Kawasaki Brute Force 750 4x4i - Manuals

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 theCalifornia Air Resources Board.1. Crankcase Emission Control SystemA sealed-type cra...

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only) To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance whilemaintaining a low noise level. Please do not remove these...

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 andrepair work. A basic knowledge of mechanics,the proper use...

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification................................................................................

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 hav...

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 disassembledand clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including subass...

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 toa snug fit. Then tighten them according to the specified se-quence to prevent case warpage or deformation which canlead...

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 usesmooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ...

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, applythe specific oil or grease as specified. Direction of Engine Rotation...

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.

1-8 GENERAL INFORMATION General Specifications Items KVF750-A1, B1 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 in.) Dry Mass 274 kg ...

GENERAL INFORMATION 1-9 General Specifications Items KVF750-A1, B1 Engine oil: Type API SF or SGAPI SH or SJ with JASO MA class Viscosity SAE 10W-40 Capacity 2.6 L (2.75 US qt) Drive Train Primary Reduction System: Type Belt converter Reduction Ratio 3.122 ∼ 0.635 Transmission: Type 2-speed and reve...

1-10 GENERAL INFORMATION General Specifications Items KVF750-A1, B1 Front tire: Type Tubeless Size AT25 × 8 – 12 Rear tire: Type Tubeless Size AT25 × 10 – 12 Suspension: Front: Type Double Wishbone Wheel Travel 171 mm (6.73 in.) Rear: Type Double Wishbone Wheel Travel 200 mm (7.87 in.) Brake: Front ...

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)...

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart .............. 2-3 Torque and Locking Agent................. 2-5 Specifications .................................... 2-11 Special Tools ..................................... 2-13 Periodic Maintenance Procedu...

2-2 PERIODIC MAINTENANCE Lubrication ................................... 2-40 Bolts and Nuts Tightening............... 2-41 Tightness Inspection .................... 2-41

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. First FREQUENCY Service Regular Service OPERATION After 10 h...

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart First FREQUENCY Service Regular Service OPERATION After 10 hrs. or 100 km (60 mi.) of use Every 10 days or200 km (120 mi.) of use Every 30 days or600 km (360 mi.) of use Every 90 days, 1 700 km (1 100 mi.) or when belt indicator light turns on (100...

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times t...

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb Water Pipe Mounting Bolts 8.8 0.90 78 in·lb Rocker Shaft Bolts 20 2.0 14 Valve Adjusting Screw Locknuts 12 1.2 104 in·lb Chain Tensioner Mounting Bolts 8.8 0.90 78 in...

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Engine Mounting Bolt 62 6.3 46 Engine Mounting Nut 62 6.3 46 Crankshaft/Transmission Connecting Rod Big End Cap Nuts 34 3.5 25 MO Engine Drain Plug 20 2.0 14 Crankcase Bolts (M8) 75 mm (2.95 in.) 20 2.0 14 S Cr...

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Front Final Gear Case Left Cover Bolts (M6) 9.8 1.0 87 in·lb L Ring Gear Bolts 57 5.8 42 LB Front Final Gear Case Center Cover Bolts (M6) 9.8 1.0 87 in·lb L Front Final Gear Case Center Cover Bolts (M8) 24 2.4 ...

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Stabilizer Holder Bolts 23 2.3 17 Stabilizer Joint Nuts 48 4.8 35 Rear Suspension Arm Pivot Nuts 48 4.8 35 Rear Knuckle Mounting Nuts 48 4.8 35 Steering Handlebar Holder Bolts 29 3.0 22 S Steering Stem Clamp Bo...

2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Radiator Fan Switch 18 1.8 13 Coolant Temperature Warning Light Switch 6.9 0.70 61 in·lb SS Oil Pressure Switch 15 1.5 11 SS Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb Regulator/Rectifier Mounting Bol...

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 ...

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 or SJ of JASO MA class – – – Viscosity SAE 10W-40 – – – Oil Level Filler opening bottom – – – Capacity 0.40 L (0.42 US qt) – – – Rear Final Gear Case:...

PERIODIC MAINTENANCE 2-13 Special Tools Oil Filter Wrench:57001-1249 Carburetor Drain Plug Wrench, Hex 3:57001-1269 Flywheel & Pulley Holder:57001-1343 Filler Cap Driver:57001-1454 Pulley Holder Attachment:57001-1472

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection • Check that the throttle lever [A] moves smoothly from fullopen to close, and the throttle closes quickly and com-pletely in all steering positions by the return spring.If the throttle lever do...

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 ofplay....

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 iscorrect. ○ Open and close the throttle a few times to make sure thatthe idle speed is within the specified range. F...

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Air Cleaner Element Cleaning and Inspection NOTE ○ In dusty areas, the element should be cleaned morefrequently than the recommended interval. ○ After riding through rain or muddy terrains, the elementshould be cleaned immediately. ○ Also, if...

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout thevehicle life without any maintenance, however, if the ve-hicle is not properly handled, the pressure inside the fuelline can cause fuel to leak [A] or ...

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Remove: Clamps [A]Fuel Hoses [B] • Replace the fuel hoses with new ones. • When installing the fuel hose, route the hose accordingto Cable, Wire, and Hose Routing section in Appendixchapter. • When installing the fuel hose, avoid sharp bend...

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and Connection Inspection ○ The high pressure inside the radiator hose can causecoolant to leak [A] or the hose to burst if the line is notproperly maintained. Visually inspect the hoses for signsof deterioration. Squeeze the ho...

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Remove: Clamp [A]Reserve Tank Screws [B]Reserve Tank [C] with Hose • Remove the reserve tank cap, and pour the coolant intoa container. • Place a container under the drain plug [A] at the bottomof the water pump [B], then remove the drain p...

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Tighten the drain plug. Torque - Coolant Drain Plug: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Support the vehicle on a stand or the jack so that the frontwheels are off the ground. This makes air bleeding easier. • Fill the radiator up to the radia...

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Check the valve clearance only when the engine is cold(at room temperature). • Remove: Left Side Cover (see Frame chapter)Battery Case (see Frame chapter)Valve Adjusting Caps [A]Recoil Starter ...

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Then, turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until “T-R” mark [A] onthe alternator rotor aligns with the notch [B] as shown:the end of the compression stroke in the rear cylinderhead. • Measure the c...

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Converter System Drive Belt Inspection Inspection of the drive belt is required at least every 90 days of vehicle use (average 12 mile/day) not to exceed 1700 km (1 100 mile) or belt indicator light turn on (100 hoursof use) counted by the ho...

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Measure the belt deflection [A] as shown: ○ Place a straightedge [B] on top of the belt between thedrive pulley [C] and the driven pulley [D]. ○ Use a ruler to push the belt away from the straightedge.Push hard, but with no more force than ...

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Assemble the driven pulley (see Converter System chap-ter). • With the transmission in neutral, rotate the driven pulleyto allow the belt to return to the top of the sheaves beforemeasuring the belt deflection. • Measure the belt deflection...

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...

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Final Drive Variable Differential Control Lever Play Inspection • Pull the variable differential control lever [A] towards thehandlebar grip [B] with a spring scale until it reads 30 N(3 kgf, 7 lb) of force. ○ The differential control in the ...

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 willpick up any sediment and drain easily. Then stop thevehicle. • Park the vehicle so that it is level, both side-to-side andfront-to-rear. • Remove th...

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 willpick up any sediment and drain easily. Then stop thevehicle. • Park the vehicle so that it is level, both side-to-side andfront-to-rear. • Place an o...

2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Universal Joint Lubrication • Remove: Rear Propeller Shaft (see Final Drive chapter) • Force grease into the grease nipples [A] until the greasecomes out from the nipple, and wipe off any excessgrease. [B] Grease Gun Brakes Front Brake Pad We...

PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Front Brake Hose Replacement • Pump the brake fluid out of the line as explained in theBrake 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 s...

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change • Remove the reservoir cap and the rubber cap on the bleedvalve. • Attach a clear plastic hose to the bleed valve on thecaliper, and run the other end of the hose into a con-tainer. • Fill the reservoir with new brake fluid...

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Rear Brake Plates Replacement • Replace the steel plates and friction plates in accordancewith the specified interval (see Rear Final Gear Case sec-tion in the Final Drive chapter). Rear Brake Lever Free Play Inspection • Check the rear brake...

2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection • Turn the handlebar left and right, and check the steeringaction.If the steering action is not smooth, or if the steering bindsor catches before the stop, lubricate the steering stembearing. NOTE ○ The cables and...

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Brake Light Switch Inspection • Turn on the ignition switch. • Check the operation of the rear brake light switch by de-pressing the brake pedal.If it does not as specified, adjust the brake light timing. Brake Light Timing Standard: On after...

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Joint Boots Inspection Front Axle/Knuckle Joint Boot 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 FinalDrive cha...

2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots withrust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle...

PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Slide Points: Lubricate with Grease. Brake LeverBrake Pedal Pivot ShaftThrottle Lever Shaft Bolts and Nuts Tightening Tightness Inspection • Check the tightness of the bolts and nuts listed here inaccordance with the Periodic Maintenance Char...

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 ....

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 Lever3. Choke Cable4. Throttle Cable5. Throttle Lever6. Jet Needle7. Pilot Jet8. Main Jet9. Needle Jet 10. Pilot Screw 11. Priming Pump 12. Air Temperature Sensor ...

