Kawasaki PRAIRIE 360 4×4, KVF 360 4×4 Service Manual
PRAIRIE 360 4×4
KVF 360 4×4
All Terrain Vehicle
Service Manual
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System 3 j
Engine Top End 4 j
Converter System 5 j
Recoil Starter 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Crankshaft/Transmission 9 j
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
Appendix 17 j
PRAIRIE 360 4×4
KVF 360 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 Division/Motorcycle & Engine 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.
© 2002 Kawasaki Heavy Industries, Ltd. Eleventh Edition (0) : Mar. 3, 2011
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) Ω ohm(s)
L liter(s)
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2), and evaporative emission (3) control systems in compliance with
applicable regulations of the United States Environmental Protection Agency and 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 catalytic converter in the muffler (US and Canada (KVF360AA/CA ∼) models), a modified car-
buretor and 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.
3. Evaporative Emission Control System
The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a
fuel tank.
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 s uch
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 ino perative 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 ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the vehicle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering i noperative 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)
TAMPERING WITH EMISSION CONTROL SYSTEM P ROHIBITE D:
Federal regulations and California State law prohibit the following acts or the causing thereof:
(1) the removal or rendering inoperative by any person other than for purposes of maintenance,
repair, or replacement, of any device or element of design incorporated into any new vehicle for
the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it
is in use, or (2) the use of the vehicle after such device or element of design has been removed
or rendered inoperative by any person.
Do not tamper with the original emission related parts:
Carburetor or internal parts
•
Spark Plug
•
Magneto ignition system
•
Air Cleaner element
•
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
* Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
* Removal of the muffler(s) or any internal portion of the muffler(s).
* Removal of the air box or air box cover.
* Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.
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 Vehi-
•
cle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are introduced by the Service Man-
ual. Genuine parts provided as spare parts
are listed in the Parts Catalog.
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see symbols, heed their instructions! Always follow safe operating and
maintenance practices.
DANGER
DANGER indicates a hazardous situa-
tion which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situa-
tion which, if not avoided, could result
in death or serious injury.
NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more symbols
which will help you distinguish different types
of information.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease o r a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-9
Unit Conversion Table ............................................................................................................ 1-15
1
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 cables from the battery to prevent the engine
from accidentally turning over. Disconnect the negative cable (–) first and then the positive cable (+). When completed
with the service, first connect the positive cable (+) to the
positive cable (+) terminal of the battery then the negative
cable (–) to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
GENERAL INFORMATION 1-3
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips, cotter pins or self-locking nuts 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
non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and
cause serious damage.
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
GENERAL INFORMATION 1-5
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Leads
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
leads must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for a n accurate
measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead
to improper adjustments.
Model Identification
KVF360-A1 Left Side
GENERAL INFORMATION 1-7
KVF360-A1 Right Side
1-8 GENERAL INFORMATION
Model Identification
KVF360-C1 Left Side
KVF360-C1 Right Side
GENERAL INFORMATION 1-9
General Specifications
Items KVF360-A1 ∼ A3, A6 ∼ A8/C1 ∼ C3, C6 ∼ C8
Dimensions
Overall Length 2 065 mm (81.30 in.)
Overall Width 1 205 mm (47.44 in.)
Overall Height 1 175 mm (46.26 in.)
Wheelbase 1 250 mm (49.21 in.)
Ground Clearance:
Rear Final Gear Case 195 mm (7.68 in.)
Center of Frame 250 mm (9.84 in.)
Seat Height 910 mm (35.83 in.)
Dry Mass
Curb Mass:
Front 154 kg (340 lb) KVF360-A1/C1 ∼ A3/C3
Rear
Fuel Tank Capacity 13.5 L (3.6 US gal)
Performance
Minimum Turning Radius 3.1 m (10.17 ft)
Engine
Type
Cooling System
Bore and Stroke 80.0 × 72.0 mm (3.15 × 2.83 in.)
Displacement 362 cm³ (22.1 cu in.)
