Kawasaki KVF 750 4x4, Brute Force 750 4x4i User Manual

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BRUTE FORCE 750 4×4i

KVF 750 4×4

All Terrain Vehicle

Service Manual

Quick R eference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System 3 j

Cooling System 4 j

Engine Top End 5 j

Converter System 6 j

Recoil Starter 7 j

Engine Lubrication System 8 j

This quick reference guide will assist you in locating a desired topic or procedure.

•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.

•Refer to the sectional table of contents for the exact pages to locate the specific topic required.

Engine Removal/Installation 9 j

Crankshaft/Transmission 10 j

Wheels/Tires 11 j

Final Drive 12 j

Brakes 13 j

Suspension 14 j

Steering 15 j

Frame 16 j

Electrical System 17 j

Appendix 18 j

BRUTE FORCE 750 4×4i

KVF 750 4×4

All Terrain Vehicle

Service Manual

All r ights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

LIST OF ABBREVIATIONS

ABDC after bottom dead center

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC bottom dead center PS horsepower

BTDC before top dead center psi pound(s) per square inch

°C degree(s) Celcius r revolution

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

ampere(s)

pounds(s)

meter(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the California Air Resources Board.

1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow

-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from

the crankcase, and then returned back to the bottom of crankcase.

2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that

consist of a modified carburetor and an ignition system having optimum ignition timing characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum

fuel economy with a suitable air cleaner and exhaust system.

A maintenance free ignition system provides the most favorable ignition timing and helps main-

tain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is

commonly referred to as the Act’s " tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed

on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading

motor vehicles or motor vehicle engines, or who operates a f leet of m otor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."

NOTE

The phrase "remove or render inoperative any device or element of design" has been generally

○

interpreted a s follows :

1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in o rder to perform maintenance.

2. Tampering could include:

a.Maladjustment of vehicle components such that the emission standards are ex-

ceeded.

b.Use of replacement parts or accessories which adversely affect the performance

or durability of the vehicle.

c.Addition of components or accessories that result in the vehicle exceeding the stan-

dards.

d.Permanently removing, disconnecting, or rendering inoperative any component or

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,

THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING $10,000 PER VIOLATION.

PLEASE DO NOT TAMPER WITH NOISE CONTR OL SYSTEM

(US MODEL only)

To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level.

Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

For the duration of the warranty period,

we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

Follow the Periodic M aintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Vehi-

•

cle parts. Special tools, gauges, and testers

that are necessary when servicing Kawasaki

vehicles are introduced by the Special Tool

Catalog or Manual. Genuine parts provided

as spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference

Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution sym bol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This m anual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

lows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-8

Unit Conversion Table ............................................................................................................ 1-11

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the vehicle, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (–) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (–) wire to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high-flush point solvent when cleaning parts. High

-flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

GENERAL INFORMATION 1-3

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.

Often, the tightening sequence is f ollowed twice initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling.

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a Non-Permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

Before Servicing

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

Model Identification

KVF750-A1 Left Side View

GENERAL INFORMATION 1-7

KVF750-A1 Right Side View

The KVF750–B1 is a camouflage-surface-treated model and identical to the KVF750–A1, the base

model, in every other aspect: controls, features, and specifications.

1-8 GENERAL INFORMATION

General Specifications

Items KVF750-A1, B1

Dimensions

Overall Length 2 192 mm (86.30 in.)

Overall Width 1 177 mm (46.34 in.)

Overall Height 1 249 mm (49.17 in.)

Wheelbase 1 283 mm (50.51 in.)

Ground Clearance: 269 mm (10.59 in.)

Seat Height 935 mm (36.81 in.)

Dry Mass 274 kg (604 lb), (EUR) 274.5 kg (605 lb)

Curb Mass:

Front 147.5 kg (325 lb), (EUR) 148 kg (326 lb)

Rear 149 kg (329 lb)

Fuel Tank Capacity 19.5 L (5.2 US gal)

Performance

Minimum Turning Radius 3.2 m (10.5 ft)

Engine

Type 4-stroke, SOHC, V2-cylinders

Cooling System Liquid-cooled

Bore and Stroke 85 × 66 mm (3.35 × 2.60 in.)

Displacement 749 mL (45.7 cu in.)

Compression Ratio 8.8 : 1

Maximum Horsepower 37.4 kW (50.9 PS) @6 500 r/min (rpm), (US) -

Maximum Torque 60.7 N·m (6.2 kgf·m, 45 ft·lb) @5 000 r/min (rpm)

Carburetion System Carburetor, Keihin CVKR-34

Starting System Electric Starter & Recoil Starter

Ignition System Digital DC-CDI

Timing A dvance Electronically advanced

Ignition Timing From 5° BTDC @1 150 r/min (rpm)

to 28° BTDC @5 000 r/min (rpm)

Spark Plug NGK CR7E, DENSO U22ESR-N

Cylinder Numbering Method Front to rear, 1-2

Firing Order 1-2

Valve Timing:

Inlet:

Open 20° BTDC

Close 44° ABDC

Duration 244°

Exhaust:

Open 44° BBDC

Close 20° ATDC

Duration 244°

Lubrication Aystem Forced lubrication (wet sump)

General Specifications

Items KVF750-A1, B1

Engine oil:

Type

Viscosity SAE 10W-40

Capacity 2.6 L (2.75 US qt)

Drive Train

Primary Reduction System:

Type Belt converter

Reduction Ratio 3.122 ∼ 0.635

Transmission:

Type 2-speed and reverse

Gear Ratios:

Forward:

High

Low

Reverse 4.028 (16/12 × 18/16 × 29/18 × 20/12)

Final Drive System:

Type Shaft 2WD/4WD

Reduction Ratio 4.375 (35/8)

Overall Drive Ratio:

Forward:

High 42.32 ∼ 8.61 Low 66.02 ∼ 13.43

Reverse 55.01 ∼ 11 . 19

Front Final Gear Case Oil:

Type API SF or SG

Viscosity SAE10W-40

Capacity 0.40 L (0.42 US qt)

Rear Final Gear Case Oil:

Type

Capacity 0.72 L (0.76 US qt)

Frame

Type Double tubular

Caster (Rake Angle) 5.5°

Camber 0°

King Pin Angle 11°

Trail 28 mm (1.10 in.)

Tread:

Front 915 mm (36.23 in.)

Rear 875 mm (34.45 in.)

API SF or SG

API SH or SJ with JASO MA class

3.098 (30/26 × 29/18 × 20/12)

4.833 (36/20 × 29/18 × 20/12)

API SH or SJ with JASO MA class

MOBIL FLUID 424, CITGO TRANSGARD TRACTOR HYDRAULIC FLUID, o r EXXON HYDRAUL 560

GENERAL INFORMATION 1-9

1-10 GENERAL INFORMATION

General Specifications

Items KVF750-A1, B1

Front tire:

Type Tubeless

Size AT25 × 8 – 1 2

Rear tire:

Type Tubeless

Size AT25 × 10 – 12

Suspension:

Front:

Type Double Wishbone

Wheel Travel 171 mm (6.73 in.)

Rear:

Type Double Wishbone

Wheel Travel 200 mm (7.87 in.)

Brake:

Front Disc × 2

Rear Enclosed wet multi-plate

Parking Brake Enclosed wet multi-plate

Electrical Equipment

Battery 12 V 12 Ah

Headlight:

Type Semi-sealed beam

Bulb 12 V 40/40 W × 2

Tail/brake Light:

Bulb 12 V 5/21 W

Reverse Light:

Bulb

Alternator:

Type Three - phase AC

Rated Output 24.2 A, 14 V @6 000 r/min (rpm)

(EUR) 12V 10W

Specifications are subject to change without notice, and may not apply to every country. US: United States Model EUR: Europe Model

Unit Conversion Table

GENERAL INFORMATION 1-11

Prefixes for Units:

Prefix Symbol

mega M × 1 000 000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Power

Units of Mass:

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume:

L × 0.2642 = gal (US)

L × 0.2200 = gal (imp)

L×1.057=

L × 0.8799 =

L × 2.113 = pint (US)

L × 1.816 = pint (imp)

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (imp)

mL × 0.06102 = cu in

qt (US)

qt (imp)

Units of Length:

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = N·m × 0.7376 = ft·lb N·m × 8.851 = in·lb kgf·m × 9.807 = N·m kgf·m × 7.233 = ft·lb kgf·m

× 86.80 = in·lb

kgf·m

Units of Pressure:

kPa × 0.01020 = kgf/cm² kPa × 0.1450 = psi kPa × 0.7501 = cmHg kgf/cm² × 98.07 = kPa kgf/cm² cmHg × 1.333 = kPa

× 14.22 = psi

Units of Speed:

km/h

× 0.6214 = mph

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Temperature

Units of Power:

kW × 1.360 =

kW × 1.341 = HP PS × 0.7355 = kW PS × 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart .............. 2-3

Torque and Locking Agent................. 2-5

Specifications .................................... 2-11

Special Tools ..................................... 2-13

Periodic Maintenance Procedures..... 2-14

Fuel System.................................... 2-14

Throttle Lever Free Play

Inspection .................................. 2-14

Throttle Lever Free Play

Adjustment ................................ 2-14

Choke Lever Free Play

Inspection .................................. 2-14

Choke Lever Free Play

Adjustment ................................ 2-15

Idle Speed Inspection .................. 2-15

Idle Speed Adjustment................. 2-16

Fuel System Cleanliness

Inspection .................................. 2-16

Air Cleaner Element Cleaning and

Inspection .................................. 2-17

Air Cleaner Draining..................... 2-17

Fuel Hose and Connection

Inspection .................................. 2-18

Fuel Hose Replacement .............. 2-18

Cooling System............................... 2-19

Radiator Cleaning ........................ 2-19

Radiator Hose and Connection

Inspection .................................. 2-20

Coolant Change........................... 2-20

Engine Top End .............................. 2-23

Valve Clearance Inspection ......... 2-23

Valve Clearance Adjustment ........ 2-24

Spark Arrester Cleaning............... 2-24

Converter System ........................... 2-25

Drive Belt Inspection .................... 2-25

Drive Belt Deflection Inspection... 2-25 Drive Belt Deflection Adjustment . 2-26 Actuator Lever (Engine Brake

Control Lever) Assembly

Inspection .................................. 2-27

Engine Lubrication System............. 2-27

Engine Oil Change....................... 2-27

Oil Filter Replacement ................. 2-28

Wheels/Tires................................... 2-28

Tire Inspection ............................. 2-28

Final Drive....................................... 2-29

Variable Differential Control Lever

Play Inspection.......................... 2-29

Variable Differential Control Lever

Play Adjustment ........................ 2-29

Front Final Gear Case Oil

Change...................................... 2-30

Rear Final Gear Case Oil Change 2-31

Universal Joint Lubrication........... 2-32

Brakes............................................. 2-32

Front Brake Pad Wear Inspection 2-32 Front Brake Hoses and

Connections Inspection............. 2-32

Front Brake Hose Replacement... 2-33

Brake Fluid Level Inspection........ 2-33

Brake Fluid Change ..................... 2-34

Front Brake Master Cylinder

Piston Assembly and Dust Seal

Replacement ............................. 2-34

Front Brake Caliper Piston Seal

and Dust Seal Replacement ..... 2-34

Rear Brake Plates Replacement.. 2-35 Rear Brake Lever Free Play

Inspection.................................. 2-35

Brake Pedal Free Play Inspection 2-35 Rear Brake Lever and Pedal Free

Play Adjustment ........................ 2-35

Steering .......................................... 2-36

Steering Inspection ...................... 2-36

Electrical System ............................ 2-36

Spark Plug Cleaning/Inspection ... 2-36

Spark Plug Gap Inspection .......... 2-36

Brake Light Switch Inspection...... 2-37

Brake Light Timing Adjustment .... 2-37

Drive Belt Failure Detection

System Inspection..................... 2-37

Joint Boots Inspection..................... 2-39

Front Axle/Knuckle Joint Boot

Inspection.................................. 2-39

Front Propeller Shaft Boot

Inspection.................................. 2-39

Tie-rod End Boot Inspection ........ 2-39

Rear Propeller Shaft Joint Boot

Inspection.................................. 2-39

Rear Axle/Stabilizer Joint Boot

Inspection.................................. 2-39

General Lubrication ........................ 2-40

2-2 PERIODIC MAINTENANCE

Lubrication ................................... 2-40

Bolts and Nuts Tightening............... 2-41

Tightness Inspection .................... 2-41

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good

running condition. The initial maintenance is vitally important and must not be neglected.

