BRUTE FORCE 750 4×4i
KVF 750 4×4
All Terrain Vehicle
Service Manual
Quick Reference Guide
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.
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 |
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 rights 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.
© 2004 Kawasaki Heavy Industries, Ltd. |
Second Edition (1) : Jul. 6, 2004 |
|
|
|
|
A |
ampere(s) |
lb |
pounds(s) |
ABDC |
after bottom dead center |
m |
meter(s) |
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) |
|
|
Read OWNER’S MANUAL before operating.
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 maintain 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 fleet of motor 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 as follows:
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are exceeded.
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 standards.
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, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.
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.
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 Maintenance Chart in the
•Service Manual.
Be alert for problems and non-scheduled
•maintenance.
Use proper tools and genuine Kawasaki Vehicle 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 maintenance 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 personal injury, or loss of life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.
This manual 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 particular interest for more efficient and convenient operation.
•Indicatesdone. a procedural step or work to be ○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 inspection in the procedural step or sub-step it follows.
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 |
1 |
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:
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.
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.
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.
GENERAL INFORMATION 1-3
Before Servicing
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.
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.
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 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.
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
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.
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 followed twice initial tightening and final tightening with torque wrench.
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.
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.
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.
GENERAL INFORMATION 1-5
Before Servicing
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.
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.
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.
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
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.
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).
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.
GENERAL INFORMATION 1-7
Model Identification
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 Advance |
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) |
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GENERAL INFORMATION 1-9 |
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General Specifications |
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Items |
|
KVF750-A1, B1 |
|
Engine oil: |
|
|
|
Type |
API SF or SG |
|
|
|
API SH or SJ with JASO MA class |
|
|
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 |
3.098 (30/26 × 29/18 × 20/12) |
|
|
Low |
4.833 (36/20 × 29/18 × 20/12) |
|
|
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 |
|
|
|
API SH or SJ with JASO MA class |
|
|
Viscosity |
SAE10W-40 |
|
|
Capacity |
0.40 L (0.42 US qt) |
|
|
Rear Final Gear Case Oil: |
|
|
|
Type |
MOBIL FLUID 424, CITGO TRANSGARD TRACTOR |
|
|
HYDRAULIC FLUID, or EXXON HYDRAUL 560 |
||
|
|
||
|
Capacity |
0.72 L (0.76 US qt) |
|
|
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.) |
|
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1-10 GENERAL INFORMATION
General Specifications
|
|
Items |
KVF750-A1, B1 |
Front tire: |
|
Type |
Tubeless |
Size |
AT25 × 8 – 12 |
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 |
(EUR) 12V 10W |
Alternator: |
|
Type |
Three - phase AC |
Rated Output |
24.2 A, 14 V @6 000 r/min (rpm) |
Specifications are subject to change without notice, and may not apply to every country. US: United States Model
EUR: Europe Model
GENERAL INFORMATION 1-11
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Unit Conversion Table |
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Prefixes for Units: |
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Units of Length: |
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km |
× |
0.6214 |
= |
mile |
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Prefix |
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Symbol |
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Power |
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m |
× |
3.281 |
= |
ft |
|
mega |
|
M |
|
× 1 000 000 |
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mm |
× |
0.03937 |
= |
in |
|
|
kilo |
|
k |
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× |
1 000 |
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centi |
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c |
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× |
0.01 |
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Units of Torque: |
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milli |
|
m |
|
× |
0.001 |
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micro |
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µ |
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× 0.000001 |
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N·m |
× |
0.1020 |
= |
kgf·m |
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N·m |
× |
0.7376 |
= |
ft·lb |
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N·m |
× |
8.851 |
= |
in·lb |
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kgf·m |
× |
9.807 |
= |
N·m |
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Units of Mass: |
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|
kgf·m |
× |
7.233 |
= |
ft·lb |
|||
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kgf·m |
× |
86.80 |
= |
in·lb |
||||
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kg |
× |
2.205 |
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= |
lb |
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g |
× |
0.03527 |
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= |
oz |
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Units of Pressure: |
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||
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Units of Volume: |
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|
kPa |
× |
0.01020 |
= |
kgf/cm² |
|||
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kPa |
× |
0.1450 |
= |
psi |
||||
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L |
× |
0.2642 |
|
= |
gal (US) |
|
|
kPa |
× |
0.7501 |
= |
cmHg |
|
L |
× |
0.2200 |
|
= |
gal (imp) |
|
|
kgf/cm² |
× |
98.07 |
= |
kPa |
|
L |
× |
1.057 |
|
= |
qt (US) |
|
|
kgf/cm² |
× |
14.22 |
= |
psi |
|
L |
× |
0.8799 |
|
= |
qt (imp) |
|
|
cmHg |
× |
1.333 |
= |
kPa |
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L |
× |
2.113 |
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= |
pint (US) |
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L |
× |
1.816 |
|
= |
pint (imp) |
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Units of Speed: |
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||
|
mL |
× |
0.03381 |
|
= |
oz (US) |
