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Kawasaki BRUTE FORCE 750 4X4I - Service Manual

Other manuals for BRUTE FORCE 750 4X4I -: Service Manual, Owner's Manual, Datasheet

Summary of BRUTE FORCE 750 4X4I -

  • Page 1

    Brute force 750 4×4i kvf 750 4×4 all terrain vehicle service manual.

  • Page 3: Quick Reference Guide

    This quick reference guide will assist you in locating a desired topic or pro- cedure. •bend the pages back to match the black tab of the desired chapter num- ber 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 th...

  • Page 5: Brute Force 750 4×4I

    Brute force 750 4×4i kvf 750 4×4 all terrain vehicle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written per...

  • Page 6

    List of abbreviations a ampere(s) lb pounds(s) abdc after bottom dead center m meter(s) ac alternating current min minute(s) atdc after top dead center n newton(s) bbdc before bottom dead center pa pascal(s) bdc bottom dead center ps horsepower btdc before top dead center psi pound(s) per square inc...

  • Page 7

    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 united states environmental protection agency and california air resources board. 1...

  • Page 8: (Us Model Only)

    Please do not tamper with noise control system (us model only) tampering with emission control system prohibited: federal regulations and california state law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of mainten...

  • Page 9: Foreword

    Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the prope...

  • Page 11: General Information 1-1

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 12: 1-2 General Information

    1-2 general information before servicing before starting to perform an inspection service or carry out a disassembly and reassembly oper- ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions ha...

  • Page 13: General Information 1-3

    General information 1-3 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 subas...

  • Page 14: 1-4 General Information

    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 se- quence to prevent case warpage or deformation which can l...

  • Page 15: General Information 1-5

    General information 1-5 before servicing press for items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball bearing and needle bearing do not remove presse...

  • Page 16: 1-6 General Information

    1-6 general information before servicing lubrication it is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of engine rotati...

  • Page 17: General Information 1-7

    General information 1-7 model identification kvf750-a1 left side view kvf750-a1 right side view the kvf750-b1 is a camouflage-surface-treated model and identical to the kvf750-a1, the base model, in every other aspect: controls, features, and specifications. The kvf750c is identical to the kvf750a i...

  • Page 18: 1-8 General Information

    1-8 general information general specifications items kvf750-a1, a6f ∼, b1, b6f ∼, c6f ∼ dimensions overall length 2 192 mm (86.30 in.) overall width 1 177 mm (46.34 in.) overall height 1 249 mm (49.17 in.) wheelbase 1 283 mm (50.51 in.) ground clearance: 269 mm (10.59 in.) seat height 935 mm (36.81 ...

  • Page 19: General Information 1-9

    General information 1-9 general specifications items kvf750-a1, a6f ∼, b1, b6f ∼, c6f ∼ engine oil: type api sf or sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity 2.6 l (2.7 us qt) drive train primary reduction system: type belt converter reduction ratio 3.122 ∼ 0.635 transmission: ty...

  • Page 20: 1-10 General Information

    1-10 general information general specifications items kvf750-a1, a6f ∼, b1, b6f ∼, c6f ∼ rim size: front 12 × 6.0 rear 12 × 7.5 front tire: type tubeless size at25 × 8-12 rear tire: type tubeless size at25 × 10-2 suspension: front: type double wishbone wheel travel 171 mm (6.73 in.) rear: type doubl...

  • Page 21: General Information 1-11

    General information 1-11 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 ...

  • Page 23: Periodic Maintenance 2-1

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-3 torque and locking agent..................................................................................

  • Page 24: 2-2 Periodic Maintenance

    2-2 periodic maintenance front brake fluid change................................................................................................. 2-34 front brake master cylinder piston assembly and dust cover replacement ................. 2-34 front brake caliper fluid seal replacement...............

  • Page 25: Periodic Maintenance 2-3

    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 regular service operation after 10 h...

  • Page 26: 2-4 Periodic Maintenance

    2-4 periodic maintenance periodic maintenance chart frequency first service regular service operation after 10 hrs. Or 100 km (60 mi.) of use every 10 days or 200 km (120 mi.) of use every 30 days or 600 km (360 mi.) of use every 90 days, 1 700 km (1 100 mi.) of use or when belt indicator light turn...

  • Page 27: Periodic Maintenance 2-5

    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: l: apply a non-permanent locking agent. Lb: apply a non...

  • Page 28: 2-6 Periodic Maintenance

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks rocker shaft bolts 22 2.2 16 valve adjusting screw locknuts 12 1.2 104 in·lb chain tensioner mounting bolts 8.8 0.90 78 in·lb chain tensioner cap bolt 22 2.2 16 position plate bolts 8.8 0.90 78 in·lb intermedia...

  • Page 29: Periodic Maintenance 2-7

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine mounting nut 62 6.3 46 crankshaft/transmission connecting rod big end cap nuts 34 3.5 25 mo engine oil drain plug 20 2.0 14 crankcase bolts (m8) 75 mm (2.95 in.) 20 2.0 14 s crankcase bolts (m8) 110 mm (...

  • Page 30: 2-8 Periodic Maintenance

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks (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 c...

  • Page 31: Periodic Maintenance 2-9

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks front suspension arm pivot nuts 42 4.3 31 steering knuckle joint nuts 29 3.0 22 rear shock absorber mounting nuts 34 3.5 25 stabilizer holder bolts 23 2.3 17 stabilizer joint nuts 48 4.9 35 rear suspension arm ...

  • Page 32: 2-10 Periodic Maintenance

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine brake actuator mounting bolts 8.8 0.90 78 in·lb forward/reverse detecting sensor mounting bolt 15 1.5 11 speed sensor mounting bolt 8.8 0.90 78 in·lb neutral position switch 15 1.5 11 reverse position s...

  • Page 33: Periodic Maintenance 2-11

    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 1 150 ±50 r/min (rpm) – – – air cleaner element oil high-quality foam air filter oil – – – cooling s...

  • Page 34: 2-12 Periodic Maintenance

    2-12 periodic maintenance specifications item standard service limit final drive front final gear case: gear case oil: type api sf or sg – – – api sh, sj or sl with jaso ma – – – viscosity sae 10w-40 – – – oil level filler opening bottom – – – capacity 0.40 l (0.42 us qt) – – – rear final gear case:...

  • Page 35: Periodic Maintenance 2-13

    Periodic maintenance 2-13 special tools oil filter wrench: 57001-1249 carburetor drain plug wrench, hex 3: 57001-1269 filler cap driver: 57001-1454 pulley holder attachment: 57001-1472 flywheel & pulley holder: 57001-1605 belt measuring gauge: 57001-1646.

  • Page 36: 2-14 Periodic Maintenance

    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 com- pletely in all steering positions by the return spring. If the throttle lever...

  • Page 37: Periodic Maintenance 2-15

    Periodic maintenance 2-15 periodic maintenance procedures choke lever free play adjustment • remove: handlebar cover screws [a] • 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 pla...

  • Page 38: 2-16 Periodic Maintenance

    2-16 periodic maintenance periodic maintenance procedures 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....

  • Page 39: Periodic Maintenance 2-17

    Periodic maintenance 2-17 periodic maintenance procedures warning clean the element in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not u...

  • Page 40: 2-18 Periodic Maintenance

    2-18 periodic maintenance periodic maintenance procedures • when installing the fuel hoses, 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 w...

  • Page 41: Periodic Maintenance 2-19

    Periodic maintenance 2-19 periodic maintenance procedures • fit the fuel hose [b] onto the pipe fully and install the clamps beyond the raised rib (see fuel hose and con- nection inspection). Cooling system radiator cleaning caution clean the radiator screen and the radiator in ac- cordance with the...

  • Page 42: 2-20 Periodic Maintenance

    2-20 periodic maintenance periodic maintenance procedures 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. Immediat...

  • Page 43: Periodic Maintenance 2-21

    Periodic maintenance 2-21 periodic maintenance procedures • 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 ...

  • Page 44: 2-22 Periodic Maintenance

    2-22 periodic maintenance periodic maintenance procedures caution soft or distilled water must be used with the an- tifreeze 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. Wat...

  • Page 45: Periodic Maintenance 2-23

    Periodic maintenance 2-23 periodic maintenance procedures • remove: left side cover (see left side cover removal in the frame chapter) battery case valve adjusting caps [a] recoil starter (see recoil starter removal in the recoil starter chapter) • remove the timing inspection plug [a]. Special tool...

  • Page 46: 2-24 Periodic Maintenance

    2-24 periodic maintenance 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 ...

  • Page 47: Periodic Maintenance 2-25

    Periodic maintenance 2-25 periodic maintenance procedures • remove the torque converter cover (see torque con- verter cover in the converter system chapter). • measure the width [a] of the belt at several locations with a pair of suitable straightedges [b] as shown. If any measurements exceed the se...

  • Page 48: 2-26 Periodic Maintenance

    2-26 periodic maintenance 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 tha...

  • Page 49: Periodic Maintenance 2-27

    Periodic maintenance 2-27 periodic maintenance procedures • 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 th...

  • Page 50: 2-28 Periodic Maintenance

    2-28 periodic maintenance periodic maintenance procedures 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 • replace the filter with a new one. • when installing the oil filter, be careful of the f...

  • Page 51: Periodic Maintenance 2-29

    Periodic maintenance 2-29 periodic maintenance procedures final drive variable differential control lever play inspection • pull the variable differential control lever [a] towards the handlebar grip [b] with a spring scale until it reads 30 n (3 kgf, 7 lb) of force. ○ the differential control in th...

  • Page 52: 2-30 Periodic Maintenance

    2-30 periodic maintenance periodic maintenance procedures 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...

  • Page 53: Periodic Maintenance 2-31

    Periodic maintenance 2-31 periodic maintenance procedures 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 a...

  • Page 54: 2-32 Periodic Maintenance

    2-32 periodic maintenance periodic maintenance procedures universal joint lubrication • remove: rear propeller shaft (see rear propeller shaft removal in the final drive chapter) • force grease into the grease nipples [a] until the grease comes out from the nipple, and wipe off any excess grease. [b...

  • Page 55: Periodic Maintenance 2-33

    Periodic maintenance 2-33 periodic maintenance procedures 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...

  • Page 56: 2-34 Periodic Maintenance

    2-34 periodic maintenance periodic maintenance procedures 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 con- tainer. • fill the reservoir with new br...

  • Page 57: Periodic Maintenance 2-35

    Periodic maintenance 2-35 periodic maintenance procedures 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 f...

  • Page 58: 2-36 Periodic Maintenance

    2-36 periodic maintenance periodic maintenance procedures 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...

  • Page 59: Periodic Maintenance 2-37

    Periodic maintenance 2-37 periodic maintenance procedures • 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 a...

  • Page 60: 2-38 Periodic Maintenance

    2-38 periodic maintenance periodic maintenance procedures rear brake light timing adjustment • remove the right footboard (see right footboard re- moval in the frame chapter). • adjust the brake light switch [a] up or down. To change the switch position, turn the adjusting nut [b]. Light sooner as t...

  • Page 61: Periodic Maintenance 2-39

    Periodic maintenance 2-39 periodic maintenance procedures.

  • Page 62: 2-40 Periodic Maintenance

    2-40 periodic maintenance periodic maintenance procedures joint boots inspection front axle/steering knuckle joint boots inspection • visually inspect the front axle joint boots [a]. If the joint boot is torn, worn, deteriorated, or leaks grease, replace the joint boot or front axle assembly (see fr...

  • Page 63: Periodic Maintenance 2-41

    Periodic maintenance 2-41 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 vehicl...

  • Page 64: 2-42 Periodic Maintenance

    2-42 periodic maintenance periodic maintenance procedures slide points: lubricate with grease. Brake lever brake pedal pivot shaft throttle lever shaft bolts and nuts tightening tightness inspection • check the tightness of the bolts and nuts listed here in accordance with the periodic maintenance c...

  • Page 65: Fuel System 3-1

    Fuel system 3-1 3 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......

  • Page 66: 3-2 Fuel System

    3-2 fuel system exploded view.

  • Page 67: Fuel System 3-3

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 idle adjusting screw bracket bolt 8.8 0.90 78 in·lb 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. Air temperature ...

  • Page 68: 3-4 Fuel System

    3-4 fuel system exploded view.

  • Page 69: Fuel System 3-5

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 element cover screw 3.5 0.35 31 in·lb 2 element holder screws 3.5 0.35 31 in·lb 3 clamp bracket bolt 9.8 1.0 87 in·lb 4 fuel pump mounting nuts 7.8 0.80 69 in·lb 5 fuel tap plate screws 0.8 0.08 7 in·lb 6 fuel tap mounting b...

  • Page 70: 3-6 Fuel System

    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-34 – – – main jet: front #152 – – – rear #158 – – – m...

  • Page 71: Fuel System 3-7

    Fuel system 3-7 special tools fuel level gauge: 57001-1017 pilot screw adjuster, a: 57001-1239 carburetor drain plug wrench, hex 3: 57001-1269 vacuum gauge: 57001-1369.

  • Page 72: 3-8 Fuel System

    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 ca...

  • Page 73: Fuel System 3-9

    Fuel system 3-9 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 owne...

  • Page 74: 3-10 Fuel System

    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 r...

  • Page 75: Fuel System 3-11

    Fuel system 3-11 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. Choke lever and cable installation • lubricate the choke cable before installation. • install the wave w...

  • Page 76: 3-12 Fuel System

    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 r...

  • Page 77: Fuel System 3-13

    Fuel system 3-13 carburetor • connect two suitable hoses [a] to the fuel level gauge [b] and the float chamber of the carburetors. Special tool - fuel level gauge: 57001-1017 • mark the additional graduation [c] 15 mm (0.59 in.) higher than the top graduation [d]. • hold the gauge so that the additi...

  • Page 78: 3-14 Fuel System

    3-14 fuel system carburetor service fuel level adjustment warning gasoline is extremely flammable and can be ex- plosive 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 appli...

  • Page 79: Fuel System 3-15

    Fuel system 3-15 carburetor • remove the rear vacuum hose [a] and install the vacuum hose for vacuum gauge. • connect: vacuum gauge [a] special tool - vacuum gauge: 57001-1369 • connect the fuel hose of a suitable fuel tank [b] to the carburetor. • start the engine and read the intake vacuum of each...

  • Page 80: 3-16 Fuel System

    3-16 fuel system carburetor • remove: air cleaner housing (see air cleaner housing removal) • drain the fuel from the carburetors. • remove: fuel hose [a] heater and ground lead connectors [b] • remove: screws [a] and throttle link case cover [b] • remove: locknut [a] throttle cable lower end [b] • ...

  • Page 81: Fuel System 3-17

    Fuel system 3-17 carburetor • remove: screw [a] holder plate [b] choke plunger carburetor installation • confirm the groove of the carburetor holder [a] fits on the projection [b] of the cylinder head. • check fuel leakage from the carburetors. Warning fuel spilled from the carburetors is hazardous....

  • Page 82: 3-18 Fuel System

    3-18 fuel system 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 detac...

  • Page 83: Fuel System 3-19

    Fuel system 3-19 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...

  • Page 84: 3-20 Fuel System

    3-20 fuel system 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...

  • Page 85: Fuel System 3-21

    Fuel system 3-21 carburetor • remove: link case screws [a] link case [b] • separate the carburetors. Carburetor joining • install link case and tighten link case screws. • apply grease to the link pins [a]. • install the link arm as shown. Washers [b] collars [c] link arm [d] cotter pins [e] • bend ...

  • Page 86: 3-22 Fuel System

    3-22 fuel system carburetor caution do not use compressed air on an assembled carbu- retor, 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 carbure- tor with a cleanin...

  • Page 87: Fuel System 3-23

    Fuel system 3-23 carburetor • 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 choke plunger cap. If any of the diaphragm o...

  • Page 88: 3-24 Fuel System

    3-24 fuel system air cleaner air cleaner element removal • remove: seat (see seat removal in the frame chapter) clips [a] air cleaner housing cap [b] • remove: element cover screw [a] element cover [b] element [c] • after removing the element, stuff pieces of lint-free, clean cloth into the air clea...

  • Page 89: Fuel System 3-25

    Fuel system 3-25 air cleaner • remove: screws [a] element holder [b] spark arrester [c] • remove: screw [a] air intake duct [b] air cleaner housing bolt [c] • remove: air cleaner housing bolt [a] • loosen the clamp screws [a]. • remove: breather hose [a].

  • Page 90: 3-26 Fuel System

    3-26 fuel system air cleaner • remove: screw [a] carburetor breather tank [b] air cleaner housing [c] air cleaner housing installation • fit the projection [a] of the housing in the groove [b] of the joint duct [c] (front and rear), and tighten the clamp screws. • install: dust seal [a] air cleaner ...

  • Page 91: Fuel System 3-27

    Fuel system 3-27 air cleaner • apply the soap and water solution over the trim seal [a]. • install: element holder • tighten: torque - element holder screws: 3.5 n·m (0.35 kgf·m, 31 in·lb) • install: element (see air cleaner element installation).

  • Page 92: 3-28 Fuel System

    3-28 fuel system fuel tank fuel tank removal • remove: electrical parts case (see electrical parts case re- moval in the frame chapter) rear fender (see rear fender removal in the frame chapter) storage case [a] (optional part) check valve hose [b] • remove: two right footboard bolts [a] • insert a ...

