maintenance is vitally impor-
tant and must not be neglected.
With a basic knowledge of mechanics and the proper use of tools, you should be
able to carry out many of the maintenance items described in this chapter. If you
lack proper experience or doubt your ability, all adjustments, maintenance, and
repair work should be completed by a qualified technician.
Please note that Kawasaki c annot assume any responsibility for damage result-
ing from incorrect or improper adjustment done by the owner.
72 MAINTENANCE AND ADJUSTMENT
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 incorporated
an evaporative emission control system (3) in compliance with applicable regu-
lations of the United States E nvironmental Protection Agency and California Air
Resources Board.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere.
Instead, the vapors are routed through an oil separator to the intake side of the
engine. While the engine is operating, the vapors are drawn into the combustion
chamber, where they are burned along with the fuel and air supplied by the fuel
injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere
by the exhaust of this motorcycle. The fuel, ignition and exhaust systems of this
motorcycle have been carefully designed and constructed to ensure an efficient
engine with low exhaust pollutant levels. The exhaust system of this model mo-
torcycle includes a catalytic converter system.
MAINTENANCE AND ADJUSTMENT 73
3. Evaporative Emission Control System
The evaporative emission control system for this vehicle consists of low per-
meation fuel hoses and a fuel tank.
3. Evaporative Emission Control System (California)
Vapors caused by fuel evaporation in the fuel system are not vented into the
atmosphere. Instead, fuel vapors are routed into the running engine to be burned,
or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor
separator and returned to the fuel tank.
High Altitude Performance Adjustment Information
High altitude adjustment is not required.
74 MAINTENANCE AND ADJUSTMENT
MAINTENANCE AND WARRANTY
Proper maintenance is necessary to ensure that your motorcycle will continue to
have low emission levels. This Owners Manual contains those maintenance rec-
ommendations for your motorcycle. Those items identified by the Periodic Mainte-
nance Chart are necessary to ensure compliance with the applicable standards.
As the owner of this motorcycle, you have the responsibility to make sure that
the recommended maintenance is carried out according to the instructions in this
Owner’s Manual at your own expense.
The Kawasaki Limited Emission Control System Warranty requires that y ou re-
turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty.
Please read the warranty carefully, and keep it valid by complying with the owners
obligations it contains.
You should keep a maintenance record for your motorcycle. To assist you in
keeping this record, we have provided space on pages 160 through 165 of this
manual where an authorized Kawasaki dealer, or someone equally competent, can
record the maintenance. You should also retain copies of m aintenance work orders,
bills, e tc., as verification of this maintenance.
MAINTENANCE AND ADJUSTMENT 75
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) the removal or
rendering inoperative by any person other than for purposes of maintenance, re-
pair, or replacement, of any device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the vehicle after such device or
element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
*Replacement of the original exhaust system or muffler with a component not in
compliance with Federal regulations.
*Removal of the muffler(s) or any internal portion of the muffler(s).
*Removal of the air box or air box cover.
*Modifications to the muffler(s) or air intake system by cutting, drilling, or other
means if such modifications result in increased noise levels.
76 MAINTENANCE AND ADJUSTMENT
Periodic Maintenance Chart
K : Should be serviced by an authorized Kawasaki dealer.
* : Fo r higher odometer readings, repeat at the frequency interval established here.
# : S ervice more frequently when op erating in severe conditions: dusty, we t, muddy,
high speed, o r frequent starting/stopping.
