W800

Motorcycle
Assembly & Preparation
Manual
 Foreword
In order to ship Kawasaki vehicles as effi- DANGER
ciently as possible, they are partially disassem- DANGER indicates a hazardous situa-
bled before crating. Since some of the most tion which, if not avoided, will result in
commonly removed parts have a direct bear- death or serious injury.
ing on a vehicle’s reliability and safety, consci-
entious pre-sale assembly and preparation be-
comes extremely important. Good setup pro-
WARNING
cedures can prevent needless warranty claims WARNING indicates a hazardous situa-
and give customers a greater sense of confi- tion which, if not avoided, could result
dence in Kawasaki and their Kawasaki Dealers. in death or serious injury.
This Assembly and Preparation Manual ex-
plains step by step procedures of the following NOTICE
items for all Kawasaki W800.
NOTICE is used to address practices not
related to personal injury.
1. Uncrating
2. Assembly
3. Preparation NOTE
○This note symbol indicates points of particular
The selling dealer assumes sole responsibil- interest for more efficient and convenient op-
ity for any unauthorized modifications prior to eration.
sale. Refer to your Service Binder for any Ser-
vice Bulletins specifying Factory Directed Mod-
ifications (Special Claims) which must be per- Kawasaki Heavy Industries, Ltd. accepts no
formed before the vehicle is ready for sale. liability for any inaccuracies or omissions in this
Whenever you see the following symbols publication, although every possible measure
heed their instructions! Always follow safe has been taken to make it as complete and ac-
operating and maintenance practices. curate as possible. All procedures and specifi-
cations subject to change without notice.

© 2010 Kawasaki Heavy Industries, Ltd. Sep., 2012

 Table of Contents

Uncrating ...................................................................................... 3
Opening Crate ............................................................................. 3
Parts Check ................................................................................. 4
Assembly ...................................................................................... 5
Handlebar.................................................................................... 5
Rear View Mirrors (Left and Right), (EJ800AB/AC)..................... 5
Rear View Mirrors (Left and Right), (EJ800AD) .......................... 6
Preparation ................................................................................... 6
Battery Service ............................................................................ 6
French Labels (EJ800AB/AC) ..................................................... 11
Front Brake Fluid......................................................................... 11
Brake Disc Cleaning .................................................................... 12
Rear Brake Adjustment ............................................................... 12
Clutch Lever and Cable ............................................................... 13
Drive Chain.................................................................................. 14
Rear Shock Absorber .................................................................. 16
Tire Air Pressures........................................................................ 16
Fuel ............................................................................................. 17
Engine Oil (4-stroke) ................................................................... 17
Throttle Grip and Cable ............................................................... 18
Rear Brake Light Switch .............................................................. 19
Idle Speed Adjustment ................................................................ 19
Headlight Aim .............................................................................. 20
Fastener Check ........................................................................... 22
Standard Torque Table ................................................................ 24
Test Ride the Motorcycle ............................................................. 24
A & P Check List ......................................................................... 24
 UNCRATING 3

Uncrating • First, remove the lower bolts (D = 12, L = 16)

(2) at the handlebar holder and discard them.
Opening Crate • Remove the upper bolts (D = 8, L = 12) (2) to
take off the crate bracket and discard them.
WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrat-
ing to prevent injury.

A. Upper Bolts (D = 8, L = 12)

B. Crate Bracket
C. Lower Bolts (D = 12, L = 16)

NOTE
○Remove the dummy bolts after rolling the ve-
hicle off the crate base.
WARNING
The steel crate panel plates and fasten- • Take out all the bolts and screws and remove
the top and sides of the crate.
ers have sharp edges. Always wear pro-
tective gloves, boots and eye protection
when uncrating to prevent injury.

• Clear a space about 6 m (20 ft) square to give

yourself plenty of space to work.
• Place the crate upright on its base.
• Remove the
Remove cardboard cover.
• the parts box.
NOTICE
When removing the crate bracket from
the motorcycle, be careful not to drop
any parts or the bracket onto the fuel
tank and other components, and not to
scratch the fuel tank or other compo-
nents with the crate bracket.
4 UNCRATING

Parts Check
• Open the parts box, and check the parts against the illustrations. There may be minor differences
between these illustrations and the actual vehicle parts. In the following charts under Remarks, D
= diameter in millimeters, and L = length in millimeters.

