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Kawasaki Z800 ABS Owner's Manual
Summary of Z800 ABS
Page 1
Kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 2: Quick Reference Guide
Quick reference guide safety information j general information j how to ride the motorcycle j maintenance and adjustment j appendix j maintenance record j this quick reference guide will assist you in finding the information you’re looking for. A table of contents is included after the foreword. Kaw...
Page 3: Danger
Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and main- tenance practices. Danger danger indicates a hazardous situation which, if not avoided, will result in death or serious in- jury. Warning warning indicates a hazardous situation which, if not av...
Page 4: Notice
Notice this product has been manufactured for use in a reasonable and prudent manner by a qualified op- erator and as a vehicle only. Kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 5: Foreword
Foreword congratulations on your purchase of a new kawasaki motorcycle. Your new mo- torcycle is the product of kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this owner’s manual carefully before riding so th...
Page 6
This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold. All rights reserved. No part of this publication may be reproduced without our prior written permission. This publication includes the latest information available at the time o...
Page 7: (Australian Model Only)
(australian model only) tampering with noise control system prohibited owners are warned that the law may prohibit: (a) the removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehic...
Page 8: Table Of Contents
Table of contents safety information .................... 10 read owner’s manual ..................... 10 training ............................................ 10 daily safety checks and periodic maintenance ................................. 10 loading and accessories information.......................
Page 9
Side stand ....................................... 68 seats ................................................ 69 tying hooks ..................................... 72 tool kit ............................................. 72 rear view mirror .............................. 73 event data recorder..........
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Owner satisfaction ........................... 154 environmental protection ................. 156 maintenance record ................. 157 kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 11: Safety Information
10 safety information j safety information read owner’s manual read this owner’s manual care- fully before riding so that you will be thoroughly familiar with the proper op- eration of your motorcycle’s controls, its features, capabilities, and limita- tions. This manual offers many safe riding tips...
Page 12: Loading And Accessories
Safety information 11 j to ensure your motorcycle is ser- viced using the latest servicing infor- mation, it is recommended that an authorized kawasaki dealer performs the periodic maintenance as directed in the owner’s manual. If you notice any irregular operat- ing condition, have your motorcycle ...
Page 13: Note
12 safety information j or use of accessories, or motorcycle modification, will void the motorcycle warranty; can negatively affect perfor- mance, stability and safety; and can even be illegal. In selecting and using accessories, and in loading the motorcycle, you are personally responsible for your...
Page 14: Baggage And Luggage
Safety information 13 j 4. Do not carry passengers unless passenger footpegs are installed. Instruct any passenger before riding to keep his or her feet on the pas- senger footpegs and hold on to the operator or seat strap. Do not carry a passenger unless he or she is tall enough to reach the footpe...
Page 15: Other Load
14 safety information j or any other aspects of the motor- cycle’s operation. 2. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can re- sult in an unsafe riding condition. 3. Fairings, windshields, backrests, and other large items have the ca- pabi...
Page 16: Safe Operation
Safety information 15 j and regulations if any other person, ve- hicle or property is involved. Do not attempt to continue riding without first evaluating your motorcy- cle’s condition. Inspect for fluid leaks, check critical nuts and bolts, and check the handlebars, control levers, brakes, and whee...
Page 17: Fueling
16 safety information j fueling warning gasoline is extremely flammable and can be explosive under cer- tain conditions. To avoid a possible fire or explo- sion, turn the ignition switch to “off.” do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this i...
Page 18: Eye Protection
Safety information 17 j eye protection always use eye protection. If your helmet does not have a visor installed, wear goggles. Gloves wear gloves which have suitable protection for your hands, especially against abrasion. Clothing wear protective clothing. - wear bright, highly visible clothing tha...
Page 19: Use Engine Brake
18 safety information j view mirror; you may misjudge a vehi- cle’s distance and speed, or you may not see it at all. Accelerate and brake smoothly in general your actions should be smooth as sudden acceleration, brak- ing or turning may cause loss of control, especially when riding in wet condition...
Page 20: Ride Prudently
Safety information 19 j ride prudently riding at the proper speed and avoid- ing unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for long ve- hicle life and quieter operation. Riding on rough roads exercise caution, slow down, and grip the fuel tan...
Page 21: Brakes
20 safety information j brakes the importance of the brakes, es- pecially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly. Steering looseness in the steering can cause loss of control. Check to see that the handlebar turns...
Page 22: General Information
General information 21 j general information specifications performance maximum horsepower 83.0 kw (113 ps) @10 200 r/min (rpm) maximum torque 83.0 n·m (8.5 kgf·m, 61 ft·lb) @8 000 r/min (rpm) minimum turning radius 3 m (118 in.) dimensions overall length 2 100 mm (82.7 in.) overall width 800 mm (31...
Page 23
22 general information j displacement 806 cm³ (49.2 cu in.) bore × stroke 71.0 × 50.9 mm (2.8 × 2.0 in.) compression ratio 11.9 : 1 starting system electric starter cylinder numbering method left to right, 1-2-3-4 firing order 1-2-4-3 fuel system fi (fuel injection) ignition system battery and coil ...
