• Install a new cotter pin.
NOTE

○When inserting the cotter pin, if the slots in the
nut do not align with the cotter pin hole in the
axle, tighten the nut clockwise up to the next
alignment.
○It should be within 30 degrees.
○Loosen once and tighten again when the slot
goes past the nearest hole.

A.
B.
C.
D.

Grease Applying Area
Front Axle
About 10 mm (0.4 in.)
About 70 mm (2.8 in.)

the front axle from the left side of the
• Insert
wheel.
the axle nut and washer from the right
• Install
side of the wheel.

A. Cotter Pin
B. Turning Clockwise

• Bend the cotter pin over the nut.

12 ASSEMBLY

WARNING
It may take several applications of the
brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an
accident resulting in injury or death. Do
not attempt to ride the motorcycle until a
firm brake lever is obtained by pumping
the lever until the pads are against the
disc.

• Install the rubber cap (europe model only).

A. Cotter Pin
B. Nut

WARNING
A loose axle nut can lead to an accident resulting in serious injury or death.
Tighten the axle nut to the proper torque
and be sure the cotter pin is installed
correctly.
the right front brake caliper mounting
• Tighten
bolts (D = 8, L = 35) to the specified torque.
Torque: 25 N·m (2.5 kgf·m, 18 ft·lb)

A. Rubber Cap

the front wheel rotation sensor (ABS
• Install
equipped models).
a non-permanent locking agent to the
• Apply
threads of the front wheel rotation sensor

Rear View Mirrors (Left and Right)

mounting bolt and tighten it (ABS equipped
models).
Torque: 8.0 N·m (0.82 kgf·m, 71 in·lb)

up the rubber boot.
• Slide
the mounting area of the right rear view
• Screw
mirror into the holder all the way, and tighten

•
•

the lower hexagonal area securely.
Turn the stay to assure visibility to the rear
with the operator sitting on the motorcycle.
While holding the lower hexagonal area,
tighten the upper hexagonal area (locknut).

NOTE

○The upper hexagonal area (locknut) has left
hand threads.

A. Front Caliper
B. Front Caliper Mounting Bolts (D = 8, L
= 35)
C. Front Wheel Rotation Sensor (ABS
Equipped Models)
D. Front Wheel Rotation Sensor Mounting
Bolt (ABS Equipped Models)

• Check the front brake.

ASSEMBLY 13

A. Rubber Boot
B. Lower Hexagonal Area for Tightening
C. Upper Hexagonal Area (Locknut)
D. Rear View Mirror (Right)

A. Windshield
B. Plastic Washers (D = 11.4 × 18) and
Bolts (D = 6, L = 14)

the rubber boot to the original position.
• Slide
Adjust
rear view mirror by slightly moving
• only thethemirror
portion of the assembly.

Handle Cover (KLE300A Model)

A. Stay
B. Mirror

A. Right Handle Cover
B. Damper

and adjustment of the left side mir• Installation
ror is common with the right side mirror. Fol-

the collars and washer (D = 6.2 × 15)
• Install
to the right handle cover.

low the procedure specified for the right side
mirror.

the damper is in place on the right han• Install
dle cover.

Windshield

the windshield.
• Install
Install
and
the four plastic washers (D
• = 11.4 × 18)tighten
and the bolts (D = 6, L = 14) on
the windshield securely.

A. Right Handle Cover
B. Collars
C. Washer (D = 6.2 × 15)

14 ASSEMBLY

the right handle cover to the brake lever
• Install
assembly.
the socket bolt (D = 6, L = 12) and lock
• Install
nut (D = 5).

A. Left Fog Light Stay
B. Clamps
C. Left Fog Light Lead
A. Right Handle Cover
B. Socket Bolt (D = 6, L = 12)
C. Lock Nut (D = 5)

the left fog light stay and bolts (D = 8,
• Install
L = 12) and tighten them.
Torque: 17 N·m (1.7 kgf·m, 13 ft·lb)

the left handle cover in the same man• Install
ner as the right handle cover to the clutch
lever assembly.

