kawasaki KVF750 / brute force
SERVICE MANUAL
KAWASAKI KVF750 - BRUTE FORCE 750 - WORKSHOP, SERVICE, REPAIR MANUAL - English Service Manual to ATV Kawasaki KVF750 / Brute Force 750. CONTENTS: FOREWORD GENERAL INFORMATION - Before starting to perform an inspection service or carry out a - Battery Ground - Edges of Parts - Solvent - Cleaning Vehicle before Disassembly - Arrangement and Cleaning of Removed Parts - Storage of Removed Parts - Inspection - Replacement Parts - Assembly Order - Tightening Sequence - Tightening Torque - Force - Gasket, O-ring - Liquid Gasket, Locking Agent - Press - Ball Bearing and Needle Bearing - Oil Seal, Grease Seal - Circlips, Cotter Pins - Lubrication - Direction of Engine Rotation - Electrical Wires - Instrument - KVF750D8F Left Side View - KVF750D8F Right Side View - Frame Number - Engine Number - Prefixes for Units: - Units of Temperature PERIODIC MAINTENANCE - The scheduled maintenance must be done in accordance with this c - The following tables list the tightening torque for the major fa - Oil Filter Wrench: - Fuel System - Throttle Lever Free Play Inspection - Throttle Lever Free Play Adjustment - Idle Speed Inspection - Idle Speed Adjustment - Air Cleaner Element Cleaning and Inspection - Air Cleaner Draining - Fuel Hose Inspection (fuel leak, damage, installation condition) - Fuel Hose Replacement - Cooling System - Engine Top End - Converter System - Engine Lubrication System - Wheels/Tires - Final Drive - Brakes - Steering - Electrical System - Joint Boots Inspection - General Lubrication - Bolts and Nuts Tightening FUEL SYSTEM (DFI) - DFI System - DFI System Wiring Diagram - FI Indicator Light (LCD) [A] - Vacuum Gauge Adapter: - DFI Servicing Precautions - Outline - Special Tool - - Sealant - - Special Tool - - DFI Diagnosis Flow Chart - Inquiries to Rider - NOTE - Self-diagnosis Outline - Self-diagnosis Procedures - How to Read Service Codes - How to Erase Service Codes - Service Code Table - Backups - Throttle Sensor Removal/Adjustment - Throttle Sensor Input Voltage Inspection - Throttle Sensor Output Voltage Inspection - Throttle Sensor Resistance Inspection - Throttle Sensor Circuit - CAUTION - Inlet Air Pressure Sensor Removal - Inlet Air Pressure Sensor Installation - Inlet Air Pressure Sensor Input Voltage Inspection - Inlet Air Pressure Sensor Output Voltage Inspection - Inlet Air Pressure Sensor Circuit - Inlet Air Temperature Sensor Removal/Installation - Inlet Air Temperature Sensor Output Voltage Inspection - Inlet Air Temperature Sensor Resistance Inspection - Inlet Air Temperature Sensor Circuit - Water Temperature Sensor Removal/Installation - Water Temperature Sensor Output Voltage Inspection - Water Temperature Sensor Resistance Inspection - Water Temperature Sensor Circuit - Start the engine and switch the diagnosis mode to Dealer 1 mode - Crankshaft Sensor Removal/Installation - Crankshaft Sensor Inspection - Crankshaft Sensor Circuit - Speed Sensor Removal - Speed Sensor Installation - Speed Sensor Inspection - Input Voltage Inspection - Output Voltage Inspection - Speed Sensor Circuit - Vehicle-down Sensor Removal - Vehicle-down Sensor Installation - Vehicle-down Sensor Inspection - Vehicle-down Sensor Circuit - Fuel Pump Relay Removal - Fuel Pump Relay Inspection - Fuel Pump Relay Circuit - Ignition Coil ##1: Ignition Coil for Front Cylinder (Service Code - Ignition Coil Removal/Installation - Input Voltage Inspection - Fuel Injector Removal - Fuel Injector Installation - Audible Inspection - Fuel Injector Power Source Voltage Inspection - Fuel Injector Output Voltage Inspection - Injector Signal Test - Injector Resistance Inspection - Injector Unit Test - Injector Fuel Line Inspection - Fuel Injector Circuit - Inspection Flow Chart - Light Inspection - FI Indicator Light (LCD) Circuit - CAUTION - ECU Removal - ECU Installation - ECU Power Supply Inspection - ECU Power Source Circuit - Fuel Pressure Inspection - Special Tools - - Fuel Flow Rate Inspection - Fuel Pump Removal - Fuel Pump Installation - Fuel Pump Operation Inspection - Fuel Pump Operating Voltage Inspection - Pressure Regulator Removal - Pump Screen, Fuel Filter Cleaning - Fuel Pump Circuit - Throttle Lever Free Play Inspection - Throttle Lever Free Play Adjustment - Throttle Case Removal/Disassembly - Throttle Case Assembly/Installation - Throttle Cable Installation - Throttle Case Inspection - Throttle Cable Lubrication and Inspection - Idle Speed Inspection - Throttle Body Assy Removal - Throttle Body Assy Installation - Throttle Body Assy Disassembly - Throttle Body Assy Assembly - Engine Vacuum Synchronization Inspection - Engine Vacuum Synchronization Adjustment - ISC Valve Removal - ISC Valve Installation - ISC Valve Inspection - Air Cleaner Element Removal - Air Cleaner Element Installation - Air Cleaner Element Cleaning and Inspection - Air Cleaner Housing Removal - Air Cleaner Housing Installation - Fuel Tank Removal - Fuel Tank Installation - Fuel Tank Cleaning COOLING SYSTEM - Permanent type antifreeze is used as a coolant to protect the co - Bearing Driver Set: - Coolant Deterioration Inspection - Coolant Level Inspection - Coolant Draining - Coolant Filling - Pressure Testing - Water Pump Cover Removal - Water Pump Cover Installation - Water Pump Impeller Removal - Water Pump Impeller Installation - Water Pump Impeller Inspection - Water Pump Leakage Inspection - Mechanical Seal Replacement - Radiator Removal - Radiator Installation - Radiator Fan Removal - Radiator Fan Installation - Radiator Inspection - Radiator Cleaning - Radiator Cap Inspection - Thermostat Removal - Thermostat Installation - Thermostat Inspection - Water Temperature Sensor Removal/Installation - Water Temperature Sensor Inspection ENGINE TOP END - Outside Circlip Pliers: - Camshaft Chain Tensioner Removal - Camshaft Chain Tensioner Installation - Rocker Case Removal - Special Tool - - Rocker Case Installation - Rocker Arm Removal - Rocker Arm Installation - Rocker Arm Inspection - Rocker Shaft Diameter Measurement - Camshaft Removal - Camshaft Installation - Camshaft Assembly - Cam Wear Inspection - Camshaft Bearing Wear Inspection - KACR Inspection - KACR Removal - KACR Installation - Camshaft Chain Removal - Camshaft Chain Installation - Camshaft Chain Guide Wear Inspection - Cylinder Compression Measurement - Special Tools - - Cylinder Head Removal - Cylinder Head Installation - Cylinder Head Cleaning - Cylinder Head Warp Inspection - Valve Clearance Inspection - Valve Clearance Adjustment - Valve Removal - Valve Installation - Valve Guide Removal - Valve Guide Installation - Valve-to-Guide Clearance Measurement - Valve Seat Inspection - Valve Seat Repair (Valve Lapping) - Cylinder Removal - Piston Removal - Cylinder, Piston Installation - Cylinder Wear Inspection - Piston Wear Inspection - Piston/Cylinder Clearance Inspection - Piston Ring, Piston Ring Groove Wear Inspection - Piston Ring Groove Width Inspection - Piston Ring Thickness Inspection - Piston Ring End Gap Inspection - This vehicle is equipped with a spark arrester approved for off- - Spark Arrester Cleaning - Muffler and Exhaust Pipe Removal - Muffler and Exhaust Pipe Installation CONVERTER SYSTEM - Outside Circlip Pliers: - WARNING - Torque Converter Cover Removal - Torque Converter Cover Installation - Torque Converter Cover Disassembly - Actuator Lever (Engine Brake Control Lever) Assembly Inspection - Torque Converter Cover Assembly - Drive Belt Removal - Drive Belt Installation - Drive Belt Deflection Inspection - Drive Belt Deflection Adjustment - Drive Belt Inspection - Drive Pulley Removal - Special Tool - - Torque - - Special Tools - - Drive Pulley Disassembly - Drive Pulley Inspection - Spider Shoe Side Clearance Inspection/Adjustment - Drive Pulley Assembly - Drive Pulley Installation - Driven Pulley Removal - Special Tools - - Driven Pulley Disassembly - Driven Pulley Inspection - Driven Pulley Assembly - Driven Pulley Installation - Specifications ENGINE LUBRICATION SYSTEM - Oil Pressure Gauge, 10 kgf/cm : - WARNING - Oil Level Inspection - Engine Oil Change - Oil Filter Change - Oil Screen Removal - Oil Screen Cleaning - Oil Pressure Measurement - Oil Pressure Switch Removal - Oil Pressure Switch Installation - Oil Pressure Relief Valve Removal - Oil Pressure Relief Valve Installation - Oil Pressure Relief Valve Inspection - Oil Pump Removal - Oil Pump Installation - Oil Pipe Removal - Oil Pipe Installation ENGINE REMOVAL/INSTALLATION - Engine Removal - Engine Installation CRANKSHAFT/TRANSMISSION - Outside Circlip Pliers: - Crankcase Disassembly - Crankcase Assembly - Crankshaft Removal - Crankshaft Installation - Connecting Rod Removal - Connecting Rod Installation - Crankshaft/Connecting Rod Cleaning - Connecting Rod Bend Inspection - Connecting Rod Twist Inspection - Connecting Rod Big End Side Clearance Inspection - Connecting Rod Big End Bearing/Crankpin Wear Inspection - Crankshaft Runout Inspection - Crankshaft Main Bearing/Journal Wear Inspection - Shift Lever Removal - Shift Lever Installation - Transmission Removal - Transmission Installation - Shift Fork Bending Inspection - Shift Fork/Gear and Shifter Groove Wear Inspection - Transmission and Shift Mechanism Inspection - Ball and Needle Bearing Replacement - Special Tool - - Ball and Needle Bearing Wear Inspection - Oil Seal Inspection WHEELS/TIRES - Jack: - Toe-in is the difference between the distance of front and the o - Steering Centering Inspection - Steering Centering Adjustment - Toe-in Inspection - Toe-in Adjustment - Wheel Removal - Special Tool - - Wheel Installation - Wheel (Rim) Inspection - Wheel (Rim) Replacement - Tire Removal - Tire Installation - Tire Inspection - Front Hub Removal - Front Hub Installation - Front Hub Disassembly/Assembly - Rear Hub Removal - Rear Hub Installation - Rear Hub Disassembly/Assembly FINAL DRIVE - Dummy Page - Bearing Puller: - Output Drive Bevel Gear Removal - Special Tool - - Output Drive Bevel Gear Installation - Output Drive Bevel Gear Disassembly - Output Drive Bevel Gear Assembly - Output Driven Bevel Gear Removal - Output Driven Bevel Gear Installation - Output Driven Bevel Gear Disassembly - Output Driven Bevel Gear Assembly - Output Bevel Gears Adjustment - Output Bevel Gear (Backlash-related Parts) - Front Propeller Shaft Removal - Front Propeller Shaft Installation - Front Axle Removal - Front Axle Installation - Front Axle Joint Boot Inspection - Front Axle Joint Boot Replacement - Front Final Gear Case Oil Level Inspection - Torque - - Front Final Gear Case Oil Change - Variable Differential Control Lever Play Inspection - Variable Differential Control Lever Play Adjustment - Variable Differential Control Lever Removal - Variable Differential Control Lever Installation - Variable Differential Control Cable Installation - Variable Differential Control Cable Lubrication - Variable Differential Control Cable Inspection - Front Final Gear Case Removal - Front Final Gear Case Installation - Front Final Gear Case Disassembly - Front Final Gear Case Coupling Inspection - Front Final Gear Case Assembly - Oil Seal Installation - Ring Gear Disassembly - Ring Gear Assembly - LSD Clutch Torque Inspection - Pinion Gear Unit Disassembly - Pinion Gear Unit Assembly - Front Final Bevel Gear Adjustment - Front Final Gear Case (Backlash-related Parts) - Correct Tooth Contact Pattern: No adjustment is required. - Incorrect Tooth Contact Patterns (Example 1) - Incorrect Tooth Contact Patterns (Example 2) - Rear Propeller Shaft Removal - Rear Propeller Shaft Installation - Rear Propeller Shaft Joint Boot Inspection - Rear Propeller Shaft Inspection - Rear Axle Removal - Rear Axle Installation - Rear Axle Joint Boot Inspection - Rear Axle Joint Boot Replacement - Rear Final Gear Case Oil Level Inspection - Torque - - Rear Final Gear Case Oil Change - Rear Final Gear Case Removal - Rear Final Gear Case Installation - Rear Final Gear Case Disassembly - Rear Final Gear Case Right Cover Assembly - Rear Final Gear Case Front Cover Assembly - Rear Final Gear Case Assembly - Rear Final Bevel Gear Adjustment - Rear Final Gear Case (Backlash-related Parts) - Ball or Needle Bearing Inspection - Oil Seal Inspection BRAKES - Inside Circlip Pliers: - WARNING - Front Brake Fluid Recommendation - Front Brake Fluid Level Inspection - Front Brake Fluid Change - Front Brake Line Air Bleeding - Front Brake Master Cylinder Removal - Front Brake Master Cylinder Installation - Front Brake Master Cylinder Disassembly - Front Brake Master Cylinder Assembly - Front Master Cylinder Inspection (Visual Inspection) - Front Brake Caliper Removal - Front Brake Caliper Installation - Front Brake Caliper Disassembly - Front Brake Caliper Assembly - Front Brake Caliper Piston and Cylinder Damage Inspection - Front Brake Caliper Holder Shaft Wear Inspection - Front Brake Pad Removal - Front Brake Pad Installation - Front Brake Pad Wear Inspection - Front Brake Disc Cleaning - Front Brake Disc Removal - Front Brake Disc Installation - Front Brake Disc Wear Inspection - Front Brake Disc Runout Inspection - Front Brake Hose Inspection - Front Brake Hose Replacement - Rear Brake Pedal Position Inspection - Rear Brake Pedal Position Adjustment - Rear Brake Lever Free Play Inspection - Rear Brake Pedal Free Play Inspection - Rear Brake Lever and Brake Pedal Free Play Adjustment - Rear Brake Pedal Removal - Rear Brake Pedal Installation - Rear Brake Cable Removal - Rear Brake Cable Installation - Rear Brake Cable Lubrication - Internal Wet Brake Disassembly - Internal Wet Brake Assembly SUSPENSION - Inside Circlip Pliers: - Front Shock Absorber Preload Adjustment - Special Tool - - Front Shock Absorber Removal - Front Shock Absorber Installation - Front Shock Absorber Inspection - Front Shock Absorber Scrapping - Rear Shock Absorber Preload Adjustment - Rear Shock Absorber Removal - Rear Shock Absorber Installation - Rear Shock Absorber Inspection - Rear Shock Absorber Scrapping - Front Suspension Arm Removal - Front Suspension Arm Installation - Front Suspension Arm Disassembly - Front Suspension Arm Assembly - Rear Suspension Arm Removal - Rear Suspension Arm Installation - Rear Suspension Arm Disassembly - Rear Suspension Arm Assembly - Stabilizer Removal - Stabilizer Installation STEERING - Inside Circlip Pliers: - Steering Stem Removal - Steering Stem Installation - Steering Knuckle Removal - Steering Knuckle Installation - Steering Knuckle Bearing Removal - Steering Knuckle Bearing Installation - Tie-rod Removal - Tie-rod Installation - Tie-rod End Removal - Tie-rod End Installation - Steering Inspection - Steering Stem Straightness Inspection - Steering Bearing Sleeve Lubrication - Steering Stem Clamp Inspection - Steering Stem Bearing Inspection - Steering Knuckle Bearing Inspection - Tie-rod End Inspection - Steering Knuckle Joint Inspection - Handlebar Removal - Handlebar Installation FRAME - Seat Removal - Seat Installation - Front Carrier Removal - Front Carrier Installation - Front Carrier Bracket Installation - Rear Carrier Removal - Rear Carrier Installation - Rear Carrier Bracket Installation - Front Fender Removal - Front Fender Installation - Rear Fender Removal - Rear Fender Installation - Middle Cover Removal - Middle