FirstFREQUENCY

Service

Every

After 10

hrs. or

100 km

(60 mi.)

of use

OPERATION

ENGINE

Converter drive belt wear - inspect *

Converter drive belt deflection - inspect *

Drive belt failure detection system function

-inspect*

Engine brake control lever - inspect *

Air cleaner - inspect *

Throttle lever play - i nspect

Choke lever play - inspect

Idle speed - inspect

Valve clearance - inspect

Fuel system cleanliness - inspect *

Engine oil - change *

Oil filter - replace *

Spark plug - clean and gap

Spark arrester - clean

Fuel hoses and connections - inspect

Fuel hose - replace 4 years 2-18

• •

10 days or 200 km

(120

mi.) of

use

Regular Service

days, 1 700

Every

30 days or 600 km

(360

mi.) of

use

km (1 100

when belt

light turns

hrs of use)

whichever

comes first

•

Every 90

mi.) or

indicator

on (100

•

Every

year of

use

•

See

page

2-25

2-37

2-27

2-17

2-14

2-15

2-23

2-16

2-27

2-28

2-36

2-24

2-18

Radiator - clean*

Radiator hoses and connections - check*

Coolant - change*

CHASSIS

Joint boots - inspect *

Rear brake pedal and lever play - inspect *

Rear brake plates - replace * every 10 000 km (6 000 mi.) 2-35

Bolts and nuts - tighten

Front brake pad wear - inspect *

Brake light switch - inspect *

Steering - inspect

Differential control lever play - inspect

• •

•

2 years 2-20

• •

2-19

2-20

2-39

2-35

2-41

2-32

2-37

2-36

2-29

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FirstFREQUENCY

Service

Every

After 10

hrs. or

100 km

(60 mi.)

of use

OPERATION

Tire wear - inspect *

Front and rear final gear case oil - change

Rear propeller shaft universal joint lubrication

General lubrication *

Front brake fluid level - inspect

Front brake fluid - change

Front brake hoses and connections inspect

Front brake master cylinder piston assembly and dust seal - replace

Front brake caliper piston seal and dust seal - replace

Front brake hose - replace 4 years 2-33

• •

10 days or 200 km

(120

mi.) of

use

Regular Service

Every 90

days, 1 700

Every

30 days or 600 km

(360

mi.) of

use

km (1 100

mi.) or

when belt

indicator

light turns

on (100

hrs of use)

whichever

comes first

Every

year of

use

•

2 years 2-34

See

page

2-28

2-30 2-31

2-32

2-40

2-33

2-34

2-32

*: Service more frequently when operated in mud, dust, or other harsh riding conditions, or when

carrying heavy loads or pulling a trailer.

: Clean, adjust, lubricate, torque, or replace parts as necessary.

•

PERIODIC MAINTENANCE 2-5

Torque and Lo cking Agent

The following tables list the t ightening torque for the major fasteners, and the parts requiring use of

a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately t wo times to ensure even tightening torque.

L: Apply a non-permanent locking agent.

LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue).

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide

grease in a weight ratio 10:1). R: Replacement Parts S: Follow the specific tightening sequence.

SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

St: Stake the fasteners to prevent loosening.

TB: Apply a non-permanent locking agent (Three Bond TB1363A, Red).

Fastener

Fuel System

Idle Adjusting Screw Bracket Bolt 8.8 0.90 78 in·lb

Element Cover Screw 3.5 0.35 31 in·lb

Element Holder Screws 3.5 0.35 31 in·lb

Clamp Bracket Bolt 9.8 1.0 87 in·lb

Fuel Pump Mounting Nuts 7.8 0.80 69 in·lb

Fuel Tap Plate Screws 0.8 0.08 7in·lb

Fuel Tap Mounting Bolts 4.9 0.50 43 in·lb

Fuel Tap Cover Screws 9.8 1.0 87 in·lb

Fuel Tap Bracket Bolts 7.8 0.80 69 in·lb

Fuel Level Sensor Mounting Bolts 2.0 0.20 18 in·lb

Cooling System

Radiator Mounting Bolts 8.8 0.90 78 in·lb

Radiator Fan Switch 18 1.8 13

Radiator Fan Assembly Bolts 4.9 0.50 43 in·lb

Thermostat Housing Cover Bolts 8.8 0.90 78 in·lb

Coolant Temperature Warning Light Switch 6.9 0.70 61 in·lb SS

Air Bleeder Bolt 8.8 0.90 78 in·lb

Water Pump Cover Bolts 8.8 0.90 78 in·lb

Coolant Drain Plug 8.8 0.90 78 in·lb

Water Pump Impeller 7.8 0.80 69 in·lb

Water Pipe Mounting Bolts 8.8 0.90 78 in·lb

Engine Top End

Rocker Case Bolts 55 mm (2.2 in.)

Rocker Case Bolts 130 mm (5.1 in.) 9.8 1.0 87 in·lb S

Rocker Case Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb S

Rocker Case Bolts 25 mm (1.0 in.) 9.8 1.0 87 in·lb S

Cylinder Head B olts (M10), first torque 25 2.5 18 S, MO

Cylinder Head Bolts (M10), final torque 49 5.0 36 S

Cylinder Head Bolts (M6) 9.8 1.0 87 in·lb

N·m kgf·m ft·lb

8.8 0.90 78 in·lb

Torque

Remarks

2-6 PERIODIC MAINTENANCE

Torque and Locki ng Agent

Fastener

Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb

Water Pipe Mounting Bolts 8.8 0.90 78 in·lb

Rocker Shaft Bolts 20 2.0 14

Valve Adjusting Screw Locknuts 12 1.2 104 in·lb

Chain Tensioner Mounting Bolts 8.8 0.90 78 in·lb

Chain Tensioner Cap Bolt 22 2.2 16

Position Plate Bolts 8.8 0.90 78 in·lb

Intermediate Shaft Chain Guide Bolts 8.8 0.90 78 in·lb

Intermediate Shaft Chain Tensioner Bolts 8.8 0.90 78 in·lb

Camshaft Splocket Bolts 12 1.2 104 in·lb L

Cylinder Bolts 40 mm (1.6 in.) 9.8 1.0 87 in·lb

Cylinder Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb

Front Cylinder Camshaft Chain Guide Bolt 20 2.0 14

Rear Cylinder Camshaft Chain Guide Bolt 20 2.0 14

Exhaust Pipe Cover Bolts 8.8 0.90 78 in·lb

Muffler Clamp Bolts

Muffler Mounting First Nuts 15 1.5 11 S

Muffler Mounting Second Nuts 31 3.2 23 S

Muffler Cover Bolts 8.8 0.90 78 in·lb

Converter System

Drive Pulley Bolt 93 9.5 69 R, Lh

Driven Pulley Nut 93 9.5 69

Drive Pulley Cover Bolt 13 1.3 113 i n·lb

Ramp Waight Nuts 6.9 0.70 61 in·lb

Spider

JointDuctBolts 8.8 0.90 78 in·lb

Converter Cover Bolts 8.8 0.90 78 in·lb S

Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb

Recoil Starter

Recoil Starter Mounting Bolts 5.9 0.60 52 in·lb L

Engine Lubrication System

Oil Filter 18 1.8 13 R

Oil Pressure Switch 15 1.5 11 SS

Oil Pipe Bolts 8.8 0.90 78 in·lb

Engine Drain Plug 20 2.0 14

Oil Pressure Relief Valve 15 1.5 11 L

Oil Pump Bolts 8.8 0.90 78 in·lb

Chain Guide Bolts 8.8 0.90 78 in·lb

Oil Pump Drive Chain Tensioner Bolt 25 2.5 18

Oil Filter Mounting Bolts 25 2.5 18 L(15 mm)

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Engine Removal/Installation

Engine Bracket Mounting Bolts 72 7.3 53

N·m kgf·m ft·lb

8.8 0.90 78 in·lb

275 28 203 Lh

Torque

Remarks

Torque and Lo cking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Engine Mounting Bolt 62 6.3 46

Engine Mounting Nut 62 6.3 46

Crankshaft/Transmission

Connecting Rod Big End Cap Nuts 34 3.5 25 MO

Engine Drain Plug 20 2.0 14

Crankcase Bolts (M8) 75 mm (2.95 in.) 20 2.0 14 S

Crankcase Bolts (M8) 110 mm (4.33 in.) 20 2.0 14 S

Crankcase Bolt (M8) 110 m m (4.33 in.) 20 2.0 14 S, L(1)

Crankcase Bolts (M6) 40 mm (1.57 in.) 9.8 1.0 87 in·lb

Crankcase Bolts (M6) 65 mm (2.56 in.) 9.8 1.0 87 in·lb

Bearing Position Plate Screws 4.9 0.50 43 in·lb L

Grip Hold Nut 9.8 1.0 87 in·lb

Shift Lever Assembly Bracket Bolts 20 2.0 14

Tie-rod End Front Locknut 9.8 1.0 87 in·lb Lh

Tie-Rod End Rear Locknut 9.8 1.0 87 in·lb

Tie-rod End Nut 20 2.0 14

Shift Lever Assembly Nut 20 2.0 14

Tie-rod End Bolt 9.8 1.0 87 in·lb

Shift Shaft Positioning Bolt 25 2.5 18

Shift Shaft Spring Bolt 25 2.5 18 L

Shift Shaft Cover Bolts 8.8 0.90 78 in·lb

Tie-rod End Locknut 20 2.0 14

Neutral Position Switch 15 1.5 11

Reverse Position Switch 15 1.5 11

Wheel/Tires

Tie-rod Locknuts 37 3.8 27

Tie-rod End Nuts 42 4.3 31

Wheel Nuts (First Torque) 15 1.5 11 S

Wheel Nuts (Final Torque) 76 7.8 56 S

Front Axle Nuts 197 20 145

Rear Axle Nuts 265 27 195

Final Drive

(Output Bevel Gears)

Output Driven Bevel Gear Housing Bolts

Output Drive Bevel Gear Housing Bolts 26 2.7 20

Bearing Holder 137 14 101 L

Bevel Gear Holder Nut

Bearing Holder 11 8 12 87 L

Output Shaft Holder Nut 157 16 11 6 L

Rotor Mounting Bolts 12 1.2 104 in·lb

Output Drive Bevel Gear Cover Bolts 8.8 0.90 78 in·lb

(Front Final Gear Case)

Variable Differential Control Shift Shaft Lever Bolt

N·m kgf·m ft·lb

26 2.7 20

157 16 11 6 L

8.8 0.90 78 in·lb

Torque

Remarks

2-8 PERIODIC MAINTENANCE

Torque and Locki ng Agent

Fastener

Front Final Gear Case Left Cover Bolts (M6) 9.8 1.0 87 in·lb L

Ring Gear Bolts 57 5.8 42 LB

Front Final Gear Case Center Cover Bolts (M6) 9.8 1.0 87 in·lb L

Front Final Gear Case Center Cover Bolts (M8) 24 2.4 17 L

Front Final Gear Case Oil Filler Cap 29 3.0 22

Pinion Gear Bearing Holder Nut 127 13 94 St

Pinion Gear Bearing Holder 137 14 101 L

Front Final Gear Case Coupling Nut 25 2.5 18

Front Final Gear Case O il Drain Plug 15 1.5 11

2WD/4WD Actuator Mounting Bolts

Variable Differential Control Cable Locknut 17 1.7 12

Variable Differential Control Lever Bolt – – – L

Front Final Gear Case Nuts 59 6.0 43

(Rear Final Gear Case)