Fog Light Stay (KLE300A Model)

the bolts (D = 6, L = 25) and washers.
• Remove
Remove
the fog lights.
• Remove the
bolts (D = 8, L = 12).
• Take off the crate
bracket and discard it.
•

A.
B.
C.
D.

Bolts (D = 6, L = 25) and Washers
Fog Lights
Bolts (D = 8, L = 12)
Crate Bracket

the left fog light lead clamps to the left
• Install
fog light stay.

A. Left Fog Light Stay
B. Bolts (D = 8, L = 12)
the left fog light, bolts (D = 6, L = 25)
• Install
and washers.

ASSEMBLY 15

A. Left Fog Light
B. Bolts (D = 6, L = 25) and Washers
C. Left Fog Light Stay
the pad is in place on the right fog light
• Install
stay.

A. Left Saddlebag Bracket
B. Plug

• Remove the saddlebag bracket bolts.

A. Saddlebag Bracket Bolts
the left saddlebag bracket and tighten
• Install
the saddlebag bracket bolts.
Torque: 25 N·m (2.5 kgf·m, 18 ft·lb)

A.
B.
C.
D.

Pad
Right Fog Light Stay
40 mm (1.6 mm)
Section E-E

the right fog light stay in the same man• Install
ner as the left fog light stay.

Saddlebag (KLE300A Model)

the plug is in place on the left saddle• Check
bag bracket.

A. Left Saddlebag Bracket
B. Saddlebag Bracket Bolts
the dampers, collars and plugs are
• Check
place on the left saddlebag.

16 ASSEMBLY

A. Left Saddlebag
B. Dampers and Collars
C. Plugs

A. Tire and Load Data
B. Important Drive Chain Information

the left saddlebag to the left saddlebag
• Install
bracket.
• Tighten the bolts (D = 6, L = 23).

C. Rear Carrier Load Limit Warning

Brake Disc Cleaning
A. Bolts (D = 6, L = 23)
B. Left Saddlebag
C. Left Saddlebag Bracket
the right saddlebag in the same man• Install
ner as the left saddlebag.

French Labels (For Canada Model)
When required, apply French labels in the
parts bag over English labels on the vehicle.
Wipe off any oil or grease from the English
label. Refer to the following figure for the label
location.
Peel the French label off the backing sheet
and apply it over the English label.

the front and rear brake discs using
• Clean
oilless solvent.

WARNING
An anticorrosive treatment applied to
the brake discs will increase braking
distance and can cause an accident
resulting in serious injury or death. Remove the anticorrosive treatment using
an oilless solvent.

•
•

A. Brake Disc

PREPARATION 17

Preparation
Battery Service
The battery used in this motorcycle is a sealed
type and never needs to be refilled. Follow the
procedure for activating a new battery to ensure
the best possible battery performance.

Battery Activation
Electrolyte Filling

sure that the model name of the elec• Make
trolyte container matches the model name of
the battery. These names must be the same.

Battery Model Name
KLE300A/B/C: FTX9-BS

Battery Removal

the ignition key into the seat lock.
• Insert
Lift
the
rear part of the seat while turning the
• key clockwise.
the seat backward.
• Remove
• Remove the ignition key.

A. Model Name of the Electrolyte
B. Model Name of the Battery

NOTICE
A. Ignition Key
B. Seat
the band.
• Remove
Remove
the
battery and terminal bolts.
• Clean the battery
terminals.
•

Each battery comes with its own specific
electrolyte container; using the wrong
container may overfill the battery with
incorrect electrolyte, which can shorten
battery life and deteriorate battery performance. Be sure to use the electrolyte
container with the same model name as
the battery since the electrolyte volume
and specific gravity vary with the battery
type.

NOTICE
Do not remove the aluminum sealing
sheet from the filler ports until just prior
to use. Be sure to use the dedicated
electrolyte container for correct electrolyte volume.
A. Band
B. Battery
C. Terminal Bolts

DANGER
Sulfuric acid in battery electrolyte can
cause severe burns. To prevent burns,
wear protective clothing and safety
glasses when handling electrolyte. If
the electrolyte comes in contact with
your skin or eyes, wash the area with
liberal amounts of water and seek medical attention for more severe burns.

