Kawasaki PRAIRIE 650, PRAIRIE 650 4X4 Service Manual

PRAIRIE 650

KVF 650

PRAIRIE 650 4X4

KVF 650 4X4

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.

© 2002 Kawasaki Heavy Industries. Ltd. 3rd Edition (1) : Jun. 21, 2002 (K)

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 incor porated 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 atomosphere.

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 carefully. Don’t

take shor tcuts.

•

Remember to keep complete records of maintenance

and repair with dates and any new parts installed.

How to Use This Manual

In preparing this manual, we divided the product into
its major systems. These systems became the manual’s
chapters. All information for a particular system from
adjustment through disassembly and inspection is located
in a single chapter.

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.

The Periodic Maintenance Chart is located in the
General Information chapter. The chart gives a time
schedule for required maintenance operations.

If you want spark plug information, for example, go to
the Periodic Maintenance Chart first. The chart tells you
how frequently to clean and gap the plug. Next, 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 Spark Plug section.

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

This warning symbol identifies special instruc-

tions or procedures which, if not correctly fol-

lowed, could result in personal injury, or loss of

life.

CAUTION

This caution symbol identifies special instruc-

tions or procedures which, if not strictly ob-

served, 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.

•

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 inspection in the procedural

step or sub-step it follows.

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

1

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

Model Identification ........................................................................................................................................................... 1-4

General Specifications ...................................................................................................................................................... 1-7

Periodic Maintenance Chart..............................................................................................................................................1-9

Technical Information — Engine .....................................................................................................................................1-11

Technical Information — K-EBC System ........................................................................................................................ 1-12

Technical Information — Selectable 2WD/4WD ............................................................................................................. 1-19

Technical Information — Drive Belt Failure Detection System.......................................................................................1-24

Techinical Information — Variable Limited Slip Differential Control................................................................................1-26

Technical Information — Rear Brake..............................................................................................................................1-28

Torque and Locking Agent .............................................................................................................................................. 1-30

Special Tools and Sealant...............................................................................................................................................1-35

Cable, Wire, and Hose Routing ......................................................................................................................................1-42

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:

(1) Dirt

Before removal and disassembly, clean the vehicle. Any dirt entering the engine will shorten the life of the vehicle.

For the same reason, before installing a new part, clean off any dust or metal filings.

(2) Battery Ground

Disconnect the ground (–) wire from the battery before performing any disassembly operations on the vehicle. This
prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while
disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation,
first connect the positive wire to the positive (+) terminal of the battery

(3) Installation, Assembly

Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly
sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during
removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record
the locations and routing whenever possible.

(4) Tightening Sequence

When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure
to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and
tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them
to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not
given, tighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4–turn before removing them.

(5) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to
serious damage. Use a good quality, reliable torque wrench.

(6) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially
difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap
lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removing screws
held by non-permanent locking agent) in order to avoid damaging the screw heads.

(7) Edges

Watch for sharp edges, as they could cause injury through careless handling, especially during major engine
disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over.

(8) High-Flash Point Solvent

A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North
America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use
of any solvent.

(9) Gasket, O-Ring

Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating
surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks.

(10) Liquid Gasket, Locking Agent

Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly.
Excessive amount may block engine oil passages and cause serious damage.

(11) Press

When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area
where the two parts come in contact to ensure a smooth fit.

(12) Ball Bearing and Needle Bearing

Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle
bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying
pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and
press it evenly over the base component.

(13) Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or
grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until
the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease
seal which has manufacturer’s marks, press it in with the marks facing out.

GENERAL INFORMATION 1-3

Before Servicing

(14) Circlip, Retaining Ring, and Cotter Pin

When installing circlips and retaining rings, take care to compress or expand them only enough to install them and

no more. Install the circlip with its chamfered side facing load side as well.

Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and
deforms them. If old ones are reused, they could become detached while the vehicle is driven, leading to a major
problem.

(15) Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have
an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been
cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as
abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular should
be used only in certain applications and may be harmful if used in an application for which they are not intended.

(16) Direction of Engine Rotation

To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is
counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary
to rotate the engine in the direction of positive rotation as well.

(17) Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are removed.

Replacement parts will be damaged or lose their original function once they are removed. Therefore, always
replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring,
ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective
text, they are replacement parts.

(18) Electrical Wires

All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and
then the stripe color. For example, a yellow wire with thin red stripes is referred to as a “yellow/red” wire; it would
be a “red/yellow” wire if the colors were reversed. Unless instructed otherwise, electrical wires must be connected to
wires of the same color.

Two-Color Electrical

(19) Inspection

When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If
there is any doubt as to the condition of them, replace them with new ones.

Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure

(20) Specifications

Specification terms are defined as follows:

"Standards" show dimensions or performances which brand-new parts or systems have.

"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance,
replace the damaged parts.

(21) Instrument

Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thgoughly
before using the meter. Incorrect values may lead to improper adjustments.

1-4 GENERAL INFORMATION

Model Identification

KVF650–A1

GENERAL INFORMATION 1-5

Model Identification

KVF650–A2

1-6 GENERAL INFORMATION

Model Identification

KVF650–B1, B2

GENERAL INFORMATION 1-7

General Specifications

Items KVF650-A1, B1 KVF650-A2, B2

Dimensions:

Overall length 2 155 mm (84.84 in.)
Overall width 1 170 mm (46.06 in.)
Overall height 1 150 mm (45.28 in.)
Wheelbase 1 295 mm (50.98 in.)
Ground clearance:

Rear final gear case 193 mm (7.60 in.)

Center of frame 240 mm (9.45 in.)
Seat height 855 mm (33.66 in.)
Dry mass 274 kg (604 lb)
Curb mass: Front 155 kg (342 lb)

Rear 138 kg (304 lb)

Fuel tank capacity 17 L (4.5 US gal)

Performance:

Minimum turning radius 3.1 m (10.17 ft)

Engine:

Type 4-stroke, SOHC, V2-cylinders
Cooling system Liquid-cooled
Bore and stroke 80.0 x 63.0 mm (3.15 x 2.48 in.)
Displacement 633 mL (38.6 cu in.)
Compression ratio 9.9:1
Maximum horsepower 30.9 kW (42 PS) @6 500 r/min (rpm), (US) ­Maximum torque 52.1 N1m (5.3 kgf1m, 38.33 ft1lb) @4 000 r/min (rpm)
Carburetion system Carburetor, Keihin CVKR-D32
Starting system Electric Starter & Recoil Starter
Ignition system Digital DC-CDI
Timing advance Electronically advanced
Ignition timing From 5BTDC @1 100 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 30BTDC

Close 34ABDC
Duration 244



Exhaust: Open 54BBDC

Close 10ATDC
Duration 244



Lubrication system Forced lubrication (wet sump)
Engine oil: Grade API SF or SG class

API SH or SJ with JASO MA class

Viscosity

SAE10W-40

Capacity 2.05 L (2.17 US qt)

Drive Train:

Primary reduction system:

Type Belt converter
Reduction ratio 3.122 0.635

1-8 GENERAL INFORMATION

General Specifications

Items

KVF650-A1, B1 KVF650-A2, B2

Transmission:

Type 2-speed plus reverse
Gear ratios:

Forward: High 3.098 (30/26 x 29/18 x 20/12)

Low 4.833 (36/20 x 29/18 x 20/12)

Reverse: 4.028 (16/12 x 18/16 x 29/18 x 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: Grade API SF or SG class

API SH or SJ with JASO MA class

Viscosity

SAE10W-40

Capacity 0.43 L (0.45 US qt)

Rear final gear case oil: Type MOBIL Fluid 424

MOBIL Fluid 424 or
CITGO TRANSGARD
TRACTOR
HYDRAULIC FLUID

Capacity 0.9 L (0.95 US qt)

Frame:

Type Double tubular
Caster (rake angle) 3.5



Camber 0@1 G
King pin angle 15.5



Trail 15 mm (0.59 in.)
Tread Front 914 mm (35.98 in.)

Rear 910 mm (35.83 in.)

Front tire: Type Tubeless

Size AT25 x 8 – 12

Rear tire: Type Tubeless

Size AT25 x 10 – 12

Suspen­sion:

Front Type

MacPherson strut

Wheel travel 170 mm (6.69 in.)

Rear Type Swingarm

Wheel travel 184 mm (7.24 in.)

Brake: Front Disc (Hydraulic) x 2

Rear Enclosed Wet Multi-Plate

Electrical Equipment:

Battery 12 V 12 Ah
Headlight: Type Semi-sealed beam

Bulb 12 V 45/45 W x 2
Tail/brake light Bulb 12 V 8/27 W 12 V 5/21 W
Alternator: Type Three - phase AC

Rated output 25 A, 14 V @6 000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country.

US: U.S.A. Model

GENERAL INFORMATION 1-9

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.