Rear Final G ear Case Front Cover Bolts 24 2.4 17

Gasket Screws 13 0.13 11 in·lb

Pinion Gear Bearing Holder Nut 157 16 116 L

Pinion Gear Bearing Holder 137 14 101 L

Rear Final Gear Case Right Cover Bolts (M12) 93 9.5 69 L

Rear Final Gear Case Right Cover Bolts (M10) 49 5.0 36 L

Rear Final Gear Case Right Cover Bolts (M8) 24 2.4 17 L

Rear Final Gear Case Oil Filler Cap

Rear Final Gear Case Oil Drain Plug 13 1.3 113 in·lb

Bracket Bolts 59 6.0 43

Rear Final Gear Case Nuts

Brakes

Reservoir Cap Screws 1.5 0.15 13 in·lb

Brake Lever Pivot Bolt 6.0 0.60 53 in·lb

Brake Lever Pivot Bolt Locknut 6.0 0.60 53 in·lb

Master Cylinder Clamp Bolts 9.0 0.92 80 in·lb S

Bake Hose Banjo Bolt 25 2.5 18

Brake Caliper Mounting Bolts 25 2.5 18

Bleed Valves 5.4 0.55 48 in·lb

Brake Disc Mounting Bolts 37 3.8 27 L

Caliper Holder Shaft 17 1.7 13

Pad Mounting Bolts 17 1.7 13

Variable Differential Control Lever Bolt – – – L

Gasket Screws – – – L

Suspension

Front Shockabsorber M ounting Nuts 34 3.5 25

Front Suspension Arm Pivot Nuts 42 4.3 31

Front Knuckle Joint Nuts 29 3.0 22

Rear Shockabsorber Mounting Nuts 34 3.5 25

N·m kgf·m ft·lb

9.8 1.0 87 in·lb

29 3.0 22

72 7.3 53 TB

Torque

Remarks

L, S

Torque and Lo cking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Stabilizer Holder Bolts 23 2.3 17

Stabilizer Joint Nuts 48 4.8 35

Rear Suspension Arm Pivot Nuts 48 4.8 35

Rear Knuckle Mounting Nuts 48 4.8 35

Steering

Handlebar Holder Bolts 29 3.0 22 S

Steering Stem Clamp Bolts 25 2.5 18

Tie-rod End Nuts 42 4.3 31

Tie-rod Locknuts 37 3.8 27

Steering Stem Bearing Joint Bolts 23 2.3 17 L

Steering Stem Bottom End Nut 62 6.3 46

Front Knuckle Joint Nuts 29 3.0 22

Master Cylinder Clamp Bolts 9.0 0.92 80 in·lb

Variable Differential Control Lever Bolt – – – L

Frame

Front Guard Bolts 37 3.8 27

Front Carrier Bolts, L=50 mm (2.0 in.) 25 2.5 18

Front Carrier Bolts, L=70 mm (2.8 in.) 25 2.5 18

Front Carrier Bracket Bolts 32 3.3 24

Rear Carrier Bolts, L=14 mm (0.6 in.) 54 5.5 40

Rear Carrier Bolts, L=41 mm (1.6 in.) 54 5.5 40

Rear Carrier Bracket Bolts

Footboard Bracket Bolts 37 3.8 27

Hitch Bracket Bolts 82 8.3 60

Electrical System

Starter Motor Mounting Bolts 8.8 0.90 78 in·lb

Starter Motor Terminal Nut 4.9 0.50 43 in·lb

Starter Motor Terminal Locknut

Starter Motor Bolts 4.9 0.50 43 in·lb

Starter Motor Clutch Bolts 34 3.5 25 L

Alternator Stator Bolts 13 1.3 113 in·lb

Crankshaft Sensor Mounting Bolts 5.9 0.60 52 in·lb

Alternator Cover Plugs 18 1.8 13

Alternator Rotor Bolt 127 13 94

Alternator Cover Bolts 8.8 0.90 78 in·lb

Spark Plugs 13 1.3 113 in·lb

2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·lb L,S

Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb

Forward/Reverse Detectring Sensor Mounting Bolt 15 1.5 11

Speed Sensor Mounting Bolt 8.8 0.90 78 in·lb

Neutral Position Switch 15 1.5 11

Reverse Position Switch 15 1.5 11

Ignition Coil Mounting Bolts 8.8 0.90 78 in·lb

N·m kgf·m ft·lb

42 4.3 31

6.9 0.70 61 in·lb

Torque

Remarks

2-10 PERIODIC MAINTENANCE

Torque and Locki ng Agent

Fastener

N·m kgf·m ft·lb

Radiator Fan Switch 18 1.8 13

Coolant Temperature Warning Light Switch 6.9 0.70 61 in·lb SS

Oil Pressure Switch 15 1.5 11 SS

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Regulator/Rectifier M ounting Bolts 8.8 0.90 78 in·lb

Fuel Level Sensor Mounting Bolts 2.0 0.20 18 in·lb

The tables below, relating tightening torque to thread diameter, lists the basic torque for the 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.

Torque

Remarks

Basic Torque for General Fasteners of Engine Parts

Threads dia. Mark of Torque

mm (in.) bolt head N·m kgf·m ft·lb

6 (0.24) 9T 12 ∼ 15 1.2 ∼ 1.5 104 ∼ 130 in·lb 6 (0.24) 7T 7.8 ∼ 9.8 0.8 ∼ 1.0 69 ∼ 87 in·lb 6 (0.24) 4T 3.9 ∼ 4.9 0.4 ∼ 0.5 35 ∼ 43 in·lb 8 (0.31) 7T 18 ∼ 22 1.8 ∼ 2.2 13 ∼ 16 8 (0.31) 4T 10 ∼ 14 1.0 ∼ 1.4 87 ∼ 122 in·lb

10 (0.39)

5 (0.20) 4T 2.2 ∼ 2.6 0.22 ∼ 0.27 19 ∼ 23 in·lb

7T 39 ∼ 44 4.0 ∼ 4.5 29 ∼ 33 4T 20 ∼

2.0

∼ 2.4

14 ∼

Basic Torque for General Fasteners of Frame Parts

Threads dia. Torque

mm (in.) N·m kgf·m ft·lb

5 (0.20) 3.4 ∼ 4.9 0.35 ∼ 0.5 30 ∼ 43 in·lb 6 (0.24) 5.9 ∼ 7.8 0.6 ∼ 0.8 52 ∼ 69 in·lb

8 (0.31) 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5 10 (0.39) 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 12 (0.47) 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14 (0.55) 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72

16 (0.63)

18 (0.71)

20 (0.79) 225 ∼ 325 23 ∼ 33 165 ∼ 240

115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165

PERIODIC MAINTENANCE 2-11

Specifications

Item Standard Service Limit

Fuel System

Throttle Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Choke Lever Free Play about 3 mm (0.12 in.) –––

Idle Speed 1 150 ± 50 r/min (rpm) –––

Air Cleaner Element Oil High-quality foam air filter oil

Cooling System

Coolant:

Type (Recommended) Permanent type antifreeze –––

Color Green –––

Mixed Ratio Soft water 50%, Coolant 50% –––

Freezing Point −35°C (−31°F) –––

Total Amount 2.2 L (2.3 US qt.) –––

Engine Top End

Valve Clearance:

Exhaust 0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.) ––– Inlet 0.10 ∼ 0.15 m m (0.0039 ∼ 0.0059 in.) –––

Converter System

Belt Width 29.7 ∼ 30.3 mm (1.169 ∼ 1.193 in.) 28.0 mm (1.102 in.) Belt Deflection 22 ∼ 27 mm (0.87 ∼ 1.06 in.) –––

Actuator Lever Guide Shoe Wear

Engine Lubrication System

Engine Oil:

Type API SF or SG –––

Viscosity SAE10W-40 –––

Capacity 2.1 L (2.2 US qt) –––

Wheels/Tires

Tire Tread Depth:

Front ––– 3 mm (0.12 in.)

Rear –––

Standard tire:

Front AT 25 × 8-12 –––

Rear AT 25 × 10-12 –––

–––

API SH or SJ with JASO MA class –––

(When filter is not removed)

2.2 L (2.3 US qt) –––

(When filter is removed)

2.6 L (2.7 US qt) –––

(When engine is completely dry)

DUNLOP, KT191, Tubeless

DUNLOP, KT195, Tubeless –––

–––

6 mm (0.24 in.)

4 mm (0.16 in.)

–––

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Final Drive

Front Final Gear Case:

Gear Case Oil:

Type API SF or SG –––

API SH or SJ of JASO MA class –––

Viscosity SAE 10W-40 –––

Oil Level Filler opening bottom –––

Capacity 0.40 L (0.42 US qt) –––

Rear Final Gear Case:

Gear Case Oil:

Type

Oil level Filler opening bottom –––

Capacity 0.72 L (0.76 US qt) –––

Brakes

Front Brake Fluid:

Type DOT 3 or DOT 4 –––

Front Disc Brake:

Pad Lining Thickness 4mm(0.16in.) 1 mm (0.04 in.)

Rear Brake Lever, Pedal and Cables:

Rear Brake Lever Free Play 1 ∼ 2 mm (0.04 ∼ 0.08 in.) ––– Brake Pedal Free Play 15 ∼ 25 mm (0.6 ∼ 1.0 in.) –––

Electrical System

Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.) –––

Rear Brake Light Switch Timing

MOBIL Fluid 424, CITGO

TRANSGARD TRACTOR HYDRAULIC FLUID, or EXXON HYDRAUL 560

ON after 10 mm (0.4 in.) of pedal travel

–––

Special Tools

PERIODIC MAINTENANCE 2-13

Oil Filter Wrench: 57001-1249

Carburetor Drain Plug Wrench, Hex 3: 57001-1269

Flywheel & Pulley Holder: 57001-1343

Filler Cap Driver: 57001-1454

Pulley Holder Attachment: 57001-1472

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Throttle Lever Free Play Inspection

Check that the throttle lever [A] 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 cable routing, lever free play, and cable damage. Then lubricate the throttle cable. 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. Stop the engine and check the throttle lever free play [B].

•

If the free play is not within the specified range, adjust the cable.

Throttle Lever Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Throttle Lever Free Play Adjustment

Remove the handle cover (see Multifunction Meter Unit

•

Removal in the Electrical System chapter). Slide the rubber cover off the adjuster at the throttle case.

•

Loosen the locknut [A] and turn the throttle cable upper

•

adjuster [B] until the cable has proper amount of play. Tighten the locknut and reinstall the rubber cover.

•

If the free play cannot be adjusted by using the upper cable adjuster, remove the left side cover (see Frame chapter) and then use t he cable adjusting nuts [A] at the lower end of the throttle cable and make the necessary free play.

Choke Lever Free Play Inspection

Check if the choke lever [A] returns properly and if the

•

inner cable slides smoothly. Make sure that the choke lever returns to its released po-

•

sition all the way. To determine the amount of choke cable play at the lever,

•

pull the choke lever to the left until feeling the operation of the lever tough; the amount of choke lever is equivalent to that of cable play. The proper amount of play ranges about 3 mm (0.12 in.)

•

at the choke lever. If the free play is not within the specified range, adjust the cable.

ChokeLeverFreePlay[B]

Standard: about 3 mm (0.12 in.)

Periodic Maintenance Procedures

Choke Lever Free Play Adjustment

Remove:

•

Handlebar Cover Screws [A]

Remove:

•

Handlebar Cover Screws [A] Handlebar Cover Front [B]

PERIODIC MAINTENANCE 2-15

Loosen the locknut [A] of the choke cable.

•

Turn the adjuster [B] until the cable has proper amount of

•

play. Tighten the l ocknut securely.

•

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides to

•

check for any changes in the idle speed. If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted incorrectly routed, or damaged. Be sure to correct any of these conditions before riding.

WARNING

Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condition.

Check idle speed with a suitable tachometer.

•

If the idle speed is out of the specified range, adjust it (see Idle Speed Adjustment).

Idle Speed

Standard: 1 150 ± 50 r/min (rpm)

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

Turn the idle adjusting screw [A] until the idle speed is

•

correct. Open and close the throttle a few times to make sure that

○

the idle speed is within the specified range.

Fuel System Cleanliness Inspection

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch O FF. 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.

