Kawasaki KVF 750 / BRUTE FORCE 750 4×4 ATV Repair Service Manual 2008

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This workshop repair service manual PDF download for the KVF 750 4×4 / BRUTE FORCE 750 4×4i Kawasaki All Terrain Vehicle has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

BRUTE FORCE 750 4×4i
KVF 750 4×4

Year Model
Beginning Frame No.

2008 KVF750D8F
JKAVFDD1□8B500001 or
JKAVF750DDB600001

2008 KVF750E8F
JKAVFDE1□8B500001

2008 KVF750E8FA
JKAVFDE1□8B500001

2008 KVF750F8F
JKAVFDF1□8B500001

TABLE OF CONTENTS :

General Information
Periodic Maintenance
Fuel System (DFI)
Cooling System
Engine Top End
Converter System
Engine Lubrication System
Engine Removal/Installation
Crankshaft/Transmission
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
Frame
Electrical System
Appendix

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99924-1394-01
Total Pages : 594

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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More Info : http://www.sitelux.com

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tables
LIST OF ABBREVIATIONS
COUNTRY AND AREA CODES
Units of Mass:
Units of Volume:
Units of Force:
Units of Length:
Units of Torque:
Units of Pressure:
Units of Speed:
Units of Power:
Basic Torque for General Fasteners of Engine Parts
Basic Torque for General Fasteners of Frame Parts
Throttle Lever Free Play
Idle Speed
Water and Coolant Mixture Ratio (when shipping)
Valve Clearance (when cold)
Valve Clearance (when cold)
Belt Width
Belt Deflection
Spacers
Actuator Lever Guide Shoe
Engine Oil
Tire Tread Depth
Standard Tire
Differential Control Lever Lock Position Length
Front Final Gear Case Oil
Rear Final Gear Case Oil
Pad Lining Thickness
Rear Brake Lever Free Play
Brake Pedal Free Play
Spark Plug Gap
Brake Light Timing
Terminal Names
Sample Diagnosis Sheet
Engine Doesn’t Start, Starting Difficulty
Poor Running at Low Speed
Poor Running or No Power at High Speed:
Connections:
Throttle Sensor Input Voltage
Input Voltage at Sensor
Wiring Connection
Throttle Sensor Output Voltage
Idle Speed
Output Voltage at Sensor
Wiring Connection
Throttle Sensor Resistance
Inlet Air Pressure Sensor Input Voltage
Input Voltage at ECU
Inlet Air Pressure Sensor Output Voltage
Inlet Air Pressure Sensor Output Voltage
Inlet Air Temperature Sensor Output Voltage
Output Voltage at ECU
Inlet Air Temperature Sensor Resistance
Water Temperature Sensor Output Voltage
Speed Sensor Input Voltage
Input Voltage at Sensor
Speed Sensor Output Voltage
Output Voltage at Sensor
Vehicle-down Sensor Power Source Voltage
Input Voltage at Sensor
Vehicle-down Sensor Output Voltage
Output Voltage at Sensor
Ignition Coil Input Voltage at ECU
Injector Power Source Voltage
Power Source Voltage at Injector
Injector Output Voltage
Output Voltage at Injector
Injector Wiring Inspection
Injector Resistance
Injector Fuel Line Maximum Pressure
ECU Grounding Inspection
ECU Power Source Inspection
Fuel Pressure (Idling)
Amount of Fuel Flow
Pump Operating Voltage at Pump
Operating Voltage at Pump Connector
Engine Vacuum Synchronization Vacuum
Throttle Sensor Output Voltage
Connections:
Standard Resistence:
Radiator Cap Relief Pressure
Thermostat Valve Opening Temperature
Rocker Arm Inside Diameter
Rocker Shaft Diameter
Cam Height
Camshaft Bearing Clearance ( 18)
Camshaft Bearing Clearance ( 22)
Camshaft Journal Diameter ( 18)
Camshaft Journal Diameter ( 22)
Cylinder Compression (Usable Range)
Cylinder Head Warp
Valve/Valve Guide Clearance (Wobble Method)
Valve Seating Surface Outside Diameter
Valve Seating Surface Width
Special Tools – Valve Seat Cutters:
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Piston Ring/Groove Clearance
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Actuator Lever Assembly Installation Length
Measurement Length [E]
Actuator Lever Assemblies
Cover Bushing Inside Diameter [A]