KVF650–A1, B1

FREQUENCY First Ser-

vice

Regular Service

OPERATION

After 10

hrs. or

100 km

(60 mi.)

of use

Every 10

days or
200 km

(120 mi.)

of use

Every 30

days or
600 km

(360 mi.)

of use

Every 90

days or

1700 km

(1100

mi.) of

use

Every

year of

use

ENGINE

Converter drive belt wear – check *

•

Converter drive belt deflection - check *

•

Drive belt failure detection system function – check*

•

Engine brake control (K-EBC) lever – check*

•

Air cleaner – service*

• •

Throttle lever play – check*

• •

Valve clearance – check*

•

Fuel system cleanliness – check*

• •

Engine oil – change *

• •

Oil filter – replace*

• •

Spark plug – clean and gap

• •

Spark arrester – clean

•

Radiator – clean*

• •

Radiator hoses, and connections – check*

•

Coolant – change* 2 years
Coolant filter of carburetor – clean

•

Fuel hoses, connections – check

•

Fuel hose – replace 4 years

CHASSIS

Joint boots – check*

• •

Rear brake pedal and lever adjustment – check*

• •

Rear brake plates – change* every 10 000 km (6 000 mi.)
Cable adjustment*

• •

Bolts and nuts – tighten

• •

Front brake pad wear – check*

• •

Brake light switch – check*

• •

Steering – check

• •

Differential control lever play– check

• •

Tire wear – check*

•

Front and rear finial gear case oil – change

• •

General lubrication*

•

Front brake fluid level – check

• •

Front brake fluid – change

•

Brake master cylinder piston assembly and dust
seal – replace

2 years

Caliper piston seal and dust seal – replace 2 years
Brake hoses, connections– check

•

Brake hose – replace 4 years

1-10 GENERAL INFORMATION

Periodic Maintenance Chart

KVF650–A2, B2

FREQUENCY

First

Service

Regular Service

OPERATION

After 10

hrs. or

100 km

(60 mi.)

of use

Every

10 days

or 200

km (120

mi.) of

use

Every

30 days

or 600

km (360

mi.) of

use

Every 90 days of

vehicle use,1700

km (1100 mi.) or

when belt indica-

tor light comes on

(100 hours)

whichever comes

first

Every

year of

use

ENGINE

Converter drive belt wear – check *

•

Converter drive belt deflection - check *

•

Drive belt failure detection system function – check*

•

(Note)

Engine brake control (K-EBC) lever – check*

•

Air cleaner – service*

• •

Throttle lever play – check*

• •

Valve clearance – check*

•

Fuel system cleanliness – check*

• •

Engine oil – change *

• •

Oil filter – replace*

• •

Spark plug – clean and gap

• •

Spark arrester – clean

•

Radiator – clean*

• •

Radiator hoses, and connections – check*

•

Coolant – change* 2 years
Coolant filter of carburetor – clean

•

Fuel hoses, connections – check

•

Fuel hose – replace 4 years

CHASSIS

Joint boots – check*

• •

Rear brake pedal and lever adjustment – check*

• •

Rear brake plates – change* every 10 000 km (6 000 mi.)
Cable adjustment*

• •

Bolts and nuts – tighten

• •

Front brake pad wear – check*

• •

Brake light switch – check*

• •

Steering – check

• •

Differential control lever play– check

• •

Tire wear – check*

•

Front and rear finial gear case oil – change

• •

General lubrication*

•

Front brake fluid level – check

• •

Front brake fluid – change

•

Brake master cylinder piston assembly and dust seal
– replace

2 years

Caliper piston seal and dust seal – replace 2 years
Brake hoses, connections– check

•

Brake hose – replace 4 years

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

•

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

NOTE



When the drive belt failure detection system is activated, return the vehile immediately to an authorized
Kawasaki dealer for drive belt inspection and adjustment or replacement.

GENERAL INFORMATION 1-11

Technical Information — Engine

Engine Main Specification

1. Newly designed, liquid-cooled, 633 cm

3

SOHC, 4–valve V-twin

engine produces 30.9 kW (42 PS)/6,500 rpm.

2. Over square bore and stroke of 80.0 mm x 63.0 mm contributes
to a high torque output of 52.1 N

1

m (5.3 kgf1m)/4,000 rpm and a

flat, user-friendly torque curve.

3. Off-setting the cylinders by 90-degree results in perfect primary
balance, for low vibration levels and comfortable riding.

4. Concave piston crown improves combustion efficiency.

5. Large, 30 mm intake and 26 mm exhaust valves are set at a
narrow 19-degree intake and 21-degree exhaust for a compact,
high-efficiency combustion chamber.

6. Dual, CVKR-D32 downdraft carburetors deliver smooth throttle
response and efficient fuel consumption.

7. An intermediate sprocket is used between the crank and cams for
more compact engine design.

[A] Intermediate Shaft

8. The propeller shaft is built into the crankcase for a compact, low
mass drive train. The capacity of cam-damper is increased.

[A] Propeller Shaft

9. The KVF650A,B comes equipped with both an electric starter and a recoil starter. Together with KACR (Kawasaki
Automatic Compression Release), starting is quick and easy. The deviation of operating degree and lift is improved.

1-12 GENERAL INFORMATION

Technical Information — K-EBC System

1. Outline

This vehicle is equipped with the K-EBC (Kawasaki Engine Brake Control) system. It can assist the operator when

descending hills by supplementing the wheel brake systems with additional braking force that is produced by the engine.

When descending hills, the K-EBC system alone may not supply enough braking force. The operator should apply the
brakes to keep the speed safe for the type of terrain, visibility, operating conditions, and operator’s experience. The K-EBC
system is applied automatically under certain conditions when the throttle is released.

This system detects the ATV’s speed and running direction electrically, and when the conditions are met, a electric
actuator presses the torque converter drive pulley resulting in connecting the drive pulley with the driven pulley through
the belt and then generating braking force by the engine.

The K-EBC is a supplemental braking system when the speed is comparatively low (about 3 km/h — 20 km/h) and does
not function in reverse.

2. Wiring Diagram

The entire system is shown in the wiring diagram. The system is powered by a 12 Volt battery. Always keep the battery
connected even when the battery is discharged and operator needs to start engine. The engine can be started with the
recoil starter with the battery disconnected. However, the controller will not operate correctly.

GENERAL INFORMATION 1-13

Technical Information — K-EBC System

3. Component Parts

This system consists of a controller, actuator, lever assembly, forward/reverse detecting sensor, and a speed sensor.

1) Controller

The controller is located under the seat and controls the engine brake

and selectable 2WD/4WD actuators.

[A] Controller
[B] Igniter

2) Engine Brake Actuator

The engine brake actuator is installed on the converter cover. It

consists of a DC motor, reduction gears, and potentiometer.

[A] Engine Brake Actuator

[A] DC Motor
[B] Potentiometer
[C] Output Shaft

Engine Brake Actuator

1-14 GENERAL INFORMATION

Technical Information — K-EBC System

3) Lever Assembly

The lever assembly is installed in the converter cover. This transmits
the actuator’s force to the drive pulley.

[A] Contact Surface

4) Forward/Reverse Detecting Sensor

The sensor is installed on the engine and uses the principle of
electromagnetic induction. The sensor generates AC voltage according
to the speed of the rotor. The output waveforms vary in accordance
with the shape of the rotor teeth. The controller detects the running
direction from the waveforms.

[A] Forward/Reverse Detecting Sensor

GENERAL INFORMATION 1-15

Technical Information — K-EBC System

[A] Magnet
[B] Pole
[C] Coil

[A] Rotor Tooth

5) Speed Sensor

The sensor is installed on the engine and generates pulses according
to the gap difference between the sensor and the rotating gear. The
controller calculates the vehicle’s speed by counting the pulse sent from
the speed sensor.

[A] Speed Sensor

1-16 GENERAL INFORMATION

Technical Information — K-EBC System

Description of Actuator Controller Operation

1. Outline

The actuator controller has a microprocessor that detects the vehicle speed, the state of the selectable 2WD/4WD shift
switch, ignition switch, and the forward/reverse movement of the vehicle in order to control the engine brake and selectable
2WD/4WD actuators.

2. Engine Brake Actuator Controls

2–1 Learning Control

After the signal from the forward/reverse detecting sensor stops and 1 second elapses, turning the ignition switch OFF
causes the learning control to start.

After the ignition switch is turned OFF and a prescribed length of time elapses, current is applied to the actuator at a
prescribed duty factor in order to move the actuator towards engine brake ON position.

After the application of the current, if the actuator does not move within a prescribed length of time, the duty factor
increases in an attempt to move the actuator. This process is repeated until the actuator moves.

Once the actuator starts moving, the actuator continues to move at that duty factor.

The lever moves the drive pulley’s movable sheave until it contacts the belt. After contact with the belt, the actuator
cannot move any further because of the small duty cycle, and no more play in the system.

After the actuator stops moving, and a prescribed length of time elapses, the voltage (0 point = datum point) of the
potentiometer that is installed in the actuator is recorded on the EEPROM. The actuator returns to the engine brake OFF
position and the power to the controller turns OFF by the power ON/OFF circuit.

Learning Control

GENERAL INFORMATION 1-17

Technical Information — K-EBC System

In case the Learning Control has failed, the previously learned value is used for the 0-point position of the actuator.

1) When the voltage of the potentiometer that is installed in the actuator exceeds a prescribed voltage.

2) When the learning control has not finished within 10 seconds.

Canceling Learning Control

1-18 GENERAL INFORMATION

Technical Information — K-EBC System

2–2 Normal Control

After forward movement is detected from the forward/reverse detecting sensor:

1) If the vehicle speed is higher than the prescribed value, the actuator moves towards engine brake ON position.

2) If the vehicle speed is less than the prescribed value, the actuator moves towards engine brake OFF position.

The maximum movement of the actuator ranges between the starting position and the ending position. The actuator
moves from the learned 0-point position to a position to which a prescribed voltage has been added.

However, if the sum of the learned value and the prescribed voltage exceeds the voltage of the ending position, the
actuator stops at the ending position.

During actuator operation, if the target value is not attained even if the actuator is moved longer than a prescribed
length of time, the controller stops the actuator temporarily. After a prescribed length of time, the controller resumes the
movement of the actuator. This process is repeated until the actuator attains the target value.

Engine Brake Normal Control

2–3 Operation During Rapid Slow Down

This control works to avoid the engine stopping when the vehicle speeds down rapidly.

When the actuator is in the engine brake ON position, if the deceleration of the vehicle is greater than a prescribed rate
and is detected within an interval time of 10 milliseconds, the actuator returns to engine brake OFF position.

