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

4.3 (3)

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

LIST OF ABBREVIATIONS

 

 

 

 

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)

ohm(s)

L

liter(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 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.

PLEASE DO NOT TAMPER WITH NOISE CONTROL 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 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:

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.

GENERAL INFORMATION 1-3

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.

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 followed 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.

GENERAL INFORMATION 1-5

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.

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.

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

GENERAL INFORMATION 1-7

Model Identification

KVF750-A1 Left Side View

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 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)

 

 

 

 

 

GENERAL INFORMATION 1-9

 

 

 

 

 

General Specifications

 

 

 

 

 

 

 

 

 

 

 

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

 

 

King Pin Angle

11°

 

 

Trail

28 mm (1.10 in.)

 

Tread:

 

 

 

Front

915 mm (36.23 in.)

 

Rear

875 mm (34.45 in.)

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

Unit Conversion Table

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Prefixes for Units:

 

 

 

 

Units of Length:

 

 

 

 

 

 

 

 

 

 

 

km

×

0.6214

=

mile

 

Prefix

 

Symbol

 

 

Power

 

 

m

×

3.281

=

ft

 

mega

 

M

 

× 1 000 000

 

 

mm

×

0.03937

=

in

 

kilo

 

k

 

×

1 000

 

 

 

 

 

 

 

 

centi

 

c

 

×

0.01

 

 

Units of Torque:

 

 

 

milli

 

m

 

×

0.001

 

 

 

 

 

micro

 

µ

 

× 0.000001

 

 

N·m

×

0.1020

=

kgf·m

 

 

 

 

 

 

 

 

 

N·m

×

0.7376

=

ft·lb

 

 

 

 

 

 

 

 

 

N·m

×

8.851

=

in·lb

 

 

 

 

 

 

 

 

 

kgf·m

×

9.807

=

N·m

 

Units of Mass:

 

 

 

 

kgf·m

×

7.233

=

ft·lb

 

 

 

 

 

kgf·m

×

86.80

=

in·lb

 

kg

×

2.205

 

=

lb

 

 

 

 

 

 

 

 

 

 

 

 

g

×

0.03527

 

=

oz

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Units of Pressure:

 

 

 

Units of Volume:

 

 

 

 

kPa

×

0.01020

=

kgf/cm²

 

 

 

 

 

kPa

×

0.1450

=

psi

 

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

 

 

 

 

 

 

 

 

 

 

L

×

2.113

 

=

pint (US)

 

 

 

 

 

 

 

 

L

×

1.816

 

=

pint (imp)

 

 

Units of Speed:

 

 

 

mL

×

0.03381

 

=

oz (US)

 

 

 

 

 

 

 

 

km/h

×

0.6214

=

mph

 

mL

×

0.02816

 

=

oz (imp)

 

 

 

 

 

 

 

 

 

 

 

 

mL

×

0.06102

 

=

cu in

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Units of Power:

 

 

 

Units of Force:

 

 

 

 

kW

×

1.360

=

PS

 

 

 

 

 

kW

×

1.341

=

HP

 

N

×

0.1020

 

=

kg

 

 

 

 

 

 

PS

×

0.7355

=

kW

 

N

×

0.2248

 

=

lb

 

 

 

 

 

 

PS

×

0.9863

=

HP

 

kg

×

9.807

 

=

N

 

 

 

 

 

 

 

 

 

 

 

 

kg

×

2.205

 

=

lb

 

 

 

 

 

 

 

Units of Temperature

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

 

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

FREQUENCY

First

 

Regular Service

 

 

 

 

Service

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Every 90

 

 

 

 

 

 

 

 

days, 1 700

 

 

 

 

 

 

Every

Every

 

km (1 100

 

 

 

 

 

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

 

 

 

 

 

 

use

use

hrs of use)

 

 

 

 

 

 

 

 

 

whichever

 

 

 

OPERATION

 

 

 

comes first

 

 

 

ENGINE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Converter drive belt wear - inspect *

 

 

 

 

 

 

2-25

 

 

 

 

 

 

 

 

 

 

Converter drive belt deflection - inspect *

 

 

 

 

 

 

 

2-25

 

 

 

 

 

 

 

 

 

 

 

Drive belt failure detection system function

 

 

 

 

 

 

2-37

 

- inspect *

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine brake control lever - inspect *

 

 

 

 

 

2-27

 

 