Compression Ratio 8.3 : 1
Maximum Horsepower 15.7 kW (21.4 PS) @7 000 r/min (rpm), (US) (CA) -
Maximum Torque 26.1 N·m (2.66 kgf·m, 19.25 ft·lb) @4 500 r/min (rpm)
Carburetion System Carburetor, Keihin CVK34
Starting System Electric Starter & Recoil Starter
Ignition System DC-CDI (KVF360-A1/C1 ∼,A6/C6)
Timing Advance Electronically advanced
Ignition Timing
Spark Plug NGK DPR8E A-9
Valve Timing:
Inlet:
Open 38° BTDC
Close 58° ABDC
Duration 276°
Exhaust:
Open 68° BBDC
Close 28° ATDC
Duration 276°
274 kg (604 lb) KVF360-A1/C1 ∼ A3/C3
274.5 kg (605 lb) KVF360A6/C6 ∼
154.5 kg (341 lb) KVF360A6/C6 ∼
135 kg (298 lb)
4-stroke, SOHC, 1-cylinder
Air-cooled
Digital DC-CDI (KVF360A7/C7 ∼)
From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @5 000 r/min
(rpm)
1-10 GENERAL INFORMATION
General Specifications
Items KVF360-A1 ∼ A3, A6 ∼ A8/C1 ∼ C3, C6 ∼ C8
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 2.3 L (2.17 US qt)
Drive Train
Primary Reduction System:
Type Belt converter
Reduction Ratio 3.122 ∼ 0.635
Transmission:
Type 2-speed automatic and reverse
Gear Ratios:
Forward:
High 3.548 (30/26 × 29/18 × 21/11)
Low 5.536 (36/20 × 29/18 × 21/11)
Reverse 4.613 (16/12 × 18/16 × 29/18 × 21/11)
Final Drive System:
Type Shaft, 2WD/4WD
Reduction Ratio 4.375 (35/8)
Overall Drive Ratio:
Forward:
High 48.474 ∼ 9.859
Low 75.619 ∼ 15.380
Reverse 63.016 ∼ 12.817
Front F inal Gear Case Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 430 mL (0.45 US qt)
Rear Final Gear Case Oil:
Type
Capacity 900 mL (0.95 US qt)
Frame
Type Double cradle, tubular steel
Caster (rake angle) 2.5°
Camber 0.5°
King Pin Angle 14.5°
Trail
Tread:
Front 890 mm (35.04 in.)
Rear 895 mm (35.24 in.)
MOBIL Fluid 424 or Kawa Chem Gear & Wet
Brake Oil (C ITGO TRANSGARD TRACTOR HYDRAULIC FLUID)
or Exxon Hydraul 560
15 mm (0.59 in.)
GENERAL INFORMATION 1-11
General Specifications
Items KVF360-A1 ∼ A3, A6 ∼ A8/C1 ∼ C3, C6 ∼ C8
Front Tire:
Type Tubeless
Size
Rear Tire:
Type Tubeless
Size AT25 × 10 - 12
Rim Size:
Front 12 × 6.0
Rear 12 × 7.5
Suspension:
Front:
Type MacPherson strut
Wheel Travel 170 mm (6.69 in.)
Rear:
Type Swingarm
Wheel Travel 180 mm (7.09 in.)
Brake:
Front Disc × 2
Rear Enclosed wet multi-plate
Electrical Equipment
Battery 12 V 14 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 30/30 W × 2
Brake/Tail Light:
Bulb 12 V 18/5 W
Alternator:
Type
Rated Output 25 A, 14 V @8 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
AT25 × 8 - 12
Three - phase AC
1-12 GENERAL INFORMATION
General Specifications
Items KVF360A9 ∼ AC/C9 ∼ CC
Dimensions
Overall Length 2 065 mm (81.30 in.)
Overall Width 1 205 mm (47.44 in.)
Overall Height (KVF360A9/C9) 1 155 mm (45.28 in.)
(KVF360AA ∼ AC/CA ∼ CC)
Wheelbase (KVF360A9/C9) 1 253 mm (49.33 in.)
(KVF360AA ∼ AC/CA ∼ CC) 1 255 mm (49.41 in.)
Ground Clearance:
Rear Final Gear Case (KVF360A9/C9) 195 mm (7.68 in.)
(KVF360AA ∼ AC/CA ∼ CC) 185 mm (7.28 in.)
Center of Frame (KVF360A9/C9) 238 mm (9.37 in.)
(KVF360AA ∼ AC/CA ∼ CC) 235 mm (9.25 in.)
Seat Height (KVF360A9/C9) 905 mm (35.63 in.)
(KVF360AA ∼ AC/CA ∼ CC) 895 mm (35.24 in.)
