DR ALL-TERRAIN Wartungshandbuch

BRUTE FORCE 750 4×4iKVF750 4×4All Terrain VehicleService Manual

ForewordThis manual is designed primarily for use bytrained mechanics in a properly equipped shop.However, it contains enough detail and basic in-form

3-36 FUEL SYSTEM (DFI)Self-Diagnosis•Connect the hand tester [A] as shown.•Set the tester to 5 mA range.Special Tool - Hand Tester: 57001-1394Connecti

FUEL SYSTEM (DFI) 3-37Self-Diagnosis

3-38 FUEL SYSTEM (DFI)Self-DiagnosisHow to Read Service Codes○Service codes are shown by a series of long and short flicks of the tester as shown belo

FUEL SYSTEM (DFI) 3-39Self-DiagnosisService Code TableServiceCodeFlicks of TesterProblems11Throttle sensor malfunction, wiringopen or short12Inlet air

3-40 FUEL SYSTEM (DFI)Self-DiagnosisBackups○The ECU takes the following measures to prevent engine damage when the DFI or the ignitionsystem parts hav

FUEL SYSTEM (DFI) 3-41Self-Diagnosisheavy, the ECU determines the injection quantity by calculating from the throttle opening (throttlesensor output v

3-42 FUEL SYSTEM (DFI)Throttle Sensor (Service Code 11)Throttle Sensor Removal/AdjustmentCAUTIONDo not remove or adjust the throttle sensor [A]since i

FUEL SYSTEM (DFI) 3-43Throttle Sensor (Service Code 11)If the input voltage is less than the standard, remove theECU and check the wiring between thes

3-44 FUEL SYSTEM (DFI)Throttle Sensor (Service Code 11)If the output voltage is normal, check the wiring for conti-nuity.○Disconnect the ECU and senso

FUEL SYSTEM (DFI) 3-45Throttle Sensor (Service Code 11)Throttle Sensor Circuit1. ECU (Electronic Control Unit)2. Throttle Sensor

GENERAL INFORMATION 1-11General InformationTable of ContentsBefore Servicing ...

3-46 FUEL SYSTEM (DFI)Inlet Ai r Pressure Sensor (Service Code 12)CAUTIONNever drop the sensor, especially on a hard surface.Such a shock to the part

FUEL SYSTEM (DFI) 3-47Inlet Air Pressure Sensor (Service Code 12)Inlet Air Pressure Sensor Output VoltageInspectionNOTE○The output voltage changes acc

3-48 FUEL SYSTEM (DFI)Inlet Ai r Pressure Sensor (Service Code 12)Suppose:Pg: Vacuum Pressure (gauge) to SensorPl: Local Atmospheric Pressure (absolut

FUEL SYSTEM (DFI) 3-49Inlet Air Pressure Sensor (Service Code 12)ID: IdlingPs: Standard Atmospheric Pressure (Absolute)Pv: Throttle Vacuum Pressure (A

3-50 FUEL SYSTEM (DFI)Inlet Ai r Pressure Sensor (Service Code 12)Inlet Air Pressure Sensor Circuit1. ECU (Electronic Control Unit)2. Inlet Air Pressu

FUEL SYSTEM (DFI) 3-51Inlet A ir Temperature Sensor (Service Code 13)Inlet Air Temperature Sensor Removal/InstallationCAUTIONNever drop the sensor, es

3-52 FUEL SYSTEM (DFI)Inlet Air Temperature S ensor (Service Code 13)Inlet Air Temperature Sensor ResistanceInspection•Remove the i nlet air temperatu

FUEL SYSTEM (DFI) 3-53Water Temperature Sensor (Service Code 14)Water Temperature Sensor Removal/InstallationCAUTIONNever drop the sensor, especially

3-54 FUEL SYSTEM (DFI)Water Temperature Sensor (Service Cod e 14)Water Temperature Sensor Output VoltageInspectionNOTE○Be sure the battery is fully ch

FUEL SYSTEM (DFI) 3-55Water Temperature Sensor (Service Code 14)Water Temperature Sensor Circuit1. ECU (Electronic Control Unit)2. Water Temperature S

1-2 GENERAL INFORMATIONBefore ServicingBefore starting to perform an inspection service or carry out a disassembly and reassembly oper-ation on a vehi

3-56 FUEL SYSTEM (DFI)Crankshaft Sensor (Service Code 21)Start the engine and switch the diagnosis mode to Dealer1 mode to know all the problem that t

FUEL SYSTEM (DFI) 3-57Speed Sensor (Service Code 24)Speed Sensor Removal•Refer to the Speed Sensor Removal in the Electrical Sys-tem chapter.Speed Sen

3-58 FUEL SYSTEM (DFI)Speed Sensor (Service Code 24)Output Voltage Inspection•Before this inspection, inspect the input voltage (see InputVoltage Insp

FUEL SYSTEM (DFI) 3-59Speed Sensor (Service Code 24)Speed Sensor Circuit1. ECU (Electronic Control Unit)2. Speed Sensor3. Engine Ground4. Multifunctio

3-60 FUEL SYSTEM (DFI)Vehicle-down Sensor (Service Code 31)Vehicle-down Sensor RemovalCAUTIONNever drop the vehicle-down sensor, especially ona hard s

FUEL SYSTEM (DFI) 3-61Vehicle-down Sensor (Service Code 31)•Remove the vehicle-down sensor (see Vehicle-downSensor Removal).○Do not disconnect the sen

3-62 FUEL SYSTEM (DFI)Vehicle-down Sensor (Service Code 31)Vehicle-down Sensor Circuit1. ECU (Electronic Control Unit)2. Vehicle-down Sensor

FUEL SYSTEM (DFI) 3-63Fuel Pump Relay (Service Code 46)Fuel Pump R elay Removal•Remove:Seat (see Seat Removal in the Frame chapter)Fuel Pump Relay [A]

3-64 FUEL SYSTEM (DFI)Fuel Pump Relay (Service Code 46)Fuel Pump Relay Circuit1. ECU (Electronic Control Unit)2. Fuel Pump Relay3. Engine Ground Termi

FUEL SYSTEM (DFI) 3-65Ignition Coils (#1, #2: Service Code 51, 52)Ignition Coil #1: Ignition Coil for Front Cylinder (ServiceCode 51)Ignition Coil #2:

GENERAL INFORMATION 1-3Before ServicingArrangement and Clea ning of Removed PartsDisassembled parts are easy to confuse. Arrange theparts according to

3-66 FUEL SYSTEM (DFI)Fuel InjectorsFuel Injector Removal•Remove:Air cleaner (see Air cleaner Housing Removal)Screw [A]Fuel Hose (from the Delivery Pi

FUEL SYSTEM (DFI) 3-67Fuel Injectors•Install the delivery pipe [A] on the throttle body assy.•Tighten:Torque - Delivery P ipe Mounting Screws [B]: 5.0

3-68 FUEL SYSTEM (DFI)Fuel InjectorsIf the meter doesn’t read as specified, check the following.Main Fuse 30 A (see Fuse Inspection in the ElectricalS

FUEL SYSTEM (DFI) 3-69Fuel InjectorsInjector Signal Test•Prepare two test light sets with terminals as shown.Rating of Bulb [A]: 12 V × (3 ∼ 3.4) WTer

3-70 FUEL SYSTEM (DFI)Fuel InjectorsInjector Unit Test•Use two leads [A] and the same test light set [B] as in“Injector Signal Test”.Rating of Bulb [C

FUEL SYSTEM (DFI) 3-71Fuel InjectorsFuel Injector Circuit1. Fuel Injector #12. Fuel Injector #23. Ignition Switch4. Fuse Box5. Fuel Pump Fuse 10 A6. M

3-72 FUEL SYSTEM (DFI)FI Indicator Light (LCD)Inspection Flow Chart

FUEL SYSTEM (DFI) 3-73FI Indicator Light (LCD)Light Inspection○The FI indicator light (LCD) [A] goes ON when the ignitionswitch is turned ON and the F

3-74 FUEL SYSTEM (DFI)ECUCAUTIONNever drop the ECU, especially on a hard surface.Such a shock to the ECU can damage it.ECU Removal•Remove:Seat (see Se

FUEL SYSTEM (DFI) 3-75ECU•Check the ECU power source voltage with a digital meter[A].○Position the terminal in accordance with terminal numbersof ECU

1-4 GENERAL INFORMATIONBefore ServicingTightening SequenceGenerally, when installing a part with several bolts, nuts,or screws, start them all in thei

3-76 FUEL SYSTEM (DFI)Fuel LineFuel Pressure InspectionNOTE○This inspection can determine which trouble the DFIsystem has, mechanical or electrical tr

FUEL SYSTEM (DFI) 3-77Fuel LineNOTE○The gauge needle will fluctuate. Read the pressure atthe average of the maximum and minimum indications.If the fue

3-78 FUEL SYSTEM (DFI)Fuel Line•Open the fuel tank cap [A] to lower the pressure in thetank.•Temporarily, install the ECU [A] and actuator controller[

FUEL SYSTEM (DFI) 3-79Fuel PumpFuel Pump RemovalCAUTIONNever drop the fuel pump, especially on a hard sur-face. Such a shock to the pump can damage it

3-80 FUEL SYSTEM (DFI)Fuel Pump•Remove:Fuel Pump Bolts [A]Plate [B]Fuel Pump [C]O-ringFuel Pump Installation•Remove dirt or dust from the fuel pump [A

FUEL SYSTEM (DFI) 3-81Fuel PumpFuel Pump Operation InspectionNOTE○Be sure the battery is fully charged.○Just listen to the pump sound in the fuel tank

3-82 FUEL SYSTEM (DFI)Fuel PumpPressure Regulator Removal○The pressure regulator [A] is built into the fuel pump [B]and cannot be removed.Pump Screen,

FUEL SYSTEM (DFI) 3-83Fuel PumpFuel Pump Circuit1. ECU (Electronic Control Unit)2. Fuel Pump Relay3. Engine Ground Terminal4. Battery 12 V 12 Ah5. Eng

3-84 FUEL SYSTEM (DFI)Throttle Lever and CableThrottle Lever Free Play Inspection•Refer to the Throttle Lever Free Play Inspection in thePeriodic Main

FUEL SYSTEM (DFI) 3-85Throttle Lever and Cable•Install the throttle case so that the projection [A] fit to thehole [B] of the handlebar.•Swing the thr

GENERAL INFORMATION 1-5Before ServicingPressFor items such as bearings or oil seals that must bepressed into place, apply small amount of oil to the c

3-86 FUEL SYSTEM (DFI)Throttle Body AssyIdle Speed Inspection•Refer to the Idle Speed Inspection in the Periodic Main-tenance c hapter.Throttle Body A

FUEL SYSTEM (DFI) 3-87Throttle Body Assy•Turn the throttle pully [A] clockwise to remove the throttlecable tip [B].•Loosen the l ocknut [C] and adjust

3-88 FUEL SYSTEM (DFI)Throttle Body Assy•Apply a thin coating of grease to the throttle cable lowerend.•Fit the throttle cable lower end [A] into the

FUEL SYSTEM (DFI) 3-89Throttle Body AssyThrottle Body Assy Assembly•Install the drain tube [A], if removed•Install the inlet air pressure sensor [B]•T

3-90 FUEL SYSTEM (DFI)Throttle Body Assy•Remove the bypass screw [A], spring [B], washer [C] andO-ring [D].○Check the bypass screw and its hole for ca

FUEL SYSTEM (DFI) 3-91ISC ValveISC Valve Removal•Remove:Front Fender (see Front Fender Removal in the Framechapter)ISC Valve Tube (Front) [A]ISC Valve

3-92 FUEL SYSTEM (DFI)Air CleanerAir Cleaner Elemen t Removal•Remove:Seat (see Seat Removal in the Frame chapter)Clips [A]Air Cleaner Housing Cap [B]•

FUEL SYSTEM (DFI) 3-93Air Cleaner•Remove:Screw [A]Air Intake Duct [B]Tube [C]ISC Valve Inlet Tube [D]•Remove:Tube [A]Air Cleaner Housing Bolts [B] (bo

3-94 FUEL SYSTEM (DFI)Air CleanerAir Cleaner Housing Installation•Install:Dust Seal [A]Air Cleaner Housing C over [B][C] Inside•Be sure to the inlet a

FUEL SYSTEM (DFI) 3-95Fuel TankFuel Tank RemovalWARNINGGasoline is extremely flammable and can be explo-sive under certain conditions. Make sure the a

1-6 GENERAL INFORMATIONBefore ServicingLubricationIt is important to lubricate rotating or sliding parts duringassembly to minimize wear during initia

3-96 FUEL SYSTEM (DFI)Fuel Tank•Remove the quick rivets [A] to speparate the fuel tank [B]and tank case [C].Fuel Tank Installation•Note the above WARN

FUEL SYSTEM (DFI) 3-97Fuel Tank•Install:Hose [A]Clamps [B]•Insert the fuel hose joint [A] straight onto the delivery pipeuntil the hose joint clicks.•

COOLING SYSTEM 4-14Cooling SystemTable of ContentsExploded View...

