Kawasaki Prairie 700, Prairie 700 4×4, KVF 700 4×4 Service Manual

Prairie 700 4×4

KVF 700 4×4

All Terrain Vehicle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System 3 j

Cooling System 4 j

Engine Top End 5 j

Converter System 6 j

Recoil Starter 7 j

Engine Lubrication System 8 j

Engine Removal/Installation 9 j

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

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

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

Crankshaft/Transmission 10 j

Wheels/Tires 11 j

Final Drive 12 j

Brakes 13 j

Suspension 14 j

Steering 15 j

Frame 16 j

Electrical System 17 j

Appendix 18 j

Prairie 700 4×4

KVF 700 4×4

All Terrain Vehicle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system,
or transmitted i n any form or by any means, electronic mechanical photocopying, recording or
otherwise, without the prior written permission of Quality Devision/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.

© 2003 Kawasaki Heavy Industries, Ltd. Fourth Edition (1) : May 23, 2005 (K)

LIST OF ABBREVIATIONS

A ampere(s) lb pounds(s)

ABDC after bottom dead center

AC

ATDC after top dead center

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

L

alternating current min

hour(s) Ω ohm(s)

liter(s)

m

N

meter(s)

minute(s)

newton(s)

Read OW

NER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

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

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

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

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

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

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

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

fuel economy with a suitable air cleaner and exhaust system.

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

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

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

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

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

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

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

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

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

NOTE

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

○

interpreted as follows :

1. Tampering does not include the temporary removal or rendering ino perative of de­vices or elements of design in order to perform maintenance.

2. Tampering could include:

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

ceeded.

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

or durability of the vehicle.

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

dards.

d.Permanently removing, disconnecting, or rendering i noperative any component or

element of design of the emission control systems.

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

THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

(US MODEL only)

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 Vehi-

•

cle parts. Special tools, gauges, and testers

that are necessary when servicing Kawasaki

vehicles are introduced by the Service Man-

ual. Genuine parts provided as spare parts

are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

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

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

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

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age 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 par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

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

lows.

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

General Specifications............................................................................................................ 1-10

Unit Conversion Table ............................................................................................................ 1-16

1

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following:

Battery Ground

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

Edges of Parts

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

Solvent

Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.

Cleaning vehicle before disassembly

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

Before Servicing

Arrangement and Cleaning of Removed Parts

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

Storage of Removed Parts

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

GENERAL INFORMATION 1-3

Inspection

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

Replacement Parts

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

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

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

Tightening Torque

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

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

Force

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

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

Gasket, O-ring

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

Liquid Gasket, Locking Agent

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

Before Servicing

Press

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

Ball Bearing and Needle Bearing

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

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

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

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

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

Circlips, Cotter Pins

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

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

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

Direction of E ngine Rotation

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

Electrical Wires

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

Instrument

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

Model Identification

KVF700-A1 Left Side View

GENERAL INFORMATION 1-7

KVF700-A1 Right Side View

1-8 GENERAL INFORMATION

Model Identification

KVF700-B1 Left Side View

KVF700-B1 Right Side View

Model Identification

KVF700-D1 Left Side View

GENERAL INFORMATION 1-9

KVF700-D1 Right Side View

1-10 GENERAL INFORMATION

General Specifications

Items KVF700-A1, B1 KVF700-A2, B2, D1

Dimensions

Overall Length 2 190 mm (86.22 in.)

Overall Width 1 180 mm (46.46 in.)

Overall Height 1 175 mm (46.26 in.)

Wheelbase 1 290 mm (50.79 in.)

Ground Clearance:

Rear Final Gear Case 192 mm (7.56 in.)

Center of Frame 240 mm (9.45 in.)

Seat Height 870 mm (34.25 in.)

Dry Mass

Curb Mass:

Front 154 kg (340 lb)

Rear 140 kg (309 lb) 139 kg (306 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 82.0 × 66.0 mm (3.23 × 2.60 in.)

Displacement 697 cm³ (42.5 cu in.)