Page 24
General information 23 j transmission transmission type 6-speed, return shift clutch type wet, multi disc driving system chain drive primary reduction ratio 1.714 (84/49) final reduction ratio 3.000 (45/15) overall drive ratio 5.633 (top gear) gear ratio: 1st 2.571 (36/14) 2nd 1.941 (33/17) 3rd 1.55...
Page 25
24 general information j tire size: front 120/70zr17 m/c (58w) rear 180/55zr17 m/c (73w) rim size: front j17m/c × mt3.50 rear j17m/c × mt5.50 fuel tank capacity 17 l (4.5 us gal) brake fluid dot4 electrical equipment battery 12 v 8 ah headlight: high beam 12 v 55 w (× 2) low beam 12 v 55 w tail/brak...
Page 26: Serial Number Locations
General information 25 j serial number locations the engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the e...
Page 27: Location Of Labels
26 general information j location of labels all warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may op- erate your vehicle. Therefore,...
Page 28
General information 27 j 2. Brake fluid (rear) 3. Battery poison/danger 4. Rear shock absorber warning kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 29
28 general information j *5. Unleaded gasoline 6. Tire and load data 7. Important drive chain information 8. Radiator cap danger *: only on australian model kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
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General information 29 j 9. Daily safety checks *10. Stationary noise test information *: only on australian model kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
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30 general information j 1) 2) 3) 4) kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 32
General information 31 j 5) 6) 7) 8) kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 33
32 general information j 9) 10) only on australia model kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 34: Location Of Parts
General information 33 j location of parts 1. Rear view mirrors 2. Clutch lever 3. Left handlebar switches 4. Meter instruments 5. Brake fluid reservoir (front) 6. Right handlebar switches 7. Front brake lever 8. Spring preload adjusters 9. Ignition switch/steering lock 10. Rebound damping force adj...
Page 35
34 general information j 1. Headlight 2. Turn signal lights 3. Spark plugs 4. Air cleaner 5. Fuel tank 6. Fuse box 7. Rider’s seat 8. Passenger’s seat 9. Tail/brake light 10. License plate light 11. Seat lock 12. Brake disc 13. Front fork 14. Brake caliper 15. Idle adjusting screw 16. Shift pedal 17...
Page 36
General information 35 j 1. Tool kit 2. Battery 3. Brake fluid reservoir (rear) 4. Fuel tank cap 5. Tying hooks (both sides) (other than australian model) 6. Tying hooks (both sides) 7. Swingarm 8. Muffler 9. Rear shock absorber 10. Rear brake light switch 11. Rear brake pedal 12. Oil level inspecti...
Page 37: Meter Instruments
36 general information j meter instruments a. Left button b. Right button c. Multifunction meter (left side) d. Tachometer e. Multifunction meter (right side) f. Green left turn signal indicator light g. Yellow engine warning indicator light h. Yellow abs indicator light (only on abs model) i. Red w...
Page 38: Note
General information 37 j note ○ for safety, do not operate the instru- ment buttons while riding the motor- cycle. Tachometer the tachometer shows the engine speed in revolutions per minute (r/min, rpm). The upper (higher) zone of the tachometer is a portion called the “red zone.” engine r/min (rpm)...
Page 39: Display Pattern Setting
38 general information j display pattern setting the tachometer display can be changed as follows: • push the left and right buttons for more than 2 seconds. The tachome- ter will sweep in the current display pattern. • pushing the left button changes the display pattern as follows. A. Zone display ...
Page 40
General information 39 j multifunction meter (right side) a. Economical riding indicator b. Speedometer c. Multifunction display - current mileage - average mileage - cruising range d. Fuel gauge/fuel warning symbol kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 41: Speedometer
40 general information j speedometer the speedometer shows the speed of the vehicle in digital values. Note ○ when the input value to the speedometer becomes less than 5 km/h (4 mph), the numerical value shows “0.” unit setting the unit setting in the multifunction meter can be changed according to ...
Page 42: Note
General information 41 j pushing the right button to select the meter display units. The display units can be shifted in the following order. Note ○ the meter display units are main- tained even if the battery is discon- nected. Multifunction display the multifunction display indicates the following...
Page 43: Note
42 general information j a. Current mileage note ○ the numerical value shows “– –.–” until 4 seconds have passed and the speedometer is rises to above 0 km/h (0 mph). ○ when the ignition switch is turned off, the current mileage resets to “0.0”. Average mileage this display mode shows the av- erage ...
Page 44: Cruising Range
General information 43 j been used and 100 m (328 ft) has been traveled. Cruising range this display mode shows the cruising range by numerical value and indicates the cruising range from the remaining fuel in the fuel tank. This cruising range display is renewed every 20 seconds. A. Cruising range ...
Page 45: Warning
44 general information j a. Economical riding indicator warning failing to properly observe the road ahead increases the chance of an accident resulting in se- vere injury or death. Do not con- centrate on the economical rid- ing indicator by taking your eyes off the road; observe using pe- ripheral...
