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Recreation Utility Vehicle Assembly & Preparation Manual

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1. 0D15B015 P A Lower Back Bar B Bolts D 10 L 14 e Install the upper back bar and tighten the mounting bolts D 10 L 14 4 ASSEMBLY 17 OD15B016 P A Upper Back Bar B Bolts D 10 L 14 e Connect the upper and lower back bar and tighten the joint bolts D 10 L 14 2 ae p y d 0D158017 P A Bolts D 10 L 14 B Upper Back Bar C Lower Back Bar Front and Rear Upper Bar Front and Rear Upper Bar Installation KRF750NAF SAF TAF Models e Install the front and rear upper bars between the right and left bars with the mounting bolts D 10 L 14 8 so that the bracket parts of the upper bars face upward MILITARY USE ONLY MILITARY USE ONLY 18 ASSEMBLY 0D15B018 P Forward Front Upper Bar Rear Upper Bar Bolts D 10 L 14 Brackets mg omwm e Tighten the right and left bar upper and lower back bar front and rear upper bar mounting bolts to the specified torque Right and Left Bar Mounting Bolt Torque 98 N m 10 kgf m 72 ft Ib Upper and Lower Back Bar Mounting Bolt Torque 47 N m 4 8 kgf m 35 ft Ib Upper and Lower Back Bar Joint Bolt Torque 47 N m 4 8 kgf m 35 ft lb Front and Rear Upper Bar Mounting Bolt Torque 47 N m 4 8 kdf m 35 ft Ib Front and Rear Upper Bar and Sun Top Cover Installation KREZS50PAF RAF Models e Install the front upper bar between the right and left bars s
2. MILITARY USE ONLY TERYX 750 FI 4x4 TERYX 750 FI 4x4 LE TERYX 750 FI 4x4 SPORT Kawasakl Recreation Utility Vehicle Assembly amp Preparation Manual MILITARY USE ONLY MILITARY USE ONLY Foreword In order to ship Kawasaki vehicles as effi ciently as possible they are partially disassem bled before crating Since some of the most commonly removed parts have a direct bear ing on a vehicle s reliability and safety consci entious pre sale assembly and preparation be comes extremely important Good setup pro cedures can prevent needless warranty claims and give customers a greater sense of confi dence in Kawasaki and their Kawasaki Dealers This Assembly and Preparation Manual ex plains step by step procedures of the follow ing items for all Kawasaki TERYX 750 FI 4x4 TERYX 750 FI 4x4 LE and TERYX 750 FI 4x4 SPORT 1 Crate Handling 2 Uncrating 3 Assembly 4 Preparation The selling dealer assumes sole responsibil ity for any unauthorized modifications prior to sale Refer to your Service Binderfor any Ser vice Bulletins specifying Factory Directed Mod ifications Special Claims which must be per formed before the vehicle is ready for sale Whenever you see the following symbols heed their instructions Always follow safe operating and maintenance practices 2009 Kawasaki Heavy Industri S LWaLITARY USE ONLY A DANGER DANGER indicates a hazardou
3. MILITARY USE ONLY 28 PREPARATION 06C05020BS1 C A Bolts B Battery Holder C Battery Battery Specifications Make Yuasa Battery Type KMX14 BS Battery Capacity 12 V 12Ah Electrolyte Capacity 0 69 L Battery Electrolyte Set P No 26012 1414 Battery Activation Filling the Battery with Electrolyte Do not remove the aluminumpsealing sheet A from the filler ports B until just prior to use Be sure to use the ded icated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet A has no peeling tears or holes in it e Remove the sealing sheet A NOTE OThe battery is vacuum sealed If the sealing Sheet has leaked air into the battery it may require a longer initial charge GPO8003BS1 C e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells MEO2006BS1 C e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt th
4. Right and Left Bar sues teta Pr t rut eer a Upper and Lower Back Bar eese Front and Rear Upper Bar eene Seat Belt f ees Windshield KRF750PAF RAF Models h Cargo Net event Aa e Front Guard Cover 4 amp 9 09e French Labels LAW Preparation Nee eaae aeaee enerne eee Charged Battery Service USMod amp l mues Uncharged Battery Service Othemthan US Model Air Cleaner aae ac o eee ee ettet aite Engine Oil ay Wf Front Final Gear Case Oil W0x Rear Final Gear Case Oil Brake Fluid u Sk Ruc asnasan sasa eres tee recae Brake Ped fllyy K Y a Brake Liglit SwitCPN8R Parking BWke PedallB a Stesnnaa V eerte n nane een ay noB yAbsorber Rear Sh ck Absorber Dh WU ECT UU LI Nina T tamana s uates qe
5. 18 B Foam Element Cover e Saturate the foam air cleaner element with a high quality foam air filter oil ex Kawachem Foam Filter Oil Bel Ray Foam Filter Oil Maxima FFT Foam Filter Treatment or equivalent cohesive type and make sure that the oil is evenly applied throughout th foam air cleaner element Squeeze out the excess oil but do not wring the foam air cleaner element as this could cause tearing In this case too much oil is better thian too little Finally pat the inside of the foam air cleaner element with a clean towel to remove any excess oil HC07010381 C A Clean Towel e Install the element onto its element frame and coat the element lip and lip seat with a thick layer of all purpose grease to assure a complete seal NOTE OBe sure that the edge of the foam element fits completely in the groove and does not rest on the edge of the element holder or become folded in the groove as shown in the illustra tions PREPARATION 31 Not Gorrect Correct A Element Holder B Foam Element e Reinstall the element cover to the specified torque so that4he wider Side faces projection of the element frame and fit the slits onto the projections Torqu 4 5 N m 0 46 kgf m 40 in Ib NE26BO12 P A Foam Element B Element Frame C Element Cover D Wider Side E Projection F Slits G Projections e Install the foam element into the air cleaner housing
6. e nstallthe cargo net buckle cover as shown in figure e Install the band to both ends of the cargo net buckle covers and tighten them NOTE Olnstall the cover with the net tension adjusting buckle and store the loose net strap into the cargo net buckle cover 0D16B006 P A Cargo Net Buckle Cover B Bands C Net Tension Adjusting Buckle Front Guard Cover Front Guard Cover Installation e Install dhe front guard cover onto the front guard e Tighten the tapping screws D 6 L 16 2 and collars D 16 L 4 2 e Tighten the screws D 6 L 16 2 and collars D 6 L 16 2 1 gy 0D17B001 P A Front Guard Cover B Tapping Screw D 6 L 16 and Collar D 16 L 4 C Screw D 6 L 16 and Collar D 16 L 4 French Labels For Canadian Model NOTE OApply the French labels over the English la bels on the unit when required MILITARY USE ONLY MILITARY USE ONLY ASSEMBLY 23 e Wipe off any oil or grease from the English labels Refer to the following photographs in the label locations e Peel each French label off the backing sheet and apply it over the English label 8 Cargo Warning 5607140112 9 Tire Information 56053 0418 10 Cargo Bed Warning 56071 0114 General Warning 56071 0053 Shifting Caution 56071 0129 Parking Brake 56030 0330 ona 12 Air Cleaner Infor
7. e Before starting the engine check that the en gine has oil e To remove the protective cover pull out the quick rivets by prying the suitable tool onto the center part of the rivet Remove the cover MILITARY USE ONLY MILITARY USE ONLY A OEO2008B G A Quick Rivets B Protective Cover e Unscrew the oil filler plug on the lower left side of the engine and wipe the dipstick dry Then screw itin again Unscrew the plug and check that the engine has oil OE02B023 P A Oil Filler Plug e When installing the pl g be sure the O ring is in place and screw the plug in finger tight NOT CE If the engine is run without oil it will be severely damaged e Start the engine and run it for several minutes at idle speed Stop the engine then wait sev eral minutes until the oil settles Unscrew the oil filler plug wipe its dipstick dry and screw it in again e Unscrew the plug and check the oil level The oil level should be between the H High and L Low lines on the dipstick PREPARATION 33 In S BL03008BM2 C A Dipstick B H High line C L Low line e If the oil level is tooshigh remove the excess oil through the oilfilleropening using a syringe or some ether suitable device e If the oil level is too low add the oil to reach the correct level e Screw the plug in finger tight Recommended Engine Oil Type API SG SH SJ SL o
