Kawasaki KVF750 - Brute Force 750 - Service Manual / Repair Manual View larger

Kawasaki KVF750 - Brute Force 750 - Service Manual / Repair Manual

English Service Manual / Repair Manual to ATV Kawasaki KVF750 / Brute Force 750.

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KAWASAKI KVF750 - BRUTE FORCE 750 - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual to ATV Kawasaki KVF750 / Brute Force 750.


CONTENTS:


FOREWORD

GENERAL INFORMATION
- Before starting to perform an inspection service or carry out a
- Battery Ground
- Edges of Parts
- Solvent
- Cleaning Vehicle before Disassembly
- Arrangement and Cleaning of Removed Parts
- Storage of Removed Parts
- Inspection
- Replacement Parts
- Assembly Order
- Tightening Sequence
- Tightening Torque
- Force
- Gasket, O-ring
- Liquid Gasket, Locking Agent
- Press
- Ball Bearing and Needle Bearing
- Oil Seal, Grease Seal
- Circlips, Cotter Pins
- Lubrication
- Direction of Engine Rotation
- Electrical Wires
- Instrument
- KVF750D8F Left Side View
- KVF750D8F Right Side View
- Frame Number
- Engine Number
- Prefixes for Units:
- Units of Temperature

PERIODIC MAINTENANCE
- The scheduled maintenance must be done in accordance with this c
- The following tables list the tightening torque for the major fa
- Oil Filter Wrench:
- Fuel System
- Throttle Lever Free Play Inspection
- Throttle Lever Free Play Adjustment
- Idle Speed Inspection
- Idle Speed Adjustment
- Air Cleaner Element Cleaning and Inspection
- Air Cleaner Draining
- Fuel Hose Inspection (fuel leak, damage, installation condition)
- Fuel Hose Replacement
- Cooling System
- Engine Top End
- Converter System
- Engine Lubrication System
- Wheels/Tires
- Final Drive
- Brakes
- Steering
- Electrical System
- Joint Boots Inspection
- General Lubrication
- Bolts and Nuts Tightening

FUEL SYSTEM (DFI)
- DFI System
- DFI System Wiring Diagram
- FI Indicator Light (LCD) [A]
- Vacuum Gauge Adapter:
- DFI Servicing Precautions
- Outline
- Special Tool -
- Sealant -
- Special Tool -
- DFI Diagnosis Flow Chart
- Inquiries to Rider
- NOTE
- Self-diagnosis Outline
- Self-diagnosis Procedures
- How to Read Service Codes
- How to Erase Service Codes
- Service Code Table
- Backups
- Throttle Sensor Removal/Adjustment
- Throttle Sensor Input Voltage Inspection
- Throttle Sensor Output Voltage Inspection
- Throttle Sensor Resistance Inspection
- Throttle Sensor Circuit
- CAUTION
- Inlet Air Pressure Sensor Removal
- Inlet Air Pressure Sensor Installation
- Inlet Air Pressure Sensor Input Voltage Inspection
- Inlet Air Pressure Sensor Output Voltage Inspection
- Inlet Air Pressure Sensor Circuit
- Inlet Air Temperature Sensor Removal/Installation
- Inlet Air Temperature Sensor Output Voltage Inspection
- Inlet Air Temperature Sensor Resistance Inspection
- Inlet Air Temperature Sensor Circuit
- Water Temperature Sensor Removal/Installation
- Water Temperature Sensor Output Voltage Inspection
- Water Temperature Sensor Resistance Inspection
- Water Temperature Sensor Circuit
- Start the engine and switch the diagnosis mode to Dealer 1 mode
- Crankshaft Sensor Removal/Installation
- Crankshaft Sensor Inspection
- Crankshaft Sensor Circuit
- Speed Sensor Removal
- Speed Sensor Installation
- Speed Sensor Inspection
- Input Voltage Inspection
- Output Voltage Inspection
- Speed Sensor Circuit
- Vehicle-down Sensor Removal
- Vehicle-down Sensor Installation
- Vehicle-down Sensor Inspection
- Vehicle-down Sensor Circuit
- Fuel Pump Relay Removal
- Fuel Pump Relay Inspection
- Fuel Pump Relay Circuit
- Ignition Coil ##1: Ignition Coil for Front Cylinder (Service Code
- Ignition Coil Removal/Installation
- Input Voltage Inspection
- Fuel Injector Removal
- Fuel Injector Installation
- Audible Inspection
- Fuel Injector Power Source Voltage Inspection
- Fuel Injector Output Voltage Inspection
- Injector Signal Test
- Injector Resistance Inspection
- Injector Unit Test
- Injector Fuel Line Inspection
- Fuel Injector Circuit
- Inspection Flow Chart
- Light Inspection
- FI Indicator Light (LCD) Circuit
- CAUTION
- ECU Removal
- ECU Installation
- ECU Power Supply Inspection
- ECU Power Source Circuit
- Fuel Pressure Inspection
- Special Tools -
- Fuel Flow Rate Inspection
- Fuel Pump Removal
- Fuel Pump Installation
- Fuel Pump Operation Inspection
- Fuel Pump Operating Voltage Inspection
- Pressure Regulator Removal
- Pump Screen, Fuel Filter Cleaning
- Fuel Pump Circuit
- Throttle Lever Free Play Inspection
- Throttle Lever Free Play Adjustment
- Throttle Case Removal/Disassembly
- Throttle Case Assembly/Installation
- Throttle Cable Installation
- Throttle Case Inspection
- Throttle Cable Lubrication and Inspection
- Idle Speed Inspection
- Throttle Body Assy Removal
- Throttle Body Assy Installation
- Throttle Body Assy Disassembly
- Throttle Body Assy Assembly
- Engine Vacuum Synchronization Inspection
- Engine Vacuum Synchronization Adjustment
- ISC Valve Removal
- ISC Valve Installation
- ISC Valve Inspection
- Air Cleaner Element Removal
- Air Cleaner Element Installation
- Air Cleaner Element Cleaning and Inspection
- Air Cleaner Housing Removal
- Air Cleaner Housing Installation
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tank Cleaning

