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MODEL APPLICATION

Year Model Beginning Frame No.


JKAVFDG1□CB500001
2012 KVF750GC
JKAVF750GGB600001
JKAVFDH1□CB500001
2012 KVF750HC
JKAVF750HHB600001
JKAVFDJ1□CB500001
2012 KVF750JC
JKAVF750HHB600001
JKAVFDL1□CB500001
2012 KVF750LC
JKAVF750LLB600001
JKAVFDG1□DB504801
2013 KVF750GD
JKAVF750GGB600901
JKAVFDH1□DB502201
2013 KVF750HD
JKAVF750HHB600501
2013 KVF750JD JKAVFDJ1□DB502201
JKAVFDL1□DB501201
2013 KVF750LD
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

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

This quick reference guide will assist


Appendix 17 j
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber 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 spe-
cific topic required.
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 idle speed control
Kawasaki automatic compression
ABDC after bottom dead center KACR
release
AC alternating current km/h kilometers per hour
Ah ampere hour L liter(s)
ATDC after top dead center lb pound(s)
BBDC before bottom dead center LCD liquid crystal display
BDC bottom dead center LED light emitting diode
BTDC before top dead center LSD limited slip differental
°C degree(s) celsius m meter(s)
cmHg centimeters of mercury min minute(s)
CPU central processing unit mmHg millimeters of mercury
cu in cubic inch(s) mph miles per hour
DC direct current N newton(s)
DFI digital fuel injection oz ounce(s)
DOT department of transportation Pa pascal(s)
ECU electronic control unit PS horsepower
EPS electric power steering psi pound(s) per square inch
F farad(s) qt quart(s)
°F degree(s) fahrenheit r revolution
ft foot, feet rpm revolution(s) per minute
g gram(s) s second(s)
gal gallon(s) TDC top dead center
h hour(s) TIR total indicator reading
HP horsepower(s) V volt(s)
IC integrated circuit W watt(s)
in. inch(s) Ω ohm(s)

COUNTRY AND AREA CODES


AU Australia GB United Kingdom
CA Canada US United States
EUR Europe
EMISSION CONTROL INFORMATION
(US and CA Models Only)

To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (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 con-
structed 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 know-
ingly 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 follow-
ing 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 de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
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 stan-
dards.
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 Guide shows you all of the product’s system
trained mechanics in a properly equipped shop. and assists in locating their chapters. Each
However, it contains enough detail and basic in- chapter in turn has its own comprehensive Ta-
formation to make it useful to the owner who de- ble of Contents.
sires to perform his own basic maintenance and For example, if you want engine oil informa-
repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locate
the proper use of tools, and workshop proce- the Engine lubrication System chapter. Then,
dures must be understood in order to carry out use the Table of Contents on the first page of
maintenance and repair satisfactorily. When- the chapter to find the Engine Oil section.
ever the owner has insufficient experience or Whenever you see symbols, heed their in-
doubts his ability to do the work, all adjust- structions! Always follow safe operating and
ments, maintenance, and repair should be car- maintenance practices.
ried out only by qualified mechanics.
DANGER
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor- DANGER indicates a hazardous situa-
oughly familiarize yourself with the procedures tion which, if not avoided, will result in
before starting work, and then do the work care- death or serious injury.
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift WARNING
tools or equipment. Precision measurements WARNING indicates a hazardous situa-
can only be made if the proper instruments are tion which, if not avoided, could result
used, and the use of substitute tools may ad- in death or serious injury.
versely affect safe operation.
For the duration of the warranty period, NOTICE
we recommend that all repairs and scheduled
maintenance be performed in accordance with NOTICE is used to address practices not
this service manual. Any owner maintenance or related to personal injury.
repair procedure not performed in accordance This manual contains four more symbols
with this manual may void the warranty. which will help you distinguish different types
To get the longest life out of your vehicle: of information.
• Follow the Periodic Maintenance Chart in the
Service Manual. NOTE
• Be alert for problems and non-scheduled ○This note symbol indicates points of par-
maintenance. ticular interest for more efficient and con-
• Use proper tools and genuine Kawasaki Vehi-
cle parts. Special tools, gauges, and testers
venient operation.

that are necessary when servicing Kawasaki • Indicates


done.
a procedural step or work to be
vehicles are introduced by the Service Man-
ual. Genuine parts provided as spare parts ○Indicates a procedural sub-step or how to do
are listed in the Parts Catalog. the work of the procedural step it follows. It
also precedes the text of a NOTE.
• Follow the procedures in this manual care-
fully. Don’t take shortcuts. Indicates a conditional step or what action to
take based on the results of the test or inspec-
• Remember to keep complete records of main-
tenance and repair with dates and any new tion in the procedural step or sub-step it fol-
parts installed. lows.
In most chapters an exploded view illustration
of the system components follows the Table of
How to Use This Manual Contents. In these illustrations you will find the
In this manual, the product is divided into instructions indicating which parts require spec-
its major systems and these systems make up ified tightening torque, oil, grease or a locking
the manual’s chapters. The Quick Reference agent during assembly.
GENERAL INFORMATION 1-1