Sheave Bushing Inside Diameter [A]
Spring Free Length [A]
Shoe Side Clearance
Drive Pulley Installation Length [A]
Measurement Length [D]
Drive Pulley Covers
Sheave Bushing Inside Diameter
Spring Free Length [A]
Oil Pressure
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing, Insert/Crankpin Clearance
Crankpin Diameter
Crankpin Diameter Marks
Connecting Rod Big End Inside Diameter Marks
Big End Bearing Insert Selection
Crankshaft Runout
Crankshaft Main Journal Diameter
Crankcase Main Bearing Bore Diameter
Shift Fork Ear Thickness
Shifter Groove Width
Toe-in of Front Wheels
Maximum Tire Air Pressure (to seat beads when cold)
Tire Air Pressure (when cold)
Drive Bevel Gear Shims for Tooth Contact Adjustment
Driven Bevel Gear Shims for Backlash Adjustment
Output Bevel Gear Backlash
Standard Length of Assembling:
Standard Length of Assembling
Front Final Gear Case Coupling Bushing Inside Diameter [B]
LSD Clutch Torque (When variable differential control lever is r
LSD Clutch Torque (When variable differential control lever is p
1. Pinion Gear Shims for Backlash Adjustment
2. Ring Gear Right Shims for Tooth Contact Adjustment
3. Ring Gear Left Shims for Tooth Contact Adjustment
Front Final Bevel Gear Backlash
Standard Length of Assembling:
Standard Length of Assembling:
6. Pinion Gear Shims for Backlash Adjustment
7. Ring Gear Shims for Tooth Contact Adjustment
8. Ring Gear Shims for Tooth Contact Adjustment
Rear Final Bevel Gear Backlash
Recommended Disc Brake Fluid
Disc Thickness
Disc Runout
Spring Action
Spring Action
Tie-rod Length
Kawasaki-recommended chargers:
Battery Terminal Voltage
Terminal Voltage: 11.5 ∼ less than 12.8 V
Terminal Voltage: less than 11.5 V
Regulator/Rectifier Output Voltage
Alternator Output Voltage
Stator Coil Resistance @20°C (68°F)
Regulator/Rectifier Resistance (Unit: kΩ)
Ignition Coil Arcing Distance
Ignition Coil Winding Resistance
Ignition Coil Primary Peak Voltage
Crankshaft Sensor Resistance
Connections:
Crankshaft Sensor Peak Voltage
Ignition Timing
Starter Motor Brush Length
Testing Relay
Radiator Fan Motor Lead Connections:
Failure Indication Pattern and Failure Part
Malfunction Mode
Actuator Internal Resistance
Actuator Internal Resistance
Controller Power Supply Voltage
Speed Sensor Output Voltage
Controller Output Voltage (at 2WD/4WD Shift Switch OFF, 4WD)
Controller Output Voltage (at 2WD/4WD Shift Switch ON, 2WD)
Controller Output Voltage (to Actuators)
Controller Output Voltage (to speed sensor)
Controller Output Voltage (to 2WD/4WD shift switch)
Controller Output Voltage (to engine brake actuator)
Controller Output Voltage (to 2WD/4WD actuator)
Forward/Reverse Detecting Sensor Resistance
Fuel Level Sensor Resistance
Water Temperature Sensor Resistance
Testing Relay
toc
EMISSION CONTROL INFORMATION
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only)
Foreword
General Information
Before starting to perform an inspection service or carry out a
Battery Ground
Edges of Parts
Solvent
Cleaning Vehicle before Disassembly
Arrangement and Cleaning of Removed Parts
Storage of Removed Parts
Inspection
Replacement Parts
Assembly Order
Tightening Sequence
Tightening Torque
Force
Gasket, O-ring
Liquid Gasket, Locking Agent
Press
Ball Bearing and Needle Bearing
Oil Seal, Grease Seal
Circlips, Cotter Pins
Lubrication
Direction of Engine Rotation
Electrical Wires
Instrument
KVF750D8F Left Side View
KVF750D8F Right Side View
Frame Number
Engine Number
Prefixes for Units:
Units of Temperature
Periodic Maintenance
The scheduled maintenance must be done in accordance with this c
The following tables list the tightening torque for the major fa
Oil Filter Wrench:
Fuel System
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Idle Speed Inspection
Idle Speed Adjustment
Air Cleaner Element Cleaning and Inspection
Air Cleaner Draining
Fuel Hose Inspection (fuel leak, damage, installation condition)
Fuel Hose Replacement
Cooling System
