Kawasaki BRUTE FORCE 750 4×4iEPS, BRUTE FORCE 750 4×4i, KVF750 4×4 EPS, BRUTE FORCE 750 4x4iEPS, BRUTE FORCE 750 4x4i Assembly & Preparation Manual

BRUTE FORCE 750 4×4iEPS

BRUTE FORCE 750 4×4i

KVF750 4×4 EPS

KVF750 4×4

All Terrain Vehicle

Assembly & Preparation

Manual

Foreword

In order to ship Kawasaki vehicles as effi­ciently as possible, they are partially disassem­bled before crating. Since some of the most
commonly removed parts have a direct bear­ing on a vehicle’s reliability and safety, consci­entious pre-sale assembly and preparation be­come extremely important. Good setup pro­cedures can prevent needless warranty claims
and give customers a greater sense of confi­dence in Kawasaki and their Kawasaki Dealers.

This Assembly and Preparation Manual ex­plains step by step procedures of the following
items for all Kawasaki BRUTE FORCE 750 4×4i
EPS, BRUTE FORCE 750 4×4i, KVF750 4×4
EPS, KVF750 4×4.

1. Uncrating

2. Assembly

3. Preparation

The selling dealer assumes sole responsibil­ity for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Ser­vice Bulletins specifying Factory Directed Mod­ifications (Special Claims) which must be per­formed before the vehicle is ready for sale.

Whenever you see the following symbols
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.

CAUTION

CAUTION indicates a hazardous situa­tion which, if not avoided, could result
in minor or moderate injury.

NOTICE

NOTICE is used to address practices not
related to personal injury.

NOTE

○This note symbol indicates points of particular

interest for more efficient and convenient op­eration.

Kawasaki Heavy Industries, Ltd. accepts no
liability for any inaccuracies or omissions in this
publication, although every possible care has
been taken to make it as completely and accu­rately as possible. All procedures and specifi­cations subject to change without prior notice.

© 2011 Kawasaki Heavy Industries, Ltd Jan., 2011

Table of Contents

Uncrating ...................................................................................... 3

Opening Crate (US and Canadian Models only) ......................... 3

Opening Crate (Other than US and Canadian Models)............... 6

Parts Check ................................................................................. 7

Assembly ...................................................................................... 10

Handlebar.................................................................................... 10

Hangtag....................................................................................... 11

French Labels.............................................................................. 11

Owner’s Manual .......................................................................... 12

Preparation ................................................................................... 13

Battery Service ............................................................................ 13

Air Cleaner .................................................................................. 16

Front Final Gear Case Oil ........................................................... 17

Rear Final Gear Case Oil ............................................................ 18

Front Brake.................................................................................. 19

Rear Brake .................................................................................. 20

Suspension.................................................................................. 21

Tire Air Pressures........................................................................ 22

Fuel ............................................................................................. 22

Coolant ........................................................................................ 22

Engine Oil .................................................................................... 23

Throttle Lever and Cable............................................................. 24

Variable Differential Control Lever and Cable ............................ 25

Rear Brake Light Switch Adjustment........................................... 26

Headlight Beam ........................................................................... 26

Front Wheel Alignment ................................................................ 26

Multifunction Meter ...................................................................... 29

Fastener Check ........................................................................... 32

Standard Torque Table ................................................................ 34

Test Ride ..................................................................................... 34

A&P Check List

...........................................................................

34

UNCRATING 3

Uncrating

Opening Crate
(US and Canadian Models only)

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 uncrat­ing to prevent injury.

WARNING

The steel crate panel plates and fasten­ers have sharp edges. Always wear pro­tective 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 o

n its base.

•

Remove the outer cover and inspect the unit
for concealed damage. If concealed damage
is evident, documen

t the damage as outlined
in the Kawasaki Warranty Policies and Pro­cedures Manual before proceeding to uncrate
the unit.

•

Remove the cardboard cover.

Returnable Steel Crate (RSC):

NOTICE

To avoid damaging the front plastic
guard, fold down the front end of
the steel crate before removing the
tie-downs.

A. Outer Cover

•

Remove the inner cover.

A. Inner Cover

To work efficiently, start work at the rear of the
crate.

•

Remove the hairpin clips (2), then push out
the clevis pins (2) to disconnect the rear diag­onal braces (2) from the rear upright.

4 UNCRATING

A. Rear Upright

B. Hairpin Clip

C. Diagonal Brace

•

Allow the diagonal braces to pivot out and
down to the g

round. They remain attached

to the pallet.

•

Install the hairpin clips (2) back into the braces
for re

turn shipment to KMM.

A. Hairpin Clip

B. Clevis Pin

C. Diagonal Brace

•

Remove the LH side rear diagonal brace,
again allowing it to pivot down. At this time,
the rear upright may be pivoted down, but it
may not be necessary to do so. Only one
upright must be pivoted down before rolling
off the vehicle. In this example, the vehicle
will be rolled out the front, which is shown
later.

•

Moving to the front, disconnect the front diag­onal braces (2) from the front upright. Pull out
the hairpin clips (2), push out the clevis pins
(2), and allow each diagonal brace to pivot
down to the ground. Install all pins and hairpin
clips back into the braces for return shipment
to KMM.

A. Front Upright

B. Hairpin Clip

C. Diagonal Brace

NOTE

○Note that the front upright is collapsible (The

rear upright is not collapsible.).

•

Hold it u

p while removing the second pin. Af-

ter pin removal, allow the upright to collapse.

A. Front Upright

B. Diagonal Brace

•

Lay down the front upright. To do so, lift up on
the front upright (lower section) to disengage
its sockets from the pallet.

