Kawasaki 3 de/ (te 17 ii Fei BAYOU 4X4 MT All Teresi Vehicle Owner’s Manual Read thiWhenever you see the symbols shown below, heed their instructions! Always follow safe operating and saainterance practices. HAZARD Failure to heed WARNINGS. WHAT CAN HAPPEN WARNINGS identify special instructions or proce- dures which, if not correctly followed, could result in Personal injury, of loss of life. HOW TO AVOID THE HAZARD Read all WARNINGS in this manual carefully and for our sefety be sure to follow the CAUTION | This caution symbol identities special instructions or Procedures which, if not strictly observed, could result In damage 10 of destruction of equipment. NOTE This note symbol indicates points of particular interest for more efficient and convenient operatior., IMPORTANT Off-road vehicle riding is 8 wonderful sport, and we hope you will enjoy it to the fullest, Read this manual carefully and completely before starting your new Kawasaki. It contains important safety information, Never operate an ATV without proper instruction, ‘Take a training course. Beginners should receive training from a certified instructor. Contact an authorized ATV. dealer or call 1-800-447-4700 to find out about the taining courses nearest you, Never allow a child under the age of 16 years to oper: ate this ATV. Use of this ATV by children under 16 years of age can lead to severe injury or death of the child. Even youths starting at age 16 may not have the skills, abilities, or judgement needed to operate this ATV safely. ‘Therefore youths starting at age 16 should have edult supervision even after they attend a rider training course. ‘And parents should never allow continued use of this ATV if the youth does not have the abilities and matu- rity to operate it safely. Failure to follow the warnings contained in this ‘manual can result in SERIOUS INJURY or DEATH. To protect the future of your sport, make sure you luse_-youir vehicle legally, show concoen for the environ: ment, and respect the rights of other people. IW improperly conducted, the sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road vehicle will ensure that these problems and conflicts do not occur,SAFE RIDING INFORMATION AN ATV IS NOT A TOY AND GAN BE HAZARDOUS TO OPERATE. An ATV hanes lfferently from other vehi- ‘les including motoreycies and cars. A collision or rollover can occur quickly, even during routine maneuvers such as {turning and driving on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result it you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described. ‘The Owner's Manual should be kept in the waterproof plastic bag andl stored in the compartment provided. Never operate an ATV without propar instruction, raining course. Beginners should receive training from a cerrified instructor. Contact an authorized ATV dealer or cali 1-800-447-4700 to find out about the training courses newest you, Never allow a ehildl under age 16 t0 operate this ATV. Never carry a passenger on an ATV. Never operate an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets Never operate an ATV an any public street, road or highway, even # dirt or gravel ane, Never operate an ATV without wearing an apjoroved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, ane lang pants, ‘Never consume alcoho! or drugs before or while operating this ATV. Alcohol and drugs impair your judgement and reaction time, Before starting: put transmission in neutral and check the throttle control for propur operation. Remember to apply the parking brake before getting off your ATV. oNever operate at excessive speedis. Always go at a speed that (s proper for the terrain, visibility and operating eondi- tions, and your experience, ‘Never attempt wheelies, iumns. or other stunts. ‘Aivays inspect your ATV each time you Use it to make sure itis in safe operating condi inspection and maintenance procedures and schedules described in this manual, ‘Always keep both hands on the handlebars and both foot on the foothegs of the ATV during operatios Always go slowly and be extra careful when operating on unfamiliar terrain, Always be alert to changing terrain conditions when operating the ATV. ‘Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary © contro! the ATV on such terrain. Always be especially cautious on these kinds of te - Always follow the‘Always follow proper procedures for turning as deseribed jn this manual. Practice turning at low speede butane attempting to turn at faster speeds. Do not turn at excessive spaed. ‘Newer operate the ATV on hills too steep tor the ATV or for your abilities, Practice on smaller nills bofore attempting larger hills. Always follow proper procedures for climbing hills as described in this manual, Check the terrain carefully before you start up any hill, Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Newer open the throttle suddenly or make sudden gear changes, Never go aver the top of any hill x high spead, ‘Always follow proper procedures far going down hills and for braking on hills as described jn this manual, Check the {utrain carefully before you start down any hill. Shift your weight backward. Never go down 9 hill at high spoed, voi going down a hill at an angle that would cause the vehicle to lean sharply to one side, Go straight down the hil whore possible, ‘Always follow proper procedures for crossing the side of a hill as described in this manual, Avoid hills with exces sively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique deseribed in this manual on level ground, Avoid crossing the side of a steep hill f possible ‘Always use proper procrdures if you stall or roll backwards wien limbing @ hill. To avoid stalling, vse proper gear ‘and maintain a steady speed when climbing a hill. If you stall or roll backwards, fallow the speciol procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill, Turn the ATW around and remount, following the procedure described in this manval. ‘Always check for obstacles before operating in a new area, Never attempt to-operste over large obstacles, such as large rocks or fallon trees. Always follow proper procedures when operating over obstacles as described in this manual Always be careful when skidding oF sliding. Learn to sately control skidding or slicing by practicing at low speed aint fn Jevel, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control ‘Newer operate an ATV in fast flowing water ar in water deeper than that specified in this manual, Remember that wot brakes may have reduced stonping ability. Test your brakes after leaving water. If necessary, apply them soveral times to let friction dey out the linings, ‘Always be sure there are no obstacles or people behind you when you operate in reverse, Whenit is safe to proceod in reverse, go slowly. ‘Always use the size and type tires specifind in this manual, Always maintain proper tire prossure es described in this ‘anual. Type of tire and inflation can affvet vehicle handling, ‘A tira pressure gauge is provided in the tool kit container. Keep it with the vehicle at all times.‘Never modify an ATV through Improper installation or use of accessories, Installation of acctssory items may affect vehicle handling, Refer to the Loading Information chapter in this manual, ‘Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo oF pulling a trailer, Allow greater distance for braking. Preserve the environment, ride responsibly and always know and bey laws and regulations governing ATV operation. Refueling: Shut engine off and make sure the area is well ventilated and free from ary source oF flame of sparks, Use an antenna flag in hilly terrain and sand dune areas FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumor Product Safety Commission at 1-800-638- 2772, or the ATV Distributors” Safety Hotline ot 1-800.852.5344,PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do Not remove these systems, of alter them in any way which results in an increase in noise levelFOREWORD Congratulations on your choice of a new Kawasaki KLF. It is the result of Kawasaki engineering expertise and a tradition of manufacturing high-quality recreational products, Please read this manual carefully before starting your new vehicle, Be sure you understand its con- trols, capabilities, limitations, and proper operating procedures, Observe the maintenance require- ‘ments listed in this book as well. More detailed service information is contained in the service manual for this model, which is avail- able from Kawasaki dealers, KAWASAKI HEAVY INDUSTRIES, LTD. CONSUMER PRODUCTS & COMPONENTS GROUP All tights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Kawasaki Heavy Industries, Ltd., Consumer Products & Components Group. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete ‘and accurate as possible. All procedures and specifications subject to change without prior notice or obligation. lus: ‘rationsin this publication are intended for reference use only and may not depict actual model component parts. © Kawasaki Heavy Industries, Ltd, 1992 June. 1992. (2). (S)WARNINGS indicate a potential hazard that could result in personal injury or death. Specifications... sesams a aren HO Serial Number Locations. 213 Location of Labels. Location of Parts Loading Information . General Information . ‘Auxillary Headlight Terminals 23 Auxiliary Electrical Accessory Terminals 24 Brake Lever Lock (Parking Brake) 25 Brake Levers and Pedal. . - 25 Choke Lever. oo... 02 cee cece eee 228 Compression Releasing Lever... .... 2... 28 Front and Rear Racks 29 Fuel Gauge. coos 30 Fuel Tank 222 30 Fuel Tap . ‘ 32 Ignition Switch . eset RS Indicator Lights. 34 Left Handlebar Switches sneaa es oS Light/Dimmer Switch 35 mmm TABLE OF CONTENTS swensnnninnmnnin Engine Stop Switch cee 35 Starter Button 35 Recoil Starter... 2... cee 36 Reverse Knob 136 BRE careers va oe ten : ShifePedal eee eee eel 88 Sub-transmission Shift Lever fee 39 Throttle Lever . Throttle Limiter Tool Kit . Trunk . Trailer Hitch Bracket . Breakin How to Ride... Daily Safety Checks, Starting the Engine Moving Off. . Shifting Gears. Braking Stopping the Engine,Stopping the KLF in an Emergency « Safe Oper Read the Owner's Manual Obey Local Laws, Adult Supervision Beginning Riders Off-Road Use Only Dress Properly Operator Only... os Ride Carefully and with Good Judgement Never Drink and Drive eet Keep Your Feet on the Pegs and Hands on the Handlebars Before Starting the Engine . . Use she Parking Brake . Modifications and Accessories Loading Your ATV... Beer she Day Set Checks Tire Air Pressure , Riding Terrain Riding in Reverse ‘Turning the Vehict Climaing Hills, Antenna Flag . Traversing Hillsides Descending Hills... Sliding and Skidding - Riding in Water... . Maintenance and Adjustment. Periodic Maintenance Chart Engine Oil . te Front and Rear Final Gear Case Oil, Spark Plug ve Valve Clearance Air Cleaner. . Spark Arrester Throttle Cable Reverse Cable Carburetor. . Clutch. . Brakes. Wheels Joint Boots . Suspension. Battery Fuse : Fuel System. Fuel Tank Vent, Headlight Beam... General Lubrication. . Cleaning § Bolt and Nut Tightening... Storage... . : Transporting the KLF Troubleshooting Gui Owner SatisfactionPERFORMANCE ‘Maximum Torque Minimum Turning Radius DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Clearance Dry Weight ENGINE 10 Type Displacement Bore x Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing (Electronically advanced) SPECIFICATIONS sre 23.5 N-m (2.4 kg-m, 17.4 ft-1b) @5,500 r/min (rpm) 2.9m (95 ft) 1,860 mm (73.23 in.) 1,120 mm (44.09 in.) 1,105 mm (43.50 in.) 1,200 mm (47.24 in.) 844 mm (33.2 in.) ‘860 mm (33.86 in.) 225 mm (8.86 in.) 260 kg (573 Ib) SOHC single cylinder, 4-stroke 290 mL (17.7 cu in.) 76.0 x 64.0 mm (2.99 x 2.52 in.) 86:1 Electric and recoil starter Keihin CVK32 Battery and coil (Transistorized ignition) 10° BTDC @1,300 r/min (rpm) ~ 30° BTDC 4,000 r/min (rpm)Spark Plug Lubrication System Engine Engine Oil Capacity TRANSMISSION Transmission Type Clutch Type: Primary Secondary Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio (Top gear) Gear Ratio: 1st 2nd 3rd 4th Sth Reverse Front Final Gear Case Oil Rear Final Gear Case Oil Front Final Gear Case Oil Capacity Rear Final Gear Case Oil Capacity NGK D8EA © NGK DRBES-L Forced lubrication (wet sump) SE or SF class 10W30, 10W40, 10W50, 20W40, or 20W50 2.2L (2.3 US qt) 10-speed plus reverse, constant mesh, return shift Automatic, centrifugal, wet Automatic, multi disc, wet Shaft drive, 4WD 2.888 (78/27) 6.910 (37/29 x 20/16 x 39/9)(High) 5.416 (33/33 x 20/16 x 39/9)(Low) 18.387 (High) 12.037 (Low) 3.090 (34/11) 1.928 (27/14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) API