Kawasaki TERYX 750 FI 4×4, TERYX 750 FI 4X4 SPORT, TERYX 750 FI 4X4 LE Assembly & Preparation Manual

TERYX 750 FI 4×4

TERYX 750 FI 4×4 LE

TERYX 750 FI 4×4 SPORT

Recreation Utility Vehicle

Assembly & Preparation

Manual

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Foreword

In order to ship Kawasaki vehicles as effi­ciently as possible, they are partially disassem­bled before crating. Since some of the most
commonly removed parts have a direct bear­ing on a vehicle’s reliability and safety, consci­entious pre-sale assembly and preparation be­comes extremely important. Good setup pro­cedures can prevent needless warranty claims
and give customers a greater sense of confi­dence in Kawasaki and their Kawasaki Dealers.

This Assembly and Preparation Manual ex­plains step by step procedures of the follow­ing items for all Kawasaki TERYX 750 FI 4×4,
TERYX 750 FI 4×4 LE and TERYX 750 FI 4×4
SPORT.

1. Crate Handling

2. Uncrating

3. Assembly

4. Preparation

The selling dealer assumes sole responsibil­ity for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Ser­vice Bulletins specifying Factory Directed Mod­ifications (Special Claims) which must be per­formed before the vehicle is ready for sale.

Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.

DANGER

DANGER indicates a hazardous situa­tion which, if not avoided, will result in
death or serious injury.

WARNING

WARNING indicates a hazardous situa­tion which, if not avoided, could result
in death or serious injury.

CAUTION

CAUTION indicates a hazardous situa­tion which, if not avoided, could result
in minor or moderate injury.

NOTICE

NOTICE is used to address practices not
related to personal injury.

NOTE

○This note symbol indicat

es points of particular
interest for more efficient and convenient op­eration.

Kawasaki Heavy Industries, Ltd. accepts no

liability for any inaccuracies or omissions in this
publication, although every possible measure
has been taken to make it as complete and ac­curate as possible. All procedures and specifi­cations subject to change without notice.

© 2009 Kawasaki Heavy Industries, Ltd. Aug., 2009

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Table of Contents

Crate Handling .............................................................................. 3

Crate Handling Precautions for RSC (Returnable Steel

Crate)(US Model only) .............................................................. 3

Crate Handling Precautions (Other than US Model) ................... 3

Uncrating ...................................................................................... 4

Opening Crate (US Model only) .................................................. 4

Opening Crate (Other than US Model)........................................ 8

Parts Check ................................................................................. 12

Assembly ...................................................................................... 16

Steering Wheel ............................................................................ 16

Right and Left Bar ....................................................................... 16

Upper and Lower Back Bar ......................................................... 17

Front and Rear Upper Bar ........................................................... 17

Seat Belt ...................................................................................... 19

Windshield (KRF750PAF/RAF Models) ....................................... 21

Cargo Net .................................................................................... 22

Front Guard Cover ...................................................................... 22

French Labels.............................................................................. 22

Preparation ................................................................................... 24

Charged Battery Service (US Model) .......................................... 24

Uncharged Battery Service (Other than US Model) .................... 27

Air Cleaner .................................................................................. 30

Engine Oil .................................................................................... 32

Front Final Gear Case Oil ........................................................... 34

Rear Final Gear Case Oi

l ............................................................

35

Brake Fluid .................................................................................. 36

Brake Pedal ................................................................................. 37

Brake Light Switch

.......................................................................

38

Parking Brake Pedal.................................................................... 38

Steering Wheel ............................................................................ 38

Front Shock Ab

sorber .................................................................

39

Rear Shock Absorber .................................................................. 41

Tire Air Pressures........................................................................ 42

Fuel ............................................................................................. 43

Coolant ........................................................................................ 43

Throttle Pedal .............................................................................. 43

Differ

ential Shift Lever and Cable ................................................

44

Idle Speed Adjustment ................................................................ 44

Headlight Beam ........................................................................... 44

Whee

l Alignment .........................................................................