Page 46
General information 45 j all of the segments and fuel warning symbol will blink in case of the open or short of the wiring. Have the wiring inspected by an authorized kawasaki dealer immediately. Kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 47
46 general information j multifunction meter (left side) a. Coolant temperature meter b. Multifunction display - odometer - trip meter a - trip meter b c. Clock d. Warning symbols kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 48: Coolant Temperature Meter
General information 47 j coolant temperature meter the coolant temperature meter in- dicates temperature of the engine coolant. A. Coolant temperature meter • if the coolant temperature is below 40°c (104°f), “– –” is displayed. When the coolant temperature rises to above 40°c (104°f), the numerical...
Page 49
48 general information j a. Coolant temperature warning symbol b. Red warning indicator light if the coolant temperature rises to above 120°c (248°f), “hi” is displayed and starts blinking, the red warning in- dicator light and coolant temperature warning symbol also go on. This warns the operator t...
Page 50: Notice
General information 49 j notice do not let the engine continue running when the coolant tem- perature shows “hi”. Prolonged engine operation will result in severe engine damage from overheating. Multifunction display the multifunction display indicates the following modes. • odometer • trip meter a ...
Page 51: Note
50 general information j note ○ the data are maintained even if the battery is disconnected. ○ when the figures come to 999999, the display is stopped and locked. Trip meter a/b the trip meter has two meters which distinguished between the “trip a” and “trip b”. The trip meter shows the distance in ...
Page 52: Note
General information 51 j • push the left button for more than 2 seconds. Both the hour and minute displays start blinking. • push the right button. The hour dis- play only blinks. Push the left button to advance the hours. • push the right button. The hour dis- play stops blinking and the minute dis...
Page 53: Indicator Lights
52 general information j ○ when the battery is disconnected, the clock is reset to 1:00 and starts working again when the battery is connected. Indicator lights green neutral indicator light n : when the transmission is in neutral, the neutral indicator light goes on. Blue high beam indicator light ...
Page 54: Warning Indicator Lights
General information 53 j warning indicator lights yellow engine warning indicator light : the engine warning indicator light goes on when the ignition key is turned on and goes off soon after en- suring that its circuit functions properly. The warning indicator light also goes on or blinking wheneve...
Page 55: Notice
54 general information j notice do not let the engine continue running when the coolant tem- perature warning symbol goes on. Prolonged engine operation will result in severe damage from overheating. Oil pressure warning symbol : the red warning indicator light and the oil pressure warning symbol ( ...
Page 56: Note
General information 55 j if the improperly coded key is used, or any incorrect communication between antenna and key is occurred. How- ever, when the properly coded key can be used, or the communication is clear, the red warning indicator light does not blink. Note ○ the red warning indicator light ...
Page 57: Keys
56 general information j keys this motorcycle has a combination key, which is used for the ignition switch/steering lock, seat lock, and fuel tank cap. Immobilizer system this motorcycle is equipped with an immobilizer system to protect your mo- torcycle from theft. This motorcycle has two ignition ...
Page 58: Notice
General information 57 j notice do not put two keys of any immo- bilizer system on the same key ring. Do not submerge any key in wa- ter. Do not expose any key to exces- sively high temperature. Do not place any key close to magnets. Do not place heavy item on any key. Do not grind any key or alter ...
Page 59: Note
58 general information j ecu and key is occurred, the engine does not start with the immobilizer warning symbol ( ) and warning indicator light blinks. A properly coded key must be used and the communication should be clear for the engine to start. When the key is turned to “off”, the warning indica...
Page 60: Ignition Switch/steering
General information 59 j ignition switch/steering lock this is a four-position, key-operated switch. The key can be removed from the switch when it is in the off, lock or position. A. Ignition switch/steering lock b. On position c. Off position d. Lock position e. Position off engine off. Electrical...
Page 61: Right Handlebar Switches
60 general information j right handlebar switches a. Engine stop switch b. Starter button engine stop switch in addition to the ignition switch, the engine stop switch must be in the position for the motorcycle to operate. The engine stop switch is for emer- gency use. If required, move the switch t...
Page 62: Note
General information 61 j note ○ although the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine. Starter button the starter button operates the elec- tric starter when the transmission is in neutral...
Page 63: Turn Signal Switch
62 general information j high beam.......( ) low beam.......( ) turn signal switch when the turn signal switch is turned to the left ( ) or right ( ), the corresponding turn signals blink on and off. To stop blinking, push the switch in. Horn button when the horn button is pushed, the horn sounds. H...
Page 64: Fuel Tank Cap
General information 63 j push the lever forward and turn the ad- juster to align the number with the mark on the lever holder. The distance from the grip to the released lever is min- imum at number 5 and maximum at number 1. A. Adjuster b. Mark fuel tank cap to open the fuel tank cap, pull up the k...
Page 65: Fuel
64 general information j a. Key hole cover b. Ignition key c. Fuel tank cap fuel fuel requirements your kawasaki engine is designed to use only unleaded gasoline with a minimum octane rating shown below. Never use gasoline with an octane rat- ing lower than the minimum specified by kawasaki to preve...