A. Front Upright

B. Lower Section

UNCRATING 5

•

Working down the sides, remove the
tie-downs (2) which secure the vehicle to
the crate pallet.

A. Tie-down

•

Now the upright may be pivoted down to the
ground. (It remains attached to the pallet.) Be
careful not to drop it on anyone.

•

Roll off the vehicle.

RETURN SHIPMENT (RSC)

•

Prepare the crate for return shipment. In this
example, we will begin at the rear of the crate.

•

Swing around the diagonal braces so that
they will lay on the crate pallet.

A. Rear Upright

B. Diagonal Brace

•

Pick up slightly on the rear upright to disen­gage its sockets. Pivot it down onto the crate
pallet. Be careful not to drop on anyone.

A. Rear Upright

B. Socket

•

Repeat these steps for the other upright. (The
front upright is shown in this example.)

A. Front Upright

B. Diagonal Brace

A. Front Upright

B. Diagonal Brace

•

The clevis pins (4) and hairpin clips (4) are
already installed into the braces. Notice that
it is necessary to collapse one upright so that
enough space exists for both uprights when
laid down.

6 UNCRATING

A. Rear Upright

B. Clevis Pins and Hairpin Clips

C. Front Upright

•

These items are discarded:

-Outer Cove

r, Inner Cover, Tie-downs (Qty.2)

•

Now the empty RSC may be stacked maxi­mum 12 high for return shipment. Each empty
RSC we

ighs about 97 kg. (215 lbs.) so a
stack of 12 is very heavy. The empty crates
interlock at each corner for stability. No stack­i

ng bands are needed.

Opening Crate (Other than US and
Canadian Models)

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 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 outer cover and inspect the unit
for concealed damage. If concealed damage
is evident, document the damage as outlined
in the Kawasaki Warranty Policies and Pro­cedures Manual before proceeding to uncrate
the unit.

•

Remove the cardboard cover.

Removing Panels

•

Using a BPS3 square drive bit (ex. IM­PORT APEX Square Recess “Power Bits­1/4 Hex-size #3” or MAGNA “Insert Bits-size
#3” with quick change holder), remove the
screws from the sides and ends.

A. “Power Bit (APEX)”

WARNING

Staples, nails and other fasteners have
sharp points that can cause injury. Re­move or bend into the wood all staples,
nails or other fasteners in the crate base.

Disposable Wooden Crate:

•

Take out all the fasteners and remove the top
and sides of the crate.

UNCRATING 7

•

Remove the top and side panels of the wood
crate.

•

Remove the inner cover.

NOTICE

Be careful not to puncture a tire with
sharp fasteners when rolling off the ve­hicle from the crate base.

•

Remove the tie-downs (2) which secure the
vehicle to the crate pallet and roll off the vehi­cle.

A. Tie-downs

Parts Check

•

Remove the parts including Owner’s Manual
from the parts bag on the footboard.

•

Remove the battery electrolyte from the rear
end of the chassis.

A. Electrolyte

8 UNCRATING

•

Check the parts against the illustrations. There may be minor differences between these
illustrations and the actual vehicle parts.

UNCRATING 9

No. Part Name

Qty

Remarks

1

French Label and Instruction for

KVF750GCF Canadian Model only

Instruction, Label 1 56030-0403

Label, Vehicle Emission Information

1 59465-0046

KVF750HCF Canadian Model only

Instruction, Label 1 56030-0730

Label, Vehicle Emission Information

1 59465-0627

KVF750JCF Canadian Model only

Instruction, Label 1 56030-0731

Label, Vehicle Emission Information

1 59465-0629

KVF750LCF Canadian Model only

Instruction, Label 1 56030-0717

Label, Vehicle Emission Information

1 59465-0604

2 French Labels for Canadian Model only

Label, Age 1 56040-1325

Label, General

1 56071-0059

Label, Passenger 1 56071-0097

Label, Tire Pressure 1 56071-0074

Label, Trailer Towing 1 56071-0080

Label, Shifting 1 56071-0092

Label, Transmission 1 56070-0039

Label, Protective Cover

1 56070-1271

Label with Band, General for English 1 56030-0194

Label with Band, General for French 1 56030-0197

Label, Air Cleaner Information 1 56033-0308

Cover, Label 1 14092-0127

3

French Labels and Instruction for European Model

Instruction, Label 1 56030-0337

Label, Protective Cover 1 56070-1271

Label, Shifting

1 56071-0092

Label, Transmission 1 56070-0039

Label, Passenger 1 56071-0097

Label, Air Cleaner Information 1 56033-0308

4 For US Model only

Label with Band, General 1 56030-0194

Label with Band, Exhaust Emission Air Index 1 49007-0706

5 Ignition Key 2 –

6 Battery Electrolyte, KMX14-BS 1 12 V 12 Ah

7 Owner’s Manual 1 –

10 ASSEMBLY

Assembly

Handlebar

Handlebar Installation

•

Remove the screws (D = 5, L = 16) (4) to
remove the front handlebar cover.

A. Screws

B. Front Handlebar Cover

•

Remove the screws (D = 5, L = 14) (3) to
remove the rear handlebar cover.

A. Rear Handlebar Cover

B. Screws

C. Well Nuts

NOTE

○Be careful not to drop the well nuts when you

removing the rear handle cover.

•

Loosen the handlebar clamp bolts and lift the
handlebar up.

•

Set the handlebar to match its punched mark
to the upper edge of the gap between the
handlebar clamp.