Radiator Cleaning
Water Hoses and Connections Inspection
Coolant Change
Torque –
Engine Top End
Valve Clearance Inspection
Special Tool –
Valve Clearance Adjustment
Torque –
Spark Arrester Cleaning
Converter System
Converter Drive Belt Wear Inspection
Special Tool –
Converter Drive Belt Deflection Inspection
Converter Drive Belt Deflection Adjustment
Special Tools –
Torque –
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
Engine Lubrication System
Engine Oil Change
Torque –
Oil Filter Replacement
Special Tool –
Special Tool –
Torque –
Wheels/Tires
Tire Inspection
Final Drive
Variable Differential Control Lever Play Inspection
Variable Differential Control Lever Play Adjustment
Front Final Gear Case Oil Change
Torque –
Torque –
Rear Final Gear Case Oil Change
Torque –
Torque –
Universal Joint Lubrication
Brakes
Front Brake Pad Wear Inspection
Front Brake Hoses and Connections Inspection
Front Brake Hose Replacement
Torque –
Front Brake Fluid Level Inspection
Torque –
Front Brake Fluid Change
Torque –
Front Brake Master Cylinder Piston Assembly and Dust Cover Repla
Front Brake Caliper Fluid Seal Replacement
Front Brake Caliper Dust Seal and Friction Boot Replacement
Rear Brake Plates Replacement
Rear Brake Lever Free Play Inspection
Rear Brake Pedal Free Play Inspection
Rear Brake Lever and Pedal Free Play Adjustment
Steering
Steering Inspection
Electrical System
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Rear Brake Light Switch Inspection
Rear Brake Light Timing Adjustment
Converter Drive Belt Failure Detection System Inspection
Joint Boots Inspection
Front Axle/Steering Knuckle Joint Boots Inspection
Front Propeller Shaft Joint Boots Inspection
Tie-rod End Boots Inspection
Rear Propeller Shaft Joint Boots Inspection
Rear Axle/Stabilizer Joint Boots Inspection
General Lubrication
Lubrication
Bolts and Nuts Tightening
Tightness Inspection
Wheels:
Brakes:
Steering/Suspension:
Engine:
Final Drive:
Others:
Fuel System (DFI)
DFI System
DFI System Wiring Diagram
FI Indicator Light (LCD) [A]
Vacuum Gauge Adapter:
DFI Servicing Precautions
Outline
Special Tool –
Sealant –
Special Tool –
DFI Diagnosis Flow Chart
Inquiries to Rider
NOTE
Self-diagnosis Outline
Self-diagnosis Procedures
Special Tool –
How to Read Service Codes
How to Erase Service Codes
Service Code Table
Notes:
Backups
Throttle Sensor Removal/Adjustment
Throttle Sensor Input Voltage Inspection
Special Tool –
Throttle Sensor Output Voltage Inspection
Special Tool –
Throttle Sensor Resistance Inspection
Throttle Sensor Circuit
CAUTION
Inlet Air Pressure Sensor Removal
Inlet Air Pressure Sensor Installation
Torque –
Inlet Air Pressure Sensor Input Voltage Inspection
Special Tool –
Inlet Air Pressure Sensor Output Voltage Inspection
Special Tool –
Special Tools –
Inlet Air Pressure Sensor Circuit
Inlet Air Temperature Sensor Removal/Installation
Inlet Air Temperature Sensor Output Voltage Inspection
Special Tool –
Inlet Air Temperature Sensor Resistance Inspection
Inlet Air Temperature Sensor Circuit
Water Temperature Sensor Removal/Installation
Water Temperature Sensor Output Voltage Inspection
Special Tool –
Water Temperature Sensor Resistance Inspection
Water Temperature Sensor Circuit
Start the engine and switch the diagnosis mode to Dealer 1 mode
Crankshaft Sensor Removal/Installation
Crankshaft Sensor Inspection
Crankshaft Sensor Circuit
Speed Sensor Removal
Speed Sensor Installation
Speed Sensor Inspection
Input Voltage Inspection
Special Tool –
Output Voltage Inspection
Special Tool –
Special Tool –
Speed Sensor Circuit
Vehicle-down Sensor Removal
Vehicle-down Sensor Installation
Vehicle-down Sensor Inspection
Special Tool –
Special Tool –
Vehicle-down Sensor Circuit
Fuel Pump Relay Removal
Fuel Pump Relay Inspection
Fuel Pump Relay Circuit
Ignition Coil ##1: Ignition Coil for Front Cylinder (Service Code
Ignition Coil Removal/Installation
Input Voltage Inspection
Special Tool –