4-2 COOLING SYSTEMExploded View

COOLING SYSTEM 4-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1 Radiator Mounting Bolts 8.8 0.90 78 in·lb2 Radiator Screen Mounting Bolts 4.0

4-4 COOLING SYSTEMCoolant Flow ChartPermanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.When the engi

COOLING SYSTEM 4-5Coolant Flow Chart1. Radiator2. Radiator Cap3. Radiator Fan4. Water Temperature Switch5. Thermostat6. Cylinder7. Cylinder Head8. Wat

4-6 COOLING SYSTEMSpecificationsItem Standard Service LimitCoolant Provided when ShippingTypePermanent type of antifreeze (soft waterand ethylene glyc

COOLING SYSTEM 4-7Special ToolsBearing Driver Set:57001-1129Bearing Remover Shaft, 9:57001-1265Bearing Remover Head, 10 × 12:57001-1266

GENERAL INFORMATION 1-7Model IdentificationKVF750D8F Left Side ViewKVF750D8F Right Side ViewThe KVF750E is a camouflage-surface-treated model and iden

4-8 COOLING SYSTEMCoolantCoolant Deterioration Inspection•Remove:Left Footboard (see Left Footboard Removal in theFrame chapter)•Visually inspect the

COOLING SYSTEM 4-9CoolantPressure Testing•Remove:Front Fender (see Front Fender Removal in the Framechapter)•Remove the radiator cap, and install a co

4-10 COOLING SYSTEMWater PumpWater Pump Cover Removal•Drain the coolant (see Coolant Change in the PeriodicMaintenance chapter).•Remove:Radiator Hose

COOLING SYSTEM 4-11Water PumpWater Pump Impeller Inspection•Visually inspect the impeller [A].If the surface is corroded or the blades are damaged, re

4-12 COOLING SYSTEMWater Pump•Apply heat-resistance grease on the oil seal lip.•From outside the alternator cover, press and insert the oilseal [A] so

COOLING SYSTEM 4-13RadiatorRadiator RemovalWARNINGThe radiator fan is connected directly to the bat-tery. The radiator fan may start even if the ignit

4-14 COOLING SYSTEMRadiator•Pull the projections [A] out of from the dampers [B], andremove the radiator [C].CAUTIONDo not touch the radiator core. Th

COOLING SYSTEM 4-15Radiator•Remove:Radiator Fan Mounting Nut [A]Radiator Fan [B]Radiator Fan Installation•Install:Radiator FanRadiator Fan Mounting Nu

4-16 COOLING SYSTEMRadiator•Install the cap [A] on a cooling system pressure tester [B].NOTE○Wet the cap sealing surfaces with water or coolant toprev

COOLING SYSTEM 4-17ThermostatThermostat Removal•Drain the coolant (see Coolant Change in the PeriodicMaintenance chapter).•Remove:Front Fender (see Fr

1-8 GENERAL INFORMATIONModel IdentificationFrame Number[A] Frame Number[B] Left Front AxleEngine Number[A] Engine Number[B] Torque Converter Cover

4-18 COOLING SYSTEMThermostatThermostat Inspection•Remove the thermostat, and inspect the thermostat valve[A] at room temperature.If the valve is open

COOLING SYSTEM 4-19Water Temperature SensorWater Temperature Sensor Removal/InstallationCAUTIONThe water temperature sensor should never be al-lowed t

ENGINE TOP END 5-15Engine Top EndTable of ContentsExploded View... 5-2Specifications ...

5-2 ENGINE TOP ENDExploded View

ENGINE TOP END 5-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Rocker Case Bolts 55 mm (2.2 in.)8.8 0.90 78 in·lbS2 Rocker Case Bolts 130 mm (

5-4 ENGINE TOP ENDExploded View

ENGINE TOP END 5-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Camshaft Chain Tensioner Mounting Bolts8.8 0.90 78 in·lb2 Camshaft Chain Tensio

5-6 ENGINE TOP ENDExploded View

ENGINE TOP END 5-7Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Exhaust Pipe Cover Bolts8.8 0.90 78 in·lb2 Muffler Clamp Bolt 8.8 0.90 78 in·lb

GENERAL INFORMATION 1-9General SpecificationsItems KVF750D8F, E8F, F8FDimensionsOverall Length 2 195 mm (86.42 in.)Overall Width 1 166 mm (45.90 in.)O

5-8 ENGINE TOP ENDSpecificationsItem Standard Service LimitRocker CaseRocker Arm Inside Diameter12.000 ∼ 12.018 mm (0.4724 ∼ 0.4731 in.) 12.05 mm (0.4

ENGINE TOP END 5-9SpecificationsItem Standard Service LimitValve/Valve Guide Clearance(Wobble Method):Exhaust0.09 ∼ 0.17 mm (0.0035 ∼ 0.0067 in.) 0.37

5-10 ENGINE TOP ENDSpecial Tools and SealantOutside Circlip Pliers:57001-144Compression Gauge, 20 kgf/cm²:57001-221Valve Spring Compressor Assembly:57

ENGINE TOP END 5-11Special Tools and SealantValve Spring Compressor Adapter, 22:57001-1202Valve Guide Arbor, 5:57001-1203Valve Guide Reamer, 5:57001-1

5-12 ENGINE TOP ENDCamshaft Chain TensionerCamshaft Chain Tensioner RemovalCAUTIONThis is a non-return type cam chain tensioner. Thepush rod does not

ENGINE TOP END 5-13Camshaft Chain TensionerCamshaft Chain Tensioner I nstallation•Push the stopper [A] to release the ratchet and push thepush rod [B]

5-14 ENGINE TOP ENDRocker CaseRocker Case RemovalFront Rocker Case•Remove:Front Fender (see Front Fender Removal in the Framechapter)Alternator Outer

ENGINE TOP END 5-15Rocker Case•Insert a suitable bar [A] under the front of the engine.•Lift [A] the front of the engine to remove the bolt [B] of the

5-16 ENGINE TOP ENDRocker Case•Apply silicone sealant to the outer surface of the cap [A]and the cylinder head upper surface [B] as shown.Sealant - Ka

ENGINE TOP END 5-17Rocker Case•Using a M8 bolt [A], remove the rocker shaft [B].•Remove:Rocker Arm [C]Washers [D]○Mark and record the rocker arm locat

1-10 GENERAL INFORMATIONGeneral SpecificationsItems KVF750D8F, E8F, F8FEngine oil:Type API SF or SGAPI SH, SJ or SL with JASO MAViscosity SAE 10W-40Ca

5-18 ENGINE TOP ENDRocker CaseRocker Shaft Diameter Measurement•Measure the diameter [A] of the rocker shaft where therocker arm pivots on it with a m

ENGINE TOP END 5-19CamshaftCamshaft Removal•Remove:Camshaft C hain Tensioners (see Camshaft Chain Ten-sioner Removal)Rocker Cases (see Rocker Case Rem

5-20 ENGINE TOP ENDCamshaft•Face the arrow [A] of the front camshaft sprocket upward(right side view).•Engage the front camshaft chain with the front

ENGINE TOP END 5-21CamshaftCamshaft Bearing Wear Inspection○The journal wear is measured using plastigage (pressgauge), which is inserted into the cle

5-22 ENGINE TOP ENDCamshaftKACR InspectionThe Kawasaki Automatic Compression Release (KACR)momentarily opens the exhaust valves on the compressionstro

ENGINE TOP END 5-23Camshaft•Remove:Circlips [A]Weights [B]Spring [C]NOTE○Do not remove the shaft [A] and pin [B].○If the parts are removed, they canno

5-24 ENGINE TOP ENDCamshaft•Remove (right side view):Torque Converter C over (see Torque Converter CoverRemoval in the Converter System chapter)•Using

ENGINE TOP END 5-25CamshaftFront Camshaft Chain•Install the circlip [A].Special Tool - Outside Circlip Pliers: 57001-144•Rotate the crankshaft clockwi

5-26 ENGINE TOP ENDCamshaft•Install the intermediate shaft chain tensioner [A] as fol-lows:•Release the stopper [B] and push the push rod [C] intothe

ENGINE TOP END 5-27Camshaft•Install:Rocker Cases (see Rocker Case Installation)Camshaft Chain Tensioners (see Camshaft Chain Ten-sioner Installation)•

GENERAL INFORMATION 1-11General SpecificationsItems KVF750D8F, E8F, F8FRim Size:Front 12 × 6.0Rear 12 × 7.5Front tire:Type TubelessSize AT25 × 8-12Rea

5-28 ENGINE TOP ENDCylinder HeadCylinder Compression Mea surementNOTE○Use the battery which is fully charged.•Warm up the engine thoroughly, and stop

ENGINE TOP END 5-29Cylinder HeadCylinder Head Removal•Drain the coolant (see Coolant Change in the PeriodicMaintenance chapter).•Remove:Throttle Body

5-30 ENGINE TOP ENDCylinder Head•Apply molybdenum disulfide oil to the threads and seatingsurface of the cylinder head bolts and both sides of thewash

ENGINE TOP END 5-31ValvesValve Clearance Inspe ction•Refer to the Valve Clearance Inspection in the PeriodicMaintenance chapter.Valv e Clearance Adjus

5-32 ENGINE TOP ENDValvesValve Guide Installation•Lightly oil the valve guide outer surface.•Using the valve guide arbor [A], drive the valve guide [B

ENGINE TOP END 5-33ValvesValve Seat Inspection•Remove the valve (see Valve Removal).•Check the valve seating surface [A] between the valve [B]and valv

5-34 ENGINE TOP ENDValvesSeat Cutter Operation Care1. This valve seat cutter is developed to grind the valveseat for repair. Therefore the cutter must

ENGINE TOP END 5-35ValvesWidened Width [A] of engagement by machining with45° cutterGround Volume [B] by 32° cutter32° [C]Correct Width [D]Ground Volu

5-36 ENGINE TOP ENDValvesIf the seat width is too wide, make the 60° [A] grind de-scribed below.If the seat width is within the specified range, lap t

ENGINE TOP END 5-37Valves

1-12 GENERAL INFORMATIONUnit Conversion TablePrefixes for Units:Prefix SymbolPowermega M × 1 000 000kilo k × 1 000centi c ×0.01milli m × 0.001micro µ

5-38 ENGINE TOP ENDCylinder and PistonCylinder Removal•Remove:Cylinder Head (see Cylinder Head Removal)Oil Pipe [A]Chain Guide [B]Cylinder Bolts [C]Cy

ENGINE TOP END 5-39Cylinder and PistonNOTE○The oil ring rails have no “top” or “bottom”.•Install the oil ring expander [A] in the bottom piston ringgr

5-40 ENGINE TOP ENDCylinder and Piston•Install:Cylinder [A]•Tighten:Torque - Cylinder Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb)•Install:Chain Guide [C]

ENGINE TOP END 5-41Cylinder and PistonPiston Ring, Piston Ring Groove Wear Inspection•Check for uneven groove wear by inspecting the ring seat-ing.The

5-42 ENGINE TOP ENDCylinder and PistonPiston Ring End Gap Inspection•Place the piston ring [A] inside the cylinder, using the pis-ton to locate the ri

ENGINE TOP END 5-43Exhaust SystemThis vehicle is equipped with a spark arrester approvedfor off-road use by the United States Forest Service. It mustb

5-44 ENGINE TOP ENDExhaust System•Remove:Front Exhaust Pipe Nuts [A]•Move the front exhaust pipe rear end [A] under the fueltank.•Move the front exhau

ENGINE TOP END 5-45Exhaust System•If the muffler cover [A], rear and middle exhaust pipe cov-ers [B] [C] are removed, tighten them.Torque - Muffler Co

CONVERTER SYSTEM 6-16Converter S ystemTable of ContentsExploded View...

PERIODIC MAINTENANCE 2-12Periodic MaintenanceTable of ContentsPeriodic Maintenance Chart ...