COOLING SYSTEM
- Permanent type antifreeze is used as a coolant to protect the co
- Bearing Driver Set:
- Coolant Deterioration Inspection
- Coolant Level Inspection
- Coolant Draining
- Coolant Filling
- Pressure Testing
- Water Pump Cover Removal
- Water Pump Cover Installation
- Water Pump Impeller Removal
- Water Pump Impeller Installation
- Water Pump Impeller Inspection
- Water Pump Leakage Inspection
- Mechanical Seal Replacement
- Radiator Removal
- Radiator Installation
- Radiator Fan Removal
- Radiator Fan Installation
- Radiator Inspection
- Radiator Cleaning
- Radiator Cap Inspection
- Thermostat Removal
- Thermostat Installation
- Thermostat Inspection
- Water Temperature Sensor Removal/Installation
- Water Temperature Sensor Inspection

ENGINE TOP END
- Outside Circlip Pliers:
- Camshaft Chain Tensioner Removal
- Camshaft Chain Tensioner Installation
- Rocker Case Removal
- Special Tool -
- Rocker Case Installation
- Rocker Arm Removal
- Rocker Arm Installation
- Rocker Arm Inspection
- Rocker Shaft Diameter Measurement
- Camshaft Removal
- Camshaft Installation
- Camshaft Assembly
- Cam Wear Inspection
- Camshaft Bearing Wear Inspection
- KACR Inspection
- KACR Removal
- KACR Installation
- Camshaft Chain Removal
- Camshaft Chain Installation
- Camshaft Chain Guide Wear Inspection
- Cylinder Compression Measurement
- Special Tools -
- Cylinder Head Removal
- Cylinder Head Installation
- Cylinder Head Cleaning
- Cylinder Head Warp Inspection
- Valve Clearance Inspection
- Valve Clearance Adjustment
- Valve Removal
- Valve Installation
- Valve Guide Removal
- Valve Guide Installation
- Valve-to-Guide Clearance Measurement
- Valve Seat Inspection
- Valve Seat Repair (Valve Lapping)
- Cylinder Removal
- Piston Removal
- Cylinder, Piston Installation
- Cylinder Wear Inspection
- Piston Wear Inspection
- Piston/Cylinder Clearance Inspection
- Piston Ring, Piston Ring Groove Wear Inspection
- Piston Ring Groove Width Inspection
- Piston Ring Thickness Inspection
- Piston Ring End Gap Inspection
- This vehicle is equipped with a spark arrester approved for off-
- Spark Arrester Cleaning
- Muffler and Exhaust Pipe Removal
- Muffler and Exhaust Pipe Installation