Fuel Injector Removal
Fuel Injector Installation
Torque –
Audible Inspection
Fuel Injector Power Source Voltage Inspection
Fuel Injector Output Voltage Inspection
Injector Signal Test
Special Tool –
Injector Resistance Inspection
Special Tool –
Injector Unit Test
Injector Fuel Line Inspection
Torque –
Fuel Injector Circuit
Inspection Flow Chart
Light Inspection
FI Indicator Light (LCD) Circuit
CAUTION
ECU Removal
ECU Installation
ECU Power Supply Inspection
Special Tool –
ECU Power Source Circuit
Fuel Pressure Inspection
Special Tools –
Fuel Flow Rate Inspection
Special Tool –
Fuel Pump Removal
Fuel Pump Installation
Torque –
Fuel Pump Operation Inspection
Fuel Pump Operating Voltage Inspection
Special Tools –
Pressure Regulator Removal
Pump Screen, Fuel Filter Cleaning
Fuel Pump Circuit
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Throttle Case Removal/Disassembly
Throttle Case Assembly/Installation
Throttle Cable Installation
Throttle Case Inspection
Throttle Cable Lubrication and Inspection
Idle Speed Inspection
Throttle Body Assy Removal
Throttle Body Assy Installation
Throttle Body Assy Disassembly
Throttle Body Assy Assembly
Torque –
Engine Vacuum Synchronization Inspection
Special Tools –
Engine Vacuum Synchronization Adjustment
Special Tool –
ISC Valve Removal
ISC Valve Installation
Torque –
ISC Valve Inspection
Special Tool –
Air Cleaner Element Removal
Air Cleaner Element Installation
Torque –
Air Cleaner Element Cleaning and Inspection
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Cooling System
Permanent type antifreeze is used as a coolant to protect the co
Bearing Driver Set:
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Water Pump Cover Removal
Water Pump Cover Installation
Torque –
Water Pump Impeller Removal
Water Pump Impeller Installation
Torque –
Water Pump Impeller Inspection
Water Pump Leakage Inspection
Mechanical Seal Replacement
Special Tools –
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Torque –
Radiator Removal
Radiator Installation
Torque –
Radiator Fan Removal
Radiator Fan Installation
Torque –
Radiator Inspection
Radiator Cleaning
Radiator Cap Inspection
Thermostat Removal
Thermostat Installation
Torque –
Thermostat Inspection
Water Temperature Sensor Removal/Installation
Water Temperature Sensor Inspection
Engine Top End
Outside Circlip Pliers:
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Torque –
Torque –
Rocker Case Removal
Special Tool –
Rocker Case Installation
Sealant –
Torque –
Torque –
Rocker Arm Removal
Rocker Arm Installation
Torque –
Rocker Arm Inspection
Rocker Shaft Diameter Measurement
Camshaft Removal
Camshaft Installation
Camshaft Assembly
Torque –
Cam Wear Inspection
Camshaft Bearing Wear Inspection
KACR Inspection
KACR Removal
KACR Installation
Torque –
Camshaft Chain Removal
Special Tool –
Special Tool –
Camshaft Chain Installation
Special Tool –
Torque –
Torque –
Special Tool –
Torque –
Camshaft Chain Guide Wear Inspection
Cylinder Compression Measurement
Special Tools –
Cylinder Head Removal
Cylinder Head Installation
Torque –
First Torque –
Final Torque –
Torque –
Cylinder Head Cleaning
Cylinder Head Warp Inspection
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Special Tools –
Valve Installation
Valve Guide Removal
Special Tool –
Valve Guide Installation
Special Tool –
Special Tool –
Valve-to-Guide Clearance Measurement
Valve Seat Inspection
Valve Seat Repair (Valve Lapping)
Cylinder Removal
Piston Removal
Special Tools –
Cylinder, Piston Installation
Torque –
Cylinder Wear Inspection
Piston Wear Inspection
Piston/Cylinder Clearance Inspection
Piston Ring, Piston Ring Groove Wear Inspection
Piston Ring Groove Width Inspection
Piston Ring Thickness Inspection
Piston Ring End Gap Inspection
This vehicle is equipped with a spark arrester approved for off-
Spark Arrester Cleaning
Muffler and Exhaust Pipe Removal
Muffler and Exhaust Pipe Installation
