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
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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.
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