2013 KAWASAKI BRUTE FORCE KVF750JD Service Repair Manual

MODEL APPLICATION Year

Model

2012

KVF750GC

2012

KVF750HC

2012

KVF750JC

2012

KVF750LC

2013

KVF750GD

2013

KVF750HD

2013

KVF750JD

2013

KVF750LD

Beginning Frame No. JKAVFDG1□CB500001 JKAVF750GGB600001 JKAVFDH1□CB500001 JKAVF750HHB600001 JKAVFDJ1□CB500001 JKAVF750HHB600001 JKAVFDL1□CB500001 JKAVF750LLB600001 JKAVFDG1□DB504801 JKAVF750GGB600901 JKAVFDH1□DB502201 JKAVF750HHB600501 JKAVFDJ1□DB502201 JKAVFDL1□DB501201 JKAVF750LLB600401

□:This digit in the frame number changes from one machine to another.

Part No.99924-1446-02

Printed in Japan

BRUTE FORCE 750 4×4i EPS BRUTE FORCE 750 4×4i KVF750 4×4 EPS KVF750 4×4

All Terrain Vehicle Service Manual

Quick Reference Guide

This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.

General Information

1 j

Periodic Maintenance

2 j

Fuel System (DFI)

3 j

Cooling System

4 j

Engine Top End

5 j

Converter System

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j

BRUTE FORCE 750 4×4i EPS BRUTE FORCE 750 4×4i KVF750 4×4 EPS KVF750 4×4

All Terrain Vehicle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

© 2011 Kawasaki Heavy Industries, Ltd.

Second Edition (0) : Apr. 24, 2012

LIST OF ABBREVIATIONS A

ampere(s)

ISC

ABDC

after bottom dead center

KACR

AC Ah ATDC BBDC BDC BTDC °C cmHg CPU cu in DC DFI DOT ECU EPS F °F ft g gal h HP IC in.

alternating current ampere hour after top dead center before bottom dead center bottom dead center before top dead center degree(s) celsius centimeters of mercury central processing unit cubic inch(s) direct current digital fuel injection department of transportation electronic control unit electric power steering farad(s) degree(s) fahrenheit foot, feet gram(s) gallon(s) hour(s) horsepower(s) integrated circuit inch(s)

km/h L lb LCD LED LSD m min mmHg mph N oz Pa PS psi qt r rpm s TDC TIR V W Ω

idle speed control Kawasaki automatic compression release kilometers per hour liter(s) pound(s) liquid crystal display light emitting diode limited slip differental meter(s) minute(s) millimeters of mercury miles per hour newton(s) ounce(s) pascal(s) horsepower pound(s) per square inch quart(s) revolution revolution(s) per minute second(s) top dead center total indicator reading volt(s) watt(s) ohm(s)

COUNTRY AND AREA CODES AU CA EUR

Australia Canada Europe

GB US

United Kingdom United States

EMISSION CONTROL INFORMATION (US and CA Models Only) To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2) and evaporative emission (3) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.

1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of crankcase.

2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this vehicle. The fuel, ignition and exhaust systems of this vehicle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere.

3. Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s "tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."

NOTE â—‹The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US and CA Models Only) TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED: Federal regulations and California State law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

• • • • • •

Do not tamper with the original emission related parts: Throttle body or internal parts Spark plugs Ignition system Fuel pump/Fuel injectors Air cleaner element Electronic control unit (ECU)

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below: * Replacement of the original exhaust system or muffler with a component not in compliance * * * *

with Federal regulations.

Removal of the muffler or any internal portion of the muffler.

Removal of the air cleaner housing or air cleaner housing cover.

Modifications to the muffler or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.

Modification to the air cleaner element.

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop.

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

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle: Follow the Periodic Maintenance Chart in the Service Manual.

Be alert for problems and non-scheduled maintenance.

Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

Follow the procedures in this manual carefully. Don’t take shortcuts.

Remember to keep complete records of maintenance and repair with dates and any new parts installed.

• • •

• •

How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference

Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

For example, if you want engine oil information, use the Quick Reference Guide to locate the Engine lubrication System chapter. Then, use the Table of Contents on the first page of the chapter to find the Engine Oil section.

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

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

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

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

This manual contains four more symbols which will help you distinguish different types of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information Table of Contents Before Servicing .....................................................................................................................

Model Identification.................................................................................................................

General Specifications............................................................................................................

Unit Conversion Table ............................................................................................................

1 1-2 1-7 1-9 1-12

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground Before completing any service on the vehicle, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (–) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (–) wire to the negative terminal.

Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.

Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.

Often, the tightening sequence is followed twice initial tightening and final tightening with torque wrench.

Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling.

Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Non-Permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

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 contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

GENERAL INFORMATION 1-7 Model Identification KVF750GC Left Side View

KVF750GC Right Side View

The KVF750H is a camouflage-surface-treated model and the KVF750J is a model with paint finish, and they are identical to the KVF750G, the base model, in every other aspect: controls, features, and specifications.

The KVF750L is a model equipped with the conventional steering system and is similar to the KVF750G other than the electrical power steering equipments in every other aspect: controls, features and specifications.

1-8 GENERAL INFORMATION Model Identification Frame Number

Engine Number

[A] Frame Number [B] Left Front Axle

[A] Engine Number [B] Torque Converter Cover

GENERAL INFORMATION 1-9 General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Ground Clearance Seat Height Curb Mass: KVF750G KVF750H/J KVF750L Front KVF750G KVF750H/J KVF750L Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower

KVF750GC ∼ GD/HC ∼ HD/JC ∼ JD/LC ∼ LD 2 195 mm (86.42 in.)