3-8 FUEL SYSTEM Throttle Lever and Cable Throttle Lever Free Play Inspection • Refer to the Throttle Lever Free Play Inspection in thePeriodic Maintenance chapter. Throttle Lever Free Play Adjustment • Refer to the Throttle Lever Free Play Adjustment in thePeriodic Maintenance chapter. Throttle Case...

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 thethrottle lever stop [C]. Tighten the locknut [D]. NOTE ○ Refer to the Owner’s...

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 thePeriodic Maintenance chapter. Choke Lever and Cable Rem...

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 cablefrom the switch case. • Pull the cable out of the vehicle. Choke Lever and Cable Installation • Lubricate the choke cable before installation. • Install the wave wa...

3-12 FUEL SYSTEM Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main-tenance chapter. Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main-tenance chapter. Pilot Screw Adjustment • Adjust the pilot screw if necessary. • Remove the air...

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.) higherthan the top graduation [D]. • Hold the gauge so that the addition...

3-14 FUEL SYSTEM Carburetor Service Fuel Level Adjustment WARNING Gasoline is extremely flammable and can be ex-plosive under certain conditions. Turn the ignitionswitch to OFF. Do not smoke. Make sure the areais well-ventilated and free from any source of flameor sparks; this includes any appliance...

FUEL SYSTEM 3-15 Carburetor • Remove the rear vacuum hose [A] and install the vacuumhose for vacuum gauge. • Connect: Vacuum Gauge [A] Special Tool - Vacuum Gauge: 57001-1369 • Connect the fuel hose of a suitable fuel tank [B] to thecarburetor. • Start the engine and read the intake vacuum of each c...

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] • Lo...

FUEL SYSTEM 3-17 Carburetor • Remove: Screw [A]Holder Plate [B]Starter Plunger Carburetor Installation • Confirm the groove of the carburetor holder [A] fits on theprojection [B] of the cylinder head. • Check fuel leakage from the carburetors. WARNING Fuel spilled from the carburetors is hazardous. ...

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, orthis could damage the jet or the carburetor body,requiring replacement. • Install the float valve needl...

3-20 FUEL SYSTEM Carburetor • Fit the projection [A] of the vacuum piston diaphragm inthe recess [B] of the body. • After installing the upper chamber cover, check to makesure that the vacuum piston moves smoothly in the car-buretor body. Carburetor Separation • Remove: Carburetor (see Carburetor Re...

FUEL SYSTEM 3-21 Carburetor • Visually synchronize the throttle (butterfly) valves. ○ Check to see that all throttle valves open and closesmoothly without binding when turning the pulley. ○ Visually check the clearance [A] between the throttlevalve and the carburetor bore in each carburetor. If ther...

3-22 FUEL SYSTEM Carburetor • Disassemble the carburetor and clean all the metal partsin a carburetor cleaning solution. • Rinse the parts in water and dry them with compressedair. • Blow through the air and fuel passages with compressedair. • Remove the float valve, spray cleaning solution from the...

3-24 FUEL SYSTEM Air Cleaner Air Cleaner Element Removal • Remove: Seat (see 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, cleancloth into the air cleaner ducts to keep dirt ou...

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] ofthe joint duct [C] (front and rear), and tighten the clampscrews. • Install: Dust Seal [A]Air Cleaner Housi...

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)

3-28 FUEL SYSTEM Fuel Tank Fuel Tank Removal • Remove: Electrical Parts Case (see Frame chapter)Rear Fender (see Frame chapter)Storage Case [A] (Optional Part)Check Valve Hose [B] • Remove: Two Right Footboard Bolts [A] • Insert a thin driver [A] in the clamp [B] to clear its stopper,and slide the c...

FUEL SYSTEM 3-29 Fuel Tank Fuel Tank Installation • Check the insulators [A] on the tank case.If the insulators are damaged or deteriorated, replacethem. • Check the rubber dampers [A] on the frame as shown.If the dampers are damaged or deteriorated, replacethem. • Install the fuel tank with case, a...

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 andshake the tank to remove dirt a...

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 break ...

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 carethat there is no spark or flame anywhere near theworking area; this includes any app...

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 areais well-ventilated and free from any source ...

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 (see F...

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...

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

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 partsin the cooling system are corroded. If the coolant isbrown, iron or steel parts are rusting. In either case, flushthe cooling sy...

COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the radiator cap, and install a cooling systempressure tester [A] on the radiator filler neck. NOTE ○ Wet the cap sealing surfaces with water or coolant toprevent pressure leakage. • Build up pressure in the system carefully until the pres-sure re...

4-10 COOLING SYSTEM Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Change in Periodic Main-tenance chapter). • Remove: Coolant Reserve TankWater Hose [A]Water Pump Cover Bolts [B]Water Pump Cover [C] Water Pump Cover Installation • Install: Knock Pins [A]New Gasket [B] • Tighte...

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 thewater pump body for coolant leakage.If ...

4-12 COOLING SYSTEM Water Pump • Apply heat-resistance grease on the oil seal lip. • From outside the alternator cover, press and insert the oilseal [A] flush [B] in the direction as shown. Special Tool - Bearing Driver Set: 57001-1129 • From inside the alternator cover, press and insert the ballbea...

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 ignitionswitch is off. NEVER TOUCH THE RADIATOR FANUNTIL THE RADIATOR FAN CONNECTOR IS DIS-CONNECTED. TOUCHING THE FAN BEFORE THECONNECTOR IS DISCONNEC...

4-14 COOLING SYSTEM Radiator • Pull the projections [A] out of from the dampers [B], andremove radiator [C]. CAUTION Do not touch the radiator core. This could damagethe radiator fins, resulting in loss of cooling effi-ciency. Radiator Installation • Insert the projections of the radiator in the dam...

COOLING SYSTEM 4-15 Radiator Radiator Inspection • Check the radiator core.If there are obstructions to air flow, remove the radiatorand remove obstructions.If the corrugated fins [A] are deformed, carefullystraighten them.If the air passages of the radiator core are blocked morethan 20% by unremova...

4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in Periodic Main-tenance chapter). • Remove: Side Cover (see Frame chapter)Coolant Temperature Warning Light Switch Lead Con-nector [A]Water Pipe Bolt [B] • Remove: Thermostat Housing Cover Bolts [A]Thermostat ...

COOLING SYSTEM 4-17 Thermostat • To check valve opening temperature, suspend the ther-mostat [A] and an accurate thermometer [B] in a containerof water with the heat-sensitive portions [C] in almost thesame depth. NOTE ○ The thermostat must be completely submerged and thethermostat and thermometer m...

4-18 COOLING SYSTEM Radiator Fan Switch Radiator Fan Switch Removal CAUTION The fan switch should never be allowed to fall on ahard surface. Such a shock to the part can damageit. • Drain the coolant (see Coolant Change in Periodic Main-tenance chapter). • Remove: Radiator Cover (see Frame chapter) ...

COOLING SYSTEM 4-19 Coolant Temperature Warning Light Switch Coolant Temperature Warning Light Switch Removal CAUTION The coolant temperature warning light switchshould 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 Perio...

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 ..........

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...

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...

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 Cutter, 60...

ENGINE TOP END 5-13 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. Thepush rod does not return to its original positiononce it moves out to take up cam chain slack. Ob-serve all the rules listed below:When removing the tensioner, do n...

ENGINE TOP END 5-15 Rocker Case Rocker Case Removal Front Rocker Case • Remove: Front Fender (see Frame chapter)Recoil Starter (see Recoil Starter chapter)Timing Inspection Plug [A] Special Tool - Filler Cap Driver [B]: 57001-1454 • Remove: Valve Adjusting Caps • Using a wrench on the alternator bol...

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 thefront right side on the rocker case. • Lift the rocker case clear of the dowel pins in the cylinderhead and slide the rocker case out of the fram...

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 - Three Bond: TB1211F or GE SILICONES TRANSLUCENT RTV128 • Tighten the rocker case bolts following the tightening se-quence shown. Torque - Rocker Cas...

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 engin...

ENGINE TOP END 5-19 Rocker Case Rocker Shaft Diameter Measurement • Measure the diameter [A] of the rocker shaft where therocker arm pivots on it with a micrometer.If the rocker shaft diameter is smaller than the servicelimit, replace it. Also check the rocker arm inside diameter(see Rocker Arm Insp...

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 crankshaft c...

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 camshaftsprocket. • Align the marks [B] on the weights with the front cylinderhead upper surface. • Install: Rocker Cases (see Rocker Case Instal...

5-22 ENGINE TOP END Camshaft Camshaft Bearing Wear ○ The journal wear is measured using plastigage (pressgauge), which is inserted into the clearance to be mea-sured. The plastigage indicates the clearance by theamount it is compressed and widened when the parts areassembled. • Cut strips of plastig...

ENGINE TOP END 5-23 Camshaft KACR Inspection The Kawasaki Automatic Compression Release (KACR) momentarily opens the exhaust valves on the compressionstroke at very low speeds. This allows some of the com-pression pressure to escape, making it easy to turn overthe engine during starting. Due to the ...

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: WeightsCirclipsSpring [A] ○ Hook the spring from the outside with the open side of thehook inw...