6-2 CONVERTER SYSTEMExploded View

CONVERTER SYSTEM 6-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1 Drive Pulley Bolt 93 9.5 68 R, Lh2 Driven Pulley Nut 93 9.5 683 Drive Pulley

6-4 CONVERTER SYSTEMExploded View

CONVERTER SYSTEM 6-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Torque Converter Cover Bolts8.8 0.90 78 in·lbS2 Engine Brake Actuator Mountin

6-6 CONVERTER SYSTEMSpecificationsItem Standard Service LimitTorque ConverterActuator Lever Guide S hoe ––– 6 mm (0.24 in.)Drive BeltBelt Width29.7 ∼

CONVERTER SYSTEM 6-7Special ToolsOutside Circlip Pliers:57001-144Drive & Driven Pulley Holder:57001-1412Drive Pulley Puller Bolt:57001-1429Pulley

6-8 CONVERTER SYSTEMSpecial ToolsFlywheel & Pulley Holder:57001-1605

CONVERTER SYSTEM 6-9Torque Converter CoverWARNINGExcessive imbalance or operating rpm could causetorque converter pulley failure resulting in severein

6-10 CONVERTER SYSTEMTorque Converter CoverTorque Converter Cover Installation•Check the actuator lever assembly installation length (seeTorque Conver

CONVERTER SYSTEM 6-11Torque Converter CoverActuator Lever (Engine Brake Control Lever)Assembly Inspection•Refer to the Actuator Lever (Engine Brake Co

2-2 P ERIODIC MAINTENANCERear Brake Lever and Pedal Free Play Adjustment ... 2-35Steering ...

6-12 CONVERTER SYSTEMTorque Converter CoverActuator Lever AssembliesPart NumberPaint Color [A]Length [B]13236-0046 Yellow0.4 ±0.1 mm (0.016 ±0.004 in.

CONVERTER SYSTEM 6-13Drive BeltDrive Belt Removal•Remove the drive pulley (see Drive Pulley Removal).NOTE○Before removing, observe the direction the b

6-14 CONVERTER SYSTEMDrive P ulleyDrive Pulley Removal•Remove:Torque Converter C over (see Torque Converter CoverRemoval)Right Footboard (see Right Fo

CONVERTER SYSTEM 6-15Drive Pulley•Set the pulley onto the pulley holder.•Remove:Drive Pulley Cover Bolts [A]Drive Pulley Cover [B]•Remove:Spring [A]Sp

6-16 CONVERTER SYSTEMDrive P ulleyDrivePulleyInspectionIf the sheave surfaces [A] appear damaged, replace thesheaves.If the cover bushing is damaged o

CONVERTER SYSTEM 6-17Drive PulleyIf the rollers [A] are damaged or worn, replace the spider[B].If the washers [C] are damaged or worn, replace the spi

6-18 CONVERTER SYSTEMDrive P ulley•Turn the m ovable sheave counterclockwise.•Measure the resulting clearance [A] between the shoe [B]and the post [C]

CONVERTER SYSTEM 6-19Drive Pulley•Hold the fixed sheave [A] with the drive pulley holder [B]in a vise.Special Tool - Drive & Driven Pulley Holder:

6-20 CONVERTER SYSTEMDrive P ulley•Install the drive pulley, stepped waster and two washerson the drive pulley bolt as shown.Crankcase Side [A]Stepped

CONVERTER SYSTEM 6-21Drive Pulley○Install the drive pulley measurement tool (legs [A] andplate [B]) on the crankcase [C].Special Tool - Drive Pulley M

PERIODIC MAINTENANCE 2-3Periodic Maintenance ChartThe scheduled maintenance must be done in accordance with this chart to keep the vehicle in goodrunn

6-22 CONVERTER SYSTEMDriven PulleyDriven Pulley Removal•Remove:Torque Converter C over (see Torque Converter CoverRemoval)Drive Pulley (see Drive Pull

CONVERTER SYSTEM 6-23Driven Pulley•Confirm the paint mark “0” [A] on the movable sheave [B]in alignment with the point [C] on the fixed sheave [D] for

6-24 CONVERTER SYSTEMDriven PulleyIf the sheave bushings [A] are damaged or worn, replacethe movable sheave.Sheave Bushing Inside DiameterStandard: 40

CONVERTER SYSTEM 6-25Driven Pulley•Align the paint mark “0” [A] on the movable sheave [B]with the point [C] on the fixed sheave [D] for phase fit ofth

6-26 CONVERTER SYSTEMDriven Pulley•Hold the drive & driven pulley holder in a vise.Special Tool - Drive & Driven Pulley Holder: 57001-1473•Scr

CONVERTER SYSTEM 6-27Driven Pulley•Install two washers [A] on the s haft as shown.Crankcase Side [B]Bolt Head Side [C]•Using the flywheel & pulley

6-28 CONVERTER SYSTEMHigh Altitude Setting InformationSpecificationsAltitude Drive Pulleym (ft) Ramp Weights Spring Spacer (qty)(1)0 ∼ 2 000(0 ∼ 6 500

ENGINE LUBRICATION SYSTEM 7-17Engine Lubrication SystemTable of ContentsExploded View...

7-2 ENGINE LUBRICATION SYSTEMExploded View

ENGINE LUBRICATION SYSTEM 7-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Oil Filter17.5 1.8 13 R2 Oil Pressure Switch 15 1.5 11 SS3 Oil Pipe

2-4 P ERIODIC MAINTENANCEPeriodic Maintenance ChartFREQUENCY FirstServiceRegular ServiceOPERATIONAfter 10hrs. or100 km(60 mi.)of useEvery10days or200

7-4 ENGINE LUBRICATION SYSTEMSpecificationsItem StandardEngine OilType API SF or SGAPI SH, SJ or SL with JASO MAViscosity SAE 10W-40Capacity 2.1 L (2.

ENGINE LUBRICATION SYSTEM 7-5Special Tools & SealantOil Pressure Gauge, 10 kgf/cm²:57001-164Oil Pressure Gauge Adapter, PT 1/8:57001-1033Kawasaki

7-6 ENGINE LUBRICATION SYSTEMEngine Oil Flow Chart1. Front Camshaft2. Oil Filter3. Crankshaft4. Oil Pressure Switch5. Oil Pipes6. Oil Pump7. Relief Va

ENGINE LUBRICATION SYSTEM 7-7Engine Oil and Oil FilterWARNINGVehicle operation with insufficient, deteriorated,or contaminated engine oil will cause a

7-8 ENGINE LUBRICATION SYSTEMEngine Oil and Oil FilterOil Screen Cleaning•Clean the oil screen [A] thoroughly whenever it is removedfor any reason.•Cl

ENGINE LUBRICATION SYSTEM 7-9Oil Pressure SwitchOil Pressure Switch Removal•Drain:Engine Oil (see Engine Oil Change in the Periodic Main-tenance c hap

7-10 ENGINE LUBRICATION SYSTEMOil Pressure Relief ValveOil Pressure Relief Valve Removal•Split the crankcase (see Crankcase Disassembly in theCranksha

ENGINE LUBRICATION SYSTEM 7-11Oil PumpOil Pump Removal•Remove:Alternator Rotor (see Alternator Rotor Removal in theElectrical System chapter)Oil P ump

7-12 ENGINE LUBRICATION SYSTEMOil Pump•Install the oil pump drive chain [A] with the oil pump as-sembly [B].•Tighten:Torque - Oil Pump Cover Bolts [C]

ENGINE LUBRICATION SYSTEM 7-13Oil PipeOil Pipe RemovalEngine Left Side Oil Pipe (Engine Inside)•Remove:Oil Pump (see Oil Pump Removal)Oil Pipe Bolt [A

PERIODIC MAINTENANCE 2-5Torque and Locking AgentThe following tables list the tightening torque for the major fasteners, and the parts requiring use o

7-14 ENGINE LUBRICATION SYSTEMOil PipeOil Pipe Installat ion•Replace the O-ring [A] with new ones.•Apply engine oil to the O-rings before installation

ENGINE REM OVAL/INSTALLATION 8-18Engine Removal/InstallationTable of ContentsExploded View...

8-2 ENGINE REMOVAL/INSTALLATIONExploded View

ENGINE REMOVAL/INSTALLATION 8-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1 Engine Mounting Bracket Bolts 72 7.3 53 L2 Engine Mounting Bolts

8-4 ENGINE REMOVAL/INSTALLATIONEngine Removal/InstallationEngine Removal•Remove:Engine Oil (drain) (see Engine Oil Change in the PeriodicMaintenance c

ENGINE REMOVAL/INSTALLATION 8-5Engine Removal/Installation•Remove:Ignition Coil [A] (rear)Spark Plug Cap [B]Shift Shaft Lever [C]Breather Hose [D]Engi

8-6 ENGINE REMOVAL/INSTALLATIONEngine Removal/Installation•Remove the engine [A] as shown.Engine Installation•Apply a non-permanent locking agent to t

CRANKSHAFT/TRANSMISSION 9-19Crankshaft/TransmissionTable of ContentsExploded View...

9-2 CRANKSHAFT/TRANSMISSIONExploded View

CRANKSHAFT/TRANSMISSION 9-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Connecting Rod Big End Cap Nuts34.3 3.5 25MO2 Engine Oil Drain Bolt 20

2-6 P ERIODIC MAINTENANCETorque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksRocker Shaft Bolts 22 2.2 16Valve Adjusting Screw Locknuts 12 1.2

9-4 CRANKSHAFT/TRANSMISSIONExploded View

CRANKSHAFT/TRANSMISSION 9-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Grip Holder Nut9.8 1.0 87 in·lb2 Shift Lever Guide Mounting Bolts 19.6

9-6 CRANKSHAFT/TRANSMISSIONSpecificationsItem Standard Service LimitCrankshaft, Connecting RodsConnecting Rod Bend–––TIR 0.2/100 mm(0.008/3.94 in.)Con

CRANKSHAFT/TRANSMISSION 9-7SpecificationsItem Standard Service LimitTransmissionShift Fork Ear Thickness5.9 ∼ 6.0 mm(0.232 ∼ 0.236 in.)5.8 m m(0.23 in

9-8 CRANKSHAFT/TRANSMISSIONSpecial Tools and SealantOutside Circlip Pliers:57001-144Bearing Driver Set:57001-1129Crankshaft Jig:57001-1174Kawasaki Bon

CRANKSHAFT/TRANSMISSION 9-9CrankcaseCrankcase Disassembly•Remove:Engine (see Engine Removal in the Engine Removal/In-stallation chapter)Starter Motor

9-10 CRANKSHAFT/TRANSMISSIONCrankcase•Remove the following parts from the right crankcase half.Transmission Shafts and Shift Rod [A] (see Transmis-sio

CRANKSHAFT/TRANSMISSION 9-11Crankcase•Install:Rear Cylinder Camshaft Chain Guide [A]•Tighten:Torque - Rear Cylinder Camshaft Chain Guide Bolt [B]: 20N

9-12 CRANKSHAFT/TRANSMISSIONCrankcase•Apply a non-permanent locking agent to the area [C] (12mm, 0.47 in.) except for the tip [D] (2 ∼ 3 mm, 0.08 ∼ 0.