General Information
Table of Contents
1
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-9
Unit Conversion Table ............................................................................................................ 1-12
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly oper-
ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, 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 ve-
hicle 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 ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, 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 be-
yond 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 disassem-
bly, 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 se-
quence 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 quar-
ter 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 dam-
age. 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 per-
formance. 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. Exces-
sive 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 con-
tact 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 in-
stalling 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. Lubri-
cation 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. Ro-
tate 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 thor-
oughly 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 [A] Engine Number


[B] Left Front Axle [B] Torque Converter Cover
GENERAL INFORMATION 1-9
General Specifications

Items KVF750GC ∼ GD/HC ∼ HD/JC ∼ JD/LC ∼ LD


Dimensions
Overall Length 2 195 mm (86.42 in.)
Overall Width 1 180 mm (45.46 in.)
Overall Height 1 220 mm (48.03 in.)
Wheelbase 1 285 mm (50.59 in.)
Ground Clearance 240 mm (9.45 in.)
Seat Height 910 mm (35.8 in.)
Curb Mass:
KVF750G (US, CA, AU) 315 kg (695 lb)
(EUR, GB) 316 kg (697 lb)
KVF750H/J (US, CA) 315 kg (695 lb)
KVF750L (US, CA) 310 kg (684 lb)
(EUR, GB) 311 kg (686 lb)
Front
KVF750G (US, CA, AU) 158 kg (348 lb)
(EUR, GB) 159 kg (351 lb)
KVF750H/J (US, CA) 158 kg (348 lb)
KVF750L (US, CA) 153 kg (337 lb)
(EUR, GB) 154 kg (340 lb)
Rear 157 kg (346 lb)
Fuel Tank Capacity 19 L (5.0 US gal)
Performance
Minimum Turning Radius 3.2 m (10.5 ft)
Engine
Type 4-stroke, SOHC, V2-cylinders
Cooling System Liquid-cooled
Bore and Stroke 85 × 66 mm (3.35 × 2.60 in.)
Displacement 749 cm3 (45.7 cu in.)
Compression Ratio 9.3 : 1
Maximum Horsepower (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 KVF750GC ∼ GD/HC ∼ HD/JC ∼ JD/LC ∼ LD


Valve Timing:
Intake:
Open 30° BTDC
Close 54° ABDC
Duration 264°
Exhaust:
Open 44° BBDC
Close 30° ATDC
Duration 254°
Lubrication System Forced lubrication (wet sump)
Engine oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1or MA2
Viscosity SAE 10W-40
Capacity 2.4 L (2.5 US qt)
Drive Train
Primary Reduction System:
Type Belt drive torque converter (CVT)
Reduction Ratio 3.122 ∼ 0.635
Transmission:
Type 2-speed and reverse
Gear Ratios:
Forward:
High 2.884 (29/27 × 29/18 × 20/12)
Low 4.833 (36/20 × 29/18 × 20/12)
Reverse 4.028 (16/12 × 18/16 × 29/18 × 20/12)
Final Drive System:
Type Shaft 2WD/4WD
Reduction Ratio 4.375 (35/8)
Overall Drive Ratio:
Forward:
High 39.39 ∼ 8.012
Low 66.02 ∼ 13.43
Reverse 55.01 ∼ 11.19
Front Final Gear Case Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 0.40 L (0.42 US qt)
Rear Final Gear Case Oil:
Type MOBIL FLUID 424, CITGO TRANSGARD TRACTOR HYDRAULIC
FLUID or EXXON HYDRAUL 560
Capacity 0.72 L (0.76 US qt)
GENERAL INFORMATION 1-11
General Specifications

Items KVF750GC ∼ GD/HC ∼ HD/JC ∼ JD/LC ∼ LD


Frame
Type Double tubular
Caster (Rake Angle) 2.0°
Camber 0.6°
King Pin Angle 10.8°
Trail 12 mm (0.47 in.)
Tread:
Front 925 mm (36.4 in.)
Rear 890 mm (35.0 in.)
Rim Size:
Front 12 × 6.0
Rear 12 × 7.5
Front tire:
Type Tubeless
Size AT25 × 8-12
Rear tire:
Type Tubeless
Size AT25 × 10-12
Suspension:
Front:
Type Double Wishbone
Wheel Travel 169 mm (6.65 in.)
Rear:
Type Double Wishbone
Wheel Travel 190 mm (7.48 in.)
Brake:
Front Disc × 2
Rear Enclosed wet multi-plate
Parking Brake Enclosed wet multi-plate
Electrical Equipment
Battery 12 V 12 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 35/35 W × 2
Tail/brake Light:
Bulb 12 V 5/21 W
Reverse Light:
Bulb (EUR, GB) 12 V 10 W
Alternator:
Type Three-phase AC
Rated Output 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: Units of Length:
km × 0.6214 = mile
Prefix Symbol Power m × 3.281 = ft
mega M × 1 000 000 mm × 0.03937 = in
kilo k × 1 000
centi c × 0.01
milli m × 0.001 Units of Torque:
micro µ × 0.000001 N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
Units of Mass:
kgf·m × 86.80 = in·lb
kg × 2.205 = lb
g × 0.03527 = oz
Units of Pressure:
kPa × 0.01020 = kgf/cm²
Units of Volume: kPa × 0.1450 = psi
L × 0.2642 = gal (US) kPa × 0.7501 = cmHg
L × 0.2200 = gal (IMP) kgf/cm² × 98.07 = kPa
L × 1.057 = qt (US) kgf/cm² × 14.22 = psi
L × 0.8799 = qt (IMP) cmHg × 1.333 = kPa
L × 2.113 = pint (US)
L × 1.816 = pint (IMP)
mL × 0.03381 = oz (US)
Units of Speed:
km/h × 0.6214 = mph
mL × 0.02816 = oz (IMP)
mL × 0.06102 = cu in