ENGINE TOP END 5-25 Camshaft • Remove (right side view): Torque Converter (see 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: Intermediate Shaft Sprocket [B]Intermediate Shaft ...

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 l...

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] intothe tensioner body. • Insert a wire [D] into the rod hole to hold the rod in place. • Install: Intermediate Shaft Chain Tensioner [A] • Tighten: Torq...

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 • Visually inspect the rubber on the guides.If the rubbe...

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 Electrical System chapter). • Attach the compression gauge [A] and adapter [B] firmlyinto the spark plu...

5-30 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in Periodic Main-tenance chapter). • Remove: Carburetor (see Fuel System chapter)Exhaust Pipe (see Engine Top End chapter)Thermostat (see Cooling System chapter)Spark Plug Cap [A]Water Pipe Bolt [B]Left W...

ENGINE TOP END 5-31 Cylinder Head Cylinder Head Cleaning • Remove the cylinder head (see Cylinder Head Removal). • Scrape the carbon out of the combustion chamber andexhaust port with a suitable tool. • Wash the head with a high-flash point solvent. • Blow out any particles which may obstruct the oi...

5-32 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the PeriodicMaintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the PeriodicMaintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Rem...

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 ...

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 tool...

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 usedfor 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 not...

5-36 ENGINE TOP END Valves Widened Width [A] of engagement by machining with45° cutterGround Volume [B] by 32° cutter32° [C]Correct Width [D]Ground Volume [E] by 60° cutter60° [F] • Measure the outside diameter of the seating surface withvernier calipers.If the outside diameter of the seating surfac...

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 valveto the seat as described below. • Grind the seat at a 60° angle until the seat width is withinthe specified range. ○ To make the 60° grind, ...

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 piston...

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 ringgroove so the ends [B] butt together. • Install the oil ring steel rails, one above the expander andone below it. ○ Spread the rail with your thum...

ENGINE TOP END 5-41 Cylinder and Piston • Install: CylinderClamp [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 thepipe. Cylinder Wear • Since there is a difference in cylinder...

5-42 ENGINE TOP END Cylinder and Piston Piston Ring, Piston Ring Groove Wear • 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 grooves, make s...

ENGINE TOP END 5-43 Cylinder and Piston Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the pis-ton to locate the ring squarely in place. Set it close to thebottom of the cylinder, where cylinder wear is low. • Measure the gap [B] between the ends of the ring with athickne...

5-44 ENGINE TOP END Exhaust System This vehicle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be prop-erly maintained to ensure its efficiency. In accordance withthe Periodic Maintenance Chart, clean the spark arrester. Spark Arrester Cleaning • Refe...

ENGINE TOP END 5-45 Exhaust System • Remove: Front Exhaust Pipe Nuts [A] • Move the front exhaust pipe rear end [A] under the fueltank and remove the pipe forward. Muffler and Exhaust Pipe Installation • If the muffler cover [A] is removed, tighten them. Torque - Muffler Cover Bolts [B]: 8.8 N·m (0....

5-46 ENGINE TOP END Exhaust System Exhaust System Inspection • Before removing the exhaust system, check for signs ofleakage at the exhaust pipe gasket in the cylinder headand at the muffler clamp.If there are signs of leakage around the exhaust pipe gas-ket, it should be replaced. If the muffler-to...

CONVERTER SYSTEM 6-1 6 Converter System Table of Contents Exploded View ........................................................................................................................ 6-2 Specifications ...........................................................................................

CONVERTER SYSTEM 6-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 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 S: Fol...

CONVERTER SYSTEM 6-9 Torque Converter WARNING Excessive imbalance or operating rpm could causetorque converter pulley failure resulting in severeinjury or death. The pulleys of the belt drive torqueconverter are precision balanced components de-signed to operate within certain rpm limits. Disas-semb...

6-10 CONVERTER SYSTEM Torque Converter Torque Converter Cover Installation • Check the actuator lever assembly installation length (seeTorque Converter Cover Assembly). • Fit the trim seal into the converter cover. ○ Set the trim seal juncture in the area [A] when insert thetrim seal in the cover. [...

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 CirclipSpringActuator Lever Assemb...

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.)

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 printedinformation [A] (such as manufacturer’s name) is facingso that it may be reinstalled on the pulleys to rotate inthe same direc...

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: 57001-1520 • Tighten the three cover bolts: Torque - Dri...

CONVERTER SYSTEM 6-15 Drive Pulley • Remove: Spring [A]Spacer • Put the drive pulley wrench [A] on the spider [B] andtighten the bolt [C]. Special Tool - Drive Pulley Wrench: 57001-1474 • Turn the wrench clockwise and remove the spider with themovable sheave. NOTE ○ The spider has left-hand threads....

6-16 CONVERTER SYSTEM Drive Pulley If the cover bushing is damaged or worn, replace the drivepulley 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 Ins...

CONVERTER SYSTEM 6-17 Drive Pulley If the spring is worn or damaged, replace the spring. Spring Free Length [A] Standard: 60.4 mm (2.38 in.) Spider Shoe Side Clearance Adjustment • Remove: Drive Pulley (see Drive Pulley Removal)Drive Pulley Cover and Spring (see Drive Pulley Disas-sembly) • Temporar...

6-18 CONVERTER SYSTEM Drive Pulley If the clearance is not the specified range after the aboveshoes are replaced, use the spacer [A] (92026-0038) ofthe option part. [B] Shoe[C] Spider[D] Post[E] Clearance Drive Pulley Assembly • Install the ramp weight [A] as shown. • Tighten: Torque - Ramp Weight N...

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 ...

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 Pulle...

CONVERTER SYSTEM 6-21 Driven Pulley Driven Pulley Removal • Remove: Torque Converter Cover (see Torque Converter CoverRemoval)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...

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] forphase fit of the sheaves. • Wipe off the molybdenum disulfide grease. • Remove the four pins [A] with a thin standard tip screw-driver [B]. • Remov...

CONVERTER SYSTEM 6-23 Driven Pulley If the sheave bushings [A] are damaged or worn, replacethe 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 sh...

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 ofthe sheaves. ○ In that case the opening [A] and hole [B] will be matchedeasily. • Apply grease WR500-No.2 (KYODO YUSHI), POWERLITE WR #2 (KYODO YUSHI...

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 ...

6-26 CONVERTER SYSTEM Driven Pulley • Install two washers [A] on the shaft as shown. Crankcase Side [B]Bolt Head Side [C] • Using a flywheel & pulley holder [A] and attachments [B],tighten the driven pulley nut [C]. Special Tools - Flywheel & Pulley Holder: 57001-1343 Pulley Holder Attachmen...

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...

RECOIL STARTER 7-1 7 Recoil Starter Table of Contents Exploded View ........................................................................................................................ 7-2 Recoil Starter ...............................................................................................

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.

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) Re...

ENGINE LUBRICATION SYSTEM 8-1 8 Engine Lubrication System Table of Contents Exploded View ........................................................................................................................ 8-2 Specifications .........................................................................

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 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 Guid...

8-4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SF or SGAPI SH or SJ with JASO MA class 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 ...

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 Oil Filter Wrench:57001-1249 Kawasaki Bond (Silicone Sealant):56019-120

8-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Front Camshaft2. Oil Filter3. Crankshaft4. Oil Pressure Switch5. Oil Pipes6. Oil Pump7. Relief Valve 8. Transmission Idle Shaft9. Oil Screen 10. Transmission Driven Shaft 11. Rear Camshaft 12. Breather Hose13. To Air Cleaner

ENGINE LUBRICATION SYSTEM 8-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated,or contaminated engine oil will cause acceleratedwear and may result in engine or transmissionseizure, accident, and injury. Oil Level Inspection • Park the vehicle so that it is level, ...

8-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Cleaning • Clean the oil screen [A] thoroughly whenever it is removedfor any reason. • Clean the oil screen with a high-flash point solvent andremove any particles stuck to it. WARNING Clean the screen in a well-ventilated area, and ...

ENGINE LUBRICATION SYSTEM 8-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Split the crankcase (see Crankcase Disassembly in theCrankshaft/Transmission chapter). • Remove the oil pressure relief valve [A]. Oil Pressure Relief Valve Installation • See crankcase assembly (See Cranksha...

8-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Alternator Rotor and Starter Clutch Gear (see ElectricalSystem chapter)Oil Pump Drive Chain Tensioner Bolt [A]Chain Guide Bolt [B] and CollarChain Guide [C] • Remove: Oil Pump Bolts [A]Oil Pump Drive Chain [B] and Oil Pump Assembly [...

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) • Appl...

8-12 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe Removal Engine Left Side Oil Pipe • Remove: Alternator Cover (see 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 Torque Converter chapter)Plate Bolts [A]P...

ENGINE REMOVAL/INSTALLATION 9-1 9 Engine Removal/Installation Table of Contents Exploded View ........................................................................................................................ 9-2 Engine Removal/Installation ........................................................

ENGINE REMOVAL/INSTALLATION 9-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Bracket Mounting Bolts 72 7.3 53 2 Engine Mounting Bolts 62 6.3 46 3 Engine Mounting Nut 62 6.3 46

9-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Remove: Engine Oil (drain)Coolant (drain)Muffler and Exhaust Pipe (see Engine Top End chapter)Footboards (see Frame chapter)Carburetor (see Fuel System chapter)Alternator Lead Connector [A]Crankshaft Sensor Lead Connector [...