1 180 mm (45.46 in.)

1 220 mm (48.03 in.)

1 285 mm (50.59 in.)

240 mm (9.45 in.)

910 mm (35.8 in.)

(US, CA, AU) 315 kg (695 lb) (EUR, GB) 316 kg (697 lb) (US, CA) 315 kg (695 lb) (US, CA) 310 kg (684 lb) (EUR, GB) 311 kg (686 lb) (US, CA, AU) 158 kg (348 lb) (EUR, GB) 159 kg (351 lb) (US, CA) 158 kg (348 lb) (US, CA) 153 kg (337 lb) (EUR, GB) 154 kg (340 lb) 157 kg (346 lb) 19 L (5.0 US gal) 3.2 m (10.5 ft)

4-stroke, SOHC, V2-cylinders Liquid-cooled 85 × 66 mm (3.35 × 2.60 in.)

749 cm3 (45.7 cu in.)

9.3 : 1 (AU) 37 kW (50.3 PS) @6 750 r/min (rpm) (EUR, GB) 36.6 kW (49.8 PS) @6 750 r/min (rpm) (US, CA) – – – Maximum Torque 59 N·m (6.0 kgf·m, 44 ft·lb) @5 250 r/min (rpm) (US, CA) – – – Carburetion System FI (Fuel Injection) Mikuni 36 × 2 Starting System Electric starter Ignition System Battery and Coil (transistorized) Timing Advance Electronically advanced (digital) Ignition Timing 10° BTDC @1 100 r/min (rpm) Spark Plug NGK CR7E Cylinder Numbering Method Front to rear, 1-2 Firing Order 1-2

1-10 GENERAL INFORMATION General Specifications Items Valve Timing: Intake: Open Close Duration Exhaust: Open Close Duration Lubrication System Engine oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Transmission: Type Gear Ratios: Forward: High Low Reverse Final Drive System: Type Reduction Ratio Overall Drive Ratio: Forward: High Low Reverse Front Final Gear Case Oil: Type Viscosity Capacity Rear Final Gear Case Oil: Type Capacity

KVF750GC ∼ GD/HC ∼ HD/JC ∼ JD/LC ∼ LD

30° BTDC 54° ABDC 264° 44° BBDC 30° ATDC 254° Forced lubrication (wet sump) API SG, SH, SJ, SL or SM with JASO MA, MA1or MA2 SAE 10W-40 2.4 L (2.5 US qt)

Belt drive torque converter (CVT) 3.122 ∼ 0.635 2-speed and reverse

2.884 (29/27 × 29/18 × 20/12) 4.833 (36/20 × 29/18 × 20/12) 4.028 (16/12 × 18/16 × 29/18 × 20/12) Shaft 2WD/4WD 4.375 (35/8)

39.39 ∼ 8.012 66.02 ∼ 13.43 55.01 ∼ 11.19 API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 0.40 L (0.42 US qt) MOBIL FLUID 424, CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 0.72 L (0.76 US qt)

GENERAL INFORMATION 1-11 General Specifications KVF750GC ∼ GD/HC ∼ HD/JC ∼ JD/LC ∼ LD

Items Frame Type Caster (Rake Angle) Camber King Pin Angle Trail Tread: Front Rear Rim Size: Front Rear Front tire: Type Size Rear tire: Type Size Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Parking Brake Electrical Equipment Battery Headlight: Type Bulb Tail/brake Light: Bulb Reverse Light: Bulb Alternator: Type Rated Output

Double tubular 2.0° 0.6° 10.8° 12 mm (0.47 in.)

925 mm (36.4 in.)

890 mm (35.0 in.)

12 × 6.0 12 × 7.5 Tubeless AT25 × 8-12 Tubeless AT25 × 10-12

Double Wishbone 169 mm (6.65 in.)

Double Wishbone 190 mm (7.48 in.)

Disc × 2 Enclosed wet multi-plate Enclosed wet multi-plate 12 V 12 Ah Semi-sealed beam 12 V 35/35 W × 2 12 V 5/21 W (EUR, GB) 12 V 10 W Three-phase AC 33.7 A/14 V @6 000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country.

1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Symbol M k c m µ

Units of Length:

× × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass: kg g

× ×

2.205 0.03527

= =

lb oz

km m mm

× × ×

0.6214 3.281 0.03937

= = =

mile ft in

= = = = = =

kgf·m ft·lb in·lb N·m ft·lb in·lb

= = = = = =

kgf/cm² psi cmHg kPa psi kPa

=

mph

= = = =

PS HP kW HP

Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m

× × × × × ×

0.1020 0.7376 8.851 9.807 7.233 86.80

Units of Pressure: Units of Volume: L L L L L L mL mL mL

× × × × × × × × ×

0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102

= = = = = = = = =

gal (US) gal (IMP) qt (US) qt (IMP) pint (US) pint (IMP) oz (US) oz (IMP) cu in

kPa kPa kPa kgf/cm² kgf/cm² cmHg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed: km/h

×

0.6214

Units of Power: Units of Force: N N kg kg

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature

= = = =

kg lb N lb

kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance Table of Contents Periodic Maintenance Chart ...................................................................................................

Torque and Locking Agent......................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Periodic Maintenance Procedures..........................................................................................

Fuel System.........................................................................................................................

Throttle Lever Free Play Inspection ..................................................................................

Throttle Lever Free Play Adjustment ................................................................................

Idle Speed Inspection .......................................................................................................