CRANKSHAFT/TRANSMISSION 9-13Crankshaft/Connection RodCrankshaft Removal•Split the crankcase (see Crankcase Disassembly).•Remove the crankshaft [A] fro

PERIODIC MAINTENANCE 2-7Torque and Locking AgentTorqueFastenerN·mkgf·m ft·lbRemarksCrankcase Bolts (M8) 75 mm (2.95 in.)20 2.0 15SCrankcase Bolts (M8)

9-14 CRANKSHAFT/TRANSMISSIONCrankshaft/Connection Rod•Apply molybdenum disulfide oil:Threads [A] of Connecting Rod Big End Cap BoltsSeating Surface [B

CRANKSHAFT/TRANSMISSION 9-15Crankshaft/Connection RodConnecting Rod Big End Side ClearanceInspection•Measure the side clearance of the connecting rod

9-16 CRANKSHAFT/TRANSMISSIONCrankshaft/Connection RodIf the measured crankpin diameter [A] is not less thanthe service limit, but does not coincide wi

CRANKSHAFT/TRANSMISSION 9-17Crankshaft/Connection RodCrankshaft Runout Inspec tion•Measure the crankshaft runout.If the measurement exceeds the servic

9-18 CRANKSHAFT/TRANSMISSIONTransmissionShift Lever Removal•Set the shift lever in the neutral position.•Remove:Right Side Cover (see Right Side Cover

CRANKSHAFT/TRANSMISSION 9-19TransmissionShift Lever Installation•Twist the tie-rod end [A] and tie-rod end locknut [B] tobottom of the screw and then

9-20 CRANKSHAFT/TRANSMISSIONTransmission•Install:Guide [A]•Tighten:Torque - Shift Lever Guide Mounting Bolts [B]: 19.6 N·m(2.0 kgf·m, 14 ft·lb)•Set th

CRANKSHAFT/TRANSMISSION 9-21Transmission○Do not lean the tie-rod rear end after tightening the frontlocknut.Right [L]Wrong [M]•Check that the shift le

9-22 CRANKSHAFT/TRANSMISSIONTransmission•Remove:Circlip [A]Special Tool - Outside Circlip Pliers: 57001-144•Remove:Spacer [A]Idle Gear Assembly [B]Was

CRANKSHAFT/TRANSMISSION 9-23Transmission•Install:Idle Shaft [A] with Gear Assembly [B]Spacer [C]Spacer [D] (P/No. 92026-1599, 48.2 × 54.3 × 1.0)•Apply

This quick reference guide will assistyou in locating a desired topic or pro-cedure.•Bend the pages back to match theblack tab of the desired chapter

2-8 P ERIODIC MAINTENANCETorque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksFront Final Gear Case Center Cover Bolts (M6) 9.8 1.0 87 in·lb LF

9-24 CRANKSHAFT/TRANSMISSIONTransmission•Apply molybdenum disulfide oil to the shift shaft [A].•Install:Shift Shaft Spring Bolt [B]Spring [C]Guide [D]

CRANKSHAFT/TRANSMISSION 9-25TransmissionTransmission and Shift Mechanism Inspection•Visually inspect:GearsDogs of Gear and ShifterIf they are damaged

9-26 CRANKSHAFT/TRANSMISSIONTransmission1. Driven Shaft2. Spacer (17.3 × 30 × 2.0)3. Reverse Gear (12T)4. Spacer (21.2 × 29 × 1.6)5. Shifter6. Circlip

CRANKSHAFT/TRANSMISSION 9-27Ball Bearing, Needle Bearing, and Oil SealBall and Needle Bearing ReplacementCAUTIONDo not remove the ball or needle beari

WHEELS/TIRES 10-110Wheels/TiresTable of ContentsExploded View...

10-2 WHEELS/TIRESExploded View

WHEELS/TIRES 10-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1 Tie-rod Locknuts 37 3.8 272 Wheel Nuts (First Torque) 15 1.5 11 S2Wheel Nuts (F

10-4 WHEELS/TIRESSpecificationsItem Standard Service LimitWheel AlignmentToe-in of front wheels: –10 ∼ 10 mm (–0.39 ∼ 0.39 in.) at 1G –––Wheels (Rims)

WHEELS/TIRES 10-5Special ToolJack:57001-1238

PERIODIC MAINTENANCE 2-9Torque and Locking AgentTorqueFastenerN·mkgf·m ft·lbRemarksSteering Knuckle Joint Nuts29 3.0 21Rear Shock Absorber Mounting Nu

10-6 WHEELS/TIRESWheel AlignmentToe-in is the difference between the distance of front andthe one of rear at the axle height position i n the front wh

WHEELS/TIRES 10-7Wheel Ali gnment•Repeat the straightedge procedure on the other side ofthe vehicle. Now the front wheels are parallel to eachother an

10-8 WHEELS/TIRESWheel AlignmentNOTE○The toe-in will be near the specified value, if the tie-rodlength [A] is 388.5 mm (15.30 in.) on each tie-rod.CAU

WHEELS/TIRES 10-9Wheels (Rims)Wheel Removal•Squeeze the brake lever slowly and hold it with a band[A].•Loosen the wheel nuts [A].•Support the vehicle

10-10 WHEELS/TIRESWheels (Rims)Wheel (Rim) Inspection•Examine both sides of the rim for dents [A]. If the rim isdented, replace it.If the tire is remo

WHEELS/TIRES 10-11TiresTire Removal•Remove the w heel.•Unscrew the valve core to deflate the tire.○Use a proper valve core tool [A].•Lubricate the tir

10-12 WHEELS/TIRESTires•Support the wheel rim [A] on a suitable stand [B] to pre-vent the tire from slipping off.•Inflate the tire until the tire bead

WHEELS/TIRES 10-13Front HubFront Hub Removal•Remove:Cap [A]Cotter Pin [B] (cut)•Loosen the axle nut [C].•Remove the front wheel (see Wheel Removal).•R

10-14 WHEELS/TIRESFront H ub•Bend the cotter pin [A] over the nut.Front Hub Disassembly/AssemblyIf any hub bolt [A] is damaged, replace the hub [B] an

WHEELS/TIRES 10-15Rear HubRear Hub Removal•Remove:Cap [A]Cotter Pin [B]•Loosen the axle nut [C].•Remove:Wheel (see Wheel Removal)Axle Nut [A]Rear Hub

2-10 PERIODIC MAINTENANCETorque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksForward/Reverse Detecting Sensor Mounting Bolt 15 1.5 11Speed Sen

10-16 WHEELS/TIRESRear HubRear Hub Disassembly/Ass emblyIf any hub bolt [A] is damaged, replace the hub [B] andbolts as a unit.•Remove the hub bolt fr

FINAL DRIVE 11-111Final DriveTable of ContentsExploded View...

11-2 FINAL DRIVERear Propeller Shaft Inspection... 11-53Rear Axle

FINAL DRIVE 11-3Exploded ViewDummy Page

11-4 FINAL DRIVEExploded View

FINAL DRIVE 11-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Output Driven Bevel Gear Housing Bolts26 2.6 202 Output Drive Bevel Gear Housing

11-6 FINAL DRIVEExploded View

FINAL DRIVE 11-7Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Variable Differential Control Shift Shaft Lever Bolt8.8 0.90 78 in·lb2 Front Fina

11-8 FINAL DRIVEExploded View

FINAL DRIVE 11-9Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Rear Final Gear Case Front Cover Bolts24 2.4 182 Rear Final Gear Case Gasket Scre

PERIODIC MAINTENANCE 2-11SpecificationsItem Standard Service LimitFuel SystemThrottle Lever Free Play 2 ∼ 3mm(0.08∼ 0.12 in.) –––Idle Speed 1 100 ±50

11-10 F INAL DRIVESpecificationsItem Standard Service LimitOutput Bevel Gear CaseOutput Bevel Gear Backlash 0.05 ∼ 0.11 mm (0.0020 ∼ 0.0043 in.) –––(a

FINAL DRIVE 11-11Special ToolsBearing Puller:57001-135Steering Stem Bearing Driver:57001-137Inside Circlip Pliers:57001-143Outside Circlip Pliers:5700

11-12 F INAL DRIVESpecial ToolsSocket Wrench, Hex 50:57001-1478Output Shaft Ho l der & Spacer, m1. 25:57001-1479Nut Holding Bolts:57001-1481Socket

FINAL DRIVE 11-13Special ToolsOilSealDriver, 70:57001-1506Output Shaft Hol d er:57001-1570

11-14 F INAL DRIVEOutput Bevel GearsOutput Drive Bevel Gear Remov al•Remove:Oil Pipe [A] (Engine Left and Outside, see Oil Pipe Re-moval in the Engine

FINAL DRIVE 11-15Output B evel Gears•Apply grease:O-rings [A]•Install:Output Drive Bevel Gear Cover [B]Oil Pipe (see Oil Pipe Installation in the Engi

11-16 F INAL DRIVEOutput Bevel Gears•Hold the output drive bevel gear housing [A] in a vise.•Loosen the bevel gear [B] using an Allen wrench aboutfour

FINAL DRIVE 11-17Output B evel GearsOutput Drive Bevel Gear Assembly•Press the new inner ball bearing until it is bottomed.Special Tool - Bearing Driv

11-18 F INAL DRIVEOutput Bevel Gears•Tap lightly the front end [A] of the output driven bevel gearshaft using a plastic mallet.○The output driven beve

FINAL DRIVE 11-19Output B evel Gears•Hold the housing assembly [A] with the holder [B] in avise.Special Tool - Holder & Guide Arbor: 57001-1476•Re

2-12 PERIODIC MAINTENANCESpecificationsItem Standard Service LimitFinal DriveFront Final Gear Case:Gear Case Oil:TypeAPI SF or SG–––API SH, SJ or SL w

11-20 F INAL DRIVEOutput Bevel Gears•Apply a non-permanent locking agent to the threads ofthe bearing holder [A] and tighten it.Special Tool - Socket

FINAL DRIVE 11-21Output B evel GearsOutput Bevel Gear (Backlash-related Parts)1. Ball Bearings2. Drive Bevel Gear Shims3. Output Drive Bevel Gear4. Be

11-22 F INAL DRIVEOutput Bevel GearsBevel Gear Backlash Adjustment○The amount of backlash is influenced by driven bevel gearposition more than by driv

FINAL DRIVE 11-23Output B evel GearsExample 1: Decrease the thickness of the drive bevel gearshim(s) by 0.1 mm (0.004 in.), and/or increase the thickn

11-24 F INAL DRIVEOutput Bevel GearsBevel Gears Inspection•Visually check the bevel gears [A] for scoring, chipping,or other damage.Replace the bevel

FINAL DRIVE 11-25Front Propeller ShaftFront Propeller Shaft Removal•Slip the O-ring clamps [A] off the grooves on the smallrubber boots [B], and then

11-26 F INAL DRIVEFront A xleFront Axle Removal•Drain the front final gear case oil (see Front Final GearCase Oil Change in the Periodic Maintenance c

FINAL DRIVE 11-27Front Axle•Tap the bearing housing [A] straight [B] with a plastic ham-mer to separate it from the shaft.CAUTIONDo not tap on the cag

11-28 F INAL DRIVEFront A xle○Tighten the boot band [A] and bend the tangs [B] securelyto hold down the end of the band.•Place the special grease tube

FINAL DRIVE 11-29Front AxleLeft Front Axle: 108.7 mm (4.28 in.) [A]•Open the edge [A] of the boot in order to equalize the airpressures.•Tighten the l

PERIODIC MAINTENANCE 2-13Special ToolsOil Filter Wrench:57001-1249Filler Cap Driver:57001-1454Pulley Holder Attachment:57001-1472Flywheel & Pulley

11-30 F INAL DRIVEFront A xle•Remove the steel balls [A].•Slide the cage [B] toward the center of the axle.•Tap the inner race [A] straight with a pla

FINAL DRIVE 11-31Front Axle•Slide the cage [A] on the inner race and install the steelballs [B].•Apply the special grease [A] to the steel balls and c

11-32 F INAL DRIVEFront A xle•Tighten the small band.•Squeeze the remaining special grease [A] into the inboardjoint boot [B].•Compress the axle assem

FINAL DRIVE 11-33Front Final Gear CaseFront Final Gear Case Oil Level Inspection•Park the vehicle so that it is level, both side-to-side andfront-to-r

11-34 F INAL DRIVEFront Final Gear CaseVariable Differential Control Lever I nstallation•Install:Variable Differential Control Cable Upper EndVariable

FINAL DRIVE 11-35Front Final Gear CaseVariable Differential Control Cable Inspection•With the variable differential control cable disconnected atboth

11-36 F INAL DRIVEFront Final Gear Case•Loosen the variable differential control cable locknut [A]and adjusting nut [B], and clear the cable lower end

FINAL DRIVE 11-37Front Final Gear Case•Insert the lower front final gear case bolts.•Tighten:Torque - Front Final Gear Case Nuts [A]: 59 N·m (6.0 kgf·

11-38 F INAL DRIVEFront Final Gear Case•Remove:Outer Disc [A]Needle Bearing•Remove:Housing [A] and D ifferential Disc Assembly [B]Inner DiscNeedle Bea

FINAL DRIVE 11-39Front Final Gear Case•Hold the front final gear case right cover [A] in a vise, andremove the bearing holder using the socket wrench

2-14 PERIODIC M AINTENANCEPeriodic Maintenance ProceduresFuel SystemThrottle Lever Free Play Inspection•Check that the throttle lever [A] moves smooth

11-40 F INAL DRIVEFront Final Gear Case•Install:Ring Gear Assembly•Apply grease to the O-ring [A] on the front final gear casecenter cover.•Install:Fr

FINAL DRIVE 11-41Front Final Gear Case•Install:Cam Lever [A]Needle Bearing [B]•Apply engine oil to the needle bearing.•Check the wear of the disc asse

11-42 F INAL DRIVEFront Final Gear Case•Apply engine oil to the needle bearing [A].•Install:Needle BearingOuter Disc [B]•Apply engine oil to the varia

FINAL DRIVE 11-43Front Final Gear Case•Apply molybdenum disulfide grease to the spline [A] ofthe shifter [B] and inner surface [C] of the coupling.•In

11-44 F INAL DRIVEFront Final Gear CaseRing Gear Disassembly•Remove:Ring Gear Assembly (see Front Final Gear Case Disas-sembly)Ring Gear Bolts [A]Ring

FINAL DRIVE 11-45Front Final Gear CaseLSD Clutch Torque InspectionIf the vehicle has the following symptoms, check the LSD(Limited Slip Differential)

11-46 F INAL DRIVEFront Final Gear CasePinion Gear Unit As sembly○The pinion gear and ring gear are lapped as a set in thefactory to get the best toot

FINAL DRIVE 11-47Front Final Gear CaseFront Final Ge ar Case (Backlash-related Parts)1. Pinion Gear Shim(s)2. Ring Gear Right Shim(s)3. Ring Gear Left

11-48 F INAL DRIVEFront Final Gear Case1. Pinion Gear Shims for Backlash AdjustmentThickness Part Number0.15 mm (0.006 in.)92180-14080.2 mm (0.008 in.

