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2010 Kawasaki Teryx KRF750RAF Service Manual 99924-1434

Contents

1. Whieels Wheel Removal Wheel Wheel Rim Ape Wheel Rim iN MR eter ted REA c Cc E dium Front Hub ent eee rettet NK Nee et e tete eei Front Hub Front Hub Installation 4 ON Front Hub Disassembly Assembly RearHub z NE ooo nien etm Rear Hub Removal EM LE Soa eee Rear Hub Installation 9 7 Rear Hub DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 10 2 WHEELS TIRES Exploded View 1K020078W85 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY WHEELS TIRES 10 3 Exploded View Torque No Fastener Nam kgf m it
2. BRAKES 12 3 Exploded View No Fastener Remarks kgf m ft Ib 1 Front Master Cylinder Reservoir Cap 3 4 0 35 30 2 Reservoir Clamp Bolt 6 2 0 63 55 in lb 3 Piston Stop Bolt 8 8 0 90 78 in lb 4 Brake Pipe Nipples 17 5 1 8 13 5 Hose Banjo Bolts 23 5 24 17 6 Front Master Cylinder Mounting Bolts 23 5 2 4 17 7 Master Cylinder Bolt 23 5 2 4 17 8 Push Rod Locknut 17 2 1 8 13 9 Parking Brake Pedal Assy Mounting Bolts 41 5 4 2 31 10 Front Brake Pad Mounting Bolts 17 2 1 8 13 11 Caliper Bleed Valves 7 8 0 80 69 1 1 13 Caliper Holder Shaft 17 2 1 8 13 14 Brake Caliper Mounting Bolts 33 3 4 24 L 15 Front Brake Disc Mounting Bolts 41 5 4 2 31 L 16 Parking Brake Indicator Light Switch Screws 0 4 0 04 4 in lb 17 Apply sealing material to the hatched area B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 4 BRAKES Exploded View DH W pw 1M020438W5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 5 Exploded View No Fastener Remarks
3. ReanSuspension Arm 0 RearSuspension Arm 111221111 Rear Suspension Arm Disassembly ip bts Rear Suspension Arm Assembly Stabilizer Remoyal Stabilizer Stabilizer Joint dese e ob e Rear Knuckle Removal ce EO Ete eb taque etu de ces Hear Knuckle Installatiori i RR ete P MH PRINS UM Ee c a Hear Knuckle Disassembly cnet ti tet toe e meme ga Rear Knuckle Assembly regente e p e Ta ned Este Oll SOA EE Ball Bearing Inspecllon eo te Eee to da bcd ERE DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 2 SUSPENSION Exploded View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 3 Exploded View Torque No Fastener Nm kgf m itib Remarks 1 Front Shock Absorber Mounting Nuts 57 5 5 9 42 R 2 Front Suspension Arm Pivo
4. Front Brake Master Cylinder Retainer Brake Pipe Brake Hoses Clamp Grommet Clamp Clamp Right clamp has red paint Left clamp is no paint Stopper Hold the brake hose with the stopper Brake Hose Stopper Touch the stopper of the brake hose to the stopper on the caliper Caliper Stopper Detail A Clamp Push the clamp to make the gap between brake hose and steering knuckle Steering Knuckle No gap DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 22 APPENDIX Cable Wire and Hose Routing xA 134 b v gt gt el am A 4 fies oe isl SS EIL C gt A gt CL S 4 4 gt Section CZ NA ii IS L 1 18082388W5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 23 Cable Wire and Hose Routing Parking Brake Cable Differential Shift Cable Band Secure the differential shift cable and t
5. 11 60 Front Final Gear Case Tooth Contact 2 400040 11 61 Bevel Gear Inspection iie 11 64 Differential Gear Inspection ede des tede Soit ne halts 11 64 Rear Propeller Shaft ato eet m 11 65 Rear Propeller Shaft Herloval ae rer Ue deci enia aeui 11 65 Rear Propeller Shaft Installation nnn 11 65 Rear Propeller Shaft Inspector out iere ep Leopoldi qu ddp 11 67 MC 11 68 Rear Axle Hemoval o eine Pu De PR Rt M as 11 68 Hear Axle InstallatlOrixz 11 68 Rear Axle Joint Boot Inspection rtr neck ta er ione e i rte ee ed RN 11 68 Rear Axle Joint Boot Beplacetent uote e Er tente eb 11 69 Rear Final Gear i eror bee ERI RO rese petu orco acc 11 75 Rear Final Gear Case Oil Level 3 11 75 Rear Final Gear Case Oil 2 0 2 11 75 Rear Final Gear Case 11 75 Rear Final Gear Case teen 11 77 Rear Final Gear Case