44

Digital Meter ................................................................................ 46

Fastener Check ........................................................................... 48

S

tandard Torque Table ................................................................50

Test Ride Checklist...................................................................... 50

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CRATE HANDLING 3

Crate Handling

Crate Handling Precautions for
RSC (Returnable Steel Crate)
(US Model only)

Crate Position:

Always place the crate upright on its base.
The crate has been designed to carry the weight
of the vehicle only in that position. The sides
and top of the crate are not strong enough to
act as the base of the crate. If the crate is tilted
very far or set on its end or side, loose parts
may be dislodged and fall inside the crate.

Loading and Unloading Trucks for

RSC:

To load or unload crates, use a fork lift. Never
attempt to unload crates by hand. NEVER
DROP crates off a truck.

Be sure to use the proper handling equip­ment for safe unloading, storing and stacking
of crated Teryx utility vehicles. The weight
of a large Teryx utility v ehicle plus the RSC
exceeds 860 kg (1,900 lbs.), therefore, t

wo
stacked crates will weigh approximately 1,660
kg (3,660 lbs.).

Use forklifts with at least 5,000 lb. lif

ting
capacity and 60-inch tapered fork blades not
greater than 1-1/2 inches thick. Forklifts should
also be equipped with all safety i

tems, such as

operator cages and fork back rests.

Pulling Crate from Trucks for RSC:

If pulling is necessary to unload from trailer,
please put rope or chain on fork pocket area at
end.

A. Pull chain around fork pocket area.

Stacking Returnable Steel Crates:

The number of crates that may be stacked on

top of one another

depends on the condition
of the crates and your forklift‘s capacity. Teryx
utility vehicle RSCs are designed for integrated
stacking.

Do not stack any other type of crate

or any other materials atop a Teryx RSC.

In any case, do not stack returnable steel

crates m

ore than two high for trucking, and

three high for storage.

Crate Handling Precautions
(Other than US Model)

Crate Pos

ition:

Always place the crate upright on its base.
The crate has been designed to carry the weight
of the v

ehicle only in that position. The sides
and top of the crate are not strong enough to
act as the base of the crate. If the crate is tilted
ver

y far or set on its end or side, loose parts

may be dislodged and fall inside the crate.

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4 UNCRAT

ING

Moving Crated Vehicle:

WARNING

Crate bands are only designed to hold
the cardboard cover in place. If used as
handles they can snap, causing you or
the crate to fall resulting in injury. Do
not move or lift the crate using the crate
bands.

Whenever moving the crate from one place to

anoth

er, use a fork lift or flat bed hand truck. Ve­hicle crates are too big and heavy to be moved
by hand. While moving a crate, never stand it
on en

d or tip it over on its side. DO NOT DROP
crated vehicles.

Loading and Unloading Trucks:

To load or unload crates, use a fork lift, a lift

-type tail gate, or a ramp. Never unload crates
by hand. NEVER DROP crates off a truck.

TyingDownCrates:

Always tie down crates when transporting
them. Put the tie downs across the crate at the
crate’s internal vertical braces. Do not use any
hooks on the crate.

Stac

king Disposable Wooden Crates:

The number of crates that may be stacked on
top of one another depends on the condition of
the c

rates more than any other single factor.
Also, take into consideration the weight of the
upper crate(s), the sizes of all the crates in a
sta

ck, and the strength of the bottom crate(s)
base on the type of crate construction (steel,
wood, bracing, etc.).

In a

ny case, do not stack crates more than two

high for trucking, and three high for storage.

Uncrating

Opening Crate (US Model only)

WARNING

Cra

tes have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
bo

ots and eye protection when uncrat-

ing to prevent injury.

WARNING

The steel crate panel plates and fasten­ers have sharp edges. Always wear pro­tective gloves, boots and eye protection
when uncrating to prevent injury.

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UNCRATI

NG 5

•

Clear a space about 6 m (20 ft.) square to
giv

e yourself plenty of space to work.

•

Place the crate upright on its base.