  • Page 93: Fuel System 3-29

    Fuel system 3-29 fuel tank fuel tank installation • check the insulators [a] on the tank case. If the insulators are damaged or deteriorated, replace them. • check the rubber dampers [a] on the frame as shown. If the dampers are damaged or deteriorated, replace them. • install the fuel tank with cas...

  • Page 94: 3-30 Fuel System

    3-30 fuel system fuel tank • install: vacuum hose [a] and clamp [b] fuel level sensor lead connector • install the removed parts. 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 dir...

  • Page 95: Fuel System 3-31

    Fuel system 3-31 fuel tank • connect the fuel hoses to the fuel tap as follows. Vacuum hose [a] fuel pump hose [b] • be sure to clamps [c] the fuel hoses to prevent leakage. Fuel tap inspection • check the fuel tap filter screen [a] for any breaks or dete- rioration. If the filter screen has any bre...

  • Page 96: 3-32 Fuel System

    3-32 fuel system fuel tank fuel tap cleaning • remove: fuel tap (see fuel tap removal) • clean the fuel tap filter screen in a high-flash point sol- vent. Warning clean the tap in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any ...

  • Page 97: Fuel System 3-33

    Fuel system 3-33 fuel pump fuel pump removal caution never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any sour...

  • Page 98: 3-34 Fuel System

    3-34 fuel system fuel pump fuel pump installation • install: bracket [a] fuel pump [b] washers [c] and nuts [d] • install: vacuum hose [a] fuel hose (carburetor side) [b] clamps [c] • install: fuel hose (fuel tap side) [a] clamp [b] bolts [c] removed parts fuel pump inspection • remove the fuel pump...

  • Page 99: Fuel System 3-35

    Fuel system 3-35 fuel pump • blow the air to the inlet fitting [a], and make sure that the blown air flow from the outlet fitting [b]. If the fuel pump does not operate as described, replace it with a new one..

  • Page 101: Cooling System 4-1

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 coolant flow chart.............................................................................................

  • Page 102: 4-2 Cooling System

    4-2 cooling system exploded view.

  • Page 103: Cooling System 4-3

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator mounting bolts 8.8 0.90 78 in·lb 2 radiator fan switch 18 1.8 13 3 radiator fan assembly bolts 4.9 0.50 43 in·lb 4 thermostat housing cover bolts 8.8 0.90 78 in·lb 5 water temperature switch 7.8 0.80 69 in·lb ss ...

  • Page 104: 4-4 Cooling System

    4-4 cooling system coolant flow chart permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump (coupled with the oil pump) turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes w...

  • Page 105: Cooling System 4-5

    Cooling system 4-5 coolant flow chart 1. Radiator 2. Radiator cap 3. Radiator fan switch 4. Radiator fan 5. Water temperature switch 6. Thermostat 7. Cylinder 8. Cylinder head 9. Water pump 10. Reserve tank black painted arrow: hot coolant white painted arrow: cold coolant.

  • Page 106: 4-6 Cooling System

    4-6 cooling system specifications item standard service limit coolant provided when shipping type permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) – – – color green – – – mixed ratio soft water 50%, coolant 5...

  • Page 107: Cooling System 4-7

    Cooling system 4-7 special tools & sealant bearing driver set: 57001-1129 bearing remover shaft, 9: 57001-1265 bearing remover head, 10 × 12: 57001-1266 kawasaki bond (silicone sealant): 56019-120

  • Page 108: 4-8 Cooling System

    4-8 cooling system coolant coolant deterioration inspection • visually inspect the coolant in the reserve tank [a]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the coolin...

  • Page 109: Cooling System 4-9

    Cooling system 4-9 coolant pressure testing • remove the radiator cap, and install a cooling system pressure tester [a] on the radiator filler neck. Note ○ wet the cap sealing surfaces with water or coolant to prevent pressure leakage. • build up pressure in the system carefully until the pres- sure...

  • Page 110: 4-10 Cooling System

    4-10 cooling system water pump water pump cover removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: coolant reserve tank water hose [a] water pump cover bolts [b] water pump cover [c] water pump cover installation • install: knock pins [a] new gasket [b] •...

  • Page 111: Cooling System 4-11

    Cooling system 4-11 water pump water pump impeller inspection • visually inspect the impeller [a]. If the surface is corroded or the blades are damaged, re- place the impeller. Water pump leakage inspection • check the drainage catch tank [a] at the bottom of the water pump body for coolant leakage....

  • Page 112: 4-12 Cooling System

    4-12 cooling system water pump • apply heat-resistance grease on the oil seal lip. • from outside the alternator cover, press and insert the oil seal [a] so that its surface is flush with the step portion of the cover as shown [b]. Special tool - bearing driver set: 57001-1129 • from inside the alte...

  • Page 113: Cooling System 4-13

    Cooling system 4-13 radiator radiator removal warning the radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is dis- connected. Touching the fan before the connector is disc...

  • Page 114: 4-14 Cooling System

    4-14 cooling system radiator • pull the projections [a] out of from the dampers [b], and remove radiator [c]. Caution do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. Radiator installation • insert the projections of the radiator in the ...

  • Page 115: Cooling System 4-15

    Cooling system 4-15 radiator radiator inspection • check the radiator core. If there are obstructions to air flow, remove the radiator and remove obstructions. If the corrugated fins [a] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by un...

  • Page 116: 4-16 Cooling System

    4-16 cooling system thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: right side cover (see right side cover removal in the frame chapter) water temperature switch lead connector [a] water pipe bolt [b] • remove: thermostat housing ...

  • Page 117: Cooling System 4-17

    Cooling system 4-17 thermostat • to check valve opening temperature, suspend the ther- mostat [a] and an accurate thermometer [b] in a container of water with the heat-sensitive portions [c] in almost the same depth. Note ○ the thermostat must be completely submerged and the thermostat and thermomet...

  • Page 118: 4-18 Cooling System

    4-18 cooling system radiator fan switch radiator fan switch removal caution the fan switch should never be allowed to fall on a hard surface. Such a shock to the part can damage it. • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: radiator cover (see radiator c...

  • Page 119: Cooling System 4-19

    Cooling system 4-19 water temperature switch water temperature switch removal caution the water temperature switch should never be al- lowed to fall on a hard surface. Such a shock to the part can damage it. • drain the coolant (see coolant change in the periodic maintenance chapter). • disconnect t...

  • Page 121: Engine Top End 5-1

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-8 special tools and sealant ................. 5-11 camshaft chain tensioner ................ 5-13 camshaft chain tensioner removal ...........

  • Page 122: 5-2 Engine Top End

    5-2 engine top end exploded view.

  • Page 123: Engine Top End 5-3

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rocker case bolts 55 mm (2.2 in.) 8.8 0.90 78 in·lb s 2 rocker case bolts 130 mm (5.1 in.) 9.8 1.0 87 in·lb s 3 rocker case bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb s 4 rocker case bolts 25 mm (1.0 in.) 9.8 1.0 87 in·lb s 5...

  • Page 124: 5-4 Engine Top End

    5-4 engine top end exploded view.

  • Page 125: Engine Top End 5-5

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 chain tensioner mounting bolts 8.8 0.90 78 in·lb 2 chain tensioner cap bolt 22 2.2 16 3 position plate bolts 8.8 0.90 78 in·lb 4 intermediate shaft chain guide bolts 8.8 0.90 78 in·lb 5 intermediate shaft chain tensioner ...

  • Page 126: 5-6 Engine Top End

    5-6 engine top end exploded view.

  • Page 127: Engine Top End 5-7

    Engine top end 5-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe cover bolts 8.8 0.90 78 in·lb 2 muffler clamp bolt 8.8 0.90 78 in·lb 3 muffler cover bolts 8.8 0.90 78 in·lb 4 muffler mounting nuts 20 2.0 14 s 5 muffler mounting locknuts 31 3.2 23 s 6 exhaust pipe holder n...

  • Page 128: 5-8 Engine Top End

    5-8 engine top end specifications item standard service limit rocker case rocker arm inside diameter 12.000 ∼ 12.018 mm (0.4724 ∼ 0.4731 in.) 12.05 mm (0.474 in.) rocker shaft diameter 11.983 ∼ 11.994 mm (0.4718 ∼ 0.4722 in.) 11.96 mm (0.471 in.) camshafts cam height: exhaust 35.363 ∼ 35.477 mm (1.3...

  • Page 129: Engine Top End 5-9

    Engine top end 5-9 specifications item standard service limit valve stem diameter: exhaust 4.955 ∼ 4.970 mm (0.1951 ∼ 0.1957 in.) 4.94 mm (0.1945 in.) inlet 4.975 ∼ 4.990 mm (0.1959 ∼ 0.1965 in.) 4.96 mm (0.1953 in.) valve guide inside diameter: exhaust 5.000 ∼ 5.012 mm (0.1969 ∼ 0.1973 in.) 5.08 mm...

  • Page 130: 5-10 Engine Top End

    5-10 engine top end specifications item standard service limit piston ring groove width: top 1.03 ∼ 1.05 mm (0.0405 ∼ 0.0413 in.) 1.13 mm (0.0445 in.) second 1.02 ∼ 1.04 mm (0.0402 ∼ 0.0409 in.) 1.12 mm (0.0441 in.) piston ring thickness: top 0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.) 0.90 mm (0.035 in.) ...

  • Page 131: Engine Top End 5-11

    Engine top end 5-11 special tools and sealant outside circlip pliers: 57001-144 compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston pin puller assembly: 57001-910 valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 32° - 28: 57001-1119 valve seat cutt...

  • Page 132: 5-12 Engine Top End

    5-12 engine top end special tools and sealant valve spring compressor adapter, 22: 57001-1202 valve guide arbor, 5: 57001-1203 valve guide reamer, 5: 57001-1204 valve seat cutter holder, 5: 57001-1208 piston pin puller adapter, 14: 57001-1211 filler cap driver: 57001-1454 compression gauge adapter, ...

  • Page 133: Engine Top End 5-13

    Engine top end 5-13 camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below: when removing the tensioner, ...

  • Page 134: 5-14 Engine Top End

    5-14 engine top end camshaft chain tensioner • tighten: torque - chain tensioner mounting bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install: pin [a] and spring [b] washer [c] and chain tensioner cap bolt [d] • tighten: torque - chain tensioner cap bolt: 22 n·m (2.2 kgf·m, 16 ft·lb).

  • Page 135: Engine Top End 5-15

    Engine top end 5-15 rocker case rocker case removal front rocker case • remove: front fender (see front fender removal in the frame chapter) recoil starter (see recoil starter removal in the recoil starter chapter) timing inspection plug [a] special tool - filler cap driver [b]: 57001-1454 • remove:...

  • Page 136: 5-16 Engine Top End

    5-16 engine top end rocker case • insert a suitable bar [a] under the front of the engine. • lift [a] the front of the engine to remove the bolt [b] of the front right side on the rocker case. • lift the rocker case to clear of the dowel pins in the cylin- der head and slide the rocker case out of t...

  • Page 137: Engine Top End 5-17

    Engine top end 5-17 rocker case • apply silicone sealant to the outer surface of the cap [a] and the cylinder head upper surface [b] as shown. Sealant - kawasaki bond (silicone sealant): 92104-0004 or ge silicones translucent rtv128 • tighten the rocker case bolts following the tightening se- quence...

  • Page 138: 5-18 Engine Top End

    5-18 engine top end rocker case • using a m8 bolt [a], remove the rocker shaft [b]. • remove: rocker arm [c] washers [d] ○ mark and record the rocker arm location so it can be in- stalled in the original position. ○ the rocker arms come off with the rocker shafts. Rocker arm installation • apply eng...

  • Page 139: Engine Top End 5-19

    Engine top end 5-19 rocker case rocker shaft diameter measurement • measure the diameter [a] of the rocker shaft where the rocker arm pivots on it with a micrometer. If the rocker shaft diameter is smaller than the service limit, replace it. Also check the rocker arm inside diameter (see rocker arm ...

  • Page 140: 5-20 Engine Top End

    5-20 engine top end camshaft camshaft removal • remove: camshaft chain tensioners (see camshaft chain ten- sioner removal) rocker cases (see rocker case removal) camshafts [a] • support the chain using a suitable tool. Camshaft installation • using a wrench on the alternator bolt, turn the crankshaf...

  • Page 141: Engine Top End 5-21

    Engine top end 5-21 camshaft • face the arrow [a] of the front camshaft sprocket upward (right side view). • engage the front camshaft chain with the front camshaft sprocket. • align the marks [b] on the weights with the front cylinder head upper surface. • install: rocker cases (see rocker case ins...

  • Page 142: 5-22 Engine Top End

    5-22 engine top end camshaft camshaft bearing wear inspection ○ the journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be mea- sured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled. • cut st...

  • Page 143: Engine Top End 5-23

    Engine top end 5-23 camshaft kacr inspection the kawasaki automatic compression release (kacr) momentarily opens the exhaust valves on the compression stroke at very low speeds. This allows some of the com- pression pressure to escape, making it easy to turn over the engine during starting. Due to t...

  • Page 144: 5-24 Engine Top End

    5-24 engine top end camshaft • remove: circlips [a] weights [b] spring [c] note ○ do not remove the shaft [a] and pin [b]. ○ if the parts are removed, they cannot be reinstalled. Kacr installation • install: weights circlips spring [a] ○ hook the spring from the outside with the open side of the hoo...

  • Page 145: Engine Top End 5-25

    Engine top end 5-25 camshaft • remove (right side view): torque converter cover (see torque converter cover removal in the converter system chapter) • using a m6 bolt [a], pull out the cover [b]. • remove (left side view): circlip [a] special tool - outside circlip pliers: 57001-144 • remove: interm...

  • Page 146: 5-26 Engine Top End

    5-26 engine top end camshaft front camshaft chain • install the circlip [a]. Special tool - outside circlip pliers: 57001-144 • rotate the crankshaft clockwise 270°. • align the key grooves [b] on the crankshaft with the em- bossed line [c] on the crankcase. • move the intermediate shaft [a] to the ...

  • Page 147: Engine Top End 5-27

    Engine top end 5-27 camshaft • install the intermediate shaft chain tensioner [a] as fol- lows: • release the stopper [b] and push the push rod [c] into the tensioner body. • insert a wire [d] into the rod hole to hold the rod in place. • install: intermediate shaft chain tensioner [a] • tighten: to...

  • Page 148: 5-28 Engine Top End

    5-28 engine top end camshaft • install: rocker cases (see rocker case installation) camshaft chain tensioners (see camshaft chain ten- sioner installation) • check the valve clearances (see valve clearance inspec- tion). Camshaft chain guide wear inspection • visually inspect the rubber on the guide...

  • Page 149: Engine Top End 5-29

    Engine top end 5-29 cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly, and stop the engine. • remove the spark plug (see spark plug removal in the electrical system chapter). • attach the compression gauge [a] and adapter [b...

  • Page 150: 5-30 Engine Top End

    5-30 engine top end cylinder head cylinder head removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: carburetor (see carburetor removal in the fuel system chapter) exhaust pipe (see muffler and exhaust pipe removal) thermostat (see thermostat removal in the...

  • Page 151: Engine Top End 5-31

    Engine top end 5-31 cylinder head • apply molybdenum disulfide oil to the threads and seating surface of the cylinder head bolts and both sides of the washers. • tighten the cylinder head bolts [a] following the tightening sequence as shown. First torque - cylinder head bolts (m10): 25 n·m (2.5 kgf·...

  • Page 152: 5-32 Engine Top End

    5-32 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head r...

  • Page 153: Engine Top End 5-33

    Engine top end 5-33 valves valve guide installation • lightly oil the valve guide outer surface. • using the valve guide arbor [a], drive the valve guide [b] until its flange touches the cylinder head. Special tool - valve guide arbor, 5: 57001-1203 • ream the valve guide with the valve guide reamer...

  • Page 154: 5-34 Engine Top End

    5-34 engine top end valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ coat the valve seat with machinist’s dye. ○ push the valve into the guide. ○ rotate the valve against the seat with a lapping too...

  • Page 155: Engine Top End 5-35

    Engine top end 5-35 valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve seat for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do no...

  • Page 156: 5-36 Engine Top End

    5-36 engine top end valves widened width [a] of engagement by machining with 45° cutter ground volume [b] by 32° cutter 32° [c] correct width [d] ground volume [e] by 60° cutter 60° [f] • measure the outside diameter of the seating surface with vernier calipers. If the outside diameter of the seatin...

  • Page 157: Engine Top End 5-37

    Engine top end 5-37 valves if the seat width is too wide, make the 60° [a] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° angle until the seat width is within the specified range. ○ to make the 60° gri...

  • Page 158: 5-38 Engine Top End

    5-38 engine top end valves.

  • Page 159: Engine Top End 5-39

    Engine top end 5-39 cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) oil pipe [a] chain guide [b] cylinder bolts [c] cylinder [d] cylinder base gasket piston removal • remove the cylinder block (see cylinder removal). • place a piece of clean cloth under the p...

  • Page 160: 5-40 Engine Top End

    5-40 engine top end cylinder and piston note ○ the oil ring rails have no “top” or “bottom”. • install the oil ring expander [a] in the bottom piston ring groove so the ends [b] butt together. • install the oil ring steel rails, one above the expander and one below it. ○ spread the rail with your th...