6. 7 11 77 Rear Final Gear Case Right Cover Assembly Iesse 11 80 Rear Final Gear Case Front Cover Assembly 11 80 Rear Final Gear Case Assembly 11 81 Pinion Gear Unit Disassembly era A Meses 11 85 Pinion Gear Unit Assembly dor Ier eret epos 11 86 Rear Final Bevel Gear 11 86 Rear Final Gear Case Backlash Adjustment 9 11 89 Tooth Contact Adjustmeril dere ettet 11 90 Bearnng arnd Oil SOA aceasta tan Behe A Ea 11 92 Ball or Needle Bearing Inspection 11 92 Seal 1 8 Me MAN UA Wm a 11 93 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 3 Exploded View This page intentionally left blank DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 4 FINAL DRIVE Exploded View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www mil
7. 2 38 Brake Hose and Pipe Inspection doom Man 2 40 Brake Hose HepldcerfileI ERE 2 41 Parking Brake Pedal IriSDectiort ios 2 43 Front Brake Pad Wear 1 EORR deri EU Re RR 2 43 Front Brake Caliper Piston Seal and Dust Seal 2 44 Rear Brake Plates etes estat de kei eed od uere dt 2 45 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 2 PERIODIC MAINTENANCE cuo e T Steering Inspection io n e b ede desque d quil Steering Joint Dust Boot InSpecliOn oreet s arredo Eae acujrcep cR Deal Belt Inspectii TE Electrical Syste bli E E RE Spark Plug GleaningAmnspectlOrtzs ceo s tt Spark Plug TnspBOllOni ss cnr aes Brake Light Switch Inspeollon Brake Light Timing Adjustment 00 JOINT Bots INSPOCLION
8. aea eif mb ee 14 6 Steering Wheel Installation 2 7 14 7 Steering Shafts 14 7 Steering Shafts Installation NM re hene te 14 8 Steering Gear Assembly tm m e t NO tiet 14 9 Steering Gear Assembly Removal 9 9 sse 14 9 Steering Gear Assembly Installation m 6 14 9 Tie rod Length Adjustment a IN aA 14 11 Steering Joint Dust Boot Inspection M 14 11 Steering Knuckles or tete or Rt eek er RR Renee 14 12 Steering Knuckle BHerrnoval toli Noe eI Ogre armate 14 12 Steering Knuckle Installation P 14 12 Knuckle Bearing Hemoval reete ctt nee 14 13 Knuckle Bearing 14 13 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 14 2 STEERING Exploded View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY STEERING 14 3 Exploded View Torque
9. o Vacant Terminal 12 Vacant Terminal pm 4 Vacant Termino Engine Brake Actuator Inspection e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Actuator Lead Connector A DOCUMENT AVAILABLE FOR MILITARY Order Online at www militaryatvparts com USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Actuator Control System e Measure the resistance between the following terminals in the actuator lead connector A Special Tool Hand Tester 57001 1394 Actuator Internal Resistance 4 Red 6 Black 3 150 1 Orange 3 Blue 3 5 6 5 2 Yellow 3 Blue 630 5 330 Q any reading is not within the specified range replace the engine brake actuator Speed Sensor Circuit Inspection NOTE OBe sure the battery is fully charged e Support the vehicle on a stand or a jack so that the wheels are off the ground e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter e Connect Controller Connector A Hand Tester B range DC 25 V Tester 4 Connector P Terminal 5 Tester Connector BK Y Terminal 10 Olnstall the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Spin a rear wheel measure the voltage Speed Sensor Output Voltage Standard r
10. 1 is e Push the rear propeller shaft A rearward and remove the front end B from the output bevel gear shaft C e Remove the rear propeller shaft and spring from the ve hicle e Remove Universal Joint A Boot B and O rings Rear Propeller Shaft Installation e Wipe off any old grease on the splines of the following parts Output Bevel Gear Shaft Propeller Shaft Universal Joint Pinion Gear Shaft of Rear Final Gear Case e Check the boots for damage x lf any damage exists replace it with a new one e Replace the O rings with new ones DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 66 FINAL DRIVE Rear Propeller Shaft e Apply molybdenum disulfide grease to the splines A of the pinion gear shaft B of rear final gear case e Install Boot A O rings B Universal Joint C e Aooly molybdenum disulfide grease to the splines A and inside B of the rear propeller shaft e Install New Circlip C on the Rear Propeller Shaft Boot D and New O rings Rear Propeller Shaft E Spring F e Align each yoke with the other yoke see Front Propeller Shaft Installation e Push the rear propeller shaft rearward G and install the front end to the output bevel gear shaft e Install the circlip C into the groove of the propeller shaft not contact the boo