CONVERTER SYSTEM
- Outside Circlip Pliers:
- WARNING
- Torque Converter Cover Removal
- Torque Converter Cover Installation
- Torque Converter Cover Disassembly
- Actuator Lever (Engine Brake Control Lever) Assembly Inspection
- Torque Converter Cover Assembly
- Drive Belt Removal
- Drive Belt Installation
- Drive Belt Deflection Inspection
- Drive Belt Deflection Adjustment
- Drive Belt Inspection
- Drive Pulley Removal
- Special Tool -
- Torque -
- Special Tools -
- Drive Pulley Disassembly
- Drive Pulley Inspection
- Spider Shoe Side Clearance Inspection/Adjustment
- Drive Pulley Assembly
- Drive Pulley Installation
- Driven Pulley Removal
- Special Tools -
- Driven Pulley Disassembly
- Driven Pulley Inspection
- Driven Pulley Assembly
- Driven Pulley Installation
- Specifications

ENGINE LUBRICATION SYSTEM
- Oil Pressure Gauge, 10 kgf/cm :
- WARNING
- Oil Level Inspection
- Engine Oil Change
- Oil Filter Change
- Oil Screen Removal
- Oil Screen Cleaning
- Oil Pressure Measurement
- Oil Pressure Switch Removal
- Oil Pressure Switch Installation
- Oil Pressure Relief Valve Removal
- Oil Pressure Relief Valve Installation
- Oil Pressure Relief Valve Inspection
- Oil Pump Removal
- Oil Pump Installation
- Oil Pipe Removal
- Oil Pipe Installation

ENGINE REMOVAL/INSTALLATION
- Engine Removal
- Engine Installation

CRANKSHAFT/TRANSMISSION
- Outside Circlip Pliers:
- Crankcase Disassembly
- Crankcase Assembly
- Crankshaft Removal
- Crankshaft Installation
- Connecting Rod Removal
- Connecting Rod Installation
- Crankshaft/Connecting Rod Cleaning
- Connecting Rod Bend Inspection
- Connecting Rod Twist Inspection
- Connecting Rod Big End Side Clearance Inspection
- Connecting Rod Big End Bearing/Crankpin Wear Inspection
- Crankshaft Runout Inspection
- Crankshaft Main Bearing/Journal Wear Inspection
- Shift Lever Removal
- Shift Lever Installation
- Transmission Removal
- Transmission Installation
- Shift Fork Bending Inspection
- Shift Fork/Gear and Shifter Groove Wear Inspection
- Transmission and Shift Mechanism Inspection
- Ball and Needle Bearing Replacement
- Special Tool -
- Ball and Needle Bearing Wear Inspection
- Oil Seal Inspection

WHEELS/TIRES
- Jack:
- Toe-in is the difference between the distance of front and the o
- Steering Centering Inspection
- Steering Centering Adjustment
- Toe-in Inspection
- Toe-in Adjustment
- Wheel Removal
- Special Tool -
- Wheel Installation
- Wheel (Rim) Inspection
- Wheel (Rim) Replacement
- Tire Removal
- Tire Installation
- Tire Inspection
- Front Hub Removal
- Front Hub Installation
- Front Hub Disassembly/Assembly
- Rear Hub Removal
- Rear Hub Installation
- Rear Hub Disassembly/Assembly

FINAL DRIVE
- Dummy Page
- Bearing Puller:
- Output Drive Bevel Gear Removal
- Special Tool -
- Output Drive Bevel Gear Installation
- Output Drive Bevel Gear Disassembly
- Output Drive Bevel Gear Assembly
- Output Driven Bevel Gear Removal
- Output Driven Bevel Gear Installation
- Output Driven Bevel Gear Disassembly
- Output Driven Bevel Gear Assembly
- Output Bevel Gears Adjustment
- Output Bevel Gear (Backlash-related Parts)
- Front Propeller Shaft Removal
- Front Propeller Shaft Installation
- Front Axle Removal
- Front Axle Installation
- Front Axle Joint Boot Inspection
- Front Axle Joint Boot Replacement
- Front Final Gear Case Oil Level Inspection
- Torque -
- Front Final Gear Case Oil Change
- Variable Differential Control Lever Play Inspection
- Variable Differential Control Lever Play Adjustment
- Variable Differential Control Lever Removal
- Variable Differential Control Lever Installation
- Variable Differential Control Cable Installation
- Variable Differential Control Cable Lubrication
- Variable Differential Control Cable Inspection