  • Page 161: Engine Top End 5-41

    Engine top end 5-41 cylinder and piston • install: cylinder clamp [a] (rear only) • tighten: torque - cylinder bolts [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install: chain guide [c] • apply oil to the o-ring on the oil pipe [d], and insert the pipe. Cylinder wear inspection • since there is a differenc...

  • Page 162: 5-42 Engine Top End

    5-42 engine top end cylinder and piston piston ring, piston ring groove wear inspection • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their g...

  • Page 163: Engine Top End 5-43

    Engine top end 5-43 cylinder and piston piston ring end gap inspection • place the piston ring [a] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • measure the gap [b] between the ends of the ring ...

  • Page 164: 5-44 Engine Top End

    5-44 engine top end exhaust system this vehicle is equipped with a spark arrester approved for off-road use by the united states forest service. It must be properly maintained to ensure its efficiency. In accor- dance with the periodic maintenance chart, clean the spark arrester. Spark arrester clea...

  • Page 165: Engine Top End 5-45

    Engine top end 5-45 exhaust system • remove: front exhaust pipe nuts [a] • move the front exhaust pipe rear end [a] under the fuel tank and remove the pipe forward. Muffler and exhaust pipe installation (kvf750-a1/b1) • if the muffler cover [a] is removed, tighten them. Torque - muffler cover bolts ...

  • Page 166: 5-46 Engine Top End

    5-46 engine top end exhaust system muffler and exhaust pipe installation (kvf750a6f ∼ /b6f ∼ / c7f ∼ ) • if the muffler cover [a] is removed, tighten them. Torque - muffler cover bolts [b]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • replace the exhaust pipe gaskets [c] and clamp gasket [d] with new ones. • in...

  • Page 167: Converter System 6-1

    Converter system 6-1 6 converter system table of contents exploded view........................................................................................................................ 6-2 specifications ............................................................................................

  • Page 168: 6-2 Converter System

    6-2 converter system exploded view.

  • Page 169: Converter System 6-3

    Converter system 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 drive pulley bolt 93 9.5 69 r, lh 2 driven pulley nut 93 9.5 69 3 drive pulley cover bolts 13 1.3 113 in·lb 4 ramp weight nuts 6.9 0.70 61 in·lb 5 spider 275 28 203 lh g: apply grease. Lh: left-hand threads r: replaceme...

  • Page 170: 6-4 Converter System

    6-4 converter system exploded view.

  • Page 171: Converter System 6-5

    Converter system 6-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 torque converter cover bolts 8.8 0.90 78 in·lb s 2 joint duct bolts 8.8 0.90 78 in·lb 3 engine brake actuator mounting bolts 8.8 0.90 78 in·lb s g: apply grease. M: apply molybdenum disulfide grease. R: replacement part...

  • Page 172: 6-6 Converter System

    6-6 converter system specifications item standard service limit torque converter actuator lever guide shoe – – – 6 mm (0.24 in.) drive belt belt width 29.7 ∼ 30.3 mm (1.169 ∼ 1.193 in.) 28.0 mm (1.102 in.) belt deflection 22 ∼ 27 mm (0.87 ∼ 1.06 in.) – – – drive pulley shoe side clearance up to 0.20...

  • Page 173: Converter System 6-7

    Converter system 6-7 special tools outside circlip pliers: 57001-144 drive & driven pulley holder: 57001-1412 drive pulley puller bolt: 57001-1429 pulley holder attachment: 57001-1472 drive & driven pulley holder: 57001-1473 drive pulley wrench: 57001-1474 spring holder set: 57001-1483 drive pulley ...

  • Page 174: 6-8 Converter System

    6-8 converter system special tools drive pulley holder: 57001-1620

  • Page 175: Converter System 6-9

    Converter system 6-9 torque converter warning excessive imbalance or operating rpm could cause torque converter pulley failure resulting in severe injury or death. The pulleys of the belt drive torque converter are precision balanced components de- signed to operate within certain rpm limits. Disas-...

  • Page 176: 6-10 Converter System

    6-10 converter system torque converter torque converter cover installation • check the actuator lever assembly installation length (see torque converter cover assembly). • fit the trim seal into the converter cover. ○ set the trim seal juncture in the area [a] when insert the trim seal in the cover....

  • Page 177: Converter System 6-11

    Converter system 6-11 torque converter actuator lever (engine brake control lever) assembly inspection • refer to the actuator lever (engine brake control lever) assembly inspection in the periodic maintenance chap- ter. Torque converter cover assembly • install: new circlip spring actuator lever as...

  • Page 178: 6-12 Converter System

    6-12 converter system torque converter actuator lever assemblies part number paint color [a] length [b] 13236-0046 yellow 0.4 ±0.1 mm (0.016 ±0.004 in.) 13236-0048 none 1.0 ±0.1 mm (0.039 ±0.004 in.) 13236-0047 green 1.6 ±0.1 mm (0.063 ±0.004 in.).

  • Page 179: Converter System 6-13

    Converter system 6-13 drive belt drive belt removal • remove the drive pulley [a] (see drive pulley removal). Note ○ before removing, observe the direction the belt’s printed information [a] (such as manufacturer’s name) is facing so that it may be reinstalled on the pulleys to rotate in the same di...

  • Page 180: 6-14 Converter System

    6-14 converter system drive pulley drive pulley removal • remove the torque converter cover (see torque con- verter cover removal). • remove the three cover bolts [a] and install the drive pul- ley holder [b]. Special tool - drive pulley holder: 57001-1620 • tighten the three cover bolts: torque - d...

  • Page 181: Converter System 6-15

    Converter system 6-15 drive pulley • remove: spring [a] spacer • put the drive pulley wrench [a] on the spider [b] and tighten the bolt [c]. Special tool - drive pulley wrench: 57001-1474 • turn the wrench clockwise and remove the spider with the movable sheave. Note ○ the spider has left-hand threa...

  • Page 182: 6-16 Converter System

    6-16 converter system drive pulley if the cover bushing is damaged or worn, replace the drive pulley cover. Cover bushing inside diameter [a] standard: 27.985 ∼ 28.085 mm (1.1018 ∼ 1.1057 in.) service limit: 28.12 mm (1.107 in.) if the sheave bushing is damaged or worn, replace it. Sheave bushing in...

  • Page 183: Converter System 6-17

    Converter system 6-17 drive pulley if the spring is worn or damaged, replace the spring. Spring free length [a] standard: 60.0 mm (2.36 in.) spider shoe side clearance inspection/adjustment • remove: drive pulley (see drive pulley removal) drive pulley cover and spring (see drive pulley disas- sembl...

  • Page 184: 6-18 Converter System

    6-18 converter system drive pulley if the clearance is not the specified range after the above shoes are replaced, use the spacer [a] (92026-0038) of the option part. [b] shoe [c] spider [d] post [e] clearance drive pulley assembly • install the ramp weight [a] as shown. • tighten: torque - ramp wei...

  • Page 185: Converter System 6-19

    Converter system 6-19 drive pulley • install the spacer. • put the spring [a] in the groove of the spider. • align the arrows [b] on the drive pulley cover and spider. • install: dowel pins [c] drive pulley cover • tighten: torque - drive pulley cover bolts: 13 n·m (1.3 kgf·m, 113 in·lb) • clean the...

  • Page 186: 6-20 Converter System

    6-20 converter system drive pulley • remove the drive pulley holder and install three drive pul- ley cover bolts to the specified torque. • adjust the installation length [a] of the drive pulley be- tween the surface of the crankcase [b] and the collar [c] on the drive pulley as followings. Drive pu...

  • Page 187: Converter System 6-21

    Converter system 6-21 driven pulley driven pulley removal • remove: torque converter cover (see torque converter cover removal) drive pulley (see drive pulley removal) drive belt (see drive belt removal) • using the flywheel & pulley holder [a] and attachments [b], remove the driven pulley nut [c] a...

  • Page 188: 6-22 Converter System

    6-22 converter system driven pulley • confirm the paint mark “0” [a] on the movable sheave [b] in alignment with the point [c] on the fixed sheave [d] for phase fit of the sheaves. • wipe off the molybdenum disulfide grease. • remove the four pins [a] with a thin standard tip screw- driver [b]. • re...

  • Page 189: Converter System 6-23

    Converter system 6-23 driven pulley if the sheave bushings [a] are damaged or worn, replace the movable sheave. Sheave bushing inside diameter standard: 40.000 ∼ 40.039 mm (1.5748 ∼ 1.5763 in.) service limit: 40.07 mm (1.578 in.) • inspect seals for damage. If seals are damaged, replace the movable ...

  • Page 190: 6-24 Converter System

    6-24 converter system driven pulley • align the paint mark “0” [a] on the movable sheave [b] with the point [c] on the fixed sheave [d] for phase fit of the sheaves. ○ in that case the opening [a] and hole [b] will be matched easily. • apply grease (wr500-no.2 (kyodo yushi), power lite wr #2 (kyodo ...

  • Page 191: Converter System 6-25

    Converter system 6-25 driven pulley • hold the drive & driven pulley holder in a vise. Special tool - drive & driven pulley holder: 57001-1473 • screw the guide bar into the holder. Special tool - spring holder set: 57001-1483 • put the driven pulley [a] onto the guide bar. • put the thrust plate [b...

  • Page 192: 6-26 Converter System

    6-26 converter system driven pulley • install two washers [a] on the shaft as shown. Crankcase side [b] bolt head side [c] • using the flywheel & pulley holder [a] and attachments [b], tighten the driven pulley nut [c]. Special tools - flywheel & pulley holder: 57001-1605 pulley holder attachment: 5...

  • Page 193: Converter System 6-27

    Converter system 6-27 high altitude setting information specifications altitude drive pulley carburetor m (ft) ramp weights spring spacer (qty) main jet (1) front: #152 (p/no. 92063-1331) (std) 0 ∼ 1 200 (0 ∼ 3 900) p/no. 39152-1081 (std, c) p/no. 92026-1603 t = 1 mm (0.04 in.) rear: #158 (p/no. 920...

  • Page 195: Recoil Starter 7-1

    Recoil starter 7-1 7 recoil starter table of contents exploded view........................................................................................................................ 7-2 recoil starter.................................................................................................

  • Page 196: 7-2 Recoil Starter

    7-2 recoil starter exploded view.

  • Page 197: Recoil Starter 7-3

    Recoil starter 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 recoil starter mounting bolts 5.9 0.60 52 in·lb l l: apply a non-permanent locking agent..

  • Page 198: 7-4 Recoil Starter

    7-4 recoil starter recoil starter recoil starter removal • remove: recoil starter mounting bolts [a] recoil starter [b] recoil starter installation • apply a non-permanent locking agent: recoil starter mounting bolts • tighten: torque - recoil starter mounting bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) r...

  • Page 199: Engine Lubrication System

    Engine lubrication system 8-1 8 engine lubrication system table of contents exploded view........................................................................................................................ 8-2 specifications ..........................................................................

  • Page 200

    8-2 engine lubrication system exploded view.

  • Page 201

    Engine lubrication system 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filter 18 1.8 13 r 2 oil pressure switch 15 1.5 11 ss 3 oil pipe bolts 8.8 0.90 78 in·lb 4 engine oil drain plug 20 2.0 14 5 oil pressure relief valve 15 1.5 11 l 6 oil pump bolts 8.8 0.90 78 in·lb 7 chain ...

  • Page 202

    8-4 engine lubrication system specifications item standard engine oil type api sf or sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity 2.1 l (2.2 us qt) (when filter is not removed) 2.2 l (2.3 us qt) (when filter is removed) 2.6 l (2.7 us qt) (when engine is completely dry) oil pressure...

  • Page 203

    Engine lubrication system 8-5 special tools & sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt 1/8: 57001-1033 kawasaki bond (silicone sealant): 56019-120

  • Page 204

    8-6 engine lubrication system engine oil flow chart 1. Front camshaft 2. Oil filter 3. Crankshaft 4. Oil pressure switch 5. Oil pipes 6. Oil pump 7. Relief valve 8. Transmission idle shaft 9. Oil screen 10. Transmission driven shaft 11. Rear camshaft 12. Breather hose 13. To air cleaner.

  • Page 205

    Engine lubrication system 8-7 engine oil and oil filter warning vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil level inspection • park the vehicle so that it is leve...

  • Page 206

    8-8 engine lubrication system engine oil and oil filter oil screen cleaning • clean the oil screen [a] thoroughly whenever it is removed for any reason. • clean the oil screen with a high-flash point solvent and remove any particles stuck to it. Warning clean the screen in a well-ventilated area, an...

  • Page 207

    Engine lubrication system 8-9 oil pressure relief valve oil pressure relief valve removal • split the crankcase (see crankcase disassembly in the crankshaft/transmission chapter). • remove the oil pressure relief valve [a]. Oil pressure relief valve installation • see crankcase assembly (see crankca...

  • Page 208

    8-10 engine lubrication system oil pump oil pump removal • remove: alternator rotor and starter clutch gear (see alternator rotor removal in the electrical system chapter) oil pump drive chain tensioner bolt [a] chain guide bolt [b] and collar chain guide [c] • remove: oil pump bolts [a] oil pump dr...

  • Page 209

    Engine lubrication system 8-11 oil pump • install the oil pump drive chain [a] with the oil pump as- sembly [b]. • tighten: torque - oil pump bolts [c]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install: chain guide [a] and collar [b] • tighten: torque - chain guide bolt: 8.8 n·m (0.90 kgf·m, 78 in·lb) • app...

  • Page 210

    8-12 engine lubrication system oil pipe oil pipe removal engine left side oil pipe • remove: alternator cover (see alternator cover removal in the electrical system chapter) oil pump (see oil pump removal) oil pipe bolts [a] oil pipes [b] engine right side oil pipe • remove: drive pulley (see drive ...

  • Page 211: Engine Removal/installation

    Engine removal/installation 9-1 9 engine removal/installation table of contents exploded view........................................................................................................................ 9-2 engine removal/installation .........................................................

  • Page 212

    9-2 engine removal/installation exploded view.

  • Page 213

    Engine removal/installation 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine mounting bracket bolts 72 7.3 53 2 engine mounting bolts 62 6.3 46 l 3 engine mounting nut 62 6.3 46 l: apply a non-permanent locking agent..

  • Page 214

    9-4 engine removal/installation engine removal/installation engine removal • remove: engine oil (drain) coolant (drain) muffler and exhaust pipe (see muffler and exhaust pipe removal in the engine top end chapter) footboards (see left and right footboard removal in the frame chapter) carburetor (see...

  • Page 215

    Engine removal/installation 9-5 engine removal/installation • remove: water pipe [a] spark plug cap [b] • remove: coolant reserve tank [a] neutral switch lead connector [b] reverse switch lead connector [c] forward/reverse detecting sensor lead connector [d] water hose [e] • remove: footboard bracke...

  • Page 217: Crankshaft/transmission

    Crankshaft/transmission 10-1 10 crankshaft/transmission table of contents exploded view........................................................................................................................ 10-2 specifications ...........................................................................

  • Page 218

    10-2 crankshaft/transmission exploded view.

  • Page 219

    Crankshaft/transmission 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 connecting rod big end cap nuts 34 3.5 25 mo 2 engine oil drain plug 20 2.0 14 3 crankcase bolts (m8) 75 mm (2.95 in.) 20 2.0 14 s 4 crankcase bolts (m8) 110 mm (4.33 in.) 20 2.0 14 s 5 crankcase bolt (m8) 110 m...

  • Page 220

    10-4 crankshaft/transmission exploded view.

  • Page 221

    Crankshaft/transmission 10-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 grip hold nut 9.8 1.0 87 in·lb 2 shift lever assembly bracket nuts 20 2.0 14 3 tie-rod end front locknut 9.8 1.0 87 in·lb lh 4 tie-rod end rear locknut 9.8 1.0 87 in·lb 5 tie-rod end nut 20 2.0 14 6 shift lever ...

  • Page 222

    10-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rods connecting rod bend – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod big end side clearance 0.16 ∼ 0.46 mm (0.0063 ∼ 0.0181 in.) 0.7 mm (...

  • Page 223

    Crankshaft/transmission 10-7 specifications item standard service limit transmission shift fork ear thickness 5.9 ∼ 6.0 mm (0.2322 ∼ 0.2362 in.) 5.8 mm (0.228 in.) shift groove width 6.05 ∼ 6.15 mm (0.2382 ∼ 0.2421 in.) 6.25 mm (0.2460 in.).

  • Page 224

    10-8 crankshaft/transmission special tools and sealant outside circlip pliers: 57001-144 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 kawasaki bond (liquid gasket - gray): 92104-1063.

  • Page 225

    Crankshaft/transmission 10-9 crankcase crankcase disassembly • remove: engine (see engine removal in the engine removal/in- stallation chapter) starter motor (see starter motor removal in the electri- cal system chapter) oil filter recoil starter cylinder blocks and pistons (see cylinder and piston ...

  • Page 226

    10-10 crankshaft/transmission crankcase • press and insert the new ball bearings until they are bot- tomed. Special tool - bearing driver set: 57001-1129 [a] ball bearing [b] ball bearing (sealed side towards crankcase) • press and insert the new needle bearings so that the bearing surfaces are flus...

