Kawasaki KVF 750 / BRUTE FORCE 750 4×4 ATV Repair Service Manual 2008

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This workshop repair service manual PDF download for the KVF 750 4×4 / BRUTE FORCE 750 4×4i Kawasaki All Terrain Vehicle has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

BRUTE FORCE 750 4×4i
KVF 750 4×4

Year Model 
Beginning Frame No.

2008 KVF750D8F 
JKAVFDD1□8B500001 or
JKAVF750DDB600001

2008 KVF750E8F 
JKAVFDE1□8B500001

2008 KVF750E8FA 
JKAVFDE1□8B500001

2008 KVF750F8F 
JKAVFDF1□8B500001


TABLE OF CONTENTS :

General Information 
Periodic Maintenance 
Fuel System (DFI) 
Cooling System 
Engine Top End 
Converter System 
Engine Lubrication System 
Engine Removal/Installation 
Crankshaft/Transmission 
Wheels/Tires 
Final Drive 
Brakes 
Suspension 
Steering 
Frame 
Electrical System 
Appendix


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99924-1394-01
Total Pages : 594


This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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tables
    LIST OF ABBREVIATIONS
    COUNTRY AND AREA CODES
    Units of Mass:
    Units of Volume:
    Units of Force:
    Units of Length:
    Units of Torque:
    Units of Pressure:
    Units of Speed:
    Units of Power:
    Basic Torque for General Fasteners of Engine Parts
    Basic Torque for General Fasteners of Frame Parts
    Throttle Lever Free Play
    Idle Speed
    Water and Coolant Mixture Ratio (when shipping)
    Valve Clearance (when cold)
    Valve Clearance (when cold)
    Belt Width
    Belt Deflection
    Spacers
    Actuator Lever Guide Shoe
    Engine Oil
    Tire Tread Depth
    Standard Tire
    Differential Control Lever Lock Position Length
    Front Final Gear Case Oil
    Rear Final Gear Case Oil
    Pad Lining Thickness
    Rear Brake Lever Free Play
    Brake Pedal Free Play
    Spark Plug Gap
    Brake Light Timing
    Terminal Names
    Sample Diagnosis Sheet
    Engine Doesn't Start, Starting Difficulty
    Poor Running at Low Speed
    Poor Running or No Power at High Speed:
    Connections:
    Throttle Sensor Input Voltage
    Input Voltage at Sensor 
    Wiring Connection
    Throttle Sensor Output Voltage
    Idle Speed
    Output Voltage at Sensor
    Wiring Connection
    Throttle Sensor Resistance
    Inlet Air Pressure Sensor Input Voltage
    Input Voltage at ECU 
    Inlet Air Pressure Sensor Output Voltage
    Inlet Air Pressure Sensor Output Voltage
    Inlet Air Temperature Sensor Output Voltage
    Output Voltage at ECU 
    Inlet Air Temperature Sensor Resistance
    Water Temperature Sensor Output Voltage
    Speed Sensor Input Voltage
    Input Voltage at Sensor
    Speed Sensor Output Voltage
    Output Voltage at Sensor 
    Vehicle-down Sensor Power Source Voltage
    Input Voltage at Sensor
    Vehicle-down Sensor Output Voltage
    Output Voltage at Sensor 
    Ignition Coil Input Voltage at ECU
    Injector Power Source Voltage
    Power Source Voltage at Injector
    Injector Output Voltage
    Output Voltage at Injector
    Injector Wiring Inspection
    Injector Resistance
    Injector Fuel Line Maximum Pressure
    ECU Grounding Inspection
    ECU Power Source Inspection
    Fuel Pressure (Idling)
    Amount of Fuel Flow
    Pump Operating Voltage at Pump
    Operating Voltage at Pump Connector
    Engine Vacuum Synchronization Vacuum
    Throttle Sensor Output Voltage
    Connections:
    Standard Resistence:
    Radiator Cap Relief Pressure
    Thermostat Valve Opening Temperature
    Rocker Arm Inside Diameter
    Rocker Shaft Diameter
    Cam Height
    Camshaft Bearing Clearance ( 18)
    Camshaft Bearing Clearance ( 22)
    Camshaft Journal Diameter ( 18)
    Camshaft Journal Diameter ( 22)
    Cylinder Compression (Usable Range)
    Cylinder Head Warp
    Valve/Valve Guide Clearance (Wobble Method)
    Valve Seating Surface Outside Diameter
    Valve Seating Surface Width
    Special Tools - Valve Seat Cutters:
    Cylinder Inside Diameter
    Piston Diameter
    Piston/Cylinder Clearance
    Piston Ring/Groove Clearance
    Piston Ring Groove Width
    Piston Ring Thickness
    Piston Ring End Gap
    Actuator Lever Assembly Installation Length
    Measurement Length [E]
    Actuator Lever Assemblies
    Cover Bushing Inside Diameter [A]
    Sheave Bushing Inside Diameter [A]
    Spring Free Length [A]
    Shoe Side Clearance
    Drive Pulley Installation Length [A]
    Measurement Length [D]
    Drive Pulley Covers
    Sheave Bushing Inside Diameter
    Spring Free Length [A]
    Oil Pressure
    Connecting Rod Bend
    Connecting Rod Twist
    Connecting Rod Big End Side Clearance
    Connecting Rod Big End Bearing, Insert/Crankpin Clearance
    Crankpin Diameter
    Crankpin Diameter Marks
    Connecting Rod Big End Inside Diameter Marks
    Big End Bearing Insert Selection
    Crankshaft Runout
    Crankshaft Main Journal Diameter
    Crankcase Main Bearing Bore Diameter
    Shift Fork Ear Thickness