Cover Installation - Storage Box Removal - Storage Case Removal - Storage Case Installation - Left Side Cover Removal - Left Side Cover Installation - Right Side Cover Removal - Right Side Cover Installation - Electrical Parts Case Removal - Electrical Parts Case Installation - Front Guard Removal - Front Guard Installation - Front Bottom Guard Removal - Front Bottom Guard Installation - Engine Bottom Guard Removal - Engine Bottom Guard Installation - Rear Bottom Guard Removal - Rear Bottom Guard Installation - Left Footboard Removal - Left Footboard Installation - Right Footboard Removal - Right Footboard Installation - Footboard Bracket installation - Trailer Hitch Bracket Removal - Trailer Hitch Bracket Installation ELECTRICAL SYSTEM - Light/Dimmer Switch [A] - Dummy Page - Timing Light: - There are a number of important precautions that should be taken - Wiring Inspection - Special Tool - - Battery Removal - Battery Installation - Battery Activation - Precautions - Interchange - Alternator Cover Removal - Special Tool - - Alternator Cover Installation - Alternator Rotor Removal - Alternator Rotor Installation - Alternator Stator Removal - Alternator Stator Installation - Regulator/Rectifier Output Voltage Inspection - Alternator Inspection - Regulator/Rectifier Removal - Regulator/Rectifier Installation - Regulator/Rectifier Inspection - Charging System Circuit - WARNING - Spark Plug Removal - Spark Plug Installation - Spark Plug Cleaning/Inspection - Spark Plug Gap Inspection - Ignition Coil Removal - Ignition Coil Installation - Ignition Coil Inspection - Ignition Coil Primary Peak Voltage Inspection - Crankshaft Sensor Removal - Crankshaft Sensor Installation - Crankshaft Sensor Inspection - Crankshaft Sensor Peak Voltage Inspection - Alternator Rotor Inspection - Ignition Timing Test - Ignition System Troubleshooting - Ignition System Circuit - Starter Motor Removal - Starter Motor Installation - Starter Motor Disassembly - Starter Motor Assembly - Brush Inspection - Commutator Cleaning and Inspection - Armature Inspection - Brush Lead Inspection - Right-hand End Cover Inspection - Starter Relay Inspection - Starter Control Relay Inspection - Electric Starter Circuit - Headlight Beam Vertical Adjustment - Headlight Bulb Replacement - Tail/Brake Light Bulb Replacement - Tail/Brake Light Removal - Lighting System Circuit - Radiator Fan Motor Inspection - Radiator Fan Breaker Inspection - Radiator Fan Breaker Installation - Radiator Fan Circuit - Multifunction Meter Unit Removal - Multifunction Meter Unit Inspection - Drive Belt Failure Mode Memory Clearing Procedure - Meter Circuit - 2WD/4WD Actuator Removal - 2WD/4WD Actuator Installation - Engine Brake Actuator Removal - Engine Brake Actuator Installation - Actuator Control System Outline - Actuator Control System - Actuator Control System Circuit - If the drive belt failure detection system activated by abnormal - Drive Belt Failure Detection System Inspection - Drive Belt Failure Detection System Circuit - Fuel Level Sensor Inspection - Special Tool - - Fuel Level Sensor Circuit - Relay Inspection - Fuse Removal - Fuse Installation - Fuse Inspection APPENDIX - NOTE - Engine Doesn't Start, Starting Difficulty: - Poor Running at Low Speed: - Poor Running or No Power at High Speed: - Overheating: - Over Cooling: - Converter Operation Faulty: - Gear Shifting Faulty: - Abnormal Engine Noise: - Abnormal Drive Train Noise: - Abnormal Frame Noise: - Exhaust Smokes Excessively: - Handling and/or Stability Unsatisfactory - Brake Doesn't Hold - Kawasaki Engine Brake Control and Selectable 2WD/4WD System Malf - Battery Discharged: - Battery Overcharged:
Kawasaki KVF750 - Brute Force 750 - Service Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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