Units of Power:
kW × 1.360 = PS
Units of Force:
kW × 1.341 = HP
N × 0.1020 = kg
PS × 0.7355 = kW
N × 0.2248 = lb
PS × 0.9863 = HP
kg × 9.807 = N
kg × 2.205 = lb
Units of Temperature
PERIODIC MAINTENANCE 2-1

Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-3
Torque and Locking Agent...................................................................................................... 2-5 2
Specifications ......................................................................................................................... 2-13
Special Tools .......................................................................................................................... 2-15
Periodic Maintenance Procedures.......................................................................................... 2-16
Fuel System......................................................................................................................... 2-16
Throttle Lever Free Play Inspection .................................................................................. 2-16
Throttle Lever Free Play Adjustment ................................................................................ 2-16
Idle Speed Inspection ....................................................................................................... 2-17
Idle Speed Adjustment...................................................................................................... 2-17
Air Cleaner Element Cleaning and Inspection .................................................................. 2-17
Air Cleaner Draining.......................................................................................................... 2-18
Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... 2-18
Fuel Hose Replacement ................................................................................................... 2-19
Cooling System.................................................................................................................... 2-21
Radiator Cleaning ............................................................................................................. 2-21
Water Hoses and Connections Inspection ........................................................................ 2-22
Coolant Change ................................................................................................................ 2-22
Engine Top End ................................................................................................................... 2-24
Valve Clearance Inspection .............................................................................................. 2-24
Valve Clearance Adjustment............................................................................................. 2-26
Spark Arrester Cleaning.................................................................................................... 2-26
Converter System ................................................................................................................ 2-27
Converter Drive Belt Wear Inspection............................................................................... 2-27
Converter Drive Belt Deflection Inspection ....................................................................... 2-27
Converter Drive Belt Deflection Adjustment...................................................................... 2-28
Actuator Lever (Engine Brake Control Lever) Assembly Inspection ................................. 2-29
Engine Lubrication System .................................................................................................. 2-29
Engine Oil Change............................................................................................................ 2-29
Oil Filter Replacement ...................................................................................................... 2-30
Wheels/Tires ........................................................................................................................ 2-30
Tire Inspection .................................................................................................................. 2-30
Final Drive............................................................................................................................ 2-31
Variable Differential Control Lever Play Inspection ........................................................... 2-31
Variable Differential Control Lever Play Adjustment ......................................................... 2-31
Front Final Gear Case Oil Change ................................................................................... 2-32
Rear Final Gear Case Oil Change .................................................................................... 2-33
Brakes.................................................................................................................................. 2-34
Front Brake Pad Wear Inspection..................................................................................... 2-34
Front Brake Hoses and Connections Inspection............................................................... 2-34
Front Brake Hose Replacement........................................................................................ 2-34
Front Brake Fluid Level Inspection ................................................................................... 2-35
Front Brake Fluid Change................................................................................................. 2-36
Front Brake Master Cylinder Piston Assembly and Dust Cover Replacement ................. 2-37
Front Brake Caliper Fluid Seal Replacement.................................................................... 2-37
Front Brake Caliper Dust Seal and Friction Boot Replacement........................................ 2-37
Rear Brake Plates Replacement....................................................................................... 2-37
Rear Brake Lever Free Play Inspection ............................................................................ 2-38
Rear Brake Pedal Free Play Inspection............................................................................ 2-38
Rear Brake Lever and Pedal Free Play Adjustment ......................................................... 2-38
2-2 PERIODIC MAINTENANCE

Steering ............................................................................................................................... 2-39


Steering Inspection ........................................................................................................... 2-39
Electrical System ................................................................................................................. 2-39
Spark Plug Cleaning/Inspection........................................................................................ 2-39
Spark Plug Gap Inspection ............................................................................................... 2-40
Front Brake Light Switch Inspection ................................................................................. 2-40
Rear Brake Light Switch Inspection .................................................................................. 2-40
Rear Brake (Pedal) Light Timing Adjustment.................................................................... 2-40
Converter Drive Belt Failure Detection System Inspection ............................................... 2-41
Joint Boots Inspection.......................................................................................................... 2-43
Front Axle/Steering Knuckle Joint Boots Inspection ......................................................... 2-43
Front Propeller Shaft Joint Boots Inspection..................................................................... 2-43
Tie-rod End Boots Inspection............................................................................................ 2-43
Rear Propeller Shaft Joint Boots Inspection ..................................................................... 2-43
Rear Axle/Stabilizer Joint Boots Inspection ...................................................................... 2-43
General Lubrication ............................................................................................................. 2-44
Lubrication ........................................................................................................................ 2-44
Bolts and Nuts Tightening.................................................................................................... 2-45
Tightness Inspection ......................................................................................................... 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
Regular Service
Service
Every 90
days, 1
700 km (1
Every Every
100 mi.)
After 10 10 30
of use or
hrs. or days or days or Every
when belt See
100 km 200 km 600 km year of
indicator page
(60 mi.) (120 (360 use
light turns
of use mi.) of mi.) of
on (100
use use
hrs of use)
whichever
OPERATION comes first
ENGINE
Converter drive belt wear-inspect* • 2-27
Converter drive belt deflection- inspect* • 2-27
Converter drive belt failure detection
system function-inspect* • 2-41

