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

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners, and the parts requiring use of

a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

L: Apply a non-permanent locking agent.

LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue).

Lh: Left-hand Threads

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

a weight ratio 10 : 1).
R: Replacement Parts
S: Follow the specific tightening sequence.

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

St: Stake the fasteners to prevent loosening.

Fastener

Fuel System

Heat Guard Plate Mounting Bolts 8.8 0.90 78 in·lb

Air Cleaner Housing Bolts (M5) 5.9 0.60 52 in·lb L

Air Cleaner Housing Bolts (M6) 28.7 mm (1.13 in.) 8.8 0.90 78 in·lb

Air Cleaner Housing Bolts (M6) 33 mm (1.30 in.) 8.8 0.90 78 in·lb

Fuel Tap Plate Screws

Air Cleaner Element Bracket Screws

Cooling System

Radiator Fan Switch 18 1.8 13

Water Pump Cover Bolts 8.8 0.90 78 in·lb

Coolant Drain Plug 8.8 0.90 78 in·lb

Water Pump Fitting Bolt 9.8 1.0 87 in·lb

Water Pump Impeller 7.8 0.80 69 in·lb

Thermostat Housing Cover Bolts 8.8 0.90 78 in·lb

Water Temperature Switch 7.8 0.80 69 in·lb SS

Radiator Fan Mounting Nut 2.7 0.28 24 in·lb L

Radiator Fan Assembly Bolts 8.8 0.90 78 in·lb

Radiator Mounting Bolts 8.8 0.90 78 in·lb

Engine Top End

Water Pipe Bolts 9.8 1.0 87 in·lb

Rocker Case Bolts 55 mm (2.2 in.)

Rocker Case Bolts 130 mm (5.1 in.)

Rocker Case Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb S

Rocker Case Bolts 25 mm (1.0 in.) 9.8 1.0 87 in·lb S

Cylinder Head Bolts (M10), First Torque 25 2.5 18 S, MO

Cylinder Head Bolt (M10), Final Torque 49 5.0 36 S

Cylinder Head Bolts (M6)

Cylinder Head Jacket Plugs

Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb

Valve Adjusting Screw Locknuts 12 1.2 104 in·lb

Rocker Shaft Bolts 8.8 0.90 78 in·lb

N·m

0.8 0.08 7in·lb

4.9 0.50 43 in·lb

8.8 0.90 78 in·lb

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb

20 2.0 14 L

Torque

kgf·m ft·lb

Remarks

S

S

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Rocker Shaft Bolts (KVF700-A2/B2/D1 ∼) 20 2.0 14

Chain Tensioner Mounting Bolts 8.8 0.90 78 in·lb

Chain Tensioner Cap Bolt

Intermediate Shaft Sprocket Nut 44 4.5 33

Intermediate Shaft Chain Guide Bolts 8.8 0.90 78 in·lb

Intermediate Shaft Chain Tensioner Bolts 8.8 0.90 78 in·lb

Camshaft Sprocket Bolts 12 1.2 104 in·lb L

Position Plate Bolts 8.8 0.90 78 in·lb

Cylinder Bolts 40 mm (1.6 in.) 9.8 1.0 87 in·lb

Cylinder Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb

Front Cylinder Camshaft Chain Guide Bolt 20 2.0 14

Rear Cylinder Camshaft Chain Guide Bolt

Exhaust Pipe Cover Bolts 8.8 0.90 78 in·lb

Muffler Cover Bolts 8.8 0.90 78 in·lb

Muffler Mounting Bolts 20 2.0 14 L

Heat Guard Plate Mounting Bolts 8.8 0.90 78 in·lb

Muffler Clamp Bolt 8.8 0.90 78 in·lb

Converter System

Drive Pulley Bolt 93 9.5 69 R, Lh

Driven Pulley Nut 93 9.5 69

Drive Pulley Cover Bolts 13 1.3 113 i n · l b

Ramp Weight Nuts 6.9 0.70 61 in·lb

Spider 275 28 203 Lh

Converter Cover Bolts 8.8 0.90 78 in·lb S

JointDuctBolts 8.8 0.90 78 in·lb

Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb

Recoil Starter

Recoil Starter Mounting Bolts 5.9 0.60 52 in·lb L

Engine Lubrication System

Oil Filter 18 1.8 13 R

Oil Pressure Switch 15 1.5 11 SS

Oil Pipe Bolts 8.8 0.90 78 in·lb

Engine Drain Plug 20 2.0 14

Oil Pressure Relief Valve 15 1.5 11 L

Oil Pump Bolts 8.8 0.90 78 in·lb

Chain Guide Bolts

Oil Pump Drive Chain Tensioner Bolt 25 2.5 18

Oil Filter Mounting Bolts 25 2.5 18 L (15 mm)

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Engine Removal/Installation

Engine Mounting Bracket Bolts 32 3.3 24

Engine Mounting Bolt 62 6.3 46

Engine Mounting Nut 62 6.3 46

N·m kgf·m ft·lb

22 2.2 16

20 2.0 14

8.8 0.90 78 in·lb

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

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.)

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 87 in·lb

Crankcase Bolts (M6) 65 mm (2.56 in.) 9.8 1.0 87 in·lb

Bearing Position Plate Screws 4.9 0.50 43 in·lb L

Grip Hold Nut

Shift Lever Assembly Bracket Bolts

Tie-rod End Front Locknut 9.8 1.0 87 in·lb Lh

Tie-rod End Rear Locknut 9.8 1.0 87 in·lb

Tie-rod End Nut 20 2.0 14

Shift Lever Assembly Nut 20 2.0 14

Tie-rod End Bolt 9.8 1.0 87 in·lb

Shift Shaft Positioning Bolt

Shift Shaft Spring Bolt 25 2.5 18 L

Shift Shaft Cover Bolts 8.8 0.90 78 in·lb

Tie-rod End Locknut 20 2.0 14

Neutral Position Switch 15 1.5 11

Reverse Position Switch 15 1.5 11

Wheel/Tires

Tie-rod 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 120 12 89 L

Output Shaft Holder Nut 157 16 116 L

Rotor Mounting Bolts 12 1.2 104 in·lb

Output Drive Bevel Gear Cover Bolts

(Front Final Gear Case)

Variable Differential Control Shift Shaft Lever Bolt 8.8 0.90 78 in·lb

Front Final Gear Case Left Cover Bolts (M6) 9.8 1.0 87 in·lb L

Ring Gear Bolts 57 5.8 42 LB

Front Final Gear Case Center Cover Bolts (M6)

Oil Filler Cap

N·m

20 2.0 14

9.8 1.0 87 in·lb

20 2.0 14

25 2.5 18

8.8 0.90 78 in·lb

9.8 1.0 87 in·lb L

29 3.0 22

Torque

kgf·m ft·lb

Remarks

S

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

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

Front Final Gear Case Coupling Nut 25 2.5 18

Oil Drain Plug 20 2.0 14

2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·lb L, S

Variable Differential Control Cable Locknut 17 1.7 12

Variable Differential Control Lever Bolt — — — L

Front Final Gear Case Nuts

(Rear Final Gear Case)

Oil Filler Cap 29 3.0 22

Oil Drain Plug 20 2.0 14

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)