11. EL TT ILO6O19BWi C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 26 FINAL DRIVE Front Propeller Shaft e Match the boot end A to the groove of the yoke B 1LO6020BS1 C Front Propeller Shaft Inspection S e Remove Front Propeller Shaft see Front Propeller Shaft Re 5 moval e Check that the universal joint A works smoothly without 7 rattling or sticking bz xlf it does rattle or stick the universal joint is damaged B Replace the universal joint e Check the splines of the propeller shaft B and universal joint x lf the splines are twisted or damaged in any way replace the damaged parts e Also inspect the splines in the universal joint of the front final gear case and the output bevel gear shaft the splines are badly worn chipped or loose replace the damaged parts 1 068073 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 27 Front Axle Front Axle Removal e Drain the front final gear case oil see Front Final Gear Case Oil Change in the Periodic Maintenance chapter e Remove Front Wheel see Wheel Removal in the Wheels Tires chapter Steering Knuckle see Steering Knuckle Removal in the Steering chapter e Pull the front axle A
12. Oil Pressure Gauge Adapter 1 8 57001 1033 7571033ST C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE LUBRICATION SYSTEM 7 7 Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear x lf the oil has just been changed start the engine and run it for several minutes to fill the oil filter NOTICE Allow the engine to idle for several minutes so that oil may reach all parts of the engine Racing a dry engine may cause severe damage e Stop the engine and wait several minutes for all the oil to drain back to the sump e Remove Left Seat see Seat Removal in the Frame chapter Quick Rivets A Heat Guard Plate B e Unscrew the oil filler cap A wipe its dipstick B dry and tighten it into the filler opening e Unscrew the oil filler cap and check the oil level The oil level should be between the upper H and lower L level lines C xIf the level is too high suck the excess oil out the filler hole with a syrin
13. 0 25 50 75 100 Battery Charge X le gt Battery Terminal Voltage CA model CES Standard 12 8 V or more E 12 5 2 12 0 k Refreshing Charge 8 Good is required 8 08010951 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 25 Battery Refreshing Charge e Remove the battery A see Battery Removal e Refresh charge by following method according to the bat tery terminal voltage A WARNING This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below GP08070581 US model Terminal Voltage 11 8 less than 12 6 V Standard Charge see following chart 6 2Ax4 12h charger 6Ax2 6h S 2 5 charger 5 0 1 1 1 L 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V 1008016851 C CA model Terminal Voltage 11 5 less than 12 8 V Standard Charge 1 2 A x 5 10 h see following chart Quick Charge 6 0 A x 1 0 h Charge Time h 9 1 1 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V If possible do not quick charge If the quick charge is done due to unavoidable circumstances do the standard charge later on Terminal Voltage less than 11 5 V
14. Grankcase Assembly mens Crankshart Connectlori Crankshaft 252 deae tere mnl P o Crankshaft Installallon cte ero thet ch Ph M aee Connecting Rod me Connecting Rod Installation ote ater re teo reto ee Crankshaft Connecting Rod 2 Connecting Rod Bend Inspection RR IP ote Connecting Rod Twist Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Crankpin Wear Crankshaft Runout Inspection ee Am Crankshaft Main Bearing Journal Wear TransrmilsslOfi te e e P Shift Lever Plemoyval oe Neal Noe ee ice eer tte ia Shift Lever Installation 52 n eer er d ether Transmission Removal 4 oe eene ee eene dederas Transmission Installation 30