Torque –
Torque –
Torque –
Torque –
Exhaust System Inspection
Converter System
Outside Circlip Pliers:
WARNING
Torque Converter Cover Removal
Torque Converter Cover Installation
Torque –
Torque Converter Cover Disassembly
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
Torque Converter Cover Assembly
Torque –
Special Tool –
Drive Belt Removal
Drive Belt Installation
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Drive Belt Inspection
Drive Pulley Removal
Special Tool –
Torque –
Special Tools –
Drive Pulley Disassembly
Special Tools –
Special Tool –
Drive Pulley Inspection
Spider Shoe Side Clearance Inspection/Adjustment
Drive Pulley Assembly
Torque –
Special Tool –
Special Tool –
Torque –
Torque –
Drive Pulley Installation
Special Tool –
Torque –
Special Tool –
Driven Pulley Removal
Special Tools –
Driven Pulley Disassembly
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Driven Pulley Inspection
Driven Pulley Assembly
Grease –
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Driven Pulley Installation
Special Tools –
Torque –
Specifications
Engine Lubrication System
Oil Pressure Gauge, 10 kgf/cm :
WARNING
Oil Level Inspection
Engine Oil Change
Oil Filter Change
Oil Screen Removal
Oil Screen Cleaning
Oil Pressure Measurement
Special Tools –
Oil Pressure Switch Removal
Oil Pressure Switch Installation
Sealant –
Torque –
Oil Pressure Relief Valve Removal
Oil Pressure Relief Valve Installation
Torque –
Oil Pressure Relief Valve Inspection
Oil Pump Removal
Oil Pump Installation
Torque –
Torque –
Torque –
Oil Pipe Removal
Oil Pipe Installation
Torque –
Engine Removal/Installation
Engine Removal
Engine Installation
Torque –
Crankshaft/Transmission
Outside Circlip Pliers:
Crankcase Disassembly
Crankcase Assembly
Special Tool –
Torque –
Special Tool –
Torque –
Sealant –
Torque –
Torque –
Torque –
Crankshaft Removal
Crankshaft Installation
Special Tools –
Connecting Rod Removal
Connecting Rod Installation
Torque –
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend Inspection
Connecting Rod Twist Inspection
Connecting Rod Big End Side Clearance Inspection
Connecting Rod Big End Bearing/Crankpin Wear Inspection
Torque –
Torque –
Crankshaft Runout Inspection
Crankshaft Main Bearing/Journal Wear Inspection
Shift Lever Removal
Shift Lever Installation
Torque –
Torque –
Torque –
Torque –
Torque –
Torque –
Torque –
Transmission Removal
Special Tool –
Special Tool –
Transmission Installation
Special Tool –
Torque –
Torque –
Shift Fork Bending Inspection
Shift Fork/Gear and Shifter Groove Wear Inspection
Transmission and Shift Mechanism Inspection
Ball and Needle Bearing Replacement
Special Tool –
Ball and Needle Bearing Wear Inspection
Oil Seal Inspection
Wheels/Tires
Jack:
Toe-in is the difference between the distance of front and the o
Steering Centering Inspection
Steering Centering Adjustment
Toe-in Inspection
Toe-in Adjustment
Torque –
Wheel Removal
Special Tool –
Wheel Installation
First Torque –
Final Torque –
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tire Removal
Tire Installation
Tire Inspection
Front Hub Removal
Front Hub Installation
Torque –
Front Hub Disassembly/Assembly
Rear Hub Removal
Rear Hub Installation
Torque –
Rear Hub Disassembly/Assembly
Final Drive
Dummy Page
Bearing Puller:
Output Drive Bevel Gear Removal
Special Tool –
Output Drive Bevel Gear Installation
Torque –
Torque –
Special Tool –
Torque –
Torque –
Output Drive Bevel Gear Disassembly
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Output Drive Bevel Gear Assembly
Special Tool –
Torque –
Special Tool –
Torque –
Output Driven Bevel Gear Removal
Output Driven Bevel Gear Installation
Torque –
Output Driven Bevel Gear Disassembly
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Special Tools –
Output Driven Bevel Gear Assembly
Special Tool –
Special Tool –
Special Tool –
Torque –
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Torque –