Remove the check valve [A] at the end of the carburetor

•

overflow hose [B]. Run the lower end of the carburetor overflow hose to a

•

suitable container.

Turn out the carburetor drain plugs [A] a few turns and

•

drain the fuel system.

Special Tool - Carburetor Drain Plug Wrench, Hex 3 [B] :

57001-1269

Check to see if water or dirt com es out.

•

Tighten the drain plugs.

•

If any water or dirt appears during the above inspection, clean the fuel system (carburetor, fuel pump, fuel tank, fuel hose).

Periodic Maintenance Procedures

Air Cleaner Element Cleaning and Inspection

NOTE

In dusty areas, the element should be cleaned more

○

frequently than the recommended interval. After riding through rain or muddy terrains, the element

○

should be cleaned immediately. Also, if there is a break in the element m aterial or any

○

other damage to the element, replace the element with a new one.

WARNING

Clean the element in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the foam element.

Remove the air cleaner element (see Fuel System chap-

•

ter).

PERIODIC MAINTENANCE 2-17

Clean the element [A] in a bath of high-flash point solvent.

•

Squeeze it dry in a clean towel [A]. Do not wring the ele-

•

ment or blow it dry; the element can be damaged. Inspect the element for damage.

•

If it is torn, punctured, or hardened, replace it. After cleaning, saturate the element with a high-quality

•

foam-air-filter oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element.

Air Cleaner Draining

If any water or oil accumulates in the tube, drain it by

•

taking off the tube plug [A]. After draining, be sure to install the tube plug and clamp firmly.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel Hose and Connection Inspection

The fuel hoses are designed to be used throughout the

○

vehicle life without any maintenance, however, if the vehicle is not properly handled, the pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps

•

are installed correctly. When installing the fuel hoses, route the hoses according

•

to Cable, Wire, and Hose Routing section in the Appendix chapter. When installing the fuel hoses, avoid sharp bending, kink-

•

ing, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed. Replace the hose if it has been sharply bent or kinked.

Fit the fuel hose [A] onto the fitting fully and install the

•

plate clamp [B] beyond the raised rib [C].

1 ∼ 2 mm (0.0039 ∼ 0.0078 in.) [D]

The hose end must reach the fillet [E] or be as near as

○

possible to the step [F]. Fit the fuel pump inlet hoses onto the Y-joint fully until

○

each end of the inlet hose touches the second raised rib.

Fuel Hose Replacement

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch O FF. 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.

Remove:

•

Right Side Cover (see Frame chapter) Electric Parts Case (see Frame chapter) Rear Fender (see Frame chapter)

Turn the fuel tap to the ON position.

•

Periodic Maintenance Procedures

Remove:

•

Clamps [A] Fuel Hoses [B]

Replace the fuel hoses with new ones.

•

When installing the fuel hose, route the hose according

•

to Cable, Wire, and Hose Routing section in Appendix chapter. When installing the fuel hose, avoid sharp bending, kink-

•

ing, flattening or twisting, and route the fuel hose w ith a minimum of bending so that the fuel flow will not be obstructed. Fit the fuel hose onto the pipe fully and install the clamps

•

beyond the raised r ib (see Fuel Hose and Connection Inspection).

PERIODIC MAINTENANCE 2-19

Cooling System

Radiator Cleaning

CAUTION

Clean the radiator screen and the radiator in accordance with the P eriodic Maintenance Chart. In dusty areas, they should be cleaned more frequently than the recommended interval. After riding through muddy terrains, the radiator screen and the radiator should be cleaned immediately.

Remove:

•

Front Guard (see Frame chapter) Front Fender (see Frame chapter) Radiator Screen Mounting Screws [A] Radiator Screen [B]

Clean the radiator screen in a bath of tap water, and then

•

dry it with compressed air or by shaking it.

Clean the radiator.

•

CAUTION

When cleaning the radiator w ith steam cleaner, be careful of the following to prevent radiator damage. Keep the steam gun away more than 0.5 m (20 in.) from the radiator core [A]. Hold the steam gun perpendicular to the core surface. Run the steam gun following the core fin direction.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Radiator Hose and Connection Inspection

The high pressure inside the radiator hose can cause

○

coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should i t be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps

•

are tightened correctly.

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wash away any coolant that spills on the frame, engine, or wheels. Since coolant is harmful to the human body, do not use for drinking.

Remove:

•

Left Footboard (see Frame chapter) Front Fender (see Frame chapter) Radiator Cover Screws [A] and Collars

Remove:

•

Radiator Cover Screws [A] and Collars Radiator Cover [B]

Periodic Maintenance Procedures

Remove:

•

Clamp [A] Reserve Tank Screws [B] Reserve Tank [C] with Hose

Remove the reserve tank cap, and pour the coolant into

•

a container.

Place a container under the drain plug [A] at the bottom

•

of the water pump [B], then remove the drain plug.

PERIODIC MAINTENANCE 2-21

Remove the radiator cap [A] in two steps. First turn the

•

cap counterclockwise to the first step. Then push and turn it further in the same direction and remove the cap. The coolant will drain from the radiator and engine.

•

Place a container under the drain plug [A] at the front

•

cylinder, then remove the drain plug.

Place a container under the drain plug [A] at the rear cylin-

•

der, then remove the drain plug.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tighten the drain plug.

•

Torque - Coolant Drain Plug: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Support the vehicle on a stand or the jack so that the front

•

wheels are off the ground. This makes air bleeding easier. Fill the r adiator up to the radiator filler neck [A] with

•

coolant.

NOTE

Pour in the coolant slowly so that the air in the engine

○

and radiator can escape.

CAUTION

Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, considerably reducing the efficiency of the cooling system.

Water and Coolant Mixture Ratio (when shipping)

Soft Water: 50%

Coolant: 50%

Freezing Point:

Total Amount:

−35°C (−31°F)

2.2 L (2.3 US qt)

NOTE

Choose a suitable mixture ratio by referring to the

○

coolant manufacturer’s directions.

Bleed the air from the cooling system as follows.

•

Start t he engine with the r adiator cap removed and run it

○

until no more air bubbles [A] can be seen in the coolant. Tap the radiator hoses to force any air bubbles caught

○

inside. Stop the engine and add coolant up to the radiator filler

○

neck. Install the radiator cap.

•

Remove the reserve tank cap.

•

Fill the reserve tank up to the F mark [A] with coolant and

•

install the cap. Start the engine, warm it up thoroughly until the radiator

•

fan turns on and then stop the engine. Check the coolant level in the reserve tank after the en-

•

gine cools down. If the coolant level is lower than the low level line, add coolant to the full level line.

CAUTION

Do not add more coolant above the full level line.

Periodic Maintenance Procedures

Engine Top E nd

Valve Clear ance Inspection

NOTE

Check the valve clearance only when the engine is cold

○

(at room temperature).

Remove:

•

Left Side Cover (see Frame chapter) Battery Case (see Frame chapter) Valve Adjusting Caps [A] Recoil Starter (see Recoil Starter chapter)

Remove the timing inspection plug [A].

•

Special Tool - Filler Cap Driver [B]: 57001-1454

PERIODIC MAINTENANCE 2-23

Turn the crankshaft counterclockwise with a wrench on

•

the alternator rotor bolt until “T-F” mark [A] on the alternator rotor aligns with the notch [B] as shown: the end of the compression stroke in the front cylinder head.

Measure the clearance for all four valves, one at a time

•

between the end of the valve stem and the adjusting screw [A] with the thickness gauge [B].

Valve Clearance (when cold)

Exhaust:

Inlet:

If the valve clearance is not correct, adjust it (see Valve Clearance Adjustment).

0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Then, turn the crankshaft counterclockwise with a

•

wrench on the alternator rotor bolt until “T-R” mark [A] on the alternator rotor aligns with the notch [B] as shown: the end of the compression stroke in the rear cylinder head. Measure the clearance for all four valves, one at a time

•

between the end of the valve stem and the adjusting screw with the thickness gauge.

Valve Clearance (when cold)

Exhaust: 0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.)

Inlet:

If the valve clearance is not correct, adjust it (see Valve Clearance Adjustment).

Valve Clearance Adjustment

Remove the valve adjusting caps.

•

Loosen the locknut and turn the adjusting screw until the

•

clearance is correct. Hold the adjusting screw [A] from turning and tighten the

•

locknut [B].

Torque - Valve Adjusting Screw Locknuts: 12 N·m (1.2

Recheck the clearance.

•

If the clearance is incorrect, repeat the adjustment procedure. If the clearance is correct, perform the adjustment procedure on the other valve.

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

kgf·m, 104 in·lb)

Spark Arrester Cleaning

WARNING

To avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run during this procedure, the muffler will become hot.

Remove the drain plug [A] on the muffler.

•

In an open area away from combustible materials, start

•

the engine w ith the transmission in neutral. Raise and lower engine speed while tapping on the muf-

•

fler with a rubber mallet until carbon particles are purged from the muffler.

WARNING

Do not run t he engine in a closed area. Exhaust gases contain carbon m onoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death.

Stop the engine.

•

Install the drain plug.

•

Periodic Maintenance Procedures

Converter System

Drive Belt Inspection

Inspection of the drive belt is required at least every 90 days of vehicle use (average 12 mile/day) not to exceed 1 700 km (1 100 mile) or belt indicator light turn on (100 hours of use) counted by the hour meter. More frequent inspection is necessary if the vehicle is subjected to hard usage.

WARNING

Neglect, abuse, or failure to maintain the transmis-

sion can result in a severely worn or damaged drive

belt locking up the transmission and wheels. This

can cause the operator to lose control and have an

accident resulting in injury or death.

Remove the torque converter cover (see Converter Sys-

•

tem chapter).

Measure the width [A] of the belt at several locations with

•

a pair of suitable straightedges [B] as shown.

If any measurements exceed the service limit, replace the

belt.

PERIODIC MAINTENANCE 2-25

Belt Width

Standard: 29.7 ∼ 30.3 mm (1.169 ∼ 1.193 in.)

Service Limit: 28.0 mm (1.102 in.)

Check the belt [A] for abnormal wear [B].

•

Measure the width [C] of the belt at abnormal wear point.

○

If any measurements exceed 0.5 mm (0.02 in.), replace

the belt.

When using the belt of large abnormal wear, the drive belt

○

failure detection switch could be activated.

Check the belt for cracks, breaks, or peeling.

•

If necessary, replace t he belt with a new one.

Belt [A] Crack [B] Broken [C] Peeling [D]

NOTE

Whenever the belt is replaced, inspect the drive and the

○

driven pulleys.

Drive Bel t Deflection Inspection

Remove the torque converter cover (see Converter Sys-

•

tem chapter).

Put the transmission in neutral and rotate the driven pulley

•

by hand to make sure the belt is shifted all the way to the

top of the driven pulley.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Measure the belt deflection [A] as shown:

•

Place a straightedge [B] on top of the belt between the

○

drive pulley [ C] and the driven pulley [D]. Use a ruler to push the belt away from the straightedge.

○

Push hard, but with no more force than 59 N (6 kgf, 13 lb).

Belt Deflection

Standard: 22 ∼ 27 mm (0.87 ∼ 1.06 in.)

If the belt deflection is not within the specified range, adjust the deflection by adding or removing spacers on the fixed sheave of the driven pulley. When adjusting the deflection, less is better than more.

•

Less deflection will maintain better performance for more time as the belt width decreases by normal wear, which causes the deflection to increase with usage.

Drive Belt Deflection Adjustment

Disassemble the driven pulley (see Converter System

•

chapter). If the belt deflection is more than 27 m m (1.06 in.), remove the spacers to decrease it. The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer

○

thickness equals about 1.3 mm (0.051 in.) change in belt deflection. If the adjustment cannot be done within the specified range even if the shim is removed, replace the drive belt. If the belt deflection is less t han 22 mm (0.87 in.), add the spacers [A] to increase it. The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer

○

thickness equals about 1.6 mm (0.063 in.) change in belt deflection.

NOTE

When using the plural spacers, install the thick spacer

○

to the movable sheave side and thin spacer to the fixed sheave side.