ENGINE REMOVAL/INSTALLATION 9-5 Engine Removal/Installation • 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 Brackets [A]Engine Mounting Bolts [B]Engine Mounting B...

CRANKSHAFT/TRANSMISSION 10-1 10 Crankshaft/Transmission Table of Contents Exploded View ........................................................................................................................ 10-2 Specifications ..........................................................................

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.)

CRANKSHAFT/TRANSMISSION 10-9 Crankcase Crankcase Disassembly • Remove: Engine (see Engine Removal/Installation chapter)Starter Motor (see Electrical System chapter)Oil FilterRecoil StarterCylinder Blocks and Pistons (see Engine Top End chap-ter)Intermediate Shaft and Chains (see Engine Top Endchapte...

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 thebearing surfaces are flush w...

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 thecrankcase. ○ 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]. • Insta...

CRANKSHAFT/TRANSMISSION 10-13 Crankshaft/Connection Rod Crankshaft Removal • Split the crankcase (see Crankcase Disassembly). • Remove the crankshaft [A] from the crankcase using apress. Crankshaft Installation • The left shaft [A] of the crankshaft is longer than the rightshaft [B]. • Apply engine ...

10-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connection Rod • Apply molybdenum disulfide oil: Threads [A] of Connecting Rod Big End Cap BoltsSeating Surface [B] of Connecting Rod Big End CapNuts [C] • Tighten: Torque - Connecting Rod Big End Cap Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Crankshaft/Connecting R...

CRANKSHAFT/TRANSMISSION 10-15 Crankshaft/Connection Rod Connecting Rod Big End Side Clearance • 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 Clearance Standard...

10-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connection Rod If the measured crankpin diameter [A] is not less thanthe service limit, but does not coincide with the originaldiameter marking on the crankshaft, make a new markon it. Crankpin Diameter Marks None: 39.984 ∼ 39.992 mm (1.5742 ∼ 1.57449 in.) : ...

CRANKSHAFT/TRANSMISSION 10-17 Crankshaft/Connection Rod Crankshaft Runout • Measure the crankshaft runout.If the measurement exceeds the service limit, replace thecrankshaft. Crankshaft Runout Standard: TIR 0.04 mm (0.0016 in.) or less Service Limit: TIR 0.10 mm (0.0039 in.) Crankshaft Main Bearing/...

10-18 CRANKSHAFT/TRANSMISSION Transmission Shift Lever Removal • Set the shift lever in the neutral position. • Remove: Right Side Cover (see Frame chapter)Shift Shaft Lever Bolt [A] • Remove the shift shaft lever [B] from the shift shaft. • Remove: Nut [A]Shift Lever Assembly [B]Front [C] • Remove:...

CRANKSHAFT/TRANSMISSION 10-19 Transmission Shift Lever Installation • Twist the tie-rod end [A] and tie-rod end locknut [B] tobottom of the screw and then turn back to dimension with77° ±10° [C] as shown. • Tighten the locknut against the tie-rod end: Torque - Tie-rod End Locknut: 20 N·m (2.0 kgf·m,...

10-20 CRANKSHAFT/TRANSMISSION Transmission • Install: Guide [A] • Tighten: Torque - Shift Lever Assembly Bracket Bolts [B]: 20 N·m (2.0 kgf·m, 14 ft·lb) • Set the lever assembly in the neutral position [C] whileturning the tie-rod [D]. NOTE ○ Do not turn the shift shaft [E] when setting the leverass...

CRANKSHAFT/TRANSMISSION 10-21 Transmission Transmission Removal • Split the crankcase (see Crankcase Disassembly). • Remove: Shift Shaft Cover Bolts [A]Shift Shaft Cover [B] • Remove: Shift Shaft Spring Bolt [A]Shift Shaft [B] • Remove: Reverse Idle Shaft [A]Spacer [B]Reverse Drive Gear [C], Needle ...

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 apress. Transm...

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) • Whe...

CRANKSHAFT/TRANSMISSION 10-25 Transmission Transmission and Shift Mechanism Inspection • Visually inspect: GearsDogs of Gear and Shifter If they are damaged or worn excessively, replace them.

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 itis necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/orthree needle bearings. NOTE ○ In the...

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 Tie-rod End Nuts 42 4.3 31 3 Wheel Nuts (First Torque) 15 1.5 11 S 3 Wheel Nuts (Final Torque) 76 78 56 S 4 Front Axle Nuts 197 20 145 5 Rear Axle Nuts 265 27 195 R: Replacement Parts S: Follow...

11-6 WHEELS/TIRES Wheel Alignment Toe-in is the amount that the front wheels are closer to- gether in front than at the rear at the axle height. Whenthere 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 getting out of ...

WHEELS/TIRES 11-7 Wheel Alignment • Repeat the straightedge procedure on the other side ofthe vehicle. Now the front wheels are parallel to eachother 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 the To...

11-8 WHEELS/TIRES Wheel Alignment NOTE ○ The toe-in will be near the specified value, if the tie-rodlength [A] is 393.3 mm (15.48 in.) on each tie-rod. CAUTION Adjust the tie-rod length so that the visible threadlength [B] is even on both ends of the tie-rod. Un-even thread length could cause tie-ro...

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 wheelsare off the ground. Special Tool - Jack: 57001-1238 • Remove: Wheel NutsWheel Wheel Installation • Check the tire rotation mark [A] on the tire, and install thewhee...

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 Ti...

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 ofthe wheel with a soap and water solution, or water [A].This helps the tire beads slip off the rim fla...

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...

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, andlet the caliper hang free. • Remove the axle nut [A] and pull off the front hub [B] andbra...

11-14 WHEELS/TIRES Front Hub Front Hub Disassembly/Assembly If any hub bolt [A] is damaged, replace it. • Remove the hub bolt from hub [B] using a press. • Press the hub bolt using a press.

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: Torqu...

11-16 WHEELS/TIRES Rear Hub Rear Hub Disassembly/Assembly If any hub bolt [A] is damaged, replace it. • Remove the hub bolt from hub [B] using a press. • Press the hub bolt using a press.

FINAL DRIVE 12-1 12 Final Drive Table of Contents Exploded View ................................... 12-3 Specifications .................................... 12-10 Special Tools ..................................... 12-11 Output Bevel Gears ........................... 12-14 Output Drive Bevel Gear Re...

12-14 FINAL DRIVE Output Bevel Gears Output Drive Bevel Gear Removal • Remove: Oil Pipe [A] (Engine Left and Outside, see Engine Lubri-cation System chapter)Output Drive Bevel Gear Cover Bolts [B]Output Drive Bevel Gear Cover [C] • Remove: Circlip [A] Special Tool - Outside Circlip Pliers: 57001-144...

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...

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 ofthe bearing holder [A] and tighten it so that the deep side[B] faces...

12-18 FINAL DRIVE Output Bevel Gears • Tap lightly the front end [A] of the output driven bevel gearshaft using a plastic mallet. ○ The output driven bevel gear shaft assembly comes offwith the housing. Output Driven Bevel Gear Installation • Apply grease: O-ring [A] • Install the output driven beve...

FINAL DRIVE 12-19 Output Bevel Gears • Hold the housing assembly [A] with the holder [B] in avise. 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 heatto sof...

12-20 FINAL DRIVE Output Bevel Gears • Apply a non-permanent locking agent to the threads ofthe 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 holder [A] in a vise, and set the output shaft [B]...

FINAL DRIVE 12-21 Output Bevel Gears Output Bevel Gear (Backlash-related Parts) 1. Ball Bearings2. Drive Bevel Gear Shims3. Output Drive Bevel Gear 4. Bearing Housings5. Output Driven Bevel Gear 6. Output Driven Shaft7. Driven Bevel Gear Shims Drive Bevel Gear Shims for Tooth Contact Adjustment Thic...

12-22 FINAL DRIVE Output Bevel Gears Bevel Gear Backlash Adjustment ○ The amount of backlash is influenced by driven bevel gearposition more than by drive bevel gear position. • Remove the output drive idle gear (see Output DriveBevel Gear Removal). • Set up a dial gauge [A] against the output 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.

FINAL DRIVE 12-25 Front Propeller Shaft Front Propeller Shaft Removal • Slip the O-ring clamps off the grooves on the small rubberboots [A], and then pull the boot. • Push the front propeller shaft [A] rearward, and removethe front end [B] from the front final gear case. • Remove the front propeller...

12-26 FINAL DRIVE Front Axle Front Axle Removal • Drain the front final gear case oil (see Front Final GearCase Oil Change in Periodic Maintenance chapter). • Remove: Front Wheel (see Wheels/Tires chapter)Knuckle (see Steering chapter) • Pull the front axle [A] in a straight line out of the front fi...

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 whenthe housing comes out. If the splined portion ofshaft cracked or damaged during disassembling ofoutboard joint, do...

12-28 FINAL DRIVE Front Axle ○ Tighten the boot band [A] and bend the tangs [B] securelyto hold down the end of the band. • Place the special grease tube nozzle in the bore of thehousing and squeeze the tube [A] until the grease comesout from the joint bearing. • Tap the shaft end [A] straight with ...

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 airpressures. • Tighten the large band [A] and bend the tangs securely tohold down the end of the band. Maximum Outside Diameter of Band: 80.2 mm (3.16 in.) (After tightenin...

