Kawasaki SUPER SHERPA - Owner's manual

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Quick Reference Guide
GENERAL INFORMATION j
HOW TO RIDE THE MOTORCYCLE j
SAFE OPERATION j
MAINTENANCE AND ADJUSTMENT j
STORAGE j
TROUBLESHOOTING GUIDE 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.
Whenever you see the symbols
shown below, heed their instructions!
Always follow safe operating and main-
tenance practices.
WARNING
This warning symbol identifies
special instructions or proce-
dures which, if not correctly fol-
lowed, could result in personal
injury, or loss of life.
CAUTION
This caution symbol identifies
special instructions or proce-
dures which, if not strictly ob-
served, could result in damage
to or destruction of equipment.
NOTE
ż
This note symbol indicates points of
particular in terest for more efficient
and c onvenient operatio n.
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 sup erio r relia bility, safety a n d performance.
Please read this Owner ’s Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of y our m otorcy cle’s controls, its fea-
tures, capabilities, and limitations. This manual offers many safe riding tips, but its
purpose is not to provide instruction in a ll the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-
cle enroll in a motorcy cle rider training program to a tta in aware ness of the mental
and physical requirements necessary for safe motorcycle operation.
To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-
formation on their Kawasaki Motorcycle, a Service Manual is available for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-
tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.
Keep this Owner ’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.
This manual should be considered a permanent part of the motorcycle and should
remain with the motorcyc le 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 of printing.
However, there may be m inor differences between the actual product and illustra-
tions and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.
Consumer Products & Machinery Company
© 2008 Kawasaki Heavy Industries, Ltd. Nov. 2008. (1). (S, Ke)
TA BLE OF CONTENTS
SPECIFICATIONS............................... 8
SERIAL NUMBER LOCATIONS......... 12
LOCATION OF PARTS ....................... 13
LOCATION OF LABELS..................... 16
LOADING INFORMATION.................. 19
GENERAL INFORMATION................. 22
Meter Instruments ............................ 22
Speedometer, Odometer/Clock,
and Trip Meter: .......................... 23
Speedometer : .............................. 23
Indicator Lights: ............................ 26
Key................................................... 27
Ignition Switch/Steering Lock ........... 28
Right Handlebar Switches................ 29
Engine Stop Switch: ..................... 29
Starter Button: .............................. 30
Left Handlebar Switches .................. 31
Dimmer Switch: ............................ 31
Turn Signal Switch:....................... 31
Horn Button: ................................. 31
Fuel Tank Cap .................................. 32
Fuel Tank ......................................... 33
Fuel Requirement: ........................ 34
Fuel Tap ........................................... 37
Stand................................................ 38
Helmet Hook .................................... 39
Tool Kit Case/Tool Kit ....................... 40
Side Cover ....................................... 41
Seat.................................................. 43
BREAK-IN ........................................... 44
HOW TO RIDE THE MOTORCYCLE .46
Starting the Engine .......................... 46
Jump Starting................................... 50
Moving Off........................................ 52
Shifting Gears .................................. 53
Braking............................................. 55
Stopping the Engine......................... 56
Stopping the Motorcycle in an
Emergency ................................... 57
Parking............................................. 58
SAFE OPERATION............................. 59
Safe Riding Technique ..................... 59
Daily Safety Checks ......................... 61
Additional Considerations for Off
Road Operation ............................ 63
MAINTENANCE AND ADJUSTMENT 64
Periodic Maintenance Chart............. 69
Engine Oil ........................................ 80
Spark Plugs...................................... 85
Valve Clearance ............................... 87
Air Cleaner ....................................... 87
Throttle Grip ..................................... 91
Carburetors ...................................... 94
Clutch............................................... 95
Drive Chain ...................................... 98
Brakes.............................................. 103
Brake Light Switches........................ 108
Rear Shock Absorber....................... 110
Wheels ............................................. 112
Battery.............................................. 115
Headlight Beam................................ 117
Fuses ............................................... 119
General Lubrication.......................... 121
Cleaning Your Motorcycle ................ 122
Bolt and Nut Tightening.................... 127
STORAGE........................................... 129
TROUBLESHOOTING GUIDE............ 133
OWNER SATISFACTION .................... 134
REPORTING SAFETY DEFECTS ...... 136
ENVIRONMENTAL PROTECTION..... 1 37
MAINTENANCE RECORD ................. 138
LABEL INFORMATION ...................... 143
8 SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS
Overall Length 2 080 mm (81.89 in.)
Overall Width 780 mm (30.71 in.)
Overall Height 1 190 mm (46.85 in.)
Wheelbase
1 375 mm (54.13 in.)
Road Clearance 270 mm (10.63 in.)
CurbMass 128kg(282lb)
ENGINE
Type
DOHC, single-cylinder, 4-stroke, air-cooled
Displacement
249cm³(15.2cuin.)
Bore x Stroke 72.0 × 61.2 mm (2.83 × 2.41 in.)