Spacers

Part No. Thickness

92026-0034

92026-1569

92026-1617

92026-1565

92026-1570 1.4 mm (0.055 in.)

0.3 mm (0.012 in.)

0.6 mm (0.024 in.)

0.8 mm (0.032 in.)

1.0 mm (0.039 in.)

Periodic Maintenance Procedures

Assemble the driven pulley (see Converter System chap-

•

ter).

With the transmission in neutral, rotate the driven pulley

•

to allow the belt to return to the top of the sheaves before

measuring the belt deflection.

Measure the belt deflection again and repeat the above

•

procedures until it is within the standard range.

Using the flywheel & pulley holder and pulley holder at-

•

tachment, tighten the driven pulley nut.

Special Tools - Flywheel & Pulley Holder: 57001-1343

Pulley Holder Attachment: 57001-1472

Torque - Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb)

Actuator Lever (Engine Brake Control Lever) Assembly Inspection

Measure the width [A] of the plastic guide shoe [B] of the

•

actuator lever assembly.

If the guide contact area width is greater than the service

limit, replace t he actuator lever assembly.

PERIODIC MAINTENANCE 2-27

Actuator Lever Guide Shoe

Service Limit: 6 mm (0.24 in.)

Engine Lubrication System

Engine Oil Change

Support the vehicle so that it is level side to side and front

•

to back after warming up the engine.

Remove the engine drain plug [A] to drain the oil.

•

The oil in the filter can be drained by removing the f ilter

○

(see Oil Filter Change).

Replace the drain plug gasket with a new one.

•

Tighten:

•

Torque - Engine Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb)

Pour in the specified type and amount of oil.

•

Engine Oil

Type: API SF or SG

API SH or SJ with JASO MA class

Viscosity: SAE 10W-40

Amount: 2.1 L (2.2 US qt)

(When filter is not removed)

2.2 L (2.3 US qt)

(When filter is removed)

2.6 L (2.7 US qt)

(When engine is completely dry)

NOTE

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.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Oil Filter Replacement

Drain the engine oil.

•

Remove the oil filter [A] with the oil filter wrench [B].

•

Special Tool - Oil Filter Wrench: 57001-1249

Replace the filter with a new one.

•

When installing the oil filter, be careful of the following.

•

Apply oil to the gasket [A] before installation.

○

Tighten the filter with the oil filter wrench.

○

Special Tool - Oil Filter Wrench: 57001-1249

Torque - Oil Filter: 18 N·m (1.8 kgf·m, 1 3 ft·lb)

Pour in the specified type and amount of oil.

○

Wheels/Tires

Tire Inspection

Examine the tire for damage and wear.

•

If the tire is cut or cracked, replace it. Lumps or high spots on the tread or sidewalls indicate

○

internal damage requiring tire replacement. Remove any foreign objects from the tread. After re-

○

moval, check for leaks with a soap and water s olution. Measure the tread depth at the center of the tread with a

•

depth gauge [A]. Since the tire may wear unevenly, take measurements at several places. If any measurements are less than the service limit, replace the tire.

Tire Tread Depth

Service Limit:

Front: 3 mm (0.12 in.)

Rear: 4 mm (0.16 in.)

Standard Tire

Front: AT 25 × 8 - 12

DUNLOP, KT191, Tubeless

Rear: AT 25 × 10 - 12

DUNLOP, KT195, Tubeless

Periodic Maintenance Procedures

Final Drive

Variable Differential Control Lever Play Inspection

Pull the variable differential control lever [A] towards the

•

handlebar grip [B] with a spring scale until it reads 30 N

(3 kgf, 7 lb) of force.

The differential control in the front final gear case must be

○

locked, then the clearance [C] between the control lever

and grip should be 20 mm (0.8 in.).

If the clearance is not the specified length, adjust the ca-

ble.

Differential Control Lever Lock Position Length

Standard: 20 mm (0.8 in.)

Variable Differential Control Lever Play Adjustment

Remove:

•

Handlebar Cover Screws [A]

PERIODIC MAINTENANCE 2-29

Remove:

•

Handlebar Cover Screws [A] Handlebar Cover Front [B]

Loosen the locknut [A] of t he differential control cable.

•

Turn the adjuster [B] until the cable has proper amount of

•

play.

Tighten the l ocknut securely.

•

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Front Final Gear Case Oil Change

Warm up the oil by running the vehicle so that the oil will

•

pick up any sediment and drain easily. Then stop the vehicle. Park the vehicle so that it is level, both side-to-side and

•

front-to-rear. Remove the front side cover (see Frame chapter).

•

Place an oil pan beneath the front final gear case and

•

remove the drain plug [A].

WARNING

When draining or filling the final gear case, be careful that no oil gets on the tire or rim. Clean off any oil that inadvertently gets on them with a high-flash point solvent.

After the oil has completely drained out, install the drain

•

plug with a new aluminum gasket, and tighten it.

Torque - Oil Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb)

Fill the gear case up to the bottom of filler opening with

•

the oil specified below.

Front Final Gea r Case Oil

Type: API SF or SG

APISHorSJwithJASOMAclass

Viscosity: SAE 10W-40

Capacity: 0.40 L (0.42 US qt)

NOTE

Depending on the atmospheric temperature of your rid-

○

ing area, the engine oil viscosity should be changed according to the chart.

Be sure the O-ring [A] is in place, and tighten the filler cap

•

[B]. Apply grease to the O-ring.

○

Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb)

Periodic Maintenance Procedures

Rear Final Gear Case Oil Change

Warm up the oil by running the vehicle so that the oil will

•

pick up any sediment and drain easily. Then stop the

vehicle.

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

•

front-to-rear.

Place an oil pan beneath the rear final gear case and

•

remove the drain plug [A].

WARNING

When draining or filling the final gear case, be care-

ful that no oil gets on the tire or rim because oil will

deteriorate the tire. Clean off any oil that inadver-

tently gets on them with a high-flash point solvent.

After the oil has completely drained out, install the drain

•

plug with a new aluminum gasket.

Torque - Oil Drain Plug: 13 N·m (1.3 kgf·m, 113 in·lb)

Fill the final gear case up to the bottom of filler opening

•

with the oil specified below.

PERIODIC MAINTENANCE 2-31

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)

Do not use mixing the above oils.

○

Be sure the O-ring [A] is in place, and tighten the filler cap

•

[B].

Apply grease to the O-ring.

○

Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb)

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Universal Joint Lubrication

Remove:

•

Rear Propeller Shaft (see Final Drive chapter)

Force grease into the grease nipples [A] until the grease

•

comes out from the nipple, and wipe off any excess grease.

[B] Grease Gun

Brakes

Front Brake Pad Wear Inspection

Check the lining thickness [A] of the pads in each caliper.

•

If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.

Pad Lining Thickness

Standard: 4 mm (0.16 in.)

Service Limit: 1 mm (0.04 in.)

Front Brake Hoses and Connections Inspection

Inspect the brake hose and fittings for deterioration,

•

cracks and signs of leakage. Thehighpressureinsidethebrakelinecancausefluidto

○

leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose if any cracks [B] or bulges [C] are noticed. Tighten any loose fittings.

•

Periodic Maintenance Procedures

Front Brake Hose Replacement

Pump the brake fluid out of the line as explained in the

•

Brake Fluid Change.

Remove the banjo bolts at both ends of the brake hose,

•

and pull the hose off the vehicle.

Immediately wipe up any brake fluid that spills.

•

CAUTION

Brake fluid quickly ruins painted surfaces; any

spilled fluid should be completely w ashed away

immediately.

Use a new flat washer for each side of the hose fittings.

•

Install the new brake hose in its place (see Appendix

•

chapter), and tighten the banjo bolts.

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Brake Fluid Level Inspection

Position the reservoir horizontal, and check that the fluid

•

level in the reservoir is higher than the lower level line [A].

If the fluid level is lower than the lower level line, check

for fluid leakage of the brake line, and add the fluid as

follows:

PERIODIC MAINTENANCE 2-33

Remove the reservoir cap, and fill the reservoir to the up-

○

per level line [A] in the reservoir with the same type and

brand of the fluid that is already in the reservoir. And then

install the reservoir cap.

WARNING

Change the fluid in the brake line completely if the

fluid must be refilled but the type and brand of the

fluid that is already in the reservoir are unidentified.

Tighten:

•

Torque - Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13

in·lb)

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Fluid Change

Remove the reservoir cap and the rubber cap on the bleed

•

valve. Attach a clear plastic hose to the bleed valve on the

•

caliper, and run the other end of the hose into a container. Fill the reservoir with new brake fluid.

•

Change the brake fluid as follows:

•

Open the bleed valve [A].

○

Apply the brake lever and hold it [B].

○

Close the bleed valve [C].

○

Release the brake lever [D].

○

Check the fluid level in the reservoir often, replenishing it

•

as necessary.

NOTE

If the fluid in the reservoir runs completely out any time

○

during fluid changing, air will enter the line, and the system must be bled.

Repeat this operation until fresh brake fluid comes out into

•

the plastic hose or the color of the fluid changes.

WARNING

Do not mix t wo brands of fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are not known.

Tighten:

•

Torque - Bleed Valves: 5.4 N·m (0.55 kgf·m, 48 in·lb)

Apply the brake lever forcefully for a few seconds, and

•

check for fluid leakage around the fittings. If necessary, bleed the air from the brake line (see Brake Line Air Bleeding section in Brakes chapter).

WARNING

If the brake lever has a soft or "spongy feeling" when it is applied, there might be air in the brake line or the brake may be defective. S ince it is dangerous to operate the vehicle under such conditions, bleed the air from the brake line immediately.

Front Brake Master Cylinder Piston Assembly and Dust Seal Replacement

Refer to the Master Cylinder section in the Brakes chap-

•

ter f or Front Brake Master Cylinder Piston Assembly and Dust Seal Replacement.

Front Brake Caliper Piston Seal and Dust Seal Replacement

Refer to the Caliper section in the Brakes chapter for Front

•

Brake Caliper Piston Seal and Dust Seal Replacement.

Periodic Maintenance Procedures

Rear Brake Plates Replacement

Replace the steel plates and friction plates in accordance

•

with the specified interval (see Rear Final Gear Case sec-

tion in the Final Drive chapter).

Rear Brake Lever Free Play Inspection

Check the rear brake lever free play [A].

•

Pull the rear brake lever lightly until the brake is applied.

○

If the play is incorrect, adjust it.

Rear Brake Lever Free Play

Standard: 1 ∼ 2mm(0.04∼ 0.0 8 in.)

Brake Pedal Free Play Inspection

Check the brake pedal free play [A].

•

Depress the brake pedal lightly by hand until the brake is

○

applied.

If the free play is incorrect, adjust it.

PERIODIC MAINTENANCE 2-35

Brake Pedal Free Play

Standard: 15 ∼ 25 mm (0.6 ∼ 1.0 in.)

Rear Brake Lever and Pedal F ree Play Adjustment

NOTE

Since the rear brake lever and pedal free play adjust-

○

ments affect each other, make them at the same time.

Rear Brake Lever:

Loosen the knurled locknut [A] and turn the adjuster [ B]

•

at the rear brake lever in as far as it will go.

Tighten the locknut.

•

Turn the brake lever adjuster [A] at the rear end of the

•

brake cable until the rear brake lever has the correct

amount of play.

Brake Pedal:

Turn the brake pedal adjuster [B] at the rear end of the

•

brake cable until the brake pedal has the correct amount

of play.

Operate the pedal a few times to see that it returns to its

•

rest position immediately upon release.

Rotate the rear wheels to check for brake drag.

•

Check braking effectiveness.

•

If there is any doubt as to the conditions of the brake,

check the brake parts for wear or damage.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering

Steering Inspection

Turn the handlebar left and right, and check the steering

•

action. If the steering action is not smooth, or if the steering binds or catches before the stop, lubricate the steering stem bearing.

NOTE

The cables and wires will have some effect on the steer-

○

ing action which must be taken into account.

Check the steering action again.