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

Air Cleaner Element Cleaning and Inspection ..................................................................

Air Cleaner Draining..........................................................................................................

Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................

Fuel Hose Replacement ...................................................................................................

Cooling System....................................................................................................................

Radiator Cleaning .............................................................................................................

Water Hoses and Connections Inspection ........................................................................

Coolant Change ................................................................................................................

Engine Top End ...................................................................................................................

Valve Clearance Inspection ..............................................................................................

Valve Clearance Adjustment.............................................................................................

Spark Arrester Cleaning....................................................................................................

Converter System ................................................................................................................

Converter Drive Belt Wear Inspection...............................................................................

Converter Drive Belt Deflection Inspection .......................................................................

Converter Drive Belt Deflection Adjustment......................................................................

Actuator Lever (Engine Brake Control Lever) Assembly Inspection .................................

Engine Lubrication System ..................................................................................................

Engine Oil Change............................................................................................................

Oil Filter Replacement ......................................................................................................

Wheels/Tires ........................................................................................................................

Tire Inspection ..................................................................................................................

Final Drive............................................................................................................................

Variable Differential Control Lever Play Inspection ...........................................................

Variable Differential Control Lever Play Adjustment .........................................................

Front Final Gear Case Oil Change ...................................................................................

Rear Final Gear Case Oil Change ....................................................................................

Brakes..................................................................................................................................

Front Brake Pad Wear Inspection.....................................................................................

Front Brake Hoses and Connections Inspection...............................................................

Front Brake Hose Replacement........................................................................................

Front Brake Fluid Level Inspection ...................................................................................

Front Brake Fluid Change.................................................................................................

Front Brake Master Cylinder Piston Assembly and Dust Cover Replacement .................

Front Brake Caliper Fluid Seal Replacement....................................................................

Front Brake Caliper Dust Seal and Friction Boot Replacement........................................

Rear Brake Plates Replacement.......................................................................................

Rear Brake Lever Free Play Inspection ............................................................................

Rear Brake Pedal Free Play Inspection............................................................................

Rear Brake Lever and Pedal Free Play Adjustment .........................................................

2-3 2-5 2-13 2-15 2-16 2-16 2-16 2-16 2-17 2-17 2-17 2-18 2-18 2-19 2-21 2-21 2-22 2-22 2-24 2-24 2-26 2-26 2-27 2-27 2-27 2-28 2-29 2-29 2-29 2-30 2-30 2-30 2-31 2-31 2-31 2-32 2-33 2-34 2-34 2-34 2-34 2-35 2-36 2-37 2-37 2-37 2-37 2-38 2-38 2-38

2

2-2 PERIODIC MAINTENANCE Steering ...............................................................................................................................

Steering Inspection ...........................................................................................................

Electrical System .................................................................................................................

Spark Plug Cleaning/Inspection........................................................................................

Spark Plug Gap Inspection ...............................................................................................

Front Brake Light Switch Inspection .................................................................................

Rear Brake Light Switch Inspection ..................................................................................

Rear Brake (Pedal) Light Timing Adjustment....................................................................

Converter Drive Belt Failure Detection System Inspection ...............................................

Joint Boots Inspection..........................................................................................................

Front Axle/Steering Knuckle Joint Boots Inspection .........................................................

Front Propeller Shaft Joint Boots Inspection.....................................................................

Tie-rod End Boots Inspection............................................................................................

Rear Propeller Shaft Joint Boots Inspection .....................................................................

Rear Axle/Stabilizer Joint Boots Inspection ......................................................................

General Lubrication .............................................................................................................

Lubrication ........................................................................................................................

Bolts and Nuts Tightening....................................................................................................

Tightness Inspection .........................................................................................................

2-39 2-39 2-39 2-39 2-40 2-40 2-40 2-40 2-41 2-43 2-43 2-43 2-43 2-43 2-43 2-44 2-44 2-45 2-45

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY

First Service

Regular Service

After 10 hrs. or 100 km (60 mi.) of use

Every 90 days, 1 700 km (1 Every Every 100 mi.)

10 30 of use or days or days or Every when belt See 200 km 600 km year of indicator page (120 (360 use light turns mi.) of mi.) of on (100 use use hrs of use) whichever comes first

OPERATION ENGINE

• • • •

Converter drive belt wear-inspect* Converter drive belt deflection- inspect* Converter drive belt failure detection system function-inspect* Engine brake control lever-inspect* Air cleaner-inspect* Throttle lever play-inspect

• •

• •

Idle speed-inspect Valve clearance-inspect Engine oil-change* Oil filter-replace* Spark plug-clean and gap

•

• • •

2-17

• • • •

• •

Rear brake plates-replace* Bolts and nuts-tighten Front brake pad wear-inspect* Brake light switch-inspect* Steering-inspect Differential control lever play-inspect

2-30 2-39, 2-40

•

•

2-18 2-20

•

• • •

•

2-21 2-21 2-43 2-38

every 10 000 km (6 000 mi.)

• • • • •

2-26 2-19

2 years

• •

2-24 2-29

5 years

Coolant-change* CHASSIS Rear brake pedal and lever play-inspect*

2-29

First 1 700 km (1 100 mile); thereafter every 3 400 km (2 200 mile)

Fuel hose-replace

Joint boots-inspect*

2-41

2-16

Fuel hoses and connections-inspect

Radiator hoses and connections-inspect*

2-27

2-17

Spark arrester-clean

Radiator-clean*

2-27

2-37 2-45

• •

2-34 2-40

•

2-39 2-31

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY

First Service

Regular Service

After 10 hrs. or 100 km (60 mi.) of use

Every 90 days, 1 700 km (1 Every Every 100 mi.)