    Shifter Groove Width
    Toe-in of Front Wheels
    Maximum Tire Air Pressure (to seat beads when cold)
    Tire Air Pressure (when cold)
    Drive Bevel Gear Shims for Tooth Contact Adjustment
    Driven Bevel Gear Shims for Backlash Adjustment
    Output Bevel Gear Backlash
    Standard Length of Assembling:
    Standard Length of Assembling
    Front Final Gear Case Coupling Bushing Inside Diameter [B]
    LSD Clutch Torque (When variable differential control lever is r
    LSD Clutch Torque (When variable differential control lever is p
    1. Pinion Gear Shims for Backlash Adjustment
    2. Ring Gear Right Shims for Tooth Contact Adjustment
    3. Ring Gear Left Shims for Tooth Contact Adjustment
    Front Final Bevel Gear Backlash
    Standard Length of Assembling:
    Standard Length of Assembling:
    6. Pinion Gear Shims for Backlash Adjustment
    7. Ring Gear Shims for Tooth Contact Adjustment
    8. Ring Gear Shims for Tooth Contact Adjustment
    Rear Final Bevel Gear Backlash
    Recommended Disc Brake Fluid
    Disc Thickness
    Disc Runout
    Spring Action
    Spring Action
    Tie-rod Length 
    Kawasaki-recommended chargers:
    Battery Terminal Voltage
    Terminal Voltage: 11.5 ∼ less than 12.8 V
    Terminal Voltage: less than 11.5 V
    Regulator/Rectifier Output Voltage
    Alternator Output Voltage
    Stator Coil Resistance @20°C (68°F)
    Regulator/Rectifier Resistance (Unit: kΩ)
    Ignition Coil Arcing Distance
    Ignition Coil Winding Resistance
    Ignition Coil Primary Peak Voltage
    Crankshaft Sensor Resistance
    Connections:
    Crankshaft Sensor Peak Voltage
    Ignition Timing
    Starter Motor Brush Length
    Testing Relay
    Radiator Fan Motor Lead Connections:
    Failure Indication Pattern and Failure Part
    Malfunction Mode
    Actuator Internal Resistance
    Actuator Internal Resistance
    Controller Power Supply Voltage
    Speed Sensor Output Voltage
    Controller Output Voltage (at 2WD/4WD Shift Switch OFF, 4WD)
    Controller Output Voltage (at 2WD/4WD Shift Switch ON, 2WD)
    Controller Output Voltage (to Actuators)
    Controller Output Voltage (to speed sensor)
    Controller Output Voltage (to 2WD/4WD shift switch)
    Controller Output Voltage (to engine brake actuator)
    Controller Output Voltage (to 2WD/4WD actuator)
    Forward/Reverse Detecting Sensor Resistance
    Fuel Level Sensor Resistance
    Water Temperature Sensor Resistance
    Testing Relay
toc
    EMISSION CONTROL INFORMATION
        PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only)
        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
                    Radiator Cleaning
                    Water Hoses and Connections Inspection
                    Coolant Change
                        Torque -
                Engine Top End
                    Valve Clearance Inspection
                        Special Tool -
                    Valve Clearance Adjustment
                        Torque -
                    Spark Arrester Cleaning
                Converter System
                    Converter Drive Belt Wear Inspection
                        Special Tool -
                    Converter Drive Belt Deflection Inspection
                    Converter Drive Belt Deflection Adjustment
                        Special Tools -
                        Torque -
                    Actuator Lever (Engine Brake Control Lever) Assembly Inspection
                Engine Lubrication System
                    Engine Oil Change
                        Torque -
                    Oil Filter Replacement
                        Special Tool -
                        Special Tool -
                        Torque -
                Wheels/Tires
                    Tire Inspection
                Final Drive
                    Variable Differential Control Lever Play Inspection
                    Variable Differential Control Lever Play Adjustment
                    Front Final Gear Case Oil Change
                        Torque -
                        Torque -
                    Rear Final Gear Case Oil Change
                        Torque -
                        Torque -
                    Universal Joint Lubrication
                Brakes
                    Front Brake Pad Wear Inspection
                    Front Brake Hoses and Connections Inspection
                    Front Brake Hose Replacement
                        Torque -
                    Front Brake Fluid Level Inspection
                        Torque -
                    Front Brake Fluid Change
                        Torque -
                    Front Brake Master Cylinder Piston Assembly and Dust Cover Repla
                    Front Brake Caliper Fluid Seal Replacement
                    Front Brake Caliper Dust Seal and Friction Boot Replacement
                    Rear Brake Plates Replacement
                    Rear Brake Lever Free Play Inspection