No. Part Name Qty Remarks

1 Handelebar Clamp Bolt 2 D = 8, L = 35
2 (EJ800AB/AC)
Rear View Mirror, LH & RH 2
3 (EJ800AD)
Rear View Mirror, LH & RH 2
Rear View Mirror Nut (Lower) 2
4 Battery Electrolyte, YTX12-BS 1 12 V 10 Ah
5 (EJ800AB/AC)
French Label for European Model only
Daily Safety Check Label 1 P/No. 56033-0715
6 Owner’s Manual 1
 ASSEMBLY 5

Assembly Handlebar Clamp Bolt Tightening

• Tighten the front handlebar clamp bolts first,
Handlebar and then the rear handlebar clamp bolts to the
specified torque. There will be a gap at the
Handlebar Installation rear part of the clamp after tightening.
• Remove the dummy bolts (2) from the han-
dlebar clamps and discard them.
Torque: 25 N·m (2.5 kgf·m, 18 ft·lb)

Rear View Mirrors (Left and Right),

(EJ800AB/AC)
• Screw the lower end of the right rear view mir-
ror into the holder all the way, and tighten the
rear view mirror nut (lower) to the specified
torque.
Rear View Mirror Nut (Lower) Torque:
30 N·m (3.1 kgf·m, 22 ft·lb)

• Loosen the rear view mirror locknut (upper)

(left-hand threads) clockwise and turn the
A. Dummy Bolts
rear view mirror stay to assure visibility to the
B. Handlebar Clamps (Upper) rear with the operator sitting on the motorcy-
cle.
• Install the handlebar clamp bolts (D = 8, L
= 35) (2) to the front holes of the handlebar NOTE
clamps. ○The threads of the rear view mirror stay are
• Check the handlebar position so that its
punched mark is aligned with the edge of the
applied with a grease by the factory. Do
not wipe off the grease from the threads be-
lower handlebar clamp. fore tightening the locknut (upper) (left-hand
• If the handlebar position is not correctly
aligned, set the handlebar to the correct po-
threads).
sition. • Hold the nut (lower) and tighten the locknut
(upper) to the specified torque.
Rear View Mirror Locknut (Upper) Torque:
30 N·m (3.1 kgf·m, 22 ft·lb)

A. Handlebar Clamp Bolts (Front) (D = 8,

L = 35)
B. Punched Mark
C. Gap
A. Nut (Lower)
D. Handlebar Clamp Bolts (Rear)
B. Locknut (Upper)
C. Stay
D. Mirror
6 PREPARATION

• Adjust the rear view mirror by slightly moving

only the mirror portion of the assembly.
Preparation
• Installation and adjustment of the left side mir-
ror is common with the right side. Follow the
Battery Service
procedure specified for the right side. Battery Removal
The battery used in this motorcycle is a sealed
type and never needs to be refilled. Follow the
Rear View Mirrors (Left and Right), procedure for activating a new battery to ensure
(EJ800AD) the best possible battery performance.
• Slide the cover. • Insert the ignition key into the seat lock and
• Screw the lower end of the right rear view mir-
ror into the holder all the way, and tighten the
turn it clockwise to remove the seat.

rear view mirror nut (lower) to the specified

torque.
Rear View Mirror Nut (Lower) Torque:
30 N·m (3.1 kgf·m, 22 ft·lb)

• Loosen the rear view mirror locknut (upper)

(left-hand threads) clockwise and turn the
rear view mirror stay to assure visibility to the
rear with the operator sitting on the motorcy-
cle.
•Hold the nut (lower) and tighten the locknut
(upper) to the specified torque. A. Seat
Rear View Mirror Locknut (Upper) Torque: B. Seat Lock
30 N·m (3.1 kgf·m, 22 ft·lb) C. Ignition Key
D. Turn Clockwise

• Pull out the ignition key from the seat lock to

prevent from bending the key.
• Remove the screws (D = 6, L = 16) (2) on the
left side cover.
• Remove the left side cover from the projection
by pushing the side cover forward and pulling
it outward.

A. Nut (Lower)
B. Locknut (Upper)
C. Stay
D. Mirror
E. Cover

• Install the cover.