Operation During Rapid Slow Down

GENERAL INFORMATION 1-19

Technical Information — Selectable 2WD/4WD

1. Feature

Selectable 2WD/4WD system allows easy changing between 2WD

and 4WD drive systems to suit changing terrain and applications.

[A] 2WD/4WD Actuator
[B] Shifter

2. System Outline and Component Parts

This system consists of a 2WD/4WD shift switch, speed sensor, 2WD/4WD actuator, controller, and indicator for 2WD/

4WD.

See the wiring diagram in the K-EBC chapter.

(1) 2WD/4WD Shift Switch

The 2WD/4WD shift switch is installed on the right side of the

handlebar. This switch should be used when the vehicle is stopped.

(2) Speed Sensor

The sensor is installed on the right rear of the engine. It generates
pulses according to the gap difference between the sensor and the
rotating gear.

1-20 GENERAL INFORMATION

Technical Information — Selectable 2WD/4WD

(3) 2WD/4WD Actuator

The actuator is installed on the front gear case. It consists of a DC

motor, reduction gears, and potentiometer.

[A] 2WD/4WD Actuator

[A] Output Shaft of Actuator

This figure shows the operation of the actuator.

(4) Controller

Refer to the K-EBC chapter.

GENERAL INFORMATION 1-21

Technical Information — Selectable 2WD/4WD

2. Selectable 2WD/4WD Actuator Control

2–1 Switching 2WD to 4WD Control

1) Normal Control

This control operates only if the vehicle speed is within the range of 1 km/h and 20 km/h, and the selectable 2WD/4WD
shift switch is in 4WD.

The movement range of the actuator is between the starting position for 2WD, and the ending position for 4WD.

During actuator operation, at the time the potentiometer voltage becomes greater than a prescribed voltage, the indicator
light on the multifunction meter changes from 2WD to 4WD.

Selectable 2WD/4WD Normal Control

1-22 GENERAL INFORMATION

Technical Information — Selectable 2WD/4WD

2) 4WD Automatic Retry Control

During actuator operation, if the actual value does not reach the indicator light switching voltage even after the actuator
moves longer than a prescribed length of time, the actuator returns temporarily in the 2WD direction. After a prescribed
length of time elapses, the actuator moves again in the 4WD direction. This process is repeated until the actuator reaches
the indicator light switching voltage.

This control applies to vehicle speeds that range between 1 km/h and 20 km/h.

4WD Automatic Retry Control

GENERAL INFORMATION 1-23

Technical Information — Selectable 2WD/4WD

3) 4WD Holding Control

During the implementation of "4WD Automatic Retry Control", control transfers to "4WD Holding Control" at the time the
potentiometer voltage becomes greater than the indicator light switching voltage and the actuator movement is less than
the ending position.

If the actuator is pushed back toward the 2WD direction, this control moves the actuator in the 4WD direction in order
to return it to the final position. The interval times of the actuator movement consist of ON time toward 4WD and OFF
times, which are repeated until the potentiometer voltage reaches the final position.

This control applies to vehicle speeds that range between 1 km/h and 100 km/h. The control ends when the potentiometer
voltage reaches the ending position voltage.

When the vehicle speed is above 20 km/h, control continues even if the selectable 2WD/4WD shift switch is switched
to 2WD. When the vehicle speed is between 1 km/h to 20 km/h, this control stops and transfers to 2WD control.

2–2 Switching 4WD to 2WD Control

This control is in effect only when the vehicle speed is between 0 km/h and 20 km/h, and the selectable 2WD/4WD shift
switch is in 2WD.

The movement range of the actuator is between the starting position for 4WD, and the ending position for 2WD.

During actuator operation, at the time the potentiometer output voltage is ending position voltage, the indicator light on
the multifunction meter changes from 4WD to 2WD.

During actuator operation, if the potentiometer output voltage does not reach the ending position voltage even after the
actuator moves longer than a prescribed length of time, the actuator returns temporarily in the 4WD direction, and moves
again in the 2WD direction. This process is repeated until the actuator reaches 2WD position.

Switching 4WD to 2WD Control

1-24 GENERAL INFORMATION

Technical Information — Drive Belt Failure Detection System

1. Outline

This vehicle is equipped with a drive belt failure detection system which detects excessive belt wear or belt damage.

When a switch in the torque converter cover is activated, the multifunction meter LCD display and reverse indicator light
flash (for A2 and B2, belt check indicator light LED) a warning to the rider. The engine slows down (not to exceed 3,600
rpm), and the vehicle will try to shift into 2WD.

Inspection of the drive belt failure detection system is required in accordance with the Periodic Maintenance Chart by
an authorized Kawasaki dealer.

If the belt failure detection system is activated, the rider will return the vehicle immediately to an authorized Kawasaki
dealer for drive belt inspection, adjustment, or replacement.

2. Components of the system

[A] Drive Belt
[B] Drive Pulley
[C] Driven Pulley
[D] Drive Belt Failure Detection Switch
[E] Switch Activated
[F] Torque Converter Cover

GENERAL INFORMATION 1-25

Technical Information — Drive Belt Failure Detection System

3. Required action of rider when the system is activated

The rider must immediately return the vehicle to an authorized Kawasaki dealer for drive belt inspection and replacement.

4. Required action of dealer

1-26 GENERAL INFORMATION

Techinical Information — Variable Limited Slip Differential Control

This vehicle is equipped with a variable limited slip differential (LSD) for the front wheels. The differential control lever
is located on the left side of the handlebar.

When either front wheel loses traction, it can slip reducing the pulling power of the other front wheel. By pulling the
differential control lever, operators can equalize driving force to both front wheels. This is useful when the vehicle is stuck
or having difficulty overcoming an obstacle. The differential control lever is effective only when “4WD” is engaged.

When increased traction is needed, the operators can pull the control lever to the hand grip. Operators release the lever
when they no longer need greater traction.

The LSD control system consists of a control lever, cam plate, ball,
friction plates, steel plates, and housing.

While pulling the LSD control lever towards the handlebar, the front
wheels will be converted to the nearly locked-axle mode producing
greater traction.

Variable Differential Control Lever

Lever is located on the left side of the handlebar

[A] Variable Differential Lever

Plate Assembly

GENERAL INFORMATION 1-27

Techinical Information — Variable Limited Slip Differential Control

Camplate

[A] Cam Ball

Plates
[A] Friction Plate (Copper)
[B] Steel Plate

Housing

1-28 GENERAL INFORMATION

Technical Information — Rear Brake

The sealed, internal wet brake used at the rear is completely sealed
from mud and dust, etc. Its compact design allows ample ground
clearance. A new type of oil (Mobilfluid 424) must be used in the
housing.

If the brake lever lock is used, the rear brake can be used as a parking
brake. To lock the brake lever, first pull in the brake lever. Then pull
in the lock lever and while hoding it against the brake lever, release
the brake lever. When applied correctly the lock lever will contact a
projection in the brake lever holder and prevent the brake lever from
returning to the off position.

To unlock the brake lever, pull in the brake lever further and release
it.

[A] Cam Plate
[B] Lever

The lever is linked to the left side of the handlebar and to the foot
pedal on the right side.

[A] Cam Ball

Friction Plate

GENERAL INFORMATION 1-29

Technical Information — Rear Brake

Steel Plate

Important Notices at Maintenance



The brake plates should be replaced in accordance with the Periodic
Maintenance Chart (every 6,000 miles). Replacement should be done
by an authorized Kawasaki Dealer.



Use only the specified oil, Mobil Fluid 424, in the final gear case.

1-30 GENERAL INFORMATION

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 (Three Bond TB2471, Blue).

MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight

ratio 10:1).

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

Lh: Left-hand Threads

R: Replacement Parts

S: Follow the specific tightening sequence.

St: Stake the fasteners to prevent loosening.

Torque

Fastener N1m kgf1m ft1lb Remarks

Fuel System:

Heat guard plate mounting bolts 8.8 0.9 78 in1lb
Air cleaner housing bolts (M5) 5.9 0.6 52 in1lb L
Air cleaner housing bolts (M6) 28.7 mm (1.13 in.) 8.8 0.9 78 in1lb
Air cleaner housing bolts (M6) 33 mm (1.30 in.) 8.8 0.9 78 in1lb
Fuel tap plate screws 0.8 0.08 7in1lb
Air cleaner element bracket screws (A2, B2) 4.9 0.5 43 in1lb

Cooling System:

Radiator fan switch 18 1.8 13
Water pump cover bolts 8.8 0.9 78 in1lb
Coolant drain plug 8.8 0.9 78 in1lb
Water pump fitting bolt 9.8 1.0 87 in1lb
Water pump impeller 7.9 0.8 69 in1lb
Thermosta housing cover bolts 8.8 0.9 78 in1lb
Coolant temperature warning light switch 7.9 0.8 69 in1lb SS
Radiator fan mounting nut 2.7 0.28 24 in1lb L
Radiator fan assembly bolts 8.8 0.9 78 in1lb

Engine Top End:

Water pipe bolts 9.8 1.0 87 in1lb
Rocker case bolts 55 mm (2.2 in.) 8.8 0.9 78 in1lb S
Rocker case bolts 130 mm (5.1 in.) 9.8 1.0 87 in1lb S
Rocker case bolts 30 mm (1.2 in.) 9.8 1.0 87 in1lb
Rocker case bolts 25 mm (1.0 in.) 9.8 1.0 87 in1lb
Cylinder head bolts (M10), first torque 25 2.5 18 S, MO
Cylinder head bolt (M10), final torque 49 5.0 36 S
Cylinder head bolts (M6) 9.8 1.0 87 in1lb
Cylinder head jacket plugs 20 2.0 14 L
Valve adjusting cap bolts 8.8 0.9 78 in1lb
Valve adjusting screw locknuts 12 1.2 104 in1lb
Rocker shaft bolts 8.8 0.9 78 in1lb
Chain tensioner mounting bolts 8.8 0.9 78 in1lb
Chain tensioner cap bolt 22 2.2 16
Intermediate shaft sprocket nut 44 4.5 33
Intermediate shaft chain guide bolts 8.8 0.9 78 in1lb
Intermediate shaft chain tensioner bolts 8.8 0.9 78 in1lb
Camshaft sprocket bolts 12 1.2 104 in1lb L
Position plate bolts 8.8 0.9 78 in1lb
Cylinder bolts 40 mm (1.6 in.) 9.8 1.0 87 in1lb
Cylinder bolts 30 mm (1.2 in.) 9.8 1.0 87 in1lb

GENERAL INFORMATION 1-31

Torque and Locking Agent

Torque

Fastener N

1

m

kgf1m ft1lb Remarks

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 0.9 78 in1lb
Muffler cover bolts 8.8 0.9 78 in1lb
Muffler mounting bolts 20 2.0 14
Heat guard plate mounting bolts 8.8 0.9 78 in1lb

Converter System:

Drive pulley bolt 93 9.5 69 R, Lh
Driven pulley nut 93 9.5 69
Drive pulley cover bolts 13 1.3 113 in1lb
Ramp weight nuts 6.9 0.7 61 in1lb
Spider 275 28 205 Lh
Converter cover bolts 8.8 0.9 78 in1lb S
Joint duct bolts 8.8 0.9 78 in1lb
Engine brake actuator mounting bolts 8.8 0.9 78 in1lb

Recoil Starter:

Recoil starter mounting bolts 5.9 0.6 104 in1lb L
Recoil starter flange nut 8.3 0.85 74 in1lb

Engine Lubrication System:

Oil filter 18 1.8 13 in1lb R
Oil pressure switch 15 1.5 11 SS
Oil pipe bolts 8.8 0.9 78 in1lb
Engine drain plug 20 2.0 14
Oil pressure relief valve 15 1.5 11 L
Oil pump bolts 8.8 0.9 78 in1lb
Chain guide bolts 8.8 0.9 78 in1lb
Oil pump drive chain tensioner bolt 25 2.5 18
Oil filter mounting bolts 25 2.5 18 L
Oil pressure switch terminal bolt 1.5 0.15 13 in1lb

Engine Removal/Installation:

Engine mounting bracket bolts 23 2.3 17
Engine mounting bolt 59 6.0 43
Engine mounting nut 59 6.0 43

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, L(1)
Crankcase bolts (M6) 40 mm (1.57 in.) 9.8 1.0 78 in1lb
Crankcase bolts (M6) 65 mm (2.56 in.) 9.8 1.0 78 in1lb
Grip hold nut 9.8 1.0 87 in1lb
Shift lever assembly bracket bolts 20 2.0 14
Tie-rod end front locknut 9.8 1.0 87 in1lb Lh
Tie-rod end rear locknut 9.8 1.0 87 in1lb
Tie-rod end nut 20 2.0 14
Shift lever aseembly nut 20 2.0 14
Tie-rod end bolt 9.8 1.0 87 in1lb
Shift shaft positioning bolt 25 2.5 18
Shift shaft spring bolt 25 2.5 18 L
Shift shaft cover bolts 8.8 0.9 78 in1lb
Tie-rod end locknut 20 2.0 14

1-32 GENERAL INFORMATION

Torque and Locking Agent

Torque

Fastener N

1

m

kgf1m ft1lb Remarks

Neutral position switch 15 1.5 11
Reverse position switch 15 1.5 11

Wheel/Tires

Tie-rod adjusting sleeve locknuts 27 2.8 20
Tie-rod end nuts 42 4.3 31
Wheel nuts 78 8.0 58
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 in1lb
Output drive bevel gear cover bolts 8.8 0.9 78 in1lb

(Front Final Gear Case)

Variable front differential control shift

shaft lever bolt 8.8 0.9 78 in1lb
Front final gear case left cover bolts (M8) 9.8 1.0 87 in1lb
Ring gear bolts 57 5.8 42 LB
Front final gear case center cover bolts (M6) 9.8 1.0 87 in1lb L
Oil filler cap 29 3.0 22
Front final gear case center cover bolts (M8) 24 2.4 17 L
Pinion gear bearing holder nut 127 13 94 St
Pinion gear bearing holder 137 14 101 L
Front final gear case coupling nut (A1, B1-M8) 20 2.0 14
Front final gear case coupling nut (A2, B2-M10) 25 2.5 18
Oil drain plug 24 2.4 17
2WD/4WD actuator mounting bolts 9.8 1.0 87 in1lb L,S
Variable differential control cable locknut 17 1.7 12
Variable differential control lever bolt — — — L
Front final gear case bolts and nuts 59 6.0 43

(Rear Final Gear Case)

Oil filler cap 29 3.0 22
Oil drain plug 24 2.4 17
Pinion gear bearing holder 137 14 101 L
Pinion gear bearing holder nut 157 16 116 L
Rear final gear case right cover bolts (M8) 24 2.4 17 L
Rear final gear case right cover bolts (M10) 49 5.0 36 L
Rear final gear case left cover bolts 49 5.0 36
Rear final gear case bolts 42 4.3 31

Brakes:

Reservoir cap screws 1.5 0.15 13 in1lb
Brake lever pivot bolt 5.9 0.6 52 in1lb
Brake lever pivot bolt locknut 5.9 0.6 52 in1lb
Master cylinder clamp bolts 11 1.1 95 in1lb
Bake hose banjo bolt 25 2.5 18
Caliper mounting bolts 25 2.5 18

GENERAL INFORMATION 1-33

Torque and Locking Agent

Torque

Fastener N

1

m

kgf1m ft1lb Remarks

Bleed valves 7.9 0.8 69 in1lb
Disc mounting bolts 37 3.8 27 L
Variable differential control lever bolt – – – L
Gasket screws – – – L

Suspension:

Suspension arm pivot bolts 88 9.0 65
Front shock absorber mounting nuts 74 7.5 54
Front shock absorber clamp bolts and nuts 42 4.3 31
Steering knuckle joint nut 42 4.3 31
Rear shock absorber spring locknut 88 9.0 65
Rear shock absorber mounting nuts 62 6.3 46
Swingarm pivot right shaft 152 15.5 112 L
Swingarm pivot left shaft 20 2.0 14
Swingarm pivot left nut 152 15.5 112

Steering:

Handlebar holder bolts 29 3.0 22 S
Tie-rod adjusting sleeve locknuts 27 2.8 20
Tie-rod end nuts 42 4.3 31
Steering stem clamp bolts 25 2.5 18
Steering stem bottom end nut 64 6.5 47
Master cylinder clamp bolts 11 1.1 95 in1lb
Front shock absorber clamp bolts and nuts 42 4.3 31
Steering knuckle joint nut 42 4.3 31
Variable differential control lever bolt – – – L

Frame

Trailer hitch bracket bolts (M8) 24 2.4 17 L
Trailer hitch bracket bolts (M10) 49 5.0 36 L
Front lower guard bolts 29 3.0 22
Rear carrier lower bolts 54 5.5 40 L
Rear carrier upper bolts and nuts 37 3.8 27
Engine mounting bracket bolts 23 2.3 17
Engine mounting nuts 59 6.0 43
Front final gear case bolts and nuts 59 6.0 43
Rear carrier upper bolts and nuts 37 3.8 27

Electrical System:

Starter motor mounting bolts 8.8 0.9 78 in1lb
Starter motor terminal nut 4.9 0.5 43 in1lb
Starter motor terminal locknut 6.9 0.7 61 in1lb
Starter motor bolts 3.9 0.4 35 in1lb
Starter motor clutch bolts 34 3.5 25 L
Alternator stator bolts 13 1.3 113 in1lb
Pickup coil mounting bolts 5.9 0.6 52 in1lb
Alternator cover plugs 18 1.8 13
Alternator rotor bolt 127 13 94 O
Alternator cover bolts 8.8 0.9 78 in1lb
Spark plugs 13 1.3 113 in1lb
2WD/4WD actuator mounting bolts 9.8 1.0 87 in1lb L,S
Engine brake actuator mounting bolts 8.8 0.9 78 in1lb
Forward/Reverse detectring sensor mounting bolt 15 1.5 11
Speed sensor mounting bolt 8.8 0.9 78 in1lb
Neutral position switch 15 1.5 11

1-34 GENERAL INFORMATION

Torque and Locking Agent

Torque

Fastener N

1

m

kgf1m ft1lb Remarks

Reverse position switch 15 1.5 11
Radiator fan switch 18 1.8 13
Coolant temperature warning light switch 7.9 0.8 69 in1lb SS
Oil pressure switch 15 1.5 11 SS
Oil pressure switch terminal bolt 1.5 0.15 13 in1lb

The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this
tabel for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry
solvent-cleaned threads.