FINAL DRIVE 11-49Front Final Gear Case•Mount a dial gauge [A] so that the tip of the gauge isagainst the splined portion [B] of the pinion gear shaft.

PERIODIC MAINTENANCE 2-15Periodic Maintenance ProceduresIdle Speed Inspection•Start the engine and warm it up thoroughly.•With the engine idling, turn

11-50 F INAL DRIVEFront Final Gear Case○The tooth contact patterns of both (drive and coast) sidesshould be centrally located between the top and bott

FINAL DRIVE 11-51Front Final Gear CaseCorrect Tooth Contact Pattern: No adjustment is required.A. Ring GearB. Pinion GearC. HeelD. BottomE. TopF. To e

11-52 F INAL DRIVERear Propeller S haftRear Propeller Shaft Removal•Remove:Footboard (see Left and Right Footboard Removal in theFrame chapter)•Slip t

FINAL DRIVE 11-53Rear Propeller Shaft•Apply molybdenum disulfide grease:Spline [A] on Output Shaft of EngineSpline [B] on Pinion Gear of Rear Final Ge

11-54 F INAL DRIVERear AxleRear Axle Removal•Drain the rear final gear case oil (see Rear Final GearCase Oil Change in the Periodic Maintenance chapte

FINAL DRIVE 11-55Rear AxleRear Axle Joint Boot ReplacementOutboard Joint Boot Removal•Remove:Rear Axle (see Rear Axle Removal)•Tap the joint portion o

11-56 F INAL DRIVERear Axle•Place the special grease tube nozzle in the bore of thehousing and squeeze the tube [A] until the grease comesout from the

FINAL DRIVE 11-57Rear Axle•Be sure outside diameter of the band [A] is less than themaximum diameter.Maximu m O u tside Diameter of Ban d : 82.9 m m (

11-58 F INAL DRIVERear Axle•Remove:Inner Race [A]Cage [B]Inboard Joint Boot [C]Inboard Joint Boot Installation•Install:New Small Band [A]New Inboard J

FINAL DRIVE 11-59Rear Axle•Squeeze about half a tube (30 grams) of the specialgrease [A] into the bearing cup [B].•Insert the balls and cage assembly

2-16 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresAir Cleaner Element Cleaning and InspectionNOTE○In dusty areas, the element should be cleaned

11-60 F INAL DRIVERear Axle•Be sure the outside diameter of the band [A] is less thanthe maximum diameter.Maximum Outside Diameter of Band: 73.4 m m (

FINAL DRIVE 11-61Rear Final G ear CaseRear Final Gear Case Oil Level Inspection•Park the vehicle so that it is level, both side-to-side andfront-to-re

11-62 F INAL DRIVERear Final Gear Case•Remove:Bolts [A] and Nut [B]Brake Cam Lever [C]Spring [D]•Remove:Bracket Bolts [A]Collars [B]Bracket [C]Vent Ho

FINAL DRIVE 11-63Rear Final G ear CaseRear Final Gear Case Installation•Install:Rear Final Gear CaseBracket [A]Collars [B]Bracket Bolts [C][D] Front[E

11-64 F INAL DRIVERear Final Gear Case•Using a press [A], sparate the ring gear [B] and coupling[C].[D] Suitable Tools•Remove:Rear Final Gear Case Fro

FINAL DRIVE 11-65Rear Final G ear Case•Remove:Steel Balls [A]•Remove:Pinion Gear Bearing Holder [A]○Hold the rear final gear case [A] in a vise, and r

11-66 F INAL DRIVERear Final Gear CaseRear Final Gear Cas e Right Cover Assembly[A] Rear Final Gear Case Right Cover•Press:Ball Bearing (until bottome

FINAL DRIVE 11-67Rear Final G ear Case•Using a press [A], press the coupling [B] to the ring gear[C] until it bottom out.[D] Suitable Tool•Visually ch

11-68 F INAL DRIVERear Final Gear Case•Install:Brake Cam Plate [A]○Fit the cam plate and brake camshaft [B] as shown.•Install:Steel Plate [A] (P/No. 4

FINAL DRIVE 11-69Rear Final G ear Case•Install:Rear Final Gear Case Front Cover [A]•Tighten:Torque - Rear Final Gear Case Front Cover Bolts [B]: 24N·m

PERIODIC MAINTENANCE 2-17Periodic Maintenance ProceduresFuel Hose Inspection (fuel leak, damage,installation condition)○The fuel hose is designed to b

11-70 F INAL DRIVERear Final Gear CaseRear Final Gear Case (Backlash-related Parts)1. Pinion Gear2. Pinion Gear Bearing Holder3. Gear Case Right Cover

FINAL DRIVE 11-71Rear Final G ear Case6. Pinion Gear Shims for Backlash AdjustmentThickness Part Number0.15 mm (0.006 in.)92180-14230.2 mm (0.008 in.)

11-72 F INAL DRIVERear Final Gear CaseIf the backlash is not within the standard, replace thepinion gear shim(s). To increase backlash, increase theth

FINAL DRIVE 11-73Rear Final G ear CasePinion Gear Unit Disassembly•Remove:Pinion Gear Unit [A] (see Rear Final Gear Case Disas-sembly)•Hold the pinion

11-74 F INAL DRIVEBearing and Oil SealBall or Needle Bearing InspectionSince the bearings are made to extremely close toler-ances, the clearance canno

FINAL DRIVE 11-75Bearing and Oil SealOil Seal Inspection•Inspect the oil seals [A].Replace any if the lips are misshapen, discolored (indicat-ing that

BRAKES 12-112BrakesTable of ContentsExploded View... 12-2Specifications ... 12-6Speci

12-2 BRAKESExploded View

BRAKES 12-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Reservoir Cap Screws1.5 0.15 13 in·lb2 Front Brake Lever Pivot Bolt 5.9 0.60 52 in·lb3

2-18 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Twist the screwdriver to disconnect the joint lock [A].•Pull the fuel hose joint [B] out of t

12-4 BRAKESExploded View

BRAKES 12-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Rear (Parking) Brake Lever Pivot Bolt2.2 0.22 19 in·lb2 Rear (Parking) Brake Lever Piv

12-6 BRAKESSpecificationsItem Standard Service LimitBrake FluidType DOT 3 or DOT 4 –––Front BrakePad Lining Thickness 4.0 mm (0.16 in.) 1 mm (0.04 in.

BRAKES 12-7Special ToolInside Circlip Pliers:57001-143

12-8 BRAKESBrake FluidWARNINGWhen working with the disc brake, observe the pre-cautions listed below.1. Never reuse old brake fluid.2. Do not use flui

BRAKES 12-9Brake FluidFront Brake Line Air Bleeding•Bleed the air whenever brake parts are replaced or re-assembled.•Remove the reservoir cap and fill

12-10 BRAKESMaster CylinderFront Brake Master Cylinder Removal•Remove:Brake Hose Banjo Bolt [A]Master Cylinder Clamp Bolts [B]Master Cylinder [C]CAUTI

BRAKES 12-11Master CylinderFront Brake Ma ster Cylinder Disassembly•Remove:Front Brake Master Cylinder (see Front Brake MasterCylinder Removal)Brake L

12-12 BRAKESMaster CylinderFront Master Cylinder Inspection (VisualInspection)•Disassemble the master cylinder (see Front Brake MasterCylinder Disasse

BRAKES 12-13CalipersFront Brake Caliper Removal•Remove the front wheel (see Wheel Removal in theWheels/Tires chapter).•Loosen the banjo bolt [A] at th

PERIODIC MAINTENANCE 2-19Periodic Maintenance Procedures•Remove:Front Guard Cover (see Front Guard Removal in theFrame chapter)Front Fender (see Front

12-14 BRAKESCalipersFront Brake Caliper Disassembly•Remove:Caliper (see Front Brake Caliper Removal)Pads (see Front Brake Pad Removal)Anti-rattle Spri

BRAKES 12-15Calipers•Apply brake fluid to the outside of the pistons [A], andpush them into the cylinder by hand. Take care that nei-ther the cylinder

12-16 BRAKESBrake PadsFront Brake Pad Removal•Detach the caliper from the disc (see Front Brake CaliperRemoval).•Remove:Pad Mounting Bolts [A]•Remove:

BRAKES 12-17Brake DiscsFront Brake Disc CleaningPoor braking can be caused by oil on a disc. Oil on a discmust be cleaned off with an oilless cleaning

12-18 BRAKESBrake HosesFront Brake Hose Inspection•Refer to the Front Brake Hose and Connections Inspec-tion in the Periodic Maintenance chapter.Front

BRAKES 12-19Rear Brake Lever, Pedal and CablesRear Brake Pedal Positio n InspectionNOTE○The position of the brake pedal has been decided bythe positio

12-20 BRAKESRear Brake Lever, Pedal and CablesRear Brake P edal Insta llation•Apply grease:Brake Pedal Pivot [A]O-ring [B]•Install:Spring [A]Brake Ped

BRAKES 12-21Rear Brake Lever, Pedal and Cables•Remove:Circlip [A]Cotter Pin, Washer and Pin [B]Brake Pedal Cable [C]Rear Brake Cable Insta llation•Gre

12-22 BRAKESInternal Wet BrakeInternal Wet Brake Disassembly•Refer to Rear Final Gear Case section in the Final Drivechapter.Internal Wet Brake Assemb

SUSPENSION 13-113SuspensionTable of ContentsExploded View...

2-20 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Remove:Reserve Tank Screws [A]Reserve Tank [B] with Hose•Remove the reserve tank cap [C], and

13-2 SUSPENSIONExploded View

SUSPENSION 13-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Front Shock Absorber Mounting Nuts34 3.5 252 Front Suspension Arm Pivot Nuts 42 4.

13-4 SUSPENSIONExploded View

SUSPENSION 13-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Rear Shock Absorber Mounting Nuts34 3.5 252 Stabilizer Holder Bolts 22 2.2 163 Sta

13-6 SUSPENSIONSpecificationsItem Standard Service LimitShock Absorbers (Usable Range)Spring Preload Setting Position:Front 2nd Step 1 ∼ 5Rear 3rd Ste

SUSPENSION 13-7Special ToolsInside Circlip Pliers:57001-143Outside Circlip Pliers:57001-144Steering Stem Nut Wrench:57001-1100Jack:57001-1238

13-8 SUSPENSIONShock AbsorbersFront Shock Absorber Preload AdjustmentThe spring adjusting sleeve [A] on the front shock ab-sorber has 5 positions so t

SUSPENSION 13-9Shock AbsorbersFront Shock Absorber Inspection•Check the bushings [A] in the upper and lower pivots.If bushings are worn, cracked, hard

13-10 SUSPENSIONShock AbsorbersRear Shock Absorber Removal•Support the vehicle on a stand or a jack so that the rearwheels are off the ground.Special

SUSPENSION 13-11Suspension ArmsFront Suspension Arm Removal•Remove:Wheel Hub (see Front Hub Removal in the Wheels/Tireschapter)Bolt [A] and Brake Hose

PERIODIC MAINTENANCE 2-21Periodic Maintenance Procedures•Tighten:Torque - Coolant Drain Bo lt: 8.8 N·m ( 0.90 kgf·m , 78 in·l b)•Support the vehicle o

13-12 SUSPENSIONSuspension Arms•Remove:Suspension Arm Pivot Bolts [A] and Nuts [B]Front Lower Suspension Arm [C]Front Suspension Arm Installation•Clea

SUSPENSION 13-13Suspension ArmsFront Lower Suspension Arm•Remove:Bolts [A]Collar [B]Axle Guard [C]Collars [D] (rear side)Oil Seals [E]Circlips [F]Spec

13-14 SUSPENSIONSuspension Arms•Install the following parts as shown.Front Lower Suspension ArmFront Side [A]:Needle Bearing [B]7.5 ±0.1 mm (0.295 ±0.