8. e Pushthe SET RESET button to advance the hours e Push the TIME SET button The hour dis play stops flashing and the minutes display starts flashing e Push the SET RESET button to advance the minutes e Push the TIME SET button The minutes display stops flashing and the clock starts working em v 2 gt SET RESET Da eye 4S8 S TE NM uc SET A87XB24682 C NOTE OPushing the SET RESET button momentar ily advances the hour or minute step by step Pushing and holding the button advances the hour or minute continuously OThe clock works normally from the back up power while the ignition switch is turned off OWhen the battery is disconnected the clock resets to AM 1 00 and starts working again when the battery is connected Check the Mph km h Display in the Digital Meter Mph km h Display can alternate between English and metric modes mph and km h in the digital meter Make sure that km h or mph is correctly displayed according to local regulations before sale NOTE ODo not operate the vehicle with the digital me ter displaying in the wrong unit mph or km h of the digital meter Shift the mph km h dis play in the digital meter as follows e Depress the brake pedal and then release the parking brake NOTE OWith depressing the parking brake pedal mph km h display can not shift in the digital meter e Display the odometer in the digital meter e The mph km h di
9. 16 92153 1740 Cargo Net 53064 0012 Buckle Cover Cargo Net 14090 1611 Band Cargo Net L 123 92072 030 Front Guard Cover Other than KRF750RAF Model 55020 0520 KRE750RAF Model Only 55020 0521 Screw Front Guard Cover D 6 L 16 92009 1621 Tapping Screw Front Guard Cover D 6 L 16 92009 1166 Collar Front Guard Cover Upper and Lower D 16 L 4 92143 1087 MILITARY USE ONLY 14 UNCRATING MILITARY USE ONLY 0C06034BW3 C No 6 Part Name KRF750PAF RAF Models Windshield Trim Windshield Gromimet Windshield Damper Windshield Collar Windshield Front Bracket Windshield Rear Bracket Windshield Damper Bracket Windshield Flanged Bolt Windshield Washer Windshield Qty Remarks D 6 8 x 10 x 14 5 c O D 6 5 x 22 L 1 6 MILITARY USE ONLY Part Number 39154 0047 53044 0044 92075 1787 92161 0725 92027 156 11055 0913 11055 0914 92161 0644 132BB0635 92200 1087 MILITARY USE ONLY UNCRATING 15 No Part Name Qty Remarks Part Number 7 French Labels and Instruction for Canadian Model only Instruction Label KRF750NAF Model only 1 56030 0364 KRF750PAF Model only 1 56030 0365 KRF750RAF Model only 1 56030 0366 KRF750SAF Model only 1 56030 0367 Label Cargo Bed 1 56071 0147 Label Drive Belt Information 1 56033 0305 Label Parking Brake 1 56030 0330 Label Specification 1 56053 7519 Label Ti
10. Belt Case Mounting Nut Torque 47 N m 4 8 kgf m 35 ft Ib e Install the cover to the seat belt bracket e Install the seat belt bracket and tighten the bolts D 10 L 16 2 and close the cover A Bolt D 10 L 16 B Cover C Seat Belt Upper Bracket Seat Belt Mounting Bolt Torque 42 N m 4 3 kgf m 31 ft Ib MILITARY USE ONLY 0D06B022 P MILITARY USE ONLY ASSEMBLY 21 Windshield KRF750PAF RAF Models Windshield Installation e Install the trim and grommet to the windshield and install the damper to the front bracket and rear bracket e Install the brackets on the right and left bars and the windshield with flanged bolt D 6 L 35 49 Collar D 6 8 x 10 x 14 5 4 and washers D 6 5 x 22 L 1 6 8 as shown in the figure and tighten them OD18000BW3 C A Windshield B Trim L 450 C Collar D 6 8 x 10 x 14 5 D Washers D 6 5 x 22 L 1 6 E Grommet F Damper 92161 0644 G Damper 92161 0725 H Front Bracket and Rear Bracket l Flanged Bolts D 6 L 35 J No gap K Front MILITARY USE ONLY MILITARY USE ONLY 22 ASSEMBLY Cargo Net Cargo Net Installation e Remove the bolts to install the cargo net A Cargo Net Bracket B Bolts C Cargo Net e Install the hook latches and set up cargo net vertically A Cargo Net B HookeLatches Cargo Net Buckle Cover Installation
11. Upper Bars and Upper Back Bar Removal e Cut the tie bands 3 that retain the right and left bars at cargo bed MILITARY USE OallQtt tHe tie bands of all bars MILITARY USE ONLY 10 UNCRATING A Tie bands Removing the Lower Back Bar and Front Tie downs Removal e Cutthe tie bands 3 thatretain the lower back bar at the front guard and remove the lower back bar from the front guard e Remove front tie downs by opening fully and disengaging latch Take care to undo these evenly as there is heavy tension in the tie down A Tie downs Front B Tie bands C Lower Back Bar Rear Tie down Removal e Remove rear tie downs by opening fully and disengaging latch Take care to undo these evenly as there is heavy tension in the tie down NOTE Olt is important to remove the top panel as the unit will rise when the tie downs are undone Failure to do sO will result in damage to the unit e Remove the crate base blocks e Roll the vehicle off the crate base after in stalling the steering wheel see Steering Wheel section on page16 in the assembly chapter MILITARY USE ONLY MILITARY USE ONLY UNCRATING 11 Dummy Page MILITARY USE ONLY 12 UNCRATING MILITARY USE ONLY Parts Check NOTE OThere may be minor differences in appearance between these illustrations and the actual vehicle parts e Remove the parts and check the c
12. adjusting mechanism may be damaged Compression Damping Settings NE13003BS1 C A Seated Position Adjuster turned fully clockwise B Standard Setting C Softer Counterclockwise D Harder Clockwise Number of turns counterclockwise usable range 5 turns or more Rebound Damping Adjustment KRF750SAF Model only e Check the position of the rebound damping adjuster at the bottom of each front shock ab sorber STD Rebound Damping 1 turn out Counterclockwise from the fully seated position OE22B005 P A Rebound Damping Adjust r B Front Shock Absorber Right e To adjust the front shock absorber rebound damping turn the r bound damping adjuster at the bottom of the front shock absorber with a flat head serewdrivef Adjust the rebound damping to the standard setting position e The right and left front shock absorber must be adjusted evenly Do not force to turn the rebound damp ing adjuster from the fully seated posi tion or the adjusting mechanism may be damaged Rebound Damping Settings c p NE13004BS1 C A Seated Position Adjuster turned fully clockwise B Standard Setting C Softer Counterclockwise D Harder Clockwise Number of turns counterclockwise usable range 2 5 turns or more MILITARY USE ONLY MILITARY USE ONLY Rear Shock Absorber Rear Shock Absorber Spring Preload Adjustment e Check
13. m 0 80 kgf m 69 in Ib e Apply the brake lever forcefully for a few sec onds and check for fluid leakage around the fittings Brake Pedal Brake Pedal Free Play Inspection e Depress the brake pedal lightly by hand e There should be 2 10 mm 0 08 0 40 in of free play e f it does not adjust the brake pedal play Brake Pedal Free Play 2 10 mm 0 08 0 40 in MILITARY USE ONLY MILITARY USE ONLY 38 PREPARATION OE05003B G A Brake Pedal B 2 10 mm 0 08 0 40 in Brake Pedal Free Play Adjustment e Loosen the locknut and turn the push rod to obtain the correct amount of free play A Locknut B Push Rod e Tighten the locknut to the specified torque Torque 18 N m 1 8 kgf m 13 ft Ib e Check for brake drag and braking effective ness A WARNING Insufficient free play can cause brake heating and drag resulting in skidding and loss of control which could cause an accident resulting in serious injury or death Be sure the brake free play is ad justed to the specification Brake Light Switch Brake Light Switch Inspection e Turn the main switch to the ON position e Depress the brake pedal The brake light should go on after about 10 mm 0 40 in of pedal travel 0E19000B G A Brake Pedal B 10 mm 0 40 in e If it does not check the bulb and if necessary adjust the brake light switch Brake Lig