Engine brake control lever-inspect* • 2-29


Air cleaner-inspect* • • 2-17
Throttle lever play-inspect • • 2-16
Idle speed-inspect • 2-17
First 1 700 km (1 100 mile); thereafter
Valve clearance-inspect 2-24
every 3 400 km (2 200 mile)
Engine oil-change* • • 2-29
Oil filter-replace* • • 2-30
2-39,
Spark plug-clean and gap • • 2-40
Spark arrester-clean • 2-26
Fuel hoses and connections-inspect • 2-18
Fuel hose-replace 5 years 2-19
Radiator-clean* • • 2-20
Radiator hoses and connections-inspect* • • 2-21
Coolant-change* 2 years 2-21
CHASSIS
Joint boots-inspect* • • 2-43
Rear brake pedal and lever play-inspect* • • 2-38
Rear brake plates-replace* every 10 000 km (6 000 mi.) 2-37
Bolts and nuts-tighten • • 2-45
Front brake pad wear-inspect* • • 2-34
Brake light switch-inspect* • • 2-40
Steering-inspect • • 2-39
Differential control lever play-inspect • • 2-31
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart

FREQUENCY First
Regular Service
Service
Every 90
days, 1
700 km (1
Every Every
100 mi.)
After 10 10 30
of use or
hrs. or days or days or Every
when belt See
100 km 200 km 600 km year of
indicator page
(60 mi.) (120 (360 use
light turns
of use mi.) of mi.) of
on (100
use use
hrs of use)
whichever
OPERATION comes first
Tire wear-inspect* • 2-30
2-32,
Front and rear final gear case oil-change • • 2-33
General lubrication-perform* • 2-44
Front brake fluid level-inspect • • 2-35
Front brake fluid-change • 2-36
Front brake hoses and connections-inspect • 2-34
Front brake master cylinder piston
2 years 2-37
assembly and dust cover-replace
Front brake caliper fluid seal and dust
2 years 2-37
seal-replace
Front brake hose-replace 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.