Curb Mass:
(US, CA) (KVF360A9/C9) 290 kg (639 lb)
(KVF360AA ∼ AC/C
(AU) (KVF360A9 ∼ AB) 290 kg (639 lb)
(EUR, GB) (KVF360A9 ∼ AC) 291 kg (642 lb)
Front
(US, CA) (KVF360A9 ∼ AC/C9 ∼ CC) 156 kg (344 lb)
(AU) (KVF360A9 ∼ AC) 156 kg (344 lb)
(EUR, GB) (KVF360A9 ∼ AC
Rear
(US, CA) (KVF360A9/C9) 134 kg (295 lb)
(KVF360AA ∼ AC/CA ∼ CC) 136 kg (300 lb)
(AU, EUR, GB) (KVF360A9 ∼ AC) 134 kg (295 lb)
Fuel Tank Capacity 13.5 L (3.6 US gal)
Performance
Minimum Turning Radius 3.1 m (10.17 ft)
Engine
Type 4-stroke, SOHC, 1-cylinder
Cooling System
Bore and Stroke 80.0 × 72.0 mm (3.15 × 2.83 in.)
Displacement
Compression Ratio 8.3 : 1
Maximum Horsepower 15.7 kW (21.4 PS) @7 000 r/min (rpm), (US) (CA) -
Maximum Torque 26.1 N·m (2.66 kgf·m, 19.25 ft·lb) @4 500 r/min (rpm)
Carburetion System Carburetor, Keihin CVK34
Starting System Electric Starter & Recoil Starter
Ignition System Digital DC-CDI
Timing Advance Electronically advanced
Ignition Timing From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @5 000
Air-cooled
362 cm³ (22.
r/min (rpm)
1cuin.)
A ∼ CC) 292 kg (644 lb)
) 157 kg (346 lb)
1 145 mm (45.08 in.)
GENERAL INFORMATION 1-13
General Specifications
Items KVF360A9 ∼ AC/C9 ∼ CC
Spark Plug NGK DPR8EA-9
Valve Timing:
Inlet:
Open 38° BTDC
Close 58° ABDC
Duration 276°
Exhaust:
Open 68° BBDC
Close 28° ATDC
Duration
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 2.3 L (2.17 US qt)
Drive Train
Primary Reduction System:
Type Belt converter
Reduction Ratio 3.122 ∼ 0.635
Transmission:
Type 2-speed automatic and reverse
Gear Ratios:
Forward:
High 3.548 (30/26 × 29/18 × 21/11)
Low 5.536 (36/20 × 29/18 × 21/11)
Reverse 4.613 (16/12 × 18/16 × 29/18 × 21/11)
Final Drive System:
Type Shaft, 2WD/4WD
Reduction Ratio 4.375 (35/8)
Overall Drive Ratio:
Forward:
High 48.474 ∼ 9.859
Low 75.619 ∼ 15.380
Reverse 63.016 ∼ 12.817
Front Final Gear Case Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 430 mL (0.45 US qt)
Rear Final Gear Case Oil:
Type MOBIL Fluid 424 or Kawa Chem Gear & Wet
Capacity 900 mL (0.95 US qt)
276°
Brake Oil (CITGO TRANSGARD TRACTOR HYDRAULIC
FLUID) or Exxon Hydraul 560
1-14 GENERAL INFORMATION
General Specifications
Items KVF360A9 ∼ AC/C9 ∼ CC
Frame
Type Double cradle, tubular steel
Caster (rake angle) 3°
Camber 0°
King Pin Angle 14°
Trail 17 mm (0.67 in.)
Tread:
Front (KVF360A9/C9) 894 mm (35.20 in.)
(KVF360AA ∼ AC/CA ∼ CC) 895 mm (35.24 in.)
Rear (KVF360A9/C9) 895 mm (35.24 in.)
(KVF360AA ∼ AC/CA ∼ CC) 900 mm (35.43 in.)
Front Tire:
Type Tubeless
Size AT25 × 8 - 12
Rear Tire:
Type Tubeless
Size
Rim Size:
Front 12 × 6
Rear 12 × 7.5
Suspension:
Front:
Type MacPherson strut
Wheel Travel 170 mm (6.69 in.)
Rear:
Type Swingarm
Wheel Travel 180 mm (7.09 in.)