Basic Torque for General Fasteners of Engine Parts

Threads dia. Mark of Torque

mm (in.) bolt head N1m kgf1m ft1lb

6 (0.24) 9T 12 15 1.2 1.5 104 130 in1lb
6 (0.24) 7T 7.8 9.8 0.8 1.0 69 87 in1lb
6 (0.24) 4T 3.9 4.9 0.4 0.5 35 43 in1lb
8 (0.31) 7T 18 22 1.8 2.2 13 16

8 (0.31) 4T 10 14 1.0 1.4 87 122 in1lb
10 (0.39) 7T 39 44 4.0 4.5 29 33
10 (0.39) 4T 20 24 2.0 2.4 14 17

5 (0.20) 4T 2.2 2.6 0.22 0.27 19 23 in1lb

Basic Torque for General Fasteners of Frame Parts

Threads dia. Torque

mm (in.) N1m kgf1m ft1lb

5 (0.20) 3.4 4.9 0.35 0.5 30 43 in1lb
6 (0.24) 5.9 7.8 0.6 0.8 52 69 in1lb

8 (0.31) 14 19 1.4 1.9 10.0 13.5
10 (0.39) 25 34 2.6 3.5 19.0 25
12 (0.47) 44 61 4.5 6.2 33 45
14 (0.55) 73 98 7.4 10.0 54 72
16 (0.63) 115 155 11.5 16.0 83 115
18 (0.71) 165 225 17.0 23.0 125 165
20 (0.79) 225 325 23 33 165 240

GENERAL INFORMATION 1-35

Special Tools and Sealant

Bearing Puller : 57001–135

Inside Circlip Pliers : 57001–143

Outside Circlip Pliers : 57001–144

Circlip Pliers : 57001–154

Oil Pressure Gauge, 10 kgf/cm2: 57001–164

Compression Gauge : 57001–221

Valve Spring Compressor Assembly : 57001–241

Piston Pin Puller Assembly : 57001–910

Fuel Level Gauge : 57001–1017

Oil Pressure Gauge Adapter, PT 1/8 : 57001–1033

1-36 GENERAL INFORMATION

Special Tools and Sealant

Oil Seal & Bearing Remover : 57001–1058

Hook Wrench : 57001–1101

Valve Seat Cutter, 45– 27.5 : 57001–1114

Valve Seat Cutter, 32– 28 : 57001–1119

Valve Seat Cutter, 60– 30 : 57001–1123

Valve Seat Cutter Holder,

5 : 57001–1208

Valve Seat Cutter Holder Bar : 57001–1128

Bearing Driver Set : 57001–1129

Valve Seat Cutter, 45– 30 : 57001–1187

Valve Seat Cutter, 32– 33 : 57001–1199

GENERAL INFORMATION 1-37

Special Tools and Sealant

Valve Spring Compressor Adapter, 22 : 57001–1202

Valve Guide Arbor, 5 : 57001–1203

Valve Guide Reamer, 5 : 57001–1204

Piston Pin Puller Adapter : 57001–1211

Jack : 57001–1238

Pilot Screw Adjuster, A : 57001–1239

Timing Light : 57001–1241

Oil Filter Wrench : 57001–1249

Bearing Remover Shaft, 9 : 57001–1265

Bearing Remover Head, 10 x 12 : 57001–1266

1-38 GENERAL INFORMATION

Special Tools and Sealant

Carburetor Drain Plug Wrench, Hex 3 : 57001–1269

Flywheel Holder : 57001–1313

Flywheel & Pulley Holder : 57001–1343

Socket Wrench : 57001–1363

Hand Tester : 57001–1394

Flywheel Puller Assembly : 57001–1405

Drive & Driven Pulley Holder : 57001–1412

Drive Pulley Puller Bolt : 57001–1429

Needle Adapter Set : 57001–1457

Pulley Holder Attachment : 57001–1472

GENERAL INFORMATION 1-39

Special Tools and Sealant

Drive & Driven Pulley Holder : 57001–1473

Drive Pulley Wrench : 57001–1474

Damper Spring Compressor Set : 57001–1475

Holder & Guide Arbor : 57001–1476

Spacer & Holder : 57001–1477

Socket Wrench, Hex 50 : 57001–1478

Output Shaft Holder & Spacer : 57001–1479

Pinion Gear Holder : 57001–1480

Nut Holding Bolts : 57001–1481

Socket Wench : 57001–1482

1-40 GENERAL INFORMATION

Special Tools and Sealant

Spring Holder Set : 57001–1483

Socket Wrench, Hex 41 : 57001–1484

Pinion Gear Holder : 57001–1485

Compression Gauge Adapter, M10 x 1.0 : 57001–1486

Oil Seal Driver: 57001–1487

Gear Holder & Socket Wrench, Hex 24 : 57001–1489

Hexagon Wench, Hex 41 : 57001–1491

Drive Pulley Measurement Tool : 57001–1498

Actuator Lever Measurement Tool : 57001–1499

Oil Seal Driver, 18 : 57001–1505

GENERAL INFORMATION 1-41

Special Tools and Sealant

Oil Seal Driver, 48: 57001–1506

Drive Pulley Holder: 57001–1520

Kawasaki Bond (Silicone Sealant) : 56019–120

1-42 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Tube

2. Clamp

3. Align the white paint mark on the tube with the adjustment mark on the crankcase.

4. Electric Starter

GENERAL INFORMATION 1-43

Cable, Wire, and Hose Routing

1. Cooling Hoses

2. Clamps (Install the clamps with the tabs direction as shown.)

3. Coolant Valve

4. Position the white marks on the tube as shown.

5. Damper

6. Clamps

1-44 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Clamp

2. Engine Ground Lead

3. Install the clamp on the engine ground lead.

GENERAL INFORMATION 1-45

Cable, Wire, and Hose Routing

1. Water Pipe

2. White Paint

3. Clamps

4. Cooling Hoses

5. Coolant Filter Body

6. Coolant Filter

7. Carburetor

8. Mark

9. Cooling Hose

10. Assemble Angle (about 45



, [4] and [9] hoses)

11. Cooling Hose

1-46 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. White Paint

2. Water Pipe

3. Clamp

4. Heat Guard Plate

5. Cooling Hose

6. To Carburetor

7. Carburetor Overflow Tube

8. Exhaust Pipe Cover

9. Tube

10. Breather

11. Pump Cover

12. Mark

13. To Radiator

14. Mat

15. Duct

GENERAL INFORMATION 1-47

Cable, Wire, and Hose Routing

1. Duct

2. Clamps

3. Clamps

4. Boots

5. Clamp

6. Vent Hose

7. Coolant Valve

8. Coolant Tube

9. Starter Cable

10. Carburetor

11. Clamps

12. Air Vent Tube

1-48 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Clamps

2. Bands

3. Ignition Coil (Rear)

4. Clamp

5. Clamp

6. Clamp

7. Drain Plug

8. Drain Hose

9. Vent Hose

GENERAL INFORMATION 1-49

Cable, Wire, and Hose Routing

1. Rear Final Gear Case Breather Tube

2. Front Final Gear Case Breather Tube

3. Radiator Fan Motor Breather Tube

4. 2WD/4WD Actuator Breather Tube

5. Clamp

6. Coolant Hose

7. Screen

8. Radiator

9. Coolant Breather Tube

10. Reservoir

11. Fan Switch

12. Fuel Breather Tube (To Frame Hole)

13. Band

1-50 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. 2WD/4WD Actuator Lead