Rear Final Gear Case Right Cover Bolts (M10) 49 5.0 36 L

Rear Final Gear Case Right Cover Bolts (M12) 93 9.5 69 L

Rear Final Gear Case Left Cover Bolts 49 5.0 36 L

Rear Final Gear Case Bolts 42 4.3 31 L,S

Brakes

Reservoir Cap Screws 1.5 0.15 13 in·lb

Front Brake Lever Pivot Bolt 6.0 0.61 53 in·lb

Front Brake Lever Pivot Bolt Locknut 6.0 0.61 53 in·lb

Front Brake Master Cylinder Clamp Bolts

Front Bake Hose Banjo Bolt 34 3.5 25

Front Brake Caliper Mounting Bolts 25 2.5 18

Bleed Valves 7.9 0.80 69 in·lb

Front Brake 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

Front Shock Absorber Clamp Bolts And Nuts 42 4.3 31 AL

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

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

N·m kgf·m ft·lb

137 14 101 L

59 6.0 43

24 2.4 17 L

8.8 0.90 78 in·lb

74 7.5 54

20 2.0 14

Torque

Remarks

S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Tie-rod End Nuts 42 4.3 31

Steering Stem Clamp Bolts 25 2.5 18

Steering Stem Bottom End Nut

Master Cylinder Clamp Bolts

Front Shock Absorber Clamp Bolts And Nuts 42 4.3 31 AL

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 Guard Bolts 29 3.0 22

Rear Carrier Lower Bolts

Rear Carrier Upper Bolts And Nuts

Engine Mounting Bracket Bolts 32 3.3 24

Engine Mounting Nuts 62 6.3 46

Front Final Gear Case Nuts 59 6.0 43

Electrical System

Starter Motor Mounting Bolts

Starter Motor Terminal Nut

Starter Motor Terminal Locknut 6.9 0.70 61 in·lb

Starter Motor Bolts 4.9 5.0 43 in·lb

Starter Motor Clutch Bolts 34 3.5 25 L

Alternator Stator Bolts 13 1.3 11 3 i n · l b

Crankshaft Sensor Mounting Bolts

Alternator Cover Plugs

Alternator Rotor Bolt 127 13 94

Alternator Cover Bolts

Spark Plugs

2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·lb L, S

Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb

Forward/Reverse Detecting Sensor Mounting Bolt

Speed Sensor Mounting Bolt 8.8 0.90 78 in·lb

Neutral Position Switch 15 1.5 11

Reverse Position Switch 15 1.5 11

Radiator Fan Switch 18 1.8 13

Water Temperature Switch

Oil Pressure Switch

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

N·m

64 6.5 47

11 1.1 95 in·lb

54 5.5 40

37 3.8 27

8.8 0.90 78 in·lb

4.9 0.50 43 in·lb

5.9 0.60 52 in·lb

18 1.8 13

8.8 0.90 78 in·lb

13 1.3 113 in·lb

15 1.5 11

7.8 0.80 69 in·lb

15 1.5 11

Torque

kgf·m ft·lb

Remarks

SS

SS

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts
and nuts. Use this table 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. Torque

mm (in.)

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

8 (0.31)

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 in·lb

Basic Torque for General Fasteners of Frame Parts

Threads dia. Torque

mm (in.)

5 (0.20) 3.4 ∼ 4
6 (0.24) 5.9 ∼ 7.8 0.6 ∼ 0.8 52 ∼ 69 in·lb

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)

16 (0.63) 115

18 (0.71) 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 (0.79) 225 ∼ 325 23 ∼ 33 165 ∼ 240

Mark of Bolt Head

4T 10 ∼ 14 1.0 ∼ 1.4 87 ∼ 122 in·lb

N·m

73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72

∼ 155

.9

N·m kgf·m ft·lb

kgf·m ft·lb

0.35 ∼

5 ∼ 16.0

11.

0.5

30 ∼ 43

83 ∼

in·lb

115

PERIODIC MAINTENANCE 2-11

Specifications

Item Standard Service Limit

Fuel System

Throttle Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Choke Lever Free Play about 3 mm (0.12 in.) –––

Idle Speed 1 100 ±50 r/min (rpm)

Air Cleaner Element Oil High-quality foam air filter oil

Cooling System

Coolant:

Type (Recommended) Permanent type antifreeze –––

Color Green –––

Mixed Ratio

Freezing Point

Total Amount 2.4 L (2.5 US qt.) –––

Engine Top End

Valve Clearance:

Exhaust 0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.) –––
Inlet 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) –––

Converter System

Actuator Lever Guide Shoe Wear ––– 6 mm (0.24 in.)

Belt Width

Belt Deflection 22 ∼ 27 mm (0.87 ∼ 1.06 in.)

Engine Lubrication System

Engine Oil:

Type API SF or SG

Viscosity SAE10W-40 –––

Capacity 1.54 L (1.63 US qt) (When filter is not

Wheels/Tires

Tire Tread Depth:

Front

Rear

Standard Tire:

Front AT 25 × 8 -12 –––

Rear AT 25 × 10-12 –––

Final Drive

Front Final Gear Case:

Gear Case Oil:

Type

Soft water 50%, Coolant 50%

–35°C (–31°F)

29.7 ∼ 30.3 mm (1.169 ∼ 1.193 in.) 28.0 mm (1.102 in.)

API SH or SJ with JASO MA class

removed)

1.75 L (1.85 US qt) (When filter is
removed)

2.05 L (2.17 US qt) (When engine is
completely dry)

15.7 mm (0.62 in.) 3 mm (0.12 in.)

14.5 mm (0.57 in.) 4 mm (0.16 in.)

DUNLOP, KT121A, Tubeless

DUNLOP, KT127A, Tubeless

API SF or SG

–––

–––

–––

–––

–––

–––

–––

–––

–––

–––

–––

–––

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Viscosity

Oil Level Filler opening bottom –––

Capacity 0.43 L (0.45 US qt)

Rear Final Gear Case:

Gear Case Oil:

Type MOBIL Fluid 424 or CITGO –––

Oil Level Filler opening bottom –––

Capacity 0.9 L (0.95 US qt) –––

Brakes

Front Brake Fluid:

Type DOT 3 or DOT 4 –––

Front Disc Brake:

Pad Lining Thickness

Rear Brake Lever, Pedal and
Cables:

Rear Brake Lever Free Play 1 ∼ 2 mm (0.04 ∼ 0.08 in.) –––
Brake Pedal Free Play 15 ∼ 25 mm (0.6 ∼ 1.0 in.) –––

Electrical System

Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

Rear Brake Light Switch Timing ON after 10 mm (0.4 in.) of pedal travel –––

API SH or SJ with JASO MA class
SAE 10W-40

TRANSGARD TRACTOR HYDRAULIC
FLUID or Exxon Hydraul 560

4 mm (0.16 in.) 1mm(0.04in.)

–––

–––

–––

Special Tools

PERIODIC MAINTENANCE 2-13

Oil Filter Wrench:
57001-1249

Carburetor Drain Plug Wrench, Hex 3:
57001-1269

Pulley Holder Attachment:
57001-1472

Filler Cap Driver:
57001-1454

Flywheel & Pulley Holder:
57001-1605

Belt Measuring Gauge:
57001-1646

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Throttle Lever Free Play Inspection

Check that the throttle lever [A] 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 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 lever free
play and the cable routing.
Stop the engine and check the throttle lever free play [B].

•

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 handlebar cover (see Multifunction Meter

•

Unit Removal in the 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.

Choke Lever Free Play Inspection

Check if the choke l ever [A] returns properly and if the

•

inner cable slides smoothly.
Make sure that the choke lever returns to its released po-

•

sition all the way.
To determine the amount of choke cable play at the lever,

•

pull the choke lever to the left until it feels that the opera­tion of lever is tough; the amount of choke lever is equiv­alent to that of cable play.
The proper amount of play [B] 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

Standard: about 3 mm (0.12 in.)

Periodic Maintenance Procedures

Choke Lever Free Play Adjustment

Remove:

•

Handlebar Cover Screws [A]
Handlebar 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.

•

PERIODIC MAINTENANCE 2-15

Idle 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 cable may be improperly adjusted incorrectly routed,
or damaged. Be sure to correct any of these conditions
before riding.

WARNING

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.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System Cleanliness I nspection

WARNING

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 check valve [A] at the end of the carburetor

•

overflow hose [B].
Run t he lower end of the carburetor overflow hose to a

•

suitable container.

Turn out the carburetor drain plugs [A] a few turns and

•

drain the fuel system.

Special Tool - Carburetor Drain Plug Wrench, Hex 3:

57001-1269

Check to see if water or dirt comes out.

•

Tighten the drain plugs.

•

If any water or dirt appears during the above inspection,
clean the fuel system (carburetor, fuel pump, fuel tank,
fuel hose).

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.
Also, if there is a break in the element material or any

○

other damage to the element, replace the element with
a new one.

WARNING

Clean the element 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
a low-flash point solvent to clean the foam element.

Remove the air cleaner element (see Air Cleaner Element

•

Removal in the Fuel System chapter).

Periodic Maintenance Procedures

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

•

Squeeze it dry in a clean towel [A]. Do not wring the ele-

•

ment 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.