A. Handlebar Clamp Bolts

B. Handlebar

C. Punched Mark

D. Clamp

Handlebar Clamp Bolt Tightening

•

Tighten the front clamp bolts first, and then
the rear clamp bolts to the specified torque. If
the handlebar clamps are correctly installed,
there will be no gap at the front and a gap at
the rear after tightening.

Handle

bar Clamp Bolt Torque:

29 N·m (3.0 kgf·m, 22 ft·lb)

A. Front Clamp Bolts

B. Rear Clamp Bolts

C. No Gap

D. Gap

NOTE

○It is recommended that the front handlebar

cover should be installed after completing the
steps in the “Throttle Lever and Cable” and
“Differential Control Lever and Cable” sec­tions in the PREPARATION chapter.

○It is recommended that the rear handlebar

cover should be installed after completing the
step in the “Throttle Lever Free Play Adjust­ment” in the PREPARATION chapter.

ASSEMBLY 11

Hangtag

Exhaust Emission Air Index Hangtag In-

stallation (For US Model)

•

There is an exhaust emission air index hang­tag included into the removed parts. Hang it
to the left handlebar as shown.

A. Exhaust Emission Air Index Hangtag

(49007-0706)

B. Left Grip

NOTE

○This hangtag is not to be removed before sale.

General Hangtag Installation (For US

and Canadian Models)

•

There is a general hangtag included into the
removed parts. Hang it to the right handlebar
as shown.

A. General Hangtag

(56030-0194, US and Canada English
Models)
(56030-0197, Canada French Model)

B. Right Grip

NOTE

○This hangtag is not to be removed before sale.

French Labels

For Canadian Model:

NOTE

○Stick the French labels onto the English labels

on the front fender, rear fender, or the seat
only when required.

•

Wipe off any oil or grease from the English
labels. Refer to the following photographs in
the label locations.

•

Peel each French label off the backing sheet
and apply it over the English label.

1. Air Cleaner Information (56033-0308)

2. Age Recommendation Warning (56040

-1325)

3. General Warning (56071-0059)

4. Shifting Caution (56070-0092)

5. Protective Cover Warning (56070-1271)

12 ASSEMBLY

6. Passenger Warning (56071-0097)

7. Tire Pressure & Maximum Loading Warning
(56071-0074)

8. Transmission Warning (56070-0039)

*9. Vehicle Emission Control Information

French Label for KVF750GCF Canadian

Model only (59465-0046)

French Label for KVF750HCF Canadian

Model only (59465-0627)

French Label for KVF750JCF Canadian

Model only (59465-0629)

French Label for KVF750LCF Canadian

Model only (59465-0604)

•

Stick the label cover (14092-0127) onto the
vehicle emission control information label
(59465-xxxx).

*: Attached in the back of the seat.

10. Trailer Towing Warning (56071-0080)

For European Model:

1. Important Air Cleaner Information (56033

-0308)

2. Shifting Caution (56071-0092)

3. Protective Cover Warning (56070-1271)

4. Transmission Warning (56070-0039)

5. Passenger Warning (56071-0097)

Owner’s Manual

•

The storage box is located on the left side
front fender. Keep this Owner’s Manual and
other light items in this storage box.

•

Keep the cover securely fastened with the
strap when driving the vehicle.

PREPARATION 13

A. Owner’s Manual

B. Cover

C. Strap

D. Storage Box

Prepar

ation

Battery Service

Battery Re

moval

The battery used in this vehicle is a sealed
type and never needs to be refilled. Follow the
procedu

res for activating a new battery to en-

sure the best possible battery performance.

Seat Removal

•

Remove the seat by pulling up the seat latch
lever located at the left rear end of the seat,
and then pull the seat up and to the rear.

A. Seat Latch Lever

•

Remove the battery holder bolt (D = 6, L = 16)
with collar (D = 6.3) to and screws (D = 6, L
= 18) (2) with collars (D = 6.3) (2) remove the
battery cover.

•

Take the battery out of the battery case.
Be careful that any rubber dampers are not
pulled out of position.

A. Bolt with Collar

B. Screws with Collars

C. Battery Cover

Battery Activation

Electrolyte Filling

•

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

Battery Model Name

KVF750G/H/J/L: KMX14-BS

A. Model Name of the Electrolyte

B. Model Name of the Battery

NOTICE

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.
This is to prevent overfilling of the elec­trolyte, shorting the battery life, and de­terioration of the battery performance.

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.

14 PREPARATION

WARNING

The electrolyte contains sulfuric acid,
which can cause severe burns. To
avoid sulfuric acid burns, wear protec­tive clothing and safety glasses when
handling electrolyte. If the electrolyte
touches the skin or eyes, wash the area
with liberal amounts of w ater and seek
medical attention for more severe burns.

•

Place the battery on a level surface.

•

Check to see that the sealing sheet has no
peeling, tears, or holes in it.

•

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.

A. Sealing Sheet

B. Filler Ports

•

Remove the electrolyte container from the
vinyl bag.

•

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 at­tempt to separate individual cells.

A. Strip of Caps

B. Sealed Cells

•

Place the electrolyte container upside down
with the six sealed cells into the filler ports
of the ba

ttery. 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
por

ts fill.

NO

TE

○Do not tilt the electrolyte container.

•

Check the electrolyte flow.

•

If no air bubbles are coming up from the filler
ports, or if the container cells have not emp­tied completely, tap the container a few times.

NOTE

○Be careful not to have the battery fall down.

PREPARATION 15

A. Air Bubbles

B. Tap the Container

•

Keep the container in place. Don’t remove
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 li

fe of the battery.

•

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.

•

Place the strip of caps loosely over the filler
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.