14. the position of the spring preload ad justing length on the rear shock absorbers Adjusting Length from center of upper mounting bolt to lower surface of adjusting nut STD Adjusting Length Other than KRF750SAF model 111 5 mm 4 39 in KRF750SAF model 116 mm 4 57 in z d B STD Adjusting Length e Loosen the locknut and turn the adjusting nut to the desired position A Wrench B Locknut C Adjusting Nut PREPARATION 41 Compression Damping Adjustment KRF750SAF Model only e Check the position of the rear shock absorber compression damping adjuster on the gas reservoir at the upper end of the rear shock absorber Do not force to turn the compression damping adjuster from the fully seated position or the adjusting mechanism may be damaged STD Compression Damping 12 clicks Counterclockwise from the fully seated position e To adjust the rear shock absorber compres sion damping turn the adjuster all the way clockwise with a screwdriver to make the damping greatest e Turn the adjuster counterclockwise to de crease damping Adjust the compression damping to the standard setting position e The right and left rear shock absorbers must be adjusted evenly A WARNING If both compression damping adjusters and both rebound damping adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Set all suspension adjusters equally to the recom
15. therefore two stacked crates will weigh approximately 1 660 kg 3 660 lbs Use forklifts with at least 5 000 Ib lifting capacity and 60 inch tapered fork blades not greater than 1 1 2 inches thick Forklifts should also be equipped with all safety items such as Operator cages and fork back rests Pulling Crate from Trucks for RSC If pulling is necessary to unload from trailer please put rope or chain on fork pocket area at end CRATE HANDLING 3 0C03018BS1 C A Pull chain around fork pocketarea Stacking Returnable Steel Crates The number of crates that may be stacked on top of one another depends on the condition of the cratesyand your forklifts capacity Teryx utility vehicle RSCs lt are designed for integrated stacking Do not stack any other type of crate or anyeothermmaterials atop a Teryx RSC In any case do not stack returnable steel crates more than two high for trucking and three high for storage Crate Handling Precautions Other than US Model Crate Position Always place the crate upright on its base The crate has been designed to carry the weight of the vehicle only in that position The sides and top of the crate are not strong enough to act as the base of the crate If the crate is tilted very far or set on its end or side loose parts may be dislodged and fall inside the crate MILITARY USE ONLY MILITARY USE ONLY 4 UNCRATING Moving Crated Vehicle
16. A WARNING Crate bands are only designed to hold the cardboard cover in place If used as handles they can snap causing you or the crate to fall resulting in injury Do not move or lift the crate using the crate bands Whenever moving the crate from one place to another use a fork lift or flat bed hand truck Ve hicle crates are too big and heavy to be moved by hand While moving a crate never stand it on end or tip it over on its side DO NOT DROP crated vehicles Loading and Unloading Trucks To load or unload crates use a f rk lift a lift type tail gate or a ramp Never unload crates by hand NEVER DROP crates off a truck Tying Down Crates Always tie down crates when transporting them Put the tie downs across the crate at the crate s internal vertical braces Do not use any hooks on the crate Tie Downs Internal Braces Stacking Disposable Wooden Crates The number of crates that may be stacked on top of one another depends on the condition of the crates more than any other single factor Also take into consideration the weight of the upper crate s the sizes of all the crates in a stack and the Strength of the bottom crate s base on the type of crate construction steel wood bracing ete In any case do not stack crates more than two high for trucking and three high for storage Uncrating Opening Crate US Model only A WARNING Crates have sha
17. ARY USE ONLY MILITARY USE ONLY 0C03001BS1 C e Top panel can be lifted from the unit Have a second person help to remove this piece as it can be awkward to handle Discard this assembly Take care when letting the screen and center bar assembly down from the top itis heavy and may fall Side Panel Removal e Remove the 18 screws shown below The panel should come loose without excess force check for any missed screws if the panel will not come off easily NOTE O Trying to break the panels off can result dn damage to the unit 0C03005BS1 C e Repeat procedure for the other side of the unit Discard these panels End Panel Removal e Remove the 4 screws shown below The panel should come loose without excess force check for any missed screws if panel will not come off easily NOTE O Trying to break the panels off can result in damage to the unit UNCRATING 9 Se oeseses 5 RLR A e 2 wee Pees 77 0C03007BS1 C e Repeat as above for the rear panel Discard these panels J AL TALI 48 B an i I A A PRESE VAN 0C03006BS1 C Removing the Right and Left Bar and Upper Bars and Upper Back Bar Front Guard Cover and Parts Box Re moval e Cut the tie band 1 that retains the front guard cover and the upper bars and remove the front guard cover from the cargo bed A Parts Box B Tie band C Front Guard Cover Right and Left Bar and
18. Crate Other than US Model A WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury Always wear protective gloves boots and eye protection when uncrat ing to prevent injury MCO3003B S e Clear a space about 6 m 20 ft square to give yourself plenty of Space to work e Place the crate upright on its base e Remove the outer cover and inspect the unit for concealed damage If concealed damage is evident document the damage as outlined in the Kawasaki Warranty Policies and Pro cedures Manual before proceeding to uncrate the unit e Remove the cardboard cover Removing Panels e Using a BPS3 square drive bit ex IM PORT APEX Square Recess Power Bits 1 4 Hex size 3 or MAGNA Insert Bits size 3 with quick change holder remove the screws from the sides and ends into the top MILITARY USE ONLY PCOSO23BS1 C A Power Bit APEX A WARNING Staples nails and other fasteners have sharp points that can cause injury Re move or bend into the wood all staples nails or otherfasteners in the crate base e Take outall the bolts nuts screws and fas teners and remove the top and side panels of the wood crate MCO3004B S Top Panel Removal e Remove the screws from the top crate e There are two screws in every corner OCO3000BS1 C e Remove two screws in every cross member MILIT
19. G This battery is sealed battery type Never remove seal sheet or cap even at charging Never add water Charge with current and time as stated below MILITARY USE ONLY MILITARY USE ONLY 26 PREPARATION 0C058076 P A Seal Sheet or Cap e Refer to the Battery Charging Time Table for the charging 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V 1908016 table below Criteria 12 6 V or higher 12 0 12 6 V nserviceable Replace attery Holder Damper Put the battery in the battery case e Reinstall the nuts battery holder rod and bat tery in the reverse of removal e Be sure not to pinch the positive cable with the battery holder e Route the battery cables as shown and first connect the red protective capped positive cable to the battery positive terminal then connect the negative cable to the negative terminal e Put a light coat of grease on the terminals to prevent corrosion e Coverthe positive terminal with its red pro tective cap MILITARY USE ONLY MILITARY USE ONLY B Positive Cable C Negative Cable D Battery Holder E Battery Uncharged Battery Service Other than US Model Conventional Battery Type OC05BO53 P A Battery The battery used inthis RUV is a conventional type Follow thesprocedure for activating a new battery t
20. GO TRANSGARD TRACTOR HYDRAULIC FLUID Exxon Hydraul 560 Capacity 1 0 L 1 06 US qt NOTE ODo not use front final gear case oil into the rear final gear case Use only the specified oil The rear final gear case contains brake plates which require a special oil type Also the two different oil types for the rear gear case oil must not be mixed in use e Check the oil level The oil level should come to the bottom thread of the filler opening If it is insufficient add oil through the oil filler opening as necessary A Rear Final Gear Case B Filler Opening C Bottom Thread e Install the filler cap Oil Filler Cap Torque 29 N m 3 0 kgf m 21 ft Ib MILITARY USE ONLY MILITARY USE ONLY 36 PREPARATION Brake Fluid Brake Fluid Level Inspection A WARNING Brake fluid that is contaminated by moisture or dirt mixed or contains air has a lower boiling point and can cause the brake to be ineffective or fail and it may cause rubber parts to deterioate resulting in an accident causing injury or death Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t add or change the fluid in the rain or when a strong wind is blowing Brak
21. Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 e If the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored tempera ture and the type of chargerused Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 8 volts repeat charging cycle e After charging is completed press down firmly with both hands to seat the strip of caps A intosthe battery don t pound or ham mer When properly installed the strip of caps will be level with the top of the battery GP080107S1 C NOTICE Once the strip of caps A is installed onto the battery never remove the caps nor add water or electrolyte to the bat tery NOTE OTo ensure maximum battery life and customer satisfaction it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 volts repeat the charging cycle and load test f still below 12 8 volts the battery is defective MILITARY USE ONLY MILITARY USE ONLY 30 PREPARATION Battery Installation NOTE OThe procedure of the installation is the same as the above Charged Battery Service US Model e Turn the main switch OFF e Check that the rubber dampers on the battery holder and the battery case are properly in place e Put the battery in the battery
22. a Opolantesy asuata ERR RENI Throttle Pedal Differential Shift Lever and Cable Idle Speed Adjustment Headlight Bear hehe ee rot poet ot Ee E exeun LATA XITo eT au I II e a aaa aa E piia Digital Meter dioe ti tse ayau e etai aai Fastener Check oett ta rete f etr b rs Standard Torque Table arar Jest Ride Checklist aie e Ee eder ions MILITARY USE ONLY MILITARY USE ONLY Crate Handling Crate Handling Precautions for RSC Returnable Steel Crate US Model only Crate Position Always place the crate upright on its base The crate has been designed to carry the weight of the vehicle only in that position The sides and top of the crate are not strong enough to act as the base of the crate If the crate is tilted very far or set on its end or side loose parts may be dislodged and fall inside the crate Loading and Unloading Trucks for RSC To load or unload crates useza fork lift Never attempt to unload crates by hand NEVER DROP crates off a truck Be sure to use the proper handling equip ment for safe unloading storing and stacking of crated Teryx utility vehicles The weight of a large Teryx utility vehicle plus the RSC exceeds 860 kg 1 900 Ibs
23. al voltage The battery is located under the left end of the driver s seat e Remove the protective caps on the battery terminals and discard them 0C05B083 P i P E A Protective Caps e Measufe the battery terminal voltage NOTE OMeasure with a digital voltmeter that can be read to at least one decimal place voltage Battery Terminal Voltage Standard 12 6 V or more e If the reading is above the specification re freshing charge is not required Go on to the next step lt 0C05B084 P A Voltmeter e If the reading is below the specification re freshing charge is required See the Battery Removal and Refreshing Charge section MILITARY USE ONLY MILITARY USE ONLY Battery Installation e Turn the main switch OFF e Route the battery cables as shown and first connect the red protective capped positive cable to the battery positive terminal then connect the negative cable to the negative terminal e Put a light coat of grease on the terminals to prevent corrosion B Positive Cable C Negative Cable D Battery Holder E Battery e Cover the positive terminal with its red pro tective cap Battery Removal e Loosen the bolts to remove the battery holder e Remove the battery holder and take the bat tery out of the battery case Be careful that any rubber dampers are not pulled out of po sition 0C05B086 P B Battery Hol
24. and install the clamp NOTE Olnstall the two breather hoses to line up as shown in figure ASSEMBLY 19 OD15B021 P 2 Breather Hose Fuel Tank Breather Hose Rear Final Gear Case Clamp 92037 1181 Clamp 92037 1104 Band moom Seat Belt Seat Belt Installation e Installctthe seat belt bracket to the lower bolt hole and tighten the right and left bar mount ing bolts D 14 L 36 together ODO6BO19 P A Bolts D 14 L 36 B Seat Belt Bracket e Tighten the right and left bar mounting bolts to the specified torque Right and Left Bar Mounting Bolt Torque 98 N m 10 kgf m 72 ft lb e Remove the seat belt case mounting bolts D 12 L 25 2 and nuts D 12 2 from the frame e Remove the seat belt case cover from the seat belt case MILITARY USE ONLY MILITARY USE ONLY 20 ASSEMBLY e Fit the projection on the recess of the frame and install the seat belt case as shown in the figure e Reinstall the seat belt case mounting bolts D 12 L 25 2 and nuts D 12 2 and tighten them together eo 1 ah Z N MEL ODOGBO20 P Bolt D 12 L 25 Seat Belt Case Cover Seat Belt Case Nut D 12 Projection Frame moomw e Reinstall the seat belt case cover over the seat belt case A Seat Belt Case Cover B Seat Belt Case e Tighten the seat belt case mounting nut to the specified torque Seat
25. ar front mounting bolt 98 10 72 7 Right and left bar rear mounting bolt 98 10 72 8 Front and rear upper bar mounting bolt Left and Right 47 4 8 35 9 Upper and lower back bar mounting bolt Eeft and Right 47 4 8 35 10 Back bar joint bolt Left and Right 47 4 8 35 Wheel 11 Wheel nut 137 14 101 Suspension 12 Front shock absorber mounting nut Left and Right 58 5 9 43 13 Rear shock absorber mounting nut Left and Right 96 9 8 71 14 Bp g and lower suspension arm pivot nut Left 88 9 0 65 15 hc hh and lower suspension arm pivot nut Left 88 9 0 65 Engine 17 Front final gear case oil filler cap 29 3 0 21 Cotter pin or Snap Pin MILITARY USE ONLY MILITARY USE ONLY 50 PREPARATION Standard Torque Table This table relating tightening torque to thread diameter lists the basic torque for bolts and nuts Use this table only for the bolts and nuts not listed above All of the values are for use with dry solvent cleaned threads General Fasteners Threads dia mm N m ft lb 5 3 4 4 9 0 35 0 50 30 43 in Ib 6 5 9 7 8 0 60 0 80 52 69 in Ib Torque 8 14 19 14 1 9 10 0 13 5 10 25 34 26 3 5 19 0 25 12 44 61 45 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 33 165 240 Test Ride Checklist e Complete the test ride checklist Steering Action is free
26. case Check the oil level The oil level should come to the bottom thread of the filler opening If it4s insufficient add oil through the oil filler opening as necessary A Front Final Gear Case B Filler Opening C Bottom Thread e Install the filler cap Front Final Gear Case Oil Equivalent to engine oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 class Viscosity SAE 10W 40 Capacity 0 70 L 0 74 US qt Although 10W 40 engine oil is the recom mended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area MILITARY USE ONLY MILITARY USE ONLY pk SAE 10W 40 SkE USD P A 20 10 0 10 20 30 4000 4 14 32 4 1i4 32 0 8 86 104 F HN e ERU SUN EE HUO9002BS1 C Oil Filler Cap Torque 29 N m 3 0 kgf m 21 ft Ib Rear Final Gear Case Oil Rear Final Gear Case Oil Level Inspec tion e With the vehicle level front to rear and side to side remove the filler cap from the rear final gear case OE16009B G A Rear Final Gear Case B Filler Cap Be careful not to allow any dirt or for eign materials to enter the rear final gear case PREPARATION 35 NOTE OFront and rear final gear cases use different types of oils Use the specified type and brand of oil in each final gear case Rear Final Gear Case Oil Type Mobil Fluid 424 CIT
27. case e Reinstall the nuts battery holder rod and bat tery in the reverse of removal e Route the battery cables as shown and first connect the red protective capped positive cable to the battery positive terminal then connect the negative cable to the negative terminal e Put a light coat of grease on the terminals to prevent corrosion e Cover the positive terminal with its red pro tective cap A Battery B Holder C Positive Cable D Negative Cable Air Cleaner Air Cleaner Element Inspection The foam air cleaner element on RUV models is oiled prior to shipping However over time the filter will dry and filtration performance will diminish e Release the rivets and remove the air cleaner top cover A Air Cleaner Top Cover B Rivets e Pull up the snaps and remove the air cleaner housing cap A Air Cleaner Housing Cap B Snaps e Inspect the foam air cleaner element for proper oiling e If the foam element is dry remove the screw D 6 L 18 and pull out the foam air cleaner element and the element frame from the air cleaner housing NE26005B G A Screw D 6 L 18 B Foam Element C Air Cleaner Housing MILITARY USE ONLY MILITARY USE ONLY e Remove the foam element cover screw D 6 L 18 and foam element cover e Take the foam element off the element frame NE26B011 P A Screw D 6 L