PERIODIC MAINTENANCE 2-17

Air Cleaner Draining

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

Fuel Hose and Connection Inspection

The fuel hoses are designed to be used throughout the

○

vehicle life without any maintenance, however, if the ve­hicle is not properly handled, the pressure inside the fuel
line can cause fuel to leak [A] or the hose to burst. Check
the fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
Check that the hoses are securely connected and clamps

•

are installed correctly.
When installing, route the hoses according to Cable,

•

Wire, and Hose Routing section in the Appendix chapter.
When installing the fuel hoses, avoid sharp bending, kink-

•

ing, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be ob­structed.
Replace the hose if it has been sharply bent or kinked.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fit the fuel hose [A] onto the fitting fully and install the

•

plate clamp [B] beyond the raised rib [C].

1 ∼ 2 mm (0.0039 ∼ 0.0078 in.) [D]

The hose end must reach the fillet [E] or be as near as

○

possible to the step [F].
Fit the fuel pump inlet hoses onto the Y-joint fully until

○

each end of the inlet hose touches the second raised rib.

Fuel Hose Replacement

WARNING

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 air cleaner cover (see Air Cleaner Cover Re-

•

moval in the Frame chapter).
Turn the fuel tap to the OFF position.

•

Remove:

•

Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Clamps [A]
Fuel Hoses [B]

Replace the fuel hoses with new ones.

•

When installing the fuel hose, route the hose according to

•

Cable, Wire, and Hose Routing in the Appendix chapter.
When installing the fuel hose, avoid sharp bending, kink-

•

ing, flattening or twisting, and route the fuel hose with a
minimum of bending so that the fuel flow will not be ob­structed.
Fit the fuel hose onto the pipe fully and install the clamps

•

beyond the raised rib (see Fuel Hose and Connection In­spection).

Cooling System

Radiator Cleaning

CAUTION

Clean the radiator screen and the radiator in ac­cordance with the Periodic Maintenance Chart.
In dusty areas, they should be cleaned more fre­quently than the recommended interval. After
riding through muddy terrains, the radiator screen
and the radiator should be cleaned immediately.

Periodic Maintenance Procedures

Remove:

•

Front Guard (see Front Guard Removal in the Frame
chapter)
Left Side Covers (see Left Side Cover Removal in the
Frame chapter)
Radiator Screen Mounting Screws [A]
Radiator Screen [B]

Clean the radiator screen in a bath of tap water, and then

•

dry it with compressed air or by shaking it.

Clean the radiator.

•

CAUTION

When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun away more than 0.5 m (20 in.)
from the radiator core [A].
Hold the steam gun perpendicular to the core sur­face.
Run the steam gun following the core fin direction.

PERIODIC MAINTENANCE 2-19

Radiator Hose and Connection Insp ection

The high pressure inside the radiator hose can cause

○

coolant to leak [A] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps

•

are tightened correctly.

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down.
Coolant on tires will make them slippery and can
cause an accident and injury. Immediately wash
away any coolant that spills on the frame, engine,
or wheels.
Since coolant is harmful to the human body, do not
use for drinking.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove:

•

Rear Fender Flap Screws [A]

Remove:

•

Reserve Tank Screws [A]
Reserve Tank [B] with Hose

Place a container under the drain plug [A] at the bottom

•

of the water pump [B], then remove the drain plug.

Remove the radiator cap [A] in two steps. First turn the

•

cap counterclockwise to the first step. Then push and turn
it further in the same direction and remove the cap.
The coolant will drain from the radiator and engine.

•

Remove the reserve tank cap, and pour the coolant into

•

a container.

Tighten the drain plug.

•

Torque - Coolant Drain Plug: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Support the vehicle on a stand or the j ack so that the front

•

wheels are off the ground. This makes air bleeding easier.
Fill the radiator up to the radiator filler neck [A] with

•

coolant.

NOTE

Pour in the coolant slowly so that the air in the engine

○

and radiator can escape.

Periodic Maintenance Procedures

CAUTION

Soft or distilled water must be used with the an­tifreeze in the cooling system.
If hard water is used in the system, it causes scale
accumulation in the water passages, considerably
reducing the efficiency of the cooling system.

Water and Coolant Mixture Ratio (when shipping)

Soft Water: 50%

Coolant: 50%

Freezing Point:

Total Amount:

Choose a suitable mixture ratio by referring to the

○

coolant manufacturer’s directions.

Bleed the air from the cooling system as follows.

•

Start the engine with the radiator cap removed and run it

○

until no more air bubbles [A] can be seen in the coolant.
Tap the radiator hoses to force any air bubbles caught

○

inside.
Stop the engine and add coolant up to the radiator filler

○

neck.
Install the radiator cap.

•

–35°C (–31°F)

2.4 L (2.54 US qt)

NOTE

PERIODIC MAINTENANCE 2-21

Remove the reserve tank cap.

•

Fill the reserve tank up to the F mark [A] with coolant and

•

install the cap.
Start the engine, warm it up thoroughly until the radiator

•

fan turns on and then stop the engine.
Check the coolant level in the reserve tank after the en-

•

gine cools down.
If the coolant level is lower than the low level line [B], add
coolant to the full level line.

CAUTION

Do not add more coolant above the full level line.

Coolant Filter Cleaning

Drain the coolant (see Coolant change).

•

Remove:

•

Air Cleaner Cover
Torque Converter Outlet Air Duct

Remove the filter [A] from the cooling hoses [B] of carbu-

•

retor system.
Blow [C] off dirt and sediment on the filter with com-

•

pressed air.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Engine Top End

Valve Clearance Inspection

NOTE

Check the valve clearance only when the engine is cold

○

(at room temperature).

Remove:

•

Air Cleaner Cover (see Air Cleaner Cover Removal in
the Frame chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Front Inner Covers (see Front Inner Cover and Front
Lower Shroud Removal in the Frame chapter)
Valve Adjusting Caps [A]
Recoil Starter (see Recoil Starter Removal in the Recoil
Starter chapter)

Remove the timing inspection plug.

•

Special Tool - Filler Cap Driver: 57001-1454

Turn the crankshaft counterclockwise withawrenchon

•

the alternator rotor bolt until “T-F” mark [A] on the alter­nator rotor aligns with the notch [B] as shown: the end of
the compression stroke in the front cylinder head.

Measure the clearance for all four valves, one at a time

•

between the end of the valve stem and the adjusting
screw [A] with the thickness gauge [B].

Valve Clearance (when cold)

Exhaust:

Inlet:

If the v alve clearance is not correct, adjust it (see Valve
Clearance Adjustment).

Then, turn the crankshaft counterclockwise with a

•

wrench on the alternator rotor bolt until “T-R” mark [A] on
the alternator rotor aligns with the notch [B] as shown:
the end of the compression stroke in the rear cylinder
head.
Measure the clearance for all four valves, one at a time

•

between the end of the valve stem and the adjusting
screw with the thickness gauge.

Valve Clearance (when cold)

Exhaust:

Inlet:

If the v alve clearance is not correct, adjust it (see Valve
Clearance Adjustment).

0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

Periodic Maintenance Procedures

Valve Clearance Adjustment

Remove the valve adjusting caps.

•

Loosen the locknut and turn the adjusting screw until the

•

clearance is correct.
Hold the adjusting screw [A] from turning and tighten the

•

locknut [B].

Torque - Valve Adjusting Screw Locknuts: 12 N·m (1.2

kgf·m, 104 in·lb)

Recheck the clearance.

•

If the clearance is incorrect, repeat the adjustment proce­dure.
If the clearance is correct, perform the adjustment proce­dure on the other valve.

Spark Arrester Cleaning

WARNING

To avoid burns, wear gloves while cleaning the
spark arrester. Since the engine must be run dur­ing this procedure, the muffler will become hot.

PERIODIC MAINTENANCE 2-23

Remove the drain plug [A] on the muffler.

•

In an open area away from combustible materials, start

•

the engine with the transmission in neutral.
Raise and lower engine speed while tapping on the muf-

•

fler with a rubber mallet until carbon particles are purged
from the muffler.

WARNING

Do not run the engine in a closed area. Exhaust
gases contain carbon monoxide; a colorless, odor­less, poisonous gas. Breathing exhaust gas leads
to carbon monoxide poisoning, asphyxiation, and
death.

Stop the engine.

•

Install the drain plug.

•

Converter System

Converter Drive Belt Inspection

Inspection of the drive belt is required at least every 90
days of vehicle use (average 12 mile/day) not to exceed 1
700 km (1 100 mile) or belt indicator light turn on (100 hours
of use) counted by the hour meter. More frequent inspection
is necessary if the vehicle is subjected to hard usage.