10 30 of use or days or days or Every See when belt 200 km 600 km year of indicator page (120 (360 use light turns mi.) of mi.) of on (100 use use hrs of use) whichever comes first

OPERATION

•

Tire wear-inspect* Front and rear final gear case oil-change

•

General lubrication-perform* Front brake fluid level-inspect

2-30

•

• • •

2-44 2-35

Front brake fluid-change

•

Front brake hoses and connections-inspect Front brake master cylinder piston assembly and dust cover-replace Front brake caliper fluid seal and dust seal-replace Front brake hose-replace

2-32, 2-33

•

2-36 2-34

2 years

2-37

2 years

2-37

4 years

2-34

*: Service more frequently when operated in mud, dust, or other harsh riding conditions, or when carrying heavy loads or pulling a trailer. : Clean, adjust, lubricate, torque, or replace parts as necessary.

•

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: EO: Apple engine oil.

L: Apply a non-permanent locking agent.

LB: Apply a non-permanent locking agent (ThreeBond TB2471, Blue or equivalent).

Lh: Left-hand Threads MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in a weight ratio: 10:1).

R: Replacement Parts S: Follow the specific tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).

St: Stake the fasteners to prevent loosening.

Fastener Fuel System Air Cleaner Housing Bolts Air Cleaner Element Holder Screw Air Cleaner Element Holder Tapping Screw Water Temperature Sensor ISC Valve Mounting Bolts Intake Air Pressure Sensor Mounting Screw Delivery Pipe Mounting Screws Valve Adjusting Cap Bolt Joint Duct Bolts Heat Guard Bolts Fuel Pump Bolts Fuel Tank Mounting Bolts Vehicle-down Sensor Mounting Bolts Throttle Lever Limiter Screw Throttle Lever Limiter Nut Throttle Case Assembly Screws Cooling System Radiator Screen Mounting Bolts Radiator Mounting Bolts Reserve Tank Mounting Screw Coolant Drain Bolts (Cylinder) Radiator Fan Assembly Bolts Air Bleed Bolt Thermostat Housing Cover Bolts Water Pipe Joint Bolts Water Pump Impeller Water Pump Cover Bolts Coolant Drain Bolt (Water Pump)

N·m

Torque kgf·m

ft·lb

8.8 3.5 1.5 12 8.8 3.5 5.0 8.8 8.8 8.8 4.0 10 5.9 3.6 3.6 3.6

0.90 0.36 0.15 1.2 0.90 0.36 0.51 0.90 0.90 0.90 0.41 1.0 0.6 0.37 0.37 0.37

78 in·lb 31 in·lb 13 in·lb 106 in·lb 78 in·lb 31 in·lb 44 in·lb 78 in·lb 78 in·lb 78 in·lb 35 in·lb 89 in·lb 52 in·lb 32 in·lb 32 in·lb 32 in·lb

4.0 8.8 4.0 7.0 8.4 7.0 8.8 8.8 7.8 8.8 7.0

0.41 0.90 0.41 0.71 0.86 0.71 0.90 0.90 0.80 0.90 0.71

35 78 35 62 74 62 78 78 69 78 62

in·lb in·lb in·lb in·lb in·lb in·lb in·lb in·lb in·lb in·lb in·lb

Remarks

L

L

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Engine Top End Valve Adjusting Cap Bolts Rocker Case Bolts 55 mm (2.2 in.)

Rocker Case Bolts 30 mm (1.2 in.)

Rocker Case Bolts 25 mm (1.0 in.)

Rocker Case Bolts 130 mm (5.1 in.)

Rocker Case Bolts 20 mm (0.8 in.)

(KVF750GD/HD/JD/LD Late Models) Cylinder Head Bolt (M6) Cylinder Head Bolts (M10), First Torque Cylinder Head Bolts (M10), Final Torque Water Pipe Bolts Valve Adjusting Screw Locknuts Rocker Shaft Bolts Camshaft Sprocket Bolts Camshaft Chain Tensioner Cap Bolts Camshaft Chain Tensioner Mounting Bolts Front Cylinder Camshaft Chain Guide Bolt Rear Cylinder Camshaft Chain Guide Bolt Position Plate Bolts Intermediate Shaft Chain Guide Bolts Intermediate Shaft Chain Tensioner Bolts Cylinder Bolts 30 mm (1.2 in.)

Cylinder Bolts 40 mm (1.6 in.)

Coolant Drain Bolts (Cylinder) Exhaust Pipe Holder Nuts Exhaust Pipe Cover Clamp Screws Muffler Clamp Bolts Muffler Mounting Bolts Converter System Drive Pulley Bolt Drive Pulley Cover Bolts Spider Ramp Weight Nuts Driven Pulley Nut Engine Brake Actuator Mounting Bolts Torque Converter Cover Bolts Joint Duct Bolts Engine Lubrication System Oil Pipe Bolts Oil Filter Oil Filter Mounting Bolt Oil Pressure Relief Valve

N·m

Torque kgf·m

8.8 8.8 9.8 9.8 9.8

0.90 0.90 1.0 1.0 1.0

78 78 87 87 87

9.8

1.0

87 in·lb

9.8 25 55 8.8 12 22 12 22 8.8 20 20 8.8 8.8 8.8 9.8 9.8 7.0 17 2.1 15 34

1.0 2.5 5.6 0.90 1.2 2.2 1.2 2.2 0.90 2.0 2.0 0.90 0.90 0.90 1.0 1.0 0.71 1.7 0.21 1.5 3.5