  • Page 227

    Crankshaft/transmission 10-11 crankcase • be sure the following parts are in place in the right crankcase half. Crankshaft transmission shafts and shift rod [a] spacers [b] oil tube [c] oil screen [d] o-ring (apply grease) [e] dowel pins [f] • apply liquid gasket [a] to mating surface of the left cr...

  • Page 228

    10-12 crankshaft/transmission crankcase • install the breather tube [a] on the crankcase fitting. ○ align the white line on the tube with the mark [b] on the crankcase. ○ face the open end of the clamp [c] towards the left side [d] as shown. • apply grease to the steel ball [a] and spring [b]. • ins...

  • Page 229

    Crankshaft/transmission 10-13 crankshaft/connection rod crankshaft removal • split the crankcase (see crankcase disassembly). • remove the crankshaft [a] from the crankcase using a press. Crankshaft installation • the left shaft [a] of the crankshaft is longer than the right shaft [b]. • apply engin...

  • Page 230

    10-14 crankshaft/transmission crankshaft/connection rod • apply molybdenum disulfide oil: threads [a] of connecting rod big end cap bolts seating surface [b] of connecting rod big end cap nuts [c] • tighten: torque - connecting rod big end cap nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) crankshaft/connecting...

  • Page 231

    Crankshaft/transmission 10-15 crankshaft/connection rod connecting rod big end side clearance inspection • measure the side clearance of the connecting rod big end [a]. ○ insert a thickness gauge [b] between the big end and ei- ther crank web to determine clearance. Connecting rod big end side clear...

  • Page 232

    10-16 crankshaft/transmission crankshaft/connection rod if the measured crankpin diameter [a] is not less than the service limit, but does not coincide with the original diameter marking on the crankshaft, make a new mark on it. Crankpin diameter marks none: 39.984 ∼ 39.992 mm (1.5742 ∼ 1.57449 in.)...

  • Page 233

    Crankshaft/transmission 10-17 crankshaft/connection rod crankshaft runout inspection • measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft runout standard: tir 0.04 mm (0.0016 in.) or less service limit: tir 0.10 mm (0.0039 in.) crankshaft ...

  • Page 234

    10-18 crankshaft/transmission transmission shift lever removal • set the shift lever in the neutral position. • remove: right side cover (see right side cover removal in the frame chapter) shift shaft lever bolt [a] • remove the shift shaft lever [b] from the shift shaft. • remove: nut [a] shift lev...

  • Page 235

    Crankshaft/transmission 10-19 transmission shift lever installation • twist the tie-rod end [a] and tie-rod end locknut [b] to bottom of the screw and then turn back to dimension with 77° ±10° [c] as shown. • tighten the locknut against the tie-rod end: torque - tie-rod end locknut: 20 n·m (2.0 kgf·...

  • Page 236

    10-20 crankshaft/transmission transmission • install: guide [a] • tighten: torque - shift lever assembly bracket nuts [b]: 20 n·m (2.0 kgf·m, 14 ft·lb) • set the lever assembly in the neutral position [c] while turning the tie-rod [d]. Note ○ do not turn the shift shaft [e] when setting the lever as...

  • Page 237

    Crankshaft/transmission 10-21 transmission ○ do not lean the tie-rod rear end after tightening the front locknut. Right [l] wrong [m] • check that the shift lever moves from right to left automat- ically. • install: spring [n] trim seal [o] • align the mark [p] of the grip [q] with the projection [r...

  • Page 238

    10-22 crankshaft/transmission transmission • remove: circlip [a] special tool - outside circlip pliers: 57001-144 • remove: spacer [a] idle gear assembly [b] washers and spacer [c] low and high gears [d] • remove: needle bearings [a] • remove the driven shaft [b] from the crankcase using a press. Tr...

  • Page 239

    Crankshaft/transmission 10-23 transmission • install: idle shaft [a] with gear assembly [b] spacer [c] spacer [d] (p/no. 92026-1599, 48.2 × 54.3 × 1.0) • apply engine oil to the inner surface of the spacer [e]. • install the spacer [e] so that the stepped side [f] faces outward. • install: spacer to...

  • Page 240

    10-24 crankshaft/transmission transmission • apply molybdenum disulfide oil to the shift shaft [a]. • install: shift shaft spring bolt [b] spring [c] guide [d] • apply a non-permanent locking agent: shift shaft spring bolt • tighten: torque - shift shaft spring bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • w...

  • Page 241

    Crankshaft/transmission 10-25 transmission transmission and shift mechanism inspection • visually inspect: gears dogs of gear and shifter if they are damaged or worn excessively, replace them..

  • Page 242

    10-26 crankshaft/transmission transmission 1. Driven shaft 2. Spacer (17.3 × 30 × 2.0) 3. Reverse gear (12t) 4. Spacer (21.2 × 29 × 1.6) 5. Shifter 6. Snap ring 7. Washer t = 1.5 8. Spacer (28.2 × 34.5 × 1.6) 9. Spacer (hi and low) 10. Spacer (48.2 × 54.3 × 1.0) 11. Drive hi gear (26t) 12. Drive low...

  • Page 243

    Crankshaft/transmission 10-27 ball bearing, needle bearing, and oil seal ball and needle bearing replacement caution do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or three needle bearings. Note ○ in t...

  • Page 245: Wheels/tires 11-1

    Wheels/tires 11-1 11 wheels/tires table of contents exploded view........................................................................................................................ 11-2 specifications .................................................................................................

  • Page 246: 11-2 Wheels/tires

    11-2 wheels/tires exploded view.

  • Page 247: Wheels/tires 11-3

    Wheels/tires 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 tie-rod locknuts 37 3.8 27 2 wheel nuts (first torque) 15 1.5 11 s 2 wheel nuts (final torque) 76 7.8 56 s 3 front axle nuts 197 20 145 4 rear axle nuts 265 27 195 r: replacement parts s: follow the specific tightening seq...

  • Page 248: 11-4 Wheels/tires

    11-4 wheels/tires specifications item standard service limit wheel alignment toe-in of front wheels: –10 ∼ 10 mm (–39 ∼ 0.39 in.) at 1g – – – wheels (rims) rim size: front 12 × 6.0 – – – rear 12 × 7.5 – – – tires standard tire: front at 25 × 8-12 – – – dunlop, kt191, tubeless rear at 25 × 10-12 – – ...

  • Page 249: Wheels/tires 11-5

    Wheels/tires 11-5 special tool jack: 57001-1238.

  • Page 250: 11-6 Wheels/tires

    11-6 wheels/tires wheel alignment toe-in is the difference between the distance of front and the one of rear at the axle height position in the front wheels. When there is toe-in, the distance a (rear) is the greater than b (front) as shown. The purpose of toe-in is to prevent the front wheels from ...

  • Page 251: Wheels/tires 11-7

    Wheels/tires 11-7 wheel alignment • repeat the straightedge procedure on the other side of the vehicle. Now the front wheels are parallel to each other and to the center line of the vehicle. Front wheel [a] vehicle center line [b] parallel each other [c] straightedges [d] rear wheels [e] • go on to ...

  • Page 252: 11-8 Wheels/tires

    11-8 wheels/tires wheel alignment note ○ the toe-in will be near the specified value, if the tie-rod length [a] is 393.3 mm (15.48 in.) on each tie-rod. Caution adjust the tie-rod length so that the visible thread length [b] is even on both ends of the tie-rod. Un- even thread length could cause tie...

  • Page 253: Wheels/tires 11-9

    Wheels/tires 11-9 wheels (rims) wheel removal • loosen the wheel nuts [a]. • support the vehicle on a stand or a jack so that the wheels are off the ground. Special tool - jack: 57001-1238 • remove: wheel nuts wheel wheel installation • check the tire rotation mark [a] on the tire, and install the w...

  • Page 254: 11-10 Wheels/tires

    11-10 wheels/tires wheels (rims) if the tire is removed, inspect the air sealing surfaces [a] of the rim for scratches or nicks. Smooth the sealing sur- faces with fine emery cloth if necessary. Wheel (rim) replacement • remove the wheel (see wheel removal). • disassemble the tire from the rim (see ...

  • Page 255: Wheels/tires 11-11

    Wheels/tires 11-11 tires tire removal • remove the wheel. • unscrew the valve core to deflate the tire. ○ use a proper valve core tool [a]. • lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water [a]. This helps the tire beads slip off the rim f...

  • Page 256: 11-12 Wheels/tires

    11-12 wheels/tires tires • support the wheel rim [a] on a suitable stand [b] to pre- vent the tire from slipping off. • inflate the tire until the tire beads seat on the rim. Maximum tire air pressure (to seat beads when cold) front and rear 250 kpa (2.5 kgf/cm², 36 psi) warning do not inflate the t...

  • Page 257: Wheels/tires 11-13

    Wheels/tires 11-13 front hub front hub removal • remove: cap [a] cotter pin [b] (cut) • loosen the axle nut [c]. • remove the wheel (see wheel removal). • remove the caliper by taking off the mounting bolts, and let the caliper hang free. • remove the axle nut [a] and pull off the front hub [b] and ...

  • Page 258: 11-14 Wheels/tires

    11-14 wheels/tires front hub front hub disassembly/assembly if any hub bolt [a] is damaged, replace the hub [b] and bolts as a unit. • remove the hub bolt from the hub using a press. • press the hub bolt using a press..

  • Page 259: Wheels/tires 11-15

    Wheels/tires 11-15 rear hub rear hub removal • remove: cap [a] cotter pin [b] • loosen the axle nut [c]. • remove: wheel (see wheel removal) axle nut [a] rear hub [b] rear hub installation • wipe dry the spline portion of the hub. • wipe dry the threads and seating surface of the nuts. • tighten: to...

  • Page 260: 11-16 Wheels/tires

    11-16 wheels/tires rear hub rear hub disassembly/assembly if any hub bolt [a] is damaged, replace the hub [b] and bolts as a unit. • remove the hub bolt from the hub using a press. • press the hub bolt using a press..

  • Page 261: Final Drive 12-1

    Final drive 12-1 12 final drive table of contents exploded view........................................................................................................................ 12-3 specifications ...................................................................................................

  • Page 262: 12-2 Final Drive

    12-2 final drive rear propeller shaft ............................................................................................................... 12-52 rear propeller shaft removal .......................................................................................... 12-52 rear propeller sha...

  • Page 263: Final Drive 12-3

    Final drive 12-3 exploded view dummy page.

  • Page 264: 12-4 Final Drive

    12-4 final drive exploded view.

  • Page 265: Final Drive 12-5

    Final drive 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 output driven bevel gear housing bolts 26 2.7 20 2 output drive bevel gear housing bolts 26 2.7 20 3 bearing holder 137 14 101 l 4 bevel gear holder nut 157 16 116 l 5 bearing holder 118 12 87 l 6 output shaft holder nut 15...

  • Page 266: 12-6 Final Drive

    12-6 final drive exploded view.

  • Page 267: Final Drive 12-7

    Final drive 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 variable differential control shift shaft lever bolt 8.8 0.90 78 in·lb 2 front final gear case left cover bolts (m6) 9.8 1.0 87 in·lb l (4), s 3 ring gear bolts 57 5.8 42 lb 4 front final gear case center cover bolts (m6) 9...

  • Page 268: 12-8 Final Drive

    12-8 final drive exploded view.

  • Page 269: Final Drive 12-9

    Final drive 12-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear final gear case front cover bolts 24 2.4 17 2 rear final gear case gasket screws 1.3 0.13 12 in·lb l 3 pinion gear bearing holder nut 157 16 116 l 4 pinion gear bearing holder 137 14 101 l 5 rear final gear case right ...

  • Page 270: 12-10 Final Drive

    12-10 final drive specifications item standard service limit output bevel gear case output bevel gear backlash 0.05 ∼ 0.11 mm (0.0020 ∼ 0.0043 in.) – – – (at output drive shaft spline) front final gear case gear case oil (same engine oil): type api sf or sg – – – api sh, sj or sl with jaso ma – – – ...

  • Page 271: Final Drive 12-11

    Final drive 12-11 special tools bearing puller: 57001-135 steering stem bearing driver: 57001-137 inside circlip pliers: 57001-143 outside circlip pliers: 57001-144 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 pinion gear holde...

  • Page 272: 12-12 Final Drive

    12-12 final drive special tools socket wrench, hex 50: 57001-1478 output shaft holder & spacer, m1.25: 57001-1479 nut holding bolts: 57001-1481 socket wench: 57001-1482 socket wrench, hex 41: 57001-1484 pinion gear holder, m1.0: 57001-1485 bearing driver, 54.3: 57001-1488 gear holder & socket wrench...

  • Page 273: Final Drive 12-13

    Final drive 12-13 special tools oil seal driver, 70: 57001-1506 output shaft holder: 57001-1570

  • Page 274: 12-14 Final Drive

    12-14 final drive output bevel gears output drive bevel gear removal • remove: oil pipe [a] (engine left and outside, see oil pipe re- moval in the engine lubrication system chapter) output drive bevel gear cover bolts [b] output drive bevel gear cover [c] forward/reverse detecting sensor mounting b...

  • Page 275: Final Drive 12-15

    Final drive 12-15 output bevel gears • apply grease: o-rings [a] • install: output drive bevel gear cover [b] • tighten: torque - output drive bevel gear cover bolts [c]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install: forward/reverse detecting sensor [a] • tighten: torque - forward/reverse detecting sens...

  • Page 276: 12-16 Final Drive

    12-16 final drive output bevel gears • hold the output drive bevel gear housing [a] in a vise. • loosen the bevel gear [b] using an allen wrench about four rotations. • remove one nut holding bolt, and look at through the hole. If the groove of the bevel gear holder nut is not seen, loosen the other...

  • Page 277: Final Drive 12-17

    Final drive 12-17 output bevel gears output drive bevel gear assembly • press the new inner ball bearing until it is bottomed. Special tool - bearing driver set [a]: 57001-1129 • apply a non-permanent locking agent to the threads of the bearing holder [a] and tighten it so that the deep side [b] fac...

  • Page 278: 12-18 Final Drive

    12-18 final drive output bevel gears • tap lightly the front end [a] of the output driven bevel gear shaft using a plastic mallet. ○ the output driven bevel gear shaft assembly comes off with the housing. Output driven bevel gear installation • apply grease: o-ring [a] • install the output driven be...

  • Page 279: Final Drive 12-19

    Final drive 12-19 output bevel gears • hold the housing assembly [a] with the holder [b] in a vise. Special tool - holder & guide arbor: 57001-1476 • remove: bearing holder [c] special tool - socket wrench, hex 50 [d]: 57001-1478 ○ if the holder seems too difficult to break free, apply heat to softe...

  • Page 280: 12-20 Final Drive

    12-20 final drive output bevel gears • apply a non-permanent locking agent to the threads of the bearing holder [a] and tighten it. Special tool - socket wrench, hex 50 [b]: 57001-1478 torque - bearing holder: 137 n·m (14 kgf·m, 101 ft·lb) • hold the output shaft holder [a] in a vise, and set the ou...

  • Page 281: Final Drive 12-21

    Final drive 12-21 output bevel gears output bevel gear (backlash-related parts) 1. Ball bearings 2. Drive bevel gear shims 3. Output drive bevel gear 4. Bearing housings 5. Output driven bevel gear 6. Output driven shaft 7. Driven bevel gear shims drive bevel gear shims for tooth contact adjustment ...

  • Page 282: 12-22 Final Drive

    12-22 final drive output bevel gears bevel gear backlash adjustment ○ the amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position. • remove the output drive idle gear (see output drive bevel gear removal). • set up a dial gauge [a] against the output dri...

  • Page 283: Final Drive 12-23

    Final drive 12-23 output bevel gears example 1: decrease the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or increase the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below. Repeat in 0.1 mm (0.004 in.) steps if necessary. Exam...

  • Page 284: 12-24 Final Drive

    12-24 final drive output bevel gears bevel gears inspection • visually check the bevel gears [a] for scoring, chipping, or other damage. Replace the bevel gears as a set if either gear is dam- aged..

  • Page 285: Final Drive 12-25

    Final drive 12-25 front propeller shaft front propeller shaft removal • slip the o-ring clamps off the grooves on the small rubber boots [a], and then pull the boot. • push the front propeller shaft [a] rearward, and remove the front end [b] from the front final gear case. • remove the front propell...

  • Page 286: 12-26 Final Drive

    12-26 final drive front axle front axle removal • drain the front final gear case oil (see front final gear case oil change in the periodic maintenance chapter). • remove: front wheel (see wheel removal in the wheels/tires chapter) steering knuckle (see steering knuckle removal in the steering chapt...

  • Page 287: Final Drive 12-27

    Final drive 12-27 front axle • tap the bearing housing [a] straight [b] with a plastic ham- mer to separate it from the shaft. Caution do not tap on the cage. Be careful not get hurt when the housing comes out. If the splined portion of shaft cracked or damaged during disassembling of outboard joint...

  • Page 288: 12-28 Final Drive

    12-28 final drive front axle ○ tighten the boot band [a] and bend the tangs [b] securely to hold down the end of the band. • place the special grease tube nozzle in the bore of the housing and squeeze the tube [a] until the grease comes out from the joint bearing. • tap the shaft end [a] straight wi...