WARNING

Neglect, abuse, or failure to maintain the transmis-

sion can result in a severely worn or damaged drive

belt locking up the transmission and wheels. This

can cause the operator to lose control and have an

accident resulting in injury or death.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove the torque converter cover (see Torque Con-

•

verter Cover Removal in the Converter System chapter).
Measure the width [A] of the belt several locations with a

•

pair of suitable straightedges [B] as shown

Belt Width

Standard: 29.7 ∼ 30.3 mm (1.169 ∼ 1.193 in.)

Service Limit: 28.0 mm (1.102 in.)

If any measurements exceed the service limit, replace the
belt.

NOTE

Use the belt measuring gauge [A] in order to make easy

○

to inspect the drive belt width.

Special Tool - Belt Measuring Gauge: 57001-1646

Fit the drive belt [B] into the belt measuring gauge.

•

If the upper surface [C] of the belt lowers than the upper
surface [D] of the gauge, replace the belt.

[E] 28 mm (1.102 in.)

Check the belt [A] for abnormal wear [B].

•

Measure the width [C] of the belt at abnormal wear point.

○

If any measurements exceed 0.5 mm (0.02 in.), replace
the belt.
When using the belt of large abnormal wear, the drive belt

○

failure detection switch could be activated.

Check the belt for cracks, breaks, or peeling.

•

If necessary, replace the belt with a new one.

Belt [A]
Crack [B]
Broken [C]
Peeling [D]

NOTE

Whenever the belt i s replaced, inspect the drive and the

○

driven pulleys.

Converter Drive Belt Deflection Inspection

Remove the torque converter cover (see Torque Con-

•

verter Cover Removal in the Converter System chapter).
Put the transmission in neutral and rotate the driven pulley

•

by hand to make sure the belt is shifted all the way to the
top of the driven pulley.

Periodic Maintenance Procedures

Measure the belt deflection [A] as shown:

•

Place a straightedge [B] on top of the belt between the

○

drive pulley [C] and the driven pulley [D].

Use a ruler to push the belt away from the straightedge.

○

Push hard, but with no more force than 59 N (6 kgf, 13 lb).

Belt Deflection

Standard: 22 ∼ 27 mm (0.87 ∼ 1.06 in.)

If the belt deflection is not within the specified range, first

measure the height of the belt parallel portion (see Drive

Belt Inspection). Adjust the deflection by adding or re-

moving spacers on the fixed sheave of the driven pulley.

When adjusting the deflection, less is better than more.

•

Less deflection will maintain better performance for more

time as the belt width decreases by normal wear, which

causes the deflection to increase with usage.

Converter Drive Belt Deflection Adjustment

Disassemble the driven pulley (see Driven Pulley Disas-

•

sembly in the Converter System chapter).

If the belt deflection is more than 27 mm (1.06 in.), remove

the spacers to decrease it.

The r

○

○

ule-of-thumb is: 0.1 mm (0.004 in.) change in spacer
thickness equals about 1.3 mm (0.051 in.) change in belt
deflection.
If the belt def
spacers [A] to increase it.
The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer
thickness equals about 1.6 mm (0.063
deflection.

lection is less than 22 mm (0.87 in.), add the

in.) change in belt

PERIODIC MAINTENANCE 2-25

NOTE

When using the plural spacers, install the thick spacer

○

to the movable sheave side and thin spacer to the fixed
sheave side.

Spacers

Part No. Thickness

92026-0034

92026-1569

92026-1617

92026-1565 1.0 mm (0.039 in.)

92026-1570

Assemble the driven pulley (see Driven Pulley Assembly

•

in the Converter System chapter).
With the transmission in neutral, rotate the driven pulley

•

to allow the belt to return to the top of the sheaves before
measuring the belt deflection.
Measure the belt deflection again and repeat the above

•

procedures until it is within the standard range.
Using the flywheel & pulley holder and pulley holder at-

•

tachment, tighten the driven pulley nut.

Special Tools - Flywheel & Pulley Holder: 57001-1605

Pulley Holder Attachment: 57001-1472

0.3 mm (0.012 in.)

0.6 mm (0.024 in.)

0.8 mm (0.032 in.)

1.4 mm (0.055 in.)

Torque - Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb)

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Actuator Lever (Engine Brake Control Lever)
Assembly Inspection

Measure the width [A] of the plastic guide shoe [B] of the

•

actuator lever assembly.

Actuator Lever Guide Shoe

Service Limit: 6 mm (0.24 in.)

If the guide contact area width is greater than the service
limit, replace the actuator lever assembly.

Engine Lubrication System

Engine Oil Change

Support the vehicle so that it is level, both side to side and

•

front to rear after warming up the engine.
Remove the engine drain plug [A] to drain the oil.

•

The oil in the filter can be drained by removing the filter

○

(see Oil Filter Change).
Replace the drain plug gasket with a new one.

•

Tighten:

•

Torque - Engine Drain Plug : 20 N·m (2.0 kgf·m, 14 ft·lb)

Pour in the specified type and amount of oil.

•

Engine Oil

Type: API SF or SG

APISHorSJwithJASOMAclass

Viscosity: SAE 10W-40

Amount: 1.54 L (1.63 US qt)

(When filter is not removed)

1.75 L (1.85 US qt)

(When filter is removed)

2.05 L (2.17 US qt)

(When engine is completely dry)

NOTE

Although 10W-40 engine oil is the recommended oil

○

for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.

Oil Filter Replacement

Drain the engine oil.

•

Remove the oil filter [A] with the oil filter wrench [B].

•

Special Tool - Oil Filter Wrench: 57001-1249

Periodic Maintenance Procedures

Replace the filter with a new one.

•

When installing the oil filter, be careful of the following.

•

Apply oil to the gasket [A] before installation.

○

Tighten the filter with the oil filter wrench.

○

Special Tool - Oil Filter Wrench: 57001-1249

Torque - Oil Filter : 18 N·m (1.8 kgf·m, 13 ft·lb)

Pour in the specified type and amount of oil.

○

Wheels/Tires

Tire Inspection

Examine the tire for damage and wear.

•

If the tire is c ut or cracked, replace it.
Lumps or high spots on the tread or sidewalls indicate

○

internal damage requiring tire replacement.
Remove any foreign objects from the tread. After re-

○

moval, check for leaks with a soap and water solution.
Measure the tread depth at the center of the tread with a

•

depth gauge [A]. Since the tire may wear unevenly, take
measurements at several places.

PERIODIC MAINTENANCE 2-27

Tire Tread Depth

Service Limit:

Front:

Rear:

If any measurements are less than the service limit, re­place the tire.

Standard Tire

Front: AT 25 × 8 - 12

Rear: AT 25 × 10 - 12

3 mm (0.12 in.)

4 mm (0.16 in.)

DUNLOP, KT121A, Tubeless

DUNLOP, KT127A, Tubeless

Final Drive

Variable Differential Control Lever Play Inspection

Pull the variable differential control lever [A] towards the

•

handlebar grip [B] with a spring s cale until it reads 30 N
(3 kgf, 7 lb) of force.
The differential control in the front final gear case must be

○

locked, then the clearance [C] between the control lever
and grip should be 20 mm (0.8 in.).

Differential Control Lever Lock Position Length

Standard: 20 mm (0.8 in.)

If the clearance is not the specified length, adjust the ca­ble.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Variable Differential Control Lever Play Adjustment

Remove:

•

Handlebar Cover Screws [A]
Handlebar Cover Front [B]

Loosen the locknut [A] of the differential control cable.

•

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

•

play.
Tighten the locknut securely.

•

Front Final Gear Case Oil Change

Warm up the oil by running the vehicle so that the oil will

•

pick up any sediment and drain easily. Then stop the
vehicle.
Park the vehicle so that it is level, both side to side and

•

front to rear.
Remove the front side cover (see Front Inner Cover and

•

Front Lower Shroud Removal in the Frame chapter).
Place an oil pan beneath the front final gear case and

•

remove the drain plug [A].

WARNING

When draining or filling the final gear case, be care­ful that no oil gets on the tire or rim. Clean off any
oil that inadvertently gets on them with a high-flash
point solvent.

After the oil has completely drained out, install the drain

•

plug with a new aluminum gasket, and tighten it.

Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb)

Periodic Maintenance Procedures

Fill the gear case up to the bottom of filler opening with

•

the oil specified below.

Front Final Gear Case Oil

Typ e :

Viscosity:

Capacity: 0.43 L (0.45 US qt)

Depending on the atmospheric temperature of your rid-

○

ing area, the engine oil viscosity should be changed ac­cording to the chart.

Be sure the O-ring is in place, and tighten the filler cap.

•

Apply grease to the O-ring.

○

Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb)

Rear Final Gear Case Oil Change

Warm up the oil by running the vehicle so that the oil will

•

pick up any sediment and drain easily. Then stop the
vehicle.
Park the vehicle so that it is level, both side to side and

•

front to rear.
Place an oil pan beneath the rear final gear case and

•

remove the drain plug [A].

API SF or SG

API SH or SJ with JASO MA class

SAE 10W-40

NOTE

PERIODIC MAINTENANCE 2-29

WARNING

When draining or filling the final gear case, be care­ful that no oil gets on the tire or rim because oil will
deteriorate the tire. Clean off any oil that inadver­tently gets on them with a high-flash point solvent.

After the oil has completely drained out, install the drain

•

plug with a new

Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb)

Fill the final gear case up to the bottom of filler opening

•

with the oil specified below.

Rear Final Gear Case Oil

Type :

Capacity: 0.9 L (0.95 US qt)

Be sure the O-ring is in place.

•

Torque - Oil Filler Cap [B]: 29 N·m (3.0 kgf·m, 22 ft·lb)

aluminum gasket.

MOBIL Fluid 424 or CITGO TRANSGARD
TRACTOR HYDRAULIC FLUID or Exxon
Hydraul 560

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brakes

Front Brake Pad Wear Inspection

Check the lining thickness [A] of the pads in each caliper.

•

Pad Lining Thickness

Standard: 4 mm (0.16 in.)

Service Limit: 1 mm (0.04 in.)

If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.

Front Brake Hoses and Connections Inspection

Inspect the brake hose and fittings for deterioration,

•

cracks and signs of leakage.
The high pressure inside the brake line can cause fluid to

○

leak [A] or the hose to burst if the line is not properly main­tained. Bend and twist the rubber hose while examining
it.
Replace the hose if any cracks [B] or bulges [C] are no­ticed.
Tighten any loose fittings.

•

Front Brake Hose Replacement

Pump the brake fluid out of the line as explained in the

•

Brake Fluid Change.
Remove the banjo bolts at both ends of the brake hose,

•

and pull the hose off the vehicle.
Immediately wipe up any brake fluid that spills.

•

CAUTION

Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely washed away
immediately.

Use a new flat washer for each side of the hose fittings.

•

Install the new brake hose in its place (see Appendix

•

chapter), and tighten the banjo bolts.

Torque - Brake Hose Banjo B olts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Front Brake Fluid Level Inspection

Position the reservoir horizontal, and check that the fluid

•

level in the reservoir is higher than the lower level line [A].
If the fluid level is lower than the lower level line, check
for fluid leakage of the brake line, and add the fluid as
follows:

Periodic Maintenance Procedures

Remove the reservoir cap, and fill the reservoir to the up-

○

per level line [A] in the reservoir with the same type and
brand of the fluid that is already in the reservoir. And then
install the reservoir cap.

WARNING

Change the fluid in the brake line completely if the
fluid must be refilled but the type and brand of the
fluid that is already in the reservoir are unidentified.

Tighten:

•

Torque - Reservoir Cap Screws : 1.5 N·m (0.15 kgf·m, 13

in·lb)

Front Brake Fluid Change

Remove the reservoir cap and the rubber cap on the bleed

•

valve.
Attach a clear plastic hose to the bleed valve on the

•

caliper, and run the other end of the hose into a con­tainer.
Fill the reservoir with new brake fluid.

•

Change the brake fluid as follows:

•

Open the bleed valve [A].

○

Apply the brake lever and hold it [B].

○

Close the bleed valve [C].

○

Release the brake lever [D].

○

Check the fluid level in the reservoir often, replenishing it

•

as necessary.

PERIODIC MAINTENANCE 2-31

NOTE

If the fluid in the reservoir runs completely out any time

○

during fluid changing, air will enter the line, and the sys­tem must be bled.

Repeat this operation until fresh brake fluid comes out into

•

the plastic hose or the color of the fluid changes.

WARNING

Do not mix two brands of fluid. Change the brake
fluid in the brake line completely if the brake fluid
must be refilled but the type and brand of the brake
fluid that is already in the reservoir are not known.

Tighten:

•

Torque - Bleed Valves: 7.9 N·m (0.80 kgf·m, 69 in·lb)

Apply the brake lever forcefully for a few seconds, and

•

check for fluid leakage around the fittings.
If necessary, bl
Line Air Bleeding in the Brakes chapter).

If the brake lever has a soft or "spongy feeling"
when it is applied, there might be air in the brake
line or the brake may be defective. Since it is dan­gerous to operate the vehicle under such condi­tions, bleed the air from the brake line immediately.

eed the air from the brake line (see Brake

WARNING

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Front Brake Master Cylinder Piston Assembly and
Dust Cover Replacement

Disassemble the master cylinder (see Front Brake Master

•

Cylinder Disassembly in the Brakes chapter).
Replace the piston assembly [A] and dust cover [B] under

•

following condition.

a)Primary and secondary cups are worn, damaged, soft-

ened (rotted) or swollen.
b)Fluid leakage is noted at the brake lever.
c)Dust cover is broken or swollen.

Front Brake Caliper Fluid Seal Replacement

The fluid seals [A] around the piston maintain the proper
pad/disc clearance. If the seals are not satisfactory, pad
wear will increase, and constant pad drag on the disc will
raise brake and brake fluid temperature.

Replace the fluid seals in accordance with the Periodic

•

Maintenance Chart or under any of the following condi-

tions: (a) fluid leakage around the pad; (b) brakes over-

heat; (c) there is a large difference in inner and outer pad

wear; (d) the seal is stuck to the piston.

If the fluid seal is replaced, replace the dust seal as well.

Also, replace all seals every other time the pads are

changed.

Front Bra ke Caliper Dust Seal and Friction Boot
Replacement

Replace the dust seals [B] in accordance with the Peri-

•

odic Maintenance Chart or check that the dust seals and

friction boots [C] are not cracked, worn swollen, or other-

wise damaged.

If they show any damage, replace them.

Rear Brake Plates Replacement

Disassemble the internal wet brake (see Internal Wet

•

Brake Disassembly in the Brakes chapter).

Replace the steel pressure plates, steel plates and friction

•

plates in accordance with the specified interval.

Rear Brake Lever Free Play Inspection

Check the rear brake lever free play [A].

•

Pull the rear brake lever lightly until the brake is applied.

○

Rear Brake Lever Free Play

Standard: 1 ∼ 2 mm (0.04 ∼ 0.08 in.)

If the play is incorrect, adjust it.

Periodic Maintenance Procedures

Rear Brake Pedal Free Play Inspection

Check the brake pedal free play [A].

•

Depress the brake pedal lightly by hand until the brake is

○

applied.

Rear Brake Pedal Free Play

Standard: 15 ∼ 25 mm (0.6 ∼ 1.0 in.)

If the free play is incorrect, adjust it.

Rear Brake Lever and Pedal Free Play Adjustment

NOTE

Since the rear brake lever and pedal free play adjust-

○

ments affect each other, make them at the same time.

Rear Brake Lever

Loosen the knurled locknut [A] and turn the adjuster [B]

•

at the rear brake lever in as far as it will go.
Tighten the locknut.

•

Turn the brake lever adjuster [A] at the rear end of the

•

brake cable until the rear brake lever has the correct
amount of play.

PERIODIC MAINTENANCE 2-33

Rear Brake Pedal

Turn the brake pedal adjuster [A] at the rear end of the

•

brake cable until the brake pedal has the correct amount
of play.
Operate the pedal a few times to see that it returns to its

•

rest position immediately upon release.
Rotate the rear wheels to check for brake drag.

•

Check braking effectiveness.

•

If there is any doubt as to the conditions of the brake,
check the brake parts for wear or damage.

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering

Steering Inspection

Turn the handlebar left and right, and check the steering

•

action.