• only thethemirror
Adjust rear view mirror by slightly moving
portion of the assembly.
A. Left Side Cover
B. Screws (D = 6, L = 16)
• ror is common with
Installation and adjustment of the left side mir-
the right side. Follow the C. Projection
procedure specified for the right side.
• Make sure the ignition switch is turned to OFF.
• Remove the tool kit then remove the screw (D
= 6, L = 20) from the bracket.
• Move the bracket and ECU aside without dis-
connecting the connectors from the ECU.
 PREPARATION 7

Battery Activation
Electrolyte Filling
• Make sure that the model name of the elec-
trolyte container matches the model name of
the battery. These names must be the same.
Battery Model Name
EJ800A: YTX12-BS

A. Screw (D = 6, L = 20)
B. Bracket
C. ECU

• Remove the front bolt (D = 6, L = 16) and

washer (D = 7 × 16), and rear bolt (D = 6, L =
25).
• Pull out the battery (+) and (–) cables.
A. Model Name of the Electrolyte
B. Model Name of the Battery

NOTICE
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 per-
formance. Be sure to use the electrolyte
container with the same model name as
A. Battery Holder the battery since the electrolyte volume
B. Front Bolt (D = 6, L = 16) and Washer and specific gravity vary with the battery
(D = 7 × 16) type.
C. Rear Bolt (D = 6, L = 25)
D. Battery (+) Cable
NOTICE
E. Battery (–) Cable Do not remove the aluminum sealing
sheet from the filler ports until just prior
• Take the battery out of the battery case. to use. Be sure to use the dedicated
electrolyte container for correct elec-
trolyte volume.

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 medi-
cal attention for more severe burns.
A. Battery

• Clean the terminals.

8 PREPARATION

• Place the battery on a level surface. NOTE

• peeling,totears,
Check see that the sealing sheet has no
or holes in it.
○Do not tilt the electrolyte container.
• Remove the sealing sheet.
NOTE
○The battery is vacuum sealed. If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.

• Check the electrolyte flow.

• Ifports,
no air bubbles are coming up from the filler
or if the container cells have not emp-
tied completely, tap the container a few times.
NOTE
○Be careful not to have the battery fall down.
A. Sealing Sheet
B. Filler Ports

• Remove
vinyl bag.
the electrolyte container from the

• Detach the strip of caps from the container

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 at-
tempt to separate individual cells.
A. Air Bubbles
B. Tap the Container

• Keep the container in place. Don’t remove

the container from the battery, the battery re-
quires all the electrolyte from the container for
proper operation.
NOTICE
Removal of the container before it is
completely empty can shorten the ser-
vice life of the battery. Do not remove the
container until it is completely empty.
A. Strip of Caps
B. Sealed Cells

• Place the electrolyte container upside down

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.
 PREPARATION 9

• After filling, let the battery sit for 20 ∼ 60

minutes with the electrolyte container kept in
• Iflowusing a recommended battery charger, fol-
the charger’s instructions for newly acti-
place, which is required for the electrolyte to vated sealed battery.
fully permeate into the plates. Kawasaki-recommended chargers:
• Make sure that the container cells have emp-
tied completely, and remove the container
Battery Mate 150-9
from the battery. OptiMate PRO 4-S/PRO S/PRO 2
• Place the strip of caps loosely over the filler
ports, press down firmly with both hands to
Yuasa MB-2040/2060
Christie C10122S
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
• Ifequivalent
the above chargers are not available, use
one.
the battery. • Let battery sit 30 minutes after initial charge,
then check voltage using a voltmeter. (Volt-
age immediately after charging becomes tem-
porarily high. For accurate measuring, let the
battery sit for given time.)
NOTE
○Charging rates will vary depending on how
long the battery has been stored, tempera-
ture, and the type of charger used. If voltage
is not at least 12.8 volts, repeat charging cy-
cle.
○To ensure maximum battery life and customer
satisfaction, it is recommended the battery be
A. Strip of Caps load tested at three times its amp-hour rating
for 15 seconds.
Re-check voltage and if less than 12.8 volts
repeat the charging cycle and load test. If still
below 12.8 volts the battery is defective.

Battery Installation
• Turn the ignition switch OFF.
• terminals
Place the battery into the battery case with its
faces to the rear.

NOTICE
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. A. Battery

Initial Charge • Run the battery cables as shown, and first

•Newly activated sealed batteries require an
initial charge.
connect the red capped positive cable to the
(+) terminal, then negative cable to the (–)
Standard Charge: 1.2 A × 5 ∼ 10 hours terminal.
• Connect the (–) negative lead connector at
the rear of the (–) terminal.
10 PREPARATION

A. Battery A. Screw (D = 6, L = 20)

B. (+) Cable B. Bracket
C. (–) Cable C. ECU
D. Connector
Side Cover Installation
E. Bottom Side
• Insert the projection on the left side cover into
the grommet on the frame to position the left
• Put a light coat of grease on the terminals to
prevent corrosion.
side cover.