28. der C Battery PREPARATION 25 Battery Specifications Battery Capacity Battery P No 12 V 14 Ah 26012 0107 Refreshing Charge A DANGER Batteries produce an explosive gas mix ture of hydrogen and oxygen that can cause serious injury and burnsifignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at thegbattery terminals which could ignite any battery gases Always remove the battery from the vehicle for charging If the battery is charged while still installed battery electrolyte may spill and corrode the frame or other parts of the vehicle Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 C 113 F during charg ing reduce the charging rate to lower the temperature and increase charging time proportionately NOTE ONever attempt to charge a frozen battery OAllow it to warm up to room temperature be fore charging ONever leave a battery on a trickle charger longer than 48 hours Serious damage to the battery will occur A WARNIN
29. e electrolyte container S ETT I we foleo GP080105S1 C e Check the electrolyte flow e If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times ARY USE ONLY MILITARY USE ONLY GPO80106S1 C e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation Removal of the container before it is completely empty can shorten the ser vice life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery elet the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 30 minutes after filling Initial Charge e Place the strip of caps loosely over the filler ports GPO8019BS1 C A Strip e Newly activated sealed batteries require an initial charge Standard Charge 1 2 Ax 5 10 hours PREPARATION 29 e If using a recommended battery charger fol low the charger s instructions for newly acti vated sealed battery Kawasaki recommended chargers Optimate lll
30. e fluid quickly ruins painted sur faces Wipe up any spilled fluid immedi ately e With the vehicle on level ground release the rubber bands on both sides e Clearthe four hook portions from the slots and lift the front cargo hood up OE21004B G A Front Cargo Hood B Band C Hook Portions e Support the hood in the tilted position with the supporting rod OE21005B G A Front Cargo Hood B Supporting Rod e Check that the fluid level in the reservoir is between the upper MAX and lower MIN level lines 0E04B030 P A Brake Fluid Reservoir B Upper Level Line MAX C Lower Level Line MIN e f the fluid level in the reservoir is lower than the lower level line check for fluid leaks in the front brake lines and fill the reservoir e Remove the brake fluid reservoir cap e Fill the reservoir to the upper level line with DOT3 brake fluid and reinstall the reservoir cap and tighten it to the specified torque Torque 3 4 N m 0 35 kgf m 30 in Ib MILITARY USE ONLY MILITARY USE ONLY 0E04B031 P A Reservoir Cap e Operate the brake pedal several times e If it feels spongy there might be air in the brake lines e If necessary bleed the air in the brake line e Also check for fluid leakage around the fit tings Brake Line Air Bleeding e With the front brake reservoir horizontal re move the front brake reservoir cap and di aphra
31. ection e Check that the throttle pedal has 5 10 mm 0 2 0 4 in of free play and moves smoothly from full open to close Throttle Pedal Free Play 5 10 mm 0 20 0 40 in MILITARY USE ONLY MILITARY USE ONLY 44 PREPARATION OE08005B G A Throttle Pedal B 5 10 mm 0 20 0 40 in Throttle Pedal Free Play Adjustment NOTE Olf the brake pedal free play adjustment is nec essary refer to the Service Manual Throttle Pedal Stop Position Adjustment The full throttle pedal stop position can be ad justed to prevent pulling the throttle cable more than required e Loosen the locknut and make the adjuster free e Depress the throttle pedal until the carburetor is fully opened and hold it there e Move the adjuster until its bottom4ouches the floor plate lightly e Tighten the locknut securely OE08006B G A Throttle Pedal B Locknut C Throttle Pedal Stop Bolt Differential Shift Lever and Cable By pulling the differential shift lever rearward the driving force of the front wheels equalizes providing more traction If the shift lever is pulled fully rearward and lock axle function is still not effective enough adjust the differential control cable NOTE Olf the differential shift lever position inspec tion adjustment is necessary refer to the Ser vice Manual Idle Speed Adjustment NOTE Oldle speed adjustment is best perfo
32. from lock to lock Suspension Check operation Engine The starter works properly and engine starts promptly Good throttlesresponse and return Belt Drive Torque Smooth operation Converter Differential Smooth operation Forward Reverse Smooth operation Shift Hi Low Shift Smooth operation 2WD 4WD Shift Smooth operation Brakes Adequate smooth stopping power Do not drag Seat Belt Proper function Electrical System Headlight check operation Tail Brake Light check operation No Unusual Noises No Fuel Oil Brake Fluid or Coolant Leaks Make a thorough visual check after the test ride PREPARATION IS COMPLETE If any of the above items were found to oper ate improperly refer to the Kawasaki TERYX 750 Fl 4x4 TERYX 750 FI 4x4 LE and TERYX 750 FI 4x4 SPORT Service Manual for repair and adjust ment procedures MILITARY USE ONLY MILITARY USE ONLY MODEL APPLICATION Year Model Name 2010 KRF750NAF TERYX 750 Fl 4x4 2010 KRF750PAF TERYX4750 Fl 4x4 LE 2010 KRF750RAF TERYX 750 Fl 4x4 LE 2010 KRF750SAF TERYX 750 Fl 4x4 SPORT 2010 KRF750SAFA TERYX 750 FI 4x4 SPORT 2010 KRF750TAF TERYX 750 FI 4x4 i 4 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99931 1515 02 MILITARY USE ONLY
33. gm and check that there is plenty of fluid in the reservoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoinruns completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Attach a clear plastic hose to the bleed valve on the caliper_and run the other end of the hose into a container e With the reservoir cap off slowly pump the brake pedal several times until no air bub bles Can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the front brake mas ter cylinder end of the line e Pump the brake pedal a few times until it becomes hard and then holding the pedal depressed quickly open turn counterclock wise and close the bleed valve Then re lease the pedal Repeat this operation until no more air can be seen coming out into the plastic hose PREPARATION 37 AA VIITTAA 92 17397725 17 777 38 AAA AAA J Z 22 lt lt 0E048021 P B Quickly open and close the bleed valve e Repeat the previous step one more time for the other front disc brake e When air bleeding is finished check that the fluid is between the upper and lower level lines e Install the diaphragm and the reservoir cap e Tighten the bleed valve s to the specified torque Torque 7 8 N
34. ht Switch Adjustment NOTE Olf the brake light switch adjustment is neces sary referto the Service Manual Parking Brake Pedal Parking Brake Pedal Inspection Adjust ment NOTE Olf the brake pedal Inspection Adjustment is necessary refer to the Service Manual Steering Wheel Steering Wheel Free Play Inspection e Check steering wheel free play e Set the vehicle s front tires straight ahead Gently turn the steering wheel left and right The steering wheel free play is the amount of travel in the steering wheel before the front wheels begin to turn Steering Wheel Free Play 0 20 mm 0 0 79 in MILITARY USE ONLY MILITARY USE ONLY 1004000BS1 C A 0 20 mm 0 0 79 in B Gently turn e If the free play is incorrect check and tighten the steering wheel mounting nut and the steering system parts and adjust the steer ing gear preload NOTE Olf the Steering Wheel Free Play Inspec tion Adjustment is necessary refer to the Service Manual Front Shock Absorber Front Shock Absorber Spring Preload Adjustment Other than KRF7S0SAF Model e Check the position of the spring preload ad juster on the front shock absorbers STD Spring Preload No 2 position x VAN N NE13002B G A Front Shock Absorber B Spring Adjusting Sleeve e Turn the adjusting sleeve to the No 2 position with the wrench in the tool kit PREPARATION 39 Fro