  • Page 289: Final Drive 12-29

    Final drive 12-29 front axle left front axle: 178.6 mm (7.03 in.) [a] • open the edge [a] of the boot in order to equalize the air pressures. • tighten the large band [a] and bend the tangs securely to hold down the end of the band. Maximum outside diameter of band: 80.2 mm (3.16 in.) (after tighten...

  • Page 290: 12-30 Final Drive

    12-30 final drive front axle • remove the steel balls [a]. • slide the cage [b] toward the center of the axle. • remove: circlip [a] special tool - outside circlip pliers [b]: 57001-144 • remove the inner race [a] using a suitable bearing re- mover [b]. • remove the inboard joint boot [c]. Inboard j...

  • Page 291: Final Drive 12-31

    Final drive 12-31 front axle • press the inner race [a] using the rotor puller [b] (57001 -1216) until it is bottomed. Special tool - rotor puller, m16/m18/m20/m22 × 1.5: 57001 -1216 • install: circlip [a] special tool - outside circlip pliers: 57001-144 • slide the cage [b] on the inner race and in...

  • Page 292: 12-32 Final Drive

    12-32 final drive front axle • install the new retaining ring [a] so that the opening [b] is aligned with one of the projections [c]. • tighten the small band. • squeeze the remaining special grease [a] into the inboard joint boot [b]. • compress the axle assembly to the specified length while relie...

  • Page 293: Final Drive 12-33

    Final drive 12-33 front axle • while the band is held at the diameter above, tap down the tangs [a] of the clamp..

  • Page 294: 12-34 Final Drive

    12-34 final drive front final gear case front final gear case oil level inspection • park the vehicle so that it is level, both side-to-side and front-to-rear. • remove the filler cap. Caution be careful not to allow any dirt or foreign materials to enter the gear case. • check the oil level. The oi...

  • Page 295: Final Drive 12-35

    Final drive 12-35 front final gear case variable differential control cable installation • lubrication the variable differential control cable before installation. • route the cable correctly according to the cable, wire, and hose routing in the appendix chapter. Warning operation with an improperly...

  • Page 296: 12-36 Final Drive

    12-36 final drive front final gear case • remove: front fender (see front fender removal in the frame chapter) front wheels (see wheel removal in the wheels/tires chapter) steering stem (see steering stem removal in the steer- ing chapter) front axles (see front axle removal) right upper suspension ...

  • Page 297: Final Drive 12-37

    Final drive 12-37 front final gear case front final gear case installation • install the gear case bolts from the vehicle left side. Torque - front final gear case nuts: 59 n·m (6.0 kgf·m, 43 ft·lb) • install the removed parts. Torque - front final gear case oil drain plug: 15 n·m (1.5 kgf·m, 11 ft·...

  • Page 298: 12-38 Final Drive

    12-38 final drive front final gear case • remove: outer disc [a] needle bearing • remove: housing [a] and differential disc assembly [b] inner disc needle bearing • remove: cam plate [a] • remove: steel balls [a] gasket [b] dowel pins [c] front final gear case center cover bolts (m6) [d] front final...

  • Page 299: Final Drive 12-39

    Final drive 12-39 front final gear case • hold the front final gear case right cover [a] in a vise, and remove the bearing holder using the socket wrench [b]. Special tool - socket wrench, hex 41: 57001-1484 ○ if the holder seems too difficult to break free, apply heat to softer the locking agent. •...

  • Page 300: 12-40 Final Drive

    12-40 final drive front final gear case • install: ring gear assembly • apply grease to the o-ring [a] on the front final gear case center cover. • install: front final gear case center cover [a] • tighten the cover bolts following the tightening sequence as shown. Torque - front final gear case cen...

  • Page 301: Final Drive 12-41

    Final drive 12-41 front final gear case • install: cam lever [a] needle bearing [b] • apply engine oil to the needle bearing. • check the wear of the disc assembly as follows. ○ measure the thickness of the inner disc [a]. • select the width [a] of the disc assembly [b] in accordance with the thickn...

  • Page 302: 12-42 Final Drive

    12-42 final drive front final gear case • apply engine oil to the needle bearing [a]. • install: needle bearing outer disc [b] • apply engine oil to the variable front differential control shift shaft [a]. • install the shaft and spring [b] in the front final gear case left cover [c] as shown. • tur...

  • Page 303: Final Drive 12-43

    Final drive 12-43 front final gear case • apply molybdenum disulfide grease to the spline [a] of the shifter [b] and inner surface [c] of the coupling. • install the shifter and coupling on the pinion gear shaft [d]. • apply grease to the oil seal lip [e]. • press the oil seal [f] in the front final...

  • Page 304: 12-44 Final Drive

    12-44 final drive front final gear case ring gear disassembly • remove: ring gear assembly (see front final gear case disas- sembly) ring gear bolts [a] ring gear [b] • remove: differential gear case cover [a] right side gear (16t) [b] pins [c] spider gear shaft [d] spider gears (10t) [e] left side ...

  • Page 305: Final Drive 12-45

    Final drive 12-45 front final gear case lsd clutch torque inspection if the vehicle has the following symptoms, check the lsd (limited slip differential) clutch torque. -the handlebar is hard to turn. -the front final gear case overheats. -abnormal noises come from the front final gear case when rou...

  • Page 306: 12-46 Final Drive

    12-46 final drive front final gear case pinion gear unit assembly ○ the pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be re- placed as a set. • visually inspect the bearing for abrasion, color change, or other damage. If there is any doubt as t...

  • Page 307: Final Drive 12-47

    Final drive 12-47 front final gear case front final gear case (backlash-related parts) 1. Pinion gear shim(s) 2. Ring gear right shim(s) 3. Ring gear left shim(s) 4. Front final gear case center cover 5. Front final gear case right cover 6. Ball bearings 7. Ring gear 8. Ring gear assembly 9. Pinion ...

  • Page 308: 12-48 Final Drive

    12-48 final drive front final gear case 1. Pinion gear shims for backlash adjustment thickness part number 0.15 mm (0.006 in.) 92180-1408 0.2 mm (0.008 in.) 92180-1409 0.5 mm (0.020 in.) 92180-1410 0.7 mm (0.028 in.) 92180-1411 0.8 mm (0.031 in.) 92180-1412 0.9 mm (0.035 in.) 92180-1413 1.0 mm (0.03...

  • Page 309: Final Drive 12-49

    Final drive 12-49 front final gear case • mount a dial gauge [a] so that the tip of the gauge is against the splined portion [b] of the pinion gear shaft. • to measure the backlash, move the pinion gear shaft back and forth [c] while holding the front axle steady. The difference between the highest ...

  • Page 310: 12-50 Final Drive

    12-50 final drive front final gear case ○ the tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe. If the t...

  • Page 311: Final Drive 12-51

    Final drive 12-51 front final gear case.

  • Page 312: 12-52 Final Drive

    12-52 final drive rear propeller shaft rear propeller shaft removal • remove: footboard (see left and right footboard removal in the frame chapter) • slide the rubber boots [a]. • push the front universal joint [b] rearward, and remove the front end [c] from the engine. • remove the rear propeller s...

  • Page 313: Final Drive 12-53

    Final drive 12-53 rear propeller shaft • apply molybdenum disulfide grease: spline [a] on output shaft of engine spline [b] on pinion gear of rear final gear case • install: o-rings [c] spring [d] rear universal joint [e] • align the front universal joint yoke [f] with the rear univer- sal joint yok...

  • Page 314: 12-54 Final Drive

    12-54 final drive rear axle rear axle removal • drain the rear final gear case oil (see rear final gear case oil change in the periodic maintenance chapter). • remove: rear wheels (see wheel removal in the wheels/tires chapter) rear knuckle (see rear suspension arm removal in the suspension chapter)...

  • Page 315: Final Drive 12-55

    Final drive 12-55 rear axle rear axle joint boot replacement outboard joint boot removal • remove: rear axle (see rear axle removal) boot bands [a] • scrap the removed boot bands. • slide the joint boot [b] toward the inboard joint. • tap the bearing housing [a] straight [b] with a plastic ham- mer ...

  • Page 316: 12-56 Final Drive

    12-56 final drive rear axle • apply the special grease slightly on the part [a] of the band installation in order to make easy to install the boot band. • tighten the small boot band [b]. ○ tighten the boot band [a] and bend the tangs [b] securely to hold down the end of the band. • place the specia...

  • Page 317: Final Drive 12-57

    Final drive 12-57 rear axle • compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot. • hold the axle at this setting. Standard length of assembling: outboard: 216.2 mm (8.51 in.) [a] • open the edge of the boot in order to equalize the air pressu...

  • Page 318: 12-58 Final Drive

    12-58 final drive rear axle • remove: circlip [a] special tool - outside circlip pliers [b]: 57001-144 • remove: inner race [a] cage [b] inboard joint boot [c] boot band [d] inboard joint boot installation • install: new small band [a] new inboard joint boot [b] cage [c] • install the inner race [a]...

  • Page 319: Final Drive 12-59

    Final drive 12-59 rear axle • apply the special grease [a] to the steel balls and cage. • squeeze about half a tube (30 grams) of the special grease [a] into the bearing cup [b]. • insert the balls and cage assembly in the bearing cup strongly. • install the new retaining ring [a] so that the openin...

  • Page 320: 12-60 Final Drive

    12-60 final drive rear axle • compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot. • hold the axle at this setting. Standard length of assembling: inboard: 174.6 mm (6.87 in.) [a] • open the edge of the boot in order to eqalize the air pres- su...

  • Page 321: Final Drive 12-61

    Final drive 12-61 rear final gear case rear final gear case oil level inspection • park the vehicle so that it is level, both side-to-side and front-to-rear. • remove the filler cap. Caution be careful not to allow any dirt or foreign materials to enter the gear case. • check the oil level. The oil ...

  • Page 322: 12-62 Final Drive

    12-62 final drive rear final gear case • remove the rear final gear case [a] as shown. Rear final gear case installation • install: rear final gear case bracket [a] collars [b] bracket bolts [c] [d] front [e] hole washers (rear side) • tighten: torque - rear final gear case nuts [f]: 91 n·m (9.3 kgf...

  • Page 323: Final Drive 12-63

    Final drive 12-63 rear final gear case • remove: rear final gear case front cover bolts [a] rear final gear case front cover assembly [b] • remove: gasket screws [a] gasket [b] • remove: set pins [a] with steel plates [b] and friction plates [c] • remove: brake cam plate [a] brake camshaft [b] and s...

  • Page 324: 12-64 Final Drive

    12-64 final drive rear final gear case • remove: pinion gear bearing holder [a] ○ hold the rear final gear case [a] in a vise, and remove the bearing holder using the socket wrench [b]. Special tool - socket wrench, hex 50: 57001-1478 ○ if it is difficult to break free the holder, apply the heat to ...

  • Page 325: Final Drive 12-65

    Final drive 12-65 rear final gear case [a] rear final gear case right cover [b] ball bearing • press: oil seal [c] (until bottomed) special tool - bearing driver set: 57001-1129 • apply grease: oil seal lips [d] rear final gear case front cover assembly [a] rear final gear case front cover • press: ...

  • Page 326: 12-66 Final Drive

    12-66 final drive rear final gear case • insert the shim(s) and pinion gear unit [a]. • apply a non-permanent locking agent to the pinion gear bearing holder, and tighten it. Special tool - socket wrench, hex 50: 57001-1478 torque - pinion gear bearing holder: 137 n·m (14 kgf·m, 101 ft·lb) when inst...

  • Page 327: Final Drive 12-67

    Final drive 12-67 rear final gear case • install: steel plate [a] (p/no. 41080-1483, two holes) set pins [b] and springs [c] • install (alternately): friction plates [a] steel plates (p/no. 41080-1484, without holes) • install: steel plate [a] (p/no. 41080-1483, two holes) ○ insert the pins [b] into...

  • Page 328: 12-68 Final Drive

    12-68 final drive rear final gear case • inspect: ball bearing [a] (see bearing and oil seal section) oil seal [b] (see bearing and oil seal section) if they are damaged, replace them. • apply grease to the oil seal lips and o-ring [c]. • install: shim [d] ring gear [e] • install: shim [a] rear fina...

  • Page 329: Final Drive 12-69

    Final drive 12-69 rear final gear case rear final gear case (backlash-related parts) 1. Pinion gear 2. Pinion gear bearing holder 3. Gear case right cover 4. Ball bearings 5. Ring gear 6. Pinion gear shim(s) 7. Ring gear shim(s) 8. Ring gear shim(s).

  • Page 330: 12-70 Final Drive

    12-70 final drive rear final gear case 6. Pinion gear shims for backlash adjustment thickness part number 0.15 mm (0.006 in.) 92180-1423 0.2 mm (0.008 in.) 92180-1424 0.5 mm (0.020 in.) 92180-1425 0.8 mm (0.031 in.) 92180-1426 1.0 mm (0.039 in.) 92180-1427 1.2 mm (0.047 in.) 92180-1428 7. Ring gear ...

  • Page 331: Final Drive 12-71

    Final drive 12-71 rear final gear case if the backlash is not within the standard, replace the pinion gear shim(s). To increase backlash, increase the thickness of the shim(s). To decrease backlash, decrease the thickness of the shim(s). Change the thickness a little at a time. • recheck the backlas...

  • Page 332: 12-72 Final Drive

    12-72 final drive rear final gear case pinion gear unit disassembly • remove: pinion gear unit [a] (see rear final gear case disas- sembly) • hold the pinion gear bearing holder nut [b] with the socket wrench [c] in a vise, and loosen the pinion gear shaft using the pinion gear holder [d]. Special t...

  • Page 333: Final Drive 12-73

    Final drive 12-73 bearing and oil seal ball or needle bearing inspection since the bearings are made to extremely close toler- ances, the clearance cannot normally be measured. Caution do not remove any bearings for inspection except the right rear axle bearing. • turn each bearing in the case or hu...

  • Page 334: 12-74 Final Drive

    12-74 final drive bearing and oil seal oil seal inspection • inspect the oil seals [a]. Replace any if the lips are misshapen, discolored (indicat- ing that the rubber has deteriorated), hardened, or been otherwise damaged..

  • Page 335: Brakes 13-1

    Brakes 13-1 13 brakes table of contents exploded view................................... 13-2 specifications .................................... 13-6 special tool ....................................... 13-7 brake fluid ........................................ 13-8 front brake fluid recommendation ...

  • Page 336: 13-2 Brakes

    13-2 brakes exploded view.

  • Page 337: Brakes 13-3

    Brakes 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 reservoir cap screws 1.5 0.15 13 in·lb 2 front brake lever pivot bolt 6.0 0.61 53 in·lb 3 front brake lever pivot bolt locknut 6.0 0.61 53 in·lb 4 front brake master cylinder clamp bolts 9.0 0.92 80 in·lb s 5 front brake hose ba...

  • Page 338: 13-4 Brakes

    13-4 brakes exploded view.

  • Page 339: Brakes 13-5

    Brakes 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 variable differential control lever bolt – – – l 2 rear final gear case gasket screws 1.3 0.13 12 in·lb l 3. Bend both hooks after installing the spring. 4. Brake pedal cotter pin g: apply grease. L: apply a non-permanent lockin...

  • Page 340: 13-6 Brakes

    13-6 brakes specifications item standard service limit brake fluid type dot 3 or dot 4 – – – front brake pad lining thickness 4.0 mm (0.16 in.) 1 mm (0.04 in.) disc thickness 3.3 ∼ 3.7 mm (0.130 ∼ 0.146 in.) 3 mm (0.12 in.) disc runout tir 0.4 mm (0.016 in.) or less tir 0.5 mm (0.020 in.) rear brake...

  • Page 341: Brakes 13-7

    Brakes 13-7 special tool inside circlip pliers: 57001-143.

  • Page 342: 13-8 Brakes

    13-8 brakes brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the...

  • Page 343: Brakes 13-9

    Brakes 13-9 brake fluid front brake line air bleeding • bleed the air whenever brake parts are replaced or re- assembled. • remove the reservoir cap and fill the reservoir with new brake fluid. • slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid f...

  • Page 344: 13-10 Brakes

    13-10 brakes master cylinder front brake master cylinder removal • remove: brake hose banjo bolt [a] master cylinder clamp bolts [b] master cylinder [c] caution brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately. Front brake master cylinder inst...

  • Page 345: Brakes 13-11

    Brakes 13-11 master cylinder front brake master cylinder disassembly • remove: front brake master cylinder (see front brake master cylinder removal) brake lever pivot bolt locknut [a] brake lever pivot bolt [b] brake lever [c] dust cover [d] circlip [e] piston [f] spring [g] special tool - inside ci...

  • Page 346: 13-12 Brakes

    13-12 brakes master cylinder front master cylinder inspection (visual inspection) • disassemble the master cylinder (see front brake master cylinder disassembly). • check that there are no scratches, rust or pitting on the inner wall of the master cylinder [a] and on the outside of the piston [b]. I...

  • Page 347: Brakes 13-13

    Brakes 13-13 calipers front brake caliper removal • remove the front wheel (see wheel removal in the wheels/tires chapter). • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. • unscrew t...

  • Page 348: 13-14 Brakes

    13-14 brakes calipers front brake caliper disassembly • remove: caliper (see front brake caliper removal) pads (see front brake pad removal) anti-rattle spring • using compressed air, remove the piston. ○ cover the caliper opening with a clean, heavy cloth [a]. ○ remove the piston by lightly applyin...

