2005 kawasaki kvf700b2 prairie factory service manual

MODEL APPLICATION Year

Model

2004

KVF700-A1

2004 2005 2005 2005 2006 2006

KVF700-B1 KVF700-A2 KVF700-B2 KVF700-D1 KVF700A6F KVF700D6F

Beginning Frame No. JKAVF6A1□4B500001 or JKAVF700AAB600001 JKAVF6B1□4B500001 JKAVF6A1□5B513401 JKAVF6B1□5B503601 JKAVF6D1□5B500001 JKAVF6A1□6B507601 JKAVF6D1□6B513401

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

Part No.99924-1319-04

Printed in Japan

Prairie 700 4×4 KVF 700 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

3 j

Cooling System

4 j

Engine Top End

5 j

Converter System

6 j

Recoil Starter

7 j

Engine Lubrication System

8 j

Engine Removal/Installation

9 j

Crankshaft/Transmission

10 j

Wheels/Tires

11 j

Final Drive

12 j

Brakes

13 j

Suspension

14 j

Steering

15 j

Frame

16 j

Electrical System

17 j

Appendix

18 j

Prairie 700 4×4 KVF 700 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 Devision/Consumer Products & Machinery 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.

© 2003 Kawasaki Heavy Industries, Ltd.

Fourth Edition (1) : May 23, 2005 (K)

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L

ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celcius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)

lb m min N Pa PS psi r rpm TDC TIR V W Ω

pounds(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the 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 The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.

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.

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.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

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 ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions!

Always follow safe operating and maintenance practices.

WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

○This note symbol indicates points of par-

ticular 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

1

Table of Contents Before Servicing .....................................................................................................................

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

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

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

1-2 1-7 1-10 1-16

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 or cotter pins 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. 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 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 adjustment.

GENERAL INFORMATION 1-7 Model Identification KVF700-A1 Left Side View

KVF700-A1 Right Side View

1-8 GENERAL INFORMATION Model Identification KVF700-B1 Left Side View

KVF700-B1 Right Side View

GENERAL INFORMATION 1-9 Model Identification KVF700-D1 Left Side View

KVF700-D1 Right Side View

1-10 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Ground Clearance: Rear Final Gear Case Center of Frame Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore And Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System

KVF700-A1, B1 2 1 1 1

190 180 175 290

192 240 870 273

mm mm mm mm

(86.22 (46.46 (46.26 (50.79

KVF700-A2, B2, D1

in.) in.) in.) in.)

mm (7.56 in.) mm (9.45 in.) mm (34.25 in.) kg (602 lb)

154 kg (340 lb) 140 kg (309 lb) 17 L (4.5 US gal)

139 kg (306 lb)

3.1 m (10.17 ft) 4-stroke, SOHC, V2-cylinders Liquid-cooled 82.0 × 66.0 mm (3.23 × 2.60 in.)

697 cm³ (42.5 cu in.)

9.9 : 1 34.3 kW (46.6 PS) @6 500 r/min (rpm), (US) 60.1 N·m (6.13 kgf·m, 44.33 ft·lb) @5 000 r/min (rpm) Carburetor, Keihin CVKR D32 Electric Starter & Recoil Starter Digital DC-CDI Electronically advanced From 5° BTDC @1 100 r/min (rpm) to 28° BTDC @5 000 r/min (rpm) NGK CR7E, DENSO U22ESR-N Front to rear, 1-2 1-2

30° BTDC 34° ABDC 244° 54° BBDC 10° ATDC 244° Forced lubrication (wet sump)

GENERAL INFORMATION 1-11 General Specifications Items 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 Frame Type Caster (Rake Angle) Camber King Pin Angle Trail Tread: Front Rear Rim Size: Front Rear

KVF700-A1, B1

KVF700-A2, B2, D1

API SF or SG API SH or SJ with JASO MA class SAE 10W-40 2.05 L (2.17 US qt)

Belt converter 3.122 ∼ 0.635 2-speed and reverse

3.098 (30/26 × 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)

42.32 ∼ 8.61 66.02 ∼ 13.43 55.01 ∼ 11.19 API SF or SG API SH or SJ with JASO MA class SAE10W-40 0.43 L (0.45 US qt) MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or Exxon Hydraul 560 0.9 L (0.95 US qt) Double tubular 3.5° 0° 15° 15 mm (0.59 in.)

906 mm (35.67 in.)

910 mm (35.83 in.)

12 × 6.0 12 × 7.5

1-12 GENERAL INFORMATION General Specifications Items Front Tire: Type Size Rear Tire: Type Size Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Electrical Equipment Battery Headlight: Type Bulb Tail/Brake Light: Bulb Reverse Light: Bulb Alternator: Type Rated Output

KVF700-A1, B1

KVF700-A2, B2, D1

Tubeless AT25 × 8 - 12 Tubeless AT25 × 10 - 12

MacPherson strut 170 mm (6.69 in.)