Compression Ratio 9.9 : 1

Maximum Horsepower 34.3 kW (46.6 PS) @6 500 r/min (rpm), (US) -

Maximum Torque 60.1 N·m (6.13 kgf·m, 44.33 ft·lb) @5 000 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 Timi

Spark Plug NGK CR7E, DENSO U22ESR-N

Cylinder Nu

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)

ng

mbering Method

273 kg (602 lb)

From 5° BTDC @1 100 r/min (rpm) to 28° BTDC @5 000 r/min
(rpm)

Front to rear, 1-2

GENERAL INFORMATION 1-11

General Specifications

Items KVF700-A1, B1 KVF700-A2, B2, D1

Engine Oil:

Type API SF or SG

API SH or SJ with JASO MA class

Viscosity SAE 10W-40

Capacity 2.05 L (2.17 US qt)

Drive Train

Primary Reduction System:

Type Belt converter

Reduction Ratio 3.122 ∼ 0.635

Transmission:

Type 2-speed and reverse

Gear Ratios:

Forward:

High 3.098 (30/26 × 29/18 × 20/12)

Low 4.833 (36/20 × 29/18 × 20/12)

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

Final Drive System:

Type

Reduction Ratio

Overall Drive Ratio:

Forward:

High 42.32 ∼ 8.61
Low 66.02 ∼ 13.43

Reverse 55.01 ∼ 11.19

Front Final Gear Case Oil:

Type

Viscosity

Capacity 0.43 L (0.45 US qt)

Rear Final Gear Case Oil:

Type MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR

Capacity 0.9 L (0.95 US qt)

Frame

Type Double tubular

Caster (Rake Angle) 3.5°

Camber 0°

King Pin Angle 15°

Trail 15 mm (0.59 in.)

Tread:

Front

Rear

Rim Size:

Front 12 × 6.0

Rear 12 × 7.5

Shaft 2WD/4WD

4.375 (35/8)

API SF or SG
API SH or SJ with JASO MA class

SAE10W-40

HYDRAULIC FLUID or Exxon Hydraul 560

906 mm (35.67 in.)

910 mm (35.83 in.)

1-12 GENERAL INFORMATION

General Specifications

Items KVF700-A1, B1 KVF700-A2, B2, D1

Front Tire:

Type Tubeless

Size

Rear Tire:

Type Tubeless

Size AT25 × 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 × 2

Rear Enclosed wet multi-plate

Electrical Equipment

Battery 12 V 12 Ah

Headlight:

Type Semi-sealed beam

Bulb

Tail/Brake Light:

Bulb

Reverse Light:

Bulb (EUR) (GB) 12 V/10 W

Alternator:

Type Three - phase AC

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

AT25 × 8 - 12

12 V 45/45 W × 2

12 V 5/21 W

Specifications are subject to change without notice, and may not apply to every country.
EUR: Europe Mo

GB: United Kingdom Model

US: United States Model

del

GENERAL INFORMATION 1-13

General Specifications

Items KVF700A6F/D6F

Dimensions

Overall Length 2 190 mm (86.22 in.)

Overall Width 1 180 mm (46.46 in.)

Overall Height 1 175 mm (46.26 in.)

Wheelbase 1 290 mm (50.79 in.)

Ground Clearance:

Rear Final Gear Case 192 mm (7.56 in.)

Center of Frame 241 mm (9.49 in.)

Seat Height 870 mm (34.25 in.)

Dry Mass

Curb Mass:

Front 155 kg (342 lb)

Rear 139 kg (306 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 82.0 × 66.0 mm (3.23 × 2.60 in.)

Displacement 697 cm³ (42.5 cu in.)

Compression Ratio 9.9 : 1

Maximum Horsepower 34.3 kW (46.6 PS) @6 500 r/min (rpm), (US) -

Maximum Torque 60.1 N·m (6.13 kgf·m, 44.33 ft·lb) @5 000 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

Spark Plug NGK CR7E, DENSO U 22ESR-N

Cylinder Numbering M ethod 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)

274 kg (604 lb)

From 5° BTDC @1 100 r/min (rpm) to 28° BTDC @5
000 r/min (rpm)

1-14 GENERAL INFORMATION

General Specifications

Items KVF700A6F/D6F

Engine Oil:

Type API SF or SG

API SH or SJ with JASO MA class

Viscosity SAE 10W-40

Capacity 2.05 L (2.17 US qt)

Drive Train

Primary Reduction System:

Type Belt converter

Reduction Ratio 3.122 ∼ 0.635

Transmission:

Type 2-speed and reverse

Gear Ratios:

Forward:

High 3.098 (30/26 × 29/18 × 20/12)

Low 4.833 (36/20 × 29/18 × 20/12)

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

Final Drive System:

Type

Reduction Ratio

Overall Drive Rati

Forward:

High 42.32 ∼ 8.61
Low 66.02 ∼ 13.43

Reverse 55.01 ∼ 11.19

Front Final Gear Case Oil:

Type API SF or SG

Viscosity

Capacity 0.43 L (0.45 US qt)

Rear Final Gear Case Oil:

Type MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR

Capacity 0.9 L (0.95 US qt)

Frame

Type Double tubular

Caster (Rake Angle) 3.5°

Camber 0°

King Pin Angle

Trail 15 mm (0.59 in.)