  • Page 349: Brakes 13-15

    Brakes 13-15 calipers • apply brake fluid to the outside of the pistons [a], and push them into the cylinder by hand. Take care that nei- ther the cylinder nor the piston skirt gets scratched. • replace the rubber boots [b] if they are damaged. • apply a thin coat of silicone grease to the caliper h...

  • Page 350: 13-16 Brakes

    13-16 brakes brake pads front brake pad removal • detach the caliper from the disc (see front brake caliper removal). • remove: pad mounting bolts [a] • remove: brake pads [a] front brake pad installation • push the caliper piston in by hand as far as it will go. • be sure that the anti-rattle sprin...

  • Page 351: Brakes 13-17

    Brakes 13-17 brake discs front brake disc cleaning poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone. Warning these cleaning fluids are usually highly flammable and harmful if breathed for prolonged peri...

  • Page 352: 13-18 Brakes

    13-18 brakes brake hoses front brake hose inspection • refer to the front brake hose and connections inspec- tion in the periodic maintenance chapter. Front brake hose replacement • refer to the front brake hose replacement in the peri- odic maintenance chapter..

  • Page 353: Brakes 13-19

    Brakes 13-19 rear brake lever, pedal and cables rear brake pedal position inspection note ○ the position of the brake pedal has been decided by the position of the adjusting bolt [a]. • check that the adjusting bolt is in the correct position as shown. Adjusting bolt position [b] standard: 5 ∼ 6 mm ...

  • Page 354: 13-20 Brakes

    13-20 brakes rear brake lever, pedal and cables rear brake pedal installation • apply grease: brake pedal pivot [a] o-ring [b] • install: spring [a] brake pedal [b] • apply grease: o-rings [c] • install: brake cable joint and pin [d] brake switch spring [e] washers [f] • replace the cotter pins [g] ...

  • Page 355: Brakes 13-21

    Brakes 13-21 rear brake lever, pedal and cables • remove: circlip [a] cotter pin, washer and pin [b] brake pedal cable [c] rear brake cable installation • grease the brake cable front ends. • replace the cotter pin with a new one. • route the brake cables according to the cable, wire, and hose routi...

  • Page 356: 13-22 Brakes

    13-22 brakes internal wet brake internal wet brake disassembly • refer to rear final gear case section in the final drive chapter. Internal wet brake assembly • refer to rear final gear case section in the final drive chapter..

  • Page 357: Suspension 14-1

    Suspension 14-1 14 suspension table of contents exploded view........................................................................................................................ 14-2 specifications .....................................................................................................

  • Page 358: 14-2 Suspension

    14-2 suspension exploded view.

  • Page 359: Suspension 14-3

    Suspension 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front shock absorber mounting nuts 34 3.5 25 2 front suspension arm pivot nuts 42 4.3 31 3 steering knuckle joint nuts 29 3.0 22 g: apply grease. R: replacement parts.

  • Page 360: 14-4 Suspension

    14-4 suspension exploded view.

  • Page 361: Suspension 14-5

    Suspension 14-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber mounting nuts 34 3.5 25 2 stabilizer holder bolts 23 2.3 17 3 stabilizer joint nuts 48 4.9 35 4 rear suspension arm pivot nuts 48 4.9 35 5 rear knuckle mounting nuts 48 4.9 35 g: apply grease. R: replacem...

  • Page 362: 14-6 Suspension

    14-6 suspension specifications item standard service limit shock absorbers (usable range) spring preload setting position (front and rear) first step 1 ∼ 5.

  • Page 363: Suspension 14-7

    Suspension 14-7 special tools inside circlip pliers: 57001-143 outside circlip pliers: 57001-144 steering stem nut wrench: 57001-1100 jack: 57001-1238.

  • Page 364: 14-8 Suspension

    14-8 suspension shock absorbers front shock absorber preload adjustment the spring adjusting sleeve [a] on the front shock ab- sorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions. If the spring ac- tion feels too soft or too stiff, adjust it in acco...

  • Page 365: Suspension 14-9

    Suspension 14-9 shock absorbers front shock absorber inspection • check the bushings [a] in the upper and lower pivots. If bushings are worn, cracked, hardened, or otherwise damaged, replace them. Front shock absorber scrapping warning since the front shock absorber contains nitrogen gas, do not inc...

  • Page 366: 14-10 Suspension

    14-10 suspension shock absorbers rear shock absorber installation • apply grease to the inside of bushing [a] and grease seal lips [b]. • install: collar [c] • install: bushing [a] (press) • tighten: torque - rear shock absorber mounting nuts [b]: 34 n·m (3.5 kgf·m, 25 ft·lb) rear shock absorber ins...

  • Page 367: Suspension 14-11

    Suspension 14-11 suspension arms front suspension arm removal • remove: front wheels (see wheel removal in the wheels/tires chapter) wheel hub [a] bolt [b] and brake hose [c] (from suspension arm) brake caliper (from brake disk) knuckle joint nuts [d] (see steering knuckle removal in the steering ch...

  • Page 368: 14-12 Suspension

    14-12 suspension suspension arms • tighten: torque - front suspension arm pivot nuts: 42 n·m (4.3 kgf·m, 31 ft·lb) steering knuckle joint nuts: 29 n·m (3.0 kgf·m, 22 ft·lb) front shock absorber mounting bolt: 34 n·m (3.5 kgf·m, 25 ft·lb) • install: brake hose front wheels (see wheel installation in ...

  • Page 369: Suspension 14-13

    Suspension 14-13 suspension arms • install the following parts as shown. Front upper suspension arm front [a] • press the needle bearing [b] until it is stopped. • press the ball joint bearing [c] until it is stopped. • install: new circlip special tool - inside circlip pliers: 57001-143 • apply gre...

  • Page 370: 14-14 Suspension

    14-14 suspension suspension arms rear suspension arm removal • remove: rear wheels (see wheel removal in the wheels/tires chapter) mounting bolts and nuts [a] rear upper suspension arm [b] • remove: stabilizer joint [a] ○ hold the joint bolt with an allen wrench [b], and remove the nut [c]. • remove...

  • Page 371: Suspension 14-15

    Suspension 14-15 suspension arms rear suspension arm disassembly rear upper suspension arm • remove out the bushings [a] rear lower suspension arm • remove: screw [a] bolts [b] collars [c] axle guard [d] collars [e] (rear side) oil seals [f] circlips [g] special tool - outside circlip pliers: 57001-...

  • Page 372: 14-16 Suspension

    14-16 suspension suspension arms rear lower suspension arm • install the following parts as shown. Front side [a]: needle bearing [b] 7.5 ±0.1 mm (0.295 ±0.004 in.) [c] rear side [a]: circlip [b] (front side) ball joint bearing [c] circlip [d] (rear side) special tool - inside circlip pliers: 57001-...

  • Page 373: Suspension 14-17

    Suspension 14-17 suspension arms stabilizer installation • install: dampers [a] and stabilizer [b] stabilizer holders [c] and bolts • tighten: torque - stabilizer holder bolts [d]: 23 n·m (2.3 kgf·m, 17 ft·lb) • install: stabilizer joints [e] ○ hold the joint bolt with an allen wrench, and tighten t...

  • Page 375: Steering 15-1

    Steering 15-1 15 steering table of contents exploded view........................................................................................................................ 15-2 specifications .........................................................................................................

  • Page 376: 15-2 Steering

    15-2 steering exploded view.

  • Page 377: Steering 15-3

    Steering 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar holder bolts 29 3.0 22 s 2 steering stem clamp bolts 25 2.5 18 3 tie-rod end nuts 42 4.3 31 4 tie-rod locknuts 37 3.8 27 5 steering stem bearing joint bolts 23 2.3 17 l 6 steering stem bottom end nut 62 6.3 46 7 stee...

  • Page 378: 15-4 Steering

    15-4 steering specifications item standard service limit tie-rods tie-rod length 393.3 mm (15.48 in.) – – –.

  • Page 379: Steering 15-5

    Steering 15-5 special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129.

  • Page 380: 15-6 Steering

    15-6 steering steering steering stem removal • remove: front fender (see front fender removal in the frame chapter) handlebar (see handlebar removal) cotter pins and tie-rod end nuts [a] steering stem bearing joint bolts [b] (right and left) caution do not loosen the locknuts [c] at the ends of the ...

  • Page 381: Steering 15-7

    Steering 15-7 steering steering stem installation • fill grease up the seal grooves [a] in the steering stem bearing. • install: collar • tighten: torque - steering stem bottom end nut: 62 n·m (6.3 kgf·m, 46 ft·lb) • bend both ends of the cotter pin. • apply a non-permanent locking agent: steering s...

  • Page 382: 15-8 Steering

    15-8 steering steering steering knuckle removal • remove: front wheel and hub (see wheel and front hub re- moval in the wheel/tiers chapter) front brake caliper (see front brake caliper removal in the brakes chapter) cotter pin [a] caution do not loosen the locknuts [b] at the ends of the tie-rod, o...

  • Page 383: Steering 15-9

    Steering 15-9 steering • install a suitable nut [a] (m12) to the knuckle joint end temporary. • tap the knuckle joint end and remove the knuckle [b]. Steering knuckle installation • inspect the spherical bearings in the knuckle joints [a]. If roughness, excessive play, or seizure is found, replace t...

  • Page 384: 15-10 Steering

    15-10 steering steering steering knuckle bearing removal • remove: steering knuckle (see steering knuckle removal) circlip [a] special tool - inside circlip pliers [b]: 57001-143 • drive the bearing [a] out using a suitable bearing driver from the bearing driver set. Special tool - bearing driver se...

  • Page 385: Steering 15-11

    Steering 15-11 steering tie-rod end removal • remove the tie-rod (see tie-rod removal). • holding the tie-rod flattened area [a], loosen the locknut [b] and unscrew the tie-rod end [c]. Note ○ the locknut near the l mark on the tie-rod has left-hand threads. Turn the wrench clockwise for loosening. ...

  • Page 386: 15-12 Steering

    15-12 steering steering maintenance steering inspection • refer to the steering inspection in the periodic mainte- nance chapter. Steering stem straightness inspection • remove the steering stem (see steering stem removal). • check the steering stem for straightness. ○ use a straightedge along the s...

  • Page 387: Steering 15-13

    Steering 15-13 steering maintenance steering knuckle bearing inspection caution do not remove any bearings for inspection. • remove the steering knuckle (see steering knuckle re- moval). • turn [a] the bearing back and forth while checking for roughness or binding. If roughness or binding is found, ...

  • Page 388: 15-14 Steering

    15-14 steering handlebar handlebar removal • remove: multifunction meter unit (see multifunction meter unit removal in the electrical system chapter) throttle case front brake master cylinder left-hand switch housing rear brake lever assembly handlebar holder bolts [a] and bracket [b] handlebar hold...

  • Page 389: Steering 15-15

    Steering 15-15 handlebar • install: left switch housing [a] rear brake lever assembly [b] punch mark [c] [d] = 6 mm (0.24 in.) ○ apply a non-permanent locking agent to the thread of the variable differential control lever bolt, and tighten it se- curely..

  • Page 391: Frame 16-1

    Frame 16-1 16 frame table of contents exploded view........................................................................................................................ 16-2 seat .........................................................................................................................

  • Page 392: 16-2 Frame

    16-2 frame exploded view.

  • Page 393: Frame 16-3

    Frame 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front guard bolts 37 3.8 27 2 front carrier bolts, l = 50 mm (2.0 in.) 25 2.5 18 3 front carrier bolts, l = 70 mm (2.8 in.) 25 2.5 18 4 front carrier bracket bolts 32 3.3 24 l 5 rear carrier bolts, l = 14 mm (0.6 in.) 54 5.5 40 l...

  • Page 394: 16-4 Frame

    16-4 frame exploded view.

  • Page 395: Frame 16-5

    Frame 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footboard bracket bolts 47 4.8 35 2 hitch bracket bolts 82 8.3 60 3 rear final gear case mounting bracket bolts – – – l 4. Trailer hitch bracket 5. Footboard mounting bolts l: apply a non-permanent locking agent. Op: optional par...

  • Page 396: 16-6 Frame

    16-6 frame exploded view.

  • Page 397: Frame 16-7

    Frame 16-7 exploded view op: optional parts.

  • Page 398: 16-8 Frame

    16-8 frame seat seat removal • remove the seat [a] by lifting the latch lever [b] and then pulling the seat up to the rear. Seat installation • insert the front seat hooks [a] into the receivers [b] in the bracket. • insert the rear seat hooks [a] into the dampers [b]. • push the rear part of the se...

  • Page 399: Frame 16-9

    Frame 16-9 carriers front carrier removal • remove: front carrier bolts [a] collars front carrier [b] front carrier installation • install: long collars, l = 44.6 mm (1.8 in.) [a] short collars, l = 21.6 mm (0.9 in.) [b] front carrier [c] • tighten: torque - front carrier bolts [d], l = 70 mm (2.8 i...

  • Page 400: 16-10 Frame

    16-10 frame carriers rear carrier bracket installation • install: rear carrier bracket [a] • tighten: torque - rear carrier bracket bolts [b]: 47 n·m (4.8 kgf·m, 35 ft·lb).

  • Page 401: Frame 16-11

    Frame 16-11 fenders front fender removal • remove: seat (see seat removal) front carrier (see front carrier removal) left and right side covers (see each side cover re- moval) middle cover quick rivets [a] (both sides) bolts [b] • remove: screws [a] and collars • remove: screws [a] and collars front...

  • Page 402: 16-12 Frame

    16-12 frame fenders • remove: seat (see seat removal) rear carrier (see rear carrier removal) screws [a] and collars • remove: screws [a] and collars • remove: screws [a] and collars bolts [b] and collars fuel tank cap [c] rear fender [d] • install the fuel tank cap after removing the rear fender. R...

  • Page 403: Frame 16-13

    Frame 16-13 covers middle cover removal • remove: middle cover screws [a] and collars • remove: middle cover screw [a] and collar • disconnect: power outlet lead connectors [a] • remove the middle cover [a] as shown. Middle cover installation • connect: power outlet lead connectors • install: middle...

  • Page 404: 16-14 Frame

    16-14 frame covers left side cover removal • remove: seat (see seat removal) middle cover screws storage case screws [a] storage case [b] • remove: screws [a] and collars • remove: screws [a] and collars left side cover [b] left side cover installation • install: left side cover [a] insulator [b] sc...

  • Page 405: Frame 16-15

    Frame 16-15 covers • remove: shift knob [a] screws [b] and collars • remove: screws [a] and collars right side cover [b] right side cover installation • install: right side cover [a] screws [b] and collars [c] washer [d] • install: storage case • fit the projection [a] on the ignition switch into th...

  • Page 406: 16-16 Frame

    16-16 frame covers • remove: screw [a] bolts [b] electrical parts case [c] electrical parts case installation • install: removed parts • connect the vehicle-down sensor lead connector. • route the electrical parts leads according to the appendix chapter. Radiator cover removal • remove: front fender...

  • Page 407: Frame 16-17

    Frame 16-17 guards front guard removal • remove: screws [a] and collars bolts [b] and collars front guard cover [c] bolts [d] and collars • remove: front carrier bracket bolts [a] radiator cover screws [e] and collars front guard bolts [c] (both sides) • remove the front guard [d] from the radiator ...

  • Page 408: 16-18 Frame

    16-18 frame guards front bottom guard installation • install the front bottom guard [a] between the frame and engine bottom guard [b]. • install: bolts [c] and collars [d] engine bottom guard removal • remove: bolts [a] and collars [b] engine bottom guard [c] engine bottom guard installation • confi...

  • Page 409: Frame 16-19

    Frame 16-19 flaps and footboards left footboard removal • remove: screws [a] and collars bolts [b] and collars • remove: screws [a] and collars bolts [b] and collars left footboard [c] left footboard installation • install: left footboard [a] bolts [b] and collars [c] screws [d] and collars [e] righ...

  • Page 410: 16-20 Frame

    16-20 frame flaps and footboards right footboard installation • install: right footboard [a] bolts [b] and collars [c] screws [d] and collars [e] footboard bracket installation • install: footboard bracket [a] • tighten: torque - footboard bracket bolts [b]: 47 n·m (4.8 kgf·m, 35 ft·lb).

  • Page 411: Frame 16-21

    Frame 16-21 trailer hitch bracket trailer hitch bracket removal • remove: trailer hitch bracket bolts [a] trailer hitch bracket [b] trailer hitch bracket installation • install the trailer hitch bracket [a] as shown. • tighten: torque - hitch bracket bolts: 82 n·m (8.3 kgf·m, 60 ft·lb).

  • Page 413: Electrical System 17-1

    Electrical system 17-1 17 electrical system table of contents parts location.................................... 17-3 exploded view................................... 17-6 specifications .................................... 17-12 kvf750a/b/c wiring diagram (united states, canada models)..... 17-14 k...

  • Page 414: 17-2 Electrical System

    17-2 electrical system engine brake actuator installation ................................. 17-75 actuator control system outline.. 17-75 actuator control system troubleshooting ........................ 17-76 drive belt failure detection system.. 17-84 drive belt failure detection system inspection....