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 Jo...

12-32 FINAL DRIVE Front Axle • Install the new retaining ring [A] so that the opening [B] isaligned with one of the projections [C]. • Tighten the small band. • Squeeze the remaining special grease [A] into the inboardjoint boot [B]. • Compress the axle assembly to the specified length whilerelievin...

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 andfront-to-rear. • Remove the filler cap. CAUTION Be careful not to allow any dirt or foreign materialsto enter the gear case. • Check the oil level. The oil ...

FINAL DRIVE 12-35 Front Final Gear Case Variable Differential Control Cable Installation • Lubrication the variable differential control cable beforeinstallation. • Route the cable correctly according to the Appendix chap-ter. WARNING Operation with an improperly adjusted, incorrectlyrouted, or dama...

12-36 FINAL DRIVE Front Final Gear Case • Remove: Front Fender (see Frame chapter)Front Wheels (see Wheels/Tires chapter)Steering Stem (see Steering chapter)Front Axles (see Front Axle Removal)Right Upper Suspension Arm (see Suspension chapter)Right Front Shock Absorber (see Suspension chapter)Front...

FINAL DRIVE 12-37 Front Final Gear Case Front Final Gear Case Disassembly • Remove: Front Final Gear Case (see Front Final Gear Case Re-moval)Variable Differential Control Shift Shaft Lever Bolt [A]and Nut [B]Variable Differential Control Shift Shaft Lever [C]2WD/4WD Actuator (see Electrical System ...

12-38 FINAL DRIVE Front Final Gear Case • Remove: Housing [A] and Differential Disc Assembly [B]Inner DiscNeedle 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 Gear Case Center Cover Bolts (M8) [E]Front Fi...

FINAL DRIVE 12-39 Front Final Gear Case • Remove: Pinion Gear Unit [A]Shim(s) Front Final Gear Case Coupling Inspection If the coupling bushing [A] is damaged or worn, replacethe front final gear case coupling. Front Final Gear Case Coupling Bushing Inside Diameter[B] Standard: 13.000 ∼ 13.018 mm (0...

12-40 FINAL DRIVE Front Final Gear Case • Install: Ring Gear Assembly • Apply grease to the O-ring [A] on the front final gear casecenter cover. • Install: Front Final Gear Case Center Cover [A] • Tighten the cover bolts following the tightening sequenceas shown. Torque - Front Final Gear Case Cente...

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 accordancewith the thicknes...

12-42 FINAL DRIVE Front Final Gear Case • Apply engine oil to the needle bearing [A]. • Install: Needle BearingOuter Disc [B] • Apply engine oil to the variable front differential controlshaft [A]. • Install the shaft and spring [B] in the front final gear caseleft cover [C] as shown. • Turn the sha...

FINAL DRIVE 12-43 Front Final Gear Case • Apply molybdenum disulfide grease to the spline [A] in theshifter [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 ...

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 Gear (16...

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 casewhen roundin...

12-46 FINAL DRIVE Front Final Gear Case Pinion Gear Unit Assembly ○ The pinion gear and ring gear are lapped as a set in thefactory to get the best tooth contact. They must be re-placed as a set. • Visually inspect the bearing for abrasion, color change, orother damage.If there is any doubt as to th...

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...

FINAL DRIVE 12-49 Front Final Gear Case • Mount a dial gauge [A] so that the tip of the gauge isagainst the splined portion [B] of the pinion gear shaft. • To measure the backlash, move the pinion gear shaftback and forth [C] while holding the front axle steady.The difference between the highest and...

12-50 FINAL DRIVE Front Final Gear Case ○ The tooth contact patterns of both (drive and coast) sidesshould be centrally located between the top and bottomof the tooth. The drive pattern can be a little closer to thetoe and the coast pattern can be a somewhat longer andcloser to the toe.If the tooth ...

12-52 FINAL DRIVE Rear Propeller Shaft Rear Propeller Shaft Removal • Remove: Footboard (see Frame chapter) • Slide the rubber boots [A]. • Push the front universal joint [B] rearward, and removethe front end [C] from the engine. • Remove the rear propeller shaft [A] from the vehicle. Rear Propeller...

FINAL DRIVE 12-53 Rear Propeller Shaft • Apply molybdenum disulfide grease: Spline [A] on Output Shaft of EngineSpline [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 yoke [G...

12-54 FINAL DRIVE Rear Axle Rear Axle Removal • Drain the rear final gear case oil (see Rear Final GearCase Oil Change). • Remove: Rear Wheels (see Wheels/Tires chapter)Rear Knuckle (see Suspension chapter)Upper Suspension Arm [A] (see Suspension chapter) • Pull the rear axle [A] in a straight line ...

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 to...

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 andfront-to-rear. • Remove the filler cap. CAUTION Be careful not to allow any dirt or foreign materialsto enter the gear case. • Check the oil level. The oil le...

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 CaseBracket [A]Collars [B]Bracket Bolts [C][D] Front[E] HoleWashers (rear side) • Apply a non-permanent locking agent (Three Bond1363A, Red) to the rear...

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 thebearing holder using the socket wrench [B]. Special Tool - Socket Wrench, Hex 50: 57001-1478 ○ If the holder seems too difficult to break free, apply heatto so...

FINAL DRIVE 12-65 Rear Final Gear Case Rear Final Gear Case Right Cover Assembly [A] Rear Final Gear Case Right Cover • Press: Ball Bearing (until bottomed) Special Tool - Bearing Driver, 54.3 [B]: 57001-1488 [A] Rear Final Gear Case Right Cover[B] Ball Bearing • Press: Oil Seal [C] (until bottomed)...

12-68 FINAL DRIVE Rear Final Gear Case • Install: Shim [A]Rear Final Gear Case Right Cover [B] • Apply a non-permanent locking agent to the rear final gearcase right cover bolts. • Tighten: Torque - Rear Final Gear Case Right Cover Bolts (M12) [A]: 93 N·m (9.5 kgf·m, 69 ft·lb) Rear Final Gear Case R...

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 ...

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 exceptthe right rear axle bearing. • Turn each bearing in the case or hub...

BRAKES 13-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Variable Differential Control Lever Bolt – – – L 2 Gasket Screws – – – L 3. Bend both hooks after installing the spring. G: Apply grease. L: Apply a non-permanent locking agent. MF: Apply MOBIL FLUID 424 or equivalent oil. R: Re...

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 b...

BRAKES 13-9 Brake Fluid Brake Line Air Bleeding • Bleed the air whenever brake parts are replaced or re-assembled. • Remove the reservoir cap and fill the reservoir with newbrake fluid. • Slowly pump the brake lever several times until no airbubbles can be seen rising up through the fluid from theho...

13-10 BRAKES Master Cylinder Master Cylinder Removal • Remove: Brake Hose Banjo Bolt [A]Master Cylinder Clamp Bolts [B]Master Cylinder [C] CAUTION Brake fluid quickly ruins painted surface; anyspilled fluid should be completely washed awayimmediately. Master Cylinder Installation • Align the punch m...

BRAKES 13-11 Master Cylinder Master Cylinder Disassembly • Remove: Master Cylinder (see Master Cylinder Removal)Brake Lever Pivot Nut [A]Brake Lever Pivot Bolt [B]Brake Lever [C]Dust Cover [D]Circlip [E]Piston [F]Spring [G] Special Tool - Inside Circlip Pliers: 57001-143 CAUTION Do not remove the se...

13-12 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the master cylinder (see Master CylinderDisassembly). • Check that there are no scratches, rust or pitting on theinner wall of the master cylinder [A] and on the outside ofthe piston [B].If the master cylinder ...

BRAKES 13-13 Calipers Caliper Removal • Remove the front wheel (see 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 thecaliper [C] from the disc. • Unscrew the banjo bolt and remove the brake ...

13-14 BRAKES Calipers Caliper Disassembly • Remove: Caliper (see Caliper Removal)Pads (see 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 applying compressed air [B]to where the...

BRAKES 13-15 Calipers • Apply brake fluid to the outside of the pistons [A], andpush 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 hol...

13-16 BRAKES Calipers Piston and Cylinder Damage • Visually inspect the piston [A] and cylinder surfaces [B].Replace the caliper if the cylinder and piston are badlyscored or rusty. Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [A]. If the bod...

BRAKES 13-17 Brake Pads Brake Pad Removal • Detach the caliper from the disc (see Caliper Removal). • Remove: Pad Mounting Bolts [A] • Remove: Brake Pads [A] Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Be sure that the anti-rattle spring is in place. • Install...

13-18 BRAKES Brake Discs 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 astrichloroethylene or acetone. WARNING These cleaning fluids are usually highly flammableand harmful if breathed for prolonged periods. Besure to...

BRAKES 13-19 Brake Hoses Brake Hose Inspection • Refer to the Front Brake Hose and Connections Inspec-tion in the Periodic Maintenance chapter. Brake Hose Replacement • Refer to the Front Brake Hose Replacement in the Peri-odic Maintenance chapter.

13-20 BRAKES Rear Brake Lever, Pedal and Cables Brake Pedal Position Inspection NOTE ○ The position of the brake pedal has been decided bythe position of the adjusting bolt [A]. • Check that the adjusting bolt is in the correct position asshown. Adjusting Bolt Position [B] Standard: 5 ∼ 6 mm (0.20 ∼...