If the steering action is not smooth, or if the steering binds

or catches before the stop, lubricate the steering stem

bearing.

NOTE

The cables and wires will have some effect on the steer-

○

ing action which must be taken into account.

Check the steering action again.

•

If steering stem bearing lubrication does not remedy the

problem, inspect the steering stem for straightness, steer-

ing stem clamps, and tie-rod bearings.

If you feel looseness, or if the steering rattles as it turns,

check the tightness of the steering bolts and nuts.

Tighten loose bolts and nuts to the specified torque (see

•

Steering chapter), and check the steering action again.

If the steering action does not change by tightening the

bolts and nuts, inspect the steering stem clamps, steer-

ing stem bearings, tie-rod bearings, and steering knuckle

joints.

Electrical System

Spark Plug Clea ning/Inspection

Remove the spark plug (see Spark Plug Removal in the

•

Electrical System chapter).

Clean the spark plug, preferably in a sandblasting device,

•

and then clean off any abrasive particles. The plug may

also be cleaned using a wire brush or other suitable tool.

If the spark plug electrodes are corroded or damaged,

or if the insulator is cracked, replace the plug. Use the

standard spark plug or its equivalent.

Spark Plug Gap Inspection

Measure the gap [A] with a wire-type thickness gauge.

•

Spark Plug Gap

0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

If the gap is incorrect, carefully bend the side electrode

[B] with a suitable tool to obtain the correct gap.

Periodic Maintenance Procedures

Rear Brake Light Switch Inspection

Turn on the ignition switch.

•

Check the operation of the rear brake light switch by de-

•

pressing the brake pedal [A].

Rear Brake Light Timing

Standard: On after about 10 mm (0.4 in.) of pedal

travel [B]

If it does not as specified, adjust the brake light timing.

Rear Brake Light Timing Adjustment

Remove the rear flap (see Rear Flap Removal in the

•

Frame chapter).
Adjust the brake light switch [A] up or down. To change

•

the switch position, turn the adjusting nut [B].

Light soon as the body rises [C]
Light later as the body lower [D]

CAUTION

To avoid damaging the electrical connections in­side the switch, be sure that the switch body does
not turn during adjustment.

PERIODIC MAINTENANCE 2-35

Drive Belt Failure Detection System Insp ection

Remove:

•

Fuel Tank Cover (see Fuel Tank Removal in the Fuel
System chapter)

Check the drive belt failure detection system according to

•

following chart.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Periodic Maintenance Procedures

Joint Boots Inspection

Front Axle/Steering Knuckle Joint Boot Inspection

Remove:

•

Bolts [A] and Washer
Front Axle Guard [B]

Visually inspect the front axle joint boots [A].

•

If the joint boot is torn, worn, deteriorated, or leaks grease,
replace t he joint boot or front axle assembly (see Front
Axle Joint Boot Replacement in the Final Drive chapter).
Visually inspect the suspension arm joint boots [B].

•

If the joint boot is torn, worn, deteriorated, or leaks grease,
replace the knuckle joint (see Suspension Arms section in
the Suspension chapter).

PERIODIC MAINTENANCE 2-37

Front Propeller Shaft Joint Boot Inspection

Visually inspect the boots [A] of the front propeller shaft.

•

If damage, tear or deterioration is found, replace the boots
(see Front Propeller Shaft section in the Final Drive chap­ter).

Rear Propeller Shaft Joint Boot Inspectio n

Visually inspect the rear propeller shaft joint boot [A].

•

If the joint boot is torn, worn, or deteriorated, replace the
joint boot and check the propeller shaft (see Rear Pro­peller Shaft section in the Final Drive chapter).

Tie-rod End Boot Inspection

Visually inspect the tie-rod end boots [A] of the tie-rods.

•

If the boot is torn, worn, deteriorated, or leaks grease, re­place the tie-rod end (see Tie-rod Removal in the Steering
chapter).

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

General Lubrication

Lubrication

Before lubricating each part, clean off any rusty spots with

•

rust remover and wipe off any grease, oil, dirt, or grime.

Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a
high-pressure spray water, perform the general lubri­cation.

Cables: Lubricate with Cable Lubricant

Rear Brake Inner Cables
Throttle Inner Cable
Choke Inner Cable
Variable Differential Control Inner Cables

Lubricate the cables by seeping the oil between the cable

•

and housing.

The cable may be lubricated by using a pressure cable

○

luber with an aerosol cable lubricant.

With the cable disconnected at the both ends, the cable

•

should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable

is frayed [B], or if the cable housing is kinked [C], replace

the cable.

Points: Lubricate with Grease.

Throttle Inner Cable Ends [A]
Choke Cable Lower End
Brake Cable Upper End
Variable Differential Control Cable Ends

Slide Points: Lubricate with Grease.

Brake Lever
Brake Pedal Pivot Shaft
Throttle Lever Shaft

Periodic Maintenance Procedures

Bolts and Nuts Tightening

Tightness Inspection

Check the tightness of the bolts and nuts listed here in

•

accordance with the Periodic Maintenance Chart. Also,
check to see that each cotter pin is in place and in good
condition.
If there are loose fasteners, retorque them to the s peci­fied torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not listed in the appropriate
chapter, see the Basic Torque Table (see Torque and
Locking Agent). For each fastener, first loosen it by 1/2
turn, then tighten it.
If cotter pins are damaged, replace them with new ones.

Bolts, Nuts, and Fasteners to be checked
Wheels

Front Axle Nuts and Cotter Pins
Rear Axle Nuts and Cotter Pins
Wheel Nuts

Brakes

Front Brake Master Cylinder Clamp Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Front Brake Caliper Mounting Bolts
Brake Pedal Cotter Pin

Steering/Suspension

Handlebar Holder Bolts
Steering Stem Clamp Bolts
Steering Stem Bearing Joint Bolts
Tie-rod End Nuts and Cotter Pins
Tie-rod Locknuts
Front Shock Absorber Mounting Nuts
Front Suspension Arm Pivot Bolts
Steering Knuckle Joint Nuts and Cotter Pins

Engine

Engine Mounting Bolts
Engine Mounting Bracket Bolts
Exhaust Pipe Holder Nuts
Muffler Mounting Bolts
Muffler Clamp Bolt