  • Page 415: Electrical System 17-3

    Electrical system 17-3 parts location light/dimmer switch [a] starter button [b] engine stop switch [c] reverse power assist switch (override) [d] rear brake light switch [e] power outlet connector [f] (120 w) 2wd/4wd shift switch [a] front brake light switch [b] ignition switch [c] battery [a] igni...

  • Page 416: 17-4 Electrical System

    17-4 electrical system parts location frame ground lead [a] water temperature switch [b] 2wd/4wd actuator [c] engine brake actuator [d] spark plug [a] engine ground lead [b] ignition coil [c] frame ground lead [d] rear brake light switch [e] speed sensor [f] drive belt failure detection switch [g] e...

  • Page 417: Electrical System 17-5

    Electrical system 17-5 parts location multifunction meter [a] “set/reset” button [b] belt check indicator light [c] neutral indicator light [d] reverse indicator light [e] oil pressure warning indicator light [f] “4wd” indicator light [g] “2wd” indicator light [h] water temperature warning symbol [i...

  • Page 418: 17-6 Electrical System

    17-6 electrical system exploded view.

  • Page 419: Electrical System 17-7

    Electrical system 17-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter motor mounting bolts 8.8 0.90 78 in·lb 2 starter motor cable mounting nut (kvf750-a1, b1, a6f, b6f, c6f) 4.9 0.50 43 in·lb starter motor cable mounting nut 6.9 0.70 61 in·lb 3 starter motor terminal nut 6.9 0....

  • Page 420: 17-8 Electrical System

    17-8 electrical system exploded view.

  • Page 421: Electrical System 17-9

    Electrical system 17-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spark plugs 13 1.3 113 in·lb 2 2wd/4wd actuator mounting bolts 9.8 1.0 87 in·lb l, s 3 engine brake actuator mounting bolts 8.8 0.90 78 in·lb 4 forward/reverse detecting sensor mounting bolt 15 1.5 11 5 speed sensor m...

  • Page 422: 17-10 Electrical System

    17-10 electrical system exploded view.

  • Page 423: Electrical System 17-11

    Electrical system 17-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator fan switch 18 1.8 13 2 water temperature switch 6.9 0.70 61 in·lb ss 3 oil pressure switch 15 1.5 11 ss 4 oil pressure switch terminal bolt 1.5 0.15 13 in·lb 5 regulator/rectifier mounting bolts 8.8 0.90 78 ...

  • Page 424: 17-12 Electrical System

    17-12 electrical system specifications item standard service limit battery type sealed battery – – – capacity 12 v 12 ah – – – charging system alternator type three-phase ac – – – charging voltage 14 ∼ 15 v – – – (regulator/rectifier output voltage) alternator output voltage 38 ∼ 58 v @3 000 r/min (...

  • Page 425: Electrical System 17-13

    Electrical system 17-13 specifications item standard service limit radiator fan switch resistance: rising temperature from off to on at 96 ∼ 100°c – – – (205 ∼ 212°f) falling temperature from on to off at 91 ∼ 95°c – – – (196 ∼ 203°f) on: less than 0.5 Ω off: more than 1 mΩ coolant temperature warni...

  • Page 426: 17-14 Electrical System

    17-14 electrical system kvf750a/b/c wiring diagram (united states, canada models).

  • Page 427: Electrical System 17-15

    Electrical system 17-15 kvf750a/b/c wiring diagram (united states, canada models).

  • Page 428: 17-16 Electrical System

    17-16 electrical system kvf750a wiring diagram (australia model).

  • Page 429: Electrical System 17-17

    Electrical system 17-17 kvf750a wiring diagram (australia model).

  • Page 430: 17-18 Electrical System

    17-18 electrical system kvf750a wiring diagram (europe model).

  • Page 431: Electrical System 17-19

    Electrical system 17-19 kvf750a wiring diagram (europe model).

  • Page 432: 17-20 Electrical System

    17-20 electrical system special tools and sealant timing light: 57001-1241 flywheel holder: 57001-1313 hand tester: 57001-1394 flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 drive pulley holder: 57001-1620 kawasaki bond (sili...

  • Page 433: Electrical System 17-21

    Electrical system 17-21 precautions there are a number of important precautions that should be taken when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○ always check batter...

  • Page 434: 17-22 Electrical System

    17-22 electrical system precautions ○ electrical connectors: female connectors [a] male connectors [b].

  • Page 435: Electrical System 17-23

    Electrical system 17-23 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is defective, replace the damaged wiring. • pull each connector [a] apart and inspect for corrosion, dirt, and damage. If the connector is corroded or dirty, cl...

  • Page 436: 17-24 Electrical System

    17-24 electrical system battery battery removal • turn off the ignition switch. • remove: seat (see seat removal in the frame chapter) battery holder bolts [a] and collars battery holder [b] • disconnect the battery negative (–) cable [c] first, and then the positive (+) cable [d]. • take out the ba...

  • Page 437: Electrical System 17-25

    Electrical system 17-25 battery caution do not remove the aluminum sealing sheet [a] from the filler ports [b] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • place the battery on a level surface. • check to see that the sealing sheet has...

  • Page 438: 17-26 Electrical System

    17-26 electrical system battery • gently remove the container from the battery. • let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance. Note ○ charging the battery immediately after filling can shorten service life. Let the...

  • Page 439: Electrical System 17-27

    Electrical system 17-27 battery if an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see refreshing charge). When a fast charge is inevitably required, do...

  • Page 440: 17-28 Electrical System

    17-28 electrical system battery if the reading is below the specified, refreshing charge is required. Battery terminal voltage standard: 12.8 v or more refreshing charge • remove the battery [a] (see battery removal). • refresh-charge by following method according to the bat- tery terminal voltage. ...

  • Page 441: Electrical System 17-29

    Electrical system 17-29 battery • determine battery condition after refreshing charge. ○ determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt- age according to the table below. Criteria judgement 12.8 v or higher good 12.0 ∼ 12.8 v or lower ...

  • Page 442: 17-30 Electrical System

    17-30 electrical system charging system alternator cover removal • drain: coolant (see coolant draining in the cooling system chapter) oil (see engine oil change in the periodic maintenance chapter) • remove: recoil starter (see recoil starter removal in the recoil starter chapter) water pump impell...

  • Page 443: Electrical System 17-31

    Electrical system 17-31 charging system alternator cover installation • be sure all of the old gasket has been removed from the alternator cover and the left crankcase sealing surfaces. • check that the dowel pins [a] are in place, and fit a new gasket on the crankcase. • check that the bearing [b] ...

  • Page 444: 17-32 Electrical System

    17-32 electrical system charging system alternator rotor removal • remove: alternator cover (see alternator cover removal) ball bearing [a] • screw the flywheel puller [a] onto the alternator rotor. Special tool - flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 • holding the flywheel pulle...

  • Page 445: Electrical System 17-33

    Electrical system 17-33 charging system alternator stator removal • remove: alternator cover (see alternator cover removal) crankshaft sensor [a] (see crankshaft sensor re- moval) bolts [b] and alternator stator [c] alternator stator installation • tighten: torque - alternator stator bolts: 13 n·m (...

  • Page 446: 17-34 Electrical System

    17-34 electrical system charging system if the battery voltage does not increase as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective. Alterna...

  • Page 447: Electrical System 17-35

    Electrical system 17-35 charging system regulator/rectifier inspection • remove: connectors [a] (disconnect) bolts [b] and regulator/rectifier [c] rectifier circuit check • check conductivity of the following pair of terminals. Rectifier circuit inspection w-bk1, w-bk2, w-bk3, tester connection bk/y...

  • Page 448: 17-36 Electrical System

    17-36 electrical system charging system regulator circuit test-2nd step • connect the test light and a 12 v battery in the same man- ner as specified in the "regulator circuit test-1st step". • apply 12 v to the br terminal. • check y1, y2, and y3 terminals. If the test light turns on, the regulator...

  • Page 449: Electrical System 17-37

    Electrical system 17-37 charging system charging system circuit 1. Ignition switch 2. Fuse box 3. Main fuse 30 a 4. Load 5. Alternator 6. Regulator/rectifier 7. Starter relay 8. Battery 12 v12 ah 9. Engine ground terminal.

  • Page 450: 17-38 Electrical System

    17-38 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. Caution do not disconnect the battery cables or any other...

  • Page 451: Electrical System 17-39

    Electrical system 17-39 ignition system spark plug cleaning/inspection • refer to the spark plug cleaning/inspection in the peri- odic maintenance chapter. Spark plug gap inspection • refer to the spark plug gap inspection in the periodic maintenance chapter. Ignition coil removal front side • remov...

  • Page 452: 17-40 Electrical System

    17-40 electrical system ignition system ignition coil inspection • remove the ignition coil. • measure the arcing distance with a coil tester [a] to check the condition of the ignition coil [b]. • connect the ignition coil (with the spark plug cap left at- tached at the end of the spark plug lead) t...

  • Page 453: Electrical System 17-41

    Electrical system 17-41 ignition system ignition coil primary peak voltage inspection note ○ be sure the battery is fully charged. • remove the spark plug cap (see spark plug removal), but do not remove the spark plug. • measure the primary peak voltage as follows. ○ connect a commercially peak volt...

  • Page 454: 17-42 Electrical System

    17-42 electrical system ignition system crankshaft sensor installation • install: stator coil leads [a] plate [b] crankshaft sensor [c] • tighten: torque - crankshaft sensor mounting bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • fit the lead grommets into the notch on the alternator cover. Grommets [a] fo...

  • Page 455: Electrical System 17-43

    Electrical system 17-43 ignition system crankshaft sensor peak voltage inspection note ○ be sure the battery is fully charged. • remove the spark plug caps, but do not remove the spark plugs. • disconnect: crankshaft sensor lead connector [a] • set the hand tester [b] to the 10 v dc range. • connect...

  • Page 456: 17-44 Electrical System

    17-44 electrical system ignition system [a] f or r mark ignition timing engine speed r/min (rpm) slot [b] aligned with: 1 100 and below advanced mark [c] on alternator rotor 5 000 and above advanced mark [d] on alternator rotor note ○ do not mix up the timing marks with mark [a]. If the ignition tim...

  • Page 457: Electrical System 17-45

    Electrical system 17-45 ignition system vehicle-down sensor removal caution never drop the vehicle-down sensor, especially on a hard surface. Shock to the sensor can damage it. • remove: rear fender (see rear fender removal in the frame chapter) vehicle-down sensor lead connector [a] screws [b] vehi...

  • Page 458: 17-46 Electrical System

    17-46 electrical system ignition system ii. Connections to connector (5 v circuit) vehicle-down sensor lead connector [a] (harness side) digital volt meter [b] meter (+) → connector y/g lead [e] meter (–) → connector bk/y lead [d] • turn the ignition switch on, and measure the power source voltage. ...

  • Page 459: Electrical System 17-47

    Electrical system 17-47 ignition system ignition system troubleshooting.

  • Page 460: 17-48 Electrical System

    17-48 electrical system ignition system ignition system circuit 1. Ignition switch 2. Reverse switch 3. Speed sensor 4. Fuse box (main fuse 30 a) 5. Multifunction meter 6. Belt failure detection switch 7. Engine stop switch 8. Reverse power assist switch (override) 9. Reset connector 10. Crankshaft ...

  • Page 461: Electrical System 17-49

    Electrical system 17-49 electric starter system starter motor removal • remove: air intake rubber duct [a] • remove: joint duct [a] and collars • remove: starter motor cable [a] starter motor mounting bolts [b] clamp [c] starter motor [d] caution do not tap the end of the starter motor shaft or the ...

  • Page 462: 17-50 Electrical System

    17-50 electrical system electric starter system • install: starter motor [a] clamp [b] (as shown) starter motor cable [c] • tighten: torque - starter motor mounting bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) starter motor cable mounting nut: 6.9 n·m (0.70 kgf·m, 61 in·lb) starter motor cable mounting nut...

  • Page 463: Electrical System 17-51

    Electrical system 17-51 electric starter system starter motor assembly • replace the o-rings. • install the brush plate assembly to the right end cover so that the projection [a] on the brush plate fits into the groove on the right end cover. • install the o-ring, insulators [b], and washer [c] in t...

  • Page 464: 17-52 Electrical System

    17-52 electrical system electric starter system • align the mark [a] on the left end cover with the mark [b] on the yoke. • tighten: torque - starter motor bolts: 4.9 n·m (0.50 kgf·m, 43 in·lb) commutator cleaning/inspection • smooth the commutator surface [a] if necessary with fine emery cloth [b],...

  • Page 465: Electrical System 17-53

    Electrical system 17-53 electric starter system starter motor brush length mesurement • measure the overall length [a] of each brush. Starter motor brush length standard: 12.5 mm (0.49 in.) service limit: 5 mm (0.20 in.) if any is worn down to the service limit, replace the brush plate assembly. Bru...

  • Page 466: 17-54 Electrical System

    17-54 electrical system electric starter system starter circuit relay inspection • remove: seat (see seat removal in the frame chapter). Starter circuit relay [a] (brake switch circuit) starter circuit relay [b] (neutral switch circuit) ○ the starter circuit relays for the brake and neutral switch c...

  • Page 467: Electrical System 17-55

    Electrical system 17-55 electric starter system electric starter circuit 1. Starter button 2. Engine stop switch 3. Parking brake light switch 4. Front brake light switch 5. Rear brake light switch 6. Main fuse 30 a 7. Starter circuit relay (brake) 8. Reset connector 9. Ignition switch 10. Starter m...

  • Page 468: 17-56 Electrical System

    17-56 electrical system electric starter system starter motor clutch removal • remove the alternator rotor (see alternator rotor re- moval). • hold the rotor with the flywheel holder and take out the starter motor clutch bolts [a]. Special tool - flywheel holder: 57001-1313 • take out the one-way cl...

  • Page 469: Electrical System 17-57

    Electrical system 17-57 electric starter system torque limiter inspection • remove: alternator rotor (see alternator rotor removal) • remove the torque limiter [a] and visually inspect it. If the limiter has wear, discoloration, or other damage, replace it as a unit..

  • Page 470: 17-58 Electrical System

    17-58 electrical system lighting system headlight beam vertical adjustment • turn the adjusting screw [a] on each headlight rim in or out to adjust the headlight vertically. Note ○ on high beam, the brightest point should be slightly be- low horizontal with the vehicle on its wheels and the rider se...

  • Page 471: Electrical System 17-59

    Electrical system 17-59 lighting system • turn the bulb socket [a] counterclockwise [b], and remove the bulb. • align the mark [a] of a new bulb socket with the mark [b] of the headlight body. • turn the bulb socket clockwise until it is stopped. • disconnect the position light lead connector. • tur...

  • Page 472: 17-60 Electrical System

    17-60 electrical system lighting system taillight bulb replacement • remove: taillight lens mounting screws [a] taillight lens [b] • push the bulb [a] in, turn it counterclockwise, and pull it out. • be sure the socket is clean. • insert the new bulb by aligning the pins [a] with the grooves in the ...

  • Page 473: Electrical System 17-61

    Electrical system 17-61 lighting system lighting system circuit 1. Multifunction meter 2. Reverse switch 3. Reverse light (eur and gb models) 4. Main fuse 30 a 5. Front brake light switch 6. Parking brake light switch 7. Rear brake light switch 8. Position light (right) 9. Headlight (right) 10. Head...

  • Page 474: 17-62 Electrical System

    17-62 electrical system radiator fan system radiator fan circuit inspection • remove: screw [a] left lower end of radiator cover [b] • disconnect the leads from the radiator fan switch [a]. • using an auxiliary wire [b], connect the radiator fan switch leads. If the fan rotates, inspect the fan swit...

  • Page 475: Electrical System 17-63

    Electrical system 17-63 radiator fan system radiator fan breaker installation • install: radiator fan breaker [a] holder [b] • connect: white lead [c] blue/white lead [d] [e] electrical parts case [f] right side radiator fan circuit 1. Radiator fan breaker 2. Radiator fan switch 3. Main fuse 30 a 4....

  • Page 476: 17-64 Electrical System

    17-64 electrical system meter multifunction meter unit removal • remove: handlebar cover screws [a] • remove: handlebar cover screws [a] handlebar cover front [b] • remove: meter lead connectors [a] handlebar cover screws [b] • remove: handlebar cover screw [a] handlebar cover rear [b] • remove: bra...

  • Page 477: Electrical System 17-65

    Electrical system 17-65 meter • remove: multifunction meter mounting nuts [a] and washers bracket [b] multifunction meter unit [c] caution do not drop the meter unit. Multifunction meter unit inspection • remove: multifunction meter unit (see multifunction meter unit removal) caution do not drop the...

  • Page 478: 17-66 Electrical System

    17-66 electrical system meter check 2: mode and time set buttons operation check • connect the wires in the same manner as check 1. • check that when the mode button [a] is pushed and held continuously, the display [b] cycles through the four modes. Odo → trip a → trip b → hour → odo if this display...

  • Page 479: Electrical System 17-67

    Electrical system 17-67 meter check 4: odometer check • connect the wires in the same manner as check 3. • pushing the mode button [a], cycles the odometer [b]. • raise the input frequency of the oscillator to see the result of this inspection. If the value indicated by the odometer does not work, r...

  • Page 480: 17-68 Electrical System

    17-68 electrical system meter • connect terminal [4] to the battery (–) terminal. ○ the 4wd indicator light (lcd) [a] should appear. If this display function does not work, replace the meter unit. Check 8: water temperature warning symbol check • connect the wires in the same manner as check 1. • co...