A. Strip of Caps

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.

Initial Charge

•

Newly activated sealed batteries require an
initial charge.

Standard Charge: 1.2 A × 5 ∼ 10 hours

•

If using a recommended battery charger, fol­low the charger’s instructions for newly acti­vated sealed battery.

Kawasaki-recommended chargers:

Batt

ery Mate 150-9

OptiMate PRO 4-S/PRO S/PRO 2

Yuasa MB-2040/2060

Christie C10122S

•

If the above chargers are not available, use
equivalent one.

•

Let battery sit 30 minutes after initial charge,
then check voltage using a voltmeter. (Volt­age immediately after charging becomes tem­porarily high. For accurate measuring, let the
battery sit for given time.)

16 PREPARATION

NOTE

○Charging 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 12.8 volts, repeat charging cy­cle.

○To ensure m aximum 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 12.8 volts
repeat the charging cycle and load test. If still
below 12.8 volts the battery is defective.

Battery Installation

•

Turn the ignition switch to OFF.

•

Check that the rubber dampers on the battery
holder and the battery case are properly in
place.

•

Put the battery in place.

•

Securely connect the red cable with protec­tive cap and the black cable with the round
terminal and the red tape to the (+) terminal,
and then securely connect the black cable to
the (–) terminal.
On the battery (+) terminal, make sure the
round terminal cable is on the red cable mak­ing about 30 degree angle with the red cable.

•

Put a light coat of grease on the terminals to
prevent corrosion.

•

Cover the (+) terminal with its protective

cap.

A. Battery

B. Positive Terminal (+)

C. Negative Terminal (–)

D. Red Tape

E. About 30°

•

Reinstall the battery cover, bolt, screws (2)
and collars (3) in the reverse order of removal.

Air Cleaner

Air Cleaner Element Inspection

The foam air cleaner element on ATV models
is oiled prior to shipping. However, over time
the filter will dry and filtration performance will
diminish.

•

Pull release the snaps and remove the air
cleaner housing cap and inspect the foam air
cleaner element for proper oiling.

A. Air Cleaner Housing Cap

B. Snaps

•

If the air cleaner element is dry, remove the
screw (D = 6, L = 5) and washer and pull out
the air cleaner element and the element frame
from the air cleaner housing.

A. Air Cleaner Element

B. Air Cleaner Housing

C. Screw and Washer

D. Element Frame

•

Remove the air filter element from the ele­ment frame.

PREPARATION 17

A. Air Cleaner Element

B. Element Frame

•

Saturate the air

cleaner element with a
high-quality foam air filter oil (ex. Kawachem
“Foam Filter Oil”, Bel Ray “Foam Filter Oil”,
Maxima “F

FT Foam Filter Treatment”, or
equivalent cohesive type) and make sure
that the oil is evenly applied throughout the
air c

leaner element. Squeeze out the excess
oil, but do not wring the air cleaner element
as this could cause tearing. In this case, too
m

uch oil is better than too little. Finally pat
the inside of the air cleaner element with a
paper towel to remove any excess oil.

•

Install the air cleaner element to the element
frame.

•

Insert and tighten the screw to the specified
torque.

Torque : 3.5 N·m (0.36 kgf·m, 31 in·l b)

•

Reinstall the air cleaner housing cap.

Seat Installation

•

Align the front hooks with the front receivers
and slide the seat forward. Make sure that
the rear hooks align to their rear receivers.
Push the seat with both hands around the rear
hooks and make sure there is a click sound of
the latches engaging.

A. Front Hooks

B. Front Receivers

C. Rear Hooks

D. Rear Receivers

E. Latches

F. Latch Lever

•

Pull up the rear end of the seat to make sure
it is securely locked.

Front Final Gear Case Oil

Front Final Gear Case Oil Level Inspec-

tion

•

With the vehicle l

evel front-to-rear and side-to

-side, remove the filler cap from the front final
gear case.

A. Front Final Gear Case

B. Filler Cap

C. Front Axle Shaft

NOTICE

Be careful not to allow any dirt or for­eign materials to enter the front final
gear case.

•

Check the oil level. The oil level should come
to the bottom thread of the filler opening. If
it is insufficient, add oil through the oil filler
opening as necessary.

18 PREPARATION

A. Front Final Gear Case

B. Filler Opening

C. Bottom Thread

Front Final G

ear Case Oil

(Equivalent to engine oil)

Type: API SG, SH, SJ, SL or SM with

JASO MA, MA1 or MA2

Viscosity: SAE 10W-40

Capacity: 0.40 L (0.42 US qt)

Although 10W-40 engine oil is the recom­mended oil for most conditions, the oil viscosity
may need to be changed to accommodate
atmospheric conditions in your riding area.

•

Install the filler cap.

Oil Filler Cap Torque:

29 N·m (3.0 kgf·m, 22 ft·lb)

Rear Final Gear Case Oil

Rear Final Gear Case Oil Level Inspec-

tion

•

With the vehicle level front-to-rear and side-to

-side, remove the filler cap from the rear final
gear case.

A. Rear Final Gear Case

B. Filler Cap

NOTICE

Be careful not to allow any dirt or for­eign materials to enter the rear final gear
case.

•

Check the oil level. The oil level should come
to the

bottom thread of the filler opening. If
it is insufficient, add oil through the oil filler
opening as necessary.

NOTE

○Front and rear final gear cases use different

types of oils. Use the specified type and brand
of oil in each final gear case.