Output Bevel Gears Adjustment
Output Bevel Gear (Backlash-related Parts)
Bevel Gears Inspection
Front Propeller Shaft Removal
Front Propeller Shaft Installation
Front Axle Removal
Front Axle Installation
Front Axle Joint Boot Inspection
Front Axle Joint Boot Replacement
Special Tool –
Front Final Gear Case Oil Level Inspection
Torque –
Front Final Gear Case Oil Change
Variable Differential Control Lever Play Inspection
Variable Differential Control Lever Play Adjustment
Variable Differential Control Lever Removal
Variable Differential Control Lever Installation
Torque –
Variable Differential Control Cable Installation
Torque –
Variable Differential Control Cable Lubrication
Variable Differential Control Cable Inspection
Front Final Gear Case Removal
Front Final Gear Case Installation
Torque –
Torque –
Front Final Gear Case Disassembly
Special Tool –
Special Tool –
Front Final Gear Case Coupling Inspection
Front Final Gear Case Assembly
Special Tool –
Torque –
Special Tool –
Torque –
Torque –
Special Tools –
Special Tool –
Special Tool –
Torque –
Torque –
Oil Seal Installation
Ring Gear Disassembly
Ring Gear Assembly
Torque –
LSD Clutch Torque Inspection
Pinion Gear Unit Disassembly
Special Tool –
Special Tool –
Pinion Gear Unit Assembly
Special Tool –
Torque –
Front Final Bevel Gear Adjustment
Front Final Gear Case (Backlash-related Parts)
Bevel Gear Inspection
Differential Gear Inspection
Correct Tooth Contact Pattern: No adjustment is required.
Incorrect Tooth Contact Patterns (Example 1)
Incorrect Tooth Contact Patterns (Example 2)
Rear Propeller Shaft Removal
Rear Propeller Shaft Installation
Rear Propeller Shaft Joint Boot Inspection
Rear Propeller Shaft Inspection
Rear Axle Removal
Rear Axle Installation
Rear Axle Joint Boot Inspection
Rear Axle Joint Boot Replacement
Special Tool –
Special Tool –
Rear Final Gear Case Oil Level Inspection
Torque –
Rear Final Gear Case Oil Change
Rear Final Gear Case Removal
Rear Final Gear Case Installation
Torque –
Rear Final Gear Case Disassembly
Special Tool –
Rear Final Gear Case Right Cover Assembly
Special Tool –
Special Tool –
Rear Final Gear Case Front Cover Assembly
Special Tool –
Rear Final Gear Case Assembly
Special Tool –
Special Tool –
Torque –
Torque –
Torque –
Torque –
Rear Final Bevel Gear Adjustment
Rear Final Gear Case (Backlash-related Parts)
Pinion Gear Unit Disassembly
Special Tools –
Special Tool –
Pinion Gear Unit Assembly
Special Tools –
Torque –
Ball or Needle Bearing Inspection
Oil Seal Inspection
Brakes
Inside Circlip Pliers:
WARNING
Front Brake Fluid Recommendation
Front Brake Fluid Level Inspection
Front Brake Fluid Change
Front Brake Line Air Bleeding
Torque –
Front Brake Master Cylinder Removal
Front Brake Master Cylinder Installation
Torque –
Torque –
Front Brake Master Cylinder Disassembly
Special Tool –
Front Brake Master Cylinder Assembly
Torque –
Front Master Cylinder Inspection (Visual Inspection)
Front Brake Caliper Removal
Front Brake Caliper Installation
Torque –
Front Brake Caliper Disassembly
Front Brake Caliper Assembly
Torque –
Torque –
Front Brake Caliper Piston and Cylinder Damage Inspection
Front Brake Caliper Holder Shaft Wear Inspection
Front Brake Pad Removal
Front Brake Pad Installation
Torque –
Front Brake Pad Wear Inspection
Front Brake Disc Cleaning
Front Brake Disc Removal
Front Brake Disc Installation
Torque –
Front Brake Disc Wear Inspection
Front Brake Disc Runout Inspection
Front Brake Hose Inspection
Front Brake Hose Replacement
Rear Brake Pedal Position Inspection
Rear Brake Pedal Position Adjustment
Rear Brake Lever Free Play Inspection
Rear Brake Pedal Free Play Inspection
Rear Brake Lever and Brake Pedal Free Play Adjustment
Rear Brake Pedal Removal
Rear Brake Pedal Installation
Rear Brake Cable Removal
Rear Brake Cable Installation
Rear Brake Cable Lubrication
Internal Wet Brake Disassembly
Internal Wet Brake Assembly
Suspension
Inside Circlip Pliers:
Front Shock Absorber Preload Adjustment
Special Tool –
Front Shock Absorber Removal
Special Tool –
Front Shock Absorber Installation
Torque –
Front Shock Absorber Inspection
Front Shock Absorber Scrapping
Rear Shock Absorber Preload Adjustment
Special Tool –
Rear Shock Absorber Removal
Special Tool –
Rear Shock Absorber Installation
Torque –
Rear Shock Absorber Inspection
Rear Shock Absorber Scrapping
Front Suspension Arm Removal
Front Suspension Arm Installation
Torque –
Front Suspension Arm Disassembly
Special Tool –
Special Tool –
Front Suspension Arm Assembly
Special Tool –
Special Tool –
Rear Suspension Arm Removal
Rear Suspension Arm Installation
Torque –
Rear Suspension Arm Disassembly
Special Tool –
Rear Suspension Arm Assembly
Special Tool –
Stabilizer Removal
Stabilizer Installation
Torque –
Torque –
Steering
Inside Circlip Pliers:
Steering Stem Removal
Steering Stem Installation
Torque –
Torque –
Torque –
Steering Knuckle Removal
Steering Knuckle Installation
Torque –
Steering Knuckle Bearing Removal
Special Tool –
Special Tool –
Steering Knuckle Bearing Installation
Special Tool –
Special Tool –
Tie-rod Removal
Tie-rod Installation
Torque –
Tie-rod End Removal
Tie-rod End Installation
Torque –
Steering Inspection
Steering Stem Straightness Inspection
Steering Bearing Sleeve Lubrication
Steering Stem Clamp Inspection
Steering Stem Bearing Inspection
Steering Knuckle Bearing Inspection
Tie-rod End Inspection
Steering Knuckle Joint Inspection
Handlebar Removal
Handlebar Installation
Torque –
Torque –
Frame
Seat Removal
Seat Installation
Front Carrier Removal
Front Carrier Installation
Torque –
Front Carrier Bracket Installation
Torque –
Rear Carrier Removal
Rear Carrier Installation
Torque –
Rear Carrier Bracket Installation
Torque –
Front Fender Removal
Front Fender Installation
Rear Fender Removal
Rear Fender Installation
Middle Cover Removal
Middle Cover Installation
Storage Box Removal
Storage Case Removal
Storage Case Installation
Left Side Cover Removal
Left Side Cover Installation
Right Side Cover Removal
Right Side Cover Installation
Electrical Parts Case Removal
Electrical Parts Case Installation
Radiator Cover Removal
Radiator Cover Installation
Headlight Cover Removal
Headlight Cover Installation
Front Guard Removal
Front Guard Installation
Torque –
Front Bottom Guard Removal
Front Bottom Guard Installation
Engine Bottom Guard Removal
Engine Bottom Guard Installation
Rear Bottom Guard Removal
Rear Bottom Guard Installation
Left Footboard Removal
Left Footboard Installation
Right Footboard Removal
Right Footboard Installation
Footboard Bracket installation
Torque –
Trailer Hitch Bracket Removal
Trailer Hitch Bracket Installation
Torque –
Electrical System
Light/Dimmer Switch [A]
Dummy Page
Timing Light:
There are a number of important precautions that should be taken
Wiring Inspection
Special Tool –
Battery Removal
Battery Installation
Battery Activation
Precautions
1)
2)
3)
4)
Interchange
Charging Condition Inspection
Refreshing Charge
Alternator Cover Removal
Special Tool –
Alternator Cover Installation
Torque –
Special Tool –
Torque –
Alternator Rotor Removal
Special Tool –
Alternator Rotor Installation
Alternator Stator Removal
Alternator Stator Installation
Torque –
Regulator/Rectifier Output Voltage Inspection
Special Tool –
Alternator Inspection
Special Tools –
Regulator/Rectifier Removal
Regulator/Rectifier Installation
Torque –
Regulator/Rectifier Inspection
Special Tool –
Charging System Circuit
WARNING
Spark Plug Removal
Special Tool –
Special Tool –
Spark Plug Installation
Torque –
Special Tool –
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Ignition Coil Removal
Ignition Coil Installation
Torque –
Ignition Coil Inspection
Special Tool –
Ignition Coil Primary Peak Voltage Inspection
Special Tools –
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Torque –
Crankshaft Sensor Inspection
Crankshaft Sensor Peak Voltage Inspection