87 in·lb 18 41 78 in·lb 106 in·lb 16 106 in·lb 16 78 in·lb 15 15 78 in·lb 78 in·lb 78 in·lb 87 in·lb 87 in·lb 62 in·lb 13 19 in·lb 11 25

93 13 275 7.0 93 8.8 8.8 8.8

9.5 1.3 28.0 0.71 9.5 0.90 0.90 0.90

69 115 in·lb 203 62 in·lb 69 78 in·lb 78 in·lb 78 in·lb

8.8 17.5 25 15

0.90 1.78 2.5 1.5

78 in·lb 12.9 18 11

ft·lb in·lb in·lb in·lb in·lb in·lb

Remarks

S

S

MO, S

L

EO

R, Lh Lh R R S S

R L (15 mm) L

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Oil Pressure Switch Oil Pump Chain Guide Bolt Oil Pump Cover Bolts Engine Oil Drain Bolt Oil Pump Drive Chain Tensioner Bolt Drive Pulley Back Plate Bolts Engine Removal/Installation Engine Mounting Bracket Bolts Engine Mounting Bolt Engine Mounting Nut Crankshaft/Transmission Connecting Rod Big End Cap Nuts Rear Cylinder Camshaft Chain Guide Bolt Bearing Position Plate Screws Engine Oil Drain Bolt Crankcase Bolt (M8, L = 110 mm) Crankcase Bolts (M8, L = 75 mm) Crankcase Bolts (M6, L = 40 mm) Crankcase Bolts (M8, L = 110 mm) Crankcase Bolts (M6, L = 65 mm) Shift Lever Guide Mounting Bolts Grip Holder Nut Tie-rod End Front Locknut Tie-rod End Rear Locknut Tie-rod End Nut Shift Lever Clamp Bolt Shift Shaft Cover Bolts Shift Lever Guide Mounting Nut Tie-rod End Bolt Tie-rod End Locknut Shift Lever Assembly Nut Neutral Switch Heat Guard Bolt Reverse Switch Shift Shaft Positioning Bolt Shift Shaft Spring Bolt Wheel/Tires Wheel Nuts (First Torque) Wheel Nuts (Final Torque) Front Axle Nuts Tie-rod Locknuts Tie-rod End Nuts Rear Axle Nuts

N·m 15 8.8 8.8 20 25 8.8

Torque kgf·m 1.5 0.90 0.90 2.0 2.5 0.90

ft·lb 11 78 in·lb 78 in·lb 15 18 78 in·lb

71.5 101.5 101.5

7.3 10.4 10.4

53 75 75

L LB R

34.3 20 4.9 20 20 20 9.8 20 9.8 19.6 9.8 9.8 9.8 19.6 13.5 8.8 19.6 9.8 19.6 19.6 15 8.8 15 25 31

3.50 2.0 0.50 2.0 2.0 2.0 1.0 2.0 1.0 2.00 1.0 1.0 1.0 2.00 1.38 0.90 2.00 1.0 2.00 2.00 1.5 0.90 1.5 2.5 3.2

25.3 15 43 in·lb 15 15 15 87 in·lb 15 87 in·lb 14.5 87 in·lb 87 in·lb 87 in·lb 14.5 119 in·lb 78 in·lb 14.5 87 in·lb 14.5 14.5 11 78 in·lb 11 18 23

MO

15 76.5 195.5 36.5 41.5 264.5

1.5 7.8 19.9 3.7 4.2 27.0

11 56 144 27 31 195

Remarks SS

L S, L S S

Lh R

R

R

LB S S Lh (2) R

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Final Drive (Output Bevel Gears) Bearing Holder Bevel Gear Holder Nut Bearing Holder Output Shaft Holder Nut Output Driven Bevel Gear Housing Bolts Output Drive Bevel Gear Housing Bolts Rotor Mounting Bolts Output Drive Bevel Gear Cover Bolts Forward/Reverse Detecting Sensor Mounting Bolt (Front Final Gear Case) Variable Differential Control Lever Bolt Variable Differential Control Cable Locknut Front Final Gear Case Oil Filler Cap 2WD/4WD Actuator Cover Mounting Bolts Variable Differential Control Shift Shaft Lever Nut Front Final Gear Case Oil Drain Bolt Ring Gear Bolts 2WD/4WD Actuator Mounting Bolts Pinion Gear Bearing Holder Nut Pinion Gear Bearing Holder Front Final Gear Case Coupling Nut Front Final Gear Case Mount Nuts Front Final Gear Case Left Cover Bolts (M6) Front Final Gear Case Center Cover Bolts (M6) Front Final Gear Case Center Cover Bolts (M8) (Rear Final Gear Case) Rear Final Gear Case Front Cover Bolts Pinion Gear Bearing Holder Nut Pinion Gear Bearing Holder Rear Final Gear Case Gasket Screws Rear Final Gear Case Oil Filler Cap Rear Final Gear Case Oil Drain Bolt Rear Final Gear Case Bracket Bolts Rear Final Gear Case Mount Nuts Rear Final Gear Case Right Cover Bolts (M10) Rear Final Gear Case Right Cover Bolts (M12) Rear Final Gear Case Right Cover Bolts (M8) Brakes Reservoir Cap Screws Front Brake Lever Pivot Bolt Front Brake Light Switch Mounting Screw