15. Shift Fork Bending Inspection sm S eo eem retentu Shift Fork Gear and Shifter Groove Wear Inspection Transmission and Shift Mechanism Ball Bearing Needle Bearing and Oil Ball and Needle Bearing 040204 00 0 0 1 Ball and Needle Bearing Wear Inspection 20 Seal IMS O e DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 9 2 9 6 p 9 9 9 9 9 9 13 9 13 9 13 9 13 9 13 9 14 9 14 9 14 9 15 9 15 9 17 9 17 9 18 9 18 9 19 9 23 9 24 9 26 9 26 9 27 9 29 9 29 9 29 9 29 DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 2 CRANKSHAFT TRANSMISSION Exploded View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener ponte Remarks N m kgf m ft lb 1 Connecting Rod Big End Cap Nuts 34 3 3 5 25 MO 2 Oil Drain Plug 20 2 0 15 3 Bolts M8 L 75 mm 2 95 20 2 0 15 S 4 Crankcase Bolts M8 L 110 mm 4 33 in 20 2 0 15 S 5 Bolt 8 L 110 mm 4 33 in 2
16. Torque No Fastener kgf m itib Remarks 1 Camshaft Sprocket Bolts 12 1 2 106 in lb L 2 Chain Tensioner Cap Bolts 22 2 2 16 Chain Tensioner Mounting Bolts 8 8 0 90 78 4 Front Cylinder Camshaft Chain Guide Bolt 20 2 0 15 5 Position Plate Bolts 8 8 0 90 78 in lb 6 Intermediate Shaft Chain Guide Bolts 8 8 0 90 78 in lb 7 Intermediate Shaft Chain Tensioner Bolts 8 8 0 90 78 8 Rear Cylinder Camshaft Chain Guide Bolt 20 2 0 15 9 Oylinder Bolts L 30 mm 1 2 in 9 8 1 0 87 in lb 10 Cylinder Bolts L 40 mm 1 6 in 9 8 1 0 87 11 Coolant Drain Plugs Cylinder 7 0 0 71 62 in Ib EO Apply engine oil G Apply grease for oil seal and O ring L Apply a non permanent locking agent R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 6 ENGINE TOP END Exploded View 1E02027885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 7 Exploded View Torque No Fastener Nm kgf m itib Remarks 1 Exhaust Pipe Nuts 17 1 7 13 2 Exhaust Pipe Cover Bolts 13 1 3 115 in lb 3 Muffler Clamp Bolts 15 1 5 11 4 Muffler Mounting Bolts 28 2 9 21 5 Spark Arrester Mounting Bolts 13 1 3 115 in Ib R Replacement Parts DOCUMENT AV
17. e Install the rotor A so that the projections B face out ward e Tighten Torque Rotor Mounting Bolts C 12 N m 1 2 kgf m 106 in Ib e Install Output Drive Idle Gear New Circlip Special Tool Outside Circlip Pliers 57001 144 100014 P DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 14 FINAL DRIVE Output Bevel Gears e Apply grease O rings A O ring B If it is removed e Install Output Drive Bevel Gear Cover C Engine Left Side Oil Pipe see Oil Pipe Installation in the Engine Lubrication System chapter e Tighten Torque Output Drive Bevel Gear Cover Bolts D 8 8 0 90 kgf m 78 in Ib OTighten the cover bolt E with the oil pipe e When installing the forward reverse detecting sensor A install it after the output drive bevel gear cover is installed e Tighten Torque Forward Reverse Detecting Sensor Mounting Bolt 14 9 N m 1 5 kgf m 11 16 Output Drive Bevel Gear Disassembly e Remove Output Drive Bevel Gear Housing A see Output Drive Bevel Gear Removal e Look through the hole B in the housing e Turn the bevel gear C until the groove of the output drive bevel gear holder nut is seen e Tighten the nut holding bolts A 4 securely into the grooves B of the bevel gear bearing holder nut C in the output drive bevel gear housing
18. 2 16 Throttle Pedal Free Play 22 1m 2 16 Idle Speed 5 0 2 17 Idle Speed AdIUSIient RI ead stems Ne ers 2 17 Air Cleaner Element Cleaning and 2 17 Air Cleaner Draining cene et tete Re Nee 2 18 Fuel Hose and Connections Inspection 488 T F uuu 2 18 Fuel Hose Replacement 8 2 19 Cooling SySteM us e coa ird peii Ele RE NM imde 2 20 Radiator Gleaning iicet NM DN re Renten ne n e Rack res 2 20 Water Hoses and Connections Inspection 4 hisss 3 2 20 Coolant Ghahjec I e Race 2 20 Engine End one NM eee ete 2 23 Valve Clearance Inspection 3 2 23 Valve ouis eden nies 2 25 Spark Arrester Cleaning 4 M eese 2 25 Converter coire ERE Eee e 2 26 Converter Drive Belt Wear 2 26 Drive Belt Deflection Inspection 7 7 2 28 Converter Drive Belt Deflect