GL-5 for LSD, SAE 140 or SAE 85 W-140 APIGL-5 SAE 90 [above 5°C (41°F)] SAE 80 [below 5°C (41°F)] 0.25 L (0.26 US qt) 0.3 L (0.32 US qt) "FRAME Type Caster Trail Tire Size: Front Rear Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Taillight © : Canadian Model 12 Tubular, double cradle r 5mm (0.2 in.) AT24 x 8-11 Tubeless. AT24 x 10-11 Tubeless 11.0 L (2.9 US gal) 12V 14Ah 12 V 25/25 W x2 12VEWx2 Specifications subject to change without notice,The engine and frame serial numbers are used to register the vehicle, 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. A. Frame Number ‘A. Engine Number B» LOCATION OF LABELS ing labels which are on your ATV are re: Peated here, Read them and understand them thor- oughly. They contain information which is important for your safety and the safety of anyone else who may ‘operate your ATV, Therafare, it ie very important that all warning labels be on your ATV in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct position, NOTE ©The sample warning labels in this section have part ‘numbers to help you and your desler obtain the ‘conect replacement, Front Rack (Carrier) Maximum Load . Shift Pattern General Warning ‘Age Recommendation Warning Storage/Transportation Warning 3. Rear Rack (Carrier) Maximum Load Battery Vent Hose Routing 3. Overloading Warning, 1. Passenger Warning ). Tire Pressure Warning Seesogsene “4AWARNING ‘TMS. VENICLE CAN OE HAZARDOUS TO OPERATE oftion raver ca areas missy oor a SEVERE RUURY OR DEATH can rast # yu ot SEFORE YOU OPERATE THIS Ary, READ THE ‘vnens" Manat AN "ALL CAEL INSTRUCTION. Boghmte should nel on ye Spee Ble RIV on faster EVER OmEATE TES AY ru ADS, NEVER, CONSIME ALCOWO. On HUGS Oe AOERLOFRATE ns Ary AT EES Ist. by condone your oupeence Sen ATTEIT EELS, Nes, OF BONO ase ® ZNSE) ‘persia te ATV 4 you we nde tenor ot 16 meat yar Srace NEVER oso te ATV ¥ yo ae thom oe 16 pe0ag 276 ® Rising as a passenger can cause the ATV 10 90 abt of contol Loss of contol ean cause a caltson er rollover, which ean NEVER rie as 8 passer 816 ® OI FRONT: 035 nation 15 ‘36040.1257 ~ s6080-756 Ta PATTERN] 360801362 DM —— MAXIMUM LOAD: 92497010) | MAXIMUM LOAD:63k9(1401bs) OI oD ® ‘ATE eT HOSE RONG 56081-1607LOCATION OF PARTS ear Brake Lever (Parking Brake) Brake Lever Lock Ignition Switch Reverse Knob Front Brake Fluid Reservoir Front Brake Lever Light/Dimmer Switeh . Starter Button . Engine Stop Switch ). Choke Lever |. Fuel Gauge . Indicator Lights . Throttle Limiter Throttle Lever v75. Hes . Front Rack lights Shock Absorber Fuel Tank Cap Fuel Tank 1. Fuel Tap |. Carburetor Air Cleaner |. Battery Fuse Seat Lever Fear Rack Front Final Gear Case |. Disc Brake Caliper 9. Sub-transmission Shift Lever Shift Pedal |. Recoil Starter . Rear Final Gear CaseTaillights Trunk 5. Tool Kit . Spark Plug . Compression Releasing Lever . Muffler (Spark Arrester) . Trailer Hitch Bracket |. Brake Lining Wear Indicator Oil Filler Cap Clutch Release Adjusting ‘Screw Oil Level Gauge Rear Brake Pedal 5. Oil Filter 9AWARNING WARNINGS indicate a potential hazard that could resul in personal injury or death, LOADING AWARNING HAZARD. Operating this ATV with improper modifications, WHAT CAN HAPPEN Improper installation of accessories or modification Of this vehicle may cause changes in handling which could lead to an accident, HOW TO AVOID THE HAZARD Nover modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Kawasaki or equiva- lent components designed for use on this ATV and. should be installed and used according to instruc. tions. If you have questions, consult an authorized ATV dealer, INFORMATION AWARNING HAZARD. Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN, Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached, Reduce speed when carrying eargo or pulling a trailer Allows greater distance for braking. Always follow the instructions provided in this section for carrying cargo or pulling a trailer. 20With the exception of genuine Kawasaki Parts and Accesscries, Kawasaki has no control over the design or application of accessories. In some cases, improper installation or use of accessories, or vehicle modifica- tions, will void the vehicle warranty, In selecting and Using aocessories, and in loading the vehicle, you are personally responsible for your own safety and the safety of other persons involved, NOTE Kawasaki Parts and Accessories have been specially ‘designed for use on Kawasoki vehicles. We strongly recommend that all parts and accessories you add to vyour vehicle be genuine Kawasaki components. Because an all terrain vehicle is sensitive to increases weight, changes in weight distribution, and aerady ‘namic forces, you must take extreme care in carrying cargo and/or in the fitting of accessories. The following general quidelines have been prepared to help you make ‘your determinations, ‘@When adding cargo and pulling a trailer reduce speed. Braking distance is increased. Use extreme caution when climbing and descending hills, and traversing slopes. Adding cargo and pulling a trailer can make the vehicle difficult to steor and affect vehicle handling in an unpredictable manner. All cargo should he carried a: low as possible to reduce the effect on the vehicle’s center of gravity. Cargo weight should also be equally distributed from side to side, Place cargo to the rear of a front rack end to the front of a rear rack. This helps maintain the stabi of the vehicle by centralizing the weight, Avoid car ‘ying cargo that extends beyond the rear of the vehicle, Do not place more than 32 kg (70 Ib) on the front rack, nor more than 63 kg (140 Ib) on the rear rack. If non-standard racks are fitted, never exceed the rack ‘manufacturer's stated load capacity. In any caso, ‘never exceed the limits stated above. Try to maintain front to rear balance by carrying twice as much weight ‘on the rear rack as on the front rack, Cargo should be securely attached, Make sure the ‘cargo will not move around while you are riding. Recheck cargo security as often as possible (not while the vehicle isin motion) and adjust as necessary. ®Do not carry heavy or bulky items even on a cargo rack, They are designed for light items, and over loading can affect handling due to changes in weight distribution and aerodynamic forces. Do not install accessories or carry cargo that impairs ‘the performance of the vehicle, Make sure that you hhave not adversely affected any lighting component, round clearance, brake or control operation, wheel ‘movement, or any other aspoct of the vehicle’s opera: tion. Always subtract trailer tongue weight from the Max: imum Load capacity. Refer to the GENERAL IN. FORMATION chapter for details on the trailer hitch bracket. a‘©Weight attached to the handlebar will increase the mass of the steering assembly and can result in an unsafe riding condition ‘Windshields, trunk boxes, and other large items have the capability of adversely affecting stability and handling of the vehicle, because of their weight and the ‘aerodynamic forces acting on these surfaces while the vehicle is in operation. Poorly designed oF installed items can result in an unsafe riding condition, Maximum Load Weight of rider and cargo must not exceed 195 kg (430 1b), 2Auxiliary Headlight Terminals The auxiliary headlight terminals aré located near the steering stem. Connect only the auxiliary headlight for the KLF3O0C to these terminals. The light switch also ‘operates the auxiliary headlight, Connect any other accessory light to the auxiliary electrical accessory terminals shown in the next section, ‘A. Auxiliary Headlight Terminals wm GENERAL INFORMATION CAUTION Do not connect any light other than the auxiliary headlight for the KLF300C, or the battery may become discharged quickly.Auxiliary Electrical Accessory Terminals ‘The auxiliary electrical accessory terminals are located under the seat. Connect electrical accessories to those terminals, A. Electrical Accessory Leads CAUTION Do not connect more than @ 20W load to the auxil- iaty electrical accessory terminals when the auxiliary headlight for KLF300C is connected to the auxiliary headlight terminals, and do not connect more than an ‘85W load to these terminals when no light is con- ected to the auxiliary headlight terminals, or the bbattery may become discharged quickly. Always install a fuse rated 15A or less in the auxiliary electric accessory circuit. The KLF has only one fuse (BOA) to protect the entire electrical system. If this fuse fails, the ignition will not function,Brake Lever Lock (Parking Brake) If the brake lever lock is used, the rear brake lever can bbe used as @ parking brake. To lock the brake lever, first pull in the brake lever. Then pull in the lock lever and while holding it against ‘the brake lever, release the brake lever. When applied correctly the lock lever will contact @ projection on the brake lever holder and prevent the brake lever from returning to the off position, To unlock the brake lever, pull further and release it, the brake lever A. Lock Lever Brake Lavers and Pedal ‘The lever on the right side of the handlebar operates the front brake, A. Brake Lever ‘The lever on the left side of the handlebar operates ‘the rear brake, and it can be used for a parking brake by using the brake lever lock at the brake lever (see Brake Lever Lock). 2526 ‘The foot pedal on the right side also operates the rear brake, ‘A. Brake Pedal On this 4WD ATV, all wheels (front and rear) are constantly driven by the drive train, This means that applying either the front brake (the right-hand brake lever) or the rear brake (the leftchand brake lever or the brake pedal) brakes both the front and rear wheels, Any brake application will brake the downhill wheels ‘when climbing or descending hills, So, avoid sudden application of either the front or rear brakes. Apply both front and rear brakes gradually. Refer to the How To Ride and Safe Operation chapters for more instructions on braking.AWARNING HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill, WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill, If you lose all forward spe ‘Keep weight uphill ‘Apply the brakes. Lock parking brake, after you are stopped, |f you begin rolling backwards ‘Keep weight uphill Newer apply either front or rear brakes suddenly while rolling backwards, Apply both front and rear brakes gradually. When fully stopped, lock parking brake, Dismount on uphill side or to a side if pointed straight uphi Turn the ATV around and remount, following the procedure described in the Safe Operation chapter. PaChoke Lever Compression Releasing Lever ‘The choke lever on the left handlebar provides a rich The compression releasing lever is located on the mixture for cold starting conditions, Upper right side of the engin Pull the choke lever all the way to the left to start the Pull up the lever first for easy cranking engine. Warm the engine up by operating the choke recoil starter is pulled up to start the engine. lover and throttle until the idle speed is stable, then push ‘the choke lever all the way back to the right. NOTE Mf the choke is left on {lever to the left) too long after the engine has warmed up, it will cause spark plug fouling and poor fuel economy. ‘A. Comprassion Releasing Lever A. Choke Lever 28Front and Rear Racks This vehicle is equipped with racks on the front and rear. HAZARD. Overloading front and rear racks or carrying cargo improperly. WHAT CAN HAPPEN. Gould cause changes in vehicle handling which could lead toan accident, HOW TO AVOID THE HAZARD. Nover exceed the stated load capacity for each rack, Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo. Allow greater distanee for braking. Always follow the instructions in your Owner's Manual for carrying cargo. Maximum Load (Rack) 32 kg (70 1 63 kg (140 ib) Vehicle Maximum Load ‘Weight of rider and cargo must not exceed 195 kg (430 1b) ‘A. Front Rack B, Rear RackAWARNING WARNINGS indicate a potential hazard that could result in personal injury or death, Fuel Gauge Fuel Tank ‘The fuel gauge shows the amount of fuel in the fuel The following octane rating gasoline is recommended tank, When the needle comes near the Elempty) posi- in the fuel tank, Avoid filling the tank in the rain or tion, refuel at the earliest opportunity. where heavy dust is blowing so that the fuel does not get contaminated, A. Fuel Tank A. Fuel Gauge 30AWARNING HAZARD Refueling without following proper precautions, WHAT CAN HAPPEN Gasoline is extremely flammable and can be explosive under certain conditions. A fire or explosion can cause severe injury or death. HOW TO AVOID THE HAZARD When refueling, do not smoke, Turn the ignition switch OFF. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. ‘Never fill the tank completely to the top! Heat may cause the fuel to expand and overflow through the vent in the tank cap, After refueling, make sure the tank cap is closed securely. If gascline is spilled on the fuel tank, wipe it off immediately. Fuel Requirement: Octane Rating The octane rating of a gasoline is a measure of its resistance to detonation or “knocking.” Use a gasoline with an octane rating equal to or higher than that shown in the table below, Tinian Octane Rating Method hare a Anuknock index BONSHONT Tg [Resa Ocae NON) a The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON). The Antiknock Index is posted on service station pumps in the U.S.A, Research Octane Number is ® commonly used term describing @ gasoline’s octane rating, 3Gasoline and Alcohol Blends Blends of gasoline and alcohol called “gasohol” can be used on an occasional basis, however continued use is not recommended, Switch back immediately to gasoline ‘which does not contain alcohol if you experience any operating irregularities, Any deterioration of fuel system components or degradation of performance resuliing from the use of gasohol will not be covered by imited Warranty, Emissions Warranties, or Good Times Protection Plan, If you decide to use gasohol, be sure to follow these simple cautions: CAUTION ‘Never use gatohol with an octane rating lower than the minimum octane rating specified by Kawasaki for thisproduct. [Never use gasohol containing more than 10% ethanol (orzin alcohol). "Never use gasohol containing more than 5% methanol (wood alcohol). Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors. Never use gasohol for extended periods and never store this product with gasohol in the fuel system. Gasoline containing alcohol can cause paint damage. Be extra careful not to spill soho! during refueling. 32 Fuel Tap ‘The fuel tap has three positions: OFF, ON, and RES (reserve). If the fuel runs out with the tap in the ON position, the last 2.0 L (0.83 US gal) of fuel can be used by turning the tap to RES, When transporting or storing the vehicle, turn the tap OFF. A. Fuel Tap. ©. OFF position B. RES position D. ON position NOTE Since riding distance is limited when on RES, refuel at the earliest opportunity. ‘Make cortain that the fuel tap is turned to ON (Not RES), after filing the fuel tank.AWARNING HAZARD. Looking at fuel tap while riding. WHAT CAN HAPPEN Can cause loss of control and result in injury or death. ‘HOW TO AVOID THE HAZARD. Practice operating the fuel tap with the vehicle stopped. To prevent an accident you should be able to operate the fuel tap while riding without taking your eves off the terrain, AWARNING HAZARD Hot engine. WHATCAN HAPPEN, Can burn your hand, HOW TO AVOID THE HAZARD Be careful not to touch the hot engine while oper- ating the fuel tap. Ignition Switch ‘The ignition switch is mounted in the center of the handlebar in the plastic cover. It is a 2-pasition, key: ‘operated switch. The key can be removed only when in an "OFF" position, The lights, ignition, and electric starter will operate only when the key is in the “ON Position. Remove the key to prevent unauthorized vehicle use ‘A. Ignition Switch B. ON position ©. OFF positionBlank Keys are available at your Kawasaki dealer. ‘Ask your dealer to make any additional spare keys you may need, using your original key a8 a master. NOTE Only blank keys are available, ) wi ‘your key number here, Indicator Lights ‘The indicator lights are next to the ignition switch, NEUTRAL: When the transmission is in neutral, the neutral indicator light is lit, REVERSE: When the transmission is in reverse gear, the reverse indicator light is lit ‘A, Noutral Indicator Light B. Reverse Indicator LightLeft Handlebar Switches Light/Dimmer Switch ‘The switch positions are identified on the housing, Headlight, taillight, and an auxiliary heedlight come on by turning the switch to LO {low beam) or HI {high beam) with the ignition key in the ON position, Select high or low beam as necessary, A, LightyDimmer Switch B. Engine Stop Switch . Starter Button Engine Stop Switch In addition to the ignition switch, the engine stop switch must be in the “RUN” position for the engine to operate. If some emergency requires stopping the engine, turn the engine stop switch to the “OFF” position, Although the engine stop switch stops the engine, it does not turn off all the electrical circuits. If the engine stop switch is used, be sure to turn off the ignition switch after stopping the vehicle, Starter Button Refer to the Starting the Engine section of the “How to Ride” chapter for starting instructions, To start the engine, push the starter button with the transmission in neutral NOTE ©For the electric starter to operate, the engine stop switch must be set to the “RUN” position, the ignition switch must be turned to the “ON” position, and the transmission must be in neutralRecoil Starter Refer to the Starting the Engine section of the “How to Ride" chapter for starting instructions. ‘The recoil starter is located on the left side of the engine. Always be sure the transmission is shifted into ‘neutral before starting the engine, Pull up the compres- sion releasing lever, then pull the handle all the way up vigorously to start the engine, A. Recoil Starter NOTE ln order for the engine to run, the engine stop switch ‘must be set to the “RUN” position and the ignition switch must be turned to the “ON” position. 36 Reverse Knob This vehicle is equipped with 2 reverse 9% reverse knob is located next to the ignition switch, To shift into reverse follow this procedure: 1, Start the engine following the procedure in the “Starting the Engine” section, 2, Make cortain the vehicle is completely stopped, the transmission is in neutral, and the engine is idling 3, Turn the reverse knob clockwise and press down the shift pedal into reverse gear. Rolease the reverse knob and shift pedal. . The vehicle can now be operated in reverse To shift out of reverse follow this procedure: Stop the vehicle completely. _ Lift the shift pedal up to neutral, The A, Reverse KnobAWARNING HAZARD, Shifting into 1st gear while moving in reverse, WHAT CAN HAPPEN Can cause the vehicle to stop suddenly and go for- ward. This can lift the front wheels off the ground and cause the operator to lore control, Or the vehicle can tip over backwards causing an accident. HOW TO AVOID THE HAZARD Never operate the shift pedal to change gears while tho vehicle is moving in reverse. AWARNING HAZARD, Improporly operating in reverse, WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury or death. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind you, When it is safe 10 proceed, go slowly. Seat To remove the seat, pull the seat lever up and lift the seat up to the rear. ‘The seat lever is located on the left side of the seat. 37Shift Pedal ‘The transmission is a S.speed return shift type with reverse. Neutral is located between first gear and reverse seat as shown. ‘A. Shift Pedal A “return shift” means that to go back to first gear from a higher gear, you must shift back through the gears one by one. “The samo is true when upshifting: each gear must be engaged before the next higher ‘gear may be selected, 38 To engage first gear from neutral (indicated by the neutral indicator light), lift up on the shift pedal then release the shift pedal. Do likewise to shift into the next higher gear To shift to the next lower gear, press down on the shift pedal and release the shift pedal. Before shifting into reverse, put the transmission in neutral. Then turn the reverse knob clockwise and press the shift pedal into reverse gear. Release the reverse knob and shift pedal. Refer to the “Reverse Knob” seetion for detailed instructions, If the engine is stopped, rolling the vehicle slightly while shifting will help shifting back to neutral. When the transmission is in neutral, the neutral indicator light is tt, CAUTION When changing gears, press firmly on the shift pedal to ensure complete, positive shifting, Careless, incomplete shifts ean cause the transmission to jump out of gear and lead to engine damage,Sub-transmission Shift Lever This vehicle is equipped with a sub-transmission to allow maximum transmission efficiency. Low gearing ives maximum torque at low speeds for climbing hills, pulling a trailer, or keeping constant low speeds for agricultural use; high gearing raises the speed range for ordinary off road use, To shift into the low range, first push in the knob jn front of the subtransmission’ shift lever, Then while hholding it against the shift lever, move the shift lever all the way rearward to the low range. To shift back into the high range, first push in and hold the knob, then move the shift lever all the wey Forward to the high range, Be sure each line on the lever aligns with the line provided on the shift lever holder. C. Substransmission Shift Lever D. Knob A. Low Range B. High Range The vehicle must be stopped when shifting from one ange to another,Throttle Lever ‘The throttle lever is located on the right side of the hhandlebar. Pushing the lever forward increases engine speed. When released, spring pressure returns the lever to the rear. Always check that the throttle lever returns normally before starting the engine, In addition, there must be adequate throttle cable play, Refer to the MAINTENANCE AND ADJUSTMENT chapter for the throttle cable adjustment procedure, A. Throttle Lever 40 Throttle Limiter The vehicle is equipped with a throttle limiter to decrease maximum engine power for an unskilled rider. ‘The limiter functions by restricting the moving distance Of the throttle lever. AWARNING HAZARD Operating this ATV }out proper instruction, WHAT CAN HAPPEN ‘The risk of an accident is greatly increased if the ‘operator does not know how to operate the ATV properly in different situations and on different types of terrain, HOW TO AVOID THE HAZARD Beginning and inexperienced operators should com- plete the certified training course offered by Kawasaki, They should then regularly practice the skills learned in the course and the operating tech- ‘niques described in the Owner's Manual. For more information about the training course, contact an authorized ATV dealer or call: 1-800-447-4700,AWARNING HAZARD. Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, ‘which can result in an accident, HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your exper Loosin the locknut and turn the screw in or out, Turing in decreases the maximum engine power and turning out increases the maximum engine power. A, Locknut B. Screw CAUTION Tn case the throttle limiter is adjusted, verify the ‘changes in throttle in an open, non-traffic area, Never try to adjust the limiter by racing the engine in neutral or in gear with brake on, or the engine oF clutch may be damaged, alocated under the rear rack, Keep this \wner’s Manual in the trunk, To open the trunk, unhook the rubber bands and ‘move the lid rearward,Trailer Hitch Bracket This vehicle is equipped with a bracket for a trailer hitch, Trailer towing equipment is not supplied with this vekicle. To woid injury and property damage, observe the following precautions: A. Trailer Hitch Bracket AWARNING HAZARD Improperly attaching and loading a trailer. Overloading a trailer. WHAT CAN HAPPEN Gan cause changes in vehicle handling which could lead to an accident, HOW TO AVOID THE HAZARD Attach a trailer to the trailer hitch bracket only. For exemple, attaching a trailer to the grab rail can cause ‘Never load more than 14 kg {30 Ib) tongue weight on the towing bracket. Do not ‘tow more than 317 kg (700 1b) t plus cargo), AWARNING “HAZARD Riding ina tailer, WHAT CAN HAPPEN Can cause the operator to lose control of the vehicle. ‘The passenger can be thrown from the trailer or hurt bby shifting cargo in the trailer, HOW TO AVOID THE HAZARD Never carry a passenger in a trailer. 43The first 10 hours of vehicle operation is designated {a the break-in period, Do not exceed % throttle during breakin period, If the vehicle is not used carefully during this period, you may end up with a “broken dower" instead of “broken in” vehicle, Breakin Period Maximum Throttle Position BREAKAN sorersrsieinneninnaneninnan First 10 hours % Throttle NOTE Do not start moving or race the engine immediately after starting it, even if the engine is already warm. ©Do not race the engine while the transmission is in neutral. ft is important to perform the initial service after the first 10 hours of operation as described in this manual and the service manual for this vehicle. See the Peri- ‘odie Maintenance Chart in the MAINTENANCE AND ADJUSTMENT chapter.PINS NTI e} Daily Safety Checks Check the following items each day before you ride these checks will help ensure you a safe, raliable ride » HOW TO RIDE sir WARNINGS indicate a potential hazard that could result in personal injury or death. ‘The time required is minimal, and habitual performance of 'f any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see Your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition, AWARNING HAZARD. Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARI Always inspect your ATV each time you use it to make sure the ATV isin safe operating condition, Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual AWARNING HAZARD. Exhaust gases are poisonous. WHAT CAN HAPPEN Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death, HOW TO AVOID THE HAZARD Do not start or run the engine in a closed area such as 4 garage. Exhaust gases contain carbon monoxide; @ colorless, odorless, poisonous gas.Fuel. Engine Oil Tiros Air Cleaner Element . . Nuts, Bolts, Fasteners Steering Brakes. . Front/Rear Final Gear Cases . ights . Engine Stop Switch Protective Clothing Enough fuel in tank, no leaks, Oil level between level lines, Air Pressure (when cold): Front 35 kPa (0,36 ka/em®, 5 psi) Rear 28 kPa (0.28 ka/em®, 4 psi) (Check for dirt; clean or replace as required, Check that steering and suspension components, axles, and all controls are properly fastoned, Action smooth but not loose from lock to lock. Control cables must not bind, Brake pedal free play 15 ~ 25 mm (0.6 ~ 1.0 in). Rear brake lever free play 1~ 2 mm (0,04 ~ 0.08 in.) No brake fluid leakage, Brake lining wear: Indicator within “USABLE RANGE.” Parking brake: Stops vehicle completely. ‘Throttle lever free play 2~ 3 mm (0,08 ~ 0.12 in.) ‘Throttle lever snaps back to idle position when released, No oil leakage. Headlight and taillight work, Stops engine. ‘The operator must wear a helmet and eye protection plus suitable protective clothing, such as boots, gloves, long trousers, and a long-sleeved shirt or jacketStarting the Engine AWARNING Running the engine without ventilation, WHATCAN HAPPEN. Breathing exhaust gas leads to carbon monoxide Poisoning, asphyxiation, and death, Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. HOW TO AVOID THE HAZARD Do not start or run the engine in a closed area such as a garage. Tur the fuel tap to the “ON” position, Check that the engine stop switch is in the “RUN' position, (9Turn the ignition switeh on, ‘Apply the parking brake, Make sure the transmission is in neutral, The neutral icator light should be lit. ‘eWhen the engine is cold (same as outside temperature), pull the choke lever all the way to the left, Keep the throttle completely closed. Note 00 not leave the choke lever pulled to the left longer than necessary or the spark plug may foul. When the engine is already warm or the weather is hot (35°C, 95°F or more}, do not use the choke, Leave the ‘throttle closed. Push the starter button or pull up the compression releasing lever and vigorously pull the recoil starter handle all the way up. Repeat until the engine starts. continuously for ‘more than § seconds. 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 battery power recover. Do not let the engine idle longer than five minutes or engine overheating and damage may occu. NOTE Mf the engine is flooded, push the choke lever all the way to the right. Then crank the engine over with the throttle fully open until the engine starts. Close the throttle immediately, a7Moving Off ‘Select the desired sub-transmission range. Lift the shift pedal with your toe to engage 1st gear. ‘©Rekase the parking brake, ©Gredually increase engine speed by pushing forward on ‘the throttle lever. NOTE Practice starting and stopping (using the brakes) until you are familiar with the controls. 48 Shifting Gears ‘®Rolease the throttle. Shift to the next higher or lower gear by pulling up ‘once or pushing down once on the shift pedal, ‘Release the shift pedal. ‘©Push the throttle lever forward part way. AWARNING HAZARD Downshifting at high speods, WHAT CAN HAPPEN. Can cause the rear wheels to slide and the operator to lose balance. The operator may lose control of the vehicle and have an accident. HOW TO AVOID THE HAZARD ‘Slow down before shifting down to a lower gear. Try ‘to match vohicle speed with the corresponding engine spoed of the lower gear before completing the shift, CAUTION When shifting down to a lower gear, do not shift at such a high speed that the engine speed jumps exces- sively. This could cause engine damage. NOTE [Do nat keep your foot an the shift pedal after shitting ‘gears, because the clutch remains disengaged.Braking lose the throttle completely. Shift cown one gear at a time so you are in Ist gear when you come to a complete stop. '*Under most conditions stop by pulling in the front brake lever and pressing down the rear brake pedal, ‘@For emergency braking disregard downshifting, and ‘concentrate on applying the brakes as hard as possible. To stop while riding in reverse, close the throttle and gredually apply the brakes. Sudden application of the front brake or the rear brake can cause the front end of the vehicle to lift off the ground, On this 4WD ATV, all wheels (front and rear) are constantly driven by the drive train. This means that applying either the front brake (the righthand brake lever) of the rear brake (the lefthand brake lever or ‘the brake pedal) brakes both the front and rear wheels, Any brake application will brake the downhill wheels when climbing or descending hills. So, avoid sudden application of either the front or rear brakes. Apply bboth front and rear brakes gradually, Refer to the Climbing Hills and Descending Hills sections in the SAFE OPERATION chapter for the braking and riding techniques you must use when climbing and descending hills, AWARNING HAZARD. Stalling, rolling backwards or improperly dismounting while climbing a hill, WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maint climbing a hill, If you lose all forward speed: Keep weight uphill. Apply the brakes, Lock parking brake, after you are stopped. 1f you begin rolling backwards: Koop weight uphill, Never apply either front or rear brakes suddenly while rolling backwards. Apply both front and rear brakes gradually. When fully stopped, lock parking brak Dismount on uphill side or to a side if pointed straight uphill, Turn the ATV around and remount, following the procedure described in the Safe Operation chapter. steady speed when 49‘Stopping the Engine ©Close the throttle completely, ‘Sh ft the transmission into neutral, ‘© Tum the ignition switch off ‘©Tum the fuel tap to the “OFF” position, 50 Parking the KLF ‘Stop the vehicle on a level surface, AWARNING HAZARD Parking on a steep incline, WHAT CAN HAPPEN May result in the vehicle overturning or rolling down the hill and causing an accident. HOW TO AVOID THE HAZARD. Do not park on steep inclines. If you must park on a l, place the vehicle diagonally so that it never faces uphill, downhill or seourely. ‘When the engine has stopped, shift the transmission into 1st gear. Apply the parking brake to help prevent the vehicle from rolling Remove the ignition switch key to prevent unauthor. ied useIf parking inside a garage or other structure, he sure it is well ventilated and the vehicle is not close to any source of flame or sparks; this includes any appliance with a pilot light. Parking near an appliance with a pilot light. Parking in a structure without ventilation, WHATCAN HAPPEN Gasoline is extremely flammable and can be explosive under certain conditions, ‘A fire or explosion can cause severe injury or death. HOW 70 AVOID THE HAZARD Park the vehicle in a well ventilated area away from, ‘any source of flame or sparks. This includes any appliance with a pilot light, Stopping the KLF in an Emergency ‘Your Kawasaki vehicle has been designed and manu: factured t0 provide you optimum safety and conven- jence. However, in order to fully benefit from Kawasaki's safety engineering and craftmanship, it is essential that you, the owner and operator, properly maintain your vehicle and become thoroughly fami Improper maintenance and insuffi cient riding skills can create a dangerous situation known 45 throttle failure, Two of the most common causes of throttle failure are: 1. During the removal of the air cleaner, dirt is allowed to enter and jam the carburetor. 2. A novice may forget which direction the throttle ‘operates; then push the throttle wide open thinking hhe has shut it off, He may panic when the vehicle accelerates suddenly instead of slowing down; and “freeze,” holding the throttle wide open. In an emergency situation such as throttle failure, Your vehicle may be stopped by turning the engine stop switch to the “OFF” position and applying the brakes, |f the engine stop switch is used, turn off the ignition switch after stopping the vehicle, 51AWARNING WARNINGS indicate a potential hazard that could result in personal i Knowing and following these rules for safe riding will increase your enjoyment af your new Kawasaki ATV and help avert serious injury or death, Refer also to page 2 for "Safe Riding Information.” Read the Owner's Manual ead and understand this Owner's Manual, and carry it with you when you ride, This is especially important for younger riders and beginners, Refer to this Owner's ‘Manual if you have any questions. Obey Local Laws Know and obey all laws and regulations governing the use of off-road vehicles in your riding area, Respect privete property: do not ride there without the express written permission of the owner. Always try to preserve nature and the environment. Adult Supervision This vehicle is not a toy. Its an off-road motor vehi: cle. Use by children under 16 years of age is not rec- ommended, 82 SAFE OPERATION +» Youths starting at age 16 should have adult super vision evon after they attend @ rider training course. Parents must ensure that their child has the skills, abilities and judgement required to operate the ATV safely, Youngsters must continue to develop their riding skills and use proper riding techniques. Parents need 10 monitor their child's progress and make certain their child avoids unsafe situations,Always equip your child with proper protective gear, It is important that your child rides an appropriate sized ATV. Never put your child on a vehicle that requires them to reach to put their feet on the footpegs and their hands on the handlebars, Study this manual with Yyour child to be sure he or she fully understands all of the special safety instructions, AWARNING HAZARD Failure to follow the age recommendations for this ATV. Failure to supervise children 16 years of age and older. WHATCAN HAPPEN Use of this ATV by children under 16 years of age ‘can lead to severe injury or death of the child, Even though a child may be within the age group for which this ATV is recommended, he or she may not hhave the skill, abilities, or judgement needed to ‘operate the ATV safely and may be involved in a serious accident, HOW TO AVOID THE HAZARD A child under 16 should never operate this ATV. Youths starting at age 16 should have adult super vision even after they attond a rider training course. Never allow continued use of this ATV by a child if he or she does not have the a operate it safely. Beginning Riders Beginning riders should practice braking and turning in an open, off-road area away from other riders, The terrain should be flat and free of obstacles with a loote or hard dirt surface, but not a mixture of both, Do not ride on pavement, ATV's are designed for off-road use only. AWARNING HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN, The risk of an accident is greatly increased if the ‘operator does not know how to operate the ATV properly in different situations and on different types of terrain, HOW TO AVOID THE HAZARD. Beginning and inexporienced operators should com- plete the certified training course offered by Ka saki, They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual, For more information about the training course, contact an authorized ATV dealer or call: 1-800-447-4700.AWARNING ite a potential hazard that could result in personal injury or death. Off-Road Use Only ‘This vehicle is designed for off-road use only. Opera: tion on public streets, roads, and highways is not ree- ommended and is not safe. ATV tires are not designed to operate on paved or concrete surfaces. The tires will not slip as necessary which may seriously affect control of the vehicle AWARNING HAZARD Operating this ATV on paved surfaces, WHAT CAN HAPPEN, ‘The ATV's tires are designed for off-road use only, not for use on pavement. Paved surfaces may seri- ‘ousy affect handling and control of the ATV, and ‘may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Never operate the ATV on any paved surfaces, including sidewalks, driveways, parking lots and strests.By operating on a public road you take the risk that you could collide with another vehicle. Also, in many states use on public streets is illegal AWARNING HAZARD. Operating this ATV on public streets, roads or highways, WHAT CAN HAPPEN You can collide with another vehicle, HOW TO AVOID THE HAZARD ‘Never operate this ATV on any public street, road or highway, even a dirt oF gravel one. {In many states it is illegal to operate ATVs on public streets, roads and highways, 55Dress Properly ‘Aiways wear an approved helmet, eye protection, and protective clothing, The proper clothing can make iding more comfortable and reduce the chance of injury if you take a spill, Long pants will also protect your legs from the hot exhaust system, 56 AWARNING HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Operating without protective clothing increases your chances of severe injury in the event of an accident, HOW TO AVOID THE HAZARD ‘Always wear an approved motoreycle helmet that fits properly. You should also wear: eye protection (gogales or face shield) loves boot: long-sleeved shirt or jacket Jong pantsOperator Only This vehicle is designed to carry only the operator. It does not have a seat strap, passenger’s grab rail, dual seat, or footpegs for a passenger. The long seat is needed for the operator to maintain vehicle control by shifting his or her body weight. A passenger interferes with the ‘operatcr’s ability to control the vehicle which can cause hharm to the operator. Also, a passenger will impair the steering response of the vehicle by shifting weight from ‘the front wheels, causing loss of control which may ‘cause an accident, And without secure seating, a passen. {ger may lose his or her balance and fall off the vehicle, Never carry a passenger. Never ride as a passenger, AWARNING HAZARD Carrying a passonger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger, HOW TO AVOID THE HAZARD Never carry a passenger, The long seat isto allow the operator to shit ion as needed during operation, It is not for carrying passengers, 87Ride Carefully and with Good Judgement ‘We want you to enjoy your riding experiences, so ride carefully and safely. Exercise good judgement. Avoid wheelies and jumps. Also, don’t ride at excessive speods, too ‘ast for conditions, or faster than your skill level Riding too fast and trying unsafe stunts can cause you to lose control of the vehicle and have an accident, Prac- tice basic maneuvers so you can ride confidently and safely, AWARNING HAZARD. ‘Attempting wheelies, jumps, and other stunts, WHAT CAN HAPPEN Increases the chance of an accident, including an overturn, HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off. AWARNING HAZARD. Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which ean result in an accident, HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terr visibility and operating conditions, and your experiAWARNING WARNINGS indicate a potential hazard that could result in personal injury or death. Never Drink and Drive Alcohol and drugs impair your judgement and slow your reactions. Even drugs prescribed by @ physician ‘can be dangerous. Check with your doctor. AWARNING Operating this ATV after consuming alcohol o drugs. WHAT CAN HAPPEN Could seriously affect your judgement. Could cause you to react more slowly. Could affect your balance and perception, Could result in an accident. HOW 70 AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. 59Keep Your Feet on the Pegs and Hands on the Handlebars Ahways ride with your feet on the footpegs. If your feet touch the ground while you are moving, you could be injured. It is possible to have the rear wheel run over your foot. If you have 2 lot of motorcycle experience, your natural reaction to the vehicle tipping or skidding may be to put @ foot down. This is a reaction you must "anlearn.” ‘Ako, removing your feet from the footpegs and removing your hands from the handlebars can cause you to lose your balance and fall off the ATV, Keep your hands and feet on the ATV always, AWARNING HAZARD hands from handlebars or feet from Footpegs during operation. WHAT GAN HAPPEN ‘even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall aff of the ATV. If you remove 2 foot from a footpeg, your foot oF log may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD ‘Always keep both hands on the handlebars and both foet on the footbegs of your ATV during operation. Before Starting the Engine ‘Three “musts” before starting the engine are: 41) Set the parking brake, 2) Put the transmission in neutral, 3) Check the throttle for proper operation. It should snap closed when released with the handlebars in any position,Use the Parking Brake Always apply the parking brake before getting off your vehicle. If it should rol, it might be damaged or ‘cause injury, Modifications and Accessories Installation of accessories may affect the handling of your ATV. See the Loading Information chapter of this manual for more detailed information, Kawasaki dovs ‘not recommend that you modify your ATV in any way. Unauthorized modifications may produce dangerous handling conditions or adversely affect vehicle reliabil ity, AWARNING HAZARD Operating this ATV with improper modifications, WHAT CAN HAPPEN. Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation. or use of accessories. All parts and accessories added ‘a this vohicle should be genuine Kewosoki or equiv- ‘alent components designed for use on this ATV and. should be installed and used according to instruc- tions. If you have questions, consult an authorized ATV dealer. oLoading Your ATV ‘Make sure all cargo is securaly attached, Don't carry hheavy or bulky items that exceed the cargo rack load capacity. Also, don’t overload your ATV. Rack Maximum Load Front_| 32g (70 1b) Rear | 63ka (140 1b) Vehicle Maximum Load Weight of rider and cargo must not exceed 195 kg (430 1b), Try to maintain front to rear balance by carrying twice as much weight on the rear rack as on the front rack, Reduce speed when carrying cargo or pulling a trailer and allow for more braking distance. Be sure to attach a trailer to the trailer hitch bracket only. Don’t attach 2 trailer to any other location than the bracket, Also, don’t overload a trailer Maximum Trailer Weight (Trailer plus cargo weight) 317 kg (700 1b) Do not load more than 14 kg (30 Ib) tongue weight fon the trailer hitch bracket, Be sure to subtract this ‘tongue weight from the Vehicle Maximum Load capac: ity AWARNING HAZARD Improperly attaching and loading a trailer. Overloading a trailer. WHAT CAN HAPPEN ‘Can cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD ‘Attach a trailer to the trailor hitch bracket only. For ‘example, attaching a trailor to the grab rail ean cause the vehicle to tip over. Never load more than 14 kg (30 Ib) tongue weight on the towing bracket. Do not tow more than 317 kg (700 Ib) trailer weight (trailer plus cargo). 62 ‘When towing @ trailer, don’t carry @ passenger in a trailer. AWARNING HAZARD Riding in a trail WHAT CAN HAPPEN Can cause the operator to lose control of the vehicle, ‘The passenger can be thrown from the trailer or hurt by shifting cargo in the trailer. HOW TO AVOID THE HAZARD ‘Never carry a passenger in a trailer. Refer to the instructions in the Loading Information cchapter of this manual. Overloading this ATV or car- rying or towing cargo improperly will adversely affect vehicle handling and could cause an accident, NAST] HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD ‘Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached, Reduce speed when carrying cargo or pulling a trailer. Allow areator distance for braking, Always follow the instructions in your Owner's Manual for carrying cargo or pulling aPerform the Daily Safety Checks Refer to the Daily Safety Checks section for alist of items to check each day before you ride, Habitual performance of these checks will help to insure a safer, more reliable ride, Be sure that any irregularities found, during these checks are corrected before riding. AWARNING HAZARD. Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN, Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD. Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual.AWARNING WARNINGS indicate a potential hazard that could result in personal injury or death. Tire Air Pressure ‘This vehicle is equipped with low pressure tires. Tire inflation and type can affect the vehicle's handling characteristics. Check the tire pressure frequently, using the tire gauge in the tool kit. Use only the recom mended tires for replacement, “HAZARD Operating this ATV with improper tires, oF with im- Proper or uneven tire proseure, WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, accident. HOW TO AVOID THE HAZARD ‘and type tires specified in the Owner's Manual far this vehicle Always maintain proper tire pressure as described in the Owner's Manual.Riding Terrain Before riding in 2 new area be sure to check for hhidden obstacles or hazards, Keep your speed down until you know the area well, You must know the land You intend to ride on and be familiar with your machine and its handling characteristics to have a safe and enjoy- able riding experience, Use existing trails and stay away from excessively rough, slippery or loose terrain, Don't attempt to ride over large obstacles, Hazardous condi tions such as these can cause loss of control and an accident. Be cautious when visibility is limited; you may ‘not be able to see obstacles in your path, AWARNING Failure to use extra care when operating this ATV on unfamiliar terrain, WHAT CAN HAPPEN. ‘You can come upon hidden rocks, bumps, or holes, ‘without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain, Always be alert to changing terrain conditions when operating the ATV. If you must ride over a small obstacle, approach it slowly. As the vehicle goes up and over the obstacle, shift your weight to stay contared over the vehicle. Use careful throttle control, Stand up if necessary to main- tain your balance,AWARNING HAZARD Improperly operating over obstacles, WHATCAN HAPPEN Could cause loss of control or a collision, Could ‘cause the ATV to overturn, HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees, When you go over obstacles, always follow proper procedures as described in the Owner's Manual, AWARNING HAZARD. Failure to use extra care when operating on exces- sively rough, slippery or loose terrain, WHAT CAN HAPPEN. Could cause loss of traction oF vehicle control, which could result in an accident, including an overturn, HOW TO AVOID THE HAZARD Do not operate on excesively rough, slippery or loose terrain until you have leaned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds ofRiding in Reverse Start the engine following the procedure in the “Starting the Engine" section, Before shifting into reverse, put the transmission in neutral, Then turn the reverse’ knob clockwise and press down the shift pedal into reverse gear, Release the reverse knob and edd. Refer to the “Reverse Knob" section, ‘Turn around and look behind you before backing up to be sure there are no obstacles or people in your way. Gradually open the throttle and begin backing up cautiously. To stop while riding in reverse, close the throttle and gradually apply the brakes. Sudden application of the front brake or the rear brake can cause the front end of the vehicle to lift off the ground, To shift out of re- verse, first stop vehicle completely. Then lift the shift pedal to neutral AWARNING “HAZARD Shifting into 1st gear while moving in reverse, WHAT CAN HAPPEN, Can cause the vehicle to stop suddenly and go for- wad. This can lift the front wheels off the ground and ‘cause the operator to lose control. Or the vehicle can tip over backwards causing an accident, HOW TO AVOID THE HAZARD. Nower operate the shi the vehicle is in reverse. pedal to change gears while AWARNING “HAZARD Improperly operating in reverse. WHAT CAN HAPPEN. You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no ‘obstacles or people behind you. When it is safe to proceed, go slowly. Remember: © Look behind you before backing up. Open the throttle gradually. To stop, gradually apply the brakes.AWARNING WARNINGS indicate a potential hazard that could result in personal injury or death. Turning the Vehicle Both rear wheels of this ATV turn at the same speed. ‘This means that to make a turn, the inside wheel must ive up traction or “slip” on the ground. This requires a turning technique which the new rider ‘must leer, AWARNING HAZARD ‘Turnieg improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn, HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this section, Practice turning at low speeds before attempting to tur at faster speeds. Do not turn at excessive speed, wr” ~ To make turns smoothly and quickly slide forward on the seat. Shift your body weight onto the footpeg on the outside of the turn, and lean your body to the inside of the turn. Turn the handlebar in the direction of the turn. The’ vehicle will turn and “slip” its inside rear wheel, Slow down before entering the turn and use the throttle to maintain an even speed through the turn, When the turn is completed, straighten the handlebar and reposition your weight equally side-to-side or move back on the seat, 69If the turning technique is not pertormed correctly, the front wheels may plow straight ahead or the vehicle ‘may tip, If the front wheels plow straight ahead, slow down and come to a stop. If the vehicle starts to tip, ina tum, lean more to the inside of the turn. It may also be necessary to reduce your speed and straighten out if possible. Don't put your foot down; keep both feet cn the footpegs always, AWARNING HAZARD. Removing hands from handlebars or feet from footpegs during operation, WHAT CAN HAPPEN. Removing even one hand or foot can reduce your ability to control the ATV or could eause you to lose ‘your balance and fall off of the ATV. If you remove a foot from a footpeg, your foot or leg may come into contact with the rear wheels, which could injure ‘you or cause an accident. HOW TO AVOID THE HAZARD ‘Always keop both hands on the handlebars and both feet on the footpegs of your ATV during operation, 70 Practice turning at low speed in a large, open practice area, The type of riding terrain has a large effect on turning. On loose surfaces the inside rear wheel will slip easily and the vehicle can be turned sharply. On hard surfaces the inside rear wheel will not slip easily, Under these conditions the vehicle may tend to plow straight ahead, resisting your effort to steor, If this should eccur, slow down and come to a stop. This plowing effect increases at higher speeds, Hard surfaces also increase the turning radius. Thus, you must allow more room to complete your turn, Romember: Slow down before entering the turn, Put your weight on the outer footpeg, Lean into the turn, Sit forward on the seat, (oMaintain an even speed through the turn,Climbing Hills Do not attempt to climb hills or steep inclines until You heve mastered the controls and basie riding tech: niques of this vehicle, Then practice hill climbing ‘techniques on gentle slopes first before you graduate to steeper hills, AWARNING HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control o cause ATV to overturn, HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manus Always check the terrain carefully before you start ‘up any hill, Never climb hills with excessively slippery or loose surfaces. ft your weight forw: Never open the throttle suddenly or make sudden ‘gear changes. The ATV could flip over backwards "Never go over the top of any hill at high speed. An ‘obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill, Don't ettempt to climb hills that are too steep for the ATV or for your abilities. When climbing a hill, lean forward to keep the front wheels from lifting. On steeper hills you may need to stand and lean forward for even more weight transfer. The front wheels must bbe kept on the ground so you can steer and also to prevent the possibility of tipping over backwards HAZARD Operating on excessively step hills. WHAT CAN HAPPEN ‘The vehicle can overturn moro easily on extremely stoep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities, Practice on smaller hills before attempting larger hills. nAvoid hills with slippery sides that will cause you to lose traction. Do not climb hills where you cannot see far enough ahead. If you cannot see what is on the other side of the crest of a hill, slow down until you can get a clear view. Do not try to elim a hill in too high a gear. Speed up before ascending the hill. Select @ low enough gear to reach the top without downshifting fr losing momentum. Don’t apply power suddenly or change gears while climbing, or the front wheels might rise off the ground. If the vehicle doesn’t have enough ower to reach the top of a hill and starts to lose for- Ward momentum, turn around and ride downhill if you have enough space. AWARNING HAZARD. Improperly turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn, HOW TO AVOID THE HAZARD ‘Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this manual on level ground, Be very careful when turning on any hill, 2 On this 4WD ATV, all wheels (front and rear) are constantly driven by the drive train, This means that applying either the front brake (the righthand brake lever) or the rear brake (the lefthand brake lever or the brake pedal) brakes both the front and rear wheels, Any brake application will brake the downhill wheels when climbing or descending ills. If the vehicle stalls on a hill, apply the brakes before the vehicle starts to roll backwards, If the vehicle should start to roll backwards on @ hill, dismount to the side immediately or apply the brakes gradually. You may tip ‘the vehicle over backwards if you apply either the front oor rear brakes suddenly after the vehicle starts to roll backwards, or if you try to apply power while rolling backwards. If you are stopped on a hillside, apply the parking brake and carefully dismount on the uphill side Of the vehicle (so it cannot roll over onto you). To turn the machine around, drag the rear end of the ATV uphill 4s far as possible. Remount the ATV from the uphill side if it is not facing straight downhill, Then, while Keeping as much of your weight as possible on the uph side, turn the handlebars downhill, Release the parking brake and ride downhillAWARNING HAZARD Stalling rolling backwards or improperly dismounting vwhile climbing a hill, WHAT CAN HAPPEN Could result in ATV overturning, HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a bill, If you lose all forward speed: Keep woight uphill ‘Apply the brakes, Lock parking brake, after you 1 you begin rolling backwards: Keep weight uphil ‘Never apply either front or rear brakes suddenly hile rolling backwards, Apply both front and rear brakes gradually. When fully stopped, lock parking brake, Dismount on uphill side or to a side if pointed straight uphill, Turn the ATV around and remount, following the procedure described in this manual. Remember: Some hills are too steep. Use common sense. Never ride past your limit of visibility. If you can't see What is on the other side of the crest of a hill, slow down until you can get a clear view. Use a low gear, ‘©Don't let the vehicle roll backward, If it does, avoid sudden braking, If you get stuck on a hill, set the parking bral dismount on the uphill side andAntenna Flag In hilly country, use an antenna flag so others can see you coming from the other side of a hill or sand dune. Take extra care when approaching blind hill tops and corners, % Traversing Hillsides When riding across the side of a hill, keep your body weight toward the top of the hill, Avoid hills with slippery sides that will cause you to lose traction, Also avoid traversing hillsides covered with rocks or other ‘obstacles which may cause you to lose your balance or tip over. If the vehicle begins to tip, steer downhill if possible to regain control, If you discover that the vehicle is in danger of rolling over, dismount on the uphill side.Descending Hills Slow down or stop at the top of a hill so you can pick 2 safe path for descent where you can clearly see far ‘enough ahead to avoid any obstacles, AWARNING HAZARD. Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn, HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills 5 described in this manual. Note: a special tech- nique is required when braking as you go down a Always check the terrain carefully before you start down any hil Shift your weight backward, Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side, Go straight down the hill where possible. 6 Normally you should descend straight down a hill, since riding at an angle could cause the vehicle to lean to fone side and possibly tip over. Shift into 2 low gear before beginning your descent, Sit back on the seat and brace yourself by straightening your arms. Hold your speed down by keeping the throttle closed, Apply the brakes as necessary. On this 4WD ATY, all wheels (front and rear) are constantly driven by the drive train. This ‘means that applying either the front brake (the right- hhand brake lever) of the rear brake (the left-hand brake lever or the brake pedal) brakes both the front and rear ‘wheels. Any brake application will brake the downhill ‘wheels when climbing or descending hills, Avoid sudden application of either the front or rear brakes; it could ‘cause the vehicle to overturn,AWARNING "HAZARD Applying brakes improperly, WHATCAN HAPPEN Could cause ATV to overturn, HOW TO AVOID THE HAZARD Apply both front and rear brakes gradually. Be careful if the surface is loose; the ti and braking effectiveness will be reduced, ‘Turning while descending a slope must be done very carefully and gradually to avoid tipping the vehicle ‘over. The rider should keep his feet on the footpegs and trarsfer his weight to the rear of the vehicle, and ‘on the ushill side of the vehicle Remember: Stop and lock for obstacles before descending a hill. Go straight downhill, Use a low gear Shift your weight to the rear. Go slowly. Avoid sudden braking, ©IF you must tum, do so carefully and gradually, keeping your weight toward the top of the hil 7Sliding and Skidding On slippery or loose surfaces, special care is required, Sliding may be hazardous because the wheels may suddenly regain traction and cause the vehicle to tip or overturn and have an accident. Therefore, never ride “over your head” when you are unprepared for the riding surface, Often you can correct a skid by turning the wheels in the direction of the skid and placing additional body ‘weight on the front wheels, Do net apply heavy braking force or accelerate when skidding, since this may cause you to lose control altogether. Learn to safely control skidding or sliding by prac- ticing at low speeds and on level, smooth terrain, 1B AWARNING HAZARD. ‘Skidding or sliding improperly. WHAT CAN HAPPEN ‘You may lose control of this ATV. You may also regain traction unexpectedly, which ‘may cause the ATV to overturn, HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by prac- ticing at low speeds and on level, smooth te On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Use caution and maintain low speeds to avoid uncon. trolled skidding on areas covered with clay, mud, ice, or snow. These conditions are particularly hazardous when descending a hill or making a turn, Remember that this vehicle is not allowed on public streets, roads, or high: ways, On loose or slippery surfaces you may be able to improve steering control by moving forward on the seat, This puts more of your weight over the front wheels,Remember: ‘We especially careful on very slippery and very high traction surfaces, ‘Steer in the direction of the skid ‘Don't ride on public streets, roads, or highways, Riding in Water Choose @ location to enter and exit the water where the banks are not too steep or slippery, Check the water before entering for rocks, holes or other obstacles which may cause you to overturn or become stuck or sub- merged, Observe the following rules for operating the vehicle in water Never operate the vehicle in rivers or streams where ‘the water is flowing quickly. Such operation could lead to an accident if the vehicle loses traction and is swept into the current. Never operate the vehicle in deep water, The max- imum fording depth is 20 em (8 in.) in quiet (slow. moving) water, Vehicle operation in deeper water ‘may be unpredictable and hazardous, and could lead to an accident, 9AWARNING HAZARD Operating this ATV through deep or fast flowing wate. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident, HOW TO AVOID THE HAZARD "Never operate this ATV in fast flowing water or in water deeper than 20 em (8 in). Remember that wet brakes may have reduced stop- ping ability, Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the pads and linings, ‘After the vehicle Is operated in water, check the sir clearer and drain any trapped water by removing the drain bolt from the rear brake panel, After prolonged exposure to water, the wheel bearings may lose their lubricant and require replacement. 80 A. Drain Bolt CAUTION If any water drains, it is an indication that the rear ¢ seal must be replaced. Have this seal checked by an authorized Kawasaki dealer as soon as possible,Wash the vehicle in fresh water if it was exposed to salt water or operated in muddy conditions Wet brakes provide little oF no efficiency and could lead to an accident and injury. After operation in water, always apply the brakes long enough for the friction to Ary the pads and linings. Also, brakes that get wet may wear out faster. Check for brake wear more frequently if the vehicle is used in water Remember: Don’t ride in fast moving water. OStay out of the water over 20 em (8 in.) deep. Dry out the brakes, >Check the air cleaner for water AWARNING WARNINGS indicate a potential hazard that could result in personal injury or death, a1Periodic Maintenance Chart In addition to the following items, always perform the Daily Safety Checks listed in the HOW TO RIDE chapter. © = Clean, adjust, lubricate, replace parts as necessary. m MAINTENANCE AND ADJUSTMENT srr Service to be performed by an Authorized Kawasaki dealer. First Regular Service Service After | Every | Every | Every | Every 10 hrs. | 10 days | 30 days | 90 days | year ofuse | ofuse | ofuse | ofuse | of use ENGINE | Air cleaner-service” . . Clutch adjustment* . . Valve clearance-check D D Fuel system cleanliness-check* ° . Engine oil--change* . . Oil filter-replace* . ° Spark plug-clean and gap . e Spark arrester-clean :Regular Service Every | Every | Every | Every 10 days | 30 days | 90 days | year ofuse | ofuse | ofuse | of use CHASSIS Joint boots-check* . ° Rear brake adjustment-check* . . Rear brake lining wear-check* . ° Front brake pad wear~check™ D D Brake fluid level~check ° Brake fluid~change D Cable adjust ments* . . Battery--check ° ° Steering-check D D General lubrication* . Bolts and nuts-tighten ° . Front and rear final gear case oil-change . ° mess ois piston assembly and dust -years'(0): Caliper piston seal and dust seal--replace 2 years (D) Brake hose-replace 2 years (D) | *Service more frequently when operated in mud, dust, or other harsh riding conditions,Engine oil In order for the engine, transmission, and clutch to function properly, maintain the engine oil at the proper level, and change the oll and oil filter in accordance with the Periodic Maintenance Chart. Not only do dirt and ‘metal particles collect in the oil, but the oil itself loses its lubricative quality if used too long. AWARNING HAZARD. Engine or transmission seizure, Can lock the rear wheels causing an accident and injury. HOW TO AVOID THE HAZARD Do not operate this vehicle with insufficient, deterio- rated, of contaminated engine oil. Oil Level inspection if the oi has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several ‘minutes until the oil settles. CAUTION the engine before the oil reaches every part can cause engine seizure ant, deteriorated, or contam: cil will cause accelerated engine wear. If the vehicle has just been used, wait several minutes for all the oil to drain down, ‘Check the engine cil level through the oll level gauge in the lower right side of the engine. With the vehicle level front-toxear and side-toside, the oil level should ‘come up between the lines next to the gauge. ©. Upper Level Line D. Lower Level Line A. Oil Filler Cap B. Oil Level Gauge‘°1F the oil level is too high, remove the excess oll, using 4 syringe or some other suitable device. If the oil level is too low, add the correct amount of oll throuch the oil filler opening. Use the same type and brand of oil that is already in the engine, AWARNING HAZARD Engine or transmission seizure, WHATCAN HAPPEN Can lock the rear wheels eausing an accident and injury. HOW 0 AVOID THE HAZARD Check engine oil level before operating vehicle, and add oilif itis low. CAUTION If the engine is run without oil, it will be severely damaged. Oil and/or Oil Filter Change Warm up the engine thoroughly, and then stop the engine, ‘¢Piace an oil pan beneath the engine, ‘Remove the engine drain plug. ‘With the vehicle on level ground, let the oil completely drain, If the oil filter is to be changed, remove the oil filter cover bolts and take off the cover with the O-itA. Oil Filter Element B. Grommet C. Element Mounting Pin ‘Pull the mounting pin off the element. ‘Replace the element with a new one. ‘Apply a little engine oil to the grommets on both sides Of the element, and push the mounting pin into the element. Be careful that the grommats do not slip out Of place. Install them with the smaller end of the pin outside NOTE Check for O-ring damage. If necessary, replace it with ‘a new one. When installing the oil filter, make sure the O-ring is in lace. ‘install the oil filter cover and tighten its bolts, ‘After the oil has completely drained out, install the engine drain plug with its gasket. Proper torque for it is shown in the table, NOTE Replace the damaged gasket with a new one. Tightening Torque Engine Drain Plug: 29 Nem (3.0 kg-m, 22 ft-lb) ‘Fill the engine up to the upper level line with a good ‘quality motor oil specified in the table,Engine Oi! Grade: SE or SF clase Viscosity: SAE 10W30, 1040, 10W50, 20W40, ‘or 2050 Capacity: 2.2L (2.3 US at) Check the oil level. Front and Rear Final Gear Casa Oil In order for the differential, pinion, and ring gears to function properly, check the oil level and change the oil in accordance with the Periodic Maintenance Chart. Operai ith insufficient, deteriorated, (oF contami case oil WHAT CAN HAPPEN Seizure of differential, pinion, and ring gears in final gear cases can lock the front and rear wheels causing an accident and injury. HOW TO AVOID THE HAZARD Do not operate this vehicle with insufficient, deterio- rated, of contaminated gear case oil, CAUTION Vehicle operation with insufficient, deteriorated, or contaminated oil causes accolerated wear of ‘the differential, pinion, and ring gears, 87ff Lever inspection ‘With the vehicle level frontto-rear and side-to-side, remove the filler caps from the front and rear final gear CAUTION Be careful not to allow any dirt or foreign materials to enter the gear eases, ©Check the oil level, If itis insufficient, adel oil through the oil filler openings as necessary. The oil level should come to the bottom thread of each filler opening ‘A. Front Final Gear Case C. Bottom Thread 8, Filler Opening‘A. Rear Final Gear Case _C. Bottom Thread B. Filler Opening install each filler cap, NOTE (Use the same type and brand of oil that is already in ‘each final gear case, 011 Change NOTE Front and rear final gear case oll drains easily and picks Lup any sediment when the oil is warmed up by running the vehic ‘eWith the vehicle level, place an oil pan beneath each ear case, ‘@Remove each filler cap and the drain plug, ‘A. Front Final Gear Case 8, Drain PlugFill each gear case up to the bottom thread of the filler opening with a good quality oll specified in the table, Front Final Gear Case Oil Oi ‘about 260 mL Capacity | (0.26 US at) Oil ‘API “GL” Hypoid gear oil for Type LSD, SAE140 or SAEB5 W140 TSestGsie Deeg Rear Final Gear Case Oil ol about 300 m After the oil has completely drained out, install the our 200 mL Capacity | (0.32 US at) drain plugs and gaskets. Replace the damaged gaskets aus an ‘with new ones. ‘API "GL oi Hypoid gear oi Type above 5°C (41°F) SAE9O AWARNING bolow 5° (41°F) SAEBO HAZARD. Getting gear case oil on tires, ‘tnstall the filler caps WHAT CAN HAPPEN, Can make them slippery which can cause an accident and injury. HOW TO AVOID THE HAZARD Clean up any spilled oil immediately using soap and water.Spark Plug ‘The standard spark plug is shown in the table. The spark plug should be taken out periodically in accord- lance with the Periodic Maintenance Chart for cleaning, Inspection, and resetting of the plug gap. Mainterance If the plug is oily or has carbon built up on it, have it cleaned, preferably in a sand-blasting device, and then clean o'f any abrasive particles. The plug may also be Cleaned using a high flash-point solvent and a wire brush oF other suitable tool. Measure the gap with a wire-type thickness gauge, and adjust the gap if incorrect by bending the outer electrode. If the spark plug electrodes are cortoded or damaged, or if the insulator is cracked, replace the plug. Use the standard plug. Spork Plug Standard NGK DEA Plug ONGK DREES-L Plug 0.6 ~0.7 mm | Gap (0.024 ~ 0.028 in.) Tightering 14Nm Torque (1.4 kg-m, 10 feb) © + Canadian model Valve Clearance Valve and valve seat wear decrease valve clearance, Upsetting valve timing, CAUTION 0.6 ~ 0.7 mm 7 (0.024 ~ 0.028 in, If valve clearance is left unadjusted, the wear will eventually cause the valves to remain partly open, which lowers performance, burns the valves and valve seats, and may cause serious engine damage. Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Maintenance Chart, Inspection and adjustment should be done by an authorized Kawasaki dealer.Air Cleaner A clogged air cleaner restricts the engine’s air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling, WHAT CAN HAPPEN May allow dirt and dust to enter the carburetor and stick the throttle open. This could cause an accident, HOW TO AVOID THE HAZARD lean the air cleaner regularly and according to the instructions in this setion, CAUTION ‘A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possibly engine damage. 92 The air cleaner element must be cleaned periodically (sce the Periodic Maintenance Chart), In dusty areas, the element should be cleaned more frequently than the recommended interval. After riding through rain for on muddy roads, the element should be cleaned immediately, Element Cleaning ‘@Remove the seat. ‘Pull up the snaps and remove the air cleaner cover. A. Al Cleaner Cover B. Snaps ‘Loosen the clamp screw, remove the element mounting screw, then pull the air cleaner element up out of the air eleaner housing.A. Clamp Screw B. Mounting Screw ©. Element Check inside the inlet tract and carburetor for dirt, If dirt is present, clean the intake tract and carburetor thorough'y. You may also need to replace the air filter and seal the airbox and init tract. ‘Push a clean, lint-free towel into the inlet tract to keep dirt or other foreign material from entering, ‘Wipe out the inside of the airbox with a clean damp towel. HAZARD Dirt or dust sllowed into the carburetor. WHAT CAN HAPPEN Can cause the throttle to stick open. This could ‘cause an accident, HOW TO AVOID THE HAZARD Be sure to cover the air cleaner opening to the car- bburetor after removing the element, Clean the air cleaner case as described in section. CAUTION If dirt gets through into the engine, excess wear and possibly engine damage will occur engine ‘@Rlemove the element stopper from the rear end of the ‘element body by removing the screw,A. Screw B. Stopper ‘©Pull the element off the body, then off the inner metal net, A. Element 4 Clean the element in a bath of high flashpoint solvent Using a soft bristle brush AWARNING HAZARD Cleaning the air cleaner element with gasoline or tow flash-point solvent. WHAT CAN HAPPEN Gasoline or low flash-point solvents are extremely flammable and can be explosive under certain con- ditions. A fire or explosion can cause severe injury or death. HOW TO AVOID THE HAZARD Use a high flash-point solvent to clean the air cleaner element. Never use gasoline or low flash-point solvents Clean the element in a well-ventilated area free from any source of flame or sparks: this includes any appliance with a pilot light. eSqueeze it dry in a clean towel. Do not wring the element or biow it dry; the element can be damaged, Inspect the element for damage, If itis torn, pune. tured, or hardened, replaces it NOTE Replace the element after cleaning it five times or if is damaged.‘After cleaning, saturate the element with a high-quality foam air filter oil, squeeze out the excess, then wrap it in a elean rag and squeeze it as dry as possible. Be careful not to tear the element, ‘instal the element on the inner metal net. Coat the lips of the element with a thick layer of all Purpose grease to assure 8 complete seal against the element body and stopper. install the element on the body, then install the element stopper ‘Apply grease to all connections and screw holes in the airbox and intake tract, ‘@Remore the towel from the inlet tract, ‘install the element in the airbox. Tighten the mount: ing screw and clamp scraw sacurely. ‘¢Smear grease around the clamp and particularly in any ‘gaps between the element body and the inlet tract. ‘install the air cleaner cover and seat. Dust and/or Water Inspection ‘*Squeeze open the drain hose on the bottom of the air leaner housing to expel dust and/or water accumu: lated inside, A. Drain HoseSpark Arrester This vehicle is equipped with a spark arrester ap- proved for off-road use by the U.S. Forest Service. It ‘must be properly maintained to ensure its efficiency. In accorjance with the Periodic Maintenance Chart, clean ‘the spark arrester. AWARNING HAZARD. Incorrectly installed spark arrester. WHAT CAN HAPPEN. (Can emit sparks which can cause a fire. HOW TO AVOID THE HAZARD. Be sure the spark arrester/muffler and drain plug are installed securely. ‘Spark Arrester Cleanina AWARNING HAZARD Hot muffle WHAT CAN HAPPEN. Can burn your hands. HOW TO AVOID THE HAZARD ‘A. Spark Arrester B. BoltIn an open area away from combustible material, start ‘the engine with the transmission in neutral. AWARNING HAZARD Cleaning the spark arrester near combustible mate- rials WHAT CAN HAPPEN Can cause a fire resulting in burns, HOW TO AVOID THE HAZARD ‘Never run the engine with the spark arrester disas- sembled near combustible materials. Hot carbon particles are emitted during the cleaning procedure. ‘Raise and lower engine speed while tapping on the ‘muffler with a rubber mallet until carbon particles are purged from the muffler. WARNINGS indicate a potential hazard that could result in personal injury or death, AWARNING HAZARD Running the engine without ventilation, WHAT CAN HAPPEN. Breathing exhaust gat leads to carbon monoxide poisoning, asphyxiation, and death. Exhoust gases contain carbon monoxide; a colorless, ~odores, Poisonous gas HOW TO AVOID THE HAZARD Do not start or run the engine in a closed area such as a garage, ‘Stop the engine ‘install the drain plug. Remove the spark arrester mounting bolt from the muffler, ‘©Pull the spark arrester out of the muffler. ‘Scrape carbon deposits off the spark arrester and slide it back into the muffler, install the mounting bolt and tighten it securely. 7Throttle Cable ‘There must be free play in the throttle mechanism, Measure the distance the throttle lever moves before the engine begins to pick up speed. Free play should be 2 ~ 3mm (0.08 ~ 0.12 A.2~3 mm (0.08 ~ 0.12in.) Adjustment ‘Slide the rubber cover off of the adjuster at the throt- tle case. ®Loosen the locknut and turn the throttle cable upper adjuster to obtain the specified free play. Tighten the locknut and reinstall the rubber cover.‘If the free play cannot be set by adjusting the upper averse Cable cable adjuster, use the adjuster at the lower end of the ‘There must be free play in the reverse mechanism, throttle cable. Be sure to securely tighten the adjuster ‘mounting nuts. Inspection ‘@Remove the left engine side cover mounting bolts and ‘take off the cover. A. Adjustor B. Nuts A. Engine Side Cover. Bolts Determine the amount of reverse cable play at the reverse knob, Turn the knob until the reverse lever at the lower end of the cable starts to move; the amount of reverse knob travel is the amount of cable play.‘©The proper amount of play is 2~ 3 mm (0.08 ~ 0.12 in.) at the reverse knob end. If there is too much or ‘00 little play, adjust the cable play as follows, Adjustment Loosen the locknuts near the reverse lever, and turn them until the knob has the proper amount of free play. Tighten the locknuts, ‘Reinstall the engine side cover,Carburetor Carburetor adjustment is done with the idle adjusting ‘A. Idle Adjusting Screw Adjustrment AWARNING HAZARD. Hot engine and exhaust pipe. WHA: Can burn your hands, HOW TO AVOID THE HAZARD Never touch a hot engine or an exhaust pipe during carburetor adjustment. Adjust the idle speed to the lowest stable speed by turning the idle adjusting screw. Open and ciose the throttle a few times to make sure that the idle speed does not change. Readjust if ‘necessary. NOTE With engine idling, turn the handlebar to each side. If ‘handlebar movement changes idle speed, the throttle ‘cable may be incorrectly routed, or it may be damaged. AWARNING HAZARD Failure to maintain the control cable, WHAT CAN HAPPEN Can result in control malfunction and an accident. Without proper maintentance the cable can become frayed, kinked, pinched, and damaged so that it ean break or jam, HOW TO AVOID THE HAZARD Be sure the control cable is properly adjusted and correctly routed. Replace the cable if it is damaged, 101Clutch ‘The clutch is automatically disengaged during shitt- ing. If it does not disengage properly, it may cause hard shifting and possible transmission damage. Adjust the clutch according to the interval listed in the Periodic Maintenance Chart. Adjustment AWARNING HAZARD. Hot engine and exhaust WHAT CAN HAPPEN, Can burn your hands. HOW TO AVOID THE HAZARD, Never touch a hot engine or an exhaust pipe during clutch adjustment, ‘Remove the clutch release adjusting screw cover by removing the screws. 102 B, Screws A. Adjusting Serew Cover Loosen the upper locknut, Turn the clutch release adjusting screw clockwise one turn, then turn the screw back counterclockwise until it becomes hard to turn, CAUTION tis not necessary to adjust the lower serew.A. Locknut B. Adjusting Screw Tighten the locknut without changing the adjusting screw position, ‘instal the adjusting screw cover. Brakes Brake Wear Inspection In accordance with the Periodic Maintenance Chart, inspect the brakes for wear. For each front dise brake if the thickness of either pad is less than 1 mm (0.04 in.) replace both pads in the caliper as a set. Pad Wear inspection and pad replacement should be done by an authorized Kawasaki dealer. 1. Lining Thickness 2, 1mm (0.04 in.) (On the rear brake panel is a brake lining wear indica- tor. If the brake lining wear indicator does not point within the USABLE RANGE when the brake is fully applied, the brake shoe linings have worn past the service limit. In this ease, the brake shoes must be replaced and ‘the drum and other brake parts examined by an author- ized Kawasaki dealer. 103A.USABLE RANGE —B. Brake Lining Wear Indicator Brake Flui In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in the reservoir and change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water, Fluid Requirement Recommended fluids are given in the table below. If none af the recommended brake fluids are available, use extra heavy-duty brake fluid only from a container marked D.0.7.4. 104 Recommended Dise Brake Fluid Castrol Girling Universal Castrol GT (LMA) Castrol Disc Brake Fluid (Check Shock Premium Heavy Duty CAUTION Do not spill brake fluid onto any painted surface. It will damage the paint. If brake fluid is spilled, wash it off immediately with water. AWARNING HAZARD. Contaminated brake fluid, WHAT CAN HAPPEN, an reduce braking performance or cause brake feilure, resulting in an accident. HOW TO AVOID THE HAZARD. Do not use brake fluid from a container that has been left open or that has been unsealed for a long time. The fl absorb moisture and may be contami nated with dust and dirt,AWARNING HAZARD. Damaged or leaking brake hoses and fittings. WHAT CAN HAPPEN Can cause brake failure resulting in an accident. HOW TO AVOID THE HAZARD Inspect brake fluid level regularly Replace any damaged or leaking brake hoses and fittings. Maintain the brake system in accordance with the Periodic Maintenance Chart. ‘A. Lower Level Line ‘If the level is low, fill the reservoir to the upper level fine with the same type and brand of fluid that is already in the reservoir, = Fluid Level inspection The brake fluid level in the reservoir must be kept above the lower level line (reservoir held horizontal). ‘A. Upper Level Line, 105Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Front Brake Disc and disc pad wear is automatically compensated for and has no effect on the brake lever action, So there ‘are no parts that require adjustment on the front brake, AWARNING HAZARD. Air in brake line, WHAT CAN HAPPEN. Canmake the brake feel mushy or soft. This may cause reduced braking performance or brake failure and result in an accidont, HOW TO AVOID THE HAZARD If brake lever travel is excessive or the brake feels mushy, have an authorized Kawasaki dealer inspect it immediately. 106 Rear Brake: Rear brake adjustment consists of three separate adjustments: brake pedal position, brake pedal free play, and brake lever free play. Always adjust the brake pedal Position frst. Brake Pedal Position Adjustment ‘®Measure from the top of the brake pedal in its rest position to the upper surface of the right footpeg. The brake pedal should be 0 ~ 5 mm (0 ~ 0.2 in.) higher ‘than the footpes, A. Footpegs, B Brake Pedal €.0~5 mm (0~0.2in.)©To adjust the pedal position, loosen the locknut, turn ‘the acjusting bolt, and then tighten the locknut. Now adjust the brake pedal free play. ‘A. Adjusting Bolt B. Locknut ‘Brake Pedal Free Play Adjustment ‘@Measure the distance the brake pedal moves before the brake starts to take hold, Pedal free play should be 15 ‘~ 25 mm (0.6~1.0in.). (©To adjust the pedal froe play, turn the adjuster at the rear end of the brake cable, AWARNING HAZARD Incorrect adjustment of the brake pedal and/or brake lever free play. WHAT CAN HAPPEN Can cause brake damage or malfunction and result in ‘an accident. HOW TO AVOID THE HAZARD Always maintain proper pedal and/or lever free play. A. Brake Pedal 8, 15~25 mm (0.6~ 1.0 in.)A. Brake Pedal Adjuster B, Brake Lever Adjuster Brake Lever Froe Play Adjustment @Locsen the locknut and turn the adjuster at the brake lever in as far a it will go. Tighten the locknut, ‘©Tum the adjuster at the rear end of the brake cable so that the brake lever has 1~2 mm (0.04 ~ 0.08 in.) of free play. 108 A. 1~2mm (0.04~0.08 in.) C. Adjuster B. Locknut NOTE ©Since the above two free play adjustments (pedal and ever) affect each other, make them at the same time. ‘After adjustments, check for brake drag (there should bbe none) and effeWheels Rims: ‘The rims are a drop-center, tubeless tire design, Take care not to damage the sealing surfaces of the tire or rim ‘when removing or installing tires. Note that the rims, like automotive rims, are not symmetrical and should be stalled in one direction only. All wheels must be installed so that the valve stoms are on the outside of the vehicle, Tires: The front tires are AT24 x 8-11 knobby tubeless tires; the rear tires are AT24 x 10-11 knobby tubeless tires. When replacing tires, check the valve stems and cores for damage. Take care not to damage the tire sealing surfaces of the rims, Standard Tire Front DUNLOP KT962. Rear DUNLOP KT962 NOTE Tires are an important part of the suspension on your ATV. Tire construction characteristics and tire infla- tion pressure can greatly influence vehicle handling. Kawasaki recommends that you always replace tires with standard replacement tires as shown above. It is ‘also very important to have tires of the same type and size, and at the same inflation pressure, on ane axle. ©lnstallation of non-standard tires, or use of different tires on one axle, can change the handling of the vehicle and possibly result in a loss of control, Stnstellavion of tubeless tires on rims requires com- pressed air and is normally recommended as a dealer service operation. However, a tube can be inserted into the tire by the operator as an emergency repair. 109Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires may adversely affect handling and performance of your vehicle and ccan result in loss of control, The maximum recom- mended load catrying capacity of this vehicle is 195 kg (430 15). Us» the tire pressure gauge in the tool kit to accu rately set tire pres-sure, AWARNING HAZARD | ‘Unequal tire pressure. WHAT CAN HAPPEN Can cause difficult and unpredictable steering re- sulting in an accident, HOW TO AVOID THE HAZARD Inflate both front tires and both rear tires to the same pressure respectively. 110 AWARNING HAZARD Operating this ATV with improper tires, or with improper tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, oF operation of this ATV with improper tire pressure, may cause loss ‘of control, increasing your risk of an accident. HOW TO AVOID THE HAZARD. Always use the size and type tires specified in the (Owner's Manual for this vehicle, Always maintain proper tire pressure as described in ‘this Owner's Manual. Tire Air Pressure (when cold) 7 35 KPa Normal ont | (0.35 ka/em?, 5 psi Use fi 28 kPa far | (0.28 ka/em*, 4 psi) eon | Ra [anu Since) | ear | (28 kalem?, 36 psd