2. Breather Tube

3. Cooling Hose

4. Bracket

5. Band

6. Clamp

GENERAL INFORMATION 1-51

Cable, Wire, and Hose Routing

1. Battery Negative Lead

2. Battery Positive Lead

3. Main Harness

4. To Engine

5. Clamp

6. To Tail Lamp

7. Band

8. Run the fuse lead under the igniter leads.

9. Band

10. Run the fuse lead under the battery negative and
positive leads.

1-52 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Brake Switch Lead

2. Rear Final Gear Case Breather Tube

3. Sensor Harness

4. Brake Cable (Parking)

5. Throttle Cable

6. Starter Cable

7. Variable Front Differential Control Cable

8. Brake Hose

9. Brake Cable (Rear)

10. Brake Switch

11. Band

GENERAL INFORMATION 1-53

Cable, Wire, and Hose Routing

1. To Throttle Lever

2. To Left Switch Box

3. To Carburetor

4. Clamp

5. To Rear Carburetor

6. To Front Carburetor

7. Bracket

8. Starter Cable

9. Reservoir

10. Band

11. Set the starter cables to the frame after installing
the cable ends to the carburetors.

1-54 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Grommet

2. Head Lamp Leads

3. Clamp

4. Band

5. Front Brake Lead

6. Lead for Speed Sensor

7. Main Harness

8. Harness (Under of Pipe)

GENERAL INFORMATION 1-55

Cable, Wire, and Hose Routing

1. Band

2. Clamp

3. Must be inside of frame

4. To Meter and Handlebar Switch

5. To Brake Switch and ACC (on the Hose)

6. Ground Lead (for Multifunction Meter)

7. On the Main Harness

8. Clamps (for the A2, B2 Models)

1-56 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Band

2. To Engine

3. Fuel Breather Tube (To Frame Hole)

4. To 2WD/4WD Actuator

GENERAL INFORMATION 1-57

Cable, Wire, and Hose Routing

1. Rear Brake Lever

2. Parking Brake Lock Lever

3. Variable Front Differential Control Cable

4. Cable Adjuster

5. Variable Front Differential Control Lever

6. Handle Holder Clamp

7. Variable Front Differential Operating Lever

1-58 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Fuel Tap

2. Clamp (Grip end faces inward.)

3. Fuel Hose

GENERAL INFORMATION 1-59

Cable, Wire, and Hose Routing

1. Band

2. Relay Assy

3. Diode

4. Harness

5. To Battery

6. To Fuel Pump

7. To 2WD/4WD Actuator

8. Clamp (Grip end faces inward.)

1-60 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Bands

2. Re-set Connector

3. Drive Belt Failure Detection Switch Connector

4. Harness

5. To Battery

6. To Fuel Pump

7. To 2WD/4WD Actuator

8. Clamp (Grip end faces inward.)

9. Clamp

FUEL SYSTEM 2-1

Fuel System

Table of Contents

2

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

Specifications............................................................. 2-6

Throttle Lever and Cable............................................2-7

Throttle Lever Free Play Inspection .................... 2-7

Throttle Lever Free Play Adjustment ...................2-7

Throttle Case Removal/Disassembly.................. 2-7

Throttle Case Assembly/Installation....................2-8

Throttle Cable Installation....................................2-8

Throttle Case Inspection ..................................... 2-9

Throttle Cable Lubrication ................................... 2-9

Throttle Cable Inspection .................................... 2-9

Choke Lever and Cable............................................2-10

Choke Lever Free Play Check...........................2-10

Choke Lever Free Play Adjustment...................2-10

Choke Lever and Cable Removal ..................... 2-10

Choke Lever and Cable Installation .................. 2-12

Choke Cable Lubrication...................................2-12

Choke Cable Inspection ....................................2-12

Carburetor................................................................ 2-13

Idling Speed Inspection.....................................2-13

Idle Speed Adjustment...................................... 2-13

Pilot Screw Adjustment ..................................... 2-13

Service Fuel Level Inspection ...........................2-13

Service Fuel Level Adjustment..........................2-14

Carburetor Synchronization Inspection............. 2-15

Carburetor Synchronization Adjustment............2-15

Fuel System Cleanliness Inspection.................2-16

Carburetor Removal .......................................... 2-16

Carburetor Installation ....................................... 2-17

Carburetor Disassembly....................................2-17

Carburetor Assembly.........................................2-18

Carburetor Separation.......................................2-19

Carburetor Joining.............................................2-19

Carburetor Cleaning .......................................... 2-20

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

Air Cleaner ...............................................................2-23

Air Cleaner Element Removal (KVF650–A1/B1)2-23
Air Cleaner Element Removal (KVF650–A2/B2)2-23
Air Cleaner Element Installation (KVF650–A1/

B1).....................................................................2-24

Air Cleaner Element Cleaning and Inspection..2-24

Air Cleaner Draining (KVF650–A1/B1)..............2-25

Air Cleaner Draining (KVF650–A2/B2)..............2-25

Air Cleaner Housing Removal...........................2-25

Air Cleaner Housing Installation........................2-27

Fuel Tank..................................................................2-29

Fuel Tank Removal............................................2-29

Fuel Tank Installation.........................................2-29

Fuel Tank Cleaning............................................2-30

Fuel Tap Removal..............................................2-30

Fuel Tap Installation .......................................... 2-30

Fuel Tap Inspection ...........................................2-31

Fuel Pump ................................................................2-32

Fuel Pump Removal..........................................2-32

Pump Filter Cleaning.........................................2-32

Fuel Pump Installation.......................................2-33

Fuel Pump Inspection........................................2-33

2-2 FUEL SYSTEM

Exploded View

FUEL SYSTEM 2-3

Exploded View

Torque

No. Fastener N1m kgf1m ft1lb Remarks

1 Heat guard plate mounting bolts 8.8 0.9 78 in1lb

2: Choke lever
3: Choke cable
4: Throttle cable

5. Throttle lever
6: Jet needle
7: Pilot jet
8: Main jet

9: Needle jet
10: Pilot screw
11: Priming pump

O: Apply engine oil.

Gr: Apply grease.

CA: Canada model

2-4 FUEL SYSTEM

Exploded View

FUEL SYSTEM 2-5

Exploded View

Torque

No. Fastener N1m kgf1m ft1lb Remarks

1 Air cleaner housing bolts (M5) 5.9 0.6 52 in1lb L

2 Air cleaner housing bolts (M6) 28.7 mm (1.13 in.) 8.8 0.9 78 in1lb

3 Air cleaner housing bolts (M6) 33 mm (1.30 in.) 8.8 0.9 78 in1lb

4 Fuel tap plate screws 0.8 0.08 7in1lb

5 Air cleaner element bracket screws 4.9 0.5 43 in1lb

6: Fuel pump

7: Fuel tank breather

8: Check valve

9: Insert the fuel breather tube end into the frame hole.

L: Apply a non-permanent locking agent.
Gr: Apply grease.

R: Replacement Part (Fuel Pump Gasket)

A1: KVF650–A1/B1
A2: KVF650–A2/B2

2-6 FUEL SYSTEM

Specifications

Item

Standard Service Limit

Throttle Case and Cable:

Throttle lever free play 2 3 mm (0.08 ~ 0.12 in.) –––

Choke Lever and Cable:

Choke lever free play about 3 mm (0.12 in.) –––

Carburetor:

Make/Type KEIHIN, CVKR-D32 –––

Main jet: Front #138 –––

Rear #142 –––

Main air jet: #80 –––

Needle jet: #6 –––

Jet needle NAZH –––

Pilot jet #40 –––

Pilot air jet #130 –––

Pilot screw 2 1/4 turns out –––

Carburetor synchronization vacuum less than 2.7 kPa (2 cmHg) –––

difference between carburetors

Starter jet #100 –––

Idle speed 1100 ± 50 r/min (rpm) –––

Service fuel level 15 ± 1 mm (0.59 ± 0.04 in.) –––

(KVF650-A1/B1)

12 ± 1 mm (0.47 ± 0.04 in.)

(KVF650-A2/B2)

below the punch mar k

Float height 4.0 ± 1 mm (0.16 ± 0.04 in.) –––

Optional parts:

Main jet:

*Altitude:

0 500 m (0 ~ 1600 ft): Front #138 (92063-1015) –––

Rear #142 (92063-1016) –––

500 1500 m (1600 ~ 4900 ft): Front #135 (92063-1014) –––

Rear #140 (92063-1013) –––

1500 2500 m (4900 ~ 8200 ft): Front #132 (92063-1076) –––

Rear #138 (92063-1015) –––

2500 3500 m (8200 ~ 11500 ft): Front #130 (92063-1075) –––

Rear #132 (92063-1076) –––

3500 4500 m (11500 ~ 14800 ft): Front #125 (92063-1069) –––

Rear #130 (92063-1075) –––

Air Cleaner:

Air cleaner element oil High-quality foam air filter oil –––

*: Refer to pg. 5–26 for high altitude setting in the converter system.

Special Tools - Fuel Level Gauge: 57001–1017

Carburetor Drain Plug Wrench, Hex 3: 57001–1269
Pilot Screw Adjuster, A: 57001–1239

FUEL SYSTEM 2-7

Throttle Lever and Cable

Throttle Lever Free Play Inspection

•

Check that the throttle lever moves smoothly from full open to close,
and the throttle closes quickly and completely in all steering positions
by the return spring.
If the throttle lever does not return properly, check the throttle cable
routing, lever free play, and for possible cable damage. Then lubricate
the throttle cable.

•

Run the engine at the idle speed, and turn the handlebar all the way
to the right and left to ensure that the idle speed does not change.
If the idle speed increases, check the throttle cable free play and the
cable routing.

•

Stop the engine and check the throttle lever free play [A].
If the free play is not within the specified range, adjust the cable.

Throttle Lever Free Play

Standard: 2

3 mm (0.08 ~ 0.12 in.)

Throttle Lever Free Play Adjustment

•

Remove the handle cover (see Multifunction Meter Unit Removal in
Electrical System chapter).

•

Slide the rubber cover off the adjuster at the throttle case.

•

Loosen the locknut [A] and turn the throttle cable upper adjuster [B]
until the cable has proper amount of play.

•

Tighten the locknut and reinstall the rubber cover.

If the free play cannot be adjusted by using the upper cable adjuster,
remove the air cleaner housing and then use the cable adjusting nuts
[A] at the lower end of the throttle cable and make the necessary free
play.

Throttle Case Removal/Disassembly

•

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

•

Slide the cable adjuster dust cover out of place.

2-8 FUEL SYSTEM

Throttle Lever and Cable

•

Remove the rubber cover [A].

•

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

•

Loosen the locknut [B] and unscrew the adjuster [C].

•

Disassemble the throttle case as follows:



Remove the throttle lever screw [D], lockwasher, and flat washer, and
lift the throttle lever [E] and return spring from the case.



Pull the throttle control lever [F] out of the case.

Throttle Case Assembly/Installation

•

Lubricate the throttle case and cable before assembly/installation.

•

Be certain that the return spring is correctly installed on the throttle
lever [A].

•

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

NOTE



Refer to the Owner’s Manual for the function of the throttle limiter
and adjustment procedure of it.

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

•

Check the throttle lever free play (see Throttle Lever Free Play
Inspection).

Throttle Cable Installation

•

Lubricate the throttle cable before installation.

•

Route the cable correctly according to the General Information
chapter.

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

•

Check the throttle cable (see Throttle Lever Free Play Inspection).

FUEL SYSTEM 2-9

Throttle Lever and Cable

Throttle Case Inspection

•

With the throttle cable disconnected from the throttle lever, the lever
should move freely and return smoothly by spring.
If the lever is heavy, disassemble the throttle case, clean and lubricate
the throttle case.

•

Examine the lever and case for cracks. Replace the case assembly
if it is cracked.

Throttle Cable Lubrication

Whenever the throttle cable is removed, lubricate the cable as follows:

•

Apply a small amount of multi-purpose grease to the cable both ends.

•

Lubricate the cable with a penetrating rust inhibitor through the
pressure cable luber.

Throttle Cable Inspection

•

With the throttle cable disconnected at both ends, the cable should
move freely within the cable housing.
If the cable does not move freely after lubricating, if the cable is frayed,
or if the housing is kinked, replace the cable.

2-10 FUEL SYSTEM

Choke Lever and Cable

Choke Lever Free Play Check

•

Check if the choke lever [A] returns properly and if the inner cable
slides smoothly.

•

Make sure that the choke lever returns to its released position all the
way.