 

 

 

 

 

 

 

Air cleaner - inspect *

 

 

 

 

 

2-17

 

 

 

 

 

 

 

 

 

Throttle lever play - inspect

 

 

 

 

 

2-14

 

 

 

 

 

 

 

 

 

Choke lever play - inspect

 

 

 

 

 

 

2-14

 

 

 

 

 

 

 

 

 

 

Idle speed - inspect

 

 

 

 

 

 

 

2-15

 

 

 

 

 

 

 

 

 

 

 

Valve clearance - inspect

 

 

 

 

2-23

 

 

 

 

 

 

 

 

 

Fuel system cleanliness - inspect *

 

 

 

 

 

2-16

 

 

 

 

 

 

 

 

 

Engine oil - change *

 

 

 

 

 

2-27

 

 

 

 

 

 

 

 

 

Oil filter - replace *

 

 

 

 

 

2-28

 

 

 

 

 

 

 

 

 

Spark plug - clean and gap

 

 

 

 

 

 

 

2-36

 

 

 

 

 

 

 

 

 

 

 

Spark arrester - clean

 

 

 

 

 

 

2-24

 

Fuel hoses and connections - inspect

 

 

 

 

 

 

2-18

 

 

 

 

 

 

 

 

 

 

Fuel hose - replace

4 years

 

 

 

2-18

 

 

 

 

 

 

 

 

 

Radiator - clean*

 

 

 

 

 

 

 

2-19

 

 

 

 

 

 

 

 

 

 

 

Radiator hoses and connections - check*

 

 

 

 

 

 

2-20

 

Coolant - change*

 

 

2 years

 

 

 

2-20

CHASSIS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Joint boots - inspect *

 

 

 

 

 

 

 

2-39

 

 

 

 

 

 

 

 

 

 

 

Rear brake pedal and lever play - inspect *

 

 

 

 

 

2-35

 

Rear brake plates - replace *

every 10 000 km (6 000 mi.)

 

2-35

 

 

 

 

 

 

 

 

 

Bolts and nuts - tighten

 

 

 

 

 

2-41

 

 

 

 

 

 

 

 

 

Front brake pad wear - inspect *

 

 

 

 

 

2-32

 

 

 

 

 

 

 

 

 

Brake light switch - inspect *

 

 

 

 

 

2-37

 

 

 

 

 

 

 

 

 

Steering - inspect

 

 

 

 

 

2-36

 

 

 

 

 

 

 

 

 

Differential control lever play - inspect

 

 

 

 

 

 

 

2-29

 

 

 

 

 

 

 

 

 

 

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

 

 

 

 

 

 

 

 

 

 

FREQUENCY First

 

Regular Service

 

 

 

 

Service

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Every 90

 

 

 

 

 

 

 

 

days, 1 700

 

 

 

 

 

 

Every

Every

 

km (1 100

 

 

 

 

 

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

 

 

 

 

 

 

use

use

hrs of use)

 

 

 

 

 

 

 

 

 

whichever

 

 

 

OPERATION

 

 

 

comes first

 

 

 

 

Tire wear - inspect *

 

 

 

 

 

 

2-28

 

 

 

 

 

 

 

 

 

 

Front and rear final gear case oil - change

 

 

 

 

 

2-30

 

 

 

 

 

 

2-31

 

 

 

 

 

 

 

 

Rear propeller shaft universal joint

 

 

 

 

 

 

2-32

 

lubrication

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

General lubrication *

 

 

 

 

 

 

2-40

 

 

 

 

 

 

 

 

 

 

Front brake fluid level - inspect

 

 

 

 

 

2-33

 

 

 

 

 

 

 

 

 

Front brake fluid - change

 

 

 

 

 

 

2-34

 

Front brake hoses and connections -

 

 

 

 

 

 

2-32

 

inspect

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Front brake master cylinder piston

 

 

2 years

 

 

 

2-34

 

assembly and dust seal - replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Front brake caliper piston seal and dust

 

 

2 years

 

 

 

2-34

 

seal - replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Front brake hose - replace

 

 

4 years

 

 

 

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:

 

 

 

 

 

AL: Tighten the two clamp bolts alternately two 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

 

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

 

 

 

 

 

Fastener

 

Torque

 

Remarks

N·m

kgf·m

ft·lb

 

 

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 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

 

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

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

 

Loading...
+ 502 hidden pages