Brake:
Front Disc × 2
Rear Enclosed wet multi-plate
Electrical Equipment
Battery 12 V 14 Ah
Headlight:
Type
Bulb
Brake/Tail Light:
Bulb 12 V 18/5 W
Alternator:
Type
Rated Output 25 A, 14 V @8 000 r/min (rpm)
AU: Australia
CA: Canada
GB: United Kingdom
EUR: Europe
US: United States
AT25 × 10 - 12
Semi-sealed beam
12 V 30/30 W × 2
Three - phase AC
Unit Conversion Table
GENERAL INFORMATION 1-15
Prefixes for Units:
Prefix Symbol Power
mega M × 1 000 000
kilo k ×1000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001
Units of Mass:
kg ×2.205=lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 =
L × 0.2200 = gal (IMP)
L × 1.057 = qt (US)
L × 0.8799 = qt (IMP)
L×2.113=
L × 1.816 =
mL × 0.03381 =
mL × 0.02816 = oz (IMP)
mL × 0.06102 = cu in
gal (US)
pint (US)
pint (IMP)
oz (US)
Units o f Force:
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
Units o f Length:
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in
Units o f Torque:
N·m × 0.1020 = kg·m
N·m × 0.7376 =
N·m × 8.851 = in·lb
kg·m × 9.807 = N·m
kg·m × 7.233 =
kg·m × 86.80 = in·lb
ft·lb
ft·lb
Units of Pressure:
kPa × 0.01020 =
kPa × 0.1450 = psi
kPa × 0.7501 = cmHg
kg/cm² × 98.07 = kPa
kg/cm² × 14.22 = psi
cmHg×1.333=kPa
kg/cm²
Units of Speed:
km/h × 0.6214 = mph
Units of Power:
kW ×1.360=PS
kW ×1.341=HP
PS × 0.7355 = kW
PS
× 0.9863 = HP
Units of Temperature:
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart .............. 2-2
Torque and Locking Agent................. 2-4
Specifications .................................... 2-10
Special Tools ..................................... 2-12
Periodic Maintenance Procedures..... 2-13
Fuel System.................................... 2-13
Throttle Lever Free Play
Inspection .................................. 2-13
Throttle Lever Free Play
Adjustment ................................ 2-13
Idle Speed Inspection .................. 2-14
Idle Speed Adjustment................. 2-14
Fuel System Cleanliness
Inspection .................................. 2-14
Air Cleaner Element Cleaning and
Inspection .................................. 2-15
Air Cleaner Draining..................... 2-15
Fuel Hose and Connection
Check ........................................ 2-16
Fuel Hose Replacement .............. 2-16
Engine Top End .............................. 2-17
Valve Clearance Inspection ......... 2-17
Valve Clearance Adjustment........ 2-17
Spark Arrester Cleaning............... 2-18
Converter System ........................... 2-18
Actuator Lever (Engine Brake
Control Lever) Assembly
Inspection .................................. 2-18
Drive Belt Inspection .................... 2-19
Drive Belt Deflection Inspection ... 2-20
Drive Belt Deflection Adjustment . 2-21
Engine Lubrication System ............. 2-22
Engine Oil Change....................... 2-22
Oil Filter Change .......................... 2-22
Oil Cooler Cleaning and
Inspection .................................. 2-23
Oil Hose and Connection Check .. 2-23
Wheels/Tires................................... 2-24
Tire Inspection ............................. 2-24
Final Drive....................................... 2-24
Variable Differential Control Lever
Position Inspection .................... 2-24
Variable Differential Control Lever
Position Adjustment .................. 2-24
Front Final Gear Case Oil
Change...................................... 2-25
Rear Final Gear Case Oil Change 2-26
Joint Boots Inspection.................. 2-27
Rear Propeller Shaft Joint Boot
Inspection.................................. 2-27
Brakes............................................. 2-28
Front Brake Pad Wear Inspection 2-28
Brake Hose and Connection
Inspection.................................. 2-28
Brake Hose Replacement ............ 2-28
Brake Fluid Level Inspection ........ 2-28
Brake Fluid Change ..................... 2-29
Front Brake Master Cylinder
Piston Assembly and Dust
Cover Replacement .................. 2-30
Front Brake Caliper Fluid Seal
Replacement............................. 2-30
Front Brake Caliper Dust Seal
and Rubber Boot, Dust Cover
Replacement............................. 2-30
Rear Brake Plates Replacement.. 2-30
Rear Brake Lever and Pedal Free
Play Inspection .......................... 2-31
Rear Brake Lever and Pedal Free
Play Adjustment ........................ 2-31
Steering .......................................... 2-32
Steering Inspection ...................... 2-32
Electrical System ............................ 2-32
Battery Inspection ........................ 2-32
Spark Plug Cleaning/Inspection... 2-32
Spark Plug Gap Inspection .......... 2-32
Drive Belt Failure Detection
System Inspection ..................... 2-32
Brake Light Switch Inspection...... 2-33
General Lubrication ........................ 2-33
Lubrication ................................... 2-33
Bolts and Nuts Tightening............... 2-35
Tightness Inspection .................... 2-35
2
2-2 PERIODIC MAINTENANCE
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
OPERATION
ENGINE
Converter drive belt wear - inspect *
Converter drive belt deflection - inspect *
Drive belt failure detection system function
- inspect*
Engine brake control lever - inspect*
Air cleaner - inspect*
Throttle lever play - inspect
Idle speed - inspect
Valve clearance - inspect
Fuel system cleanliness - inspect*
Engine oil - change *
Oil filter - replace*
Spark plug - clean and gap
Spark arrester - clean
Oil cooler- clean*
Oil hoses and connections - inspect*
Fuel hoses and conn
Fuel hose - replace 5 years
CHASSIS
Joint boots - inspect*
Rear brake pedal and lever adjustment inspect*
Rear brake plates - change* every 10 000 km (6 000 mi.)
Cables adjustment*
Bolts and nuts - tighten
Front brake pad wear - inspect*
Brake light switch - inspect*
Battery - inspect
Steering - inspect
Differential control lever play- inspect
Tire wear - inspect*
ections - inspect
First
Service
After 10
hrs. or
100 km
(60 mi.)
of use
Every
10 days
or 200
km
(120
mi.) of
use
Regular Service
Every
30 days
or 600
km
(360
mi.) of
use
100 mi.) of use,
hrs.) whichever
• •
• •
•
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
•
Every 90 days
or 1 700 km (1
or when BELT
indicator light
comes on (100
comes first
•
•
(NOTE)
•
•
•
Every
year
of
use
•
•
Periodic Maintenance Chart
PERIODIC MAINTENANCE 2-3
FREQUENCY
OPERATION
Front and rear finial gear case oil - change
General lubrication*
Front brake fluid level - inspect
Front brake fluid - change
Front brake master cylinder piston
assembly and dust seal - replace
Front caliper fluid seal and dust seal replace
Front brake hoses and connectionsinspect
Front brake hose - replace 4 years
*: 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.
•
First
Service
After 10
hrs. or
100 km
(60 mi.)
of use
Every
10 days
or 200
km
(120
mi.) of
use
Regular Service
Every
30 days
or 600
km
(360
mi.) of
use
Every 90 days
or 1 700 km (1
100 mi.) of use,
or when BELT
indicator light
comes on (100
hrs.) whichever
comes first
• •
•
• •
2 years
2 years
•
Every
year
of
use
•
NOTE
When the drive belt failure detection system is activated, inspect the drive belt.
○
2-4 PERIODIC MAINTENANCE
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:
L: Apply a non-permanent locking agent.
LB: Apply a non-permanet locking agent (ThreeBond TB2471, Blue).
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide
grease in a weight ratio 10:1).
EO: Apply engine oil.
M: Apply molybdenum disulfide grease.
SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).
Lh: Left-hand Threads
R: Replacement Parts
S: Follow the specific tightening sequence.
St: Stake the fasteners to prevent loosening.
Fastener
Fuel System
Throttle Cable Locknut 1.3 0.13 11 i n · lb
Air Cleaner Duct Front Clamp Screw 1.4 0.14 12 in·lb
Air Cleaner Duct Rear Clamp Screw 4 0.41 36 in·lb
Air Cleaner Housing Mounting Bolts 6.9 0.70 61 in·lb
Air Cleaner Intake Duct Clamp Screws 1.4 0.14 12 in·lb
Engine Top End
Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb
Cylinder Head Bolts (M11), first torque 25 2.5 18 MO, S
Cylinder Head Bolts (M11), final torque
Cylinder Head Bolts (M6) 12 1.2 104 in·lb S
Camshaft Cover Bolts 8.8 0.90 78 in·lb
Engine Breather Plate Screws 4.4 0.45 39 in·lb
Camshaft Sprocket Bolts 14 1.4 10 L
Bearing Retainer Bolts 12 1.2 104 in·lb
Rear Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb
Camshaft Chain Tensioner Mounting Bolts 8.8 0.90 78 in·lb
Camshaft Chain Guard Bolts 8.8 0.90 78 in·lb
Valve Adjusting Screw Locknuts
(KVF360-A1, C1 ∼ A6, C6) 12 1.2 104 in·lb (M6)
(KVF360A7/C7 ∼) 8.8 0.90 78 in·lb (M5)
Rocker Shaft Holder Bolts 8.8 0.90 78 in·lb
Muffler Mounting Bolts 26 2.7 20
Converter System
Drive Pulley Bolt 93 9.5 69 R, Lh
Driven Pulley Nut 93 9.5 69 R
Drive Pulley Cover Bolts 13 1.3 113 in·lb
Ramp Weight Nuts 6.9 0.70 61 in·lb R
Spider 275 28 203 Lh
Converter Cover Bolts 8.8 0.90 78 in·lb S
N·m kgf·m ft·lb
44 4.5 33
Torque
Remarks
S
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