Tread:

Front 906 mm (35.67 in.)

Rear

Rim Size:

Front 12 × 6.0

Rear 12 × 7.5

o:

Shaft 2WD/4WD

4.375 (35/8)

API SH or SJ with JASO MA class

SAE10W-40

HYDRAULIC FLUID or Exxon Hydraul 560

15°

910 mm (35.83 in.)

GENERAL INFORMATION 1-15

General Specifications

Items KVF700A6F/D6F

Front Tire:

Type Tubeless

Size

Rear Tire:

Type Tubeless

Size AT25 × 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 × 2

Rear Enclosed wet multi-plate

Electrical Equipment

Battery 12 V 12 Ah

Headlight:

Type

Bulb

Tail/Brake Light:

Bulb 12 V 5/21 W

Alternator:

Type Three - phase AC

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

AT25 × 8 - 12

Semi-sealed beam

12 V 45/45 W × 2

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

US: United States Model

1-16 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units:

Prefix Symbol Power

mega M × 1 000 000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Units of Mass:

kg × 2.205 = lb

g × 0.03527 = oz

Units of Volume:

L × 0.2642 = gal (US)

L × 0.2200 = gal (imp)

L × 1.057 = qt (US)

L × 0.8799 = qt (imp)

L×2.113=

L×1.816=

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (imp)

mL × 0.06102 = cu in

pint (US)

pint (imp)

Units of Length:

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kgf·m

N·m × 0.7376 =

N·m × 8.851 = in·lb

kgf·m × 9.807 = N·m

kgf·m × 7.233 = ft·lb

kgf·m × 86.80 = in·lb

ft·lb

Units of Pressure:

kPa × 0.01020 =

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cm Hg × 1.333 = kPa

kgf/cm²

Units of Speed:

km/h

× 0.6214 = mph

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg × 9.807 = N

kg × 2.205 = lb

Units of Temperature:

Units of Power:

kW × 1.360 = PS

kW × 1.341 = HP

PS × 0.7355 = kW

PS × 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

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

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

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

Periodic Maintenance Procedures.......................................................................................... 2-14

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

Throttle Lever Free Play Inspection .................................................................................. 2-14

Throttle Lever Free Play Adjustment ................................................................................ 2-14

Choke Lever Free Play Inspection.................................................................................... 2-14

Choke Lever Free Play Adjustment .................................................................................. 2-15

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

Idle Speed Adjustment...................................................................................................... 2-15

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

Air Cleaner Element Cleaning and Inspection .................................................................. 2-16

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

Fuel Hose and Connection Inspection .............................................................................. 2-17

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

Cooling System.................................................................................................................... 2-18

Radiator Cleaning ............................................................................................................. 2-18

Radiator Hose and Connection Inspection ....................................................................... 2-19

Coolant Change ................................................................................................................ 2-19

Coolant Filter Cleaning ..................................................................................................... 2-21

Engine Top End ................................................................................................................... 2-22

Valve Clearance Inspection .............................................................................................. 2-22

Valve Clearance Adjustment............................................................................................. 2-23

Spark Arrester Cleaning.................................................................................................... 2-23

Converter System ................................................................................................................ 2-23

Converter Drive Belt Inspection ........................................................................................ 2-23

Converter Drive Belt Deflection Inspection ....................................................................... 2-24

Converter Drive Belt Deflection Adjustment...................................................................... 2-25

Actuator Lever (Engine Brake Control Lever) Assembly Inspection ................................. 2-26

Engine Lubrication System .................................................................................................. 2-26

Engine Oil Change............................................................................................................ 2-26

Oil Filter Replacement ...................................................................................................... 2-26

Wheels/Tires........................................................................................................................ 2-27

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

Final Drive............................................................................................................................ 2-27

Variable Differential Control Lever Play Inspection ........................................................... 2-27

Variable Differential Control Lever Play Adjustment ......................................................... 2-28

Front Final Gear Case Oil Change ................................................................................... 2-28

Rear Final Gear Case Oil Change .................................................................................... 2-29

Brakes.................................................................................................................................. 2-30

Front Brake Pad Wear Inspection ..................................................................................... 2-30

Front Brake Hoses and Connections Inspection............................................................... 2-30

Front Brake Hose Replacement........................................................................................ 2-30