  • Page 481: Electrical System 17-69

    Electrical system 17-69 meter ○ the oil pressure warning light (led) [a] should flash. If the led light does not flash, replace the meter unit. Check 10: neutral indicator light check • connect the wires in the same manner as check 1. • connect terminal [8] to the battery (–) terminal. ○ the neutral...

  • Page 482: 17-70 Electrical System

    17-70 electrical system meter check 12: meter illumination check • connect the wires in the same manner as check 1. • connect terminal [6] to battery (+) terminal. ○ the meter illumination [a] should go on. If the illumination does not go on, replace the meter unit. Check 13: belt check indicator li...

  • Page 483: Electrical System 17-71

    Electrical system 17-71 meter • turn off the ignition switch. • remove the seat (see seat removal in the frame chap- ter). • disconnect both sets of 4 pin connectors [a] in the elec- trical parts case. • reconnect these 4 pin connectors to their opposite gray to black and black to gray as shown. • t...

  • Page 484: 17-72 Electrical System

    17-72 electrical system meter • connect the belt switch 2 pin connector [a]. • turn on the ignition switch. • confirm that no belt check indicator light is flashing. • put the connectors back and bend the clamps..

  • Page 485: Electrical System 17-73

    Electrical system 17-73 meter meter circuit 1. Multifunction meter 2. Neutral switch 3. Reverse switch 4. Water temperature switch 5. Actuator controller 6. 2wd/4wd switch 7. Speed sensor 8. Main fuse 30 a 9. Fuel level sensor 10. Igniter 11. Belt failure detection switch 12. Oil pressure switch 13....

  • Page 486: 17-74 Electrical System

    17-74 electrical system actuator control system 2wd/4wd actuator removal • drain the front final gear case oil (see front final gear case oil change in the periodic maintenance chapter). • remove: actuator lead connector [a] clamp [b] • remove: actuator mounting bolts [a] actuator [b] 2wd/4wd actuat...

  • Page 487: Electrical System 17-75

    Electrical system 17-75 actuator control system engine brake actuator installation • apply grease and install: o-ring [a] • apply molybdenum disulfide grease to the pin [b]. • apply grease to the trim seal [a] and install the cover [b]. • insert the pin into the collar [a] of the engine brake lever ...

  • Page 488: 17-76 Electrical System

    17-76 electrical system actuator control system actuator control system actuator control system troubleshooting when the actuator fails, the controller enters failure mode and the indicator light illuminates 2wd and 4wd alternately. [a] 2wd indicator light (lcd) [b] 4wd indicator light (lcd).

  • Page 489: Electrical System 17-77

    Electrical system 17-77 actuator control system failure indication pattern and failure part no. Failure indication pattern failure part 1 selectable 2wd/4wd actuator 2 engine brake actuator 3 both the selectable 2wd/4wd actuator and the engine brake actuator malfunction mode no. Malfunction mode pro...

  • Page 490: 17-78 Electrical System

    17-78 electrical system actuator control system • measure the resistance between the following terminals in the actuator lead connector [a]. Special tool - hand tester: 57001-1394 actuator internal resistance 4 (red) - 6 (black): 3 ∼ 15 Ω 1 (orange) - 3 (blue): 3.5 ∼ 6.5 kΩ 2 (yellow) - 3 (blue): 63...

  • Page 491: Electrical System 17-79

    Electrical system 17-79 actuator control system check 4. Speed sensor inspection note ○ be sure the battery is fully charged. • support the vehicle on a stand or a jack so that the wheels are off the ground. • remove: seat (see seat removal in the frame chapter) • connect: controller connector [a] h...

  • Page 492: 17-80 Electrical System

    17-80 electrical system actuator control system • push the switch to the 2wd position. Controller output voltage (at 2wd/4wd shift switch on, 2wd) standard: 0 v if the reading is not standard, check the 2wd/4wd shift switch or actuator controller unit. Check 6. Controller unit inspection note ○ be s...

  • Page 493: Electrical System 17-81

    Electrical system 17-81 actuator control system • disconnect the 2wd/4wd shift switch lead connector. • connect: controller connector [a] hand tester [b] (range: dc 10 v) tester (+) → connector (g) terminal [7] tester (–) → connector (bk/y) terminal [10] ○ install the needle adapters on the tester l...

  • Page 494: 17-82 Electrical System

    17-82 electrical system actuator control system • turn on the ignition switch. • shift to the 2wd position. • measure the controller output voltage for the 2wd/4wd actuator until the actuator stops. Controller output voltage (to 2wd/4wd actuator) standard: 5 ∼ 12 v if the reading is not standard, ch...

  • Page 495: Electrical System 17-83

    Electrical system 17-83 actuator control system actuator control system circuit 1. Speed sensor 2. Forward/reverse detecting sensor 3. 2wd/4wd actuator 4. Engine brake actuator 5. Actuator controller 6. Ignition switch 7. Controller fuse 10 a 8. Main fuse 30 a 9. Multifunction meter 10. 2wd/4wd shif...

  • Page 496: 17-84 Electrical System

    17-84 electrical system drive belt failure detection system if the drive belt failure detection system activated by ab- normal belt, the drive belt failure detection switch is dam- aged. Make sure replace the torque converter cover (see torque converter cover removal/installation in the con- verter ...

  • Page 497: Electrical System 17-85

    Electrical system 17-85 carburetor heater system air temperature sensor inspection • remove: air cleaner housing (see air cleaner housing removal in the fuel system chapter) air temperature sensor [a] • connect the battery [a] and hand tester [b] to the sensor lead connector [c]. Special tool - hand...

  • Page 498: 17-86 Electrical System

    17-86 electrical system carburetor heater system carburetor heater inspection • disconnect: carburetor heater lead connectors [a] ground lead connector [b] • using the hand tester, measure the resistance of the heater. • connect the tester between the heater terminal and the ground terminal. If the ...

  • Page 499: Electrical System 17-87

    Electrical system 17-87 switches and sensor fuel level sensor removal • remove: seat (see seat removal in the frame chapter) electrical parts case (see electrical parts case re- moval in the frame chapter) fuel level sensor lead connector [a] fuel level sensor mounting bolts [b] fuel level sensor [c...

  • Page 500: 17-88 Electrical System

    17-88 electrical system switches and sensor fuel level sensor circuit 1. Multifunction meter 2. Fuel level sensor 3. Ignition switch 4. Main fuse 30 a 5. Starter relay 6. Battery 7. Engine ground terminal brake light switch adjustment • refer to the brake light switch inspection and adjust- ment in ...

  • Page 501: Electrical System 17-89

    Electrical system 17-89 switches and sensor radiator fan switch resistance ○ rising temperature: from off to on at 96 ∼ 100°c (205 ∼ 212°f) ○ falling temperature: from on to off at 91 ∼ 95°c (196 ∼ 203°f) on: less than 0.5 Ω off: more than 1 mΩ • install: radiator fan switch torque - radiator fan sw...

  • Page 502: 17-90 Electrical System

    17-90 electrical system switches and sensor speed sensor removal/installation • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: right footboard (see right footboard removal in the frame chapter) bolts [a] speed sensor [b] • disconnect the speed sensor co...

  • Page 503: Electrical System 17-91

    Electrical system 17-91 switches and sensor neutral switch connection [a] neutral switch reverse switch connections [b] reverse switch 2wd/4wd shift switch oil pressure switch connections* *: engine iubrication system is in good condition drive belt failure detection switch inspection if the drive b...

  • Page 504: 17-92 Electrical System

    17-92 electrical system fuses fuse removal • remove: seat (see seat removal in the frame chapter) fuse box lid [a] • pull the fuses [a] straight out of the fuse box with needle nose pliers. Fuse installation if a fuse fails during operation, inspect the electrical sys- tem to determine the cause, an...

  • Page 505: Appendix 18-1

    Appendix 18-1 18 appendix table of contents troubleshooting guide ........................................................................................................... 18-2 cable, wire, and hose routing ..............................................................................................

  • Page 506: 18-2 Appendix

    18-2 appendix troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine doesn’t start, starting difficulty: starter motor not rot...

  • Page 507: Appendix 18-3

    Appendix 18-3 troubleshooting guide cylinder head warped valve spring broken or weak valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) compression release (kacr) cam sticks open (engine stalls when moving off) other: carburetor vacuum piston doesn’t slide s...

  • Page 508: 18-4 Appendix

    18-4 appendix troubleshooting guide over cooling: cooling system component incorrect: radiator fan switch trouble thermostat trouble converter operation faulty: belt slipping: belt dirty, worn, or wetted drive or driven pulley sheave dirty or worn drive pulley spring broken or weak converter engagem...

  • Page 509: Appendix 18-5

    Appendix 18-5 troubleshooting guide damaged side gears or pinions (front final gear case) abnormal frame noise: shock absorber noise: shock absorber damaged disc brake noise: pad installed incorrectly pad surface glazed disc warped caliper trouble rear brake noise: foreign matter in hub brake not pr...

  • Page 510: 18-6 Appendix

    18-6 appendix troubleshooting guide battery discharged: battery faulty (e.G., plates sulphated, shorted through sedimentation, elec- trolyte level too low) battery leads making poor contact load excessive (e.G., bulb of excessive wattage) ignition switch trouble regulator/rectifier trouble alternato...

  • Page 511: Appendix 18-7

    Appendix 18-7 cable, wire, and hose routing 1. Engine breather hose 2. Clamps 3. Align the white paint mark on the hose with the adjustment mark on the crankcase. 4. Starter motor 5. Install the oil pressure switch lead not to interfere with the starter motor..

  • Page 512: 18-8 Appendix

    18-8 appendix cable, wire, and hose routing 1. Starter motor lead 2. Engine ground lead (install the lead so that the flat side of the lower terminal faces toward the engine.) 3. Install the clamp on the engine ground lead terminal. 4. Drive belt failure detecting switch lead connector 5. Engine bra...

  • Page 513: Appendix 18-9

    Appendix 18-9 cable, wire, and hose routing 1. Clamp 2. Vacuum hose 3. Clamps 4. Choke cable 5. Clamps 6. Water hose 7. White paint 8. Mark 9. Water pipe 10. Coolant catch tank 11. Ignition coil 12. Ignition coil lead.

  • Page 514: 18-10 Appendix

    18-10 appendix cable, wire, and hose routing 1. Air cleaner cover 2. Breather tank 3. Carburetor breather tubes 4. Breather tube 5. Check valve 6. Duct screw 7. Air intake duct 8. Drain tube 9. Drain tube 10. Engine breather hose 11. Choke cable 12. Boot 13. Choke plunger.

  • Page 515: Appendix 18-11

    Appendix 18-11 cable, wire, and hose routing 1. Main harness 2. Bands 3. Vacuum hose (blue line) 4. Spark plug lead (it shall be installed along with the concave of exhaust dust.) 5. Torque converter air duct 6. Fuel hose (red line) 7. Vacuum hose 8. Clamps 9. Drain hose 10. Crankshaft sensor lead 1...

  • Page 516: 18-12 Appendix

    18-12 appendix cable, wire, and hose routing 1. Rear final gear case breather tube 2. Front final gear case breather tube 3. Carburetor breather tube 4. Radiator fan motor breather tube 5. Bands 6. Main harness 7. Outside 8. Fix breather tube to right frame pipe. 9. Water hose 10. Water hose 11. Rad...

  • Page 517: Appendix 18-13

    Appendix 18-13 cable, wire, and hose routing 1. Not crush fan motor breather tube to pull it. 2. Clamps 3. Radiator fan motor breather tube 4. Radiator fan motor lead connector 5. To thermostat 6. To water pump 7. Water hose 8. Band 9. Reserve tank.

  • Page 518: 18-14 Appendix

    18-14 appendix cable, wire, and hose routing 1. Water hose 2. Water pipe 3. Water temperature switch (do not bend its lead) 4. Water hose 5. Thermostat 6. Clamp 7. Reserve tank 8. Reverse switch lead 9. Neutral switch lead 10. Clamp 11. Forward/reverse detecting sensor lead connector 12. Run the for...

  • Page 519: Appendix 18-15

    Appendix 18-15 cable, wire, and hose routing 1. Clamp 2. 2wd/4wd actuator lead 3. Air intake duct 4. Band 5. Front final gear case 6. Carburetor air vent tube 7. No interference 8. Main harness 9. 2wd/4wd actuator lead connector (apply grease all around on the top surface of connector to be waterpro...

  • Page 520: 18-16 Appendix

    18-16 appendix cable, wire, and hose routing 1. Main harness 2. Drive belt failure detecting switch lead 3. Engine brake actuator lead 4. Starter motor cable 5. Clamp 6. Drive belt failure detecting switch 7. Engine brake actuator 8. Engine brake actuator lead connector (apply grease all around on t...

  • Page 521: Appendix 18-17

    Appendix 18-17 cable, wire, and hose routing 1. Vacuum hose (to rear cylinder head with blue line) 2. Connect the thick side of hose to the fuel pump. 3. Fuel hose (to carburetor with red line) 4. Clamps 5. Vacuum hose (to front cylinder head) 6. Fuel pump 7. Rubber cover 8. Air temperature sensor.

  • Page 522: 18-18 Appendix

    18-18 appendix cable, wire, and hose routing 1. Rear brake lever 2. Parking brake lock lever 3. Variable differential control cable 4. Cable adjuster 5. Variable differential control lever 6. Handle holder clamp 7. Variable differential operating lever 8. Fit the dust cap. 9. 27 ∼ 35 mm (1.1 ∼ 1.4 i...

  • Page 523: Appendix 18-19

    Appendix 18-19 cable, wire, and hose routing 1. Clamp 2. Bands 3. Radiator fan motor breather tube 4. Carburetor breather tube 5. Front final gear case breather tube 6. Joint 7. Tube 8. Dampers 9. Bands 10. 220 mm (8.66 in.) 11. 60 mm (2.36 in.) 12. “l” formed side 13. Rear final gear case breather ...

  • Page 524: 18-20 Appendix

    18-20 appendix cable, wire, and hose routing 1. Right headlight lead 2. Radiator cover 3. Frame ground lead 4. Horn switch lead (australia and europe models) 5. Alternator, crankshaft sensor and oil pressure switch leads 6. Rear brake light switch lead 7. 2wd/4wd shift switch lead 8. Left handlebar ...

  • Page 525: Appendix 18-21

    Appendix 18-21 cable, wire, and hose routing 1. Right handlebar switch lead 2. Throttle cable 3. Meter lead 4. Variable differential control cable 5. Parking brake cable 6. Choke cable 7. Left handlebar switch lead 8. Bands 9. Front brake light switch lead 10. Brake hose 11. Tubes 12. Cables and bra...

  • Page 526: 18-22 Appendix

    18-22 appendix cable, wire, and hose routing 1. Air intake duct 2. Bands 3. Parking brake cable 4. Rear brake cable 5. Bracket 6. Clamp 7. Rear brake light switch 8. Speed sensor lead connector 9. Run the lead front side of frame pipe. 10. Clamps 11. Reverse switch lead connector 12. Neutral switch ...

  • Page 527: Appendix 18-23

    Appendix 18-23 cable, wire, and hose routing 1. Fuse box 2. Igniter 3. Main harness 4. Clamp 5. Actuator controller 6. Reset connectors 7. Starter circuit relay (neutral) 8. Electric parts case 9. Vehicle down sensor 10. Starter circuit relay (brake) 11. Clamp 12. Radiator fan breaker 13. Starter re...

  • Page 528: 18-24 Appendix

    18-24 appendix cable, wire, and hose routing 1. Main harness 2. Battery (−) cable 3. Bands 4. To rear brake light switch 5. Clamps 6. Fuse box lead 7. To igniter 8. To actuator controller 9. To starter relay 10. Battery (+) cable 11. Reset connector 12. To starter circuit relay (neutral) 13. To vehi...

  • Page 529: Appendix 18-25

    Appendix 18-25 cable, wire, and hose routing 1. To left headlight 2. Run the radiator fan switch inside of frame pipe. 3. Clamps 4. To power outlet connector 5. Front ignition coil 6. To air temperature sensor 7. Clamps 8. Main harness 9. Rear ignition coil 10. Frame ground terminal 11. To carbureto...

  • Page 530: 18-26 Appendix

    18-26 appendix cable, wire, and hose routing 1. Battery 2. Red cap 3. From starter motor 4. Run the battery cable under the frame pipe. 5. Insert the clamp info the hole of bottom side. 6. Battery (+) cable 7. Battery (–) cable 8. Starter relay 9. Igniter 10. Actuator controller.

  • Page 531: Appendix 18-27

    Appendix 18-27 cable, wire, and hose routing 1. Converter intake duct 2. Bands 3. Rear final gear case breather tube 4. Rear final gear case.

  • Page 532: Model Application

    Model application year model beginning frame no. 2005 kvf750-a1 jkavfda1 □ 5b500001 or jkavf750aab600001 2005 kvf750-b1 jkavfdb1 □ 5b500001 2006 kvf750a6f jkavf750aab601201 jkavfda1 □ 6b519001 2006 kvf750b6f jkavfdb1 □ 6b519001 2006 kvf750c6f jkavfdc1 □ 6b500001 2007 kvf750a7f jkavf750aab602401 jkav...