Rear Final Gear Case Oil

Type: Mobil Fluid 424,

CITGO TRANSGARD

TRACTOR HYDRAULIC FLUID
or

EXXON HYDRAUL 560

Capacity: 0.72 L (0.76 US qt)

NOTE

○Do not apply front final gear case oil into the

rear final gear case. Apply only the specified
oil. The rear final gear case contains brake
plates which require a special oil type. Also
the two different oil types for the rear gear
case oil must not be mixed in use.

PREPARATION 19

A. Rear Final Gear Case

B. Filler Opening

C. Bottom Thread

•

Install the filler cap.

Oil Filler Cap Torque:

29 N·m (3.0 kgf·m, 22 ft·lb)

Front Brake

Front Brake Fluid Level Inspection

•

Position the front brake reservoir horizontal,
and check that the fluid level in the reservoir
is higher than the lower level line.

A. Lower Level Line

•

If the fluid level in the reservoir is lower than
the lower level line, check for fluid leaks in the
front brake lines and fill the reservoir.

•

Loosen the screws to remove the front brake
fluid reservoir cap and diaphragm.

•

Fill the reservoir to the upper level line with
DOT4 brake fluid. Inside the front brake
reservoir is a stepped line showing the upper
level line.

A. Upper Level Line

WARNING

When working with the disc brake, ob­serve the precauti

ons listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has
been left un

sealed or that has been open

for a long time.

3. Do not mix two types and brands of fluid
for use

in the brake. This lowers the
brake fluid boiling point and could cause
the brake to be ineffective. It may also
ca

use the rubber brake parts to deterio-

rate.

4. Don’t leave the reservoir cap off for any
length of time to avoid moisture contam­ination of the fluid.

5. Don’t change the fluid in the rain or when
a strong wind is blowing.

6. Brake fluid quickly ruins painted sur­faces; any spilled fluid should be com­pletely wiped up immediately.

7. If any of the brake line fittings or the
bleed valve is opened at any time,
the AIRMUSTBEBLEDFROMTHE

BRAKE LINE.

•

Operate the front brake lever several times.

•

If it feels spongy, there might be air in the
brake line.

•

If necessary, bleed the air in the rear brake
line.

•

Also check fo

r fluid leakage around the fit-

tings, and bleed the air in the front brake lines.

BrakeLineAirBleeding

•

With the front brake reservoir horizontal, re­move the front brake reservoir cap and di­aphragm, and check that there is plenty of
fluid in the reservoir.

20 PREPARATION

NOTE

○The fluid level must be checked several times

during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be done over again
from the beginning since air will have entered
the line.

•

Attach a clear plastic hose to the bleed valve
on the 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 front 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 counterclock­wise) and close the bleed valve. Then release
the lever. Repeat this operation until no more
air can be seen coming out into the plastic
hose.

A. Hold the brake lever applied.

B. Release the brake lever.

A. Quickly open and close the bleed valve.

•

Repeat the previous step one more time for
the other front disc brake.

•

When air bleeding i s finished, check that the
fluid is between the upper and lower level
lines.

•

Install the diaphragm and the reservoir cap.

•

Tighten the bleed valve(s) to the specified
torque.

Torque : 7.8 N·m (0.8 kgf·m, 69 in·lb)

•

Apply the brake lever forcefully for a few sec­onds, and check for fluid leakage around the
fittings.

Rear Brake

Brake Pedal Position Inspection

•

Measure the adjusting bolt length. It should
be 5 mm (0.20 in.).

A. Adjusting Bolt

B. Locknut

C. 5 mm (0.20 in.)

Brake Pedal Position Adjustment

•

To adjust the pedal position, loosen the lock­nut, turn the adjusting bolt and make the bolt
length 5 mm (0.20 in.), and then tighten the
locknut. Now adjust the brake pedal free play.

Brake Pedal F ree Play Inspection

•

Release the parking brake.

•

Measure the distance the brake pedal moves
before the brake starts to take hold. Pedal
free play should be 15 ∼ 25 mm (0.6 ∼ 1.0 in.).

Brake Pedal Free Play:

15 ∼ 25 mm (0.6 ∼ 1.0 in.)

PREPARATION 21

A. Brake Pedal

B. 15 ∼ 25 mm (0.6 ∼ 1.0 in.)

Brake Pedal Free Play

Adjustment

•

To adjust the pedal free play, turn the brake
pedal adjuster at the rear end of the brake
cable.

A

. Brake Lever Adjuster

B. Brake Pedal Adjuster

C. Rear Wheel (Left Side)

Rear Brake (Parking) Lever Free Play

Inspection

•

Check the rear brake lever free play. If the
free play is incorrect, adjust the free play.

Rear Brake Lever Free Play:

1 ∼ 2 mm (0.04 ∼ 0.08 in.)

Rear Brake (Parking) Lever Free Play

Adjustment

•

Slide the rubber cover.

•

Loosen the locknut and turn the adjuster at
the brake lever in as far as it will go.

•

Tighten the locknut.

•

Turn the adjuster at the rear end of the brake
cable so that the brake lever has 1 ∼ 2mm
(0.04 ∼ 0.08 in.) of free play.

A. 1 ∼ 2 mm (0.04 ∼ 0.08 in.)

B. Locknut

C. Adjuster

NOTE

○Since the above two free play adjustments

(pedal and lever) affect each other, make
them at th

esametime.

•

After adjustments, check for brake drag (there
should be none) and effectiveness.

Suspension

Front and Rear Shock Absorber Spring

Preload Adjustment

•

Check the position of the spring preload
adjusting sleeves (Turn here with a hook
wrench) on the front and rear shock ab­sorbers.