Page 66: Notice
General information 65 j notice if engine “knocking” or “ping- ing” occurs, use a different brand of gasoline of a higher octane rating. If this condition is allowed to continue, it can lead to severe engine damage. Gaso- line quality is important. Fuels of low quality or not meeting standard indust...
Page 67: (For Brazil Specification)
66 general information j (for brazil specification) use clean, fresh unleaded gasoline with an antiknock index equal to or higher than that shown in the table. The antiknock index is posted on ser- vice station pumps. The antiknock in- dex is an average of the research oc- tane number (ron) and the ...
Page 68: Warning
General information 67 j a. Tank cap b. Fuel tank c. Top level d. Filler neck warning gasoline is extremely flammable and can be explosive under cer- tain conditions, creating the po- tential for serious burns. Turn the ignition switch off. Do not smoke. Make sure the area is well ventilated and fre...
Page 69: Notice
68 general information j notice certain ingredients of gasoline may cause paint fading or dam- age. Be extra careful not to spill gasoline or gasoline oxygenates blends during refueling. Side stand the motorcycle is equipped with the side stand. A. Side stand note ○ when using the side stand, turn t...
Page 70: Note
General information 69 j note ○ the motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine does not start if the transmission is in gear and the side stand is down. Seats passenger’s seat removal • insert the ignition key into the seat lock. • pull up the front...
Page 71
70 general information j a. Bolt b. Bracket c. Rider’s seat • pull the rider’s seat backward to clear the tabs. • remove the rider’s seat. A. Tabs b. Slots c. Rider’s seat rider’s seat installation • insert the tabs at the front of the rider’s seat into the slots on the frame. • be sure that the hoo...
Page 72
General information 71 j a. Tabs b. Slots c. Hooks d. Holes e. Rider’s seat • insert the bracket into the hole at the rear of rider’s seat while pushing down the rear part of the rider’s seat. • tighten the bolt while pushing for- ward the rear part of the rider’s seat. A. Bracket b. Hole c. Rider’s...
Page 73: Tying Hooks
72 general information j • push down the front part of the pas- senger’s seat until the lock clicks. A. Tab b. Slot c. Hook d. Hole • pull up the front and rear ends of the passenger’s seat to make sure they are securely locked. Tying hooks when tying up light loads to the seat, use the tying hooks ...
Page 74: Rear View Mirror
General information 73 j the kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual. Keep the tool kit in the original place. A. Tool kit rear view mirror rear view mirror adjustment • adjust the rear view mirror by sl...
Page 75: Note
74 general information j a. Stay b. Rear view mirror tightening torque lower hexagonal area: 30 n·m (3.1 kgf·m, 22 ft·lb) upper hexagonal area: 18 n·m (1.8 kgf·m, 13 ft·lb) a. Lower hexagonal area for tightening b. Upper hexagonal area c. Rear view mirror d. Rubber boots note ○ if a torque wrench is...
Page 76: Event Data Recorder
General information 75 j event data recorder this vehicle is equipped at the fac- tory with an event data recorder (edr). The main purpose of this device is to record data that assists with under- standing of how a vehicle’s systems performed during a short period of time. Among other things, this d...
Page 77: Break-In
76 how to ride the motorcycle j how to ride the motorcycle break-in the first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “bro- ken down” instead of a “broken in” m...
Page 78: Warning
How to ride the motorcycle 77 j • do not race the engine while the transmission is in neutral. Warning new tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to estab- lish normal tire traction. During break-in, avoid sudden and max- imu...
Page 79: Note
78 how to ride the motorcycle j a. Green neutral indicator light b. Ignition switch c. On position note ○ the motorcycle is equipped with a vehicle-down sensor which causes the engine to stop automatically if the motorcycle falls down. The engine warning indicator light ( ) blinks when the starter b...
Page 80: Notice
How to ride the motorcycle 79 j the side stand is down. However, the engine can be started if the clutch lever is pulled and the side stand is fully up. A. Clutch lever b. Starter lockout switch notice do not let the engine idle longer than five minutes, or engine overheating and damage may occur. J...
Page 81: Danger
80 how to ride the motorcycle j danger battery acid generates hydro- gen gas which is flammable and explosive under certain con- ditions. It is present within a battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away from the battery. Wear eye protection wh...
Page 82: Danger
How to ride the motorcycle 81 j a. Motorcycle battery positive (+) terminal b. From booster battery positive (+) terminal c. Footpeg d. From booster battery negative (–) terminal • connect another jumper cable from the negative (–) terminal of the booster battery to your motorcy- cle footpeg or othe...
Page 83: Notice
82 how to ride the motorcycle j notice do not operate the starter con- tinuously for more than 5 sec- onds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the bat- tery power recover. • after the engin...
Page 84: Note
How to ride the motorcycle 83 j note ○ the motorcycle is equipped with a side stand switch. This switch is de- signed so that the engine does not start if the transmission is in gear and the side stand is down. Shifting gears • close the throttle while pulling in the clutch lever. • shift into the n...
Page 85: Braking
84 how to ride the motorcycle j braking • close the throttle completely, leav- ing the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. • shift down one gear at a time so that you are in 1st gear when you come to a complete stop. • when stopping, alw...