•

If steering stem bearing lubrication does not remedy the problem, inspect the steering stem for straightness, steering stem clamps, and tie-rod bearings. If you feel looseness, or if the steering rattles as it turns, check the tightness of the steering bolts and nuts. Tighten loose bolts and nuts to the specified torque (see

•

Steering chapter), and check the steering action again. If the steering action does not change by tightening the bolts and nuts, inspect the steering stem clamps, steering stem bearings, tie-rod bearings, and steering knuckle joints.

Electrical System

Spark Plug Cleaning/Inspection

Remove the spark plug (see Electrical System chapter).

•

Clean the spark plug, preferably in a sandblasting device,

•

and then clean off any abrasive particles. The plug may also be cleaned using a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.

Spark Plug Gap Inspection

Measure the gap [A] with a wire-type thickness gauge.

•

If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.)

Periodic Maintenance Procedures

Brake Light Switch Inspection

Turn on the ignition switch.

•

Check the operation of the rear brake light switch by de-

•

pressing the brake pedal.

If it does not as specified, adjust the brake light timing.

Brake Light Timing

Standard: On after about 10 mm (0.4 in.) of pedal

travel [A]

Brake Light Timing Adjustment

Remove the right hootboard (see Frame chapter).

•

Adjust the brake light switch [A] up or down. To change

•

the switch position, turn the adjusting nut [B].

CAUTION

To avoid damaging the electrical connections in-

side the switch, be sure that the switch body does

not turn during adjustment.

PERIODIC MAINTENANCE 2-37

Drive Belt Failure Detection System Inspection

Remove:

•

Seat (see Frame chapter)

Check the drive belt failure detection system according to

•

following chart.

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Joint Boots Inspection

Front Axle/Knuckle Joint Boot Inspection

Visually inspect the front axle joint boots [A].

•

If the joint boot is torn, worn, deteriorated, or leaks grease,

replace the joint boot or front axle assembly (see Final

Drive chapter).

Visually inspect the knuckle joint boots [B].

•

If the joint boot is torn, worn, deteriorated, or leaks

grease, replace the knuckle (see Steering Knuckle sec-

tion in Steering chapter).

Front Propeller Shaft Boot Inspect ion

Visually inspect the boots [A] of the front propeller shaft.

•

If damage, tear or deterioration is found, replace the boots

(see Front Propeller Shaft section in Final Drive chapter).

PERIODIC MAINTENANCE 2-39

Tie-rod End Boot Inspection

Visually inspect the tie-rod end boots [A] of the tie-rods.

•

If the boot is torn, w orn, deteriorated, or leaks grease,

replace the tie-rod end (see Steering chapter).

Rear Propeller Shaft Joint Boot Inspection

Visually inspect the boots [A] of the rear propeller shaft.

•

If the joint boot is torn, worn, or deteriorated, replace the

joint boot and check the propeller shaft (see Rear Pro-

peller Shaft section in Final Drive chapter).

Rear Axle/Stabilizer Joint Boot Inspection

Visually inspect the rear axle joint boots [A].

•

If the joint boot is torn, worn, deteriorated, or leaks grease,

replace the joint boot or rear axle assembly (see Final

Drive chapter).

Visually inspect the stabilizer joint boots [B].

•

If the joint boot is torn, worn, deteriorated, or leaks grease,

replace the stabilizer joint (see Suspension chapter).

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

General Lubrication

Lubrication

Before lubricating each part, clean off any rusty spots with

•

rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.

Cables: Lubricate with Cable Lubricant

Brake Cables Throttle Cable Choke Cables Variable Differential Control Cable

Lubricate the cables by seeping the oil between the cable

•

and housing. The c able may be lubricated by using a pressure cable

○

luber with an aerosol cable lubricant.

With the cable disconnected at the both ends, the cable

•

should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.

Points: Lubricate with Grease.

Throttle Inner Cable Ends [A] Choke Cable Lower End Brake Cable Ends Variable Differential Control Cable Ends

Periodic Maintenance Procedures

Slide Points: Lubricate with Grease.

Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft

Bolts and Nuts Tightening

Tightness Inspection

Check the tightness of the bolts and nuts listed here in

•

accordance with the Periodic Maintenance Chart. Also,

check to see that each cotter pin is in place and in good

condition.

If there are loose fasteners, retorque them to the speci-

fied torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not listed in the appropriate

chapter, see the Basic Torque Table (see Torque and

Locking Agent). For each fastener, first loosen it by 1/2

turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Bolts, Nuts, and Fasteners to be checked Wheels:

Front Axle Nuts and Cotter Pins

Rear Axle Nuts and Cotter Pins

Wheel Nuts

Brakes:

Front Brake Master Cylinder Clamp Bolts

Brake Lever Pivot Bolt

Brake Lever Pivot Nut

Front Brake Caliper Mounting Bolts

Brake Pedal Cotter Pin

Steering/Suspension:

Handlebar Clamp Bolts

Stem Clamp Bolts

Stem Bearing Housing Bolts

Tie-rod End Nuts and Cotter Pins

Tie-rod Adjusting Sleeve Locknuts

Shock Absorber Mounting Bolts and Nuts

Suspension Arm Pivot Bolts

Steering Knuckle Pivot Nuts and Cotter Pins

Engine:

Engine Mounting Bolts

Engine Mounting Bracket Bolts

Exhaust Pipe Holder Nuts

Muffler Mounting Bolts

Muffler Clamp Bolt

Front Final Drive:

Gear Case Bracket Bolts

Others:

Footboard Mounting Bolts

Throttle Mounting Bolts

Carrier Mounting Bolts

PERIODIC MAINTENANCE 2-41

Fuel System

Table of Contents

Exploded View................................... 3-2

Specifications .................................... 3-6

Special Tools ..................................... 3-7

Throttle Lever and Cable ................... 3-8

Throttle Lever Free Play

Inspection .................................. 3-8

Throttle Lever Free Play

Adjustment ................................ 3-8

Throttle Case

Removal/Disassembly............... 3-8

Throttle Case

Assembly/Installation ................ 3-8

Throttle Cable Installation ............ 3-9

Throttle Case Inspection .............. 3-9

Throttle Cable Lubrication and

Inspection .................................. 3-9

Choke Lever and Cable..................... 3-10

Choke Lever Free Play

Inspection .................................. 3-10

Choke Lever Free Play

Adjustment ................................ 3-10

Choke Lever and Cable Removal 3-10 Choke Lever and Cable

Installation ................................. 3-11

Choke Cable Lubrication and

Inspection .................................. 3-11

Carburetor ......................................... 3-12

Idle Speed Inspection .................. 3-12

Idle Speed Adjustment................. 3-12

Pilot Screw Adjustment ................ 3-12

Service Fuel Level Inspection ...... 3-12

Service Fuel Level Adjustment .... 3-14

Carburetor Synchronization

Inspection .................................. 3-14

FUEL SYSTEM 3-1

Carburetor Synchronization

Adjustment ................................ 3-15

Fuel System Cleanliness

Inspection.................................. 3-15

Carburetor Removal..................... 3-15

Carburetor Installation.................. 3-17

Carburetor Disassembly .............. 3-17

Carburetor Assembly ................... 3-19

Carburetor Separation ................. 3-20

Carburetor Joining ....................... 3-20

Carburetor Cleaning..................... 3-21

Carburetor Inspection .................. 3-22

Air Cleaner......................................... 3-24

Air Cleaner Elem ent Removal...... 3-24

Air Cleaner Element Installation... 3-24 Air Cleaner Element Cleaning and

Inspection.................................. 3-24

Air C leaner Housing Removal...... 3-24

Air C leaner Housing Installation... 3-26

Fuel Tank........................................... 3-28

Fuel Tank Removal ...................... 3-28

Fuel Tank Installation ................... 3-29

Fuel Tank Cleaning ...................... 3-30

Fuel Tap Removal ........................ 3-30

Fuel Tap Installation ..................... 3-30

Fuel Tap Inspection ...................... 3-31

Fuel Tap Cleaning ........................ 3-32

Fuel Pump ......................................... 3-33

Fuel Pump Removal .................... 3-33

Fuel Pump Installation ................. 3-34

Fuel Pump Inspection .................. 3-34

3-2 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-3

No. Fastener

Torque

N·m kgf·m ft·lb

1 Idle Adjusting Screw Bracket Bolt 8.8 0.90 78 in·lb

2. Choke Lever

3. Choke Cable

4. Throttle Cable

5. Throttle Lever

6. Jet Needle

7. Pilot Jet

8. Main Jet

9. Needle Jet

10. Pilot Screw

11. Pr i m ing P ump

12. Air Tem perature Sensor G: Apply grease. O: Apply engine oil.

CA: Canada Model

Remarks

3-4 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-5

No. Fastener

Torque

N·m kgf·m ft·lb

1 Element Cover Screw 3.5 0.35 31 in·lb

2 Element Holder Screws 3.5 0.35 31 in·lb

3 Clamp Bracket Bolt 9.8 1.0 87 in·lb

4 Fuel Pump Mounting Nuts 7.8 0.80 69 in·lb

5 Fuel Tap Plate Screws 0.8 0.08 7in·lb

6 Fuel Tap Mounting Bolts 4.9 0.50 43 in·lb

7 Fuel Tap Cover Screws 9.8 1.0 87 in·lb

8 Fuel Tap Bracket Bolts 7.8 0.80 69 in·lb

9 Fuel Level Sensor Mounting Bolts 2.0 0.20 18 in·lb

10. Fuel Pump

11. I nsert the fuel breather tube end into the hole of the right frame.

AD: Apply adhesive agent.

G: Apply grease.

R: Replacement Part

W: Apply water or soap and water solution.

Remarks

3-6 FUEL SYSTEM

Specifications

Item Standard Service Limit

Throttle Case and Cable

Throttle Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Choke Lever and Cable

Choke Lever Free Play about 3 mm (0.12 in.) –––

Carburetor

Make/Type KEIHIN, CVKR-34 –––

Main Jet:

Front #152 –––

Rear #158 –––

Main Air Jet #70 –––

Needle Jet #6 –––

Jet Needle:

Front NFKK –––

Rear NFKL –––

Pilot Jet #38 –––

Pilot Air Jet #100 –––

Pilot Screw 2 1/4 turns out –––

Carburetor Synchronization vacuum less than 2.7 kPa (2 cmHg) difference

between carburetors

Starter Jet #82 –––

Idle Speed 1 150 ±50 r/min (rpm) –––

Service Fuel Level:

Front 20.4 ±1 mm (0.80 ±0.04 in.) below

the punch mark

Rear

Float Height 2.9±1mm(0.11±0.04in.) –––

Optional Parts:

Main Jet:

*Altitude

0 ∼ 1 200 m (0 ∼ 3 900 ft):

Front #152 (92063-1331) –––

Rear #158 (92063-1344) –––

1 200 ∼ 2 500 m (3 900 ∼ 8 200 ft):

Front #145 (92063-1017) –––

Rear #152 (92063-1331) –––

2 500 ∼ 3 500 m (8 200 ∼ 11 500 ft):

Front #142 (92063-1016) –––

Rear #148 (92063-1324) –––

3 500 ∼ 4 500 m (11 500 ∼ 14 800 ft):

Front #135 (92063-1014) –––

Rear #140 (92063-1013) –––

Air Cleaner

Air Cleaner Element Oil High-quality foam air filter oil –––

19.5 ±1 mm (0.77 ±0.04 in.) below the punch mark

–––

*: Refer to pg. 6-27 for high altitude setting in the converter system.

Special Tools

FUEL SYSTEM 3-7

Fuel Level Gauge: 57001-1017

Pilot Screw Adjuster, A: 57001-1239

Carburetor Drain Plug Wrench, Hex 3 : 57001-1269

Vacuum Gauge: 57001-1369

3-8 FUEL SYSTEM

Throttle Lever and Cable

Throttle Lever Free Play Inspection

Refer to the Throttle Lever Free Play Inspection in the

•

Periodic Maintenance chapter.

Throttle Lever Free Play Adjustment

Refer to the Throttle Lever Free Play Adjustment in the

•

Periodic Maintenance chapter.