- Front Final Gear Case Removal
- Front Final Gear Case Installation
- Front Final Gear Case Disassembly
- Front Final Gear Case Coupling Inspection
- Front Final Gear Case Assembly
- Oil Seal Installation
- Ring Gear Disassembly
- Ring Gear Assembly
- LSD Clutch Torque Inspection
- Pinion Gear Unit Disassembly
- Pinion Gear Unit Assembly
- Front Final Bevel Gear Adjustment
- Front Final Gear Case (Backlash-related Parts)
- Correct Tooth Contact Pattern: No adjustment is required.
- Incorrect Tooth Contact Patterns (Example 1)
- Incorrect Tooth Contact Patterns (Example 2)
- Rear Propeller Shaft Removal
- Rear Propeller Shaft Installation
- Rear Propeller Shaft Joint Boot Inspection
- Rear Propeller Shaft Inspection
- Rear Axle Removal
- Rear Axle Installation
- Rear Axle Joint Boot Inspection
- Rear Axle Joint Boot Replacement
- Rear Final Gear Case Oil Level Inspection
- Torque -
- Rear Final Gear Case Oil Change
- Rear Final Gear Case Removal
- Rear Final Gear Case Installation
- Rear Final Gear Case Disassembly
- Rear Final Gear Case Right Cover Assembly
- Rear Final Gear Case Front Cover Assembly
- Rear Final Gear Case Assembly
- Rear Final Bevel Gear Adjustment
- Rear Final Gear Case (Backlash-related Parts)
- Ball or Needle Bearing Inspection
- Oil Seal Inspection

BRAKES
- Inside Circlip Pliers:
- WARNING
- Front Brake Fluid Recommendation
- Front Brake Fluid Level Inspection
- Front Brake Fluid Change
- Front Brake Line Air Bleeding
- Front Brake Master Cylinder Removal
- Front Brake Master Cylinder Installation
- Front Brake Master Cylinder Disassembly
- Front Brake Master Cylinder Assembly
- Front Master Cylinder Inspection (Visual Inspection)
- Front Brake Caliper Removal
- Front Brake Caliper Installation
- Front Brake Caliper Disassembly
- Front Brake Caliper Assembly
- Front Brake Caliper Piston and Cylinder Damage Inspection
- Front Brake Caliper Holder Shaft Wear Inspection
- Front Brake Pad Removal
- Front Brake Pad Installation
- Front Brake Pad Wear Inspection
- Front Brake Disc Cleaning
- Front Brake Disc Removal
- Front Brake Disc Installation
- Front Brake Disc Wear Inspection
- Front Brake Disc Runout Inspection
- Front Brake Hose Inspection
- Front Brake Hose Replacement
- Rear Brake Pedal Position Inspection
- Rear Brake Pedal Position Adjustment
- Rear Brake Lever Free Play Inspection
- Rear Brake Pedal Free Play Inspection
- Rear Brake Lever and Brake Pedal Free Play Adjustment
- Rear Brake Pedal Removal
- Rear Brake Pedal Installation
- Rear Brake Cable Removal
- Rear Brake Cable Installation
- Rear Brake Cable Lubrication
- Internal Wet Brake Disassembly
- Internal Wet Brake Assembly

SUSPENSION
- Inside Circlip Pliers:
- Front Shock Absorber Preload Adjustment
- Special Tool -
- Front Shock Absorber Removal
- Front Shock Absorber Installation
- Front Shock Absorber Inspection
- Front Shock Absorber Scrapping
- Rear Shock Absorber Preload Adjustment
- Rear Shock Absorber Removal
- Rear Shock Absorber Installation
- Rear Shock Absorber Inspection
- Rear Shock Absorber Scrapping
- Front Suspension Arm Removal
- Front Suspension Arm Installation
- Front Suspension Arm Disassembly
- Front Suspension Arm Assembly
- Rear Suspension Arm Removal
- Rear Suspension Arm Installation
- Rear Suspension Arm Disassembly
- Rear Suspension Arm Assembly
- Stabilizer Removal
- Stabilizer Installation

STEERING
- Inside Circlip Pliers:
- Steering Stem Removal
- Steering Stem Installation
- Steering Knuckle Removal
- Steering Knuckle Installation
- Steering Knuckle Bearing Removal
- Steering Knuckle Bearing Installation
- Tie-rod Removal
- Tie-rod Installation
- Tie-rod End Removal
- Tie-rod End Installation
- Steering Inspection
- Steering Stem Straightness Inspection
- Steering Bearing Sleeve Lubrication
- Steering Stem Clamp Inspection
- Steering Stem Bearing Inspection
- Steering Knuckle Bearing Inspection
- Tie-rod End Inspection
- Steering Knuckle Joint Inspection
- Handlebar Removal
- Handlebar Installation