BRAKES 13-21 Rear Brake Lever, Pedal and Cables 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] with new ...

13-22 BRAKES Rear Brake Lever, Pedal and Cables • Remove: Circlip [A]Cotter Pin, Washer and Pin [B]Brake Pedal Cable [C] 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, andHose Routing secti...

BRAKES 13-23 Internal Wet Brake Internal Wet Brake Disassembly • Refer to Rear Final Gear Case section in Final Drive chap-ter. Internal Wet Brake Assembly • Refer to Rear Final Gear Case section in Final Drive chap-ter.

SUSPENSION 14-1 14 Suspension Table of Contents Exploded View ........................................................................................................................ 14-2 Specifications ....................................................................................................

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 Front Knuckle Joint Nuts 29 3.0 22 G: Apply grease. R: Replacement Parts

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 4.8 35 4 Rear Suspension Arm Pivot Nuts 48 4.8 35 5 Rear Knuckle Mounting Nuts 48 4.8 35 G: Apply grease. R: Replacem...

14-6 SUSPENSION Specifications Item Standard Service Limit Shock Absorbers (Usable Range) Spring Preload Setting Position (Front and Rear) No.2 1 ∼ 5

14-8 SUSPENSION Shock Absorbers Front Shock Absorber Preload Adjustment The spring adjusting sleeve [A] on front shock absorber has 5 positions so that the spring can be adjusted for differ-ent terrain and loading conditions. If the spring action feelstoo soft or too stiff, adjust it in accordance w...

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 otherwisedamaged, replace them. Front Shock Absorber Scrapping WARNING Since the front shock absorber contains nitrogengas, do not incine...

14-10 SUSPENSION Shock Absorbers Rear Shock Absorber Installation • Apply grease to the inside of bushing [A] and grease seallips [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 Insp...

SUSPENSION 14-11 Shock Absorbers • Remove: Spring Seat Stopper [A] • Remove: Spring CompressorSpring Guide [A]Spring [B]Spring Adjusting Sleeve [C] • Install: Spring Adjusting Sleeve [A] • Install the replaced spring [B] so that the small end facesdownwards. • Install: Spring Guide • Use the spring ...

14-12 SUSPENSION Suspension Arms Front Suspension Arm Removal • Remove: Front Wheels (see Wheels/Tires chapter)Wheel Hub [A]Bolt [B] and Brake Hose [C] (from Suspension Arm)Brake Caliper (from Brake Disk)Knuckle Joint [D] (see Steering chapter)Front Shock Absorber Mounting Bolt [E] (lower) • Remove:...

SUSPENSION 14-13 Suspension Arms Front Suspension Arm Installation • Clean the taper surface [A] of the suspension arm [B] andshank of the knuckle joint. • Install: Front Upper Suspension ArmFront Lower Suspension ArmSuspension Arm Pivot Bolts and Nut (temporary)Knuckle Joint (see Steering chapter)F...

14-14 SUSPENSION Suspension Arms Front Suspension Arm Assembly • Apply grease: Ball Joint BearingNeedle Bearing • 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. • I...

SUSPENSION 14-15 Suspension Arms Rear Suspension Arm Removal • Remove: Rear Wheels (see 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 removethe nut [C]. • Remove: Mounting Bolts and Nut...

14-16 SUSPENSION Suspension Arms Rear Suspension Arm Disassembly Rear Upper Suspension Arm • Remove out the bushings [A] Front 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: 57001-144 •...

SUSPENSION 14-17 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: 57001-143...

14-18 SUSPENSION 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 th...

STEERING 15-1 15 Steering Table of Contents Exploded View ........................................................................................................................ 15-2 Specifications ........................................................................................................

15-6 STEERING Steering Steering Stem Removal • Remove: Front Fender (see 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 thetie-rod adjusting sleeve, or the...

STEERING 15-7 Steering • Apply a non-permanent locking agent: Steering Stem Bearing Joint Bolts [A] • Tighten: Torque - Steering Stem Bearing Joint Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb) • Apply Amoco Rykon Premium Grease No.2 EP (Green): Inside of Steering Clamp [A]Oil Seals [B] • Install: Collars [A]...

15-8 STEERING Steering • Hold the flat surfaces [A] of the tie-rod end with a thinwrench [B], and remove the tie-rod end nut [C] and wash-ers. • Tap the tie-rod end shaft lightly and remove the tie-rodend from the knuckle. • Remove: Cotter Pins and Front Knuckle Joint Nuts [A] • Install a suitable n...

STEERING 15-9 Steering • Check the joint boot [A] is not torn, worn, deteriorated, oris leaking grease.If it is found, replace the knuckle joint. • Clean the shanks [B] of the knuckle joint. • Clean the taper surface [A] in the front suspension arm[B]. • Install: Washers [A] and Knuckle Joint Nuts [...

15-10 STEERING Steering Front Knuckle Bearing Installation • The marked side of the bearing faces outward. • Press in the bearing until it is bottomed. [A] V Block Special Tool - Bearing Driver Set [B]: 57001-1129 • Replace the circlip with a new one. Special Tool - Inside Circlip Pliers: 57001-143 ...

15-12 STEERING Steering Maintenance Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte-nance chapter. Steering Stem Straightness • Remove the steering stem (see Steering Stem Removal). • Check the steering stem for straightness. ○ Use a straightedge along the stem.If the s...

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 forroughness or binding.If roughness or binding is found, rep...

15-14 STEERING Handlebar Handlebar Removal • Remove: Meter Unit (see Electrical System chapter)Throttle CaseFront Brake Master CylinderLeft-hand Switch HousingRear Brake Lever AssemblyHandlebar Holder Bolts [A] and Bracket [B]Handlebar Holders [C]Handlebar [D] Handlebar Installation • Align the punc...

FRAME 16-1 16 Frame Table of Contents Exploded View ........................................................................................................................ 16-2 Seat ........................................................................................................................

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 Bolts, L = 70 mm (2.8 in.) 25 2.5 18 4 Front Carrier Bracket Bolts 32 3.3 24 5 Rear Carrier Bolts, L = 14 mm (0.6 in.) 54 5.5 40 6 Rear Carr...

FRAME 16-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Footboard Bracket Bolts 42 4.3 31 2 Hitch Bracket Bolts 82 8.3 60 3. Trailer Hitch Bracket OP: Optional Parts

16-8 FRAME Seat Seat Removal • Remove the seat [A] by lift the latch lever [B] and thenpulling the seat up to the rear. Seat Installation • Insert the front seat hooks [A] into the receivers [B] in thebracket. • Insert the rear seat hooks [A] into the dampers [B]. • Push the rear part of the seat do...

FRAME 16-9 Carriers Front Carrier Removal • Remove: Front Carrier Bolts [A]CollarsFront 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 in.):...

16-10 FRAME Carriers Rear Carrier Bracket Installation • Install: Rear Carrier Bracket [A] • Tighten: Torque - Rear Carrier Bracket Bolts [B]:37 N·m (3.8 kgf·m, 27 ft·lb)

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 CoverQuick Rivets [A] (both sides)Bolts [B] • Remove: Screws [A] and Collars • Remove: Screws [A] and CollarsFront Fender...

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 CollarsBolts [B] and CollarsFuel Tank Cap [C]Rear Fender [D] • Install the fuel tank cap after removing the rear fender. Rear F...

FRAME 16-13 Covers Middle Cover Removal • Remove: Middle Cover Screws [A] and Collars • Remove: Middle Cover Screw [A] and Collar • Disconnect: Reverse Power Assist Switch Lead Connectors [A] • Remove the middle cover [A] as shown. Middle Cover Installation • Connect: Reverse Power Assist Switch Lea...

16-14 FRAME Covers Left Side Cover Removal • Remove: Seat (see Seat Removal)Middle Cover ScrewsStorage Case Screws [A]Storage Case [B] • Remove: Screws [A] and Collars • Remove: Screws [A] and CollarsLeft Side Cover [B] Left Side Cover Installation • Install: Left Side Cover [A]Insulator [B]Screws [...

FRAME 16-15 Covers • Remove: Shift Knob [A]Screws [B] and Collars • Remove: Screws [A] and CollarsLeft 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 the rec...

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 Appendixchapter. Radiator Cover Removal • Remove: Front Fender (s...

FRAME 16-17 Guards Front Guard Removal • Remove: Screws [A] and CollarsBolts [B] and CollarsFront Guard Cover [C]Bolts [D] and Collars • Remove: Front Carrier Bracket Bolts [A]Radiator Cover Screws [B] and CollarsFront Guard Bolts [C] (both sides) • Remove the front guard [D] from the radiator botto...

16-18 FRAME Guards Front Bottom Guard Installation • Install the front bottom guard [A] between the frame andengine 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 • Confirm...

FRAME 16-19 Flaps and Footboards Left Footboard Removal • Remove: Screws [A] and CollarsBolts [B] and Collars • Remove: Screws [A] and CollarsBolts [B] and CollarsLeft Footboard [C] Left Footboard Installation • Install: Left Footboard [A]Bolts [B] and Collars [C]Screws [D] and Collars [E] Right Foo...

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]: 42 N·m (4.3 kgf·m, 31 ft·lb)

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)

ELECTRICAL SYSTEM 17-1 17 Electrical System Table of Contents Parts Location.................................... 17-3 Exploded View ................................... 17-6 Specifications .................................... 17-12 Wiring Diagram .................................. 17-14 Special Tools...