N·m

Torque kgf·m

ft·lb

120 200 250 200 26 26 12 8.8 14.9

12.2 20.4 25.5 20.4 2.7 2.7 1.2 0.90 1.52

88.5 148 184 148 19 19 106 in·lb 78 in·lb 11.0

L LB L LB

3.4 17 29 9.8 8.8 15 57 9.8 127 137 25 59 9.8 9.8 24

0.35 1.7 3.0 1.0 0.90 1.5 5.8 1.0 13.0 14.0 2.5 6.0 1.0 1.0 2.4

30 in·lb 13 21 87 in·lb 78 in·lb 11 42 87 in·lb 93.7 101 18 44 87 in·lb 87 in·lb 18

L

24 157 450 1.25 29 15 59 90.5 49 95 24

2.4 16.0 45.9 0.127 3.0 1.5 6.0 9.23 5.0 9.7 2.4

18 116 332 11.1 in·lb 21 11 44 66.8 36 70 18

1.5 5.9 1.2

0.15 0.60 0.12

13 in·lb 52 in·lb 11 in·lb

Remarks

EO R EO LB, S L, S St L R L (4), S L L L LB, R L, St

L R, L L L L

Si

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Front Brake Lever Pivot Bolt Locknut Front Brake Master Cylinder Clamp Bolts Brake Hose Banjo Bolts Front Brake Pad Mounting Bolts Bleed Valves Front Brake Disc Mounting Bolts Front Brake Caliper Mounting Bolts Front Brake Caliper Holder Shaft Front Brake Caliper Holder Shaft Nut Rear Brake Lock Lever Pivot Screw Rear (Parking) Brake Lever Pivot Bolt Rear (Parking) Brake Lever Pivot Nut Variable Differential Control Lever Bolt Rear Final Gear Case Gasket Screws Suspension Front Shock Absorber Mounting Nuts Front Suspension Arm Pivot Upper Nuts Steering Knuckle Joint Nuts Front Suspension Arm Pivot Lower Nuts Rear Shock Absorber Mounting Nuts Stabilizer Holder Bolts Stabilizer Joint Nuts Rear Suspension Arm Pivot Nuts Rear Knuckle Mounting Nuts Steering Rear Brake Lock Lever Pivot Screw Rear (Parking) Brake Lever Pivot Bolt Rear (Parking) Brake Lever Pivot Nut Variable Differential Control Lever Bolt Left Handlebar Switch Housing Screws Throttle Case Assembly Screws Throttle Lever Limiter Screw Throttle Lever Limiter Nut Front Brake Master Cylinder Clamp Bolts Handlebar Holder Bolts Tie-rod End Nuts Tie-rod Locknuts Steering Knuckle Joint Nuts (KVF750G/H/J) Steering Shaft Upper Bracket Bolts EPS Unit Mounting Bolts EPS Unit Mounting Bracket Bolts Steering Shaft Lower Clamp Nut

N·m 5.9 8.8 25 17 7.8 36.5 24.5 17 22 2.2 2.2 3.4 3.4 1.25

Torque kgf·m 0.60 0.90 2.5 1.7 0.80 3.72 2.50 1.7 2.2 0.22 0.22 0.35 0.35 0.127

ft·lb 52 in·lb 78 in·lb 18 13 69 in·lb 26.9 18.1 13 16 19 in·lb 19 in·lb 30 in·lb 30 in·lb 11.1 in·lb

34 59 50 46.5 34 21.5 57.5 46.5 46.5

3.5 6.0 5.1 4.7 3.5 2.2 5.9 4.7 4.7

25 44 37 34 25 16 42 34 34

R R

2.2 2.2 3.4 3.4 3.5 3.6 3.6 3.6 8.8 29 41.5 36.5 50

0.22 0.22 0.35 0.35 0.36 0.37 0.37 0.37 0.90 3.0 4.23 3.72 5.1

19 in·lb 19 in·lb 30 in·lb 30 in·lb 31 in·lb 32 in·lb 32 in·lb 32 in·lb 78 in·lb 21 30.6 29.9 37

L

20 20 35 24.5

2.0 2.0 3.6 2.50

15 15 26 18.1

Remarks

S

L Si L L

L

R R R R R

L

S S R Lh (2)

S

R

2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Steering Shaft Holder Nuts (First) Steering Shaft Holder Nuts (Final) Pitman Arm Mounting Nut Steering Shaft Lower End Stopper Mounting Bolts EPS ECU Mounting Nut (KVF750L) Steering Shaft Upper Bracket Bolts Steering Shaft Lower End Holder Mounting Bolts Steering Shaft Holder Nuts Pitman Arm Mounting Nut Frame Front Carrier Bolts, L = 70 mm (2.8 in.)

Front Carrier Bolts, L = 50 mm (2.0 in.)

Front Carrier Bracket Bolts Front Guard Bolts Rear Carrier Bolts, L = 14 mm (0.55 in.)

(KVF750GC/HC/JC/LC Early Models) Rear Carrier Bolts, L = 16 mm (0.63 in.)

(KVF750GC/HC/JC/LC Late Models ∼) Rear Carrier Bolts, L = 44 mm (1.7 in.)

Rear Carrier Bracket Bolts Rear Final Gear Case Mounting Bracket Bolts Trailer Hitch Bracket Bolts Footboard Bracket Bolts Electrical System Harness Clamp Bolt Starter Motor Mounting Bolts Starter Motor Cable Mounting Nut Starter Motor Terminal Locknut Starter Motor Through Bolts Starter Motor Clutch Bolts Crankshaft Sensor Mounting Bolts Alternator Rotor Bolt Alternator Stator Bolts Breather Plate Screws Alternator Cover Plugs Alternator Rotor Bolt Cap Timing Inspection Cap Alternator Cover Bolts 2WD/4WD Actuator Cover Mounting Bolts 2WD/4WD Actuator Mounting Bolts Ignition Coil Bracket Mounting Bolts Ignition Coil Mounting Bolts

N·m 10 18 110 22.5 6.9

Torque kgf·m 1.0 1.8 11.2 2.29 0.70

ft·lb 89 in·lb 13 81.1 16.6 61 in·lb

20 35 18 90

2.0 3.6 1.8 9.2

15 26 13 66

31.5 31.5 31.5 36.5

3.21 3.21 3.21 3.72

23.2 23.2 23.2 26.9

L L L

54

5.5

40

L

54 46.5 59 81.5 46.5

5.5 4.74 6.0 8.31 4.74

40 34.3 44 60.1 34.2

L

8.8 8.8 6.8 11 5.0 34 5.9 127 13.5 2.9 17.5 2.5 5.0 8.8 9.8 9.8 8.8 5.9

0.90 0.90 0.69 1.1 0.51 3.5 0.60 13.0 1.38 0.30 1.78 0.25 0.51 0.90 1.0 1.0 0.90 0.60

78 in·lb 78 in·lb 60 in·lb 97 in·lb 44 in·lb 25 52 in·lb 93.7 119 in·lb 26 in·lb 12.9 22 in·lb 44 in·lb 78 in·lb 87 in·lb 87 in·lb 78 in·lb 52 in·lb

Remarks R, S R, S L

R

L L

L

LB L

L, S

PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Fastener Spark Plugs Engine Brake Actuator Mounting Bolts Speed Sensor Mounting Bolt Neutral Switch Heat Guard Bolt Reverse Switch Forward/Reverse Detecting Sensor Mounting Bolt Left Switch Housing Screws Throttle Lever Limiter Screw Throttle lever Limiter Nut Throttle Case Assembly Screws Radiator Fan Assembly Bolts Tail/Brake Light Lens Screws Regulator/Rectifier Mounting Bolts Oil Pressure Switch Oil Pressure Switch Terminal Bolt Joint Duct Bolts

Torque kgf·m 1.3 0.90 0.90 1.5 0.90 1.5 1.52 0.36 0.37 0.37 0.37 0.86 0.150 0.90 1.5 0.15 0.90

N·m 13 8.8 8.8 15 8.8 15 14.9 3.5 3.6 3.6 3.6 8.4 1.47 8.8 15 1.5 8.8

ft·lb 115 in·lb 78 in·lb 78 in·lb 11 78 in·lb 11 11.0 31 in·lb 32 in·lb 32 in·lb 32 in·lb 74 in·lb 13.0 in·lb 78 in·lb 11 13 in·lb 78 in·lb

Remarks

S

SS

The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners of Engine Parts Threads dia. mm (in.)

Mark of bolt head

5 (0.20) 6 (0.24) 6 (0.24) 6 (0.24) 8 (0.31) 8 (0.31) 10 (0.39) 10 (0.39)

4T 9T 7T 4T 7T 4T 7T 4T

N·m 2.2 ∼ 2.6 12 ∼ 15 7.8 ∼ 9.8 3.9 ∼ 4.9 18 ∼ 22 10 ∼ 14 39 ∼ 44 20 ∼ 24

Torque kgf·m 0.22 ∼ 0.27 1.2 ∼ 1.5 0.8 ∼ 1.0 0.4 ∼ 0.5 1.8 ∼ 2.2 1.0 ∼ 1.4 4.0 ∼ 4.5 2.0 ∼ 2.4

ft·lb 19 ∼ 23 in·lb 104 ∼ 130 in·lb 69 ∼ 87 in·lb 35 ∼ 43 in·lb 13 ∼ 16 87 ∼ 122 in·lb 29 ∼ 33 14 ∼ 17

Basic Torque for General Fasteners of Frame Parts Threads dia. mm (in.)

5 (0.20) 6 (0.24) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63)

N·m 3.4 ∼ 4.9 5.9 ∼ 7.8 14 ∼ 19 25 ∼ 34 44 ∼ 61 73 ∼ 98 115 ∼ 155

Torque kgf·m 0.35 ∼ 0.5 0.6 ∼ 0.8 1.4 ∼ 1.9 2.6 ∼ 3.5 4.5 ∼ 6.2 7.4 ∼ 10.0 11.5 ∼ 16.0

ft·lb 30 ∼ 43 in·lb 52 ∼ 69 in·lb 10.0 ∼ 13.5 19 ∼ 25 33 ∼ 45 54 ∼ 72 83 ∼ 115

2-12 PERIODIC MAINTENANCE Torque and Locking Agent 18 (0.71) 20 (0.79)

165 ∼ 225 225 ∼ 325

17.0 ∼ 23.0 23.0 ∼ 33.0

125 ∼ 165 165 ∼ 240

PERIODIC MAINTENANCE 2-13 Specifications Item Fuel System Throttle Lever Free Play Idle Speed Air Cleaner Element Oil Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Intake Converter System Belt Width Belt Deflection Actuator Lever Guide Shoe Engine Lubrication System Engine Oil: Type Viscosity Capacity

Wheels/Tires Tire Tread Depth: Front Rear Standard tire: Front Rear Final Drive Front Final Gear Case: Gear Case Oil: Type Viscosity

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

1 100 ±50 r/min (rpm) High-quality foam air filter oil

– – – – – – – – –

Permanent type antifreeze Green Soft water 50%, Coolant 50% −35°C (−31°F) 3.0 L (3.2 US qt)

– – – – –

0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

– – – – – –

30.0 ∼ 30.6 mm (1.18 ∼ 1.20 in.)

22 ∼ 27 mm (0.87 ∼ 1.06 in.)

–––

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE10W-40 1.9 L (2.0 US qt) (When filter is not removed) 2.0 L (2.1 US qt) (When filter is removed) 2.4 L (2.5 US qt) (When engine is completely dry)

13.0 mm (0.51 in.)

14.5 mm (0.57 in.)

AT 25 × 8-12 DURO, DI-K911, Tubeless AT 25 × 10-12 DURO, DI-K591, Tubeless

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40

– – – – –

– – – – –

28.6 mm (1.13 in.)

– – – 6 mm (0.24 in.)

– – – – – – – – – – – – – – –

3 mm (0.12 in.)

4 mm (0.16 in.)

– – – –

– – – –

– – – –

– – – – – –

2-14 PERIODIC MAINTENANCE Specifications Item Oil Level Capacity Rear Final Gear Case: Gear Case Oil: Type

Oil Level Capacity Brakes Front Brake Fluid: Type Front Disc Brake: Pad Lining Thickness Rear Brake Lever, Pedal and Cables: Rear Brake Lever Free Play Brake Pedal Free Play Electrical System Spark Plug Gap Brake Light Timing: Front Rear (Lever) Rear (Pedal)

Standard Filler opening bottom 0.40 L (0.42 US qt)

MOBIL FLUID 424, CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Filler opening bottom 0.72 L (0.76 US qt)

Service Limit – – – – – –

– – – – – – – – –

DOT3 or DOT4

– – –

4 mm (0.16 in.)

1 mm (0.04 in.)

1 ∼ 2 mm (0.04 ∼ 0.08 in.)

15 ∼ 25 mm (0.6 ∼ 1.0 in.)

– – – – – –

0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.)

– – –

Pulled ON Pulled ON ON after about 10 mm (0.4 in.) of pedal travel

– – – – – – – – –

PERIODIC MAINTENANCE 2-15 Special Tools Valve Adjusting Screw Holder: 57001-1217

Pulley Holder Attachment: 57001-1472

Oil Filter Wrench: 57001-1249

Flywheel & Pulley Holder: 57001-1605

Filler Cap Driver: 57001-1454

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection

that the throttle lever [A] moves smoothly from full • Check open to close, and the throttle closes quickly and com-

• •

pletely in all steering positions by the return spring.

If the throttle lever does not return properly, check the throttle cable routing, lever free play, and cable damage.

Then lubricate the throttle cable.

Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increases, check the throttle lever free play and the cable routing.

Stop the engine and check the throttle lever free play [B].

If the free play is not within the specified range, adjust the cable.

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

Throttle Lever Free Play Adjustment

the rubber cover off the adjuster at the throttle case.

• Slide Loosen locknut [A] and turn the throttle cable upper • adjuster the [B] until the cable has proper amount of play.

Tighten the locknut and reinstall the rubber cover.

•

If the free play cannot be adjusted by using the upper cable adjuster, remove the left side cover (see Left Side Cover Removal in the Frame chapter) and then use the cable adjusting nut [A] and locknut [B] at the lower end of the throttle cable and make the necessary free play.

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Idle Speed Inspection

the engine and warm it up thoroughly.

• Start the engine idling, turn the handlebar to both sides to • With check for any changes in the idle speed.

If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted, incorrectly routed, or damaged. Be sure to correct any of these conditions before riding.

WARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. Follow the service manual to make sure to correct any of these conditions. idle speed with a suitable tachometer.

• Check If the idle speed is out of the specified range, check the ISC valve (see ISC valve Inspection in the Fuel System (DFI) chapter) and vacuum hoses.

Idle Speed Standard:

1 100 ±50 r/min (rpm)

Idle Speed Adjustment NOTE

○Idle speed is adjusted automatically performed by ECU, so idle speed cannot be adjusted.

Air Cleaner Element Cleaning and Inspection NOTE

○In dusty areas, the element should be cleaned more frequently than the recommended interval. ○After riding through rain or muddy terrains, the element should be cleaned immediately. ○Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.

WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low flash-point solvents to clean the element.

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures the air cleaner element (see Air Cleaner Element • Remove Removal in the Fuel System (DFI) chapter).

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

it dry in a clean towel [A]. Do not wring the ele• Squeeze ment or blow it dry; the element can be damaged. the element for damage.

• Inspect If it is torn, punctured, or hardened, replace it. cleaning, saturate the element with a high-quality • After foam-air-filter oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element.

Air Cleaner Draining

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

Fuel Hose Inspection (fuel leak, damage, installation condition)

○The fuel hose is designed to be used throughout the vehicle’s life without any maintenance. However, if the vehicle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. that the hoses are routed according to Cable, Wire, • Check and Hose Routing section in the Appendix chapter.

Replace the hose if it has been sharply bent or kinked.

Hose Joints [A] Fuel Hose [B]

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures that the hose joints are securely connected.

•○Check Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked.

If it does not locked, reinstall the hose joint.

WARNING Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint.

Fuel Hose Replacement

WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

NOTICE When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The fuel pump pipe made from resin could be damaged. the fuel hose from the fuel pump (see Fuel • Disconnect Pump Removal in the Fuel System (DFI) chapter). sure to place a piece of cloth [A] around the fuel hose • Be joint.

WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage. off the dirt of the surface [A] around the connection • Wipe using a cloth or a soft brush.

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