Page 86: Anti-Lock Brake System
How to ride the motorcycle 85 j a. Rear brake pedal anti-lock brake system (abs) (only on abs model) abs is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight. The abs automatically regu- lates brake force. Intermittently gaining gripping forc...
Page 87: Warning
86 how to ride the motorcycle j distance of a motorcycle with abs may be longer than that of an equiv- alent motorcycle without abs. Use special caution in such areas. • abs will help prevent wheel lock-up when braking in a straight line, but it cannot control wheel slip which may be caused by braki...
Page 88: Warning
How to ride the motorcycle 87 j warning use of non-recommended tires may cause malfunctioning of abs and can lead to extended braking distance. The rider could have an accident as a re- sult. Always use recommended standard tires for this motorcy- cle. Note ○ abs indicator light may come on un- der ...
Page 89: Stopping The Engine
88 how to ride the motorcycle j • the light remains lit after the motor- cycle starts moving. • the light comes on and remains lit after the motorcycle starts moving. Remember that the abs does not function when this light is on, but if the abs fails, the conventional brake sys- tem still works norm...
Page 90: Parking
How to ride the motorcycle 89 j dangerous situation known as throt- tle failure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust to enter the throttle body and stick the throttle open. 2. During removal of the air cleane...
Page 91: Warning
90 how to ride the motorcycle j warning the engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch a hot engine, ex- haust pipe, or muffler during op- eration or after stopping the en- gine. • shift the transmission into neutral and turn the igni...
Page 92: Note
How to ride the motorcycle 91 j note ○ when stopping near traffic at night, you can leave the turn signals blink- ing for greater visibility by turning the ignition key to the position and push in the hazard switch. Kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 93: Maintenance And Adjustment
92 maintenance and adjustment j maintenance and adjustment the maintenance and adjustments outlined in this chapter must be carried out in accordance with the daily safety checks and periodic maintenance to keep the motorcycle in good running condition and to reduce air pollution.The initial main- t...
Page 94: Danger
Maintenance and adjustment 93 j danger exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. Warning the cooling fan spins at high s...
Page 95: Daily Safety Checks
94 maintenance and adjustment j daily safety checks check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the maintenance and...
Page 96
Maintenance and adjustment 95 j operation see page lubricate if dry 117 bolt, nuts and fasteners check for loose and/or missing bolts, nuts and fasteners – steering action smooth but not loose from lock to lock – no binding of control cables – brakes brake pad wear 123 brake fluid level 122 no brake...
Page 97
96 maintenance and adjustment j operation see page coolant no coolant leakage – coolant level between level lines (when engine is cold) 106 electrical equipment all lights (head, tail/brake, turn signal, warning/indicator) and horn work – engine stop switch stops engine – side stand return to its fu...
Page 98: Periodic Maintenance
Maintenance and adjustment 97 j periodic maintenance *a: service at number of years shown or indicated odometer reading intervals, whichever comes first. *b: for higher odometer readings, repeat at the frequency interval established here. *c: service more frequently when operating in severe conditio...
Page 99
98 maintenance and adjustment j odometer reading (*b) × 1 000 km (× 1 000 mile) items year (*a) 1 (0.6) 6 (3.8) 12 (7.6) 18 (11.4) 24 (15.2) see page – air cleaner element (*c) : every 36 000 km (22 500 mile) – idle speed 114 throttle control system (play, smooth return, no drag) :1 112 engine vacuu...
Page 100
Maintenance and adjustment 99 j odometer reading (*b) × 1 000 km (× 1 000 mile) items year (*a) 1 (0.6) 6 (3.8) 12 (7.6) 18 (11.4) 24 (15.2) see page coolant, water hose and o-ring :3 : every 36 000 km (22 500 mile) – valve clearance : every 42 000 km (26 250 mile) – air suction system – clutch oper...
Page 101
100 maintenance and adjustment j odometer reading (*b) × 1 000 km (× 1 000 mile) items year (*a) 1 (0.6) 6 (3.8) 12 (7.6) 18 (11.4) 24 (15.2) see page drive chain slack (*c) : every 1 000 km (600 mile) 117 drive chain wear (*c) – drive chain guide wear – brake system :1 – brake fluid level :0.5 122 ...
Page 102
Maintenance and adjustment 101 j odometer reading (*b) × 1 000 km (× 1 000 mile) items year (*a) 1 (0.6) 6 (3.8) 12 (7.6) 18 (11.4) 24 (15.2) see page suspension system :1 – steering play :1 – steering stem bearings :2 – electrical system :1 – spark plugs – chassis parts 1 – condition of bolts, nuts...
Page 103: Engine Oil
102 maintenance and adjustment j engine oil oil level inspection • if the engine is cold, start the engine and run it for several minutes at idle speed. • stop the engine, then wait several minutes until the oil settles. Notice racing the engine before the oil reaches every part can cause en- gine s...
Page 104: Warning
Maintenance and adjustment 103 j oil and/or oil filter change • warm up the engine thoroughly, and then stop it. • place an oil pan beneath the engine. • remove the engine oil drain plug. Warning engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approv...