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|||
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km/h |
× |
0.6214 |
= |
mph |
|||||
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mL |
× |
0.02816 |
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= |
oz (imp) |
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|||||
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|||||
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mL |
× |
0.06102 |
|
= |
cu in |
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Units of Power: |
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||
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Units of Force: |
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|
|
|
kW |
× |
1.360 |
= |
PS |
|||
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|
kW |
× |
1.341 |
= |
HP |
||||
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N |
× |
0.1020 |
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= |
kg |
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|||||
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PS |
× |
0.7355 |
= |
kW |
|||||
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N |
× |
0.2248 |
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= |
lb |
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|||||
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PS |
× |
0.9863 |
= |
HP |
|||||
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kg |
× |
9.807 |
|
= |
N |
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|||||
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kg |
× |
2.205 |
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= |
lb |
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PERIODIC MAINTENANCE 2-1
|
|
|
Table of Contents |
2 |
|
|
|
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 |
Tightness Inspection .................... |
2-41 |
Bolts and Nuts Tightening............... |
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.
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FREQUENCY |
First |
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Regular Service |
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Service |
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Every 90 |
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days, 1 700 |
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Every |
Every |
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km (1 100 |
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After 10 |
10 |
30 |
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mi.) or |
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hrs. or |
days or |
days or |
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when belt |
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Every |
See |
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|
100 km |
200 km |
600 km |
|
indicator |
|
year of |
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(60 mi.) |
(120 |
(360 |
|
light turns |
|
use |
page |
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|||||
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of use |
mi.) of |
mi.) of |
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on (100 |
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use |
use |
hrs of use) |
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whichever |
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OPERATION |
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comes first |
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ENGINE |
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• |
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Converter drive belt wear - inspect * |
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• |
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2-25 |
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Converter drive belt deflection - inspect * |
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2-25 |
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Drive belt failure detection system function |
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• |
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2-37 |
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- inspect * |
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• |
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Engine brake control lever - inspect * |
• |
• |
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2-27 |
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Air cleaner - inspect * |
• |
• |
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2-17 |
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Throttle lever play - inspect |
• |
• |
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2-14 |
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Choke lever play - inspect |
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• |
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2-14 |
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Idle speed - inspect |
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2-15 |
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Valve clearance - inspect |
• |
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• |
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• |
2-23 |
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Fuel system cleanliness - inspect * |
• |
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• |
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2-16 |
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Engine oil - change * |
• |
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• |
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2-27 |
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Oil filter - replace * |
• |
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• |
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2-28 |
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Spark plug - clean and gap |
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2-36 |
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Spark arrester - clean |
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• |
2-24 |
|
Fuel hoses and connections - inspect |
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• |
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|
2-18 |
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Fuel hose - replace |
• |
• |
4 years |
|
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|
2-18 |
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Radiator - clean* |
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2-19 |
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Radiator hoses and connections - check* |
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• |
2-20 |
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Coolant - change* |
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2 years |
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|
2-20 |
|
CHASSIS |
• |
• |
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Joint boots - inspect * |
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2-39 |
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Rear brake pedal and lever play - inspect * |
• |
• |
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|
2-35 |
|
Rear brake plates - replace * |
• |
every 10 000 km (6 000 mi.) |
|
2-35 |
||||
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• |
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Bolts and nuts - tighten |
• |
|
• |
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|
2-41 |
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|
Front brake pad wear - inspect * |
• |
|
• |
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|
2-32 |
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Brake light switch - inspect * |
