Segment:
Mid-size adventure touring motorcycle.
Target Audience:
Riders seeking a versatile, reliable machine for commuting, touring, and light off-road use.
Competitors Circa 2000:
Honda Transalp, Suzuki DR650SE, Yamaha XT600.
Versatility:
Combines on-road comfort with off-road capability.
Engine Type:
Parallel-twin, liquid-cooled.
Styling:
Distinctive beak-like front fairing and dual headlights.
Engine:
Complete engine disassembly, assembly, inspection, and repair of all internal and external components.
Fuel System:
Carburetor tuning, cleaning, overhaul, fuel tank, fuel lines, and petcock.
Ignition System:
CDI unit, ignition coils, spark plugs, wiring diagrams.
Cooling System:
Radiator, cooling fan, coolant circulation, thermostat.
Transmission:
Clutch operation, gearbox disassembly, assembly, inspection, and lubrication.
Drivetrain:
Chain and sprockets inspection, adjustment, and replacement; rear hub and wheel bearing service.
Suspension:
Front fork (telescopic) disassembly, assembly, oil changes, seal replacement; rear shock absorber and linkage maintenance.
Brakes:
Front and rear brake caliper overhaul, master cylinder service, brake pad replacement, fluid bleeding, and hydraulic system maintenance.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, tire mounting/dismounting.
Electrical System:
Battery maintenance, charging system (alternator/stator), starter motor, lighting circuits, horn, instrument panel.
Wiring Diagrams:
Detailed wiring schematics for all electrical components and circuits.
Frame Bodywork:
Frame inspection, fairing removal/installation, seat, tank, and fender components.
Controls:
Throttle control, clutch lever, brake levers, and cable adjustments.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, chain adjustment, valve clearance checks.
Troubleshooting:
Diagnostic guides for common issues, fault finding trees.
Repair:
Step-by-step instructions for disassembly, repair, and reassembly of all major components.
Adjustment:
Carburetor synchronization, clutch and throttle cable slack, brake lever free play.
Specifications:
Torque specifications for all fasteners, fluid capacities, clearances, and tolerances.
Depth:
Comprehensive; covers everything from basic maintenance to complete engine and gearbox rebuilds.
Engine Type:
4-stroke, Liquid-cooled, DOHC, 4-valve per cylinder, Parallel-twin.
Displacement:
498 cc (30.4 cu. in.)
Bore X Stroke:
72.0 x 61.2 mm (2.83 x 2.41 in.)
Horsepower Claimed:
Approx. 48-50 HP at 8500 RPM (varied slightly by market and specific tuning).
Torque Claimed:
Approx. 42 Nm (31 lb-ft) at 6500 RPM.
Carburetors:
Dual Keihin CVK34 carburetors.
Fuel Tank Capacity:
17 Liters (4.5 US gal.)
Oil Capacity:
2.8 Liters (2.9 US qt.) with filter change.
Ignition System:
Digital CDI
Crash Safety:
N/A (Motorcycle safety is evaluated differently than automobiles).
Braking System:
Dual piston front caliper, single piston rear caliper. Disc brakes front and rear.
Suspension Stability:
Adjustable front preload and rebound damping, adjustable rear preload and rebound damping for improved handling stability.
Lighting:
Halogen headlights (dual), LED taillight.
Hand Guards:
Standard hand guards for rider protection from elements and debris.
Oil Change:
Every 6,000 km (3,700 miles) or 6 months.
Oil Filter Change:
Every 6,000 km (3,700 miles) or with oil change. Kawasaki part number: 16099-003.
Air Filter Cleaning:
Every 6,000 km (3,700 miles), replace as needed.
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles). Recommended plugs: NGK CR9E or equivalent.
Chain Lubrication:
Every 1,000 km (600 miles) or after riding in wet conditions.
Engine Oil:
SAE 10W-40 API SG or SH. Recommended: Kawasaki Genuine Oil or equivalent.
Coolant:
Ethylene glycol based coolant, 50% mixture with distilled water. Recommended: Kawasaki Coolant or equivalent.
Fork Oil:
SAE 10W (or SAE 15W depending on desired damping). Capacity: 465 ml (0.49 US qt.) per fork leg.
Carburetor Icing:
Susceptible to carburetor icing in cold, humid conditions due to airflow.
Clutch Slippage:
Can occur with high mileage or aggressive use if clutch plates wear out or oil specifications are incorrect.
Fork Seal Leaks:
Common on many motorcycles of this era, especially with off-road use.
Charging System Reliability:
While generally robust, stator or regulator/rectifier failure can occur over time.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company, Japan.
Key Updates Pre 2000:
Initial models featured different fairing designs and minor engine tuning. The 2000 model represents the A-series generation.
Major Updates Post 2000:
Later models saw minor cosmetic updates and potentially emissions compliance changes, but the core platform remained consistent until its discontinuation.
Production Period:
1997 - 2007
Manufacturing Locations:
Primarily Japan, with some assembly possibly occurring in other regions.