Page 105: Note
104 maintenance and adjustment j note ○ if a torque wrench or required kawasaki special tool is not avail- able, this item should be serviced by a kawasaki dealer. A. Oil filter • apply a thin film of oil to the packing and tighten the cartridge to the spec- ified torque. A. Packing • install the dr...
Page 106: Note
Maintenance and adjustment 105 j tightening torque engine oil drain plug: 29 n·m (3.0 kgf·m, 21 ft·lb) cartridge: 17 n·m (1.7 kgf·m, 13 ft·lb) recommended engine oil type: api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 rating viscosity: sae10w-40 note ○ do not add any chemical additive to the oil...
Page 107: Coolant
106 maintenance and adjustment j coolant coolant level inspection • position the motorcycle so that it is perpendicular to the ground. • check the coolant level through the coolant level gauge on the reserve tank located to the left of the engine. The coolant level should be between the f (full) and...
Page 108
Maintenance and adjustment 107 j coolant filling • remove the bolts and plastic wash- ers. • clear the hooks on the ignition cover and remove it. A. Bolts and plastic washers b. Hooks (both sides) c. Ignition cover • clear the projection and tab on the left tank cover. • pull the left tank cover for...
Page 109
108 maintenance and adjustment j a. Bolts b. Screws c. Left inner shroud • remove the cap from the reserve tank and add coolant through the filler opening to the f (full) level line. A. Cap b. Reserve tank c. F (full) level line d. L (low) level line • install the left inner shroud. • install the le...
Page 110
Maintenance and adjustment 109 j a. Hook b. Fuel tank c. Slot d. Tab e. Slot f. Left tank cover g. Projection h. Hole • insert the pin on the ignition cover into the hole on the bracket. A. Pin b. Ignition cover c. Hole d. Bracket • insert the hooks on the ignition cover into the slots. • install th...
Page 111: Warning
110 maintenance and adjustment j a. Bolts and plastic washers b. Hooks (both sides) c. Ignition cover coolant change have the coolant changed by an au- thorized kawasaki dealer. Coolant requirement warning coolant containing corrosion in- hibitors for aluminum engines and radiators include harm- ful...
Page 112: Notice
Maintenance and adjustment 111 j notice if hard water is used in the sys- tem, it causes scale accumula- tion in the water passages, and considerably reduces the effi- ciency of the cooling system. Note ○ a permanent type of antifreeze is in- stalled in the cooling system when shipped. It is mixed a...
Page 113: Warning
112 maintenance and adjustment j warning oil on tires will make them slip- pery and can cause an accident and injury. Be sure to install the plug in the drain hose after drain- ing. Throttle control system throttle grip throttle grip free play inspection • check that the throttle grip moves smoothly...
Page 114
Maintenance and adjustment 113 j throttle grip free play adjustment • loosen the locknuts at the upper of the throttle cables, and screw both throttle cable adjusters completely so as to give the throttle grip plenty of play. • turn out the decelerator cable ad- juster until there is no play when th...
Page 115: Warning
114 maintenance and adjustment j be done by an authorized kawasaki dealer. • with the engine idling, turn the han- dlebar to each side. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or they may be damaged. Be sure to correct any o...
Page 116: Warning
Maintenance and adjustment 115 j • open and close the throttle a few times to make sure that the idle speed does not change. Readjust if necessary. • with the engine idling, turn the han- dlebar to each side. If handlebar movement changes the idle speed, the throttle cables may be improperly adjuste...
Page 117: Warning
116 maintenance and adjustment j a. Adjuster b. Stopper c. Clutch lever play • if the play is incorrect, adjust the lever play as follows. Clutch cable free play adjustment • loosen the locknut at the clutch lever. • turn the adjuster so that the clutch lever will have the specified free play. Warni...
Page 118: Drive Chain
Maintenance and adjustment 117 j drive chain drive chain lubrication lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for sealed chains to prevent deterioration of chain seals. If the chain is especially dirty, clean it using...
Page 119
118 maintenance and adjustment j chain midway between the engine sprocket and rear wheel sprocket. A. Chain slack • if the drive chain is too tight or too loose, adjust it so that the chain slack is within the standard value. Drive chain slack standard: 20 ∼ 30 mm (0.8 ∼ 1.2 in.) drive chain slack a...
Page 120: Note
Maintenance and adjustment 119 j • if the chain is too tight, turn out the left and right chain adjusters evenly. • turn out both chain adjusters evenly until the drive chain has the cor- rect amount of slack. To keep the chain and wheel properly aligned, the notch on the left wheel alignment indica...
Page 121: Warning
120 maintenance and adjustment j warning misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding con- dition. Align the rear wheel us- ing the marks on the swingarm or measuring the distance be- tween the center of the axle and swingarm pivot. • tighten both chain ...
Page 122: Note
Maintenance and adjustment 121 j note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise up to the next alignment. ○ it should be within 30 degrees. ○ loosen once and tighten again when the slot goes past the ne...