17-2 ELECTRICAL SYSTEM Actuator Control System Troubleshooting ........................ 17-74 Drive Belt Failure Detection System .. 17-83 Drive Belt Failure Detection System Inspection ..................... 17-83 Carburetor Heater System................. 17-84 Air Temperature Sensor Inspection .......

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]Igniter [B]A...

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]Engine Brak...

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]Coolant Temperature Warning Symbol [I]Fuel ...

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 Terminal Nut 4.9 0.50 43 in·lb 3 Starter Motor Terminal Locknut 6.9 0.70 61 in·lb 4 Starter Motor Bolts 4.9 0.50 43 in·lb 5 Starter Motor Clutch Bolts 34 ...

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...

ELECTRICAL SYSTEM 17-17 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 willburn out the diodes in the electrical parts. ○ Always check battery ...

17-18 ELECTRICAL SYSTEM Precautions ○ Electrical Connectors: Female Connectors [A] Male Connectors [B]

ELECTRICAL SYSTEM 17-19 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, clean ...

17-20 ELECTRICAL SYSTEM Battery Battery Removal • Turn off the ignition switch. • Remove: Seat (see Frame chapter)Battery Holder Bolts [A] and CollarsBattery Holder [B] • Disconnect the battery negative (–) cable [C] first, andthen the positive (+) cable [D]. • Take out the battery [E]. Battery Inst...

ELECTRICAL SYSTEM 17-21 Battery CAUTION Do not remove the aluminum sealing sheet [A] fromthe filler ports [B] until just prior to use. Be sure touse the dedicated electrolyte container for correctelectrolyte volume. • Place the battery on a level surface. • Check to see that the sealing sheet has no...

17-22 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 optimumperformance. NOTE ○ Charging the battery immediately after filling canshorten service life. Let the b...

ELECTRICAL SYSTEM 17-23 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 ...

17-24 ELECTRICAL SYSTEM Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage. • Remove the battery (see Battery Removal). CAUTION Be sure to disconnect the negative ( − ) lead first. • Measure the battery terminal voltage. NOTE ○ Measu...

ELECTRICAL SYSTEM 17-25 Battery NOTE ○ Increase the charging voltage to a maximum voltage of25 V if the battery will not accept current initially. Chargefor no more than 5 minutes at the increased voltage thencheck if the battery is drawing current. If the battery willaccept current [D], decrease th...

17-26 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Drain: Coolant (see Cooling System chapter)Oil (see Periodic Maintenance chapter) • Remove: Recoil Starter (see Recoil Starter chapter)Water Pump Impeller (see Cooling System chapter)Torque Converter Cover (see Converter System chap-...

ELECTRICAL SYSTEM 17-27 Charging System Alternator Cover Installation • Be sure all of the old gasket has been removed from thealternator cover and the left crankcase sealing surfaces. • Check that the dowel pins [A] are in place, and fit a newgasket on the crankcase. • Check that the bearing [B] is...

17-28 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal)Ball Bearing [A] • Thread 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...

ELECTRICAL SYSTEM 17-29 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 (1.3...

17-30 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures: short, open, or loss in rotor magnetism. A short or open in one of the coilwires will result in either a low output, or no output at all. Aloss in rotor magnetism, which may be caused by dropp...

ELECTRICAL SYSTEM 17-31 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-...

17-32 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 reg...

ELECTRICAL SYSTEM 17-33 Charging System Charging System Circuit 1. Ignition Switch2. Fuse Box3. Main Fuse 30 A4. Load5. Alternator6. Regulator/rectifire7. Starter Relay8. Battery 12 V12 Ah9. Engine Ground Terminal

17-34 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt-age.Do not touch the spark plug, ignition coil, or sparkplug lead while the engine is running, or you couldreceive a severe electrical shock. CAUTION Do not disconnect the battery leads or any otherelect...

ELECTRICAL SYSTEM 17-35 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 PeriodicMaintenance chapter. Ignition Coil Removal Front Side • Remove:...

17-36 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection • Remove the ignition coil. • Measure the arcing distance with a coil tester [A] to checkthe 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) to ...

ELECTRICAL SYSTEM 17-37 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 volta...

17-38 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 alternatorcover. Grommets [A] for A...

ELECTRICAL SYSTEM 17-39 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 sparkplugs. • Disconnect: Crankshaft Sensor Lead Connector [A] • Set the hand tester [B] to the 10 V DC range. • Connect ...

17-40 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 alternatorrotor 5 000 and above Advanced mark [D] on alternatorrotor NOTE ○ Do not mix up the timing marks with mark [A]. If the ignition timin...

ELECTRICAL SYSTEM 17-41 Ignition System Vehicle-down Sensor Removal CAUTION Never drop the vehicle-down sensor, especially ona hard surface. Shock to the sensor can damage it. • Remove: Rear Fender (see Frame chapter)Vehicle-down Sensor Lead Connector [A]Screws [B]Vehicle-down Sensor [C] Vehicle-dow...

17-42 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 powersource voltage. Veh...

ELECTRICAL SYSTEM 17-43 Ignition System Ignition System Troubleshooting

17-44 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch2. Reverse Switch3. Speed Sensor4. Fuse Box (Main Fuse 30 A)5. Multifunction Meter6. Belt Failure Detection Switch7. Engine Stop Switch8. Reverse Power Assist Switch (Override) 9. Reset Connector 10. Crankshaft Sensor ...

ELECTRICAL SYSTEM 17-45 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 themoto...

17-46 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 Terminal Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) • Apply grease to the O-ring [D] in the ...

ELECTRICAL SYSTEM 17-47 Electric Starter System Starter Motor Assembly • Replace the O-rings. • Install the brush plate assembly to the right end coverso that the projection [A] on the brush plate fits into thegroove on the right end cover. • Install the O-ring, insulators [B], and washer [C] in tha...

17-48 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 fineemery cloth [B], a...

ELECTRICAL SYSTEM 17-49 Electric Starter System Starter Motor Brush Length • 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 brushplate assembly. Brush Assembly ...

17-50 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection • Remove: Seat (see 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 switchcircuits are identical. ...

ELECTRICAL SYSTEM 17-51 Electric Starter System Electric Starter Circuit 1. Starter Button2. Engine Stop Switch3. Parking Brake Light Switch4. Front Brake Light Switch5. Rear Brake Light Switch6. Main Fuse 30 A7. Starter Circuit Relay (Brake)8. Reset Connector9. Ignition Switch 10. Starter Motor 11....

17-52 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 thestarter motor clutch bolts [A]. Special Tool - Flywheel Holder: 57001-1313 • Take out the one-way clut...

ELECTRICAL SYSTEM 17-53 Electric Starter System Torque Limiter Inspection • Remove:Alternator Rotor (see Electrical System chapter) • Remove the torque limiter [A] and visually inspect it.If the limiter has wear, discoloration, or other damage,replace it as a unit.

17-54 ELECTRICAL SYSTEM Lighting System Headlight Beam Vertical Adjustment • Turn the adjusting screw [A] on each headlight rim in orout 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 therider seate...

ELECTRICAL SYSTEM 17-55 Lighting System • Turn the bulb socket [A] counterclockwise [B], and removethe 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. • Turn ...

17-56 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 itout. • Be sure the socket is clean. • Insert the new bulb by aligning the pins [A] with thegrooves in the wal...

ELECTRICAL SYSTEM 17-57 Lighting System Lighting System Circuit 1. Multifunction Meter2. Reverse Switch3. Reverse Light (EUR and GB models)4. Main Fuse 30 A5. Front Brake Light Switch6. Parking Brake Light Switch7. Rear Brake Light Switch8. Position Light (Right)9. Headlight (Right) 10. Headlight (L...

17-58 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 switchleads.If the fan rotates, inspect the fan switch....

ELECTRICAL SYSTEM 17-59 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 Breaker2. Radiator Fan Switch3. Main Fuse 30 A4. Radiat...

17-60 ELECTRICAL SYSTEM Fuel Level Sensor Fuel Level Sensor Removal • Remove: Seat (see Frame chapter)Electrical Parts Case (see frame chapter)Fuel Level Sensor Lead Connector [A]Fuel Level Sensor Mounting Bolts [B]Fuel Level Sensor [C] Fuel Level Sensor Installation • Install: New GasketFuel Level ...

ELECTRICAL SYSTEM 17-61 Fuel Level Sensor Fuel Level Sensor Circuit 1. Multifunction Meter2. Fuel Level Sensor3. Ignition Switch4. Main Fuse 30 A5. Starter Relay6. Battery7. Engine Ground Terminal

17-62 ELECTRICAL SYSTEM Meter Multifunction Meter Unit Removal • Remove: Handle Cover Screws [A] • Remove: Handle Cover Screws [A]Handle Cover Front [B] • Remove: Meter Lead Connectors [A]Handle Cover Screws [B] • Remove: Handle Cover Screw [A]Handle Cover Rear [B] • Remove: Bracket Mounting Screws ...

ELECTRICAL SYSTEM 17-63 Meter • Remove: Multifunction Meter Mounting Nuts [A] and WashersBracket [B]Multifunction Meter Unit [C] CAUTION Do not drop the meter unit. Multifunction Meter Unit Inspection • Remove: Multifunction Meter Unit (see Multifunction Meter UnitRemoval) CAUTION Do not drop the me...