Final Drive

Front Final Gear Case Nuts

Others

Footpeg Mounting Bolts
Throttle Case Screws
Carrier Bolts, Nuts

PERIODIC MAINTENANCE 2-39

Fuel System

Table of Contents

Exploded View ................................... 3-2

Specifications .................................... 3-6

Special Tools ..................................... 3-7

Throttle Lever and Cable ................... 3-8

Throttle Lever Free Play

Inspection .................................. 3-8

Throttle Lever Free Play

Adjustment ................................ 3-8

Throttle Case Removal/Disas-

sembly....................................... 3-8

Throttle Case Assembly/Installa-

tion ............................................ 3-8

Throttle C able Installation ............ 3-9

Throttle C ase Inspection .............. 3-9

Throttle Cable Lubrication and

Inspection .................................. 3-9

Choke Lever and Cable..................... 3-10

Choke Lever Free Play

Inspection .................................. 3-10

Choke Lever Free Play

Adjustment ................................ 3-10

Choke Lever and Cable Removal 3-10
Choke Lever and Cable

Installation ................................. 3-11

Choke Cable Lubrication and

Inspection .................................. 3-11

Carburetor ......................................... 3-12

Idle Speed Inspection .................. 3-12

Idle Speed Adjustment................. 3-12

Pilot Screw Adjustment ................ 3-12

Service Fuel Level Inspection ...... 3-12

Service Fuel Level Adjustment .... 3-13

FUEL SYSTEM 3-1

3

Carburetor Synchronization

Inspection.................................. 3-14

Carburetor Synchronization

Adjustment ................................ 3-15

Fuel System Cleanliness

Inspection.................................. 3-15

Carburetor Removal..................... 3-15

Carburetor Installation.................. 3-16

Carburetor Disassembly .............. 3-16

Carburetor Assembly ................... 3-18

Carburetor Separation ................. 3-19

Carburetor Joining ....................... 3-19

Carburetor Cleaning..................... 3-20

Carburetor Inspection .................. 3-21

Air Cleaner......................................... 3-23

Air Cleaner Element Removal...... 3-23

Air Cleaner Element Cleaning and

Inspection.................................. 3-23

Air Cleaner Housing Removal...... 3-23

Air Cleaner Housing Installation... 3-25

Fuel Tank........................................... 3-27

Fuel Tank Removal ...................... 3-27

Fuel Tank Installation ................... 3-27

Fuel Tank Cleaning ...................... 3-28

Fuel Tap Removal ........................ 3-28

Fuel Tap Installation ..................... 3-28

Fuel Tap Inspection...................... 3-29

Fuel Pump ......................................... 3-30

Fuel Pump Removal .................... 3-30

Pump Filter Cleaning ................... 3-30

Fuel Pump Installation ................. 3-31

Fuel Pump Inspection .................. 3-31

3-2 FUEL SYSTEM

Exploded View

Exploded View

FUEL SYSTEM 3-3

No. Fastener

1

Heat Guard Plate Mounting Bolts

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

12. Throttle Case Screws

13. Plug (KVF700A6F/D6F (United States model))
G: Apply grease.
O: Apply engine oil.

CA: Canada Model

Torque

N·m

8.8 0.90 78 in·lb

kgf·m ft·lb

Remarks

3-4 FUEL SYSTEM

Exploded View

Exploded View

FUEL SYSTEM 3-5

No. Fastener

1

Air Cleaner Housing Bolts (M5)

2 Air Cleaner Housing Bolts (M6) 28.7 mm (1.13 in.) 8.8 0.90 78 in·lb

3 Air Cleaner Housing Bolts (M6) 33 mm (1.30 in.) 8.8 0.90 78 in·lb

4 Fuel Tap Plate Screws 0.8 0.08 7in·lb

5 Air Cleaner Element Bracket Screws 4.9 0.50 43 in·lb

6. Fuel Pump

7. Fuel Tank Breather

8. Check Valve

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

10. Joints
G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Part (Fuel Pump Gasket)

N·m

5.9 0.60 52 in·lb L

Torque

kgf·m ft·lb

Remarks

3-6 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 NBZL –––

Pilot Jet #40 –––

Pilot Air Jet #130 –––

Pilot Screw 1 1/2 turns out –––

Carburetor Synchronization Vacuum less than 2.7 kPa (2 cmHg) difference

between carburetors

Starter Jet #95

Idle Speed 1 100 ±50 r/min (rpm)

Service Fuel Lev

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

Optional Parts:

Main Jet:

*Altitude

0 ∼ 500 m (0 ∼ 1 600 ft):

Front #138 (92063-1015) –––

Rear #142 (92063-1016) –––

500 ∼ 1 500 m (1 600 ∼ 4 900 ft):

Front #135 (92063-1014) –––

Rear #140 (92063-1013) –––

1 500 ∼ 2500m(4900∼ 8 200 ft):

Front

Rear

2 500 ∼ 3 500

Front #130 (92063-1075) –––

Rear #132 (92063-1076) –––

3500∼ 4 500 m (11 500 ∼ 14 800 ft):

Front #125 (92063-1069) –––

Rear #130 (92063-1075) –––

Air Cleaner

Air Cleaner Element Oil High-quality foam air filter oil –––

*: Refer to page 6-28 for high altitude setting in the converter system.

el

m (8 200 ∼ 11 500 ft):

12 ±1 mm (0.47 ±0.
punch mark

#132 (92063-1076)

#138 (92063-1015)

04 in.) below the

–––

–––

–––

–––

–––

–––

Special Tools

FUEL SYSTEM 3-7

Fuel Level Gauge:
57001-1017

Carburetor Drain Plug Wrench, Hex 3:
57001-1269

Pilot Screw Adjuster, A:
57001-1239

Vacuum Gauge:
57001-1369

3-8 FUEL SYSTEM

Throttle Lever and Cable

Throttle Lever Free Play Inspection

Refer to the Throttle Lever Free Play Inspection in the

•

Periodic Maintenance chapter.

Throttle Lever Free Play Adjustment

Refer to the Throttle Lever Free Play Adjustment in the

•

Periodic Maintenance chapter.

Throttle Case Removal/Disassembly

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

•

open.
Slide the cable adjuster dust cover out of place.

•

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], lock washer, 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/in-

•

stallation.
Be certain that the return spring is correctly installed on

•

the throttle lever [A].

Throttle Lever and Cable

Swing the throttle control lever so that the carburetor throt-

•

tle 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 throt-

○

tle limiter and adjustment procedure of it.

WARNING

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 in the Periodic Maintenance chapter).

Throttle Cable Installation

Lubricate the throttle cable before installation.

•

Route the cable correctly according to the Cable, Wire

•

and Hose Routing in the Appendix chapter.

WARNING

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

FUEL SYSTEM 3-9

Check the throttle cable (see Throttle Lever Free Play In-

•

spection in the Periodic Maintenance chapter).

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 and Inspection

Whenever the throttle cable is removed or in accordance

•

with the Periodic Maintenance Chart in the Periodic Main­tenance chapter, lubricate the cable .
Refer to the General Lubrication in the Periodic Mainte-

•

nance chapter.

3-10 FUEL SYSTEM

Choke Lever and Cable

Choke Lever Free Play Inspection

Refer to the Choke Lever Free Play Inspection in the Pe-

•

riodic Maintenance chapter.

Choke Lever Free Play Adjustment

Refer to the Choke Lever Free Play Adjustment in the

•

Periodic Maintenance chapter.

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.

•

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].

Choke Lever and Cable

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.

•

FUEL SYSTEM 3-11

Choke Lever and Cable Installation

Lubricate the choke cable before installation.

•

Install the wave washer, plane washer and screw in that

•

order.
Route the choke cable according to the Cable, Wire and

•

Hose routing in the Appendix chapter.

WARNING

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

Choke Cable Lubrication and Inspection

Whenever the choke cable is removed or in accordance

•

with the Periodic Maintenance chart in the Periodic Main­tenance chapter, lubricate the cable.
Refer to the General Lubrication in the Periodic Mainte-

•

nance chapter.

3-12 FUEL SYSTEM

Carburetor

Idle Speed Inspection

Refer to the Idle Speed Inspection in the Periodic Main-

•

tenance chapter.

Idle Speed Adjustment

Refer to the Idle Speed Adjustment in the Periodic Main-

•

tenance chapter.

Pilot Screw Adjustment

Adjust the pilot screw if necessary.

•

Remove the air cleaner cover (see Air Cleaner Cover Re-

•

moval in the Frame chapter).
For United States model (KVF700A6F/D6F), it is neces-

○

sary to remove the plug (see Carburetor Disassembly).
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: 1 1/2 turns out

Service Fuel Level Inspection

WARNING

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).

•

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 so that the outlet s ide 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]

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 carbu-

○

retor 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.

FUEL SYSTEM 3-13

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].

•

Service Fuel Level

Standard: 12±1mm(0.47±0.04in.) belowthe

punch mark

If the fuel level is incorrect, adjust it.
Tighten the drain screw.

•

Repeat the same procedure for the other carburetor.

•

Service Fuel Level Adjustment

WARNING

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].

•

3-14 FUEL SYSTEM

Carburetor

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

•

the float height.

Float Height

Standard: 4.0 ±1 mm (0.16 ±0.04 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 de-

○

creasing 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 the idle speed.

•

Remove:

•

Air Cleaner Cover (see Air Cleaner Cover Removal in
the Frame chapter)
Rubber Air Duct [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.

Special Tool - Vacuum Gauge: 57001-1369

Start the engine and read the intake vacuum of each car-

•

buretor when idling.

Carburetor Synchronization Vacuum

Standard: Less than 2.7 kPa (2 cmHg) difference

between carburetors

If the vacuum is out of the specified range, adjust it.

Carburetor

Carburetor Synchronization Adjustment

Turn the adjusting screw [A] to synchronize the carbure-

•

tors.
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 the idle speed.

•

Fuel System Cleanliness I nspection

Refer to the Fuel System Cleanliness Inspection in the

•

Periodic Maintenance chapter.

Carburetor Removal

WARNING

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.

FUEL SYSTEM 3-15

Drain the coolant (see Coolant Draining in the Cooling

•

System chapter).

Remove:

•

Air Cleaner Housing (see Air Cleaner Housing Removal)
Side Cover (see Left Side C over Removal in the 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.

•

3-16 FUEL SYSTEM

Carburetor

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

•

Pull out of the starter plungers.