18 PREPARATION

the battery on a level surface.
• Place
Check
see that the sealing sheet has no
• peeling,totears,
or holes in it.
Remove
the
sealing
sheet.
•

NOTE

○Do not tilt the electrolyte container.

NOTE

○The battery is vacuum sealed.

If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.

the electrolyte flow.
• Check
air
are coming up from the filler
If
no
• ports, orbubbles
if the container cells have not emptied completely, tap the container a few times.

NOTE

○Be careful not to have the battery fall down.

A. Sealing Sheet
B. Filler Ports
the electrolyte container from the
• Remove
vinyl bag.
the strip of caps from the container
• Detach
and set aside, these will be used later to seal
the battery.

NOTE

○Do not pierce or otherwise open the sealed
cells of the electrolyte container. Do not attempt to separate individual cells.

A. Air Bubbles
B. Tap the Container
the container in place. Don’t remove
• Keep
the container from the battery, the battery requires all the electrolyte from the container for
proper operation.

NOTICE
Removal of the container before it is
completely empty can shorten the service life of the battery. Do not remove the
container until it is completely empty.
A. Strip of Caps
B. Sealed Cells
the electrolyte container upside down
• Place
with the six sealed cells into the filler ports
of the battery. Hold the container level, push
down to break the seals of all six cells. You
will see air bubbles rising into each cell as the
ports fill.

After filling, let the battery sit for 20  60
• minutes
with the electrolyte container kept in

•

place, which is required for the electrolyte to
fully permeate into the plates.
Make sure that the container cells have emptied completely, and remove the container
from the battery.

PREPARATION 19

the strip of caps loosely over the filler
• Place
ports, press down firmly with both hands to
seat the strip of caps into the battery (don’t
pound or hammer). When properly installed,
the strip of caps will be level with the top of
the battery.

the above chargers are not available, use
• Ifequivalent
one.
battery sit 30 minutes after initial charge,
• Let
then check voltage using a voltmeter. (Voltage immediately after charging becomes temporarily high. For accurate measuring, let the
battery sit for given time.)

○Charging

NOTE

rates will vary depending on how
long the battery has been stored, temperature, and the type of charger used. If voltage
is not at least 12.6 volts, repeat charging cycle.
○To ensure maximum battery life and customer
satisfaction, it is recommended the battery be
load tested at three times its amp-hour rating
for 15 seconds.
Re-check voltage and if less than 12.6 volts
repeat the charging cycle and load test. If still
below 12.6 volts the battery is defective.

A. Strip of Caps

Battery Installation

NOTICE

the ignition switch off.
• Turn
Place
the battery upright on the battery case.
• Connect
the red capped positive (+) cable to
• the (+) terminal
first.
connect the negative (–) cable to the (–)
• Then
terminal.
a light coat of grease on the terminals to
• Put
prevent corrosion.
the (+) terminal with the red cap.
• Cover
the
band.
Install
•

Once the strip of caps is installed onto
the battery, never remove the caps, nor
add water or electrolyte to the battery.

NOTE

○Charging the battery immediately after filling
can shorten service life.

Initial Charge

activated sealed batteries require an
• Newly
initial charge.
Standard Charge:

1.2 A × 5  10 hours

a recommended battery charger, fol• Iflowusing
the charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO 2
Yuasa MB-2040/2060
Christie C10122S

A. Red Cap and Positive (+) Terminal
B. Negative (–) Terminal
C. Band

Seat Installation

the hooks of the seat under the frame.
• Insert
Insert
at the rear parts of the
• seat intothetheprojection
latch hole on the frame.
down the rear part of the seat until the
• Push
lock clicks.

20 PREPARATION

A. Reserve Tank Cap

A. Seat
B. Hooks
C. Frames
D. Projection
E. Latch Hole

• Reinstall the reserve tank cap.
NOTE

○A permanent type of antifreeze is installed in
the cooling system when shipped. It is mixed
at 50% and has the freezing point of –35 °C
(–31 °F).

Coolant
Coolant Level Inspection

the motorcycle so that it is perpen• Position
dicular to the ground.