SUSPENSION 13-15Suspension Arms•Remove:Screw [A]Bolts [B]Axle Guard [C]•Remove:Rear Shock Absorber Mounting Bolt [A] and Nut (lower)Suspension Arm Bol

13-16 SUSPENSIONSuspension ArmsRear Lower Suspension Arm•Remove:Screw [A]Bolts [B]Collars [C]Axle Guard [D]Collars [E] (rear side)Oil Seals [F]Circlip

SUSPENSION 13-17Suspension ArmsRear Side [A]:Circlip [B] (front side)Ball Joint Bearing [C]Circlip [D] (rear side)Special Tool - Inside Circlip Pliers

STEERING 14-114SteeringTable of ContentsExploded View...

14-2 STEERINGExploded View

STEERING 14-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1 Handlebar Holder Bolts 29 3.0 21S2 Steering Stem Clamp Bolts 25 2.5 183 Tie-rod End

2-22 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresEngine Top EndValve Clearance InspectionNOTE○Check the valve clearance only when the engine is

14-4 STEERINGSpecificationsItem Standard Service LimitTie-rodsTie-rod Length 388.5 mm (15.30 in.) –––

STEERING 14-5Special ToolsInside Circlip Pliers:57001-143Bearing Driver Set:57001-1129

14-6 STEERINGSteeringSteering Stem Removal•Remove:Handlebar (see Handlebar Removal)Cotter Pins and Tie-rod End Nuts [A]CAUTIONDo not loosen the locknu

STEERING 14-7SteeringSteering Stem Installation•Fill grease up the seal grooves [A] in the steering stembearing.•Install:Collar•Tighten:Torque - Steer

14-8 STEERINGSteeringSteering Knuckle Removal•Remove:Front Hub (see F ront Hub Removal in the Wheel/Tierschapter)Cotter Pin [A]CAUTIONDo not loosen th

STEERING 14-9SteeringSteering Knuckle Installation•Inspect the spherical bearings in the knuckle joints [A].If roughness, excessive play, or seizure i

14-10 STEERINGSteering•Drive the bearing [A] out using a suitable bearing driverfrom the bearing driver set.Special Tool - Bearing Driver Set: 57001-1

STEERING 14-11SteeringTie-rod End Removal•Removethetie-rod(seeTie-rodRemoval).•Holding the tie-rod flattened area [A], loosen the locknut[B] and unscr

14-12 STEERINGSteering MaintenanceSteering Inspection•Refer to the Steering Inspection in the Periodic Mainte-nance chapter.Steering Stem Straightness

STEERING 14-13Steering MaintenanceSteering Knuckle Bearing InspectionCAUTIONDo not remove any bearings for inspection.•Remove the steering knuckle (se

PERIODIC MAINTENANCE 2-23Periodic Maintenance Procedures•Measure the clearance for all four valves, one at a timebetween the end of the valve stem and

14-14 STEERINGHandlebarHandlebar Removal•Remove:Multifunction Meter Unit (see Multifunction Meter UnitRemoval in the Electrical System chapter)Throttl

STEERING 14-15Handlebar•Install:Left Switch Housing [A]Rear Brake Lever Assembly [B]Punch Mark [C][D] = 6 mm (0.24 in.)○Apply a non-permanent locking

FRAME 15-115FrameTable of ContentsExploded View... 15-2Seat ... 15-8Se

15-2 FRA MEExploded View

FRAME 15-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Front Guard Bolts46 4.7 342 Front Carrier Bolts, L = 50 mm (2.0 in.) 32 3.3 24 L3 Front

15-4 FRA MEExploded View

FRAME 15-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1 Footboard Bracket Bolts 46 4.7 342 Trailer Hitch Bracket Bolts 82 8.4 60 L3 Rear Final

15-6 FRA MEExploded View

FRAME 15-7Exploded ViewOP: Optional Parts

2-24 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Remove the drain plug [A] on the muffler.•In an open area away from combustible materials, st

15-8 FRA MESeatSeat Removal•Remove the seat [A] by lifting the latch lever [B] and thenpulling the seat up to the rear.Seat Installation•Insert the fr

FRAME 15-9CarriersFront Carrier Removal•Remove:Front Carrier Bolts [A]CollarsFront Carrier [B]Front Carrier Installation•Install:Long Collars, L = 44.

15-10 FRAMECarriersRear Carrier Installation•Install:Collar [A]Rear Carrier [B]Rear Carrier Bolts, L = 44 mm (1.7 in.) [C]Rear Carrier Bolts, L = 14 m

FRAME 15-11FendersFront Fender Removal•Remove:Seat (see Seat Removal)Front Carrier (see Front Carrier Removal)Footboard (see each Footboard Removal)Mi

15-12 FRAMEFenders•Remove:Screws [A] and CollarsBolts [B] and CollarsFuel Tank Cap [C]Rear Fender [D]•Install the fuel tank cap after removing the rea

FRAME 15-13CoversMiddle Cover Removal•Disconnect:Power Outlet Lead Connectors [A]•Remove:Middle Cover Screws [A] and Collars•Remove:Middle Cover Screw

15-14 FRAMECovers•Remove:Screws [A]•Remove:Screws [A]Storage Box [B]Storage Case Removal•Remove:Ignition Switch Nut [A]Screws [B]Storage Case [C]Stora

FRAME 15-15Covers•Remove:Screws [A] and CollarsLeft Side Cover [B]Left Side Cover Installation•Install:Left Side Cover [A]Insulator [B]Screws [C] and

15-16 FRAMECoversElectrical Parts Case Removal•Remove:Seat (see Seat Removal)Rear Fender (see Rear Fender Removal)Vehicle-down Sensor [A] (see Vehicle

FRAME 15-17Covers•Remove:Radiator Cover Screws [A] and CollarsRadiator Cover [B]Radiator Cover Installation•Install the seal [A] so that along it to t

PERIODIC MAINTENANCE 2-25Periodic Maintenance Procedures•Check the belt [A] for abnormal wear [B].○Measure the width [C] of the belt at abnormal wear

15-18 FRAMEGuardsFront Guard Removal•Remove:Front Bottom G uard (see Front Bottom Guard Removal)Bolts [A] and CollarsFront Guard C over [B]•Remove:Fro

FRAME 15-19GuardsFront Bottom Guard Removal•Remove:Bolts [A] and Collars•Remove:Bolts [A] and CollarsQuickRivets[B]Front Bottom Guard [C]Front Bottom

15-20 FRAMEGuardsRear Bottom Guard Removal•Remove:Bolts (M6) [A] and CollarsBolt (M8) [B] and CollarRear Bottom Guard [C]Rear Bottom Guard Installatio

FRAME 15-21Flaps and FootboardsLeft Footboard Removal•Remove:Screws [A] and CollarsBolts [B] and Collars•Remove:Screws [A] and CollarsBolts [B] and Co

15-22 FRAMEFlaps and FootboardsRight Footboard Installation•Install:Right Footboard [A]Bolts [B] and Collars [C]Screws [D] and Collars [E]Footboard Br

FRAME 15-23Trailer Hitch BracketTrailer Hitch Bracket Removal•Remove:Trailer Hitch Bracket Bolts [A]Trailer Hitch Bracket [B]Trailer Hitch Bracket Ins

ELECTRICAL SYSTEM 16-116Electrical SystemTable of ContentsParts Location...

16-2 ELECTRICAL SYSTEMArmature Inspection... 16

ELECTRICAL SYSTEM 16-3Parts Lo cationLight/Dimmer Switch [A]Starter Button [B]Engine Stop Switch [C]Reverse Power Assist Switch (Override) [D]Rear Bra

2-26 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresConverter Drive Belt Deflection Adjustment•Disassemble the driven pulley (see Driven Pulley D

16-4 ELECTRICAL SYSTEMParts Lo cationIgnition Coil (Rear) [A]Engine Brake Actuator [B]Drive Belt Failure Detection Switch [C]Engine Ground [D]Spark Pl

ELECTRICAL SYSTEM 16-5Parts Lo cationRegulator/Rectifier [A]2WD/4WD Actuator [A]Multifunction Meter [A]“SET/RESET” Button [B]Belt Check Indicator Ligh

16-6 ELECTRICAL SYSTEMExploded View

ELECTRICAL SYSTEM 16-7Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Starter Motor Mounting Bolts8.8 0.90 78 in·lb2 Starter Motor Cable Mounting

16-8 ELECTRICAL SYSTEMExploded View

ELECTRICAL SYSTEM 16-9Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Spark Plugs13 1.3 115 in·lb2 2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·

16-10 ELECTRICAL SYSTEMExploded View

ELECTRICAL SYSTEM 16-11Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Oil Pressure Switch15 1.5 11SS2 Oil Pressure Switch Terminal Bolt 1.5 0.15

16-12 ELECTRICAL SYSTEMSpecificationsItem Standard Service LimitBatteryType Sealed Battery –––Model Name KMX14-BS –––Capacity12 V 12 Ah –––Voltage 12.

ELECTRICAL SYSTEM 16-13Wiring DiagramDummy Page

PERIODIC MAINTENANCE 2-27Periodic Maintenance ProceduresActuator Lever (Engine Brake Control Lever)Assembly Inspection•Measure the width [A] of the pl

16-14 ELECTRICAL SYSTEMWiring Diagram

ELECTRICAL SYSTEM 16-15Wiring Diagram

16-16 ELECTRICAL SYSTEMSpecial Tools and SealantTiming Light:57001-1241SparkPlugWrench,Hex16:57001-1262Flywhe el Holder:57001-1313Hand Tester:57001-13

ELECTRICAL SYSTEM 16-17PrecautionsThere are a number of important precautions that shouldbe taken when servicing electrical systems. Learn and ob-serv

16-18 ELECTRICAL SYSTEMPrecautions○Electrical Connectors:Connectors [A]Connectors [B]

ELECTRICAL SYSTEM 16-19Electrical WiringWiring Inspection•Visually inspect the wiring for signs of burning, fraying,etc.If any wiring is defective, re

16-20 ELECTRICAL SYSTEMBatteryBattery Removal•Turn off the ignition switch.•Remove:Seat (see Seat Removal in the Frame chapter)Battery Holder Bolts [A

ELECTRICAL SYSTEM 16-21BatteryCAUTIONDo not remove the aluminum sealing sheet [A] fromthe filler ports [B] until just prior to use. Be sure touse the

16-22 ELECTRICAL SYSTEMBattery•Gently remove the container from the battery.•Let the battery sit for 30 minutes prior to charging to allowthe electrol

ELECTRICAL SYSTEM 16-23BatteryIf an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has beendischarged. Give ref

BRUTE FORCE 750 4×4iKVF750 4×4All Terrain VehicleService ManualAll rights reserved. No parts of this publication may be reproduced, stored in a retrie

2-28 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Replace the filter with a new one.•When installing the oil filter, be careful of the followin

16-24 ELECTRICAL SYSTEMBatteryIf the reading is below the specified, refreshing charge isrequired.Battery Terminal VoltageStandard:12.8 V or moreTermi

ELECTRICAL SYSTEM 16-25Battery•Determine battery condition after refreshing charge.○Determine the condition of the battery 30 minutes aftercompletion

16-26 ELECTRICAL SYSTEMCharging SystemAlternator Cover Remova l•Drain:Coolant (see Coolant Change in the Periodic Mainte-nance chapter)Engine Oil (see

ELECTRICAL SYSTEM 16-27Charging System•Open the clamps [A].•Holding the drive pulley w ith the drive pulley holder,loosen the alternator rotor bolt [A