Front Brake Fluid Level Inspection ................................................................................... 2-30

2

2-2 PERIODIC MAINTENANCE

Front Brake Fluid Change................................................................................................. 2-31

Front Brake Master Cylinder Piston Assembly and Dust Cover Replacement ................. 2-32

Front Brake Caliper Fluid Seal Replacement.................................................................... 2-32

Front Brake Caliper Dust Seal and Friction Boot Replacement........................................ 2-32

Rear Brake Plates Replacement....................................................................................... 2-32

Rear Brake Lever Free Play Inspection ............................................................................ 2-32

Rear Brake Pedal Free Play Inspection............................................................................ 2-33

Rear Brake Lever and Pedal Free Play Adjustment ......................................................... 2-33

Steering ............................................................................................................................... 2-34

Steering Inspection ........................................................................................................... 2-34

Electrical System ................................................................................................................. 2-34

Spark Plug Cleaning/Inspection........................................................................................ 2-34

Spark Plug Gap Inspection ............................................................................................... 2-34

Rear Brake Light Switch Inspection .................................................................................. 2-35

Rear Brake Light Timing Adjustment ................................................................................ 2-35

Drive Belt Failure Detection System Inspection................................................................ 2-35

Joint Boots Inspection.......................................................................................................... 2-37

Front Axle/Steering Knuckle Joint Boot Inspection ........................................................... 2-37

Front Propeller Shaft Joint Boot Inspection ...................................................................... 2-37

Rear Propeller Shaft Joint Boot Inspection ....................................................................... 2-37

Tie-rod End Boot Inspection ............................................................................................. 2-37

General Lubrication ............................................................................................................. 2-38

Lubrication ........................................................................................................................ 2-38

Bolts and Nuts Tightening.................................................................................................... 2-39

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

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

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

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

FREQUENCY First

Service

Every

After 10

hrs. or

100 km

(60 mi.)

of use

OPERATION

ENGINE

Converter drive belt wear - inspect *

Converter drive belt deflection - inspect *

Converter Drive belt failure detection system
function - inspect *

Engine brake control lever - inspect *

Air cleaner - inspect *

Throttle lever play - inspect

Choke lever play - inspect

Idle speed - inspect

Valve clearance - inspect

Fuel system cleanliness - inspect *

Engine oil - change *

Oil filter - replace *

Spark plug cleaning and gap - inspect

Spark arrester - clean

Fuel hoses and connections - inspect

Fuel hose - replace 4years 2-18

Radiator - clean*

Radiator hoses and connections - inspect*

Coolant - change* 2years 2-19

Coolant filter of carburetor - clean

CHASSIS

Joint boots - inspect *

Rear brake pedal and lever play - inspect *

Rear brake plates - replace * every 10 000 km (6 000 mile) 2-32

Bolts and nuts - tighten

Front brake pad wear - inspect *

10 days

or 200

km

(120

mi.) of

use

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

Regular Service

700 km (1

Every

30 days

or 600

km

(360

mi.) of

use

when belt

light turns

whichever

comes first

•

Every 90

days, 1

100 mi.)

of use or

indicator

on (100
hrs. of

use)

•

•

•

•

•

Every

year of

use

•

•

•

•

See

page

2-23

2-24

2-35

2-26

2-16
2-17

2-14

2-14

2-15

2-22

2-16

2-26

2-26

2-34

2-23

2-17

2-18

2-19

2-21

2-37

2-32

2-39

2-30

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY First

Service

Every

After 10

hrs. or

100 km

(60 mi.)

of use

OPERATION

Brake light switch - inspect *

Steering - inspect

Differential control lever play - inspect

Tire wear - inspect *

Front and rear final gear case oil - change

General lubrication - perform*

Front brake fluid level - inspect

Front brake fluid - change

Front brake hoses and connections- inspect

Front brake master cylinder piston assembly
and dust cover - replace

Front brake caliper fluid seal and dust seal

-replace

Front brake hose - replace 4years 2-30

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

carrying heavy loads or pulling a trailer.

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

•

10 days

or 200

km

(120

mi.) of

use

• •

• •

• •

• •

• •

Regular Service

Every 90

days, 1

700 km (1

Every

30 days

or 600

km

(360

mi.) of

use

100 mi.)

of use or

when belt

indicator

light turns

on (100
hrs. of

use)

whichever

comes first

Every

year of

use

•

•

•

•

2years 2-32

2years 2-32

See

page

2-35

2-34

2-27

2-27

2-28
2-29

2-38

2-30

2-31

2-30