Page 123: Warning
122 maintenance and adjustment j warning air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake lever or pedal feels mushy when it is applied, there might be air in the brake lines or the brake may be defective. Have the brake checked...
Page 124
Maintenance and adjustment 123 j a. Rear brake fluid reservoir b. Upper level line c. Lower level line • if the fluid level is lower than the lower level line it may indicate that the fluid is leaking. In this case, have the brake system inspected by an au- thorized kawasaki dealer. Brake pad wear i...
Page 125: Brake Light Switches
124 maintenance and adjustment j a. Rear brake pads b. Lining thickness c. Service limit brake light switches brake light switch inspection • turn the ignition switch on. • the brake light should go on when the front brake is applied. • if it does not, ask your authorized kawasaki dealer to inspect ...
Page 126: Notice
Maintenance and adjustment 125 j • if the light does not come on, the rear brake light switch should be adjusted by an authorized kawasaki dealer. Brake pedal travel 10 mm (0.4 in.) a. Rear brake light switch notice to avoid damaging the electrical connections inside the switch, be sure that the swi...
Page 127
126 maintenance and adjustment j spring preload adjustment the adjuster is located at the top of each front fork leg. Standard 9 mm (0.4 in.) from the top of the adjuster. • turn the spring preload adjuster into the nut to increase spring force and out to decrease spring force. The adjusting range s...
Page 128: Notice
Maintenance and adjustment 127 j • turn the adjuster clockwise with a screwdriver to increase damping force. • turn the adjuster counterclockwise to decrease damping force. Notice do not turn the adjuster beyond the fully seated position or the adjusting mechanism may be damaged. A. Rebound damping ...
Page 129: Notice
128 maintenance and adjustment j rebound damping force adjustment the adjuster is located at the lower end of the rear shock absorber. A. Rebound damping force adjuster b. To increase damping force c. To decrease damping force standard 1 1/4 turns out out from the fully seated position (turned fully...
Page 130: Setting Tables
Maintenance and adjustment 129 j setting tables front fork spring preload setting softest setting limit standard hardest setting limit adjuster position 19 mm (0.7 in.) 9 mm (0.4 in)* 4 mm (0.2 in.)* spring action weak ←→ strong setting soft ←→ hard load light ←→ heavy road good ←→ bad speed low ←→ ...
Page 131
130 maintenance and adjustment j front fork damping force settings softest setting limit standard hardest setting limit adjuster position: rebound 26 clicks** 12 clicks** 0* damping force weak ←→ strong setting soft ←→ hard load light ←→ heavy road good ←→ bad speed low ←→ high *: this position is t...
Page 132
Maintenance and adjustment 131 j rear shock absorber damping force settings softest setting limit standard hardest setting limit adjuster position: rebound 2 2/4 turns out** 1 1/4 turns out** 0* damping force weak ←→ strong setting soft ←→ hard load light ←→ heavy road good ←→ bad speed low ←→ high ...
Page 133: Wheels
132 maintenance and adjustment j wheels tire pressure inspection • remove the air valve cap. • check the tire pressure often, using an accurate gauge. • make sure to install the air valve cap securely. Note ○ measure the tire pressure when the tires are cold (that is, when the mo- torcycle has not b...
Page 134
Maintenance and adjustment 133 j so it is false economy and unsafe to use the tires until they are bald. Tire wear inspection • measure the depth of the tread with a depth gauge, and replace any tire that has worn down to the minimum allowable tread depth. A. Tire depth gauge minimum tread depth fro...
Page 135: Note
134 maintenance and adjustment j a. Crack or cur b. Nail c. Swelling or high spot d. Stone • remove any imbedded stones or other foreign particles from the tread. Note ○ have the wheel balance inspected whenever a new tire is installed. Warning tires that have been punctured and repaired do not have...
Page 136: Warning
Maintenance and adjustment 135 j ○ when operating on public roadways, keep maximum speed under traffic law limits. Standard tire (tubeless) front make, type: dunlop, sportmax d214 fj size: 120/70zr17 m/c (58w) rear make, type: dunlop, sportmax d214 j size: 180/55zr17 m/c (73w) warning mixing tire br...
Page 137: Notice
136 maintenance and adjustment j notice never remove the sealing strip, or the battery can be damaged. Do not install a conventional battery in this motorcycle, or the electrical system cannot work properly. Battery maintenance it is the owner’s responsibility to keep the battery fully charged. Fail...
Page 138: Danger
Maintenance and adjustment 137 j for more details, ask your kawasaki dealer. Battery charging • charge the battery following the in- structions of your battery charger. • the charger will keep the battery fully charged until you are ready to re- install the battery in the motorcycle (see battery ins...
Page 139
138 maintenance and adjustment j • clear the hooks on the frame, and remove the rubber band. • clear the hook of the fuse box, and remove it. • pull up the battery slightly. A. Hooks b. Rubber band c. Hook d. Fuse box e. Battery • slide the red cap from the positive (+) terminal. • disconnect the ca...
Page 140: Notice
Maintenance and adjustment 139 j battery installation • run the cables outside the battery case and under the main harness. A. (+) cable (with red cap) b. (–) cable c. Projection d. Battery case e. Main harness • place the battery on the battery case. • connect the (+) cable to the (+) ter- minal, a...