19. Brake Master Cylinder Cup and Dust Seal Replacement e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove the piston stop bolt A and washer B e Remove the dust seal C and then the retainer D with the circlip pliers Special Tool Inside Circlip Pliers 57001 143 e ORemove the piston assembly two pistons by lightly tap mu G DU the master cylinder on a wooden block Pistons E Springs F Secondary Cups G Primary Cups H Master Cylinder I DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures OBe careful of the secondary cup A direction B e Assemble the master cylinder OClean all the parts including the master cylinder with brake fluid or alcohol and apply brake fluid to the removed parts and the inner wall of the cylinder Use only brake fluid isopropyl alcohol or ethyl al cohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline motor oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventu ally deteriorate the rubber used in the brake OPush the piston assembly in all the way with a screwdriver and instal
20. e Temporarily install the rear axles in the gear case and hold them e Mount a dial gauge A so that the tip of the gauge is against the splined portion B of the pinion gear shaft e To measure backlash turn the pinion gear shaft right and left C while holding the rear axles steady The differ ence between the highest and lowest gauge reading is the amount of backlash OMeasure backlash at three locations equally spaced on the splines Rear Final Bevel Gear Backlash Standard 0 05 0 11 mm 0 002 0 004 at pinion gear spline x If the backlash is not within the standard replace the ring gear shims according to the below NOTE To increase backlash decrease the thickness of the shim s 1 and increase the thickness of the shim s 2 To decrease backlash increase the thickness of the shim s 1 and decrease the thickness of the shim s 2 NOTE O The total of the ring gear shims 1 and 2 should be less than D the clearance between the ring gear as sembly and gear case covers OExample D z 2 34 mm 1 2 2 30 mm D 2 26 mm 1 2 2 25 mm OThe second decimal of the total of 1 and 2 should be 0 or x5 nearest of D e Recheck the backlash and readjust if necessary Tooth Contact Adjustment Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth of the pinion gear NOTE OApply checking compound to the teeth in a thin
21. 0 80 kgf m 69 in Ib e Install the rubber cap e Repeat the previous step for front calipers A e After the air bleeding tighten the caliper bleed valves Torque Caliper Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e When air bleeding is finished add fluid up to the upper level in the reservoir e Tighten Torque Front Master Cylinder Reservoir Cap 3 4 0 35 kgf m 30 in Ib e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 10 BRAKES Brake Pedal and Master Cylinder Brake Pedal Play Inspection e Refer to the Brake Pedal Play Inspection in the Periodic Maintenance chapter Brake Pedal Removal e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Lift and hold the front fender rear see Front Fender Rear Removal in the Frame chapter e Remove Brake Light Switch Spring A e Remove Cotter Pin and Pin A Cotter Pin and Brake Shaft B Spring C Brake Pedal D Brake Pedal Installation e Apply grease to the brake shaft A e Install Brake Pedal B Spring C Bushings D Brake Shaft Push Rod E and Pin F New Cotter Pins G e Bend the cotter pins over the shaft and pin ends e Install Brake Light Switch Spring A e After the spring is in
22. 2 00 0 17 6 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 2 APPENDIX Troubleshooting Guide NOTE ORefer to the Fuel System chapter for most of DFI trouble shooting guide OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Starter and circuit relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor clutch trouble Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure No fuel flow No fuel in tank Fuel tank air vent obstructed Fuel line clogged Fuel pump damaged or circuit trouble Fuel air mixture incorrect Bypass screw maladjusted Air cleaner clogged poorly sealed or miss ing No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good