Swingarm 184 mm (7.24 in.)

Disc × 2 Enclosed wet multi-plate 12 V 12 Ah Semi-sealed beam 12 V 45/45 W × 2 12 V 5/21 W (EUR) (GB) 12 V/10 W Three - phase AC 25 A, 14 V @6 000 r/min (rpm)

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

EUR: Europe Model GB: United Kingdom Model US: United States Model

GENERAL INFORMATION 1-13 General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Ground Clearance: Rear Final Gear Case Center of Frame Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore And Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System

KVF700A6F/D6F 2 1 1 1

190 180 175 290

192 241 870 274

mm mm mm mm

(86.22 (46.46 (46.26 (50.79

in.) in.) in.) in.)

mm (7.56 in.) mm (9.49 in.) mm (34.25 in.) kg (604 lb)

155 kg (342 lb) 139 kg (306 lb) 17 L (4.5 US gal) 3.1 m (10.17 ft) 4-stroke, SOHC, V2-cylinders Liquid-cooled 82.0 × 66.0 mm (3.23 × 2.60 in.)

697 cm³ (42.5 cu in.)

9.9 : 1 34.3 kW (46.6 PS) @6 500 r/min (rpm), (US) 60.1 N·m (6.13 kgf·m, 44.33 ft·lb) @5 000 r/min (rpm) Carburetor, Keihin CVKR D32 Electric Starter & Recoil Starter Digital DC-CDI Electronically advanced From 5° BTDC @1 100 r/min (rpm) to 28° BTDC @5 000 r/min (rpm) NGK CR7E, DENSO U22ESR-N Front to rear, 1-2 1-2

30° BTDC 34° ABDC 244° 54° BBDC 10° ATDC 244° Forced lubrication (wet sump)

1-14 GENERAL INFORMATION General Specifications Items 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 Frame Type Caster (Rake Angle) Camber King Pin Angle Trail Tread: Front Rear Rim Size: Front Rear

KVF700A6F/D6F API SF or SG API SH or SJ with JASO MA class SAE 10W-40 2.05 L (2.17 US qt)

Belt converter 3.122 ∼ 0.635 2-speed and reverse

3.098 (30/26 × 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)

42.32 ∼ 8.61 66.02 ∼ 13.43 55.01 ∼ 11.19 API SF or SG API SH or SJ with JASO MA class SAE10W-40 0.43 L (0.45 US qt) MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or Exxon Hydraul 560 0.9 L (0.95 US qt) Double tubular 3.5° 0° 15° 15 mm (0.59 in.)

906 mm (35.67 in.)

910 mm (35.83 in.)

12 × 6.0 12 × 7.5

GENERAL INFORMATION 1-15 General Specifications Items Front Tire: Type Size Rear Tire: Type Size Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Electrical Equipment Battery Headlight: Type Bulb Tail/Brake Light: Bulb Alternator: Type Rated Output

KVF700A6F/D6F Tubeless AT25 × 8 - 12 Tubeless AT25 × 10 - 12

MacPherson strut 170 mm (6.69 in.)

Swingarm 184 mm (7.24 in.)

Disc × 2 Enclosed wet multi-plate 12 V 12 Ah Semi-sealed beam 12 V 45/45 W × 2 12 V 5/21 W Three - phase AC 25 A, 14 V @6 000 r/min (rpm)

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

US: United States Model

1-16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Units of Length:

Symbol M k c m μ

× × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass: kg g

× ×

2.205 0.03527

= =

lb oz

= = = = = = = = =

gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US)

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

oz (imp) cu in

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: kPa kPa kPa kgf/cm² kgf/cm² cm Hg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed: km/h

×

0.6214

Units of Force: N N kg kg

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature:

= = = =

kg lb N lb

Units of Power: kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance 2

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

Choke Lever Free Play Inspection....................................................................................

Choke Lever Free Play Adjustment ..................................................................................

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

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

Fuel System Cleanliness Inspection .................................................................................

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

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

Fuel Hose and Connection Inspection ..............................................................................

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

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

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

Radiator Hose and Connection Inspection .......................................................................

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

Coolant Filter Cleaning .....................................................................................................

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

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

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

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

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

Converter Drive Belt 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 ...................................................................................

2-3 2-5 2-11 2-13 2-14 2-14 2-14 2-14 2-14 2-15 2-15 2-15 2-16 2-16 2-17 2-17 2-18 2-18 2-18 2-19 2-19 2-21 2-22 2-22 2-23 2-23 2-23 2-23 2-24 2-25 2-26 2-26 2-26 2-26 2-27 2-27 2-27 2-27 2-28 2-28 2-29 2-30 2-30 2-30 2-30 2-30

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

Steering ...............................................................................................................................

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

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

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

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

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

Rear Brake Light Timing Adjustment ................................................................................

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

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

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

Front Propeller Shaft Joint Boot Inspection ......................................................................