•

To determine the amount of choke cable play at the lever, pull the
choke lever to the left until feeling the operation of the lever tough;
the amount of choke lever is equivalent to that of cable play.

•

The proper amount of play ranges about 3 mm (0.12 in.) at the choke
lever.
If the free play is not within the specified range, adjust the cable.

Choke Lever Free Play [B]

Standard: about 3 mm (0.12 in.)

Choke Lever Free Play Adjustment

•

Remove:

Handle Cover Screws [A]
Handle Cover Front [B]

•

Loosen the locknut [A] of the choke cable.

•

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

•

Tighten the locknut securely.

Choke Lever and Cable Removal

•

Remove the air cleaner housing (see Air Cleaner Housing Removal).

•

Remove the carburetor from the carburetor holder.

•

Remove the holder plates [A] and screws.

•

Pull out the starter plungers.

FUEL SYSTEM 2-11

Choke Lever and Cable

•

Hold the starter plunger springs compressed, and free the choke
cable lower ends [A] from the plungers [B].

•

Remove:

Choke Lever Mounting Screw [A], Plane Washer, and Wave Washer

Switch Case Mounting Screws [B]

•

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

•

Pull off the retaining clip [A].

•

Fit the cable end [A] in the grommet [B], and free the cable from the
switch case.

•

Pull the cable out of the vehicle.

2-12 FUEL SYSTEM

Choke Lever and Cable

Choke Lever and Cable Installation

•

Lubricate the choke cable before installation.

•

Install the wave washer, plaine washer and screw in that order.

•

Route the choke cable according to the General Information chapter.

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

Choke Cable Lubrication

Whenever the choke cable is removed, lubricate the cable as follows:

•

Lubricate the cable with a penetrating rust inhibitor through the
pressure cable luber.

Choke Cable Inspection

•

With the choke cable disconnected at both ends, the cable should
move freely in the cable housing.
If the cable does not move freely after lubricating, if the cable is frayed,
or if the housing is kinked, replace the cable.

FUEL SYSTEM 2-13

Carburetor

Idling Speed Inspection

•

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides to check for
any changes in the idle speed.
If handlebar movement changes the idle speed, the throttle cables
may be improperly adjusted incorrectly routed, or damaged. Be sure
to correct any of these conditions before riding.

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

•

Check idle speed with a suitable tachometer.
If the idle speed is out of the specified range, adjust it.

Idle Speed

Standard: 1,100 ± 50 r/min (rpm)

Idle Speed Adjustment

•

Start the engine and warm it up thoroughly.

•

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



Open and close the throttle a few times to make sure that the idle
speed is within the specified range. Readjust if necessary.

Pilot Screw Adjustment

•

Adjust the pilot screw if necessary.

•

Remove the air cleaner cover (see Frame chapter).

•

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

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

CAUTION

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

•

Back the pilot screw out the specified number of turns.

Carburetor Pilot Screw Setting

Standard: 2 1/4 turns out

Service Fuel Level Inspection

Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch OFF. Do not
smoke. Make sure the area is well ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.

•

Remove the carburetor (see Carburetor Removal).

2-14 FUEL SYSTEM

Carburetor

•

Set the carburetor [A], fuel level gauge [B], and fuel [C] as follows.

Special Tool - Fuel Level Gauge: 57001–1017



Place the additional graduation [D] 10 mm (0.39 in.) higher than the
top graduation [E].



Put the carburetor horizontally and so that the outlet side faces
downward.



Connect the fuel gauge and hose to the drain fitting of the carburetor.



Connect the fuel to the fuel inlet fitting.

210 mm (8.27 in.) [F]
12 mm (0.47 in.) [G]



Hold the gauge so that the additional graduation is placed slightly
higher than the punch mark [H].



Feed the fuel into the carburetor, then loosen the carburetor drain
screw.

Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001–1269

•

Wait until the fuel level in the gauge settles.

•

Hold the gauge vertically and lower it slowly so that the additional
graduation aligns with the punch mark.

NOTE



Do not align the additional graduation on the gauge lower than the
punch mark. If it is lowered and then raised, the gauge will show
a fluid level that is higher than the actual level, which will require a
remeasurement.

•

Read the fuel level [G].
If the fuel level is incorrect, adjust it.

Service Fuel Level

Standard: 12 ± 1 mm (0.47 ± 0.04 in.) below the punch mark

•

Tighten the drain screw.

•

Repeat the same procedure for the other carburetor.

Service Fuel Level Adjustment

Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch to OFF. Do not
smoke. Make sure the area is well-ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.

•

Remove the carburetors, and drain the fuel.

•

Remove the float chamber.

•

Remove the screw [A].

•

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

•

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

FUEL SYSTEM 2-15

Carburetor

Float Height

Standard: 4.0 ± 1 mm (0.157 ± 0.040 in.)



Measure the float height [A] from the mating surface [B] of float by
tilting the carburetor so that the tang of the float [C] just touches
the needle rod [D]. At this time, the float valve [E] rod must not be
depressed.



Increasing the float height lowers the fuel level and decreasing the
float height raises the fuel level.

•

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

Carburetor Synchronization Inspection

•

Check idle speed.

•

Remove:

Air Cleaner Cover

Fuel Tap [A]

Caps [B] on the Carburetor Holder

•

Connect the battery wires to the battery.

•

Attach a suitable vacuum gauge [A] to the fitting on the carburetor
holder.

•

Start the engine and read the intake vacuum of each carburetor when
idling.
If the vacuum is out of the specified range, adjust it.

Carburetor Synchronization Vacuum

Standard: Less than 2.7 kPa (2 cmHg) difference between

carburetors

Carburetor Synchronization Adjustment

•

Turn the adjust screw [A] to synchronize the carburetors.
If the carburetor synchronization cannot be obtained by using the
adjusting screw, check for dirt or blockage, and then check the pilot
screw settings.

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

•

Check the carburetor synchronization again.

NOTE



Do not turn the pilot screws carelessly during carburetor synchro­nization. You may cause poor running at low engine speed.

•

Check idle speed.

2-16 FUEL SYSTEM

Carburetor

Fuel System Cleanliness Inspection

Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch to OFF. Do not
smoke. Make sure the area is well-ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.

•

Place a suitable container under the drain plugs [A].

•

Remove the carburetor drain plug and check to see if water or dirt
comes out.
If any water or dirt appears during the above inspection, clean the
carburetors and the fuel tank.

Carburetor Removal

Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch OFF. Do not
smoke. Make sure the area is well ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.

•

Drain the coolant (see Cooling System chapter).

•

Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)
Side Cover (see Frame chapter)
Bolts [A] and Heat Guard Plate [B]
Throttle Cable Lower End
Fuel Hose
Coolant Hoses

•

Loosen the clamp screws [A] on the carburetor holders.

•

Remove the carburetor out of the frame.

•

Remove the screws [A] and holder plates [B].

•

Pull out of the starter plungers.

FUEL SYSTEM 2-17

Carburetor

Carburetor Installation

•

Check fuel leakage from the carburetors.

Fuel spilled from the carburetors is hazardous.

•

Adjust the idle speed (see Idle Speed Adjustment).

•

Check the throttle cable (see Throttle Lever Free Play Inspection).

•

Tighten:

Torque - Heat Guard Plate Mounting Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)

Carburetor Disassembly

•

Remove the carburetors (see Carburetor Removal).

Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch to OFF. Do not
smoke. Make sure the area is well-ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.

NOTE



The carburetors can be disassembled in the joined state.

•

Remove the upper chamber cover [A], spring [B], and vacuum piston
[C].

CAUTION

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

•

Remove the jet needle [D] from the vacuum piston. These can be
detached together with the spring seat [E].



Do not remove the pilot screw if possible, synchronization of the
carburetors is necessary if pilot screws are removed (see Pilot Screw
Adjustment).

•

Remove:

Screws [A]
Float Chamber [B]

2-18 FUEL SYSTEM

Carburetor

•

Remove:

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

•

Remove:

Screws [A]
Coasting Enricher Cover [B]

•

Remove:

Diaphragm [A]
O-ring [B]

Carburetor Assembly

Fuel spilled from the carburetors is hazardous.

CAUTION

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

•

Install the float valve needle in the valve seat and hook the needle
hanger [A] onto the float tang.

•

Insert the float pivot pin [B] into the pivot post and the float.

•

Tighten the screw [C].

•

Set the float to the standard height (see Service Fuel Level Adjust­ment).

FUEL SYSTEM 2-19

Carburetor

•

Insert the jet needle [A] into the hole in the center of the vacuum
piston [B], and place the spring seat [C] over the needle.

•

Slip the needle through the hole in the center of the vacuum piston,
and put the spring seat [A] on the top of the needle. Turn the seat so
that it does not block the hole [B] at the bottom of the vacuum piston.

•

After installing the upper chamber cover, check that the vacuum piston
slides up and down smoothly without binding in the carburetor bore.

•

Fit the projection [A] of the vacuum piston diaphragm in the recess
[B] of the body.

•

After installing the upper chamber cover, check to make sure that the
vacuum piston moves smoothly in the carburetor body.

Carburetor Separation

•

Remove:

Carburetor (see Carburetor Removal)

Carburetor Joining Bolts [A] and Nuts

•

Separate the carburetors.

Carburetor Joining

•

The center lines of the carburetor bores must be parallel both
horizontally and vertically. If they are not, loosen the mounting screws
and align the carburetors on a flat surface.

•

Retighten the carburetor joining bolts.

2-20 FUEL SYSTEM

Carburetor

•

Visually synchronize the throttle (butterfly) valves.



Check to see that all throttle valves open and close smoothly without
binding when turning the pulley.