17-64 ELECTRICAL SYSTEM Meter Check 2: MODE and TIME SET Buttons OperationCheck • Connect the wires in the same manner as Check 1. • Check that when the MODE button [A] is pushed andheld continuously, the display [B] cycles through the fourmodes. ODO → TRIP A → TRIP B → Hour → ODO If this display fu...

ELECTRICAL SYSTEM 17-65 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 resultof this inspection.If the value indicated by the odometer does not work, re-...

17-66 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 meterunit. Check 8: Coolant Temperature Warning Symbol Check • Connect the wires in the same manner as Check 1. • Co...

ELECTRICAL SYSTEM 17-67 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 ...

17-68 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 Lig...

ELECTRICAL SYSTEM 17-69 Meter • Turn off the ignition switch. • Remove the seat (see Frame chapter). • Disconnect both sets of 4 pin connectors [A] in the elec-trical parts case. • Reconnect these 4 pin connectors to their opposite grayto black and black to gray as shown. • Turn on the ignition swit...

ELECTRICAL SYSTEM 17-71 Meter Meter Circuit 1. Multifunction Meter2. Neutral Switch3. Reverse Switch4. Coolant Temperature Switch5. Actuator Controller6. 2WD/4WD Switch7. Speed Sensor8. Main Fuse 30 A9. Fuel Level Sensor 10. Igniter 11. Belt Failure Detection Switch 12. Oil Pressure Switch13. Frame ...

17-72 ELECTRICAL SYSTEM Actuator Control System 2WD/4WD Actuator Removal • Drain the front final gear case oil (see Front Final GearCase Oil Change in Periodic Maintenance chapter). • Remove: Actuator Lead Connector [A]Clamp [B] • Remove: Actuator Mounting Bolts [A]Actuator [B] 2WD/4WD Actuator Inst...

ELECTRICAL SYSTEM 17-73 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 levera...

17-74 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)

17-76 ELECTRICAL SYSTEM Actuator Control System Check 1. 2WD/4WD Actuator Inspection • Remove: Actuator Lead Connector [A]Clamp [B] • Measure the resistance between the following terminalsin the actuator lead connector [A]. Special Tool - Hand Tester: 57001-1394 Actuator Internal Resistance 4 (Red) ...

ELECTRICAL SYSTEM 17-77 Actuator Control System Check 3. Controller Power Supply Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Seat (see Frame chapter) • Connect: Controller Connector [A]Hand Tester [B] (range: DC 25 V)Tester (+) → Connector (BR) Terminal [9] Tester (–) → Connect...

17-78 ELECTRICAL SYSTEM Actuator Control System Check 5. 2WD/4WD Shift Switch Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Seat (see Frame chapter) • Connect: Controller Connector [A]Hand Tester [B] (range: DC 10 V)Tester (+) → Connector (G) Terminal [7] Tester (–) → Connector (...

ELECTRICAL SYSTEM 17-79 Actuator Control System • Disconnect the speed sensor lead connector. • Connect: Controller Connector [A]Hand Tester [B] (range: DC 10 V)Tester (+) → Connector (P) Terminal [5] Tester (–) → Connector (BK/Y) Terminal [10] ○ Install the needle adapters on the tester leads. Spec...

17-80 ELECTRICAL SYSTEM Actuator Control System • Support the vehicle on a stand or a jack so that the wheelsare off the ground. • Connect: Controller Connector [A]Hand Tester [B] (range: DC 25 V)Tester (+) → Connector (W/R) Terminal [15] Tester (–) → Connector (BK/Y) Terminal [10] ○ Install the nee...

ELECTRICAL SYSTEM 17-81 Actuator Control System Check 7. Forward/Reverse Detecting Sensor Inspection • Disconnect forward/reverse detecting sensor lead con-nector [A]. • Measure the forward/reverse detecting sensor resis-tance. ○ Connect the hand tester between the BK lead and the Wlead. ○ Set the t...

17-82 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Circuit 1. Speed Sensor2. Forward/Reverse Detecting Sensor3. 2WD/4WD Actuator4. Engine Brake Actuator5. Actuator Controller6. Ignition Switch7. Controller Fuse 10 A8. Main Fuse 30 A 9. Multifunction Meter 10. 2WD/4WD Shift Switc...

ELECTRICAL SYSTEM 17-83 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 (seeConverter System chapter). Drive Belt Failure Detection System In...

17-84 ELECTRICAL SYSTEM Carburetor Heater System Air Temperature Sensor Inspection • Remove: Air Cleaner Housing (see Fuel System chapter)Air Temperature Sensor [A] • Connect the battery [A] and hand tester [B] to the sensorlead connector [C]. Special Tool - Hand Tester: 57001-1394 Battery (+) → Red...

ELECTRICAL SYSTEM 17-85 Carburetor Heater System Carburetor Heater Inspection • Disconnect:Carburetor Heater Lead Connectors [A]Ground Lead Connector [B] • Using the hand tester, measure the resistance of theheater. • Connect the tester between the heater terminal and theground terminal.If the teste...

17-86 ELECTRICAL SYSTEM Switches Brake Light Switch Adjustment • Refer to the Brake Light Switch Inspection and Adjust-ment in the Periodic Maintenance chapter. Radiator Fan Switch Inspection • Remove: Radiator Fan Switch (see Cooling System chapter) • Suspend the fan switch [A] in a container of co...

ELECTRICAL SYSTEM 17-87 Switches Coolant Temperature Warning Light Switch Inspection • Remove: Coolant Temperature Warning Light Switch (see CoolingSystem chapter) • Suspend the switch [A] in a container of coolant so thatthe temperature sensing projection and threaded portionare submerged. • Suspen...

17-88 ELECTRICAL SYSTEM Switches 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 If the drive belt failure detection ...

ELECTRICAL SYSTEM 17-89 Fuses Fuse Removal • Remove: Seat (see Frame chapter)Lid [A] • Pull the fuses [A] straight out of the fuse box with needlenose pliers. Fuse Installation If a fuse fails during operation, inspect the electrical sys-tem to determine the cause, and then replace it with anew fuse...

APPENDIX 18-1 18 Appendix Table of Contents Troubleshooting Guide ........................................................................................................... 18-2 Cable, Wire, and Hose Routing ..............................................................................................

18-2 APPENDIX Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving everypossible cause for each problem listed. Itis meant simply as a rough guide to assistthe troubleshooting for some of the morecommon difficulties. Engine Doesn’t Start, Starting Difficulty: Starter motor not rotatin...

APPENDIX 18-3 Troubleshooting Guide Cylinder head gasket damagedCylinder head warpedValve spring broken or weakValve not seating properly (valve bent, worn, or carbon accumulation on theseating surface) Compression release cam (K.A.C.R.) sticks open (Engine stalls when moving off) Other: Carburetor ...

APPENDIX 18-9 Cable, Wire, and Hose Routing 1. Clamp2. Vacuum Hose3. Clamps4. Boot5. Clamps6. Choke Cable Plunger7. Water Hose8. White Paint9. Mark 10. Water Pipe 11. Coolant Catch Tank 12. Ignition Coil13. Ignition Coil Lead

18-10 APPENDIX Cable, Wire, and Hose Routing 1. Air Cleaner Cover2. Breather Tank3. Breather Hoses4. Breather Hose5. Check Valve6. Duct Screw7. Air Intake Duct8. Drain Tube9. Drain Tube 10. Engine Breather Hose

18-12 APPENDIX Cable, Wire, and Hose Routing 1. Rear Final Gear Case Breather Tube2. Front Final Gear Case Breather Tube3. Fuel Breather Tube4. Radiator Fan Motor Breather Tube5. Bands6. Main Harness7. Outside8. Fix breather tube to right frame pipe.9. Water Hose 10. Water Hose 11. Radiator Mounting...

18-14 APPENDIX Cable, Wire, and Hose Routing 1. Water Hose2. Water Pipe3. Coolant Temperature Warning Light Switch4. Water Hose5. Thermostat6. Clamp7. Reserve Tank8. Reverse Switch Lead9. Neutral Switch Lead 10. Clamp 11. Forward/Reverse Detecting Sensor Lead Connector 12. Run the forward/reverse de...

18-20 APPENDIX Cable, Wire, and Hose Routing 1. Right Headlight Lead2. Radiator Cover3. Frame Ground Lead4. Horn Switch Lead (Australia and Europe Models)5. Alternator, Crankshaft Sensor and Oil Pressure Switch Leads6. Rear Brake Light Switch Lead7. 2WD/4WD Shift Switch Lead8. Left Handlebar Switch ...

18-22 APPENDIX Cable, Wire, and Hose Routing 1. Air Intake Duct2. Bands3. Parking Brake Cable4. Foot Brake Cable5. Bracket6. Clamp7. Foot Brake Light Switch8. Speed Sensor Lead Connector9. Run the lead front side of frame pipe. 10. Clamps 11. Reverse Switch Lead Connector 12. Neutral Switch Lead Con...

MODEL APPLICATION Year Model Beginning Frame No. 2005 KVF750-A1 JKAVFDA1 □ 5B500001 or JKAVF750AAB600001 2005 KVF750-B1 JKAVFDB1 □ 5B500001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1334-02 Printed in Japan