                    Rear Brake Pedal Free Play Inspection
                    Rear Brake Lever and Pedal Free Play Adjustment
                Steering
                    Steering Inspection
                Electrical System
                    Spark Plug Cleaning/Inspection
                    Spark Plug Gap Inspection
                    Rear Brake Light Switch Inspection
                    Rear Brake Light Timing Adjustment
                    Converter Drive Belt Failure Detection System Inspection
                Joint Boots Inspection
                    Front Axle/Steering Knuckle Joint Boots Inspection
                    Front Propeller Shaft Joint Boots Inspection
                    Tie-rod End Boots Inspection
                    Rear Propeller Shaft Joint Boots Inspection
                    Rear Axle/Stabilizer Joint Boots Inspection
                General Lubrication
                    Lubrication
                Bolts and Nuts Tightening
                    Tightness Inspection
                        Wheels:
                        Brakes:
                        Steering/Suspension:
                        Engine:
                        Final Drive:
                        Others:
        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
                    Special Tool -
                How to Read Service Codes
                How to Erase Service Codes
                Service Code Table
                    Notes:
                Backups
            Throttle Sensor Removal/Adjustment
                Throttle Sensor Input Voltage Inspection
                    Special Tool -
                Throttle Sensor Output Voltage Inspection
                    Special Tool -
                Throttle Sensor Resistance Inspection
                Throttle Sensor Circuit
            CAUTION
                Inlet Air Pressure Sensor Removal
                Inlet Air Pressure Sensor Installation
                    Torque -
                Inlet Air Pressure Sensor Input Voltage Inspection
                    Special Tool -
                Inlet Air Pressure Sensor Output Voltage Inspection
                    Special Tool -
                    Special Tools -
                Inlet Air Pressure Sensor Circuit
            Inlet Air Temperature Sensor Removal/Installation
                Inlet Air Temperature Sensor Output Voltage Inspection
                    Special Tool -
                Inlet Air Temperature Sensor Resistance Inspection
                Inlet Air Temperature Sensor Circuit
            Water Temperature Sensor Removal/Installation
                Water Temperature Sensor Output Voltage Inspection
                    Special Tool -
                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
                    Special Tool -
                Output Voltage Inspection
                    Special Tool -
                    Special Tool -
                Speed Sensor Circuit 
            Vehicle-down Sensor Removal
                Vehicle-down Sensor Installation
                Vehicle-down Sensor Inspection
                    Special Tool -
                    Special Tool -
                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
                    Special Tool -
            Fuel Injector Removal
                Fuel Injector Installation
                    Torque -
                Audible Inspection
                Fuel Injector Power Source Voltage Inspection
                Fuel Injector Output Voltage Inspection
                Injector Signal Test
                    Special Tool -
                Injector Resistance Inspection
                    Special Tool -
                Injector Unit Test
                Injector Fuel Line Inspection
                    Torque -
                Fuel Injector Circuit
            Inspection Flow Chart
                Light Inspection
                FI Indicator Light (LCD) Circuit
            CAUTION
                ECU Removal
                ECU Installation
                ECU Power Supply Inspection
                    Special Tool -
                ECU Power Source Circuit
            Fuel Pressure Inspection
                Special Tools -
                Fuel Flow Rate Inspection
                    Special Tool -
            Fuel Pump Removal
                Fuel Pump Installation
                    Torque -
                Fuel Pump Operation Inspection
                Fuel Pump Operating Voltage Inspection
                    Special Tools -
                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
                    Torque -
                Engine Vacuum Synchronization Inspection
                    Special Tools -
                Engine Vacuum Synchronization Adjustment
                    Special Tool -
            ISC Valve Removal
                ISC Valve Installation
                    Torque -
                ISC Valve Inspection
                    Special Tool -