Visually check the clearance [A] between the throttle valve and the
carburetor bore in each carburetor.
If there is a difference between two carburetors, turn the balance
adjusting screw [B] to obtain the same clearance.

•

Install the carburetors (see Carburetor Installation).

•

Adjust the synchronization (see Synchronization Adjustment).

Carburetor Cleaning

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

CAUTION

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

•

Disassemble the carburetor and clean all the metal parts in a
carburetor cleaning solution.

•

Rinse the parts in water and dry them with compressed air.

•

Blow through the air and fuel passages with compressed air.

•

Remove the float valve, spray cleaning solution from the valve seating
surface into the fuel passage, and clean the strainer (press-fitted) with
compressed air [A].

•

Assemble the carburetor (see Carburetor Assembly).

Carburetor Inspection

Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch OFF. Do not
smoke. Make sure the area is well ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.

•

Remove the carburetor (see Carburetor Removal).

•

Before disassembling the carburetors, check the fuel level (see Fuel
Level Inspection).

FUEL SYSTEM 2-21

Carburetor

•

Turn the throttle cable pulley [A] to check that the throttle butterfly
valve [B] moves smoothly and return back with the spring tension.
If the throttle valve does not move smoothly, replace the carburetor.

•

Disassemble the carburetors (see Carburetor Disassembly).

•

Clean the carburetor (see Carburetor Cleaning).

•

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

•

Check the plastic tip [A] of the float valve needle. It should be smooth,
without any grooves, scratches, or tears.
If the plastic tip is damaged [B], replace the float valve [C].

•

Push the rod [D] in the other end of the float valve needle and then
release it.
If it does not spring out, replace the float valve.

•

Check the tapered portion [A] of the pilot screw for wear or damage.
If the pilot screw is worn or damaged on the tapered portion, it will
prevent the engine from idling smoothly. Replace it.

2-22 FUEL SYSTEM

Carburetor

•

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

FUEL SYSTEM 2-23

Air Cleaner

Air Cleaner Element Removal (KVF650–A1/B1)

•

Remove:

Air Cleaner Upper Cover (see Frame chapter)

Clips [A]

Air Cleaner Housing Cap [B]

•

Remove:

Element [A]

•

After removing the element, stuff pieces of lint-free, clean cloth into
the air cleaner ducts to keep dirt out of the carburetor and engine.

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

CAUTION

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

•

Remove:

Upper Holder [A]

Element [B]

Lower Holder [C]

Air Cleaner Element Removal (KVF650–A2/B2)

•

Remove:

Air Cleaner Upper Cover (see Frame chapter)

Clips [A]

Air Cleaner Housing Cap [B]

2-24 FUEL SYSTEM

Air Cleaner

•

Remove:

Thumbscrew [A]
Metal mesh [B] with element

•

After removing the element, stuff pieces of lint-free, clean cloth into
the air cleaner ducts to keep dirt out of the carburetor and engine.

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

CAUTION

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

•

Separate metal mesh [A] and element [B].

Air Cleaner Element Installation (KVF650–A1/B1)

•

Install the element with the yellow side facing up.

Air Cleaner Element Cleaning and Inspection

NOTE



In dusty areas, the element should be cleaned more frequently than
the recommended interval.



After riding through rain or muddy terrains, the element should be
cleaned immediately.



Since repeated cleaning opens the pores of the element, replace it
with a new one in accordance with the Periodic Maintenance Chart.



Also, if there is a break in the element material or any other damage
to the element, replace the element with a new one.

Clean the element in a well-ventilated area, and make sure that
there are no sparks or flame anywhere near the working area.
Because of the danger of highly flammable liquids, do not use
gasoline or a low flash-point solvent to clean the element.

•

Remove the air cleaner element.

FUEL SYSTEM 2-25

Air Cleaner

•

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

•

Squeeze it dry in a clean towel. Do not wring the element or blow it
dry; the element can be damaged.

•

Inspect the element for damage.
If it is torn, punctured, or hardened, replace it.

•

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

Air Cleaner Draining (KVF650–A1/B1)

A drain tube [A] is connected to the bottom of the air cleaner housing

to drain water or oil accumulated in the housing.

•

Visually check the drain tube if the water or oil accumulates in the
tube.
If any water or oil accumulates in the tube, drain it by taking off the
tube. After draining, be sure to install the tube and clamp firmly.

Air Cleaner Draining (KVF650–A2/B2)

•

If any water or oil accumulates in the tube, drain it by taking off the
tube plugs [A]. After draining, be sure to install the tube plugs and
clamp fir mly.

Air Cleaner Housing Removal

•

Remove:

Air Cleaner Cover (see Frame chapter)

Air Cleaner Housing Cap

Air Cleaner Element (Air Cleaner Element Removal)

2-26 FUEL SYSTEM

Air Cleaner

•

Remove: (KVF650–A2/B2)

Screws [A]
Element Bracket [B]

•

Remove:

Air Cleaner Housing Bolts (M5) [A]

•

Remove:

Air Cleaner Housing Bolts [A]

•

Remove:

Rivets [A]

•

Move the rubber cover [B] to loosen the clamp screw.

FUEL SYSTEM 2-27

Air Cleaner

•

Loosen the clamp screw [A].

•

Remove the housing [B] from the duct [C].

•

Remove:

Breather Hose [A]

Air Vent Hose [B]

Air Cleaner Housing [C]

Air Cleaner Housing Installation

•

Install:

Drain Tube [A]

Grommets [B]

Air Ducts [C]

•

Install:

Breather Hose [A]

Air Vent Hose [B]

•

Insert the carburetor air vent tube [C] in the fitting [D] of the housing.

•

Insert the fitting of the housing in the duct [A], and fit the projection
[B] under the fitting in the groove [C] in the duct.

2-28 FUEL SYSTEM

Air Cleaner

•

Apply a non-permanent locking agent to the air cleaner housing bolts
(M5) [A] and tighten them.

Torque - Air Cleaner Housing Bolts (M5): 5.9 N1m (0.6 kgf1m, 52 in1lb)

•

Tighten:

Torque - Air Cleaner Housing Bolts (M6):

28.7 mm (1.13 in.) [B]: 8.8 N

1

m (0.9 kgf1m, 78 in1lb)

33 mm (1.30 in.) [C]: 8.8 N

1

m (0.9 kgf1m, 78 in1lb)

•

Tighten:

Clamp Screw

•

Install:

Rubber cover
Rivets
Air Cleaner Element (see Air Cleaner Element Installation)

FUEL SYSTEM 2-29

Fuel Tank

Fuel Tank Removal

•

Remove:

Rear Fender (see Frame chapter)

Fuel Hose [A]

Fuel Pump Lead Connector [B]

Breather Hose [C]

•

Remove:

Fuel Tank Bolts [A] and Collars

Fuel Tank [B]

•

Remove:

Screw [A]

Tank Cover [B]

Fuel Tank Installation

•

Check the rubber dampers [A] and grommet [B] on the frame as
shown.
If the dampers are damaged or deteriorated, replace them.

•

Install:

Screw and Tank Cover [A]

Breather Hoses [B]

Grommets and Collars [C]

•

Insert the projection [D] on the fuel tank into the grommet in the frame.

•

Be sure the fuel hose is clamped to the fuel pump fitting.

2-30 FUEL SYSTEM

Fuel Tank

Fuel Tank Cleaning

•

Remove the fuel tank and drain it (see Fuel Tank Removal).

•

Pour some high flash-point solvent into the fuel tank and shake the
tank to remove dirt and fuel deposits.

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

•

Pour the solvent out the tank.

•

Install the fuel tank (see Fuel Tank Installation).

Fuel Tap Removal

•

Remove:

Fuel Hose [A]
Fuel Tap Mounting Bolts [B]

•

Remove:

Fuel Hose [A]

Fuel Tap Installation

•

Connect the fuel hoses to the fuel tap as follows.

Carburetor Hose to Fitting [A]
Fuel Tank Hose to Fitting [B]

•

Be sure to clamp the fuel hoses to the fuel tap to prevent leakage.

FUEL SYSTEM 2-31

Fuel Tank

Fuel Tap Inspection

•

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

•

Apply grease to the lever [B].

•

Tighten:

Torque - Fuel Tap Plate Screws [C]: 0.8 N1m (0.08 kgf1m, 7 in1lb)

2-32 FUEL SYSTEM

Fuel Pump

Fuel Pump Removal

CAUTION

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

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

•

Remove the fuel tank (see Fuel Tank Removal).



Be careful of fuel spillage from the fuel tank since fuel still remains in
the fuel tank and fuel pump.

•

Unscrew the fuel pump bolts [A], and take out the fuel pump assembly
[B] and gasket.



Do not contact the float and fuel filter with the fuel tank.

•

Discard the fuel pump gasket.

Pump Filter Cleaning

Clean the pump filter in a well-ventilated area, and take care
that there are no sparks or flame anywhere near the working
area. Because of the danger of highly flammable liquids, do
not use gasoline or low-flash point solvent to clean the pump
filter.

•

Remove the fuel pump [A] along with the pump filter [B].

•

Prepare a container [C] filled with a high-flash point solvent.

•

Dip and shake the fuel filter only in the solvent to remove dirt and fuel
deposits from the filter.

•

Dry the pump and filter by lightly applying compressed air.

•

Install the fuel pump (see Fuel Pump Installation).

FUEL SYSTEM 2-33

Fuel Pump

Fuel Pump Installation

•

Clean the pump filter (see Pump Filter Cleaning).

•

Remove dirt or dust from the fuel pump by lightly applying com­pressed air.

•

Replace the fuel pump gasket [A] with a new one.

•

Install the fuel pump assembly so that the float and fuel filter do not
contact with the fuel tank.

Fuel Pump Inspection

Refer to the Electrical System chapter.