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2012 KAWASAKI BRUTE FORCE KVF750GC Service Repair Manual .pdf



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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


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
○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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