(e): Emission Related Item
MAINTENANCE AND ADJUSTMENT 77
1. Periodic Inspection (Engine Related Items)
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000 (mile × 1 000)
Operation (Engine
Items) Every 1
(0.6)
6
(3.75)
12
(7.5)
18
(11.25)
24
(15)
30
(18.75)
36
(22.5)
See
Page
Valve clearance -
inspect (e) 103
Throttle control system
(play, smooth return,
no drag) - inspect (e)
year 106
Idle speed - inspect (e) 108
KFuel leak (fuel hose
and pipe) - inspect year
KFuel hoses damage -
inspect year
KFuel hoses installation
condition - inspect year
78 MAINTENANCE AND ADJUSTMENT
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000 (mile × 1 000)
Operation (Engine
Items) Every 1
(0.6)
6
(3.75)
12
(7.5)
18
(11.25)
24
(15)
30
(18.75)
36
(22.5)
See
Page
Coolant level - inspect 97
Coolant leak - inspect year
Radiator hose damage
- inspect year 94
Radiator hoses
installation condition -
inspect
year 94
Air suction system
damage - inspect (e) 103
Evaporative emission
control system -
function (California
model only) (e)
• • • 102
MAINTENANCE AND ADJUSTMENT 79
2. Periodic Inspection (Chassis Related Items)
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000 (mile × 1 000)
Operation
(Chassis Items) Every 1
(0.6)
6
(3.75)
12
(7.5)
18
(11.25)
24
(15)
30
(18.75)
36
(22.5)
See
Page
Clutch and drive train:
Clutch ope ration
(play, engagement,
disengagement) -
inspect
110
KDrive belt deflection
- inspect 101
KDrive belt wear -
inspect 101
Wheels and tires:
Tire air pressure -
inspect year 124
80 MAINTENANCE AND ADJUSTMENT
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000 (mile × 1 000)
Operation
(Chassis Items) Every 1
(0.6)
6
(3.75)
12
(7.5)
18
(11.25)
24
(15)
30
(18.75)
36
(22.5)
See
Page
Wheels/tires
damage - inspect 124
Tire tread wear,
abnormal wear -
inspect 124
KWheel bearings
damage - inspect year
Brake system:
Brake fluid leak -
inspect year 112
KBrake hoses
damage - inspect year 112
Brake pad wear -
inspect # 112
MAINTENANCE AND ADJUSTMENT 81
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000 (mile × 1 000)
Operation
(Chassis Items) Every 1
(0.6)
6
(3.75)
12
(7.5)
18
(11.25)
24
(15)
30
(18.75)
36
(22.5)
See
Page
K
Brake hose
installation condition
- inspect
year 112
Brake fluid level -
inspect year 112
Brake operation
(effectiveness, play,
drag) - inspect
year 115
Brake light switch
operation - inspect 116
82 MAINTENANCE AND ADJUSTMENT
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000 (mile × 1 000)
Operation
(Chassis Items) Every 1
(0.6)
6
(3.75)
12
(7.5)
18
(11.25)
24
(15)
30
(18.75)
36
(22.5)
See
Page
Suspensions:
K
Front forks/rear
shock absorber
operation (damping
and smooth stroke)
- inspect
K
Front forks/rear
shock absorber oil
leak - in s pect
year
KSwing arm pivot -
lubricate
KUni-trak rocker arm
operation - inspect
KUni-trak tie rods
operation - inspect
MAINTENANCE AND ADJUSTMENT 83
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000 (mile × 1 000)
Operation
(Chassis Items) Every 1
(0.6)
6
(3.75)
12
(7.5)
18
(11.25)
24
(15)
30
(18.75)
36
(22.5)
See
Page
KUni-trak rocker arm
bearings - lubricate
KUni-trak tie rods
bearings - lubricate
Steering system:
KSteering play -
inspect year
KSteering stem
bearings - lubricate 2 y ears
Electrical system:
Lights and switches
operation - inspect year
Headlight aiming -
inspect year 134
84 MAINTENANCE AND ADJUSTMENT
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000 (mile × 1 000)
Operation
(Chassis Items) Every 1
(0.6)
6
(3.75)
12
(7.5)
18
(11.25)
24
(15)
30
(18.75)
36
(22.5)
See
Page
Side stand switch
operation - inspect year
Engine stop switch
operation - inspect year
Chassis:
Chassis parts -
lubricate year 139
Bolts and nuts
tightness - inspect 146
MAINTENANCE AND ADJUSTMENT 85
3. Periodic Replacement
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000
(mile × 1 000)
Change/Replacement Items Every 1
(0.6)
12
(7.5)
24
(15)
36
(22.5)
48
(30)
See
Page
KAir cleaner element - replace #
(e) every 18 000 km (12 000 mile) 104
Engine oil - change # year • • 89
Oil filter - re place year • • 89
K Fuel hoses - replace 5 years
KCoolant - change 3 years 100
KRadiator hoses and O-ring s -
replace 3 years
K Brake hoses - re place 4 years
KBrake fluid (front and rear) -
change 2 years 115
86 MAINTENANCE AND ADJUSTMENT
Frequency Whichever
comes
first
*Odometer Reading
km × 1 000
(mile × 1 000)
Change/Replacement Items Every 1
(0.6)
12
(7.5)
24
(15)
36
(22.5)
48
(30)
See
Page
KRubber parts of master cylinder
and calip er - replace 4 years
K Spark plug - replace (e) • • 101
MAINTENANCE AND ADJUSTMENT 87
Engine Oil
In order for the engine, transmission,
and clutch to function properly, main-
tain the engine oil at the proper level,
and change the oil and replace the oil
filter in accordance with the Periodic
Maintenance Chart. Not only do dirt
and metal particles collect in the oil, but
the oil itself loses its lubricative quality
if used too long.
WARNING
Motorcycle operation with insuf-
ficient, deteriorated, or contam-
inated engine oil will cause ac-
celerated wear and may result in
engine or transmission seizure,
accident, and injury. Check the
oil level before each ride and
change the oil according to the
periodic maintenance chart in
the Owners Manual.
Oil Level Inspection
If the oil has just been changed, start
the engine and run it for several min-
utes at idle speed. This fills the oil
filter with oil. Stop the engine, then
wait several minutes until the oil set-
tles.
NOTICE
Racing the engine before the oil
reaches every part can cause en-
gine seizure.
88 MAINTENANCE AND ADJUSTMENT
If the motorcycle has just been used,
wait several minutes for all the oil to
drain down.
Check the engine oil level through
the oil level inspection window. With
the motorcycle held level, the oil level
should come up between the upper
and lower level lines next to the oil
level inspection window.
A. Oil Level Inspection Window
B. Oil Filler Cap
C. Upper Level Line
D. Low Level Line
If the oil level is t oo high, remove the
excess oil through the o il filler open-
ing using a syringe or some other
suitable device.
If the oil level is too low, add the oil
to reach the correct level. Use the
same type and brand of oil that is
already in the engine.
NOTICE
If the engine oil gets extremely
low or if the oil pump does not
function properly or oil pas-
sages are clogged, the warning
indicator light in the speedome-
ter will light. If this light stays on
when the engine speed is above
the idle speed, stop the engine
immediately and find the cause.
MAINTENANCE AND ADJUSTMENT 89
A. Oil Pressure Warning Indicator Light
Oil and/or Oil Filter Change
Warm up the engine thoroughly, and
then stop it.
Place an oil pan beneath the engine.
Remove the engine oil drain plug.
A. Engine Oil Drain Plug
Let the oil completely drain with
the motorcycle perpendicular to the
ground.
WARNING
Engine oil is a toxic substance.
Dispose of used oil properly.
Contact your local authorities
for approved disposal methods
or possible recycling.
90 MAINTENANCE AND ADJUSTMENT
Remove the cover.
A. Cover
B. Bolt
Remove the regulator/rectifier.
A. Regulator/Rectifier
B. Bolt
MAINTENANCE AND ADJUSTMENT 91
Remove the bracket.
A. Bracket
B. Bolt
Remove the oil filter cartridge and re-
place it w ith a new one.