            Air Cleaner Element Removal
                Air Cleaner Element Installation
                    Torque -
                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
                    Torque -
                Water Pump Impeller Removal
                Water Pump Impeller Installation
                    Torque -
                Water Pump Impeller Inspection
                Water Pump Leakage Inspection
                Mechanical Seal Replacement
                    Special Tools -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Torque -
            Radiator Removal
                Radiator Installation
                    Torque -
                Radiator Fan Removal
                Radiator Fan Installation
                    Torque -
                Radiator Inspection
                Radiator Cleaning
                Radiator Cap Inspection
            Thermostat Removal
                Thermostat Installation
                    Torque -
                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
                    Torque -
                    Torque -
            Rocker Case Removal
                Special Tool -
                Rocker Case Installation
                    Sealant -
                    Torque -
                    Torque -
                Rocker Arm Removal
                Rocker Arm Installation
                    Torque -
                Rocker Arm Inspection
                Rocker Shaft Diameter Measurement
            Camshaft Removal
                Camshaft Installation
                Camshaft Assembly
                    Torque -
                Cam Wear Inspection
                Camshaft Bearing Wear Inspection
                KACR Inspection
                KACR Removal
                KACR Installation
                    Torque -
                Camshaft Chain Removal
                    Special Tool -
                    Special Tool -
                Camshaft Chain Installation
                    Special Tool -
                    Torque -
                    Torque -
                    Special Tool -
                    Torque -
                Camshaft Chain Guide Wear Inspection
            Cylinder Compression Measurement
                Special Tools -
                Cylinder Head Removal
                Cylinder Head Installation
                    Torque -
                    First Torque -
                    Final Torque -
                    Torque -
                Cylinder Head Cleaning
                Cylinder Head Warp Inspection
            Valve Clearance Inspection
                Valve Clearance Adjustment
                Valve Removal
                    Special Tools -
                Valve Installation
                Valve Guide Removal
                    Special Tool -
                Valve Guide Installation
                    Special Tool -
                    Special Tool -
                Valve-to-Guide Clearance Measurement
                Valve Seat Inspection
                Valve Seat Repair (Valve Lapping)
            Cylinder Removal
                Piston Removal
                    Special Tools -
                Cylinder, Piston Installation
                    Torque -
                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
                    Torque -
                    Torque -
                    Torque -
                    Torque -
                    Exhaust System Inspection
        Converter System
            Outside Circlip Pliers:
            WARNING
                Torque Converter Cover Removal
                Torque Converter Cover Installation
                    Torque -
                Torque Converter Cover Disassembly
                Actuator Lever (Engine Brake Control Lever) Assembly Inspection
                Torque Converter Cover Assembly
                    Torque -
                    Special Tool -
            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
                    Special Tools -
                    Special Tool -
                Drive Pulley Inspection
                Spider Shoe Side Clearance Inspection/Adjustment
                Drive Pulley Assembly
                    Torque -
                    Special Tool -
                    Special Tool -
                    Torque -
                    Torque -
                Drive Pulley Installation
                    Special Tool -
                    Torque -
                    Special Tool -
            Driven Pulley Removal
                Special Tools -
                Driven Pulley Disassembly
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                Driven Pulley Inspection
                Driven Pulley Assembly
                    Grease -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                Driven Pulley Installation
                    Special Tools -
                    Torque -
            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