35. mation 56033 0348 13 Drive Belt Information 56033 0305 0D12020B G 5 Cargo Bed Warning 56071 7504 6 Cargo Bed Notice 56071 0147 7 ROPS Specification 56053 7519 0D12024B G 14 Trailer Towing Warning 56071 0100 MILITARY USE ONLY MILITARY USE ONLY 24 PREPARATION 0D12025B G 15 Vehicle Emission Control Information KRF750NAF Model 59464 1705 KRF750PAF Model 59464 1706 KRF750RAF Model 59464 1707 KRF750SAF Model 59464 1708 16 Cover Label Emission Control 14092 0127 Preparation Charged Battery Service US Model Pre filled Pre charged Battery 0058072 P The battery used in this RUV is a pre filled pre charged sealed battery eliminating the need for dealers to prepare the battery by filling it with electrolyte However dealers should still check each battery s state of charge periodically to be sure it meets the minimum 12 6 volt specifica tion and charge it to 10096 state of charge dur ing Assembly amp Preparation The new battery is built to automotive industry standards and should hold a charge of 75 or above for approximately six months at 72 77 F Because the battery will discharge at different rates based on varying conditions it is recom mended that it be checked every three months on any inventory unit Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery termin
36. mended settings A Compression Damping Adjuster MILITARY USE ONLY MILITARY USE ONLY 42 PREPARATION Compression Damping Settings i 20 1918171615 14131211109 8 7 6 5 4 3 2 1 p I NE13005BS1 C A Seated Position Adjuster turned fully clockwise B Standard Setting C Softer Counterclockwise D Harder Clockwise Number of turns counterclockwise usable range 20 clicks or more Rebound Damping Adjustment KRF750SAF Model only e Check the position of the rebound damping adjuster at the bottom of the rear shock ab sorber STD Rebound Damping 1 turn out Counterclockwise from the fully seated position e pP X a INO4B054 P A Rebound Damping Adjuster e To adjust the rear shock absorber rebound damping turn the rebound damping adjuster with a flat head screwdriver Adjust the re bound damping to the standard setting posi tion e The right and left front shock absorbers must be adjusted evenly Do not force to turn the rebound damp ing adjuster from the fully seated posi tion or the adjusting mechanism may be damaged Rebound Damping Settings p NE13006BS1 C A Seated Position Adjuster turned fully clockwise B Standard Setting C Softer Counterclockwise D Harder Clockwise Number of turns counterclockwise usable range 3 turns or more Tire Air Pressures Ti
37. nt Shock Absorber Spring Preload Adjustment KRF750SAF Model only e Check the position of the spring preload ad justing length on the front shock absorbers Adjusting Length from center of upper mounting bolt to lower surface of adjusting nut STD Adjusting Length 82 5 mm 3 25 in e Refer to the Front Shock Absorber Preload Adjustment procedure in the Service Manual Compression Damping Adjustment KRF750SAF Model only e Check the position of the compression damp ing adjuster on the top of each front shock ab sorber STD Compression Damping 3 1 2 turns out Counterclockwise from the fully seated position e To adjust the front shock absorber compres sion damping turn the compression damping adjuster at the top of the front shock absorber with a flat head screwdriver Adjust the com pression damping to the standard setting po sition e The right and left front shock absorbers must be adjusted evenly A WARNING If both compression damping adjusters and both rebound damping adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Set all suspension adjusters equally to the recommended settings MILITARY USE ONLY MILITARY USE ONLY 40 PREPARATION 0F22B004 P A Compression Damping Adjuster B Front Shock Absorber Right Do not force to turn the compression damping adjuster from the fully seated position or the
38. nt side and at the level ofthe axle height e Ground the front wheels e Set the steering wheel straight ahead e At the level of the axle height measure the distance between tHe scribed lines with a measure IK04001B S e Move the vehicle rearward until the marks on the front tires are at the rear side and at the same level as the axle e Measure the distance between the scribed lines PREPARATION 45 e Subtract the measurement of the front from the measurement of the rear to get the toe in Toe in of Front Wheels Standard 20 40 mm 0 79 1 57 in at 1G e f the length is out of specification adjust the tie rod length e Loosen the locknuts A on each tie rod and turn theyadjusting rods B the same number of turns and the same direction on both sides to achieve the specified toe in gt NOTE OThe toe in will be near the specified range if the length of the tie rod distance between the rod groove A and the locknut B is 80 mm 3 15 in C on both the left and right tie rods IK04002BS1 C MILITARY USE ONLY MILITARY USE ONLY 46 PREPARATION e Check the toe in again e Tighten the tie rod end locknuts to the speci fied torque Torque 44 N m 4 5 kgf m 32 ft Ib e Test drive the vehicle Digital Meter Clock Adjustment e Turn the ignition key to ON e Push the TIME SET button The hour dis play starts flashing
39. o ensure the best possible battery per formance Activating the battery requires two steps filling the battery with electrolyte and charging Read the Battery Safety label shown below and following procedures carefully before battery activation Incorrect Battery Activation will reduce battery performance and service life Be sure to strictly follow the Battery Service instructions in this Manual PREPARATION 27 A DANGER Heed the battery safety label shown here 4 DANGER POISON PROPOSITION 65 WARNING BATTERY POSTS TERMINALS SULFURIC FLUSH EYES Mio CONTAIN LEAD AND CANCAUSE WITH WATER An compouNDs BLINDNESS OR BLINDNESS OR CHEMICALS KNOWN INJURY SMOKING SEVERE BURNS HELP FAST TO THE STATE OF CALIFORNIA TO KEEP OUT OF REACH OF CHILDREN CAUSE CANCER AND REPRODUCTIVE 9004 0A Ne 26012 3728 CL27003B S e Make sure to use theselectrolyte packed in the crate with the unit e Make sure that the model name of the elec trolytecontainermmatches the model name of the battery These names must be the same Battery Model Name for KRFE750NAF PAF RAF SAF KMX14 BS PAXX0029S1 C A Model Name of the Electrolyte B Model Name of the Battery Battery Removal e Loosen the nuts to remove the battery holder e Remove the battery holder and take the bat tery out of the battery case Be careful that any rubber dampers are not pulled out of po sition MILITARY USE ONLY
40. o that the bracket parts of the upper bars face upward and tighten the bolt D 10 L 14 with the brackets 11055 0156 and 11055 0255 as shown in the figure Front Upper Bar Rear Upper Bar Bolts D 10 L 14 Bracket 11055 0156 Bracket 11055 0255 Brackets Forward o m m 9 o m gt e When installing the pads install them on the rib of the sun top cover as shown in the figure AE T n il N I I AD e W 0D15005BS2 C Sun Top Cover Pads 49 mm 1 93 in Installing side for the pads oom MILITARY USE ONLY MILITARY USE ONLY e Install the sun top cover on the brackets with the screws D 6 L 16 8 and oollars D 16 L 6 3 8 and tighten them A Sun Top Cover B Screws D 6 L 16 and Collars D 16 L 6 3 e Tighten the right and left bar upper and lower back bar front and rear upper bar mounting bolts to the specified torque Right and Left Bar Mounting Bolt Torque 98 N m 10 kgf m 72 ft Ib Upper and Lower Back Bar Mounting Bolt Torque 47 N m 4 8 kgf m 35 ft4b Upper and Lower Back Bar Joint Bolt Torque 47 N m 4 8 kgf mp35 ftlb Front and Rear Upper Bar Mounting Bolt Torque 47 N m 4 8 Kgf m 35 ft lb Breather Hose Installation e Install the breather hose Rear Final Gear Case to outside lower fitting and install the clamp e nstalPthe breather hose Fuel Tank to inside upper fitting