•

Remove the outer cover and inspect the unit
for

concealed damage. If concealed damage
is evident, document the damage as outlined
in the Kawasaki Warranty Policies and Pro­ce

dures Manual before proceeding to uncrate

the unit.

•

Remove the cardboard cover.

To work efficiently, start work at the rear of the

crate.

•

Remove the hairpin clips (2), then push out
the clevis pins (2) to disconnect the rear diag­on

al braces (2) from the rear upright.

•

Repeat these steps for the front upright.

•

Allow the diagonal braces to pivot out and
d

own to the ground. They remain attached

to the pallet.

A. Rear Upright

B. Hairpin Clip

C. Diagonal Brace

•

Install the hairpin clips (4) back into the braces
for return to KMM.

A. Hairpin Clip

B. Clevis Pin

C. Diagonal Brace

•

Lay down the front and rear uprights. To do
so, lift up on the upright to disengage its sock­ets from the pallet.

•

Now the upright may be pivoted down to the
ground. (It remains attached to the pallet.) Be
careful not to drop it on anyone.

A. Upright

Removing the Right and Left Bar and

Upper Bars and Upper Back B ar

Front Guard Cover and Parts Box Re-

moval

•

Cut the tie-band (1) that retains the front
guard cover and the upper bars, and remove
the front guard cover from the cargo bed.

•

Remove the parts box from the cargo bed.

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6 UNCRAT

ING

A. Parts Box

B. Tie-band

C. Front Guard Cover

Right and Left Bar and Upper Bars and

Upper Back Bar Removal

•

Cut the tie-bands (3) that retain the right and
left bars at cargo bed.

•

Cut the tie-bands of all bars.

A. Tie-bands

Windshield and Sun Top Cover

(KRF750PAF/RAF Model only)

•

Cut the tie-bands (2) that retain the sun top
cover with the windshield, and remove the
windshield from the sun top cover

A. Tie-bands

B. Sun Top Cover

•

Remove the bolts and nuts of right and left
that retain the plate, and remove the sun top
cover from the plate.

•

Discard the bolts and nuts.

A. Bolt (Right)

B. N

ut (Right)

C. Plate (Right)

D. Sun Top Cover

•

Remove the bolts (4) and plates (2) from front
bar, and discard them.

A. Bolts

B. Plates

C. Front Bar

•

Cut the tie-bands (2), and remove the wind­shield from the sun top cover.

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UNCRATI

NG 7

A. Tie-bands

B. Windshield

C. Sun Top Cover

Removing the Lower Back Bar and

Front Tie-downs Removal

•

Cut the tie-bands (3) that retain the lower back
bar at the front guard, and remove the lower
back bar from the front guard.

•

Remove front tie-downs by opening fully and
disengaging latch. Take care to undo these
evenly as there is heavy tension in the tie

-down.

A. Tie-downs (Front)

B. Tie-bands

C. Lower Back Bar

Rear Tie-down Removal

•

Remove rear tie-downs by opening fully and
disengaging latch. Take care to undo these
evenly as there is heavy tension in the tie

-down.

A. Tie-downs (Rear)

•

Roll the vehicle off the crate base after i n­stalling the steering wheel (see “Steering
Wheel” section on page16 in the assembly
chapter).

RETURN SHIPMENT

•

Prepare the crate for return shipment.

•

Fold braces in so they lay on the crate pallet.

A. Braces

•

Lift the rear upright to disengage its sockets.
Pivot it down onto the crate pallet. Be careful
not to drop on anyone.

A. Uprights

•

Repeat these steps for the other upright.

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8 UNCRAT

ING

•

The

se items are discarded:

- Outer Cover, Tie-downs (Qty. 4)

Opening Crate
(Other than US Model)

WARNING

Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrat­ing to prevent injury.

•

Clear a space about 6 m (20 ft.) square to
give yourself plenty of space to work.

•

Place the crate upright on its base.

•

Remove the outer cover and inspect the unit
for concealed damage. If concealed damage
is evident, document the damage as outlined
in the Kawasaki Warranty Policies and Pro­cedures Manual before proceeding to uncrate
the unit.

•

Remove the cardboard cover.