Special Tools –
Alternator Rotor Inspection
Ignition Timing Test
Special Tool –
Special Tool –
Ignition System Troubleshooting
Ignition System Circuit
Starter Motor Removal
Starter Motor Installation
Torque –
Torque –
Starter Motor Disassembly
Starter Motor Assembly
Torque –
Torque –
Brush Inspection
Commutator Cleaning and Inspection
Armature Inspection
Special Tool –
Brush Lead Inspection
Special Tool –
Right-hand End Cover Inspection
Special Tool –
Starter Relay Inspection
Starter Control Relay Inspection
Electric Starter Circuit
Starter Motor Clutch Removal
Special Tool –
Starter Motor Clutch Installation
Torque –
Starter Motor Clutch Inspection
Torque Limiter Inspection
Headlight Beam Vertical Adjustment
Headlight Bulb Replacement
Tail/Brake Light Bulb Replacement
Torque –
Tail/Brake Light Removal
Lighting System Circuit
Radiator Fan Motor Inspection
Radiator Fan Breaker Inspection
Radiator Fan Breaker Installation
Radiator Fan Circuit
Multifunction Meter Unit Removal
Multifunction Meter Unit Inspection
Drive Belt Failure Mode Memory Clearing Procedure
Meter Circuit
2WD/4WD Actuator Removal
2WD/4WD Actuator Installation
Torque –
Engine Brake Actuator Removal
Engine Brake Actuator Installation
Torque –
Actuator Control System Outline
Actuator Control System
Actuator Controller Removal
Actuator Controller Installation
Actuator Control System Troubleshooting
Special Tool –
Special Tool –
Special Tools –
Special Tools –
Special Tools –
Special Tools –
Special Tools –
Special Tools –
Special Tools –
Special Tools –
Special Tool –
Actuator Control System Circuit
If the drive belt failure detection system activated by abnormal
Drive Belt Failure Detection System Inspection
Drive Belt Failure Detection System Circuit
Fuel Level Sensor Inspection
Special Tool –
Fuel Level Sensor Circuit
Brake Light Switch Adjustment
Water Temperature Sensor Inspection
Speed Sensor Removal/Installation
Torque –
Speed Sensor Inspection
Special Tool –
Switch Inspection
Neutral Switch Connection
Reverse Switch Connections
2WD/4WD Shift Switch
Oil Pressure Switch Connections*
Drive Belt Failure Detection Switch Inspection
Relay Inspection
Fuse Removal
Fuse Installation
Fuse Inspection
Appendix
NOTE
Engine Doesn’t Start, Starting Difficulty:
Starter motor not rotating:
Starter motor rotating but engine doesn’t turn over:
Engine won’t turn over:
No fuel flow:
Engine flooded:
Fuel/air mixture incorrect:
No spark; spark weak:
Compression Low:
Poor Running at Low Speed:
Spark weak:
Fuel/air mixture incorrect:
Compression low:
Other:
Poor Running or No Power at High Speed:
Firing incorrect:
Fuel/air mixture incorrect:
Compression low:
Knocking:
Miscellaneous:
Overheating:
Firing incorrect:
Fuel/air mixture incorrect:
Compression high:
Engine load faulty:
Lubrication inadequate:
Front or rear final gear case overheating:
Coolant incorrect:
Cooling system component incorrect:
Over Cooling:
Cooling system component incorrect:
Converter Operation Faulty:
Belt slipping:
Converter engagement speed too low:
Converter engagement speed too high:
Shifting too quickly:
Shifting too slowly:
Gear Shifting Faulty:
Doesn’t go into gear:
Jumps out of gear:
Overshifts:
Abnormal Engine Noise:
Knocking:
Piston Slap:
Valve noise:
Other noise:
Abnormal Drive Train Noise:
Converter noise:
Transmission noise:
Front or rear final gear case noise:
Abnormal Frame Noise:
Shock absorber noise:
Disc brake noise:
Rear brake noise:
Other noise:
Exhaust Smokes Excessively:
White smoke:
Black Smoke:
Brown smoke:
Handling and/or Stability Unsatisfactory
Handlebar hard to turn:
Noise when turning:
Handlebar shakes or excessively vibrates:
Handlebar pulls to one side:
Shock absorption unsatisfactory:
Brake Doesn’t Hold
Front brake:
Rear Brake:
Kawasaki Engine Brake Control and Selectable 2WD/4WD System Malf
Battery Discharged:
Battery Overcharged:

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