• Cover (+) the terminal with its protective cap. • Install the screws (D = 6, L = 16) (2) to the left
side cover.
• Reinstall the battery holder with front bolt (D
= 6, L = 16) and washer (D = 7 × 16), and rear
bolt (D = 6, L = 25).
• Tighten the bolts.

A. Left Side Cover

B. Projection
C. Grommet
A. Battery (+) Cable
B. Battery (–) Cable Seat Installation
C. Battery Holder • Insert the tab on the front of the seat into the
hole on the bracket, and the projections on
D. Clamp the middle of the seat into the holes in the
E. Front Bolt (D = 6, L = 16) and Washer frame.
(D = 7 × 16)
F. Rear Bolt (D = 6, L = 25)

• Secure the leads and cable with the clamp.

• case, thenthetighten
Reinstall ECU and bracket on the battery
the screw (D = 6, L = 20).
 PREPARATION 11

A. Seat A. Front Brake Fluid Reservoir

B. Tab B. Lower Level Line
C. Hole
D. Projections
• Ifthethelower
fluid level in the reservoir is lower than
level line, check for fluid leaks in the
E. Holes front brake lines, and fill the reservoir.

• Pull up the seat to make sure it is securely

• Loosen the screws to remove the front brake
fluid reservoir cap and diaphragm.
locked.
• Fill the reservoir to the upper level line with
DOT4 brake fluid. Inside the front brake
French Labels (EJ800AB/AC) reservoir is a stepped line showing the upper
level line.
Label Installation (For European Mod-
els)
• Wipe off any oil or grease from the area to
be sticking the label. Refer to the following
photograph for the label location.
• Peel the French label (Daily Safety Checks;
P/No. 56033-0715) off the backing sheet and
stick it next to the English label under the seat
as shown.

A. Front Brake Fluid Reservoir

B. Upper Level Line

WARNING
Brake fluid that is contaminated by
moisture or dirt, mixed or contains air
has a lower boiling point and can cause
the brake to be ineffective or fail, and it
may cause rubber parts to deterioate,
1. English Label
resulting in an accident causing injury
2. French Label (Arrow indicate the top or death. Never reuse old brake fluid.
of label) Do not use fluid from a container that
has been left unsealed or that has been
open for a long time. Do not mix two
Front Brake Fluid types and brands of fluid for use in the
brake. Don’t leave the reservoir cap off
Front Brake Fluid Level Inspection for any length of time to avoid moisture
• With the front brake fluid reservoir held hori-
zontal, check that the fluid level is above the
contamination of the fluid. Don’t add or
change the fluid in the rain or when a
lower level line. strong wind is blowing.
12 PREPARATION

NOTICE • When air bleeding is finished, check that the

fluid level is between the upper and lower
Brake fluid quickly ruins painted sur-
faces. Wipe up any spilled fluid immedi- level lines.
ately. •Install the diaphragm and reservoir cap.
•Tighten the bleed valve to the specified
• Operate the brake lever several times. torque.
• brake line.spongy, there might be air in the
If it feels Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Ifline.necessary, bleed the air in the front brake • Apply the brake forcefully for a few seconds,
and check for fluid leakage around the fittings.
• Also
tings.
check for fluid leakage around the fit-
Brake Disc Cleaning
Front Brake Line Air Bleeding
• Remove the reservoir cap and diaphragm, • Clean
vent.
the front brake disc using oilless sol-
and check that there is plenty of fluid in the
reservoir. WARNING
NOTE An anticorrosive treatment applied to
the brake discs will increase braking
○The fluid level must be checked several times distance and can cause an accident
during the bleeding operation and replenished resulting in serious injury or death. Re-
as necessary. If the fluid in the reservoir runs move the anticorrosive treatment using
completely out any time during bleeding, the an oilless solvent.
bleeding operation must be repeated from the
beginning since air will have entered the line.

• Attach a clear plastic hose to the bleed valve

on the front brake caliper and run the other
end of the hose into a container.
• With the reservoir cap off, slowly pump the
brake lever several times until no air bubbles
can be seen rising up through the fluid from
the holes at the bottom of the reservoir. This
bleeds the air from the brake master cylinder
end of the line.
• Pump the brake lever a few times until it
becomes hard and then, holding the lever
squeezed, quickly open (turn counterclock-
wise) and close the bleed valve. Then release
Rear Brake Adjustment
the lever. Repeat this operation until no more
air can be seen coming out into the plastic Brake Pedal Free Play Inspection
hose.
• The brake pedal should have 20 ∼ 30 mm
(0.8 ∼ 1.2 in.) of free play when the pedal is
pushed down lightly by hand.
Brake Pedal Free Play:
20 ∼ 30 mm (0.8 ∼ 1.2 in.)

A. Hold the brake lever applied.

B. Quickly open and close the bleed valve.
C. Release the brake lever.
 PREPARATION 13

Clutch Lever and Cable

Clutch Lever Free Play Inspection
• Check that the clutch lever has the specified
amount of free play as shown in the figure.
Clutch Lever Free Play:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)

A. Brake Pedal
B. Free Play

• Rotate the wheel to check for brake drag.

• returns totheitspedal
Operate a few times to see that it
rest position immediately upon
release.
• Check braking effectiveness.
• If the pedal has improper play, adjust it.
Brake Pedal Free Play Adjustment A. Adjuster
• Turn the adjusting nut at the brake cam lever
so that the pedal has 20 ∼ 30 mm (0.8 ∼ 1.2
B. Locknut
C. Free Play: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
in.) of play.
• Ifplay.
the free play is incorrect, adjust the free

Clutch Lever Free Play Adjustment

• Loosen the locknut and turn the adjuster so
that the clutch lever will have 2 ∼ 3 mm (0.08
∼ 0.12 in.) of free play.
• If it cannot be done at the clutch lever, use the
adjusting nuts on the lower end of the clutch
cable.
• Loosen the left front footpeg bolt to move the
footpeg aside.

A. Adjusting Nut
• Remove the gear shift pedal and engine
sprocket cover.
• Check that there is no brake drag.
• Check braking effectiveness.
WARNING
An improperly adjusted brake could
drag and cause the brake to overheat,
damaging the brake assembly and pos-
sibly locking the rear wheel, resulting
in loss of control. Always maintain the
proper brake adjustment.

A. Left Front Footpeg Bolt

B. Gear Shift Pedal
C. Engine Sprocket Cover
14 PREPARATION

• Loosen the locknut and adjust the clutch lever

free play by turning the adjusting nut. Drive Chain
• Hold the adjusting nut using the wrench and
tighten the locknut. Drive Chain Slack and Wheel Alignment
Inspection
• Set the motorcycle up on its side stand.
• fied amount
Make sure that the drive chain has the speci-
of play, and that the left and right
notches are on the same marks or points on
the left and right of the swingarm.
WARNING
Misalignment of the wheel will result in
abnormal tire wear and can cause an un-
safe riding condition. Be sure the wheel
is properly aligned.
A. Locknut
B. Adjusting Nut
• Rotate the rear wheel to find the position
where the chain is tightest, and measure
C. Clutch Cable the maximum chain slack by pulling up and
pushing down the chain midway between the
• Install the engine sprocket cover and tighten
the bolts.
engine sprocket and rear sprocket.
Drive Chain Slack:
Torque: 12 N·m (1.2 kgf·m, 106 in·lb) 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

• Position the left front footpeg in place and

tighten the bolt.
Torque: 59 N·m (6.0 kgf·m, 44 ft·lb)

• Install the gear shift pedal, it should be posi-

tioned approx. 31 mm (1.2 in.) lower than the
top of the footpeg.

A. 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

• Ifjusttheit drive chain is too tight or too loose, ad-

so that the chain slack will be within the
standard value.
WARNING
A. Engine Sprocket Cover A chain that breaks or jumps off the
sprockets could snag on the engine
B. Left Front Footpeg sprocket or lock the rear wheel, severely
C. Gear Shift Pedal damaging the motorcycle and causing
D. Approx. 31 mm (1.2 in.) it to go out of control. Inspect the chain
for damage and proper adjustment.
NOTE
Drive Chain Slack Adjustment
○After the adjustment is made, start the engine
and check that the clutch does not slip and • Remove
link nut.
the snap pin and loosen the torque
that it releases properly.
○For minor corrections, use the adjuster at the
clutch lever.
 PREPARATION 15

A. Torque Link A.Marks

B. Snap Pin B.Notch
C. Torque Link Nut C.Indicator
D.Drive Chain Adjuster (Left and Right)
• Loosen
nuts.
the left and right chain adjuster lock-
E. Drive Chain Adjuster Locknut (Left and
• Remove
axle nut.
the cotter pin, and loosen the rear Right)

NOTE
○Wheel alignment can also be checked using
the straightedge or string method.

• Tighten both chain adjuster locknuts.

• torque. the rear axle nut to the specified
Tighten

Torque: 98 N·m (10 kgf·m, 72 ft·lb)

• Tighten
torque.
the torque link nut to the specified

Torque: 32 N·m (3.3 kgf·m, 24 ft·lb)

A. Rear Axle Nut
• Install the snap pin.
B.
C.
Cotter Pin
Drive Chain Adjuster (Left and Right)
• again atthethewheel,
Rotate measure the chain slack
tightest position, and readjust if
D. Drive Chain Adjuster Locknut (Left and necessary.
Right) • Check the wheel alignment.
• Install a new cotter pin.
• Ifright
the chain is too loose, turn out the left and
chain adjusters evenly. NOTE
• chainchain
If the is too tight, turn in the left and right
adjusters evenly.
○When inserting the cotter pin, if the slots in the
nut do not align with the cotter pin hole in the
• Turn both chain adjusters evenly until the
drive chain has the correct amount of slack.
axle, tighten the nut clockwise up to the next
alignment.
To keep the chain and wheel properly aligned, ○It should be within 30 degrees.
the wheel alignment indicator notches should ○Loosen once and tighten again when the slot
align with the same marks on each side of goes past the nearest hole.
the swingarm.
16 PREPARATION

A. Cotter Pin A. Spring Preload Adjuster

B. Turning Clockwise B. Screwdriver
C. Stopper
• Bend the cotter pin over the nut.
• Turn the both preload adjuster to the 2nd po-
sition.

Tire Air Pressures

• To prevent flat-spotting during shipment, the
tires are over-inflated before crating. Adjust
the pressures to the specified values in the
front and rear, and make sure to tighten the
caps securely.
Tire Air Pressure [when cold]:
Front: 200 kPa (2.00 kgf/cm², 28 psi)
A. Cotter Pin Rear: 225 kPa (2.25 kgf/cm², 32 psi)
B. Nut

• Check the rear brake effectiveness.

WARNING
A loose axle nut can lead to an acci-
dent resulting in serious injury or death.
Tighten the axle nut to the proper torque
and be sure the cotter pin is installed
correctly.

Rear Shock Absorber

Spring Preload Inspection A. Tire Air Pressure Gauge
• Check the position of the spring preload ad-
juster on the rear shock absorbers.
STD Spring Preload: 2nd position

NOTE
○The spring preload position is the seating po-
sition of the adjuster against the stopper on
the damper body.
 PREPARATION 17

Fuel
WARNING
Gasoline is extremely flammable and
can be explosive under certain condi-
tions, creating the potential for serious
burns. Turn the ignition switch “OFF”.
Do not smoke. 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. If the tank A. Engine Oil Drain Plug
is filled completely to the top, heat may
• Park the vehicle on level ground.
cause the fuel to expand and overflow
through the vents in the tank cap. Af- • gine hasstarting
Before
oil.
the engine, check that the en-
ter refueling, make sure the tank cap is
closed securely. If gasoline is spilled on • With the motorcycle held level, check that the
engine has oil through the oil level inspection
the fuel tank, wipe it off immediately. window in the lower right side of the engine.

• Open the fuel tank cap, and check for debris

in the fuel tank.
NOTICE
If the engine is run without oil, it will be
• Fill the fuel tank with one gallon or four liters
of unleaded gasoline. Use a gasoline with a
severely damaged.

minimum octane rating shown below.

Use clean, fresh unleaded gasoline with an
• Start the engine and run it for several minutes
at idle speed. Stop the engine, then wait sev-
octane rating equal to or higher than that shown eral minutes until the oil settles.
in the table.
Fuel Type Unleaded Gasoline
• With the motorcycle held level, check the en-
gine oil level through the oil level inspection
Minimum window. The oil level should come up be-
Research Octane Number (RON) tween the upper and lower level lines next to
Octane
91 the gauge.
Rating

• Close
leaks.
the fuel tank cap, and check for any

Engine Oil (4-stroke)

Engine Oil Level Inspection
NOTE
○This vehicle’s engine is filled with 10W-40 oil
from the factory. DO NOT DRAIN and refill
the crankcase before use. Check oil level and
drain plug tightness. A. Oil Level Inspection Window
Engine Oil Drain Plug Torque: B. Upper Level Line
29 N·m (3.0 kgf·m, 21 ft·lb) C. Lower Level Line
D. Oil Filler Cap
18 PREPARATION

• Ifoilthethrough
oil level is too high, remove the excess
the oil filler opening, using a sy-
ringe or some other suitable device.
• If the oil level is too low, add oil to reach the
correct level. Use the same type of oil that is
already in the engine.
• When installing the oil filler cap, be sure the
O-ring is in place, and tighten the cap in finger
tight.
Recommended Engine Oil
Type: API SG, SH, SJ, SL or SM with
JASO MA, MA1 or MA2
A. Throttle Grip
Viscosity: SAE 10W-40
B. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Capacity: 2.7 L (2.9 US qt)
[when filter is not removed] • Check that the throttle grip moves smoothly
from full open to close, and the throttle closes
2.9 L (3.1 US qt)
quickly and completely in all steering posi-
[when filter is removed] tions by the return spring. If the throttle grip
does not return properly, check the throttle ca-
NOTE ble routing, grip free play, and for possible ca-
○Do not add any chemical additive to the oil. ble damage. Then lubricate the throttle ca-
Oils fulfilling the above requirements are fully bles.
formulated and provide adequate lubrication • Run the engine at idle speed, and turn the
handlebar all the way to the right and left to
for both the engine and the clutch.
ensure that the idle speed does not change.
Although 10W-40 engine oil is the recom- If the idle speed increases, check the throttle
mended oil for most conditions, the oil viscosity grip free play.
may need to be changed to accommodate
atmospheric conditions in your riding area. WARNING
Operation with incorrectly routed, im-
properly adjusted or damaged cables
could result in an unsafe riding con-
dition. Be sure the cables are routed
correctly, properly adjusted and are not
damaged in any way.

Throttle Grip Free Play Adjustment

• Loosen both locknuts of the throttle cables
and turn both adjusters in completely to give
the throttle grip plenty of play.
• Turn out the decelerator cable adjuster until
there is no play when the throttle grip is com-
pletely closed. Tighten the locknut.
Throttle Grip and Cable
Throttle Grip Free Play Inspection
• Inspect the throttle grip free play. If the free
play is incorrect, adjust the throttle cables.
Throttle Grip Free Play:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
 PREPARATION 19

A. Accelerator Cable A. Rear Brake Light Switch

B. Decelerator Cable B. Adjusting Nut
C. Adjusters C. Lights sooner
D. Locknuts D. Lights later

• Turn out the accelerator cable adjuster un-

til the specified amount of play is obtained.
NOTICE
Tighten the locknut. To avoid damaging the electrical con-
nections inside the switch, be sure that
the switch body does not turn during ad-
Rear Brake Light Switch justment.
Rear Brake Light Switch Adjustment
• Turn on the ignition switch. The brake light
should illuminate when the brake pedal is de- Idle Speed Adjustment
pressed about 15 mm (0.6 in.)
• Start the engine and warm it up thoroughly.
• (rpm) bytheturning
Adjust idle speed to 1 150 ∼ 1 250 r/min
the idle adjusting screw.
Idle Speed: 1 150 ∼ 1 250 r/min (rpm)

A. Brake Pedal
B. Pedal Travel

• Ifbrake
it does not, turn the adjusting nut at the rear
light switch as required. A. Idle Adjusting Screw
• To adjust the rear brake light switch, move the
switch up or down by turning the adjusting nut. WARNING
The engine gets extremely hot during
normal operation and can cause serious
burns. Never touch a hot engine.
20 PREPARATION

• Open and close the throttle grip a few times

to make sure that the idle speed does not
change.
• With the engine idling, turn the handlebar to
each side. If handlebar movement changes
the idle speed, check the throttle cable routing
and free play.
WARNING
Operation with incorrectly routed or
damaged throttle cable could result in
an unsafe riding condition. Be sure the
throttle cable is routed correctly, prop-
erly adjusted and is not damaged in any
way.

• Check for any exhaust leaks and correct if

necessary.

Headlight Aim
The headlight beam is adjustable both hori-
zontally and vertically. Headlight aim must be
correctly adjusted for safe riding as well as on-
coming drivers. In most areas it is illegal to ride
with improperly adjusted headlights.
Horizontal Adjustment
• Turn the horizontal adjuster in or out until the
beam points straight ahead.

A. Horizontal Adjuster
B. Vertical Adjuster

Vertical Adjustment
• Turn the vertical adjuster in or out to adjust
the headlight vertically.
NOTE
○On high beam, the brightest point should be
slightly below horizontal with the motorcycle
on its wheels and the rider seated. Adjust
the headlight to the proper angle according to
local regulation.
 PREPARATION 21

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22 PREPARATION

Fastener Check
• The torque values listed are for assembly and preparation items only, see the appropriate Service
Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before
retail delivery. Also check to see that each cotter pin or circlip is in place.
 PREPARATION 23

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
Steering
1 Handlebar clamp bolt 25 2.5 18 S
Brake
2 Front master cylinder clamp bolt 11 1.1 97 in·lb S
3 Front caliper bleed valve 7.8 0.80 69 in·lb
4 Front caliper mounting bolt 34 3.5 25
5 Rear brake pedal mount bolt (EJ800AB) 25 2.5 18
Rear brake pedal mount bolt (EJ800AC ∼ ) 34 3.5 25
6 Rear brake torque link bolt and nut 32 3.3 24
Wheels
7 Front axle clamp bolt (Left) 20 2.0 15
8 Front axle nut 98 10 72
Suspension
9 Front fork upper clamp bolt (Left and Right) 20 2.0 15
10 Front fork lower clamp bolt (Left and Right) 29 3.0 21
Rear shock absorber mounting nut (Left and
11 59 6.0 44
Right)
Rear shock absorber mounting bolt (Left and
12 44 4.5 32
Right)
13 Swingarm pivot shaft nut 98 10 72
Others
14 Front footpeg bracket bolt (Left and Right) 59 6.0 44
15 Engine oil drain plug 29 3.0 21
Rear view mirror locknut (upper) (Left and
16 30 3.1 22 LH
Right)
17 Rear view mirror nut (lower) (Left and Right) 30 3.1 22
Cotter Pins, Circlips or Snap Pins
18 Rear axle nut cotter pin – – –
19 Front footpeg pin circlip (Left and Right) – – –
20 Rear footpeg pin circlip (Left and Right) – – –
Rear brake pedal torque link bolt and nut snap
21 – – –
pins

S: Tighten the upper/front clamp bolt first, and then the lower/rear clamp bolt.
LH: Left-hand threads.
24 PREPARATION

Electrical System:
Standard Torque Table Headlight - check high and low beams.
This table relating tightening torque to thread Taillight - check operation.
diameter, lists the basic torque for bolts and Brake Light - check operation.
nuts. Use this table for only the bolts and nuts
which do not require a specific torque value. Turn Signal Lights - check operation.
All of the values are for use with dry solvent Horn - check operation.
-cleaned threads. Instrument Lights and Indicator Lights -
General Fasteners Check operation.
Threads Torque Engine Stop Switch Works:
dia. Starter Interlock Switch Works:
(mm) N·m kgf·m ft·lb
No Unusual Noises:
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
No Fuel, Oil, or Brake Fluid Leaks:
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
PREPARATION COMPLETE.
8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 WARNING
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 New tires are slippery and may cause
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72 loss of control and serious injury or
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115 death. A break-in period of 160 km (100
miles) is necessary to establish nor-
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
mal tire traction. During break-in, avoid
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240 sudden and maximum braking, acceler-
ation, and hard cornering.

Test Ride the Motorcycle

• Complete the test ride checklist. A & P Check List
Control Cables:
Throttle cables must work without binding
• Complete the A & P Check List.
in any steering position.
Steering:
Action is free from lock-to-lock.
Suspension:
Check operation front and rear.
Engine:
Electric starter works properly and engine
starts promptly. Good throttle response and
return.
Transmission and Clutch:
Smooth operation.
Brakes:
Adequate, smooth stopping power, No drag.
Meter:
Check operation
 MODEL APPLICATION
Year Model Name
2011 EJ800AB W800
2012 EJ800AC W800
2013 EJ800AD W800

Part No. 99939-1334-03