•

Carburetor Installation

Check the fuel leakage from the carburetors.

•

WARNING

Fuel spilled from the carburetors is hazardous.

Adjust the idle speed (see Idle Speed Adjustment in Pe-

•

riodic Maintenance chapter).
Check the throttle cable (see Throttle Lever Free Play In-

•

spection in the Periodic Maintenance chapter).
Tighten:

•

Torque - Heat Guard Plate Mounting Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

Carburetor Disassembly

Remove the carburetors (see Carburetor Removal).

•

WARNING

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 pilot screw with spring, washer and O-ring.

•

For the United States model (KVF700A6F/D6F), remove

○

the pilot screw plug as follows: punch a hole in the plug
and pry there with an awl or other suitable tool.
Turn in the pilot screw and count the number of turns until

○

it seats fully but not tightly, and then remove the s crew.
This is to set the screw to its original position when as­sembling.

Carburetor

Remove the upper chamber cover [A], spring [B], and vac-

•

uum 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).

FUEL SYSTEM 3-17

Remove:

•

Screws [A]
Float Chamber [B]

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]

3-18 FUEL SYSTEM

Carburetor

Remove:

•

Diaphragm [A]
O-ring [B]

Carburetor Assembly

WARNING

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.

Turn in the pilot screw [A] fully but not tightly, and then

•

back it out the same number of turns counted during dis­assembly.
For the United States model (KVF700A6F/D6F), install

○

the pilot screw plug as follows: install a new plug [B] in
the pilot screw hole of the carburetor body [C], and apply a
small amount of a bonding agent [D] to the circumference
oftheplugtofixtheplug.

CAUTION

Do not apply too much bonding agent to the plug,
or the pilot screw itself may be fixed.

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).

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 vac-

•

uum 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.

FUEL SYSTEM 3-19

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
carburetor joining bolts and align the carburetors on a flat
surface.
Retighten the carburetor joining bolts.

•

3-20 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 Adjust-

•

ment).

Carburetor Cleaning

WARNING

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

Carburetor Inspection

WARNING

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).

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.

FUEL SYSTEM 3-21

Disassemble the carburetors (see Carburetor Disassem-

•

bly).
Clean the carburetor (see Carburetor Cleaning).

•

Check the vacuum piston diaphragm [A], and the O-rings

•

[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.

3-22 FUEL SYSTEM

Carburetor

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 [C], replace the float valve [B].
Push the rod [D] in the other end of the float valve needle

•

and then release it [E].
If it does not spring out, replace the float valve.

Check the tapered portion [A] of the pilot screw [B] 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.

Check that the vacuum piston moves smoothly in the car-

•

buretor 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.

Air Cleaner

Air Cleaner Element Removal

Remove:

•

Air Cleaner Upper Cover (see Air Cleaner Upper Cover
Removal in the Frame chapter)
Clips [A]
Air Cleaner Housing Cap [B]

Remove:

•

Thumbscrews [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.

WARNING

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

FUEL SYSTEM 3-23

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 Cleaning and Inspection

Refer to the Air Cleaner Element Cleaning and Inspection

•

in the Periodic Maintenance chapter.

Air Cleaner Housing Removal

Remove:

•

Air Cleaner Cover (see Air Cleaner Cover Removal in
the Frame chapter)
Air Cleaner Housing Cap
Air Cleaner Element (see Air Cleaner Element Removal)

Remove:

•

Screws [A]
Element Bracket [B]

3-24 FUEL SYSTEM

Air Cleaner

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.

•

Loosen the clamp screw [A].

•

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

•

Remove:

•

Breather Hose [A]
Air Cleaner Housing [B]

Air Cleaner

Air Cleaner Housing Installation

Install:

•

Grommets [A]
Air Ducts [B]
Air Vent Hose [C]
Drain Hose [D] (with Plug)
Drain Tube [E]

Route the air vent hose and drain hose correctly accord-

•

ing the Cable, Wire and Hose Routing in the Appendix
chapter.
Install:

•

Breather Hose [A]

Insert the carburetor air vent tube [B] in the fitting [C] of

•

the housing.

FUEL SYSTEM 3-25

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.

Install the torque converter air outlet duct [A] as shown.

•

Air Cleaner Housing [B]

3-26 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 N·m (0.60

kgf·m, 52 in·lb)

Tighten:

•

Torque - Air Cleaner Housing Bolts (M6):

28.7 mm (1.13 in.) [B]: 8.8 N·m (0.90 kgf·m, 78
in·lb)
33 mm (1.30 in.) [C]: 8.8 N·m (0.90 kgf·m, 78
in·lb)

Air Cleaner Element Bracket Screws: 4.9 N·m

(0.50 kgf·m, 43 in·lb)

Tighten:

•

Clamp Screw

Install:

•

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

Fuel Tank

Fuel Tank Removal

Remove:

•

Rear Fender (see Rear Fender Removal in the Frame
chapter)
Fuel Hose [A]
Fuel Pump Lead Connector [B]
Breather Hose [C]

Remove:

•

Fuel Tank Bolts [A] and Collars
Fuel Tank [B]

FUEL SYSTEM 3-27

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.

•

3-28 FUEL SYSTEM

Fuel Tank

Fuel Tank Cleaning

Remove the fuel tank and drain it (see Fuel Tank Re-

•

moval).
Pour some high-flash point solvent into the fuel tank and

•

shake the tank to remove dirt and fuel deposits.

WARNING

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 Tank

Fuel Tap Inspection

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

•

age.
Apply grease to the lever [B].

•

Tighten:

•

Torque - Fuel Tap Plate Screws [C]: 0.8 N·m (0.08 kgf·m, 7

in·lb)

FUEL SYSTEM 3-29

3-30 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.

WARNING

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

WARNING

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 sol-

•

vent.
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 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 Fuel Pump Inspection in the Electrical System

•

chapter.

FUEL SYSTEM 3-31

COOLING SYSTEM 4-1

Cooling System

Table of Contents

Exploded View ........................................................................................................................ 4-2

Coolant Flow Chart................................................................................................................. 4-4

Specifications ......................................................................................................................... 4-6

Special Tools & Sealant.......................................................................................................... 4-7

Coolant ................................................................................................................................... 4-8

Coolant Deterioration Inspection....................................................................................... 4-8

Coolant Level Inspection................................................................................................... 4-8

Coolant Draining ............................................................................................................... 4-8

Coolant Filling ................................................................................................................... 4-8

Pressure Testing............................................................................................................... 4-9

Water Pump ............................................................................................................................ 4-10

Water Pump Cover Removal ............................................................................................ 4-10

Water Pump Cover Installation ......................................................................................... 4-10

Water Pump Impeller Removal ......................................................................................... 4-10

Water Pump Impeller Installation ...................................................................................... 4-10

Water Pump Impeller Inspection ....................................................................................... 4-11

Water Pump Leakage Inspection ...................................................................................... 4-11

Mechanical Seal Replacement ......................................................................................... 4-11

Radiator.................................................................................................................................. 4-13

Radiator Removal ............................................................................................................. 4-13

Radiator Installation .......................................................................................................... 4-14

Radiator Fan Removal ...................................................................................................... 4-14

Radiator Fan Installation ................................................................................................... 4-15

Radiator Inspection ........................................................................................................... 4-16

Radiator Cleaning ............................................................................................................. 4-16

Radiator Cap Inspection ................................................................................................... 4-16

Thermostat ............................................................................................................................. 4-17

Thermostat Removal......................................................................................................... 4-17

Thermostat Installation...................................................................................................... 4-17

Thermostat Inspection ...................................................................................................... 4-17

Radiator Fan Switch ...............................................................................................................4-19

Radiator Fan Switch Removal .......................................................................................... 4-19

Radiator Fan Switch Installation ....................................................................................... 4-19

Radiator Fan Switch Inspection ........................................................................................ 4-19

Water Temperature Switch ..................................................................................................... 4-20

Water Temperature Switch Removal ................................................................................ 4-20

Water Temperature Switch Installation ............................................................................. 4-20

Water Temperature Switch Inspection .............................................................................. 4-20

Coolant Filter/Valve ................................................................................................................ 4-21

Coolant Filter Cleaning ..................................................................................................... 4-21

Coolant Valve Inspection .................................................................................................. 4-21

4

4-2 COOLING SYSTEM

Exploded View