Vehicle Segment:
Sport Touring Motorcycle
Target Audience:
Motorcyclists seeking versatility for commuting, touring, and spirited riding
Key Competitors:
Yamaha TDM900, Suzuki V-Strom 650, Honda NC700X (in later years), BMW F800GT
Engine Platform:
Shared parallel-twin engine with the ER-6n/f models
Design Philosophy:
Versatile chassis and suspension for diverse riding conditions, adjustable windscreen for comfort
Manual Purpose:
To provide comprehensive technical guidance for repair, maintenance, and diagnostics for owners and professional mechanics
Engine:
Complete engine overhaul, diagnosis, removal, installation, internal component repair (pistons, rings, valves, camshafts, crankshaft, lubrication, cooling systems)
Fuel System:
Fuel injection system (injectors, throttle body, fuel pump, fuel pressure regulator), fuel tank, lines
Ignition System:
Ignition coils, spark plugs, ECU control, timing
Transmission:
Clutch operation, gearbox removal and installation, gear inspection, shift mechanism
Suspension:
Front fork (disassembly, assembly, oil levels, seals), rear shock absorber, linkage, swingarm maintenance
Brakes:
Front and rear brake systems, caliper service, pad replacement, master cylinder, brake fluid bleeding, ABS system (if applicable to specific trims)
Electrical System:
Wiring diagrams, lighting, battery, charging system (alternator, regulator/rectifier), starter system, fuses, relays, switches, ECU
Cooling System:
Radiator, fan, water pump, coolant replacement, thermostat
Exhaust System:
Exhaust pipe inspection, muffler replacement
Frame And Bodywork:
Frame inspection, fairings, body panel removal and installation, seat, fuel tank removal
Wheels And Tires:
Wheel bearing inspection, tire replacement, wheel balancing
Controls:
Throttle cable, clutch cable, brake lever, gear shift lever adjustment and replacement
Maintenance:
Regular maintenance tasks, service interval checks, lubrication points, fluid changes
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding charts, symptom-based diagnosis
Repair:
Detailed step-by-step repair procedures for all major vehicle components and systems
Disassembly:
Complete instructions for dismantling all parts of the motorcycle
Assembly:
Comprehensive guides for reassembling all vehicle components after repair or replacement
Installation:
Procedures for installing new or replacement parts and accessories
Adjustment:
Precise instructions for adjusting various systems like clutch, throttle, suspension, and brakes
Special Tools:
Identification and usage instructions for specialized tools required for specific repair operations
Depth:
Comprehensive from basic maintenance to complete engine and chassis rebuilds
Detail Level:
Includes step-by-step instructions, pictorial diagrams, exploded views, and technical specifications
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve parallel-twin
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.4:1
Claimed Horsepower:
Approx. 72 hp @ 8,500 rpm (Varies slightly by market and specific tuning)
Claimed Torque:
Approx. 47 lb-ft @ 7,000 rpm (Varies slightly by market and specific tuning)
Fuel Delivery:
Digital Fuel Injection with dual 38mm Keihin throttle bodies
Fuel Type:
Unleaded gasoline
Oil Type Spec:
SAE 10W-40 API SG or SH, JASO MA
Cooling Medium:
Ethylene Glycol based coolant
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months, whichever comes first (refer to manual for detailed schedule)
Air Filter Check:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Refer to manual for specific mileage (typically around 24,000 km or 15,000 miles)
Coolant:
Kawasaki Coolant KLC 125 or equivalent (50/50 mix of ethylene glycol and distilled water)
Common Wear Items:
Clutch plates, brake pads, fork seals, chain and sprockets
Potential Electrical Concerns:
Occasional regulator/rectifier issues on some Kawasaki models of this era (diagnostics covered in manual)
Engine Performance Notes:
Generally robust engine, but proper maintenance of fuel system and cooling is crucial for longevity.