Removing Panels

•

Using a BPS3 square drive bit (ex. IM­PORT APEX Square Recess “Power Bits­1/4 Hex-size #3” or MAGNA “Insert Bits-size
#3” with quick change holder), remove the
screws from the sides and ends into the top.

A. “Power Bit (APEX)”

WARNING

Staples, nails and other fasteners have
sharp points that can cause injury. Re­move or bend into the wood all staples,
nails or other fasteners in the crate base.

•

Take out all the bolts, nuts, screws, and fas­teners and remove the top and side panels of
the wood crate.

Top Panel Removal

•

Remove the screws from the top crate.

•

There are two screws in every corner.

•

Remove two screws in every cross member.

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UNCRATI

NG 9

•

Top

panel can be lifted from the unit. Have
a second person help to remove this piece
as it can be awkward to handle. Discard this
ass

embly. Take care when letting the screen
and center bar assembly down from the top,
it is heavy and may fall.

Side Panel Removal

•

Remove the (18) screws shown below. The
panel should come loose without excess
force; check for any missed screws if the
panel will not come off easily.

NOTE

○Tr

ying to break the panels off can result in

damage to the unit.

•

Repeat procedure for the other side of the
unit. Discard these panels.

End Panel Removal

•

Remove the (4) screws shown below. The
panel should come loose without excess
force, check for any missed screws if panel
will not come off easily.

NOTE

○Trying to break the panels off can result in

damage to the unit.

•

Rep

eat as above for the rear panel. Discard

these panels.

Removing the Right and Left Bar and

Upper Bars and Upper Back B ar

Front Guard Cover and Parts Box Re-

moval

•

C

ut the tie-band (1) that retains the front
guard cover and the upper bars, and remove
the front guard cover from the cargo bed.

•

R

emove the parts box from the cargo bed.

A. Parts Box

B. Tie-band

C. Front Guard Cover

Right and Left Bar and Upper Bars and

Upper Back Bar Removal

•

Cut the tie-bands (3) that retain the right and
left bars at cargo bed.

•

Cut the tie-bands of all bars.

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10 UNCRA

TING

A. Tie-bands

Removing the Lower Back Bar and

Front Tie-downs Removal

•

Cut the tie-bands (3) that retain the lower back
bar at the front guard, and remove the lower
back bar from the front guard.

•

Remove front tie-downs by opening fully and
disengaging latch. Take care to undo these
evenly as there is heavy tension in the tie

-down.

A. Tie-downs (Front)

B. Tie-bands

C. Lower Back Bar

Rear Tie-down Removal

•

Remove rear tie-downs by opening fully and
disengaging latch. Take care to undo these
evenly as there is heavy tension in the tie

-down.

A. Tie-downs (Rear)

NOTE

○It is important to remove the top panel as the

unit will rise when the tie-downs are undone.
Failure to do so will result in damage to the
unit.

•

Remove the crate base blocks.

A. Crate Base Blocks

•

Roll the vehicle off the crate base after in­stalling the steering wheel (see “Steering
Wheel” section on page16 in the assembly
chapter).

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UNCRATI

NG 11

Dummy Page

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12 UNCRA

TING

Parts Check

NOTE

○There may be minor differences in appearance between these illustrations and the actual vehicle

parts.

•

Remove the parts and check the crate base and packaged materials carefully for lost parts. Order
any parts that are missing from the crate. Part numbers are provided in the following charts. Check
the parts against the illustrations. In the following charts under Remarks, D = diameter in millimeters,
and L = length in millimeters. In the following charts under Q ty, ( ) = component of assembly parts.

