Model Segment:
Dual-sport / Adventure-touring motorcycle
Key Selling Points:
Reliability, ruggedness, versatility for both on-road and off-road use, affordability, long-distance capability.
Primary Competitors:
BMW F650GS (older generations), Honda Transalp, Suzuki V-Strom (early models), Yamaha XT660R/X.
Design Philosophy:
Purpose-built for utility and durability, emphasizing practical performance over outright speed or luxury.
Engine:
Complete engine overhaul, lubrication system, cooling system, fuel system (carburetor), ignition system, exhaust system, cylinder head and valve train, cylinder block and crankshaft, piston and connecting rod, cam chain, starter clutch.
Transmission:
Gearbox inspection, disassembly, assembly, shift drum and forks, clutch operation and maintenance, lubrication.
Chassis:
Frame inspection and repair, front fork service and overhaul, rear shock absorber service and replacement, steering system maintenance, wheel and tire service, brake system (front and rear disc brakes) overhaul and bleeding, chain drive maintenance and adjustment.
Electrical:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), ignition system troubleshooting, lighting system, indicators, horn, starter motor operation and testing, fuses and relays.
Fuel System:
Carburetor (CVK) disassembly, cleaning, adjustment, jetting information, fuel tank and petcock inspection.
Maintenance:
Regular maintenance schedules, oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain lubrication and adjustment, brake pad inspection and replacement, coolant checks and changes, valve clearance adjustment.
Troubleshooting:
Diagnostic charts for common problems, electrical system troubleshooting, engine performance issues, starting difficulties, braking problems.
Repair Overhaul:
Complete disassembly and reassembly procedures for all major components, engine rebuilds, suspension component overhauls, brake caliper rebuilds, carburetor rebuilding.
Depth Of Coverage:
Comprehensive; covers basic rider maintenance to advanced engine and electrical system diagnostics and repair. Includes torque specifications, clearances, and detailed component diagrams.
Searchable Text:
Likely searchable if properly OCR'd
Printability:
High-quality, printable pages for workshop use
Original Binding:
Original factory binding (typically spiral or perfect bound for service manuals)
Original Paper Quality:
Durable, glossy paper suitable for workshop environments
Engine Type:
4-stroke, single-cylinder, DOHC, 4 valves
Bore X Stroke:
100.0 mm x 83.0 mm
Cooling System:
Liquid-cooled
Horsepower:
Approx. 48 HP @ 6,500 RPM (for the generation)
Torque:
Approx. 42 lb-ft @ 5,000 RPM (for the generation)
Carburetor Type:
Mikuni BSR32 (Constant Velocity Bi-Speed)
Fuel Type:
Unleaded gasoline
Ignition System:
Digital CDI
Oil Type:
API SG, SF, SE, SAE 10W-40 or 10W-50 motorcycle oil
Oil Capacity With Filter Change:
2.2 L (2.3 US qt)
Starting System:
Electric starter
Transmission Type:
5-speed constant mesh
Final Drive:
O-ring sealed chain
Clutch Type:
Wet, multi-disc
Gear Ratios:
Detailed in manual (e.g., 1st: 2.600, 2nd: 1.750, 3rd: 1.333, 4th: 1.100, 5th: 0.857)
Transmission Oil Type:
API GL-4, SAE 80 or 80W-90 gear oil
Transmission Oil Capacity:
0.9 L (0.95 US qt)
Crash Test Data:
Motorcycle safety data is typically not assessed by standard automotive crash test agencies.
Braking System:
Dual hydraulic disc brakes (front and rear)
Suspension Frontend:
41mm telescopic fork, adjustable preload
Suspension Backend:
Monoshock, adjustable preload and rebound damping
Lighting:
Halogen headlight, LED taillight
Instrumentation:
Analog tachometer, digital speedometer, odometer, trip meter, clock, indicator lights.
ABS:
Not available on 2008-2009 models.
Power Output:
12V DC accessory power outlet not standard, but often added by owners.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Air Filter Cleaning Interval:
Every 6,000 km (3,700 miles), replace as needed
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles)
Valve Clearance Check Interval:
Every 12,000 km (7,500 miles)
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after riding in wet conditions
Coolant Type:
Permanent type ethylene glycol based coolant (50% solution with distilled water)
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, rear shock absorber seals, starter motor brushes.
Carburetor Tuning:
Carburetor can require fine-tuning for altitude or aftermarket exhausts.
Charging System:
Regulator/rectifier can be a failure point on some models, especially with accessory loads.
Manufacturer:
Kawasaki Heavy Industries, Ltd.
Heritage Focus:
Longstanding reputation for robust and reliable motorcycles, particularly in the off-road and dual-sport categories.
Original Launch Year:
1987
Generation 1 Period:
1987-2007
Generation 2 Period:
2008-2018 (This manual covers the early part of this generation)
Key Changes 08-09:
Updated styling, larger fuel tank, revised fairing, improved instrumentation, larger disc brakes (though still not ABS). Engine remained largely the same but with minor refinements.
Manufacturing Location:
Japan (primarily)