Torque
Fastener Remarks
N·m kgf·m ft·lb
Fuel System
Air Cleaner Housing Bolts 8.8 0.90 78 in·lb
Air Cleaner Element Holder Screw 3.5 0.36 31 in·lb
Air Cleaner Element Holder Tapping Screw 1.5 0.15 13 in·lb
Water Temperature Sensor 12 1.2 106 in·lb
ISC Valve Mounting Bolts 8.8 0.90 78 in·lb
Intake Air Pressure Sensor Mounting Screw 3.5 0.36 31 in·lb
Delivery Pipe Mounting Screws 5.0 0.51 44 in·lb
Valve Adjusting Cap Bolt 8.8 0.90 78 in·lb
Joint Duct Bolts 8.8 0.90 78 in·lb
Heat Guard Bolts 8.8 0.90 78 in·lb
Fuel Pump Bolts 4.0 0.41 35 in·lb
Fuel Tank Mounting Bolts 10 1.0 89 in·lb
Vehicle-down Sensor Mounting Bolts 5.9 0.6 52 in·lb L
Throttle Lever Limiter Screw 3.6 0.37 32 in·lb
Throttle Lever Limiter Nut 3.6 0.37 32 in·lb
Throttle Case Assembly Screws 3.6 0.37 32 in·lb
Cooling System
Radiator Screen Mounting Bolts 4.0 0.41 35 in·lb
Radiator Mounting Bolts 8.8 0.90 78 in·lb
Reserve Tank Mounting Screw 4.0 0.41 35 in·lb L
Coolant Drain Bolts (Cylinder) 7.0 0.71 62 in·lb
Radiator Fan Assembly Bolts 8.4 0.86 74 in·lb
Air Bleed Bolt 7.0 0.71 62 in·lb
Thermostat Housing Cover Bolts 8.8 0.90 78 in·lb
Water Pipe Joint Bolts 8.8 0.90 78 in·lb
Water Pump Impeller 7.8 0.80 69 in·lb
Water Pump Cover Bolts 8.8 0.90 78 in·lb
Coolant Drain Bolt (Water Pump) 7.0 0.71 62 in·lb
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Engine Top End
Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb
Rocker Case Bolts 55 mm (2.2 in.) 8.8 0.90 78 in·lb S
Rocker Case Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb
Rocker Case Bolts 25 mm (1.0 in.) 9.8 1.0 87 in·lb
Rocker Case Bolts 130 mm (5.1 in.) 9.8 1.0 87 in·lb S
Rocker Case Bolts 20 mm (0.8 in.)
9.8 1.0 87 in·lb
(KVF750GD/HD/JD/LD Late Models)
Cylinder Head Bolt (M6) 9.8 1.0 87 in·lb
Cylinder Head Bolts (M10), First Torque 25 2.5 18
MO, S
Cylinder Head Bolts (M10), Final Torque 55 5.6 41
Water Pipe Bolts 8.8 0.90 78 in·lb
Valve Adjusting Screw Locknuts 12 1.2 106 in·lb
Rocker Shaft Bolts 22 2.2 16
Camshaft Sprocket Bolts 12 1.2 106 in·lb L
Camshaft Chain Tensioner Cap Bolts 22 2.2 16
Camshaft Chain Tensioner Mounting Bolts 8.8 0.90 78 in·lb
Front Cylinder Camshaft Chain Guide Bolt 20 2.0 15
Rear Cylinder Camshaft Chain Guide Bolt 20 2.0 15
Position Plate Bolts 8.8 0.90 78 in·lb
Intermediate Shaft Chain Guide Bolts 8.8 0.90 78 in·lb EO
Intermediate Shaft Chain Tensioner Bolts 8.8 0.90 78 in·lb
Cylinder Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb
Cylinder Bolts 40 mm (1.6 in.) 9.8 1.0 87 in·lb
Coolant Drain Bolts (Cylinder) 7.0 0.71 62 in·lb
Exhaust Pipe Holder Nuts 17 1.7 13
Exhaust Pipe Cover Clamp Screws 2.1 0.21 19 in·lb
Muffler Clamp Bolts 15 1.5 11
Muffler Mounting Bolts 34 3.5 25
Converter System
Drive Pulley Bolt 93 9.5 69 R, Lh
Drive Pulley Cover Bolts 13 1.3 115 in·lb
Spider 275 28.0 203 Lh
Ramp Weight Nuts 7.0 0.71 62 in·lb R
Driven Pulley Nut 93 9.5 69 R
Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb S
Torque Converter Cover Bolts 8.8 0.90 78 in·lb S
Joint Duct Bolts 8.8 0.90 78 in·lb
Engine Lubrication System
Oil Pipe Bolts 8.8 0.90 78 in·lb
Oil Filter 17.5 1.78 12.9 R
Oil Filter Mounting Bolt 25 2.5 18 L (15 mm)
Oil Pressure Relief Valve 15 1.5 11 L
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Oil Pressure Switch 15 1.5 11 SS
Oil Pump Chain Guide Bolt 8.8 0.90 78 in·lb
Oil Pump Cover Bolts 8.8 0.90 78 in·lb
Engine Oil Drain Bolt 20 2.0 15
Oil Pump Drive Chain Tensioner Bolt 25 2.5 18
Drive Pulley Back Plate Bolts 8.8 0.90 78 in·lb
Engine Removal/Installation
Engine Mounting Bracket Bolts 71.5 7.3 53 L
Engine Mounting Bolt 101.5 10.4 75 LB
Engine Mounting Nut 101.5 10.4 75 R
Crankshaft/Transmission
Connecting Rod Big End Cap Nuts 34.3 3.50 25.3 MO
Rear Cylinder Camshaft Chain Guide Bolt 20 2.0 15
Bearing Position Plate Screws 4.9 0.50 43 in·lb L
Engine Oil Drain Bolt 20 2.0 15
Crankcase Bolt (M8, L = 110 mm) 20 2.0 15 S, L
Crankcase Bolts (M8, L = 75 mm) 20 2.0 15 S
Crankcase Bolts (M6, L = 40 mm) 9.8 1.0 87 in·lb
Crankcase Bolts (M8, L = 110 mm) 20 2.0 15 S
Crankcase Bolts (M6, L = 65 mm) 9.8 1.0 87 in·lb
Shift Lever Guide Mounting Bolts 19.6 2.00 14.5
Grip Holder Nut 9.8 1.0 87 in·lb
Tie-rod End Front Locknut 9.8 1.0 87 in·lb Lh
Tie-rod End Rear Locknut 9.8 1.0 87 in·lb
Tie-rod End Nut 19.6 2.00 14.5 R
Shift Lever Clamp Bolt 13.5 1.38 119 in·lb
Shift Shaft Cover Bolts 8.8 0.90 78 in·lb
Shift Lever Guide Mounting Nut 19.6 2.00 14.5 R
Tie-rod End Bolt 9.8 1.0 87 in·lb
Tie-rod End Locknut 19.6 2.00 14.5
Shift Lever Assembly Nut 19.6 2.00 14.5 R
Neutral Switch 15 1.5 11
Heat Guard Bolt 8.8 0.90 78 in·lb
Reverse Switch 15 1.5 11
Shift Shaft Positioning Bolt 25 2.5 18
Shift Shaft Spring Bolt 31 3.2 23 LB
Wheel/Tires
Wheel Nuts (First Torque) 15 1.5 11 S
Wheel Nuts (Final Torque) 76.5 7.8 56 S
Front Axle Nuts 195.5 19.9 144
Tie-rod Locknuts 36.5 3.7 27 Lh (2)
Tie-rod End Nuts 41.5 4.2 31 R
Rear Axle Nuts 264.5 27.0 195
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Final Drive
(Output Bevel Gears)
Bearing Holder 120 12.2 88.5 L
Bevel Gear Holder Nut 200 20.4 148 LB
Bearing Holder 250 25.5 184 L
Output Shaft Holder Nut 200 20.4 148 LB
Output Driven Bevel Gear Housing Bolts 26 2.7 19
Output Drive Bevel Gear Housing Bolts 26 2.7 19
Rotor Mounting Bolts 12 1.2 106 in·lb
Output Drive Bevel Gear Cover Bolts 8.8 0.90 78 in·lb
Forward/Reverse Detecting Sensor Mounting Bolt 14.9 1.52 11.0
(Front Final Gear Case)
Variable Differential Control Lever Bolt 3.4 0.35 30 in·lb L
Variable Differential Control Cable Locknut 17 1.7 13
Front Final Gear Case Oil Filler Cap 29 3.0 21 EO
2WD/4WD Actuator Cover Mounting Bolts 9.8 1.0 87 in·lb
Variable Differential Control Shift Shaft Lever Nut 8.8 0.90 78 in·lb R
Front Final Gear Case Oil Drain Bolt 15 1.5 11 EO
Ring Gear Bolts 57 5.8 42 LB, S
2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·lb L, S
Pinion Gear Bearing Holder Nut 127 13.0 93.7 St
Pinion Gear Bearing Holder 137 14.0 101 L
Front Final Gear Case Coupling Nut 25 2.5 18
Front Final Gear Case Mount Nuts 59 6.0 44 R
Front Final Gear Case Left Cover Bolts (M6) 9.8 1.0 87 in·lb L (4), S
Front Final Gear Case Center Cover Bolts (M6) 9.8 1.0 87 in·lb L
Front Final Gear Case Center Cover Bolts (M8) 24 2.4 18 L
(Rear Final Gear Case)
Rear Final Gear Case Front Cover Bolts 24 2.4 18 L
Pinion Gear Bearing Holder Nut 157 16.0 116 LB, R
Pinion Gear Bearing Holder 450 45.9 332 L, St
Rear Final Gear Case Gasket Screws 1.25 0.127 11.1 in·lb
Rear Final Gear Case Oil Filler Cap 29 3.0 21
Rear Final Gear Case Oil Drain Bolt 15 1.5 11
Rear Final Gear Case Bracket Bolts 59 6.0 44 L
Rear Final Gear Case Mount Nuts 90.5 9.23 66.8 R, L
Rear Final Gear Case Right Cover Bolts (M10) 49 5.0 36 L
Rear Final Gear Case Right Cover Bolts (M12) 95 9.7 70 L
Rear Final Gear Case Right Cover Bolts (M8) 24 2.4 18 L
Brakes
Reservoir Cap Screws 1.5 0.15 13 in·lb
Front Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si
Front Brake Light Switch Mounting Screw 1.2 0.12 11 in·lb
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Front Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
Front Brake Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
Brake Hose Banjo Bolts 25 2.5 18
Front Brake Pad Mounting Bolts 17 1.7 13
Bleed Valves 7.8 0.80 69 in·lb
Front Brake Disc Mounting Bolts 36.5 3.72 26.9 L
Front Brake Caliper Mounting Bolts 24.5 2.50 18.1
Front Brake Caliper Holder Shaft 17 1.7 13 Si
Front Brake Caliper Holder Shaft Nut 22 2.2 16 L
Rear Brake Lock Lever Pivot Screw 2.2 0.22 19 in·lb L
Rear (Parking) Brake Lever Pivot Bolt 2.2 0.22 19 in·lb
Rear (Parking) Brake Lever Pivot Nut 3.4 0.35 30 in·lb
Variable Differential Control Lever Bolt 3.4 0.35 30 in·lb L
Rear Final Gear Case Gasket Screws 1.25 0.127 11.1 in·lb
Suspension
Front Shock Absorber Mounting Nuts 34 3.5 25 R
Front Suspension Arm Pivot Upper Nuts 59 6.0 44 R
Steering Knuckle Joint Nuts 50 5.1 37
Front Suspension Arm Pivot Lower Nuts 46.5 4.7 34 R
Rear Shock Absorber Mounting Nuts 34 3.5 25 R
Stabilizer Holder Bolts 21.5 2.2 16
Stabilizer Joint Nuts 57.5 5.9 42 R
Rear Suspension Arm Pivot Nuts 46.5 4.7 34 R
Rear Knuckle Mounting Nuts 46.5 4.7 34 R
Steering
Rear Brake Lock Lever Pivot Screw 2.2 0.22 19 in·lb L
Rear (Parking) Brake Lever Pivot Bolt 2.2 0.22 19 in·lb
Rear (Parking) Brake Lever Pivot Nut 3.4 0.35 30 in·lb
Variable Differential Control Lever Bolt 3.4 0.35 30 in·lb L
Left Handlebar Switch Housing Screws 3.5 0.36 31 in·lb
Throttle Case Assembly Screws 3.6 0.37 32 in·lb
Throttle Lever Limiter Screw 3.6 0.37 32 in·lb
Throttle Lever Limiter Nut 3.6 0.37 32 in·lb
Front Brake Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
Handlebar Holder Bolts 29 3.0 21 S
Tie-rod End Nuts 41.5 4.23 30.6 R
Tie-rod Locknuts 36.5 3.72 29.9 Lh (2)
Steering Knuckle Joint Nuts 50 5.1 37
(KVF750G/H/J)
Steering Shaft Upper Bracket Bolts 20 2.0 15 S
EPS Unit Mounting Bolts 20 2.0 15
EPS Unit Mounting Bracket Bolts 35 3.6 26
Steering Shaft Lower Clamp Nut 24.5 2.50 18.1 R
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Steering Shaft Holder Nuts (First) 10 1.0 89 in·lb R, S
Steering Shaft Holder Nuts (Final) 18 1.8 13 R, S
Pitman Arm Mounting Nut 110 11.2 81.1
Steering Shaft Lower End Stopper Mounting Bolts 22.5 2.29 16.6 L
EPS ECU Mounting Nut 6.9 0.70 61 in·lb
(KVF750L)
Steering Shaft Upper Bracket Bolts 20 2.0 15
Steering Shaft Lower End Holder Mounting Bolts 35 3.6 26
Steering Shaft Holder Nuts 18 1.8 13 R
Pitman Arm Mounting Nut 90 9.2 66
Frame
Front Carrier Bolts, L = 70 mm (2.8 in.) 31.5 3.21 23.2 L
Front Carrier Bolts, L = 50 mm (2.0 in.) 31.5 3.21 23.2 L
Front Carrier Bracket Bolts 31.5 3.21 23.2 L
Front Guard Bolts 36.5 3.72 26.9
Rear Carrier Bolts, L = 14 mm (0.55 in.)
(KVF750GC/HC/JC/LC Early Models)
54 5.5 40 L
Rear Carrier Bolts, L = 16 mm (0.63 in.)
(KVF750GC/HC/JC/LC Late Models ∼)
Rear Carrier Bolts, L = 44 mm (1.7 in.) 54 5.5 40 L
Rear Carrier Bracket Bolts 46.5 4.74 34.3
Rear Final Gear Case Mounting Bracket Bolts 59 6.0 44 L
Trailer Hitch Bracket Bolts 81.5 8.31 60.1 L
Footboard Bracket Bolts 46.5 4.74 34.2
Electrical System
Harness Clamp Bolt 8.8 0.90 78 in·lb
Starter Motor Mounting Bolts 8.8 0.90 78 in·lb
Starter Motor Cable Mounting Nut 6.8 0.69 60 in·lb
Starter Motor Terminal Locknut 11 1.1 97 in·lb
Starter Motor Through Bolts 5.0 0.51 44 in·lb
Starter Motor Clutch Bolts 34 3.5 25 L
Crankshaft Sensor Mounting Bolts 5.9 0.60 52 in·lb
Alternator Rotor Bolt 127 13.0 93.7
Alternator Stator Bolts 13.5 1.38 119 in·lb LB
Breather Plate Screws 2.9 0.30 26 in·lb L
Alternator Cover Plugs 17.5 1.78 12.9
Alternator Rotor Bolt Cap 2.5 0.25 22 in·lb
Timing Inspection Cap 5.0 0.51 44 in·lb
Alternator Cover Bolts 8.8 0.90 78 in·lb
2WD/4WD Actuator Cover Mounting Bolts 9.8 1.0 87 in·lb
2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·lb L, S
Ignition Coil Bracket Mounting Bolts 8.8 0.90 78 in·lb
Ignition Coil Mounting Bolts 5.9 0.60 52 in·lb
PERIODIC MAINTENANCE 2-11
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Spark Plugs 13 1.3 115 in·lb
Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb S
Speed Sensor Mounting Bolt 8.8 0.90 78 in·lb
Neutral Switch 15 1.5 11
Heat Guard Bolt 8.8 0.90 78 in·lb
Reverse Switch 15 1.5 11
Forward/Reverse Detecting Sensor Mounting Bolt 14.9 1.52 11.0
Left Switch Housing Screws 3.5 0.36 31 in·lb
Throttle Lever Limiter Screw 3.6 0.37 32 in·lb
Throttle lever Limiter Nut 3.6 0.37 32 in·lb
Throttle Case Assembly Screws 3.6 0.37 32 in·lb
Radiator Fan Assembly Bolts 8.4 0.86 74 in·lb
Tail/Brake Light Lens Screws 1.47 0.150 13.0 in·lb
Regulator/Rectifier Mounting Bolts 8.8 0.90 78 in·lb
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb
Joint Duct Bolts 8.8 0.90 78 in·lb