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UNCRATI

NG 13

No. Part Name

Qty

Remarks Part Number

1

Steering Wheel

1 46003-0114

Steering Wheel Cap 1 11065-0171

2 Right B

ar

1 55047-

0022

Left Bar

1 55047-0021

Flanged Bolt, Right and Left Bar 8 D = 14, L = 36 92153-1282

Upper

Back Bar

1 39043

-0005

Lower Back Bar 1 39043-0008

Flanged Bolt, Upper and Lower Back Bar 10 D = 10, L = 14 130CB1014

Front Upper Bar 1 39043-0001

Rear Upper Bar 1 39043-0007

Flanged Bolt, Front and Rear Upper Bar 8 D = 10, L = 14 130CB1014

Clamp, Breather Hose (Fuel Tank) 1 92037-1181

Clamp, Breather Hose (Rear Final Gear Case) 1 92037-1104

Flanged Bolt, Battery Terminal (U.S. Model) 2 D = 6, L = 16 130BA0616

Plate

Nut, Battery Terminal (U.S. Model)

2 D=6 92210-1352

KRF750PAF/RAF Models

Sun Top Cover 1 14091-1770

Pad, Sun Top Cover 4 39156-0479

Screw, Sun Top Cover 8 D = 6, L = 16 92009-1621

Collar, Sun Top Cover 8 D = 16, L = 6.3 92143-1087

Bra

cket, Sun Top Cover

2 11055-0156

Bracket, Sun Top Cover

2 11055–0255

3 Seat Belt with 2 53061-0007

Cover, Seat Belt Upper Bracket (2) 11065-0287

Flanged Bolt, Seat Belt Case, Upper 2 D = 10, L = 16 92153-1740

4 Cargo Net 1 53064-0012

Bu

ckle Cover, Cargo Net

2 14090-1611

Band, Cargo Net

4 L = 123 92072-030

5 Front Guard Cover

Other than KRF750RAF Model 1 55020-0520

KRF750RAF Model Only 1 55020-0521

Screw, Front Guard Cover 2 D = 6, L = 16 92009-1621

T

apping Screw, Front Guard Cover

2 D = 6, L = 16 92009-1166

Collar, Front Guard Cover (Upper and Lower)

4 D = 16, L = 4 92143-1087

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14 UNCRA

TING

No. Part Name Qty Remarks Part Number

6 KRF750PAF/RAF Models

Windshield 1 39154-0047

T

rim, Windshield

1 L

= 450

5

3044-0044

Grommet, Windshield

4 92075-1787

Damper, Windshield 4 92161-0725

Collar, Windshield 4 D = 6.8 × 10 × 14.5 92027-156

Front Bracket, Windshield 4 11055-0913

Rear Bracket, Windshield 4 11055-0914

D

amper, Bracket, Windshield

8 9

2161-0644

Flanged Bolt, Windshield 4 D = 6, L = 35 132BB0635

Washer, Windshield 8 D = 6.5 × 22, L = 1.6 92200-1087

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UNCRATI

NG 15

No. Part Name

Qty

Remarks Part Number

7

French Labels and Instruction for Canadian Model
only

Instruction, Label

KRF750NAF Model only 1 56030-0364

KRF750PAF Model only 1 56030-0365

KRF750RAF Model only 1 56030-0366

KRF750SAF Model only 1 56030-0367

Label, Cargo Bed 1 56071-0147

Label

, Drive Belt Information

1 56033-0305

Label, Parking Brake 1 56030-0330

Label, Specification 1 56053-7519

Label

, Tire/Max.Load

56053-0418

Label, Shifting

1 56071-0129

Label, Protective Cover 1 56070-1271

Label, Warning, General 1 56071-0053

Label, Warning, Trailer Towing 1 56071-0100

Label, Warning, Cargo 1 56071-0112

Label, Warning, Cargo Bed 1 56071-0114

Label, Warning, Cargo Bed 1 56071-7504

Label, Warning, Refueling 1 56071-7505

Labe

l, Vehicle Emission Control Information

KRF750NAF Model only 1 59464-1705

KRF750PAF Model only 1 59464-1706

KRF7

50RAF Model only

1 5946

4-1707

KRF750SAF Model only

1 59464-1708

Label, Air Cleaner Information 1 56033-0348

Cover, Label, Emission Control 1 14092-0127

8 Battery Electrolyte, KMX14-BS (non-U.S. Model) 1 12 V 12 Ah 26022-1040

9 Owner’s Manual 1 –

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