FRAME
- Seat Removal
- Seat Installation
- Front Carrier Removal
- Front Carrier Installation
- Front Carrier Bracket Installation
- Rear Carrier Removal
- Rear Carrier Installation
- Rear Carrier Bracket Installation
- Front Fender Removal
- Front Fender Installation
- Rear Fender Removal
- Rear Fender Installation
- Middle Cover Removal
- Middle Cover Installation
- Storage Box Removal
- Storage Case Removal
- Storage Case Installation
- Left Side Cover Removal
- Left Side Cover Installation
- Right Side Cover Removal
- Right Side Cover Installation
- Electrical Parts Case Removal
- Electrical Parts Case Installation
- Front Guard Removal
- Front Guard Installation
- Front Bottom Guard Removal
- Front Bottom Guard Installation
- Engine Bottom Guard Removal
- Engine Bottom Guard Installation
- Rear Bottom Guard Removal
- Rear Bottom Guard Installation
- Left Footboard Removal
- Left Footboard Installation
- Right Footboard Removal
- Right Footboard Installation
- Footboard Bracket installation
- Trailer Hitch Bracket Removal
- Trailer Hitch Bracket Installation

ELECTRICAL SYSTEM
- Light/Dimmer Switch [A]
- Dummy Page
- Timing Light:
- There are a number of important precautions that should be taken
- Wiring Inspection
- Special Tool -
- Battery Removal
- Battery Installation
- Battery Activation
- Precautions
- Interchange
- Alternator Cover Removal
- Special Tool -
- Alternator Cover Installation
- Alternator Rotor Removal
- Alternator Rotor Installation

- Alternator Stator Removal
- Alternator Stator Installation
- Regulator/Rectifier Output Voltage Inspection
- Alternator Inspection
- Regulator/Rectifier Removal
- Regulator/Rectifier Installation
- Regulator/Rectifier Inspection
- Charging System Circuit
- WARNING
- Spark Plug Removal
- Spark Plug Installation
- Spark Plug Cleaning/Inspection
- Spark Plug Gap Inspection
- Ignition Coil Removal
- Ignition Coil Installation
- Ignition Coil Inspection
- Ignition Coil Primary Peak Voltage Inspection
- Crankshaft Sensor Removal
- Crankshaft Sensor Installation
- Crankshaft Sensor Inspection
- Crankshaft Sensor Peak Voltage Inspection
- Alternator Rotor Inspection
- Ignition Timing Test
- Ignition System Troubleshooting
- Ignition System Circuit
- Starter Motor Removal
- Starter Motor Installation
- Starter Motor Disassembly
- Starter Motor Assembly
- Brush Inspection
- Commutator Cleaning and Inspection
- Armature Inspection
- Brush Lead Inspection
- Right-hand End Cover Inspection
- Starter Relay Inspection
- Starter Control Relay Inspection
- Electric Starter Circuit
- Headlight Beam Vertical Adjustment
- Headlight Bulb Replacement
- Tail/Brake Light Bulb Replacement
- Tail/Brake Light Removal
- Lighting System Circuit
- Radiator Fan Motor Inspection
- Radiator Fan Breaker Inspection
- Radiator Fan Breaker Installation
- Radiator Fan Circuit
- Multifunction Meter Unit Removal
- Multifunction Meter Unit Inspection
- Drive Belt Failure Mode Memory Clearing Procedure
- Meter Circuit
- 2WD/4WD Actuator Removal
- 2WD/4WD Actuator Installation
- Engine Brake Actuator Removal
- Engine Brake Actuator Installation
- Actuator Control System Outline
- Actuator Control System
- Actuator Control System Circuit
- If the drive belt failure detection system activated by abnormal
- Drive Belt Failure Detection System Inspection
- Drive Belt Failure Detection System Circuit
- Fuel Level Sensor Inspection
- Special Tool -
- Fuel Level Sensor Circuit
- Relay Inspection
- Fuse Removal
- Fuse Installation
- Fuse Inspection

APPENDIX
- NOTE
- Engine Doesn't Start, Starting Difficulty:
- Poor Running at Low Speed:
- Poor Running or No Power at High Speed:
- Overheating:
- Over Cooling:
- Converter Operation Faulty:
- Gear Shifting Faulty:
- Abnormal Engine Noise:
- Abnormal Drive Train Noise:
- Abnormal Frame Noise:
- Exhaust Smokes Excessively:
- Handling and/or Stability Unsatisfactory
- Brake Doesn't Hold
- Kawasaki Engine Brake Control and Selectable 2WD/4WD System Malf
- Battery Discharged:
- Battery Overcharged: