Servicing

This is the service guide as per the Kawasaki Manual I guess most of us are a little lacks on a few of the recommendations.

Every 5000km

Battery level

Brake pads

Brake fluid level

The manual recommends Dot 3 I use Dot 4 as I couldn't find Dot 3. Do remember you should never mix different grades of fluid as this lowers the boiling point of the fluid hence reducing the effectiveness of the brakes.

Clutch adjustment

Set up as per manual. The result should give you 2-3mm of play at the leavel

Carbs

As manual, tick over should be a smooth 8-900 rpm.

Throttle cables

As manual, ensure the butterfly opens and closes properly with2-3mm play on the throttle.

Steering play

The steering should move from side to side smoothly with no knocking or grinding. When the front end is jacked up there should be no forward and backward movement in the forks. Adjust as per manual

Forks

Fork oil SAE 10W20 each leg holds 360cc or with the springs out and fork compressed the oil should be 155.5mm from the top. The tool described in the manual for splitting the forks is easily replaced:- 3/4inch copper pipe does the job perfectly.

Rear shocks

Check for leaks.

Nuts and bolts etc

Make sure nothings coming undone.

Spark plugs

BP6ES with a gap of 0.7-0.8mm

The firing order is L-R 1-5-3-6-2-4

Valve clearance

As per the manual but if you know what you are doing this chart should help. (Good luck)

Suction Valves

This is a read valve that allows fresh air to pass from the air filter into the exhaust port. It is a non return valve only allowing airflow one way. If you have idle problems or lack of engine power check this valve. Check for a good seal and that the read has no splits in it. Do not scrap any deposits off as you may damage the seal. Use a good high flash point paint solvent to clean. In the event of the read being damaged replace it.

Tyres

Front 110/90V18

Back 130/90V17

Check for wear and for punctures.

Engine oil

Replace

SAE 10W40, 10W50, 20W40 OR 20W50.

Oil Filter

Replace every second oil change.

Lubricate machine

Cables

Mainstand

Choke linkages

Speedo cable

Tacho cable

Brake levers