Throttle Case Removal/Disassembly

Remove the throttle case screws [A] and pull the case

•

open. Slide the cable adjuster dust cover out of place.

•

Remove the rubber cover [A].

•

Pull the cable tip [A] out of the throttle lever catch with the

•

throttle lever opened. Loosen the locknut [B] and unscrew the adjuster [C].

•

Disassemble the throttle case as follows:

•

Remove the throttle lever screw [D], lockwasher, and flat

○

washer, and lift the throttle lever [E] and return spring from the case. Pull the throttle control lever [F] out of the case.

○

Throttle Case Assembly/Installation

Lubricate the throttle case and cable before assembly/in-

•

stallation. Be certain that the return spring is correctly installed on

•

the throttle lever [A].

Throttle Lever and Cable

Swing the throttle control lever so that the carburetor throt-

•

tle valve is fully open. Turn the throttle limiter screw [A] until it is spaced about 1 mm (0.04 in.) [B] away from the throttle lever stop [C]. Tighten the locknut [D].

NOTE

Refer to the Owner’s Manual for the function of the throt-

○

tle limiter and adjustment procedure of it.

WARNING

Operation with an improperly assembled throttle case could result in an unsafe riding condition.

Check the throttle lever free play (see Throttle Lever Free

•

Play Inspection in Periodic Maintenance chapter).

Throttle Cable Installation

Lubricate the throttle cable before installation.

•

Route the cable correctly according to the Appendix chap-

•

ter.

WARNING

FUEL SYSTEM 3-9

Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition.

Check the throttle cable (see Throttle Lever Free Play In-

•

spection in Periodic Maintenance chapter).

Throttle Case Inspection

With the throttle cable disconnected from the throttle

•

lever, the lever should move freely and return smoothly by spring. If the lever is heavy, disassemble the throttle case, clean and lubricate the throttle case. Examine the lever and case for cracks. Replace the case

•

assembly if it is cracked.

Throttle Cable Lubrication and Inspection

Whenever the throttle cable is removed or in accordance

•

with the Periodic Maintenance Chart in the Periodic Maintenance chapter, lubricate the cable . Refer to the General Lubrication in the Periodic Mainte-

•

nance chapter for the cable lubrication and inspection.

3-10 FUEL SYSTEM

Choke Lever and Cable

Choke Lever Free Play Inspection

Refer to the Choke Lever Free Play Inspection in the Pe-

•

riodic Maintenance chapter.

Choke Lever Free Play Adjustment

Refer to the Choke Lever Free Play Adjustment in the

•

Periodic Maintenance chapter.

Choke Lever and Cable Removal

Remove the air cleaner housing (see Air Cleaner Housing

•

Removal). Remove the carburetor from the carburetor holder (see

•

Carburetor Removal). Remove the screws [A] and holder plates [B] from both

•

carburetors. Pull out the starter plungers.

•

Hold the starter plunger springs compressed, and free the

•

choke cable lower ends [A] from the plungers [B].

Remove:

•

Choke Lever Mounting Screw [A], Plane Washer, and Wave Washer Switch Case Mounting Screws [B]

Free the choke cable upper end [A] from the choke lever

•

[B].

Choke Lever and Cable

Pull off the retaining clip [A].

•

Fit the cable end [A] in the grommet [B], and free the cable

•

from the switch case. Pull the cable out of the vehicle.

•

FUEL SYSTEM 3-11

Choke Lever and Cable Installa tion

Lubricate the choke cable before installation.

•

Install the wave washer, plane washer and screw in that

•

order. Route the choke cable according to the Appendix chapter.

•

WARNING

Operation with an incorrectly routed, or damaged cable could result in an unsafe riding condition.

Choke Cable Lubrication and Inspection

Whenever the choke cable is removed or in accordance

•

with the Periodic Maintenance chart i n the Periodic Maintenance chapter, lubricate the cable. Refer to the General Lubrication in the Periodic Mainte-

•

nance chapter for the cable lubrication and inspection

3-12 FUEL SYSTEM

Carburetor

Idle Speed Inspection

Refer to the Idle Speed Inspection in the Periodic Main-

•

tenance chapter.

Idle Speed Adjustment

Refer to the Idle Speed Adjustment in the Periodic Main-

•

tenance chapter.

Pilot Screw Adjustment

Adjust the pilot screw if necessary.

•

Remove the air cleaner cover (see Frame chapter).

•

Turn the carburetor pilot screw [A] all the way in until it

•

seats lightly.

Special Tool - Pilot Screw Adjuster, A: 57001-1239 [B]

CAUTION

Do not overtighten the pilot screw or the carburetor body will be damaged and require replacement.

Back the pilot screw out the specified number of turns.

•

Carburetor Pilot Screw Setting

Standard: 2 1/4 turns out

Service Fuel Level Inspection

WARNING

Park the vehicle on a level surface.

•

Remove:

•

Side Covers (see Frame chapter) Throttle Link Case Cover Carburetor Drain Hose

Carburetor

Connect two suitable hoses [A] to the fuel level gauge [B]

•

and the float chamber of the carburetors.

Special Tool - Fuel Level Gauge: 57001-1017

Mark the additional graduation [C] 15 mm (0.59 in.) higher

•

than the top graduation [D]. Hold the gauge so that the additional graduation is placed

•

slightly higher than the punch mark [E].

[F] Front Carburetor [G] Rear Carburetor

Run the engine at idle speed.

•

Loosen the carburetor drain screw.

•

Special Tool - Carburetor Drain Plug Wrench, Hex 3:

57001-1269

Wait until the fuel level in the gauge settles.

•

Hold the gauge vertically and lower it slowly so that the

•

additional graduation aligns with punch mark.

NOTE

Do not align the additional graduation on the gauge

○

lower than the punch mark. If it is lowered and then raised, the gauge will show a fluid level that is higher than the actual level, which will require a remeasurement.

FUEL SYSTEM 3-13

Read the fuel level [ H].

•

If the fuel level is incorrect, adjust it.

Fuel Level

Standard:

Front 20.4 ±1 mm (0.80 ±0.04 in.) below the

punch mark

Rear 19.5 ±1 mm (0.77 ±0.04 in.) below the

punch mark

Stop the engine.

•

Tighten the drain screw.

•

Repeat the same procedure for the other carburetor.

•

3-14 FUEL SYSTEM

Carburetor

Service Fuel Level Adjustment

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. 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.

Remove the carburetors, and drain the fuel.

•

Remove the float chamber.

•

Remove the screw [A].

•

Slide out the pivot pin [B] and remove the float [C].

•

Bend the tang [A] on the float arm very slightly to change

•

the float height.

Float Height

Standard: 2.9 ±1 mm (0.11 ±0.04 in.)

Measure the float height [A] from the mating surface [B]

○

of float by tilting the carburetor so that the tang of the float [C] just touches the needle rod [D]. At this time, the float valve [E] rod must not be depressed. Increasing the float height lowers the fuel level and de-

○

creasing the float height raises the fuel level. Assemble the carburetor and recheck the fuel level.

•

If the fuel level cannot be adjusted by this method, the float or the float valve is damaged.

Carburetor Synchronization Inspection

Remove:

•

Side Covers (see Frame chapter) Throttle Link Case Cover

Check idle speed.

•

Remove the front vacuum hose [A ] and install the vacuum

•

hose for vacuum gauge.

Carburetor

Remove the rear vacuum hose [A] and install the vacuum

•

hose for vacuum gauge.

Connect:

•

Vacuum Gauge [A]

Special Tool - Vacuum Gauge: 57001-1369

Connect the fuel hose of a suitable fuel tank [B] to the

•

carburetor. Start the engine and read the intake vacuum of each car-

•

buretor when idling. If the vacuum is out of the specified range, adjust it.

FUEL SYSTEM 3-15

Carburetor Synchronization Vacuum

Standard: Less than 2.7 kPa (2 cmHg) difference

between c arburetors

Carburetor Synchronization Adjustment

Turn the adjust screw [A] to synchronize the carburetors.

•

If the carburetor synchronization cannot be obtained by using the adjusting screw, check for dirt or blockage, and then check the pilot screw settings.

Special Tool - Pilot Screw Adjuster, A: 57001-1239

Check the carburetor synchronization again.

•

NOTE

Do not turn the pilot screws carelessly during carburetor

○

synchronization. You may cause poor running at low engine speed.

Check idle speed.

•

Fuel System Cleanliness Inspection

Refer to the Fuel System Cleanliness Inspection in the

•

Periodic Maintenance chapter.

Carburetor Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. 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.

3-16 FUEL SYSTEM

Carburetor

Remove:

•

Air Cleaner Housing (see Air Cleaner Housing Removal)

Drain the fuel from the carburetors.

•

Remove:

•

Fuel Hose [A ] Heater and Ground Lead Connectors [B]

Remove:

•

Screws [A] and Throttle Link Case Cover [B]

Remove:

•

Locknut [A] Throttle Cable Lower End [B]

Loosen the carburetor clamp screws [C].

•

Remove the carburetor out of the frame.

•

Remove:

•

Screw [A] Holder Plate [B]

Remove:

•

Starter Plunger [A]

Carburetor

Remove:

•

Screw [A] Holder Plate [B] Starter Plunger

Carburetor Insta llation

Confirm the groove of the carburetor holder [A] fits on the

•

projection [B] of the cylinder head. Check fuel leakage from the carburetors.

•

WARNING

Fuel spilled from the carburetors is hazardous.

Adjust the idle speed (see Idle Speed Adjustment in Pe-

•

riodic Maintenance chapter). Check the throttle cable (see Throttle Lever Free Play In-

•

spection in Periodic Maintenance chapter).

FUEL SYSTEM 3-17

Carburetor Disassembly

Remove the carburetors (see Carburetor Removal).

•

WARNING

NOTE

The carburetors c an be disassembled in the joined

○

state.

3-18 FUEL SYSTEM

Carburetor

Remove the upper chamber cover [A], spring [B], and vac-

•

uum piston [C].

CAUTION

During carburetor disassembly, be careful not to damage the diaphragm. Never use a sharp edge to remove the diaphragm.

Remove the jet needle [D] from the vacuum piston. These

•

can be detached together with the spring seat [E]. Do not remove the pilot screw if possible, synchronization

○

of the carburetors is necessary if pilot screws are removed (see Pilot Screw Adjustment).

Remove:

•

Screws [A] Float Chamber [B]

Remove:

•

Screw [A] Float Pivot Pin [B], Float [C], and Float Needle Valve Pilot Jet [D] Main Jet [E] Starter Jet [F]

Remove:

•

Screws [A] Coasting Enricher Cover [B]

Carburetor

Remove:

•

Diaphragm [A] O-ring [B]

Carburetor Assembly

WARNING

Fuel spilled from the carburetors is hazardous.

CAUTION

Do not apply force to the jet or overtighten it, or this could damage the jet or the carburetor body, requiring replacement.

FUEL SYSTEM 3-19

Install the float valve needle in the valve seat and hook

•

the needle hanger [A] onto the float tang. Insert the float pivot pin [B] into the pivot post and the float.

•

Tighten the screw [C].

•

Set the float to the standard height (see Service Fuel

•

Level Adjustment).

Insert the jet needle [A] into the hole i n the center of the

•

vacuum piston [B], and place the spring seat [C] over the needle.

Slip the needle through the hole in the center of the vac-

•

uum piston, and put the spring seat [A] on t he top of the needle. Turn the seat so that it does not block the hole [B] at the bottom of the vacuum piston. After installing the upper chamber cover, check that the

•

vacuum piston slides up and down smoothly without binding in the carburetor bore.

3-20 FUEL SYSTEM

Carburetor

Fit the projection [A] of the vacuum piston diaphragm in

•

the recess [B] of the body. After installing the upper chamber cover, check to make

•

sure that the vacuum piston moves smoothly in the carburetor body.

Carburetor Separation

Remove:

•

Carburetor (see Carburetor Removal) Screws [A] Fuel Hose Fittings [B]

Remove:

•

Cotter Pins [A], Collars and Washers Link Arm [ B]

Remove:

•

Link Case Screws [A] Link Case [B]

Separate the Carburetors.