Compression Ratio
9.3 : 1
Starting System
Electric starter
Carburetors MIKUNI BST34
Ignition System CDI
SPECIFICATIONS 9
Ignition Timing
(Electronically advanced)
10° BTDC @1 300 r/min (rpm) 30° BTDC @5 750
r/min (rpm)
Spark Plugs NGK CR8E or ND U24 ESR-N
Lubrication System Forced lubrication (wet sump)
Engine Oil
Type:
API SE, SF or SG
API SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
Capacity:
1.5 L (1.6 US qt)
TRANSMISSION
Transmission Type
6-speed, return shift
Clutch Type
Wet, multi disc
Driving System Chain drive
Primary Reduction Ratio
2.800 (84/30)
Final Reduction Ratio
3.071 (43/14)
Overall Drive Ratio 7.326 (Top gear)
10 SPECIFICATIONS
Gear Ratio
1st
3.090 (34/11)
2nd
2.125 (34/16)
3rd
1.500 (27/18)
4th
1.148 (31/27)
5th
0.962 (25/26)
6th
0.852 (23/27)
FRAME
Castor 28°
Trail
107 mm (4.21 in.)
Tire Size:
Front 2.75-21 45P
Rear
4.10-18 59P
Rim Size:
Front 21 × 1.60
Rear
18 × 2.15
Fuel Tank Capacity 9.0 L (2.38 US gal)
SPECIFICATIONS 11
ELECTRICAL EQUIPMENT
Battery 12V6Ah
Headlight
12 V 60/55 W
Tail/Brake Light 12 V 5/21 W
Specifications subject to change without notice.
12 SERIAL NUMBER LOCATIONS
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 event of theft, the investigating authorities will require both numbers
as well as the model type and any peculiar features of your machine that can help
them identify it.
Frame No.
A. Frame Number
Engine No.
A. Engine Number
LOCATION OF PARTS 13
LOCATION OF PARTS
1. Clutch Lever
2. Meter Instruments
3. Choke Knob
4. Brake Fluid Reservoir (Front)
5. Front Brake Lever
6. Left Handlebar Switches
7. Ignition Switch/Steering Lock
8. Right Hand lebar Switch es
9. Throttle Grip
14 LOCATION OF PARTS
10. Front Fork
11. Headlight
12. Turn Signal Light
13. Fuel Tank Cap
14. Fuel Tank
15. Fuel Tap
16. Rear Shock Absorber
17. Battery
18. Helmet Hook
19. Tool Kit Case/Tool Kit
20. Brake Disc
21. Brake C aliper
22. Shift Pedal
23. Idle Adjusting Screw
24. Side Co ver
25. Side Stan d
26. Drive Chain
LOCATION OF PARTS 15
27. Tail/Brake Light
28. Muffler
29. Air Cleaner El ement
30. Seat
31. Front Brake Light
Switch
32. Brake Flu id Reserv oir
(Rear)
33. Rear Brake Light
Switch
34. Rear Brake Pedal
35. Oil Level Gauge
36. Carburetor
16 LOCATION OF LABELS
LOCATION OF LABELS
1. Important Break-In Instructions
2. Tire and Load D ata
3. Important Drive Chain Information
4. Vehicle Emission Control Information
5. Daily Safety Checks
(For further information of label,
refer to the “L ABEL INFORMATION”
chapter.)
LOCATION OF LABELS 17
6. Battery Poison/Danger
7. Engine Oil and Oil Filte r
8. Brake Fluid (Rear)
9. Brake Fluid (Front)
(For further information of label,
refer to the “LABEL INFORMATION”
chapter.)
18 LOCATIO N OF LABELS
10. Noise Emission Co ntrol I nfo rmation
11. Weight and Manufacture
(For further information of label,
refer to the “L ABEL INFORMATION”
chapter.)
LOADING INFORMAT ION 19
LOADING INFORMATION
WARNING
Incorrect loading, improper in-
stallation or use of accessories,
or modification of your motorcy-
cle may result in an unsafe rid-
ing condition. Before you ride
the motorcycle, make sure that
the motorcycle is not overloaded
and that you have followed these
instructions.
With the exception of genuine
Kawasaki Parts and Accessories,
Kawasaki has no control over the
design or application of accessories.
In some cases, improper installation
or use of accessories, or motorcycle
modification, will void the motorcycle
warranty. In selecting and using acces-
sories, and in loadin g the m otorcycle,
you are personally responsible for your
own safety and the safety of other per-
sons involved.
NOTE
ż
Kawasaki Parts and Accessories
have been specially designed for
use on Kawasaki motorcy cles. We
strongly recommend that all parts
and accessories you add to your
motorcycle be genuine Kawasaki
components.
Because a motorcycle is sensitive to
changes in weight and aerodynamic
forces, you must take extreme care
in carrying cargo, passengers and/or
in the fitting of additional accessories.
/