• |
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• |
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2-37 |
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Steering - inspect |
• |
• |
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2-36 |
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Differential control lever play - inspect |
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|
2-29 |
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2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
|
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FREQUENCY First |
|
Regular Service |
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||||
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Service |
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||||
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Every 90 |
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days, 1 700 |
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Every |
Every |
|
km (1 100 |
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|
After 10 |
10 |
30 |
|
mi.) or |
|
|
|
|
|
hrs. or |
days or |
days or |
|
when belt |
|
Every |
See |
|
|
100 km |
200 km |
600 km |
|
indicator |
|
year of |
|
|
|
(60 mi.) |
(120 |
(360 |
|
light turns |
|
use |
page |
|
|
|
|
|
|||||
|
|
of use |
mi.) of |
mi.) of |
|
on (100 |
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|
use |
use |
hrs of use) |
|
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|
whichever |
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|
OPERATION |
|
|
|
comes first |
|
|
|
||
|
Tire wear - inspect * |
|
|
• |
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|
2-28 |
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Front and rear final gear case oil - change |
• |
|
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• |
2-30 |
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2-31 |
|||
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|||
|
Rear propeller shaft universal joint |
|
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|
• |
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|
2-32 |
|
lubrication |
|
|
|
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||
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||
|
General lubrication * |
|
|
• |
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|
2-40 |
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Front brake fluid level - inspect |
• |
|
• |
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|
2-33 |
|
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||
|
Front brake fluid - change |
|
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|
• |
2-34 |
|
Front brake hoses and connections - |
|
|
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|
• |
|
|
2-32 |
|
inspect |
|
|
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|
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|
||
|
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||
|
Front brake master cylinder piston |
|
|
2 years |
|
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|
2-34 |
|
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assembly and dust seal - replace |
|
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|||
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Front brake caliper piston seal and dust |
|
|
2 years |
|
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|
2-34 |
|
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seal - replace |
|
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|||
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Front brake hose - replace |
|
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4 years |
|
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|
2-33 |
*: 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 Locking Agent
The following tables list the tightening 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: |
|
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|
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. |
|
||||
L: Apply a non-permanent locking agent. |
|
|
|
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|
LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue). |
|
|
|
||
Lh: Left-hand Threads |
|
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|
|
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide |
|||||
grease in a weight ratio 10:1). |
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R: Replacement Parts |
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S: Follow the specific tightening sequence. |
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SS: Apply silicone sealant (Kawasaki Bond: 56019-120). |
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St: Stake the fasteners to prevent loosening. |
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|
TB: Apply a non-permanent locking agent (Three Bond TB1363A, Red). |
|
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||
|
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|
Fastener |
|
Torque |
|
|
Remarks |
N·m |
kgf·m |
ft·lb |
|
||
|
|
|
|||
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 |
7 in·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.) |
8.8 |
0.90 |
78 in·lb |
|
S |
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 Bolts (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 |
|
|
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
|
|
|
|
|
|
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
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 |
8.8 |
0.90 |
78 in·lb |
|
|
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 in·lb |
|
|
Ramp Waight Nuts |
6.9 |
0.70 |
61 in·lb |
|
|
Spider |
275 |
28 |
203 |
Lh |
|
Joint Duct Bolts |
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 |
S |
|
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 |
|
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
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Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
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Engine Mounting Bolt |
62 |
6.3 |
46 |
|
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Engine Mounting Nut |
62 |
6.3 |
46 |
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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 mm (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 |
|
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Reverse Position Switch |
15 |
1.5 |
11 |
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Wheel/Tires |
|
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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 |
|
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(Output Bevel Gears) |
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|
|
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Output Driven Bevel Gear Housing Bolts |
26 |
2.7 |
20 |
|
|
Output Drive Bevel Gear Housing Bolts |
26 |
2.7 |
20 |
|
|
Bearing Holder |
137 |
14 |
101 |
L |
|
Bevel Gear Holder Nut |
157 |
16 |
116 |
L |
|
Bearing Holder |
118 |
12 |
87 |
L |
|
Output Shaft Holder Nut |
157 |
16 |
116 |
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 |
8.8 |
0.90 |
78 in·lb |
|
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
|
|
|
|
|
|
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
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 Oil Drain Plug |
15 |
1.5 |
11 |
|
|
2WD/4WD Actuator Mounting Bolts |
9.8 |
1.0 |
87 in·lb |
L, S |
|
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 Gear 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 |
29 |
3.0 |
22 |
|
|
Rear Final Gear Case Oil Drain Plug |
13 |
1.3 |
113 in·lb |
|
|
Bracket Bolts |
59 |
6.0 |
43 |
|
|
Rear Final Gear Case Nuts |
72 |
7.3 |
53 |
TB |
|
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 Mounting 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 |
|