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. Torque
Mark of bolt head
mm (in.) N·m kgf·m ft·lb
5 (0.20) 4T 2.2 ∼ 2.6 0.22 ∼ 0.27 19 ∼ 23 in·lb
6 (0.24) 9T 12 ∼ 15 1.2 ∼ 1.5 104 ∼ 130 in·lb
6 (0.24) 7T 7.8 ∼ 9.8 0.8 ∼ 1.0 69 ∼ 87 in·lb
6 (0.24) 4T 3.9 ∼ 4.9 0.4 ∼ 0.5 35 ∼ 43 in·lb
8 (0.31) 7T 18 ∼ 22 1.8 ∼ 2.2 13 ∼ 16
8 (0.31) 4T 10 ∼ 14 1.0 ∼ 1.4 87 ∼ 122 in·lb
10 (0.39) 7T 39 ∼ 44 4.0 ∼ 4.5 29 ∼ 33
10 (0.39) 4T 20 ∼ 24 2.0 ∼ 2.4 14 ∼ 17

Basic Torque for General Fasteners of Frame Parts


Torque
Threads dia. mm (in.)
N·m kgf·m ft·lb
5 (0.20) 3.4 ∼ 4.9 0.35 ∼ 0.5 30 ∼ 43 in·lb
6 (0.24) 5.9 ∼ 7.8 0.6 ∼ 0.8 52 ∼ 69 in·lb
8 (0.31) 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 (0.39) 25 ∼ 34 2.6 ∼ 3.5 19 ∼ 25
12 (0.47) 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 (0.55) 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 (0.63) 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
2-12 PERIODIC MAINTENANCE
Torque and Locking Agent

