Kawasaki W800 2015 Owner's manual

Quick Reference Guide

This Quick Reference Guide will
assist you in finding the information
you’re looking for.

A Table of Contents is included after
the Foreword.

GENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

Whenever you see the symbols
shown below, heed their instructions!
Always follow safe operating a nd main­tenance practices.

NOTICE

NOTICE is used to address prac­ticesnotrelatedtopersonalin­jury.

DANGER

DANGER indicates a hazardous

situation which, if not avoided,

will result in death or serious in-

jury.

WARNING

WARNING indicates a hazardous

situation which, if not avoided,

could result in death or serious

injury.

NOTE

NOTE indicates information that may

○

help or guide you in the operation or
service of the vehicle.

NOTICE

THIS PRODUCT HAS BEEN
MANUFACTURED FOR USE IN A
REASONABLE AND PRUDENT
MANNER BY A QUALIFIED OP­ERATOR AND AS A VEHICL E
ONLY.

TAMPERING WITH NOISE CONTROL SYSTEM

PROHIBITED

Owners are warned that the law may prohibit:

(a) The removal or rendering inoperative by any person other than for purposes

of maintenance, repair or replacement, of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while it is in use; and

(b) The use of the vehicle after such device or element of design has been

removed or rendered inoperative by any person.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo­torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety and performance.

Please read this Owner ’s Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycle’s controls, its fea­tures, c apabilities, and limita tio ns. This manual offers many safe riding tips, but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi­cle enroll in a motorcycle rider training p ro gram to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in­formation on their Kawasaki Motorcycle, a Service Manual is available for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains de­tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.

This manual should be considered a permanent part of the motorcycle and should

remain with th e motorcycle whe n it is sold.

All rights reserved. No part of this publication may be reproduced without our

prior written permission.

This publication includes the latest information available at the time of printing.
However, there may be minor differences between the actual product and illustra­tions and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

© 2014 Kawasaki Heavy Industries, Ltd. Jun. 16, 2014. (1)

TABLE OF CO NTE NTS

SPECIFICATIONS............................... 10

LOCATION OF PARTS....................... 14

LOADING INFORMATION.................. 17

GENERAL INFORMATION................. 20

Meter Instruments ............................ 20

Speedometer and Tachometer ..... 21

LCD (Clock, Odometer, Trip

Meter)........................................ 22

Warning/Indicator Lights ............... 25

Key................................................... 27

Ignition Switch/Steering Lock ........... 27

Right Handlebar Switches ................ 29

Engine Stop Switch: ..................... 29

Starter Button: .............................. 30

Left Handlebar Switches .................. 30

Dimmer Switch: ............................ 30

Turn Signal Switch:....................... 31

Horn Button: ................................. 31

Brake/Clutch Lever Adjuster ............ 31

Fuel Tank Cap .................................. 32

Fuel .................................................. 33

Fuel Requirement: ........................ 33

Filling the Tank:............................. 35

Stands.............................................. 37

Seat.................................................. 38

Helmet Hook/Holding Cable............. 40

Tool Kit ............................................. 41

Document Compartment .................. 42

Tying Hooks ..................................... 42

Rear View Mirror .............................. 43

BREAK-IN ........................................... 44

HOW TO RIDE THE MOTORCYCLE .46

Starting the Engine .......................... 46

Jump Starting ................................... 48

Moving Off........................................ 51

Shifting Gears .................................. 52

Braking............................................. 53

Stopping the Engine ......................... 55

Stopping the Motorcycle in an

Emergency ................................... 55

Parking............................................. 56

Catalytic Converter........................... 58

SAFE OPERATION............................. 60

Safe Riding Technique ..................... 60

Daily Checks .................................... 63

Additional Considerations for High

Speed Operation .......................... 66

MAINTENANCE AND ADJUSTMENT 68

Periodic Maintenance Chart ............. 68

Engine Oil ........................................ 78

Spark Plugs...................................... 84

Kawasaki Clean Air System ............. 85

Valve Clearance ............................... 86

Air Cleaner ....................................... 86

Throttle Control System ................... 91

Engine Vacuum Synchronization ..... 93

Idle Speed ........................................ 94

Clutch............................................... 95

Drive Chain ...................................... 97

Brakes.............................................. 105

Brake Light Switch ........................... 110

Front Fork......................................... 112

Rear Shock Absorber ....................... 113

Wheels ............................................. 116

Spoke and Rim: ............................ 119

Battery.............................................. 120

Headlight Beam................................ 127

Fuses ............................................... 128

General Lubrication.......................... 131

Cleaning Your Motorcycle ................ 132

STORAGE........................................... 138

ENVIRONMENTAL PROTECTION ..... 141

OWNER SATISFACTION................. 142

LOCATION OF LABELS ..................... 144

10 SPECIFICATIONS

SPECIFICATIONS

PERFORMAN

Maximum Horsepower

Maximum Torque

Minimum Turning Radius

DIMENSIO

Overall L

Overall

Overall

Wheelbase

Road Cle

Curb Ma

ENGINE

Type

Displacement

Bore ×

CE

NS

ength

Width

Height

arance

ss

Stroke

35 kW (48 PS

60 N·m (6.1 kgf·m, 44.3 ft·lb) @2 500 r/min (rpm)

2.7 m (8.9

2190mm(8

790 mm (3

1075mm(

1465mm(

125 mm (4

217 kg (

SOHC, 2-cylinder, 4 -stroke, air-cooled

773 cm

77.0 ×

) @6 500 r/min (rpm)

ft)

6.22 in.)

1.10 in.)

42.32 in.)

57.68 in.)

.92 in.)

478 lb)

3

(47.2 cu in.)

83.0 mm (3.03 × 3.27 in.)

SPECIFICATIONS 11

Compression Ratio 8.4 : 1

Starting System Electric starter

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Fuel System FI (Fuel Injection)

Ignition System Battery and coil (transistorized i gnition)

Ignition Timing 0° BTDC @1 200 r/min (rpm)

Spark Plug NGK CR8E

Lubrication System Forced lubrication (wet sump)

Engine Oil

Typ e :

API SG, SH, SJ, SL or SM with JASO MA, MA1
or MA2

Viscosity:

SAE 10W-40

Capacity : 3.2 L (3.4 US qt)

TRANSMISSION

Transmission Type

Clutch Type

5-speed, constant mesh, return shift

Wet, multi disc

Driving System Chain drive

12 SPECIFICATIONS

Primary Reduction Ratio 2.095 (88/42)

Final Reduction Ratio 2.467 (37/15)

Overall Drive Ratio 4.403 (Top gear)

Gear Ratio 1st 2.353 (40/17)

2nd 1.591 (35/22)

3rd 1.240 (31/25)

4th 1.000 (28/28)

5th 0.852 (23/27)

FRAME

Caster 27°

Trail 108 mm (4.3 in.)

Tire Size: Front 100/90-19M/C 57H

Rear 130/80-18M/C 66H

Rim Size: Front J19 × 2.15

Rear J18M/C × MT2.75

Fuel Tank Capacity 14 L (3.7 US gal)

ELECTRICAL EQUIPMENT

Battery 12V10Ah(10HR)

Headlight High beam 12 V 60 W

Low beam 12 V 55 W

Brake/Tail Light 12 V 21/5 W

Specifications are subject to change without notice.

SPECIFICATIONS 13

14 LOCATION OF PARTS

LOCATION OF PARTS

1. Clutch Lever

2. Left Handlebar S witches

3. Starter Lockout Switch

4. Meter Instruments

5. Brake Fluid Reservoir (Front)

6. R ight Handlebar Switches

7. Fr on t Brake Lever

8. Ig nit ion Switch/Steering Lock

9. T hro ttle Grip

LOCATION OF PARTS 15

1. Front Fork

2. Headlight

3. Turn Si gnal Lights

4. Fuel Tank Cap

5. Idle Adjusting S crew

6. Air Cleaner Element

7. Junction Box (Fuse Box)

8. Seat Lock

9. Helmet Hook

10. Grab Rail

11. Tying Hook

12. Tail/Brake L igh t

13. Brake Disc

14. Shift Pedal

15. Center Stand

16. Side Stand

17. Battery

18. Muffler

19. Rear Shock Absorber

20. Drive Chain

16 LOCATION OF PARTS

1. Helmet Holding Cable

2. Tool Kit

3. Air Cleaner Element

4. Seat

5. Rear Brake Pedal

6. Spark Plugs

7. Brake Lining Wear Indicator

8. R ear Brake Light Swi tch

9. Oil Filler Cap

10. Oil Level Inspection Window

11. Oil Drain B olt

12. O il Filter

13. H orn

14. B rake Caliper

LOADING INFORMATION

LOADING INFORMATION 17

WARNING

Incorrect loading, improper in­stallation or use of accessories,
or modification of your motorcy­cle may result in an unsafe riding
condition. Before you ride the
motorcycle, make sure it is not
overloaded and that you have
followed these instructions.

With the exception of genuine
Kawasaki Parts and Accessories,
Kawasaki has no control over the
design or application of accessories.
In some cases, improper installation
or use of accessories, or motorcycle
modification, will void the motorcycle
warranty, can negatively affect per­formance, and can even be illegal.

In selecting and using accessories,
and in loading the motorcycle, 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 Kawasaki motorcycles. We
strongly recommend that all parts
and accessories you add to your
motorcycle be genuine Kawasaki
components.

Because a motorcycle is s en sitive to
changes in weight and aerodynamic
forces, you must take extreme care
in carrying cargo, passengers and/or
in the fitting of additional accessories.

18 LOADING INFORMATION

The following general guidelines have
been prepared to assist you in making
your determinations.

1. Any passenger should be thor­oughly familiar with motorcycle op­eration. The passenger can affect
control of the motorcycle by im­proper positioning during cornering
and sudden movements. It is impor­tant that the passenger sit still while
the motorcycle is in motion and not
interfere with the operation of the
motorcycle. Do not carry animals
on your motorcycle.

2. You should instruct any passenger
before riding to keep his feet on the
passenger footpegs and hold on to
the operator or grab rail. Do not
carry a passenger unless he or she
is tall enough to reach the footpegs
and footpegs are provided.

3. All baggage should be carried as
low as possible to reduce the effect

on the motorcycle center of gravity.
Baggage weight should also be dis­tributed equally on both sides of the
motorcycle. Avoid carrying baggage
that extends beyond the rear of the
motorcycle.

4. Baggage should be securely at­tached. Make sure that the baggage
will not move around while you are
riding. Recheck baggage security
as often as possible (not while the
motorcycle is in motion) and adjust
as necessary.

5. Do not carry heavy or bulky items on
a luggage rack. They are designed
for light items, and overloading can
affect handling due to changes in
weight distribution and aerodynamic
forces.

6. Do not install accessories or carry
baggage that impairs the perfor­mance of the motorcycle. Make
sure that you have not adversely

LOADING INFORMATION 19

affected any lighting components,
road clearance, banking cap a bility
(i.e., lean angle), control operation,
wheel travel, front fork movement,
or any other aspect of the motorcy­cle’s operation.

7. Weight attached to the handlebar or
front fork will increase the mass of
the steering assembly and can r e­sult in an unsafe riding condition.

8. Fairings, windshields, backrests,
and other large items have the ca­pability of adversely affecting stabil­ity and handling of the motorcycle,
not only because of their weight, but
also due to the aerodynamic forces
acting on these surfaces while the
motorcycle is in operation. Poorly
designed or installed items can re­sult in an unsafe riding condition.

9. This motorcycle was not intended
to be equipped with a sidecar or to

be used to tow any trailer or other
vehicle. Kawasaki does not manu­facture sidecars or trailers for mo­torcycles and cannot predict the ef­fects of such accessories on han­dling or stability, but can only warn
thattheeffectscanbeadverseand
that Kawasaki cannot assume re­sponsibility for the results of such
unintended use of the motorcycle.
Furthermore, any adverse effects on
motorcycle components caused by
the use of such accessories will not
be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage,
and accessories must not exceed 183 kg
(403 lb).

20 GENERAL INFOR M ATION

Meter Instruments

A. Speedometer
B. MODE Button
C. RESET Button
D. Tachometer
E. Red Zone
F. FI Warning Indicator Light
G. Oil Pressure Warning

Indicator Light

H. Right Turn Signal Indicator

Light

I. Fuel Level Warning

Indicator Light
J. Neutral Indicator Light
K. High Beam Indicator Light
L. Left Turn Signal Indicator

Light
M. LCD (Odometer/Trip

Meter/Clock)

GENERAL INFORMATION

GENERAL INFORMATION 21

Speedometer and Tachometer

The speedometer shows the speed
of the vehicle. The needle of the
speedometer and tachometer momen­tarily sweeps from the minimum to
maximum and back to minimum when
the ignition switch is turned to “ON”.
This checks the operation of the meter
needles. So if they do not operate cor­rectly, have the function checked by an
authorized Kawasaki dealer.

The tachometer shows the engine
speed in the revolutions per minute
(r/min, rpm). On the right side of the

tachometer face is a portion called
the “red zone.” Engine r/min (rpm) in
the red zone is above maximum rec­ommended engine speed and is also
above the range for good performance.

NOTICE

Engine r/min (rpm) should not
be allowed to enter the red zone;
operation in the red zone will
overstress the engine and may
cause serious engine damage.

22 GENERAL INFOR M ATION

LCD (Clock, Odometer, Trip Meter)

The LCD (Liquid Crystal Display) lo­cated in the speedometer face is used
to display the Clock, Odometer and
Trip Meter. Pushing the MODE but­ton shifts the display through the fol­lowing three modes: CLOCK, ODO,
andTRIP.Whentheignitionswitchis
turned to “ON”, all the LCD segments
are displayed for three seconds, then
the clock or meters operate normally
depending on the mode selected.

WARNING

For Safety, do not operate the

meter buttons while riding the

motorcycle.

A. MODE Button
B. RESET Button

Clock -

To adjust the hours a nd minutes:

Turntheignitionswitchto“ON”.

•

Push the MODE button to display the

•

clock.
Push the RESET button for more

•

than two seconds. Both the hour and
minute displays start blinking.

GENERAL INFORMATION 23

Push the RESET button. The hour

•

display only blin ks. Push the MOD E
button to advance the hours.

Push the RESET button. The hour

•

display stops blinking and the minute
display s tarts blinking . Push the
MODEbuttontoadvancethemin­utes.

Push the RESET b u tton. Both the

•

hour and minute displays start blink­ing again.
Push the MODE button. The dis-

•

plays stop blinking and the clock
starts working.

NOTE

Pushing the MODE button momen-

○

tarily advances the hour or minute
step by step. Pushing and hold­ing the button advance the hour or
minute continuously.
The clock works normally from the

○

back-up power while the ignition
switch is turned off.

24 GENERAL INFOR M ATION

When the battery is disconnected,

○

the clock resets to 1:00 and starts
working again when the battery is
connected.

Odometer -

The odometer shows the total dis­tance in kilometers the vehicle has
been ridden. This meter cannot be
reset.

NOTE

The data is maintained even if the

○

battery is disconnected.

When the figures come to 999999,

○

they are stopped and locked.

Trip Mete r -

The trip meters show the distance in
kilometers traveled since it was last re­set to zero.

To r e s e t th e t r i p m e te r :

Push the MODE button to display the

•

trip meter.
Push the MODE button and hold it in.

•

After two seconds, the figure display

•

turns to 0.0, and then starts counting
when the vehicle is operated. The
meter counts until it is reset.

GENERAL INFORMATION 25

NOTE

The data is maintained even if the

○

battery is disconnected.
When the trip meter reaches 9999.9

○

while running, the meter reset to 0.0
and continues counting.

Warning/Indicator Lights

: The oil pressure warning indica­tor light goes on whenever the oil pres­sure is dangerously low or the ignition
switch is in the ON position with the en­gine not running, and goes off when the
engine oil pressure is high enough. Re­fer to the Maintenance and Adjustment
chapter for more detailed engine oil in­formation.

: W hen the headlight is on high
beam, the high beam indicator light is
lit.

26 GENERAL INFOR M ATION

: When the turn signal switch is
turned to left or right, the turn signal
indicator light blinks on and off.

N : When the transmission is in neutral,
the neutral indicator light goes on.

FI: The fuel injection (FI) warning in­dicator light goes on when the ignition
switch is turned to “ON” and goes off
soon after ensuring that its circuit func­tions properly.

The warning indicator light also goes
on whenever the troubles occur in dig­ital fuel injection syste m (DFI). If the
warning indicator light blinks on, have
the DFI system checked by an autho­rized Kawasaki dealer.

: The fuel level warning indicator

light goes on when the ignition switch is

turned to “ON” and goes off soon after
ensuring that its circuit functions prop­erly.

The warning indicator light also goes
on and “FUEL” blinks in the LCD when
approximately 3.1 L (0.8 US gal) of fuel
remains.

Refuel at the earliest opportunity
when the fuel level warning indicator
light goes on and “FUEL” blinks.

Whenvehiclestandswithsidestand,
fuel level warning indicator light cannot
show the amount of fuel in the fuel tank
exactly. Stand upright the vehicle to
check the fuel level.

GENERAL INFORMATION 27

Key

This motorcycle has a combination
key,whichisusedfortheignition
switch/steering lock, seat lock, helmet
hook and fuel tank cap.

Blank keys are available at your
Kawasaki dealers. Ask your dealer to
make any additional spare keys you
may need, using your original key as a
master.

Ignition Switch/Steering Lock

This is a four-position, key-operated
switch. The key can be removed from
theswitchwhenitisintheOFF,LOCK
or P (Park) position.

A. Ignition Switch/Steering Lock
B. LOCK position
C. OFF position
D. ON position
E. P (Park) position

28 GENERAL INFOR M ATION

OFF

ON

LOCK

P(Park)

Engine off. Electrical circuits
off.

Engine on. All electrical
equipment can be used.

Steering locked. Engine off.
Electrical circuits off.

Steering locked. Engine off.
Tail and city lights on. Other
electrical circuits cut out.

NOTE

The taillight is on whenever the igni-

○

tion switch is in the ON position. One
headlight goes on when the starter
button is released after starting the
engine. To avoid battery discharge,
always start the engine immediately
after turning the ignition switch to
“ON”.

If you leave the P (Park) position on

○

for a long time (one hour), the battery
may become totally discharged.

GENERAL INFORMATION 29

Right Handlebar Switches

Engine Stop Switch:

In addition to the ignition switch,

theenginestopswitchmustbein
the

operate.

gency u se. If required, move the switch
to the

position for the motorcycle to

The engine stop switch is for emer-

position.

NOTE

Although the engine stop switch

○

stops the engine, it does not turn off
all the electrical circuits. Ordinarily,
the ignition switch should be used to
stop the engine.

A. Engine Stop Switch
B. Starter Button