41. ojections of steering wheel into the holders 00048034 P A Steering Wheel Cap B Nut D 12 C Washer D 12 1 x 25 L 1 6 D Steering Wheel Be careful not to puncture a tire with sharp fasteners when rolling off the ve hicle from the crate base e Remove any nails from the crate base that might not puncture a tire e Roll the vehicle off the crate base Right and Left Bar Seat Removal e Remove the seat by pulling up the seat latch lever located at the front of the seat and then pull the seat up and to the front 0D06B018 P A Seat Latch Lever NOTE Olt is recommended that the seat should be installed after completing the steps in the Charged Battery Service or Uncharged Battery Service and Engine Oil sections in the PREPARATION chapter MILITARY USE ONLY MILITARY USE ONLY Right and Left Bar Installation e With the help of a second person install one side bar onto the frame and tighten the front mounting bolts D 14 L 36 4 and only the upper part of the rear mounting bolt D 14 L 36 2 Install another side bar the same way 14 L 36 B Front Mounting Bolts D 14 L 36 NOTE OThe lower part of the rear mounting bolt s tightened with belt bracket later Upper and Lower Back Bar Upper and Lower Back Bar Installation e Install the lower back bar and tighten the mounting bolts D 10 L 14 4
42. pe Unleaded Gasoline Minimum Antiknock Index RON MON Octane Rating 87 2 For Australia Specifications Use clean fresh unleaded gasoline with an octane rating equal to or higher than that shown in the table Fuel Type Unleaded Gasoline Research Octane Number RON 91 e Close the fuel tank cap and check for any leaks and correct them Coolant Coolant Reservoir Tank Level Check e Check the coolant level through the coolant level gauge on the reserve tank PREPARATION 43 The coolant level should be between the F Full and L Low marks NOTE OCheck the level when the engine is cold room or atmospheric temperature OE21006B G Reserve Tank Cap F Bull Mark L Low Mark U O m gt e If the amount of coolant is insufficient un screw the cap from the reserve tank and add coolant through the filler opening to the F Full mark Install the cap Recommended Coolant Solution Coolant Mixture Ratio Water 50 Antifreeze 50 1 1 Recommended Antifreeze Permanent type antifreeze ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiator NOTE OA permanent type of antifreeze is installed in the cooling system when shipped It is col ored green and contains ethylene glycol It is mixed at 50 and has the freezing point of 35 C 31 F Throttle Pedal Throttle Pedal Free Play Insp
43. prights To do So lift up on the upright to disengage its sock ets from the pallet e Now the upright may be pivoted down to the gro nd Itremains attached to the pallet Be careful not to drop it on anyone 0C03021BS1 C A Upright Removing the Right and Left Bar and Upper Bars and Upper Back Bar Front Guard Cover and Parts Box Re moval e Cut the tie band 1 that retains the front guard cover and the upper bars and remove the front guard cover from the cargo bed e Remove the parts box from the cargo bed MILITARY USE ONLY MILITARY USE ONLY 6 UNCRATING A Parts Box B Tie band C Front Guard Cover Right and Left Bar and Upper Bars and Upper Back Bar Removal e Cut the tie bands 3 that retain the right and left bars at cargo bed e Cut the tie bands of all bars LL P A Tie bands Windshield and Stn Top Cover KRF750PAF RAF Model only e Cut the tie bands 2 that retain the sun top cover with the windshield and remove the windshield ND the Sun top cover 0C03B078 P A Tie bands B Sun Top Cover e Remove the bolts and nuts of right and left that retain the plate and remove the sun top cover from the plate e Discard the bolts and nuts A Bolt Right b g B Nut Right NO C Plate Right D Sun p Cover e Remove the Bolts 4 and plates 2 from front d bar and Gisgard them A Bolts B Plates C Front Bar e C
44. r SM with JASO MA MA1 or MA2 class Viscosity SAE 10W 40 Capacity 2 4 L 2 5 US qt when filter is not removed 2 5 L 2 6 US qt when filter is removed Although 10W 40 engine oil is the recom mended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area SAE 208 50 L I ee AE 20W 40 e SAE 10W 50 rrr Aa SAE 10W 40 pepe SAE 10W 30 SAE 5W 30 2 6 10 0 30 40 0 50 8 86 104 F BLO3006BM2 C e Install the protective cover and insert the two quick rivets MILITARY USE ONLY MILITARY USE ONLY 34 PREPARATION A Quick Rivets B Protective Cover e To install the seat insert the projections at the rear of the seat into the seat holders and push down on the seat at the front The seat lock clicks A WARNING A loose seat can cause the operator or passenger to lose control or fall out of the vehicle causing severe injury or death Be sure the seat is securely latched A Seat B Projections Ca Seat Holders Front Final Gear Case Oil Front Final Gear Case Oil Level Inspec tion e With the vehicle level front to rear and side to side remove the filler cap from the front final gear case OE16B008 A Front Final Gear Case B Filler Cap C Front Axle Shaft Be careful not to all w any dirt or for eign materials to enter the front final gear
45. rate base and packaged materials carefully for lost parts Order any parts that are missing from the crate Part numbers are provided in the following charts Check the parts against the illustrations In the following charts under Remarks D diameter in millimeters and L length in millimeters In the following charts under Qty component of assembly parts 0006035BW4 C MILITARY USE ONLY MILITARY USE ONLY UNCRATING 13 Part Name Remarks Part Number Steering Wheel 46003 0114 Steering Wheel Cap 11065 0171 Right Bar 55047 0022 Left Bar 55047 0021 Flanged Bolt Right and Left Bar D 14 L 36 92153 1282 Upper Back Bar 39043 0005 Lower Back Bar 39043 0008 Flanged Bolt Upper and Lower Back Bar D 10 L 14 130CB1014 Front Upper Bar 39043 0001 Rear Upper Bar 39043 0007 Flanged Bolt Front and Rear Upper Bar D 10 L 14 130CB1014 Clamp Breather Hose Fuel Tank 92037 1181 Clamp Breather Hose Rear Final Gear Case 92037 1104 Flanged Bolt Battery Terminal U S Model D 6 L 16 130BA0616 Plate Nut Battery Terminal U S Model D 6 92210 1352 KRF750PAF RAF Models Sun Top Cover 14091 1770 Pad Sun Top Cover 39156 0479 Screw Sun Top Cover D 6 L 16 92009 1621 Collar Sun Top Cover D 16 L 6 3 92143 1087 Bracket Sun Top Cover 11055 0156 Bracket Sun Top Cover 11055 0255 Seat Belt with 53061 0007 Cover Seat Belt Upper Bracket 11065 0287 Flanged Bolt Seat Belt Case Upper D 10 L
46. re Air Pressure Adjustment e Adjust the pressures to the specified values in the front and rear and make sure to tighten the caps securely Tire Air Pressures when cold Normal Use Front 60 kPa 0 60 kgf cm 8 7 psi Rear 90 kPa 0 90 kgf cm 13 1 psi A Air Pressure Gauge MILITARY USE ONLY MILITARY USE ONLY NOTE OTo accurately measure the pressure use a low air pressure gauge included in the tool kit of RUV Do not use an automotive air pres sure gauge because the specified tire air pres sures of RUV is too low Fuel A WARNING Gasoline is extremely flammable and can be explosive under certain condi tions creating the potential for serious burns 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 Never fill the tank completely to the top If the tank is filled completely to the top heat may cause the fuel to expand and overflow through the vents in the tank cap Af ter refueling make sure the tank cap is closed securely If gasoline is spilled on the fuel tank wipe it off immediately e Open the fuel tank cap and check for debris in the fuel tank e Fill the fuel tank with one gallon or four liters of unleaded gasoline Use a gasoline with a minimum octane rating shown below For US and Canada Specifications Fuel Ty
