Periodic Maintenance

Engine oil & oil-filter change

Warm the engine first, then stand the bike vertical (not on the side stand) for accurate draining and filling.

1. 1

   Warm the engine to operating temperature, then stand the motorcycle vertical.

2. 2

   Remove the oil filler cap on the transmission cover.

3. 3

   Remove the left and right oil-pan drain plugs and let the oil drain.

4. 4

   Remove the clutch drain plug on the outer clutch cover — this third plug must come out to drain the engine fully.

5. 5

   Remove the oil filter with the filter wrench and discard it.

   ℹ Note

   The filter has an internal bypass valve that cannot be removed — just fit a complete new filter.

6. 6

   Replace the left drain-plug gasket if damaged; fit new O-rings to the right drain plug and the clutch-cover drain plug.

7. 7

   Refit and tighten the three drain plugs.

   TorqueLeft 20 · Right 15 · Clutch-cover 20 N·m

   Spec-table values; the procedure text transposes the two pan plugs — the table governs.

8. 8

   Lightly oil the new filter’s gasket, fit it and tighten with the filter wrench.

   Torque17.5 N·m

   Spec table 17.5 N·m; the procedure text states 18 N·m.

9. 9

   Pour in the specified oil through the filler.

   4.6 L when the filter is removed (4.4 L if only the oil is changed).

10. 10

    Refit the filler cap, run the engine briefly, then check the level between the lines 2–3 minutes after stopping.

Spark plug replacement

1. 1

   Remove the fuel tank to reach the rear plug (see the Fuel System chapter); pull off the spark-plug caps.

2. 2

   Remove each plug with the 16 mm plug wrench, held vertically.

   ▲ Caution

   The insulator can break if the wrench is tilted while loosening or tightening — keep it square to the plug.

3. 3

   Fit the new plug by hand first, then tighten with the wrench held vertically.

   Torque18 N·m

   Gap 1.0 – 1.1 mm.

4. 4

   Refit the plug caps; tug each lightly to confirm it is seated.

Air cleaner element replacement

1. 1

   Remove the air-cleaner cover screws and the cover.

2. 2

   Unscrew the element screw and remove the element; discard it.

3. 3

   Fit a new element with the mesh side facing upward.

   ▲ Caution

   Use only Kawasaki element 11013-0002. The wrong element wears the engine prematurely and lowers performance.

4. 4

   Refit the cover and screws.

Coolant change

1. 1

   Place a container under the radiator drain bolt and remove the bolt.

2. 2

   Remove the fuel tank (see the Fuel System chapter).

3. 3

   Remove the radiator cap in two steps: turn anticlockwise to the first stop, then push down and turn further to remove. Coolant drains from radiator and engine.

4. 4

   Empty the reserve tank with a hose into a suitable container, then refit it.

5. 5

   Refit and tighten the coolant drain bolt.

   Torque9.8 N·m
6. 6

   Mix and pour in fresh coolant.

   Soft water 50% / coolant 50%, total 2.5 L, freezing point −35 °C.

   ▲ Caution

   Use only soft or distilled water. Hard water leaves scale in the passages and badly reduces cooling efficiency.

7. 7

   Pour coolant in slowly so trapped air can escape; fill the radiator to the filler neck.

8. 8

   Loosen the air-bleeder bolt on the thermostat housing and top up until coolant flows out the bleeder hole (all air expelled); tap the hoses to free bubbles.

9. 9

   Refit the radiator cap and tighten the air-bleeder bolt.

   Torque7.8 N·m
10. 10

    Run the engine and check the cooling system for leaks.

Belt deflection inspection

1. 1

   Confirm wheel alignment: the left and right belt-adjuster notches must point to the same marks on the swingarm. If not, adjust alignment first.

2. 2

   Lift the rear wheel off the ground with the jack under the frame-pipe ribs.

3. 3

   Visually inspect the belt for damage; replace it if damaged.

4. 4

   Mark the initial belt position on the lower belt-cover window.

5. 5

   With the tension gauge, push up 45 N (4.5 kgf) at the centre of the belt and measure the deflection from the mark.

   Push only at the centre and sight parallel to the belt — edge loading or an angled view gives a false reading.

6. 6

   Repeat at two positions by rotating the rear wheel ~90°; use the larger deflection figure.

7. 7

   Compare with spec and adjust if out of range.

   Standard 2.5 – 4.0 mm (45 N). New belt / engine remounted: 2.5 mm.

Belt deflection adjustment

1. 1

   Remove the muffler body (see Engine Top End chapter) and the upper belt cover.

2. 2

   Remove the axle cotter pin and loosen the axle nut; lift the rear wheel.

3. 3

   Loosen the left and right belt-adjuster locknuts. If the belt is too tight, back out both adjuster nuts and kick the wheel forward until it is loose.

4. 4

   Turn both adjuster nuts in evenly until deflection is correct, keeping the left and right notches on the same swingarm mark so the wheel stays aligned.

5. 5

   Tighten both adjuster locknuts, torque the axle nut and fit a new cotter pin.

   TorqueRear axle nut 108 N·m

   ⚠ Warning

   Wheel misalignment causes abnormal belt wear and an unsafe riding condition. Always confirm both adjuster notches align.