Page 141: Note
140 maintenance and adjustment j horizontal adjustment the headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. • turn the horizontal adjuster in or out until the beam points straight ahead. A. Horizontal adjust...
Page 142: Fuses
Maintenance and adjustment 141 j fuses fuses are arranged in the fuse boxes located under the rider’s seat. The main fuse is located at the battery com- partment. If a fuse fails during opera- tion, inspect the electrical system to de- termine the cause, and then replace it with a new fuse of proper...
Page 143: Warning
142 maintenance and adjustment j a. Main fuse warning substituting fuses can cause wiring to overheat, catch fire and/or fail. Do not use any sub- stitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse boxes and main fuse. A. Normal b. ...
Page 144: Pivots
Maintenance and adjustment 143 j before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. Apply engine oil to the following pivots • side stand • clutch lever • front brake lever • rear brake pedal lubricate the following cables with a p...
Page 145: Cleaning Your Motorcycle
144 maintenance and adjustment j cleaning your motorcycle general precautions frequent and proper care of your kawasaki motorcycle will enhance its appearance, optimize overall per- formance, and extend its useful life. Covering your motorcycle with a high quality, breathable motorcycle cover will h...
Page 146: Washing Your Motorcycle
Maintenance and adjustment 145 j • be sure the engine and exhaust are cool before washing. • avoid applying degreaser to seals, brake pads, and tires. • avoid all harsh chemicals, solvents, detergents, and household cleaning products such as ammonia-based window cleaners. • gasoline, brake fluid, an...
Page 147: Note
146 maintenance and adjustment j • use a soft cloth to dry your motorcy- cle. As you dry, inspect your motor- cycle for chips and scratches. Do not let the water air dry as this can dam- age the painted surfaces. • start the engine and let it idle for sev- eral minutes. The heat from the en- gine wi...
Page 148: Notice
Maintenance and adjustment 147 j notice using high-pressure water, as from a car wash facility, could damage the radiator fins and im- pair the radiator’s effectiveness. Do not obstruct or deflect air- flow through the radiator by installing unauthorized acces- sories in front of the radiator or beh...
Page 149: Notice
148 maintenance and adjustment j notice plastic parts may deteriorate and break if they come in con- tact with chemical substances or household cleaning products such as gasoline, brake fluid, window cleaners, thread-locking agents, or other harsh chemi- cals. If a plastic part comes in contact with...
Page 150: Warning
Maintenance and adjustment 149 j warning rubber protectants can be slip- pery and, if used on the tread area, cause loss of traction re- sulting in accident causing in- jury or death. Do not apply rub- ber protectant to any tread area. Kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 151: Appendix
150 appendix j appendix storage preparation for storage • clean the entire vehicle thoroughly. • run the engine for about five minutes to warm the oil, shut it off, and drain the engine oil. Warning engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for app...
Page 152: Warning
Appendix 151 j warning gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. Turn the ignition key to “off”. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any applian...
Page 153: Preparation After Storage
152 appendix j • spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or in the brakes. • lubricate the drive chain and all the cables. • remove the battery, and store it where it will not be exposed to direct sunlight, moisture, or freezing temperatures. D...
Page 154: Troubleshooting Guide
Appendix 153 j troubleshooting guide engine does not start starter motor won’t turn • engine stop switch off • transmission not in neutral • fuse blown • battery leads do not make good electrical contact with battery terminals • battery discharged engine cranks, but won’t start • no fuel in tank • f...
Page 155: Engine Stalls
154 appendix j engine stalls just when shifting into 1st gear • side stand has been left down • clutch does not properly disengage while riding • no fuel in tank • fuel tank air vent is obstructed • overheating • battery discharged owner satisfaction (for products sold in australia only) your satisf...
Page 156
Appendix 155 j with your satisfaction and your future business. For this reason the owner is in the best position to assist you. Also, all warranty and service matters are handled and resolved through the authorized kawasaki dealer network. If you are unsatisfied after working with your kawasaki dea...
Page 157: Environmental Protection
156 appendix j customer relations: technical service department kawasaki motors pty., ltd. Private mail bag 24 rydalmerer n.S.W. 2116 a.C.N.: 002 840 315 environmental protection to help preserve the environment, properly discard used batteries, tires, oils and fluids, or other vehicle components th...
Page 158: Maintenance Record
Maintenance record 157 j maintenance record owner name....................................................................................... Address .............................................................................................. Phone number .............................................
Page 159
158 maintenance record j date odometer reading maintenance performed dealer name dealer address kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 160
Maintenance record 159 j date odometer reading maintenance performed dealer name dealer address kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 161
160 maintenance record j date odometer reading maintenance performed dealer name dealer address kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 162
Maintenance record 161 j date odometer reading maintenance performed dealer name dealer address kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 163
162 maintenance record j date odometer reading maintenance performed dealer name dealer address kawasaki z800 owner's manual http://www.Motorcycle.In.Th.
Page 164
Kawasaki z800 owner's manual http://www.Motorcycle.In.Th.