Rear Propeller Shaft Joint Boot Inspection .......................................................................

Tie-rod End Boot Inspection .............................................................................................

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

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

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

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

2-31 2-32 2-32 2-32 2-32 2-32 2-33 2-33 2-34 2-34 2-34 2-34 2-34 2-35 2-35 2-35 2-37 2-37 2-37 2-37 2-37 2-38 2-38 2-39 2-39

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

OPERATION ENGINE

First Service

Regular Service

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

Every Every After 10 10 days 30 days of use or hrs. or or 200 or 600 when belt Every See indicator year of km km 100 km page light turns (360 (60 mi.) (120 use of use mi.) of mi.) of on (100 hrs. of use use use) whichever comes first

• • • •

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 Choke lever play - inspect Idle speed - inspect

• • •

• • •

Valve clearance - inspect Fuel system cleanliness - inspect * Engine oil - change * Oil filter - replace * Spark plug cleaning and gap - inspect Spark arrester - clean

•

Radiator hoses and connections - inspect*

•

•

Coolant - change*

2 years

CHASSIS Rear brake pedal and lever play - inspect * Rear brake plates - replace * Bolts and nuts - tighten Front brake pad wear - inspect *

• • • •

2-16 2-17

•

2-22 2-16 2-26 2-26 2-34

•

2-23 2-17 2-18 2-18

Coolant filter of carburetor - clean Joint boots - inspect *

2-26

2-15

• • • • 4 years

•

2-35

2-14

Fuel hoses and connections - inspect Radiator - clean*

2-24

2-14

• • • •

Fuel hose - replace

2-23

•

2-19

•

2-21

2-19

• •

2-37

•

2-39

2-32

every 10 000 km (6 000 mile)

•

2-32 2-30

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY

OPERATION Brake light switch - inspect * Steering - inspect Differential control lever play - inspect Tire wear - inspect * Front and rear final gear case oil - change

First Service

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

Every Every After 10 10 days 30 days of use or hrs. or or 200 or 600 when belt Every See indicator year of km km 100 km page light turns (360 (60 mi.) (120 use of use mi.) of mi.) of on (100 hrs. of use use use) whichever comes first

• • •

Front brake fluid - change

• •

•

•

2-34 2-27

•

2-27

• • •

2-28 2-29 2-38 2-30

•

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

2-35

•

General lubrication - perform* Front brake fluid level - inspect

Regular Service

•

2-31 2-30

2 years

2-32

2 years

2-32

4 years

2-30

*: 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: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

L: Apply a non-permanent locking agent.

LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue).

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.

SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

St: Stake the fasteners to prevent loosening.

Fastener Fuel System Heat Guard Plate Mounting Bolts Air Cleaner Housing Bolts (M5) Air Cleaner Housing Bolts (M6) 28.7 mm (1.13 in.)

Air Cleaner Housing Bolts (M6) 33 mm (1.30 in.)

Fuel Tap Plate Screws Air Cleaner Element Bracket Screws Cooling System Radiator Fan Switch Water Pump Cover Bolts Coolant Drain Plug Water Pump Fitting Bolt Water Pump Impeller Thermostat Housing Cover Bolts Water Temperature Switch Radiator Fan Mounting Nut Radiator Fan Assembly Bolts Radiator Mounting Bolts Engine Top End Water Pipe Bolts Rocker Case Bolts 55 mm (2.2 in.)

Rocker Case Bolts 130 mm (5.1 in.)

Rocker Case Bolts 30 mm (1.2 in.)

Rocker Case Bolts 25 mm (1.0 in.)

Cylinder Head Bolts (M10), First Torque Cylinder Head Bolt (M10), Final Torque Cylinder Head Bolts (M6) Cylinder Head Jacket Plugs Valve Adjusting Cap Bolts Valve Adjusting Screw Locknuts Rocker Shaft Bolts

N·m

Torque kgf·m

ft·lb

8.8 5.9 8.8

0.90 0.60 0.90

78 in·lb 52 in·lb 78 in·lb

8.8 0.8 4.9

0.90 0.08 0.50

78 in·lb 7 in·lb 43 in·lb

18 8.8 8.8 9.8 7.8 8.8 7.8 2.7 8.8 8.8

1.8 0.90 0.90 1.0 0.80 0.90 0.80 0.28 0.90 0.90

13 78 in·lb 78 in·lb 87 in·lb 69 in·lb 78 in·lb 69 in·lb 24 in·lb 78 in·lb 78 in·lb

9.8 8.8 9.8 9.8 9.8 25

1.0 0.90 1.0 1.0 1.0 2.5

87 in·lb 78 in·lb 87 in·lb 87 in·lb 87 in·lb 18

49 9.8 20 8.8 12 8.8

5.0 1.0 2.0 0.90 1.2 0.90

36 87 in·lb 14 78 in·lb 104 in·lb 78 in·lb

Remarks

L

SS L

S S S S S, MO S L

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