                    Special Tools -
            Oil Pressure Switch Removal
                Oil Pressure Switch Installation
                    Sealant -
                    Torque -
            Oil Pressure Relief Valve Removal
                Oil Pressure Relief Valve Installation
                    Torque -
                Oil Pressure Relief Valve Inspection
            Oil Pump Removal
                Oil Pump Installation
                    Torque -
                    Torque -
                    Torque -
            Oil Pipe Removal
                Oil Pipe Installation
                    Torque -
        Engine Removal/Installation
            Engine Removal
                Engine Installation
                    Torque -
        Crankshaft/Transmission
            Outside Circlip Pliers:
            Crankcase Disassembly
                Crankcase Assembly
                    Special Tool -
                    Torque -
                    Special Tool -
                    Torque -
                    Sealant -
                    Torque -
                    Torque -
                    Torque -
            Crankshaft Removal
                Crankshaft Installation
                    Special Tools -
                Connecting Rod Removal
                Connecting Rod Installation
                    Torque -
                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
                    Torque -
                    Torque -
                Crankshaft Runout Inspection
                Crankshaft Main Bearing/Journal Wear Inspection
            Shift Lever Removal
                Shift Lever Installation
                    Torque -
                    Torque -
                    Torque -
                    Torque -
                    Torque -
                    Torque -
                    Torque -
                Transmission Removal
                    Special Tool -
                    Special Tool -
                Transmission Installation
                    Special Tool -
                    Torque -
                    Torque -
                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
                    Torque -
            Wheel Removal
                Special Tool -
                Wheel Installation
                    First Torque -
                    Final Torque -
                Wheel (Rim) Inspection
                Wheel (Rim) Replacement
            Tire Removal
                Tire Installation
                Tire Inspection
            Front Hub Removal
                Front Hub Installation
                    Torque -
                Front Hub Disassembly/Assembly
            Rear Hub Removal
                Rear Hub Installation
                    Torque -
                Rear Hub Disassembly/Assembly
        Final Drive
            Dummy Page
            Bearing Puller:
            Output Drive Bevel Gear Removal
                Special Tool -
                Output Drive Bevel Gear Installation
                    Torque -
                    Torque -
                    Special Tool -
                    Torque -
                    Torque -
                Output Drive Bevel Gear Disassembly
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                Output Drive Bevel Gear Assembly
                    Special Tool -
                    Torque -
                    Special Tool -
                    Torque -
                Output Driven Bevel Gear Removal
                Output Driven Bevel Gear Installation
                    Torque -
                Output Driven Bevel Gear Disassembly
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tools -
                Output Driven Bevel Gear Assembly
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Torque -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Torque -
                Output Bevel Gears Adjustment
                Output Bevel Gear (Backlash-related Parts)
                    Bevel Gears Inspection
            Front Propeller Shaft Removal
                Front Propeller Shaft Installation
            Front Axle Removal
                Front Axle Installation
                Front Axle Joint Boot Inspection
                Front Axle Joint Boot Replacement
                    Special Tool -
            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
                    Torque -
                Variable Differential Control Cable Installation
                    Torque -
                Variable Differential Control Cable Lubrication
                Variable Differential Control Cable Inspection
                Front Final Gear Case Removal
                Front Final Gear Case Installation
                    Torque -
                    Torque -
                Front Final Gear Case Disassembly
                    Special Tool -
                    Special Tool -
                Front Final Gear Case Coupling Inspection