STD Position:

Fron

t: No. 2

Rear: No. 2

A. Rear Shock Absorber

B. Spring Adjusting Sleeve

22 PREPARATION

•

Turn the adjusting sleeve on the shock ab­sorbers to the standard position with a hook
wrench.

•

Check to see that each pairs of adjusting
sleeves are turned to the same relative posi­tion.

WARNING

If a pair of adjusting sleeves are not
adjusted equally, handling may be im­paired and a hazardous condition may
result. Adjust the sleeves equally.

Tire Air Pressures

Tire Air Pressure Adjustment

•

Adjust the pressures to the specified values
in the front and rear, and make sure to tighten
the caps securely.

Tire Air Pressures (when cold):

[Normal Use]

Front:

35 kPa (0.35 kgf/cm², 5 psi)

Rear:

35 kPa (0.35 kgf/cm², 5 psi)

A. Air Pressure Gauge

NOTE

○To accurately measure the pressure, use a

low air pressure gauge included in the tool kit
of ATV. Do not use an automotive air pressure
gauge because the specified tire air pressures
of ATV is too low.

Fuel

WARNING

Gasoline is extremely flammable and
can be explosive under certain condi­tions, creating the potential for serious
burns. When filling the tank, turn the
ignition switch to “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.

•

Fill the fuel tank with one gallon/or four liters of
unleaded gasoline. Use gasoline with a min­imum octane rating indicated in the following
table.

The antiknock index is an average of the Re­search Octane Number (RON) and the Motor
Octane Number (MON), as shown in the table.

For US and Canadian Models

Minimum

Octane Rating Method

Rating

Antiknock

(RON + MON)

Index 2

87

For Other than US and Canadian Mo dels

Minimum

Octane Rating Method

Rating

Research Octane Number (RON) 91

•

Close the fuel tank cap and check for any
leaks and correct them.

Coolant

Coolant Reservoir Tank Level Check

•

Situate the vehicle on level ground.

•

Check the coolant level through the coolant
level gauge on the reserve tank. The coolant
level should be between the “F” (Full) and “L”
(Low) marks.

NOTE

○Check the level when the engine is cold (room

or atmospheric temperature).

PREPARATION 23

A. Reserve Tank

B. “F” (Full) Mark

C. “L” (Low) Mark

D. Cap

E. Front Shock Absorber (Right Side)

•

If the amount of coolant is insufficient, un­screw th

e cap from the reserve tank and add
coolant through the filler opening to the “F”
(Full) mark. Install the cap.

Recommended Coolant Solution

Coolant Mixture Ratio:

Water 50%: Coolant 50% (1:1)

R

ecommended Coolant:

Permanent type coolant (ethylene
glycol plus corrosion and rust inhibitor
chemicals for aluminum engines and
radiator).

NOTE

○A permanent type of antifreeze is installed in

the cooling system when shipped. It is col­ored green and contains ethylene glycol. It is
mixed at 50% and has the freezing point of
–35°C (–31°F).

Engine Oil

Engine Oil Level Inspection

NOTE

○This vehicle’s engine is filled with 10W-30 oil

from the factory. DO NOT DRAIN and refill
the crankcase before use. Check oil level and
drain plug tightness.

Engine Oil Drain Plug Torque:

20 N·m (2.0 kgf·m, 15 ft·lb)

A. Oil Drain Plug

•

Park the vehicle so that it is level, both side-to

-side and front-to-rear.

•

Before starting the engine, check that the en­gine has oil.

•

Unscrew the oil filler plug on the lower left side
of the engine and wipe the dipstick dry. Then
screw it in again. Unscrew the plug and check
that the engine has oil.

A. Oil Filler Plug

•

When replacing the plug, be sure the O-ring
is in place, and screw the plug in finger tight.

NOTICE

If the engine is run without oil, it will be
severely damaged.

•

Start the engine and run it for several minutes
at idle speed. Stop the engine, then wait sev­eral minutes until the oil settles.

•

Unscrew the oil filler plug, wipe its dipstick dry,
and screw it in again.

•

Unscrew the plug and check the oil level. The
oil level should be between the H (High) and
L (Low) lines on the dipstick.

24 PREPARATION

A.

Oil Filler Plug and Dipstick

B.

Screw in the oil filler plug fully to
inspect the oil level

C. “H” (High) Line

D.

“L” (Low) Line

•

If the oil level is too high, remove the excess
oil th

rough the oil filler opening using a syringe

or some other suitable device.

•

If the oil level is too low, add the oil to reach
t

he correct level.

•

Screw the plug in finger tight.

Recommended Engine Oil

Type: API SG, SH, SJ, SL or SM with

JASO MA, MA1 or MA2

Viscosity: SAE 10W-40

Capacity: 1.9 L (2.0 US qt)

[when filter is not removed]

2.0 L (2.1 US qt)

[when filter is removed]

Although 10W-40 engine oil is the recom­mended oil for most conditions, the oil viscosity
may need to be changed to accommodate
atmospheric conditions in your riding area.

Throttle Lever and Cable

Throttle Lever Free Play Inspection

•

Check the throttle lever free play. If the free
play is incorrect, adjust the throttle cable.

Throttle Lever Free Play:

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

•

Check that the throttle lever moves smoothly
from full open to close, and the throttle closes
quickly and completely in all steering posi­tions by the return spring. If the throttle lever
does not return properly, check the throttle
lever free play, cable routing, and for possi­ble cable damage. Then lubricate the throttle
cable.

A. 2 ∼

3mm(0.08∼ 0.12 in.)

•

Run the engine at the idle speed, and turn the
handlebar all the way to the right and left to
ensure that the idle speed does not change.
If the idle speed increases, check the throttle
lever free play and the cable routing.