A. Cartridge
NOTE
If a torque wrench or required
Kawasaki special tool is not avail-
able, this item should be serviced by
an authorized Kawasaki dealer.
92 MAINTENANCE AND ADJUSTMENT
Apply a thin film of oil to the packing
and tighten the cartridge to the spec-
ified torque.
A. Packing
Install the engine oil drain plug with
a new gasket and tighten it to the
specified torque.
NOTE
Replace any gasket with a new one.
Fill the engine oil up to the upper
level line with a good quality engine
oil specified in the table.
Start the engine.
Check the oil level and for oil leak-
age.
Be sure to install the parts removed.
Tightening Torque
Engine Drain Plug:
20 N·m (2.0 kgf·m, 14.5 ft·lb)
Cartridge:
18 N·m (1.8 kgf·m, 13 ft·lb)
Regulator/Rectifier Bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
MAINTENANCE AND ADJUSTMENT 93
Recommen ded Engine O il
Type: Kawasaki Performance
4-Stroke Motorcycle Oil*
Kawasaki Performance
4-Stroke Semi-Synthetic
Oil*
Kawasaki Performance
4-Stroke Full Synthetic Oil*
or other 4-stroke oils with
API SG, SH, SJ, SL, SM and
JASO MA, MA1, MA2 rating
Viscosity: SAE 10W-40
*Kawasaki Performance Oils and
Lubricants have been s pecifically en-
gineered for your vehicle. Consistent
use of these products meets or ex-
ceeds warranty and service require-
ments and can help to e xtend the life
of your Kawasaki.
NOTE
Do not add any chemical additive to
the oil. Oils fulfilling the above re-
quirements are fully formulated and
provide adequate lubrication for both
the engine and the c lutch.
Engine Oil Capacity
Capacity: 3.0 L (3.2 US qt)
[when filter is not removed]
3.2 L (3.4 US qt)
[when filter is removed]
3.7 L (3.9 US qt)
[when engine is completely
dry]
94 MAINTENANCE AND ADJUSTMENT
Although 10W-40 engine oil is the
recommended oil for most condi-
tions, the o il viscosity may need to
be changed to accommodate atmo-
spheric conditions in your riding area.
Cooling System
Radiator and Cooling Fan -
Check the radiator fins for obstruc-
tion by insects or mud. Clean off
any obstructions with a stream of
low-pressure water.
WARNING
The cooling fan spins at high
speed and can cause serious
injuries. Keep your hands and
clothing away from the cooling
fan blades at all times.
MAINTENANCE AND ADJUSTMENT 95
NOTICE
Using high-pressure water, as
from a car wash facility, could
damage the radiator fins and im-
pair the radiators effectiveness.
Do not obstruct or deflect air-
flow through the radiator by
installing unauthorized acces-
sories in front of the radiator or
behind the cooling fan. Inter-
ference with the radiator airflow
can lead to overheating and con-
sequent engine damage.
Radiator Hoses -
Check the radiator hoses for leakage,
cracks or deterioration, and connec-
tions for leakage, or looseness each
day before riding the motorcycle, and
in accordance with the Periodic Main-
tenance Chart.
Coolant -
Coolant absorbs excessive heat from
the engine and transfers it to the air
at the radiator. If the coolant level be-
comes low, the engine overheats and
may suffer severe damage. Check the
coolant level each day before riding the
motorcycle, also in accordance with the
periodic maintenance chart and replen-
ish coolant if the level is low. Change
the coolant in accordance with the Pe-
riodic Maintenance Chart.
Information for Coolant
To protect the cooling s ys tem (con-
sisting of the aluminum engine and
radiator) from rust and corrosion, the
use of corrosion and rust inhibitor
chemicals in the coolant is essential. If
coolant containing corrosion and rust
inhibitor chemicals are not used, over
a period of time, the cooling system
96 MAINTENANCE AND ADJUSTMENT
accumulates rust and scale in the wa-
ter jacket and radiator. This will clog
up the coolant passages, and con-
siderably reduce the efficiency of the
cooling system.