                Front Final Gear Case Assembly
                    Special Tool -
                    Torque -
                    Special Tool -
                    Torque -
                    Torque -
                    Special Tools -
                    Special Tool -
                    Special Tool -
                    Torque -
                    Torque -
                Oil Seal Installation
                Ring Gear Disassembly
                Ring Gear Assembly
                    Torque -
                LSD Clutch Torque Inspection
                Pinion Gear Unit Disassembly
                    Special Tool -
                    Special Tool -
                Pinion Gear Unit Assembly
                    Special Tool -
                    Torque -
                Front Final Bevel Gear Adjustment
                Front Final Gear Case (Backlash-related Parts)
                    Bevel Gear Inspection
                    Differential Gear Inspection
                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
                    Special Tool -
                    Special Tool -
            Rear Final Gear Case Oil Level Inspection
                Torque -
                Rear Final Gear Case Oil Change
                Rear Final Gear Case Removal
                Rear Final Gear Case Installation
                    Torque -
                Rear Final Gear Case Disassembly
                    Special Tool -
                Rear Final Gear Case Right Cover Assembly
                    Special Tool -
                    Special Tool -
                Rear Final Gear Case Front Cover Assembly
                    Special Tool -
                Rear Final Gear Case Assembly
                    Special Tool -
                    Special Tool -
                    Torque -
                    Torque -
                    Torque -
                    Torque -
                Rear Final Bevel Gear Adjustment
                Rear Final Gear Case (Backlash-related Parts)
                    Pinion Gear Unit Disassembly
                        Special Tools -
                        Special Tool -
                    Pinion Gear Unit Assembly
                        Special Tools -
                        Torque -
            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
                    Torque -
            Front Brake Master Cylinder Removal
                Front Brake Master Cylinder Installation
                    Torque -
                    Torque -
                Front Brake Master Cylinder Disassembly
                    Special Tool -
                Front Brake Master Cylinder Assembly
                    Torque -
                Front Master Cylinder Inspection (Visual Inspection)
            Front Brake Caliper Removal
                Front Brake Caliper Installation
                    Torque -
                Front Brake Caliper Disassembly
                Front Brake Caliper Assembly
                    Torque -
                    Torque -
                Front Brake Caliper Piston and Cylinder Damage Inspection
                Front Brake Caliper Holder Shaft Wear Inspection
            Front Brake Pad Removal
                Front Brake Pad Installation
                    Torque -
                Front Brake Pad Wear Inspection
            Front Brake Disc Cleaning
                Front Brake Disc Removal
                Front Brake Disc Installation
                    Torque -
                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
                    Special Tool -
                Front Shock Absorber Installation
                    Torque -
                Front Shock Absorber Inspection
                Front Shock Absorber Scrapping
                Rear Shock Absorber Preload Adjustment
                    Special Tool -
                Rear Shock Absorber Removal
                    Special Tool -
                Rear Shock Absorber Installation
                    Torque -
                Rear Shock Absorber Inspection
                Rear Shock Absorber Scrapping
            Front Suspension Arm Removal
                Front Suspension Arm Installation
                    Torque -
                Front Suspension Arm Disassembly
                    Special Tool -
                    Special Tool -
                Front Suspension Arm Assembly
                    Special Tool -
                    Special Tool -
                Rear Suspension Arm Removal
                Rear Suspension Arm Installation
                    Torque -
                Rear Suspension Arm Disassembly
                    Special Tool -
                Rear Suspension Arm Assembly
                    Special Tool -
                Stabilizer Removal
                Stabilizer Installation
                    Torque -
                    Torque -
        Steering
            Inside Circlip Pliers:
            Steering Stem Removal