16-28 ELECTRICAL SYSTEMCharging System•Check that the bearing [A] is in place.•Fit the grommets [A] into the notch in the cover.•Grease the alternator

ELECTRICAL SYSTEM 16-29Charging SystemAlternator Rotor R emoval•Remove:Alternator Cover (see A lternator Cover Removal)•Screw the flywheel puller [A]

16-30 ELECTRICAL SYSTEMCharging SystemAlternator Stator Removal•Remove:Alternator Cover (see Alternator Cover Removal)Crankshaft Sensor [A] (see Crank

ELECTRICAL SYSTEM 16-31Charging SystemIf the battery voltage does not increase as the enginespeed increases, then the regulator/rectifier is defective

16-32 ELECTRICAL SYSTEMCharging System•Check the stator coil resistance as follows:○Stop the engine.○Disconnect the alternator connector.○Connect a ha

ELECTRICAL SYSTEM 16-33Charging SystemRegulator/Rectifier Inspection•Remove:Regulator/Rectifier (see Regulator/Rectifier Removal)•Set the hand tester

PERIODIC MAINTENANCE 2-29Periodic Maintenance ProceduresVariable Differential Control Le ver PlayAdjustment•Remove:Handlebar Cover Screws [A]•Remove:H

16-34 ELECTRICAL SYSTEMIgnition SystemWARNINGThe ignition system produces extremely high volt-age.Do not touch the spark plug, ignition coil, or spark

ELECTRICAL SYSTEM 16-35Ignition System•While lifting up the air duct [A], remove the spark plug cap[B].•Using a spark plug wrench, remove the spark pl

16-36 ELECTRICAL SYSTEMIgnition SystemRear Side•Remove:Right Side Cover (see Right Side Cover Removal in theFrame chapter)Rubber Air Duct (see Spark P

ELECTRICAL SYSTEM 16-37Ignition SystemIgnition Coil Inspection•Remove the ignition coil.•Measure the arcing distance with a coil tester [A] to checkth

16-38 ELECTRICAL SYSTEMIgnition SystemIgnition Coil Primary Peak Voltage InspectionNOTE○Be sure the battery is fully charged.•Remove the spark plug ca

ELECTRICAL SYSTEM 16-39Ignition SystemCrankshaft Sensor Installatio n•Install:Stator Coil Leads [A]Plate [B]Crankshaft Sensor [C]•Tighten:Torque - Cra

16-40 ELECTRICAL SYSTEMIgnition SystemCrankshaft Sensor Peak Voltage InspectionNOTE○Be sure the battery is fully charged.•Removal the middle cover (se

ELECTRICAL SYSTEM 16-41Ignition System•Attach a timing light [A] and a tachometer in the mannerprescribed by the manufacturer.Special Tool - Timing Li

16-42 ELECTRICAL SYSTEMIgnition SystemIgnition System Troubleshooting

ELECTRICAL SYSTEM 16-43Ignition SystemIgnition System Circuit1. Throttle Sensor2. Ignition Switch3. Reverse Switch4. Neutral Switch5. Speed Sensor6. F

2-30 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Fill the gear case up to the bottom of filler opening withthe oil specified below.Front Final

16-44 ELECTRICAL SYSTEMElectric Starter SystemStarter Motor Removal•Loosen:Clamp Bolts [A]•Remove:Air Intake Rubber Duct [B]•Remove:Bolts [A]JointDuct

ELECTRICAL SYSTEM 16-45Electric Starter SystemIf the O-ring [A] shows wear or damage, or if it is hard-ened, replace it with a new one.•Apply a small

16-46 ELECTRICAL SYSTEMElectric Starter System•Pull out the armature [A] out of the yoke [B].NOTE○Do not remove the circlip [C] from the shaft.•Remove

ELECTRICAL SYSTEM 16-47Electric Starter System•Replace the O-ring [A] with a new one.•Install the following parts to the starter motor terminal [B].O-

16-48 ELECTRICAL SYSTEMElectric Starter System•Tighten:Torque - Starter Motor Through Bolts [A]: 5.0 N·m (0.51kgf·m, 44 in·lb)Brush Inspection•Measure

ELECTRICAL SYSTEM 16-49Electric Starter SystemBrush Lead Inspection•Using the × 1 Ω hand tester range, measure the resis-tance as shown.Terminal Bolt

16-50 ELECTRICAL SYSTEMElectric Starter SystemElectric Starter Circuit1. Ignition Switch2. Neutral Switch3. Rear Brake Light Switch (Lever)4. Front Br

ELECTRICAL SYSTEM 16-51Electric Starter SystemStarter Motor Clutch Removal•Remove the alternator rotor (see Alternator Rotor Re-moval).•Hold the rotor

16-52 ELECTRICAL SYSTEMElectric Starter SystemTorque Limiter Inspection•Remove:Alternator Rotor (see Alternator Rotor Removal)•Remove the torque limit

ELECTRICAL SYSTEM 16-53Lighting SystemHeadlight Beam Vertical Adjustment•Turn the adjusting screw [A] on each headlight rim in orout to adjust the hea

PERIODIC MAINTENANCE 2-31Periodic Maintenance Procedures•Be sure the O-ring [A] is in place, and tighten the filler cap[B].○Apply grease to the O-ring

16-54 ELECTRICAL SYSTEMLighting System•Turn the bulb socket [A] counterclockwise [B], and removethe bulb.○The headlight bulb can not be removed from t

ELECTRICAL SYSTEM 16-55Lighting System•Install the removed parts.[A] Bolt and Collar [L = 6 mm (0.24 in.)][B] Bolt and Collar [L = 4 mm (0.16 in.)][C]

16-56 ELECTRICAL SYSTEMLighting System•Remove:Tail/Brake Light Mounting Nuts [A]Tail/Brake Light [B]Lighting System Circuit1. Ignition Switch2. Revers

ELECTRICAL SYSTEM 16-57Radiator Fan SystemRadiator Fan Motor Inspection•Disconnect the connector [A] in the fan lead.•Using two auxiliary wires, suppl

16-58 ELECTRICAL SYSTEMRadiator Fan SystemRadiator Fan Circuit1. Ignition Switch2. Radiator Fan Breaker 10 A3. Fuse Box4. Main Fuse 30 A5. ECU (Electr

ELECTRICAL SYSTEM 16-59MeterMultifunction Meter Unit R emoval•Remove:Handlebar Cover Screws [A]•Remove:Handlebar Cover Screws [A]Handlebar Cover Front

16-60 ELECTRICAL SYSTEMMeterMultifunction Meter Unit Inspection•Remove:Multifunction Meter Unit (see Multifunction Meter UnitRemoval)CAUTIONDo not dro

ELECTRICAL SYSTEM 16-61Meter•Cycle the meter to TRIP A or TRIP B mode.•Check that when the SET/RESET button [A] is pushed,the display turns to 0.0.If

16-62 ELECTRICAL SYSTEMMeterCheck 5: Trip Meter A/B Check•Connect the wires in the same manner as Check 3.•PushingtheMODEbutton[A],cyclesthetripmeterA

ELECTRICAL SYSTEM 16-63Meter○The 4WD indicator light (LCD) [A] should appear.If this display function does not work, replace the meterunit.Check 8: Wa

2-32 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresFront Brake Hose Replacement•Pump the brake fluid out of the line as explained in theBrake Flu

16-64 ELECTRICAL SYSTEMMeterCheck 10: Neutral Indicator Light Check•Connect the wires in the same manner as Check 1.•Connect terminal [8] to the batte

ELECTRICAL SYSTEM 16-65Meter○The meter illumination [A] should go on.If the illumination does not go on, replace the meter unit.Check 13: Belt Check I

16-66 ELECTRICAL SYSTEMMeterDrive Belt Failure Mode Memory ClearingProcedureA flashing BELT check indicator LED (Light EmittingDiode) l ight means tha

ELECTRICAL SYSTEM 16-67Meter•Disconnect the mismatched 4 pin connector sets and re-connect them normally. (Black to black, gray to gray) [A]•Connect t

16-68 ELECTRICAL SYSTEMMeterMeter Circuit1. Ignition Switch2. Reverse Switch3. Neutral Switch4. Fuse Box5. Main Fuse 30 A6. Fuel Level Sensor7. Actuat

ELECTRICAL SYSTEM 16-69Actuator Control System2WD/4WD Actuator Re mo val•Drain the front final gear case oil (see Front Final GearCase Oil Change in t

16-70 ELECTRICAL SYSTEMActuator Control SystemEngine Brake Actuator Installation•Apply grease and Install:O-ring [A]•Apply molybdenum disulfide grease

ELECTRICAL SYSTEM 16-71Actuator Control SystemActuator Control SystemActuator Controller Removal•Remove:Seat (see Seat Removal in the Frame chapter)Ac

16-72 ELECTRICAL SYSTEMActuator Control SystemActuator Control System TroubleshootingWhen the actuator fails, the controller enters failure modeand th

ELECTRICAL SYSTEM 16-73Actuator Control SystemFailure I ndication Pattern and Failure PartNo. Failure Indication Pattern Failure Part1Selectable 2WD/4

PERIODIC MAINTENANCE 2-33Periodic Maintenance ProceduresFront Brake Fluid Change•Remove the reservoir cap and the rubber cap on the bleedvalve.•Attach

16-74 ELECTRICAL SYSTEMActuator Control System•Measure the resistance between the following terminalsin the actuator lead connector [A].Special Tool -

ELECTRICAL SYSTEM 16-75Actuator Control SystemCheck 4. Speed Sensor InspectionNOTE○Be sure the battery is fully charged.•Support the vehicle on a s ta

16-76 ELECTRICAL SYSTEMActuator Control System•Push the switch to the 2WD position.Controller Output Voltage (at 2WD/4WD Shift Switch ON,2WD)Standard:

ELECTRICAL SYSTEM 16-77Actuator Control System•Disconnect the 2WD/4WD shift switch lead connector.•Connect:Controller Connector [A]Hand Tester [B] (ra

16-78 ELECTRICAL SYSTEMActuator Control System•Turn ON the ignition switch.•Shift to the 2WD position.•Measure the controller output voltage for the 2

ELECTRICAL SYSTEM 16-79Actuator Control SystemActuator Control System Circuit1. Ignition Switch2. Speed Sensor3. Fuse Box4. Actuator Controller Fuse 1

16-80 ELECTRICAL SYSTEMDrive Belt Failure Detection Syst emIf the drive belt failure detection system activated by ab-normal belt, the drive belt fail

ELECTRICAL SYSTEM 16-81Switches and SensorFuel Level Sens or Inspection•Remove:Fuel Pump (see Fuel Pump Removal in the Fuel System(DFI) chapter)•Check

16-82 ELECTRICAL SYSTEMSwitches and SensorFuel Level Sensor Circuit1. Multifunction Meter2. Ignition Switch3. Fuse Box4. Main Fuse 30 A5. Fuel Level S

ELECTRICAL SYSTEM 16-83Switches and SensorWater Temperature Sensor Inspection•Remove the water temperature s ensor (see Water Tem-perature Sensor Remo

2-34 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresFront Brake Calip er Fluid Seal ReplacementThe fluid seals [A] around the piston maintain the

16-84 ELECTRICAL SYSTEMSwitches and Sensor•Trace [A] each side of the speed sensor surface with thescrew driver.○Then the tester indicator s hould fli

ELECTRICAL SYSTEM 16-85Switches and SensorDrive Belt Failure Detection Switch InspectionIf the drive belt failure detection system i s activated byabn

16-86 ELECTRICAL SYSTEMRelayRelay Inspection•Remove:Seat (see Seat Removal in the Frame chapter)Starter Control Relay (Neutral) [A]Radiator Fan Relay

ELECTRICAL SYSTEM 16-87FusesFuse Removal•Remove:Seat (see Seat Removal in the Frame chapter)Fuse Box Lid [A]•Pull the fuses [A] straight out of the fu

APPENDIX 17-117AppendixTable of ContentsTroubleshooting Guide ...

17-2 APPE NDIXTroubleshooting GuideNOTE○Refer to the Fuel System chapter for mostof DFI trouble shooting guide.○This is not an exhaustive list, giving

APPENDIX 17-3Troubleshooting GuideBrake draggingFront or rear final gear case oil viscosity toohighPoor Running or No Power at High Speed:Firing incor

17-4 APPE NDIXTroubleshooting GuideDrive pulley movable sheave doesn’t movesmoothlyDrive pulley spring incorrect installed (tootight)Driven pulley mov

APPENDIX 17-5Troubleshooting GuideHandling and/or Stability UnsatisfactoryHandlebar hard to turn:Ti re air pressure too lowSteering stem bearing damag

PERIODIC MAINTENANCE 2-35Periodic Maintenance ProceduresRear Brake Lever and Pedal Free Play AdjustmentNOTE○Since the rear brake lever and pedal free

17-6 APPE NDIXCable, Wire, and Hose Routing

APPENDIX 17-7Cable, Wire, and Hose Routing1. Band2. Main Harness3. Clamp4. To Fuel Injectors and Throttle Sensor5. Fuel Injector Throttle Sensor Subha

17-8 APPE NDIXCable, Wire, and Hose Routing1. Front Fender Inner Cover2. Tube (for Winch Harness)3. Band (Pass the band through the hole of the frame

APPENDIX 17-9Cable, Wire, and Hose Routing1. Engine Breather Hose2. Clamps (Install the clamps direction as shown.)3. Align the white paint of the bre

17-10 APPENDIXCable, Wire, and Hose Routing1. Starter Motor Cable2. Engine Ground Lead (Install the lead so that the flat side of the lower terminal f

APPENDIX 17-11Cable, Wire, and Hose Routing1. Water Hose (Thermostat Housing ∼ Front Cylinder Head)2. Water Hose Clamp3. Clamps4. White Paint of Water

17-12 APPENDIXCable, Wire, and Hose Routing1. Main Harness2. Bands3. Rear Final Gear Case Vent Hose4. Spark Plug Lead of Rear Ignition Coil(Run the sp

APPENDIX 17-13Cable, Wire, and Hose Routing1. Rear Final Gear Case Vent Hose2. Front Final Gear Case Vent Hose3. Vacuum Hose4. Radiator Fan Motor Vent

17-14 APPENDIXCable, Wire, and Hose Routing1. Do not crush the radiator fan motor vent hose to pull it.2. Clamps3. Clamp the reserve tank hose to the

APPENDIX 17-15Cable, Wire, and Hose Routing1. Water Hose (Thermostat Housing ∼ Front Cylinder Head)2. Water Pipe (Thermostat Housing ∼ Rear Cylinder H

2-36 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Check the steering action again.If steering stem bearing lubrication does not remedy theprobl

17-16 APPENDIXCable, Wire, and Hose Routing1. Clamp2. 2WD/4WD Actuator Lead3. Air Intake Duct4. Band5. Front Final Gear Case6. Run the 2WD/4WD actuato

APPENDIX 17-17Cable, Wire, and Hose Routing1. Main Harness2. Drive Belt Failure Detecting Switch Lead3. Engine Brake Actuator Lead4. Starter Motor Cab

17-18 APPENDIXCable, Wire, and Hose Routing1. Rear Brake Lever2. Parking Brake Lock Lever3. Variable Differential Control Cable4. Cable Adjuster5. Var

APPENDIX 17-19Cable, Wire, and Hose Routing1. Clamp2. Bands3. Radiator Fan Motor Vent Hose4. Vacuum Hose5. Front Final Gear Case Vent Hose6. Fitting7.

17-20 APPENDIXCable, Wire, and Hose Routing1. Right Headlight Lead2. Radiator Cover3. Frame Ground Lead4. Horn Switch Lead (Australia and EuropeModels

APPENDIX 17-21Cable, Wire, and Hose Routing1. Right Handlebar Switch Lead2. Throttle Cable3. Meter Unit Lead4. Variable Differential Control Cable5. P

17-22 APPENDIXCable, Wire, and Hose Routing1. Air Intake Duct2. Bands3. Parking Brake Cable4. Rear Brake Cable5. Bracket6. Clamp7. Rear Brake Light Sw

APPENDIX 17-23Cable, Wire, and Hose Routing1. Fuse Box2. ECU3. Main Harness (Run the main harness un-der the frame pipe.)4. Clamps5. Actuator Controll

17-24 APPENDIXCable, Wire, and Hose Routing1. Main Harness (Run the main harness un-der the frame pipe.)2. Battery (–) Cable3. Bands4. To Rear Brake L

APPENDIX 17-25Cable, Wire, and Hose Routing1. To Left Headlight Lead2. Clamps (Insert the clamp into the hole ofthe radiator cover.)3. Clamps4. To Pow

PERIODIC MAINTENANCE 2-37Periodic Maintenance ProceduresConverter Drive Belt Failure De tection SystemInspection•Remove:Seat (see Seat Removal in the

17-26 APPENDIXCable, Wire, and Hose Routing1. Battery2. Red Cap3. Battery (–) Cable4. Battery (+) Cable5. Clamp (Insert the clamp into the hole of the

APPENDIX 17-27Cable, Wire, and Hose Routing1. Air Intake Duct2. Bands3. Rear Final Gear Case Vent Hose4. Rear Final Gear Case

17-28 APPENDIXCable, Wire, and Hose Routing1. ISC Valve Tube (Rear)2. Tube3. ISC Valve Tube (Primary)4. Clamps5. ISC Valve Tube (Front)6. ISC Valve7.

APPENDIX 17-29Cable, Wire, and Hose Routing1. ISC Valve Tube (Rear)2. ISC Valve Tube (Primary)3. ISC Valve4. ISC Valve Tube (Front)5. Clamp6. Fuel Inj

MODEL APPLICATIONYear Model Beginning Frame No.2008 KVF750D8FJKAVFDD1□8B500001 orJKAVF750DDB6000012008 KVF750E8F JKAVFDE1□8B5000012008 KVF750E8FA JKAV

LIST OF ABBREVIATIONSA ampere(s) lb pounds(s)ABDC after bottom dead centermmeter(s)ACalternating current minminute(s)ATDC after top dead centerNnewton

2-38 PERIODIC MAINTENANCEPeriodic Maintenance Procedures

PERIODIC MAINTENANCE 2-39Periodic Maintenance ProceduresJoint Boots InspectionFront Axle/Steering Kn uckle Joint BootsInspection•Visually inspect the

2-40 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresGeneral LubricationLubrication•Before lubricating each part, clean off any rusty spots withrus

PERIODIC MAINTENANCE 2-41Periodic Maintenance ProceduresSlide Points: Lubricate with Grease.Brake LeverBrake Pedal Pivot ShaftThrottle Lever ShaftBolt

FUEL SYSTEM (DFI) 3-13Fuel System (DFI)Table of ContentsExploded View...

3-2 FUEL SYSTEM (DFI)Fuel Pump Relay Removal ... 3-63Fuel

FUEL SYSTEM (DFI) 3-3Fuel Tank ...

3-4 FUEL SYSTEM (DFI)Exploded View

FUEL SYSTEM (DFI) 3-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Air Cleaner Housing Bolts8.8 0.90 78 in·lb2 ISC Valve Mounting Bolts 8.8 0.9

EMISSION CONTROL INFORMATIONTo protect the environment in which we all live, Kawasaki h as incorporated crankcase emission(1) and exhaust emission (2)

3-6 FUEL SYSTEM (DFI)Exploded View

FUEL SYSTEM (DFI) 3-7Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1 Fuel Pump Bolts 4.0 0.41 35 in·lb2 Fuel Tank Mounting Bolts 9.8 1.0 87 in·l

3-8 FUEL SYSTEM (DFI)DFI SystemDFI System

FUEL SYSTEM (DFI) 3-9DFI System1. Battery 12 V 12 Ah2. ECU (Electronic Control Unit)3. Inlet Air Pressure Sensor4. Throttle Sensor5. Injectors6. Crank

3-10 FUEL SYSTEM (DFI)DFI SystemDFI System Wiring Diagram

FUEL SYSTEM (DFI) 3-11DFI SystemPart Name1. Throttle Sensor2. Fuel Injector #13. Fuel Injector #24. Ignition Switch5. Speed Sensor6. Fuse Box7. Fuel P

3-12 FUEL SYSTEM (DFI)DFI SystemTerminal Names1. Inlet Air Pressure Sensor Signal2. Inlet Air Temperature Sensor Signal3. Power Supply to Sensors4. Re

FUEL SYSTEM (DFI) 3-13DFI Parts LocationFI Indicator Light (LCD) [A]Water Temperature Sensor [A]Spark Plug (Front) [B]Ignition Coil (Front) [C]Cranksh

3-14 FUEL SYSTEM (DFI)DFI Parts LocationInlet Air Temperature Sensor [A]Speed Sensor [A]ECU (Electronic Control Unit) [A]Battery 12V 12Ah [B]Fuel Pump

FUEL SYSTEM (DFI) 3-15SpecificationsItem StandardDigital Fuel Injection SystemIdle Speed 1 100 ±50 r/min (rpm)Throttle Body Assy:Type Two barrel typeB

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

3-16 FUEL SYSTEM (DFI)SpecificationsItem StandardSpeed Sensor:Input Voltage Battery Voltage at ignition Switch ONOutput Voltageless than CD 0.8 Vor ov

FUEL SYSTEM (DFI) 3-17Special Tools and SealantVacuum Gauge Adapter:57001-401Oil Pressure Gauge, 5 kgf/cm²:57001-125Pilot Screw Adjuster, A:57001-1239

3-18 FUEL SYSTEM (DFI)Special Tools and SealantFuel Pressure Gauge Adapter:57001-1593Fuel Hose:57001-1607Speed Sensor Measuring Adapter:57001-1667Fuel

FUEL SYSTEM (DFI) 3-19DFI Servicing PrecautionsDFI Servicing PrecautionsThere are a number of important precautions that shouldbe followed servicing t

3-20 FUEL SYSTEM (DFI)DFI Servicing Precautions○To maintain the correct fuel/air mixture (F/A), there mustbe no inlet air leaks in the DFI system. Be

FUEL SYSTEM (DFI) 3-21Troubleshooting the DFI SystemOutlineWhen an abnormality in the DFI system occurs, the FIindicator light (LCD) goes on to alert

3-22 FUEL SYSTEM (DFI)Troubleshooting the DFI System○The DFI part connectors [A] have seals [B], including theECU.•Join the connector and insert the n

FUEL SYSTEM (DFI) 3-23Troubleshooting the DFI System•Pull each connector [A] apart and inspect it for corrosion,dirt, and damage.If the connector is c

3-24 FUEL SYSTEM (DFI)Troubleshooting the DFI System○There are two ways to inspect the DFI system. One isvoltage Check Method and the other is Resista

FUEL SYSTEM (DFI) 3-25Troubleshooting the DFI SystemDFI Diagnosis Flow ChartInquiries to Rider○Each rider reacts to problems in different ways, so it

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM(US MODEL only)TAMPERING WITH EMISSION CON TROL SYSTEM PROHIBITED:Federal regulations and California Sta

3-26 FUEL SYSTEM (DFI)Troubleshooting the DFI SystemSample Diagnosis SheetRider name: Registration No. (license plate No.):Year of initial registratio

FUEL SYSTEM (DFI) 3-27Troubleshooting the DFI System□other□spark plug loose (tighten it)□spark plug dirty, broken, or gap maladjusted (remedy it)□spar

3-28 FUEL SYSTEM (DFI)DFI System Troubleshooting GuideNOTE○This is not an exhaustive list, giving every possible cause for each problem listed. It is

FUEL SYSTEM (DFI) 3-29DFI System Troubleshooting GuideSymptoms or possible Causes Actions (chapter)Brake lever or pedal not pulled in and gear notin n

3-30 FUEL SYSTEM (DFI)DFI System Troubleshooting GuideSymptoms or possible Causes Actions (chapter)ValvespringbrokenorweakInspect and replace (see cha

FUEL SYSTEM (DFI) 3-31DFI System Troubleshooting GuideSymptoms or Possible Causes Actions (chapter)Fuel injector trouble Inspect (see chapter 3).Throt

3-32 FUEL SYSTEM (DFI)DFI System Troubleshooting GuideSymptoms or Possible Causes Actions (chapter)Too low fuel pressure Inspect (see chapter 3).Water

FUEL SYSTEM (DFI) 3-33DFI System Troubleshooting GuideSymptoms or Possible Causes Actions (chapter)Engine overheating (see Overheating of Troubleshoot

3-34 FUEL SYSTEM (DFI)DFI System Troubleshooting GuideSymptoms or Possible Causes Actions (chapter)Piston ring bad (worn, weak, broken or sticking) In

FUEL SYSTEM (DFI) 3-35Self-DiagnosisSelf-diagnosis OutlineThe self-diagnosis system has two modes and can beswitched to another mode by grounding the