Kawasaki W800 2015 Owner's manual

Quick Reference Guide

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

GENERAL INFORMATION	j
HOW TO RIDE THE MOTORCYCLE	j
SAFE OPERATION	j
MAINTENANCE AND ADJUSTMENT	j
STORAGE	j

A Table of Contents is included after the Foreword.

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

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

NOTICE is used to address practices not related to personal 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 VEHICLE 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, capabilities, and limitations. 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 program 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 the motorcycle when it is sold.

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

This publication includes the latest information available at the time 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 CONTENTS

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
PERFORMANCE
Maximum Horsepower	35 kW (48 PS) @6 500 r/min (rpm)
Maximum Torque	60 N·m (6.1 kgf·m, 44.3 ft·lb) @2 500 r/min (rpm)
Minimum Turning Radius	2.7 m (8.9 ft)
DIMENSIONS
Overall Length	2 190 mm (86.22 in.)
Overall Width	790 mm (31.10 in.)
Overall Height	1 075 mm (42.32 in.)
Wheelbase	1 465 mm (57.68 in.)
Road Clearance	125 mm (4.92 in.)
Curb Mass	217 kg (478 lb)
ENGINE
Type	SOHC, 2-cylinder, 4-stroke, air-cooled
Displacement	773 cm3 (47.2 cu in.)
Bore × Stroke	77.0 × 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 ignition)
Ignition Timing		0° BTDC @1 200 r/min (rpm)
Spark Plug		NGK CR8E
Lubrication System		Forced lubrication (wet sump)
Engine Oil	Type :	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		5-speed, constant mesh, return shift
Clutch Type		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)

SPECIFICATIONS 13

ELECTRICAL EQUIPMENT
Battery	12 V 10 Ah (10 HR)
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.

14 LOCATION OF PARTS

LOCATION OF PARTS

1.	Clutch Lever	6.	Right Handlebar Switches
2.	Left Handlebar Switches	7.	Front Brake Lever
3.	Starter Lockout Switch	8.	Ignition Switch/Steering Lock
4.	Meter Instruments	9.	Throttle Grip
5.	Brake Fluid Reservoir (Front)

LOCATION OF PARTS 15

1.	Front Fork	11.	Tying Hook
2.	Headlight	12.	Tail/Brake Light
3.	Turn Signal Lights	13.	Brake Disc
4.	Fuel Tank Cap	14.	Shift Pedal
5.	Idle Adjusting Screw	15.	Center Stand
6.	Air Cleaner Element	16.	Side Stand
7.	Junction Box (Fuse Box)	17.	Battery
8.	Seat Lock	18.	Muffler
9.	Helmet Hook	19.	Rear Shock Absorber
10.	Grab Rail	20.	Drive Chain

16 LOCATION OF PARTS

1.	Helmet Holding Cable	8.	Rear Brake Light Switch
2.	Tool Kit	9.	Oil Filler Cap
3.	Air Cleaner Element	10.	Oil Level Inspection Window
4.	Seat	11.	Oil Drain Bolt
5.	Rear Brake Pedal	12.	Oil Filter
6.	Spark Plugs	13.	Horn
7.	Brake Lining Wear Indicator	14.	Brake Caliper

LOADING INFORMATION 17

LOADING INFORMATION

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 sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in the fitting of additional accessories.

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

affected any lighting components, road clearance, banking capability (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 result 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

LOADING INFORMATION 19

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 that the effects can be adverse and 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 INFORMATION

GENERAL INFORMATION

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)

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

GENERAL INFORMATION 21

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 INFORMATION

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, and TRIP. When the ignition switch is 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 and minutes:

•Turn the ignition switch to “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 blinks. Push the MODE button to advance the hours.

•Push the RESET button. The hour display stops blinking and the minute display starts blinking. Push the MODE button to advance the minutes.

•Push the RESET button. Both the hour and minute displays start blinking again.

•Push the MODE button. The displays stop blinking and the clock starts working.

NOTE

○Pushing the MODE button momentarily 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 INFORMATION

○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

○When the figures come to 999999, they are stopped and locked.

Trip Meter -

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

To reset the trip meter:

•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.

○The data is maintained even if the battery is disconnected.

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.

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

26 GENERAL INFORMATION

: 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 system (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.

When vehicle stands with side stand, 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.

Key

This motorcycle has a combination key, which is used for the ignition 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.

GENERAL INFORMATION 27

Ignition Switch/Steering Lock

This is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF, LOCK or P (Park) position.

A.Ignition Switch/Steering Lock

B.LOCK position

C.OFF position

D.ON position

E.P (Park) position

28 GENERAL INFORMATION

		OFF	Engine off. Electrical circuits
			off.
		ON	Engine on. All electrical
			equipment can be used.
		LOCK	Steering locked. Engine off.
			Electrical circuits off.

Steering locked. Engine off. P (Park) Tail and city lights on. Other

electrical circuits cut out.

NOTE

○The taillight is on whenever the ignition 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.

Right Handlebar Switches

Engine Stop Switch:

In addition to the ignition switch, the engine stop switch must be in

theposition for the motorcycle to operate.

The engine stop switch is for emergency use. If required, move the switch

to the position.

GENERAL INFORMATION 29

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