WARNING
Coolant containing corrosion in-
hitors for alminum engines and
radiators include harmful chem-
icals for human body. Drinking
coolant can result in serious in-
jury or death. Use coolant in ac-
cordance with the instractions of
the manufacturer.
Soft or distilled water must be used
with the antifreeze (see below for an-
tifreeze) in the cooling system.
NOTICE
If hard water is used in the sys-
tem, it causes scale accumula-
tion in the water passages, and
considerably reduces the effi-
ciency of the cooling system.
If the lowest ambient temperature en-
countered falls below the freezing point
of water, use permanent antifreeze in
the coolant to protect the cooling sys-
tem against engine and radiator freeze
-up, as well as from rust and corrosion.
Use a permanent type of antifreeze
(soft water and ethylene glycol plus cor-
rosion and rust inhibitor c hemicals for
aluminum engines and radiators) in the
cooling system. On the mixture ratio
of coolant, choose the suitable one re-
ferring to the relation between freezing
point and strength directed on the con-
tainer.
MAINTENANCE AND ADJUSTMENT 97
NOTICE
Permanent types of antifreeze on
the market have anti-corrosion
and anti-rust properties. When it
is diluted excessively, it loses its
anti-corrosion property. Dilute a
permanent type of antifreeze in
accordance with the instructions
of the manufacturer.
NOTE
A permanent type of antifreeze is in-
stalled in the cooling system when
shipped. It is colored green and con-
tains ethylene glycol. It is mixed at
50% and has the freezing point of
− −35°C ( 31°F).
Coolant Level Inspection
Situate the motorcycle so that it is
perpendicular to the ground.
Check the coolant level through the
coolant level gauge. The coolant
level should be between the F (Full)
and L (Low) marks.
NOTE
See the reserve tank at the inside of
the reserve tank cover under the left
side cover.
Check the level when the engine is
cold (room or atmospheric tempera-
ture).
98 MAINTENANCE AND ADJUSTMENT
A. F (Full) Level Line
B. L (Low) Level Line
C. Reserve Tank
If the amount of coolant is insuffi-
cient, add coolant.
Coolant Filling
Remove the seat.
Remove the left side cover by remov-
ing the screw.
A. Screw
B. Left Side Cover
MAINTENANCE AND ADJUSTMENT 99
Remove the reserve tank cover.
A. Reserve Tank Cover
B. Bolt
Open the cap from the reserve tank,
and add coolant through the filler
opening to the F (Full) mark.
A. Reserve Tank
B. Reserve Tank Cap
Install the cap after filling coolant.
Install the parts removed.
100 MAINTENANCE AND ADJUSTMENT
NOTE
When installing the left side cover, be
sure to insert the projections of the
left side cover to each holes.
A. Projections
B. Left Side Cover
NOTE
In an emergency you can add wa-
ter alone to the coolant reserve tank,
however it must be returned to the
correct mixture ratio by the addition
of antifreeze concentrate as soon as
possible.
NOTICE
If coolant must be added of-
ten, or the reserve tank com-
pletely runs dry, there is proba-
bly leakage in the system. Have
the cooling system inspected
by your authorized Kawasaki
dealer.
Coolant Change
Have the coolant changed by an au-
thorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT 101
Drive Belt
In order for the belt and belt pulleys to
function properly, check the drive belt
in accordance with the Periodic Main-
tenance Chart.
Belt check and adjustment should
be done by an authorized Kawasaki
dealer.
NOTICE
Improper drive belt deflection
can resul t in belt damage.
Spark Plugs
The standard spark plug is shown in
the table. The spark plugs should be
replaced in accordance with the Peri-
odic Maintenance Chart.
Spark plug removal should be done
by an authorized Kawasaki dealer.