47. re Max Load 56053 0418 Label Shifting 1 5607 1 0129 Label Protective Cover 1 56070 1271 Label Warning General 1 56071 0053 Label Warning Trailer Towing 1 56071 0100 Label Warning Cargo 1 56071 0112 Label Warning Cargo Bed 1 56071 0114 Label Warning Cargo Bed 1 56071 7504 Label Warning Refueling 1 56071 7505 Label Vehicle Emission Control Information KRF750NAF Model only 1 59464 1705 KRF750PAF Model only 1 59464 1706 KRF750RAF Model only 1 59464 1707 KRF750SAF Model only 1 59464 1708 Label Air Cleaner Information 1 56033 0348 Cover Label Emission Control 1 14092 0127 8 Battery Electrolyte KMX14 BS non U S Model 1 12 V 12 Ah 26022 1040 9 Owner s Manual 1 _ MILITARY USE ONLY MILITARY USE ONLY 16 ASSEMBLY Assembly Steering Wheel Steering Wheel Installation e Remove the steering wheel nut D 12 and the washer D 12 1 x 25 L 1 6 from the steering shaft A Steering Wheel nut B Steering Wheel Washer C Steering Shaft b EN 0D048032 P e Set the front wheels straight ahead e Mount the steering wheel on the steering shaft as shown below and reinstall the steer ing wheel nut D 12 and washer D 12 1 x 25 L 1 6 e Tighten the nut to the specified torque Torque 54 N m 5 5 kgf m 40 ft Ib Ee 0D04B033 P A Washer D 12 1 x 25 L 1 6 B Nut D 12 C Steering Wheel e To install the steering wheel cap insert the pr
48. rmed by ECU so idle speed cannot be adjusted Idle Speed Adjustment Idle Speed 1 10050 r min rpm HeadlightBeam The headlight beams can be adjusted verti Cally e Turn the adjusting screw at the back of the each headlight rim in or out to adjust the head light vertically OE20004B G A Headlight Body B Adjusting Screw e Close the hood in the reverse order of open ing the hood Wheel Alignment Toe in is the amount that the front wheels are closer together in front than at the rear at the axle height When there is toe in the dis tance A Rear is greater than B Front as shown The purpose of toe in is to prevent the front wheels from getting out of parallel at any time and to prevent any slipping or scuff ing action between the tires and the ground If toe in is incorrect the front wheels will be MILITARY USE ONLY MILITARY USE ONLY dragged along the ground scuffing and wear ing the tread knobs Caster and camber are built in and require no adjustment A Rear B Front Amount of Toe in Distance A and B are measured at hub height 1KO4000B S Toe in Adjustment e Lift the front wheels off the ground e Apply a heavy coat of chalk near the center of the front tires e Using a needle nose scriber make a thin mark near the center of the chalk coating while turning the wheel e Set the wheels so that the marks on4he tires are at the fro
49. rp edges and may have nails or screws that can cause cuts and injury Always wear protective gloves boots and eye protection when uncrat ing to prevent injury MCO3003B S A WARNING The steel crate panel plates and fasten ers have sharp edges Always wear pro tective gloves boots and eye protection when uncrating to prevent injury MILITARY USE ONLY MILITARY USE ONLY MCO3004B S e Clear a space about 6 m 20 ft square to give yourself plenty of space to work e Place the crate upright on its base e Remove the outer cover and inspect the unit for concealed damage If concealed damage is evident document the damage as outlined in the Kawasaki Warranty Policies and Pro cedures Manual before proceeding to uncrate the unit e Remove the cardboard cover To work efficiently start work at the rear of the crate e Remove the hairpin clips 2 then push out the clevis pins 2 to disconnect the reaf diag onal braces 2 from the rear upright e Repeat these steps for the front upright e Allow the diagonal braces to pivot out and down to the ground They remain attached to the pallet 0C03010BS1 C A Rear Upright B Hairpin Clip C Diagonal Brace e Install the hairpin clips 4 back into the braces for return to KMM UNCRATING 5 NC03002BS1 C A Hairpin Clip B Clevis Pin C Diagonal Brace e Lay down the ffront nd rear u
50. s situa tion which if not avoided will result in death or serious injury WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a hazardous situa tion which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to personal injury NOTE OThis note symbol indicates points of particular interest for more efficient and convenient op eration Kawasaki Heavy Industries Ltd accepts no liability for any inaccuracies or omissions in this publication although every possible measure has been taken to make it as complete and ac curate as possible All procedures and specifi cations subject to change without notice Aug 2009 MILITARY USE ONLY Table of Contents Crate Handling ute Dr epe duties etate G2 Crate Handling Precautions for RSC Returnable Steel Crate US Model only ei nadtieaecoedise ac dedods Crate Handling Precautions Other than US Model U eratinig oer IR Opening Crate US Model only Opening Crate Other than US Model Parts Check ttd e Y RUND ARR ERE SEV RAS nd aaa AE Assembly 35x iE tbe taies cto t lm Steering Wheel ae W
51. so that the wider side faces up and insert tabs and both sides of the element cover into the holder of the air cleaner hous ing MILITARY USE ONLY MILITARY USE ONLY 32 PREPARATION A Foam Element B Air Cleaner Housing C Wider Side Faces D Tabs E Holder e Tighten the screw to the specified torque Torque 4 5 N m 0 46 kgf m 40 in Ib e Insert tabs of air cleaner top cover into the slits of the engine upper cover A Slits B Tabs C Air Cleaner Top Cover e Reinstall the air cleaner top cover air cleaner element and the air cleaner housing cap in the reverse of removal e Install the rivets to the air cleaner top cover Engine Oil Engine Oil Level Inspection A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas In haling carbon monoxide can cause seri ous brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area NOTE OThis vehicle s engine is filled with 10W 30 oil from the factory DO NOT DRAIN and refill the crankcase before use Check oil level and drain plug tightness Engine Oil Drain Plug Torque 20 N m 2 0 kgf m 15 ft lb e Remove the bottom guard and bottom guard bolts 0E02007B G A Bottom G ard Bolts B Bottom Guard 0E02000B G A Oil Drain Plug e Park the vehicle so that it is level both side to side and front to rear
52. splay shifts by pushing the SET RESET button while the MODE but ton pushed in CG N R w I SETIRESET OE24001B G A Mph km h Display e The mph km h display shifts as follows MILITARY USE ONLY MILITARY USE ONLY PREPARATION 47 Kig eo 0E24002BS1 C A Km h Display B Mph Display C Push SET RESET Button with MODE Button pushed in NOTE OThe data is maintained even if the battery is disconnected MILITARY USE ONLY 48 PREPARATION MILITARY USE ONLY Fastener Check e The torque values listed are for assembly and preparation items only see the appropriate Service Manual for a more comprehensive list Check tightness of all fasteners that are in the table before retail delivery Also check to see that each cotter pin or circlip is in place 0E11B087 P OE11B089 P 0E11B088 P MILITARY USE ONLY MILITARY USE ONLY 0E118054 P PREPARATION 49 Torque No Fastener Nm kgf m f Rib Remarks Steering 1 Tie rod end locknut Left and Right 44 4 5 32 Brake 2 Brake caliper bleed valve Left and Right 7 8 0 80 69 in lb 3 Rear master cylinder bleed valve 7 8 0 80 69 in lb Frame 4 Seat belt mounting bolt Left and Right 42 4 3 31 5 Seat belt case mounting nut Left and Right 47 4 8 35 6 Right and left b
53. ut the tie bands 2 and remove the wind shield from the sun top cover MILITARY USE ONLY MILITARY USE ONLY 0C03B081 P A Tie bands B Windshield C Sun Top Cover Removing the Lower Back Bar and Front Tie downs Removal e Cutthe tie bands 3 that retain the lower back bar at the front guard and remove the lower back bar from the front guard e Remove front tie downs by opening fully and disengaging latch Take care to undo these evenly as there is heavy tension in the tie down A Tie downs Front Bs Tie bands C Lower Back Bar Rear Tie down Removal e Remove rear tie downs by opening fully and disengaging latch Take care to undo these evenly as there is heavy tension in the tie down UNCRATING 7 0C03013BS1 C A Tie downs Rear e Roll the vehicle off the crate base after in staling the steering wheel see Steering Wheel section on page16 in the assembly chapter RETURN SHIPMENT e Prepare the crate for return shipment e Foldsbraces in so they lay on the crate pallet 0C03015BS1 C A Braces e Lift the rear upright to disengage its sockets Pivot it down onto the crate pallet Be careful not to drop on anyone 0C03016BS1 C A Uprights e Repeat these steps for the other upright MILITARY USE ONLY 8 UNCRATING 0C03017BS1 C e These items are discarded Outer Cover Tie downs Qty 4 Opening

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