18 (0.71) 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165


20 (0.79) 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240
PERIODIC MAINTENANCE 2-13
Specifications

Item Standard Service Limit


Fuel System
Throttle Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –
Idle Speed 1 100 ±50 r/min (rpm) – – –
Air Cleaner Element Oil High-quality foam air filter oil – – –
Cooling System
Coolant:
Type (Recommended) Permanent type antifreeze – – –
Color Green – – –
Mixed Ratio Soft water 50%, Coolant 50% – – –
Freezing Point −35°C (−31°F) – – –
Total Amount 3.0 L (3.2 US qt) – – –
Engine Top End
Valve Clearance:
Exhaust 0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.) – – –
Intake 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) – – –
Converter System
Belt Width 30.0 ∼ 30.6 mm (1.18 ∼ 1.20 in.) 28.6 mm (1.13 in.)
Belt Deflection 22 ∼ 27 mm (0.87 ∼ 1.06 in.) – – –
Actuator Lever Guide Shoe ––– 6 mm (0.24 in.)
Engine Lubrication System
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA,
– – –
MA1 or MA2
Viscosity SAE10W-40 – – –
1.9 L (2.0 US qt) – – –
Capacity
(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)
Wheels/Tires
Tire Tread Depth:
Front 13.0 mm (0.51 in.) 3 mm (0.12 in.)
Rear 14.5 mm (0.57 in.) 4 mm (0.16 in.)
Standard tire:
Front AT 25 × 8-12 – – –
DURO, DI-K911, Tubeless – – –
Rear AT 25 × 10-12 – – –
DURO, DI-K591, Tubeless – – –
Final Drive
Front Final Gear Case:
Gear Case Oil:
Type API SG, SH, SJ, SL or SM with JASO MA,
– – –
MA1 or MA2
Viscosity SAE 10W-40 – – –
2-14 PERIODIC MAINTENANCE
Specifications

Item Standard Service Limit


Oil Level Filler opening bottom – – –
Capacity 0.40 L (0.42 US qt) – – –
Rear Final Gear Case:
Gear Case Oil:
Type MOBIL FLUID 424, CITGO
TRANSGARD TRACTOR HYDRAULIC – – –
FLUID or EXXON HYDRAUL 560
Oil Level Filler opening bottom – – –
Capacity 0.72 L (0.76 US qt) – – –
Brakes
Front Brake Fluid:
Type DOT3 or DOT4 – – –
Front Disc Brake:
Pad Lining Thickness 4 mm (0.16 in.) 1 mm (0.04 in.)
Rear Brake Lever, Pedal and
Cables:
Rear Brake Lever Free Play 1 ∼ 2 mm (0.04 ∼ 0.08 in.) – – –
Brake Pedal Free Play 15 ∼ 25 mm (0.6 ∼ 1.0 in.) – – –
Electrical System
Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.) – – –
Brake Light Timing:
Front Pulled ON – – –
Rear (Lever) Pulled ON – – –
ON after about 10 mm (0.4 in.) of pedal
Rear (Pedal) – – –
travel
PERIODIC MAINTENANCE 2-15
Special Tools
Valve Adjusting Screw Holder: Pulley Holder Attachment:
57001-1217 57001-1472

Oil Filter Wrench: Flywheel & Pulley Holder:


57001-1249 57001-1605

Filler Cap Driver:


57001-1454
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System
Throttle Lever Free Play Inspection
• Check that the throttle lever [A] moves smoothly from full
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


• Slide the rubber cover off the adjuster at the throttle case.
• adjuster the
Loosen locknut [A] and turn the throttle cable upper
[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
• Start the engine and warm it up thoroughly.
• With the engine idling, turn the handlebar to both sides to
check for any changes in the idle speed.
If handlebar movement changes the idle speed, the throt-
tle 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.

• Check idle speed with a suitable tachometer.


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 any-
where near the working areas. Do not use gasoline
or low flash-point solvents to clean the element.
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• Remove the air cleaner element (see Air Cleaner Element


Removal in the Fuel System (DFI) chapter).
• Clean the element [A] in a bath of high flash-point solvent.

• Squeeze it dry in a clean towel [A]. Do not wring the ele-


ment or blow it dry; the element can be damaged.
• Inspect the element for damage.
If it is torn, punctured, or hardened, replace it.
• After cleaning, saturate the element with a high-quality
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


• Iftaking
any water or oil accumulates in the tube, drain it by
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 vehi-
cle’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. Re-
move 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.

• Check that the hoses are routed according to Cable, Wire,


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

•○Check that the hose joints are securely connected.


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 in-
stalled correctly on the delivery pipe by sliding the
joint.

Fuel Hose Replacement


WARNING
Gasoline is extremely flammable and can be ex-
plosive 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.

• Disconnect the fuel hose from the fuel pump (see Fuel
Pump Removal in the Fuel System (DFI) chapter).
• Be sure to place a piece of cloth [A] around the fuel hose
joint.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.

• Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.
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