WARNING

Operation with incorrectly routed or im­properly adjusted cables could result in
an unsafe riding condition. Be sure the
cables are routed correctly and properly
adjusted.

Throttle Lever Free Play Adjustment

•

Slide the rubber cover off of the adjuster at the
throttle 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.

PREPARATION 25

A. Adjuster

B. Locknut

•

Reinstall the rear handlebar cover with the
screws (D = 5, L = 14)

(3), and tighten them.

A. Rear Handlebar Cover

B. Screws

C. Well Nuts

Variable Differential Control Lever
and Cab le

By pulling the control lever toward the handle­bar, the driving force of the front wheels can be
equalized to provide more traction. If the differ­ential control lever has excessive play, adjust
the differential control cable.

Variable Differential Control Lever Posi-

tion Inspection

•

Pull the variable differential control lever to­wards the handlebar grip with a spring scale
until it reads 30 N (3 kgf, 7 lb) of force. The
clearance between the control lever and grip
should be 20 mm (0.8 in.). If the clearance is
not within specification, adjust the cable.

Variable Differential Control Lever Posi­tion:

20 mm (0.8 in.) from the grip

A. Variable Differential Control Lever

B. Handlebar Grip

C. 20 mm (0.8 in.)

Variable Differential Control Lever Posi-

tion Adjustment

•

Loosen the screws (D = 5, L = 16) (4) to re­move bolt front handle cover.

A.Screws(D=5,L=16)

B. Front Handle Cover

•

Loosen the locknut at the middle of differential
control cable.

•

Turn the adjuster until the cable has the
proper amount of play.

•

Tighten the locknut after adjustment.

26 PREPARATION

A. Variable Differential Control Cable

B. Locknut

C. Adjuster

•

Reinstall the front handlebar cover with the
screws (D = 5, L = 16) (4), and tighten them.

Rear Brake Light Switch
Adjustment

Rear Brake Light Switch Adjustment

•

Turn the ignition switch to "ON" position.

•

Depress the brake pedal. The brake light
should go on after about 10 mm (0.4 in.) of
pedal travel.

A. Brake Pedal

B. 10 mm (0.4 in.)

•

To adjust the brake light switch (located near
the brake pedal), move the switch forward or
rearward by turning the adjusting nut.

NOTICE

To avoid damaging the electrical con­nections inside the switch, be sure that
the switch body does not turn during ad­justment.

A. Brake Light Switch

B. Adjusting Nut

C. Lights later

D. Lights sooner

Headlight Beam

•

The headlight beams can be adjusted verti­cally.

•

Turn the adjusting screw on each headlight
rim in or out to adjust the headlight vertically.

A. Adjusting Screw

B. Headlight Body

Front Wheel Alignment

Toe-in is the amount that the front wheels are
closer together in front than at the rear at the
axle height. When there is toe-in, the distance
A (Rear) is greater than B (Front) as shown.
If toe-in is incorrect, the front wheels will be
dragged along the ground, scuffing and wearing
the tread knobs. Caster and camber are built-in
and require no adjustment.

A (Rear) – B (Front) = Amount of Toe-in (Dis­tance A and B are measured at axle height with
the vehicle sitting on the ground, or at 1G.)

PREPARATION 27

Steering Centering Inspection

•

Test ride the vehicle. If the handlebar is
straight when the vehicle is traveling in a
straight line, go on to the Toe-in Inspection
procedure. Otherwise, go on to the Steering
Centering Adjustment procedure.

Steering Centering Adjustment

•

Hold a straightedge against the rear wheel rim
on one side at axle height.

A. Straightedge

•

With the handlebar straight ahead, loosen
the locknuts [A] [B] and turn the tie-rod until
the front wheel on that side is parallel to the
straightedge.

NOTE

○The locknut [A] on the tie-rod has left-hand

threads. Turn the wrench clockwise for loos­ening.

A. Locknut (Left-hand Threads)

B. Locknut (Wheel Side)

C. Tie-rod

NOTICE

Adjust the tie-rod so that the visible
thread length is even on both ends of
the tie-rod, or the threads could be dam­aged.

A. Visible Thread Length

•

Repeat the straightedge procedure on the
other side of the vehicle. Now the front
wheels are parallel to each other and to the
center line of the vehicle.

•

Go on to the Toe-in Inspection procedure.

28 PREPARATION

A. Front Wheels

B. Vehicle Center Line

C. Parallel each other.

D. Straightedges

E. Rear Wheels

Toe-in Inspection

•

Apply a heavy

coat of chalk o r a paint line near

the center of the front tires.

•

Using a needle nose scriber, make a thin
mark nea

r the center of the chalk coating

while turning the wheel.

•

With the front wheels on the ground, set the
handlebar straight ahead.

•

At the level of the axle height, measure the
distance between the scribed or painted lines
for both front and rear of the front tires.

•

Subtract the measurement of the front from
the measurement of the rear to get the toe-in.
If the toe-in is not in the specified range, go
on to the Toe-in Adjustment procedure.

Toe-in of Front Wheels

Standard: –5 ∼ 15 mm (–0.20 ∼ 0.59 in.)

at 1G

Toe-in Adjustment

•

Loosen the locknuts [A] [B] and turn the tie

-rod the same number of turns on both sides
to achieve the specified toe-in.

NOTE

○The locknut [A] on the tie-rod has left-hand

threads. Turn the locknut clockwise for loos-

ening.