                Steering Stem Installation
                    Torque -
                    Torque -
                    Torque -
                Steering Knuckle Removal
                Steering Knuckle Installation
                    Torque -
                Steering Knuckle Bearing Removal
                    Special Tool -
                    Special Tool -
                Steering Knuckle Bearing Installation
                    Special Tool -
                    Special Tool -
                Tie-rod Removal
                Tie-rod Installation
                    Torque -
                Tie-rod End Removal
                Tie-rod End Installation
                    Torque -
            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
                    Torque -
                    Torque -
        Frame
            Seat Removal
                Seat Installation
            Front Carrier Removal
                Front Carrier Installation
                    Torque -
                Front Carrier Bracket Installation
                    Torque -
                Rear Carrier Removal
                Rear Carrier Installation
                    Torque -
                Rear Carrier Bracket Installation
                    Torque -
            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
                    Radiator Cover Removal
                    Radiator Cover Installation
                    Headlight Cover Removal
                    Headlight Cover Installation
            Front Guard Removal
                Front Guard Installation
                    Torque -
                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
                    Torque -
            Trailer Hitch Bracket Removal
                Trailer Hitch Bracket Installation
                    Torque -
        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
                    1)
                    2)
                    3)
                    4)
                Interchange
                    Charging Condition Inspection
                    Refreshing Charge 
            Alternator Cover Removal
                Special Tool -
                Alternator Cover Installation
                    Torque -
                    Special Tool -
                    Torque -
                Alternator Rotor Removal 
                    Special Tool -
                Alternator Rotor Installation
                Alternator Stator Removal
                Alternator Stator Installation
                    Torque -
                Regulator/Rectifier Output Voltage Inspection
                    Special Tool -
                Alternator Inspection
                    Special Tools -
                Regulator/Rectifier Removal
                Regulator/Rectifier Installation
                    Torque -
                Regulator/Rectifier Inspection
                    Special Tool -
                Charging System Circuit
            WARNING
                Spark Plug Removal
                    Special Tool -
                    Special Tool -
                Spark Plug Installation
                    Torque -
                    Special Tool -
                Spark Plug Cleaning/Inspection
                Spark Plug Gap Inspection
                Ignition Coil Removal
                Ignition Coil Installation
                    Torque -
                Ignition Coil Inspection
                    Special Tool -
                Ignition Coil Primary Peak Voltage Inspection
                    Special Tools -
                Crankshaft Sensor Removal
                Crankshaft Sensor Installation
                    Torque -
                Crankshaft Sensor Inspection
                Crankshaft Sensor Peak Voltage Inspection
                    Special Tools -
                Alternator Rotor Inspection
                Ignition Timing Test
                    Special Tool -
                    Special Tool -
                Ignition System Troubleshooting
                Ignition System Circuit
            Starter Motor Removal
                Starter Motor Installation
                    Torque -
                    Torque -
                Starter Motor Disassembly
                Starter Motor Assembly
                    Torque -
                    Torque -
                Brush Inspection
                Commutator Cleaning and Inspection
                Armature Inspection
                    Special Tool -
                Brush Lead Inspection
                    Special Tool -
                Right-hand End Cover Inspection
                    Special Tool -
                Starter Relay Inspection
                Starter Control Relay Inspection
                Electric Starter Circuit
                    Starter Motor Clutch Removal
                        Special Tool -
                    Starter Motor Clutch Installation
                        Torque -