•

Carburetor Joining

Install link case and tighten link case screws.

•

Apply grease to the link pins [A].

•

Install the link arm as shown.

•

Washers [B] Collars [C] Link Arm [ D] Cotter Pins [E]

Bend the ends of the cotter pins.

•

Install the fuel hose fittings, and tighten the screws.

•

Carburetor

Visually synchronize the throttle (butterfly) valves.

•

Check to see that all throttle valves open and close

○

smoothly without binding when turning the pulley. Visually check the clearance [A] between the throttle

○

valve and the carburetor bore in each carburetor.

If there is a difference between two carburetors, turn the balance adjusting screw [A] to obtain the same clearance. Install the carburetors (see Carburetor Installation).

•

Adjust the synchronization (see Synchronization Adjust-

•

ment).

FUEL SYSTEM 3-21

Carburetor Cleaning

WARNING

Clean the carburetor in a well-ventilated area and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the carburetor.

CAUTION

Do not use compressed air on an assembled carburetor, the f loat m ay be crushed by the pressure, and the vacuum piston diaphragm may be dam aged. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high-flash point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.

3-22 FUEL SYSTEM

Carburetor

Disassemble the carburetor and clean all the metal parts

•

in a carburetor cleaning solution. Rinse the parts in water and dry them with compressed

•

air. Blow through the air and fuel passages with compressed

•

air. Remove the float valve, spray cleaning solution from the

•

valve seating surface into the fuel passage, and clean the strainer (press-fitted) with compressed air [A]. Assemble the carburetor (see Carburetor Assembly).

•

Carburetor Inspection

WARNING

Remove the carburetor (see Carburetor Removal).

•

Before disassembling the carburetors, check the fuel level

•

(see Fuel Level Inspection).

Turn the throttle cable pulley [A] to check that the throttle

•

butterfly valves [B] move smoothly and return back with the spring tension. If the t hrottle valves do not move smoothly, replace the carburetor.

Carburetor

Disassemble the carburetors (see Carburetor Disassem-

•

bly). Clean the carburetor (see Carburetor Cleaning).

•

Check the vacuum piston diaphragm [A], and the O-rings

•

[B] on the float bowl, pilot screw, coasting enricher, and starter plunger cap. If any of the diaphragm or O-rings are not in good condition, replace them.

FUEL SYSTEM 3-23

Check the plastic tip [A] of the float valve needle. It should

•

be smooth, without any grooves, scratches, or tears. If the plastic tip is damaged [C], replace the float valve [B]. Push the rod [D] in the other end of the float valve needle

•

and then release it [E]. If it does not spring out, replace the float valve.

Check the tapered portion [A] of the pilot screw [B] for

•

wear or damage. If the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace it.

Check that the vacuum piston moves smoothly in t he car-

•

buretor body. The surface of the piston must not be excessively worn. If the vacuum piston does not move smoothly, or if it is very loose in the carburetor body, replace both the body and the vacuum piston.

3-24 FUEL SYSTEM

Air Cleaner

Air Cleaner Element Removal

Remove:

•

Seat (see Frame chapter) Clips [A] Air Cleaner Housing Cap [B]

Remove:

•

Element Cover Screw [A] Element Cover [B] Element [C]

After removing the element, stuff pieces of lint-free, clean

•

cloth i nto the air cleaner ducts to keep dirt out of the carburetor and engine.

WARNING

If dirt or dust is allowed to pass through into the carburetors, the throttle may become stuck, possibly causing an accident.

CAUTION

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Air Cleaner Element Installation

Install:

•

Element Element Cover

Tighten:

•

Torque - Element Cover Screw: 3.5 N·m (0.35 kgf·m, 31

in·lb)

Air Cleaner Element Cleaning and Inspection

Refer to the Air Cleaner Element Cleaning and Inspection

•

in the Periodic Maintenance chapter.

Air Cleaner Housing Removal

Remove:

•

Side Covers (see Frame chapter) Air Cleaner Housing Cap Air Cleaner Element (see Air Cleaner Element Removal)

Air Cleaner

Remove:

•

Screws [A] Element Holder [B] Spark Arrester [C]

Remove:

•

Screw [A] Air Intake Duct [B] Air Cleaner Housing Bolt [C]

FUEL SYSTEM 3-25

Remove:

•

Air Cleaner Housing Bolt [A]

Loosen the clamp screws [A].

•

Remove:

•

Breather Hose [A]

3-26 FUEL SYSTEM

Air Cleaner

Remove:

•

Screw [A] Carburetor Breather Tank [B] Air Cleaner Housing [C]

Air Cleaner Housing Installation

Fit the projection [A] of the housing in the groove [B] of

•

the joint duct [C] (front and rear), and tighten the clamp screws.

Install:

•

Dust Seal [A] Air Cleaner Housing Cover [B] [C] Inside

Install the air cleaner housing and joint duct on the carbu-

•

retor. Install:

•

Breather Hose and Clamp Carburetor Breather Tank

Fit the joint duct on the fitting of the carburetor securely

•

and tighten the clamp screws. Tighten the air cleaner housing bolts.

•

Install the spark arrester [A] so that the swelling faces

•

upward.

Air Cleaner

Apply the soap and water solution over the trim seal [A].

•

Install:

•

Element Holder

Tighten:

•

Torque - Element Holder Screws: 3.5 N·m (0.35 kgf·m, 31

in·lb)

Install:

•

Element (see A ir Cleaner Element Installation)

FUEL SYSTEM 3-27

3-28 FUEL SYSTEM

Fuel Tank

Fuel Tank Removal

Remove:

•

Electrical Parts Case (see Frame chapter) Rear Fender (see Frame chapter) Storage Case [A] (Optional Part) Check Valve Hose [B]

Remove:

•

Two Right Footboard Bolts [A]

Insert a thin driver [A] in the clamp [B] to clear its stopper,

•

and slide the clamp forward.

Move the main harness [A] inside as shown.

•

Remove:

•

Fuel Level Sensor Lead Connector [B] Vacuum Hose [C] Fuel Hose [D ] Bolts [E] Damper Bracket Bolt [F] Damper Bracket [G]

Remove:

•

Fuel Tank [A] with Tank Case [B]

Fuel Tank

Fuel Tank Installation

Check the insulators [A] on the tank case.

•

If the insulators are damaged or deteriorated, replace them.

Check the rubber dampers [A] on the frame as shown.

•

If the dampers are damaged or deteriorated, replace them.

FUEL SYSTEM 3-29

Install the fuel tank with case, and tighten the bolts.

•

Check the damper [A] on the damper bracket [B].

•

If the damper is damaged or deteriorated, replace it. Tighten the damper bracket bolt.

•

Install the check valve so that the arrow [A] faces fuel tank.

•

[B] Black Color [C] Blue Color

Install:

•

Hose [A] Clamps [B]

3-30 FUEL SYSTEM

Fuel Tank

Install:

•

Vacuum Hose [A] and Clamp [B] Fuel Level Sensor Lead Connector

Install the removed parts.

•

Fuel Tank Cleaning

Remove the fuel tank and drain it (see Fuel Tank Re-

•

moval). Pour some high-flash point solvent into the fuel tank and

•

shake the tank to remove dirt and fuel deposits.

WARNING

Clean the tank in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. B ecause of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank. A fire or explosion could result.

Pour the solvent out the tank.

•

Dry the tank with compressed air.

•

Install the fuel tank (see Fuel Tank Installation).

•

Fuel Tap Removal

Remove:

•

Fuel Pump (see Fuel Pump Removal) Fuel Tap Mounting Bolts [A] Vacuum Hose [B] Fuel Tap [C]

Fuel Tap Installation

Be sure the O-ring [A] is in good condition to prevent leak-

•

age.

Fuel Tank

Connect the fuel hoses to the fuel tap as follows.

•

Vacuum Hose [A] Fuel Pump Hose [B]

Be sure to clamps [C] the fuel hoses to prevent leakage.

•

Fuel Tap Inspection

Check the fuel tap filter screen [A] for any breaks or dete-

•

rioration. If the filter screen has any break or is deteriorated, it may allow dirt to reach the carburetor, causing poor running. Replace the fuel tap.

FUEL SYSTEM 3-31

If the fuel tap leaks, replace the damaged gasket [A] or O-rings [B].

Apply grease to the lever [A].

•

Tighten:

•

Torque - Fuel Tap Plate Screws [A]: 0.8 N·m (0.08 kgf·m, 7

in·lb)

3-32 FUEL SYSTEM

Fuel Tank

Fuel Tap Cleaning

Remove:

•

Fuel Tap (see Fuel Tap Removal)

Clean the fuel tap filter screen in a high-flash point sol-

•

vent.

WARNING

Clean the tap in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tap. A fire or explosion could result.

Pour high-flash point solvent through the tap in PRI posi-

•

tion. Dry the fuel tap with compressed air.

•

Install t he fuel tap (see Fuel Tap Installation).

•

Fuel Pump

Fuel Pump Removal

CAUTION

Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it.

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (-) terminal. To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

Fuel Pump Removal

Remove:

•

Electrical Parts Case (see Frame chapter) Bolts [A] Fuel Hose [B]

FUEL SYSTEM 3-33

Remove:

•

Vacuum Hose [A] Fuel Hose [B]

Remove:

•

Nuts [A] and Washers Fuel Pump [B ]

3-34 FUEL SYSTEM

Fuel Pump

Fuel Pump Installation

Install:

•

Bracket [A] Fuel Pump [B] Washers [ C] and Nuts [D]

Install:

•

Vacuum Hose [A] Fuel Hose (Carburetor Side) [B] Clamps [C]

Install:

•

Fuel Hose (Fuel Tap Side) [A] Clamp [B] Bolts [C] Removed Parts

Fuel Pump Inspection

Remove the fuel pump (see Fuel Pump Removal).

•

If the hose connection areas [A] of the fittings are damaged, replace the fuel pump.

Blow the air to the outlet fitting [A], and make sure does

•

not flow the blown air from the inlet fitting [B]. If the fuel pump does not operate as described, replace it with a new one.

Fuel Pump

Inhale the air to the inlet fitting [A], and make sure does

•

not inhale the blown air from the outlet fitting [B]. If the fuel pump does not operate as described, replace it with a new one.

FUEL SYSTEM 3-35

Kawasaki KVF 750 4x4, Brute Force 750 4x4i User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

LIST OF ABBREVIATIONS

EMISSION CONTROL INFORMATION

Foreword

General Information

Battery Ground

Edges of Parts

Solvent

Cleaning vehicle before disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Locking Agent

Press

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

Lubrication

Direction of Engine Rotation

Electrical Wires

KVF750-A1 Left Side View

KVF750-A1 Right Side View

Prefixes for Units:

Units of Mass:

Units of Volume:

Units of Length:

Units of Torque:

Units of Pressure:

Units of Speed:

Units of Force:

Units of Temperature

Units of Power:

Periodic Maintenance

Basic Torque for General Fasteners of Engine Parts

Basic Torque for General Fasteners of Frame Parts

Fuel System

Throttle Lever Free Play Inspection

Throttle Lever Free Play

Throttle Lever Free Play Adjustment

Choke Lever Free Play Inspection

ChokeLeverFreePlay[B]

Choke Lever Free Play Adjustment

Idle Speed Inspection

Idle Speed

Idle Speed Adjustment

Fuel System Cleanliness Inspection

Air Cleaner Element Cleaning and Inspection

Air Cleaner Draining

Fuel Hose and Connection Inspection

Fuel Hose Replacement

Cooling System

Radiator Cleaning

Radiator Hose and Connection Inspection

Coolant Change

Water and Coolant Mixture Ratio (when shipping)

Engine Top E nd

Valve Clear ance Inspection

Valve Clearance (when cold)

Valve Clearance (when cold)

Valve Clearance Adjustment

Spark Arrester Cleaning

Converter System

Drive Belt Inspection

Belt Width

Drive Bel t Deflection Inspection

Belt Deflection

Drive Belt Deflection Adjustment

Spacers

Actuator Lever (Engine Brake Control Lever) Assembly Inspection

Actuator Lever Guide Shoe

Engine Lubrication System