A. Locknut (Left-hand Threads)

B. Locknut (Wheel Side)

C. Tie-rod

NOTE

○The toe-in will be near the specified value, if

the tie-rod length [A] is 388.5 mm (15.30 in.)

on each tie-rod.

NOTICE

Adjust the tie-rod length so that the visi­ble thread length is even on both ends of
the tie-rod. Uneven thread length could
cause tie-rod damage.

PREPARATION 29

A. Visible Thread Length

•

Check the toe-in.

•

Tighten the tie-rod locknuts to the specified
torque.

Torque : 36 N·m (3.7 kgf·m, 27 ft·lb)

•

Test ride the vehicle.

Multifunction Meter

Check the km/h·

mph Displ ay in the Mul-

tifunction Meter

The km/h·mph display can alternate between

metric and E

nglish modes (km/h and mph) in
the meter unit. Make sure that km/h or mph
is correctly displayed according to local regu­lations

before riding. If the measurement unit
displayed in the multifunction meter is not cor­rect, switch it to the correct unit as follows.

A. km/h·mph Display

•

Turn the ignition key to “ON”.

•

Check to see if the ODO is displayed in the
multifunction meter.

NOTE

○The km/h or mph display can be switched over

only when the meter is in the ODO display
mode.

A. ODO Display

•

If the ODO is not displayed, switch the me­ter display m

ode by pushing the left button
several times to shift the display mode to the
ODO.

A. ODO Display

B. TRIP A Display

C. TRIP B Display

D. HR Display

E. Push Left Button.

A. Left Button

B. Right Button

30 PREPARATION

•

The km/h·mph display is shifted by pushing
the Right button for less than two seconds
while pushing in the Left button during the
odometer is displayed.

•

Turn the ignition key to “OFF”.

PREPARATION 31

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32 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 33

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Frame/Steering

1 Tie-rod locknuts (Left and Right) 36 3.7 27

Brake

2 Front master cylinder clamp bolts 8.8 0.90 78 in·lb S1

3 Front brake bleed valves (Left and Right) 7.8 0.80 69 in·lb

4 Front brake caliper mounting bolts (Left and Right) 25 2.5 18

Wheel

5 Front and rear wheel nuts (First Torque) 15 1.5 11 S2

Front and rear wheel nuts (Final Torque) 76 7.8 56 S2

Suspension

6

Front and rear shock absorber mounting n

uts (Left

and Right)

34 3.5 25

7 Front upper suspension arm pivot nuts (Left and

Right)

59 6.0 44

8 Front lower suspension arm pivot nuts (Left and

Right)

47 4.8 35

9 Rear upper and lower suspensio

n arm pivot nuts

(Left and Right)

47 4.8 35

Engine

10 Engine oil drain plug 20 2.0 15

11

Front final gear case oil drain plug

15 1.5 11

12 Front final gear case oil filler cap 29 3.0 22

13 Rear final gear case oil drain plug 15 1.5 11

14 Rear final gear case oil filler cap 29 3.0 22

Cotter pin or Circlip

15

Tie-rod end nut cott

er pins (Left and Right)

– – –

16

Steering knuckle joint nut cotter pins (Left and
Right)

– – –

17 Rear brake cable cotter pin – – –

S1: Tighten the

upper clamp bolt first, and then the lower clamp bolt.

S2: Tighten the nuts in a criss-cross pattern to the first and final specified torques.

34 PREPARATION

Standard To rq ue Table

This table relating tightening torque to thread
diameter, lists the basic torque for bolts and
nuts. Use this table for only the bolts and nuts
which do not require a specific torque value.
All of the values are for use with dry solvent

-cleaned threads.

General Fasteners:

Threads Tor qu e

dia. mm N·m kgf·m ft·lb

5 3.4~4.9 0.35~0.50 30~43 in·lb

6 5.9~7.8 0.60~0.80 52~69 in·lb

8 14~19 1.4~1.9 10.0~13.5

10 25~34 2.6~3.5 19.0~25

12 44~61 4.5~6.2 33~45

14 73~98 7.4~10.0 54~72

16 115~155 11.5~16.0 83~115

18 165~225 17.0~23.0 125~165

20 225~325 23~33 165~240

Test Ride

•

Complete the test ride c hecklist.

Control Cables:

The control cables must
work without binding 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.

Belt Drive Torque
Converter:

Smooth operation.

Differential: Smooth operation.

Forward-Reverse
Shift:

Smooth operation.

Hi-Low Shift: Smooth operation.

2WD-4WD Shift: Smooth operation.

Brakes: Adequate, smoot

h
stopping power. Do
not drag.

Multifunction Meter:

Speedometer - check operation.

Fuel Level Gauge - check operation.

Clock - check operation.

Odo/Trip/Hour Meters - check operation.

Electrical System:

Headlight - check operation.

Taillight - check operation.

Brake Light - check operation.

Instrument Lights and Indicator Lights -

check operation.

European and UK Models only:

Reverse Light - check operation.

Other than US and Canadian Models:

Horn - check operation.

Engine Stop Switch Works:

No Unusual Noises:

No Fuel, Oil, Brake Fluid, or Coolant
Leaks:

PREPARATION COMPLETE.

A&P Check List

•

Complete the A&P Check List.

MODEL APPLICATION

Year Model Name

2012

KVF750GCF

BRUTE FORCE 750 4×4i EPS
KVF750 4×4 EPS

2012 KVF750HCF BRUTE FORCE 750 4×4i EPS

2012 KVF750JCF BRUTE FORCE 750 4×4i EPS

2012

KVF750LCF

BRUTE FORCE 750 4×4i
KVF750 4×4

Part No. 99 931-1524-02