1. Kawasaki 750 Brute Force Problems

Kawasaki Service Repair Manual Free PDF z750, ninja 300, z800, z1000, er-5, versys, zx6r, klr650, kx65, ninja, zx9r, zx10r, zx12r, vulcan, kx250.

. BRUTE FORCE 750 4×4i KVF 750 4×4 All Terrain Vehicle Service Manual Property of www.SmallEngineDiscount.com - Not for Resale. Property of www.SmallEngineDiscount.com - Not for Resale.

Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Converter System Recoil Starter Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission 10 j Wheels/Tires 11 j Final Drive 12 j Brakes 13 j Suspension 14 j Steering 15 j Frame 16 j. Property of www.SmallEngineDiscount.com - Not for Resale.

Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. Property of www.SmallEngineDiscount.com - Not for Resale © 2004 Kawasaki Heavy Industries, Ltd.

Second Edition (1): Jul. LIST OF ABBREVIATIONS ampere(s) pounds(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celcius revolution direct current. EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the California Air Resources Board. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only) To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level.

Use proper tools and genuine Kawasaki Vehi- cle parts. Special tools, gauges, and testers.

Indicates a procedural step or work to be that are necessary when servicing Kawasaki done. Property of www.SmallEngineDiscount.com - Not for Resale. GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing.Model Identification.

General Specifications.Unit Conversion Table.1-11 Property of www.SmallEngineDiscount.com - Not for Resale. 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. Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. 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. 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. 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.

GENERAL INFORMATION 1-7 Model Identification KVF750-A1 Left Side View KVF750-A1 Right Side View The KVF750–B1 is a camouflage-surface-treated model and identical to the KVF750–A1, the base model, in every other aspect: controls, features, and specifications. Property of www.SmallEngineDiscount.com - Not for Resale. 1-8 GENERAL INFORMATION General Specifications Items KVF750-A1, B1 Dimensions Overall Length 2 192 mm (86.30 in.) Overall Width 1 177 mm (46.34 in.) Overall Height 1 249 mm (49.17 in.) Wheelbase 1 283 mm (50.51 in.) Ground Clearance: 269 mm (10.59 in.) Seat Height 935 mm (36.81 in.) Dry Mass.

GENERAL INFORMATION 1-9 General Specifications Items KVF750-A1, B1 Engine oil: Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE 10W-40 Capacity 2.6 L (2.75 US qt) Drive Train Primary Reduction System: Type Belt converter 3.122 ∼. 1-10 GENERAL INFORMATION General Specifications Items KVF750-A1, B1 Front tire: Type Tubeless Size AT25 × 8 – 12 Rear tire: Type Tubeless Size AT25 × 10 – 12 Suspension: Front: Type Double Wishbone Wheel Travel 171 mm (6.73 in.) Rear: Type Double Wishbone Wheel Travel. GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 micro µ. Property of www.SmallEngineDiscount.com - Not for Resale. PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart.Variable Differential Control Lever Torque and Locking Agent.Play Inspection.2-29 Specifications.2-11 Variable Differential Control Lever Special Tools.2-13 Play Adjustment.2-29 Periodic Maintenance Procedures.2-14 Front Final Gear Case Oil Fuel System. 2-2 PERIODIC MAINTENANCE Lubrication.2-40 Tightness Inspection.2-41 Bolts and Nuts Tightening.2-41 Property of www.SmallEngineDiscount.com - Not for Resale.

Kawasaki 750 Brute Force Problems

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. 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY First Regular Service Service Every 90 days, 1 700 Every Every km (1 100 After 10 mi.) or hrs.

Or days or days or when belt Every 100 km 200 km 600 km indicator year of page. R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 56019-120). St: Stake the fasteners to prevent loosening. TB: Apply a non-permanent locking agent (Three Bond TB1363A, Red).

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Valve Adjusting Cap Bolts 0.90 78 inlb Water Pipe Mounting Bolts 0.90 78 inlb Rocker Shaft Bolts Valve Adjusting Screw Locknuts 104 inlb Chain Tensioner Mounting Bolts 0.90 78 inlb Chain Tensioner Cap Bolt.