                    Starter Motor Clutch Inspection
                    Torque Limiter Inspection
            Headlight Beam Vertical Adjustment
                Headlight Bulb Replacement
                Tail/Brake Light Bulb Replacement
                    Torque -
                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
                    Torque -
                Engine Brake Actuator Removal
                Engine Brake Actuator Installation
                    Torque -
                Actuator Control System Outline
                Actuator Control System
                    Actuator Controller Removal
                    Actuator Controller Installation
                    Actuator Control System Troubleshooting
                        Special Tool -
                        Special Tool -
                        Special Tools -
                        Special Tools -
                        Special Tools -
                        Special Tools -
                        Special Tools -
                        Special Tools -
                        Special Tools -
                        Special Tools -
                        Special Tool -
                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
                    Brake Light Switch Adjustment
                    Water Temperature Sensor Inspection
                    Speed Sensor Removal/Installation
                        Torque -
                    Speed Sensor Inspection
                        Special Tool -
                    Switch Inspection
                    Neutral Switch Connection
                    Reverse Switch Connections
                    2WD/4WD Shift Switch
                    Oil Pressure Switch Connections*
                    Drive Belt Failure Detection Switch Inspection
            Relay Inspection
            Fuse Removal
                Fuse Installation
                Fuse Inspection
        Appendix
            NOTE
                Engine Doesn't Start, Starting Difficulty:
                    Starter motor not rotating:
                    Starter motor rotating but engine doesn't turn over:
                    Engine won't turn over:
                    No fuel flow:
                    Engine flooded:
                    Fuel/air mixture incorrect:
                    No spark; spark weak:
                    Compression Low:
                Poor Running at Low Speed:
                    Spark weak:
                    Fuel/air mixture incorrect:
                    Compression low:
                    Other:
                Poor Running or No Power at High Speed:
                    Firing incorrect:
                    Fuel/air mixture incorrect:
                    Compression low:
                    Knocking:
                    Miscellaneous:
                Overheating:
                    Firing incorrect:
                    Fuel/air mixture incorrect:
                    Compression high:
                    Engine load faulty:
                    Lubrication inadequate:
                    Front or rear final gear case overheating:
                    Coolant incorrect:
                    Cooling system component incorrect:
                Over Cooling:
                    Cooling system component incorrect:
                Converter Operation Faulty:
                    Belt slipping:
                    Converter engagement speed too low:
                    Converter engagement speed too high:
                    Shifting too quickly:
                    Shifting too slowly:
                Gear Shifting Faulty:
                    Doesn't go into gear:
                    Jumps out of gear:
                    Overshifts:
                Abnormal Engine Noise:
                    Knocking:
                    Piston Slap:
                    Valve noise:
                    Other noise:
                Abnormal Drive Train Noise:
                    Converter noise:
                    Transmission noise:
                    Front or rear final gear case noise:
                Abnormal Frame Noise:
                    Shock absorber noise:
                    Disc brake noise:
                    Rear brake noise:
                    Other noise:
                Exhaust Smokes Excessively:
                    White smoke:
                    Black Smoke:
                    Brown smoke:
                Handling and/or Stability Unsatisfactory
                    Handlebar hard to turn:
                    Noise when turning:
                    Handlebar shakes or excessively vibrates:
                    Handlebar pulls to one side:
                    Shock absorption unsatisfactory:
                Brake Doesn't Hold
                    Front brake:
                    Rear Brake:
                Kawasaki Engine Brake Control and Selectable 2WD/4WD System Malf
                Battery Discharged:
                Battery Overcharged:
                
                -