Spark Plug
Standard
Plug NGK CPR7EA-9
Plug Gap 0.8 0.9 mm
(0.032 0.036 in.)
Tightening
Torque 18 N·m (1.8 kgf·m, 13 ft·lb)
NOTE
Fit the plug cap securely onto the
spark plug, and pull the cap lightly to
make sure that it is properly installed.
102 MAINTENANCE AND ADJUSTMENT
Evaporative Emission Control
System (California m odel
only)
This system routes fuel vapors from
the fuel system into the running engine
or stores the vapors in a canister when
the engine is stopped. Although no ad-
justments are required, a thorough vi-
sual inspection must be made at the in-
tervals specified by the Periodic Main-
tenance Chart.
Inspection
Check that the hoses are securely
connected.
Replace any kinked, deteriorated, or
damaged hoses.
104 MAINTENANCE AND ADJUSTMENT
in accordance with the Periodic Main-
tenance Chart. Also, inspect the air
suction valves whenever stable idling
cannot be obtained, engine power is
greatly reduced, or there are abnormal
engine noise.
Air suction valve removal and inspec-
tion should be done by an authorized
Kawasaki dealer.
Air Cleaner
A clogged air cleaner restricts the en-
gine’s air intake, increasing fuel con-
sumption, reducing engine power, and
causing spark plug fouling.
The air cleaner element must be re-
placed in accordance with the Periodic
Maintenance Chart. This motorcycle’s
air cleaner element consists of a wet
paper filter, which cannot be cleaned.
In dusty, rainy, or on muddy conditions,
the air cleaner element should be ser-
viced more frequently than the recom-
mended interval.
MAINTENANCE AND ADJUSTMENT 105
Element Removal
Remove the bolts of the air cleaner
cover located on the right-side of the
engine.
A. Air Cleaner Cover
B. Bolt
Remove the air cleaner screw and
the air cleaner. If any part of the ele-
ment is damaged, the element must
be replaced.
A. Air Cleaner Element
B. Air Cleaner
C. Screw
106 MAINTENANCE AND ADJUSTMENT
WARNING
If dirt or dust is allowed to pass
through into the fuel injection
system, the throttle may stick or
become inoperable resulting in a
hazardous operating condition.
NOTICE
If dirt gets through into the en-
gine, excessive engine wear and
possibly engine damage will oc-
cur.
NOTE
Element installation is performed in
the reverse order of removal.
Throttle Control System
Check the throttle grip play, in accor-
dance with the Periodic Maintenance
Chart, and adjust the throttle grip play.
Throttle Grip -
The throttle grip controls the butterfly
valves in the throttle body. If the throt-
tle grip has excessive play due to ei-
ther cable stretch or maladjustment, it
will cause a delay in throttle response,
especially at low engine speed. Also,
the throttle valve may not open fully at
full throttle. On the other hand, if the
throttle grip has no play, the throttle will
be hard to control, and idle speed will
be erratic.
110 MAINTENANCE AND ADJUSTMENT
Clutch
Due to friction plate wear and clutch
cable stretch over a long period of use,
the clutch must be adjusted in accor-
dance with the Periodic Maintenance
Chart.
WARNING
The engine and exhaust system
get extremely hot during normal
operation and can cause serious
burns. Never touch a hot engine
or an exhaust pipe during clutch
adjustment.
Inspection
Check that the clutch lever has 2 3
mm (0.08 0.12 in.) of play as shown
in the figure.
A. Locknut
B. Adjuster
C. 2
3 mm (0.08
0.12 in.)
If the play is incorrect, adjust the lever
play as follows.
136 MAINTENANCE AND ADJUSTMENT
Remove the seat.
Remove the left side cover (see
“Cooling System” section in this
chapter).
A. Fuse Box
B. Spare Fuse
Remove the screw
A. Screw
B. Right Side Cover


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Marka: Kawasaki
Kategoria: Silnik
Model: Vulcan 900 Custom (2018)

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