23. 3 86 Engine Vacuum Synchronization Inspection 2 3 86 Engine Vacuum Synchronization 3 87 Tr A 3 88 ISG Valve Removal ti ete iud 3 88 ISG Valve Installato N 3 88 ISC Valve InspectlOn eerte e acere retener em ete m REA RE ebur decedere 3 88 I DOS T 3 89 Air Cleaner Element 3 89 Air Cleaner Element InstallatiOn ii oo 3 90 Air Cleaner Element Cleaning and Inspection 3 91 Air Cleaner Housing and Duct Remoy l inset cti te pe i eec 3 91 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 3 Air Cleaner Housing and Duct Fuel Tank and Fuel Hose erre nhe rero EE ERE EROR EXER Rd Fuel Tank Removals rem ende a int e e Meer ee dd ed ta e et eean eaae e eed e d fa Fuel Tank Installation i eie tene tto t n ee h need dee a a e e e a RR ene Lee pado Publ Tank OTIO FIO oet deste esee Reate aues Ada al c
24. DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 29 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and repair fuel line see chapter 3 Bacfiigwhendecleralom o 7 spect see chapter 3 Inspect Inspect see chapter 3 Water temperature sensor trouble Inspect Inlet air temperature sensor trouble Inspect After fire Spark plug burned or gap maladjusted Replace see chapter 2 Fuel injector trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Other Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 see chapter 3 see chapter 3 Poor Running or No Power at High Speed Symptoms or Possible Causes Actions chapter Firing incorrect Ignition coil shorted or not in good contact Inspect or Reinstall see chapter 16 Fuelainmixture incorrect S Air cleaner clogged poorly sealed or missing Clean element or
25. Right and Left Bars Installation e Install Right and Left Bar A Lower Seat Bracket B both sides Mounting Bolts C temporarily DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 41 Bars e Install Lower Back Bar A Upper Back Bar B Back Bar Mounting Bolts C temporarily 05005851 C e Install Rear Upper Bar A Front Upper Bar B Upper Bar Mounting Bolts C temporarily Olnstall the rear upper bar A so that the hand grip B faces forward IP05007BS1 C e When installing the fittings A install them to lower back bar B as shown in the figure IPOSO08BS1 C e Tighten Torque Right and Left Bar Mounting Bolts 98 10 kgf m 72 ft lb Back Bar Mounting Bolts 46 5 4 7 kgf m 34 ft Ib Upper Bar Mounting Bolts 46 5 N m 4 7 kgf m 34 ft Ib e Install the upper seat bracket see Seat Belt Installation e Install the removed parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 42 FRAME Bars P05004B8W2 C A Right Bar B Left Bar C Lower Seat Brackets both sides D Right and Left Bar Mounting Bolts E Lower Back Bar F Upper Back Bar G Back Bar Mounting Bolts H Rear Upper Bar I Front Upper Bar J Up
26. Torque No Fastener Nm kg m ilb Remarks 1 Differential Control Shift Shaft Lever Nut 8 8 0 90 78 R 2 Differential Shift Cable Holder Bolt 8 8 0 90 78 in b 3 Front Final Gear Case Oil Filler Cap 29 3 0 21 4 Front Final Gear Case Oil Drain Plug 15 1 5 11 5 2WD AWD Shift Cable Holder Bolts 8 8 0 90 78 L 6 2WD AWD Shift Shaft Cover Bolts 8 8 0 90 78 L 7 2WD AWD Shift Shaft Lever Nut 20 2 0 15 R 8 Gear Bearing Holder Nut 2 20 4 148 LB Pinion Gear Bearing Holder 00 i i 250 n 2 E 14 15 16 17 18 19 20 AWD Position Switch 15 21 Vacuum Actuator Bracket Bolts CG Apply Chevron Black Pearl Grease EP NLGI 2 or equivalent grease EO Apply engine oil G Apply grease L Apply a non permanent locking agent LB Apply a non permanent locking agent Three Bond TB2471 Blue LO Apply non permanent locking agent Three Bond TB2440B Orange M Apply molybdenum disulfide grease R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 8 FINAL DRIVE Exploded View 1L020368W5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 9 Exploded View Torque No Fastener kaim itib R
27. gt S Au lt Sof 08020158 5 E DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage 38020138 5 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed cU Press new oil seals with manufacture and size marks facing ve Nu out Make sure the seal is aligned properly when installing bJ r l8 LI j 954 0602019 5 Apply specified greasesto the lip of Seal before installing the seal Grease GB02046BS1 C Circlips Cotter Pins Replace circlips or cotter pins that were removed with new SA one
28. A m 4 10 Water Pump Cover eaa nn nn n 4 10 Water Pump Cover Installation 3 4 4 10 Water Pump Impeller Removal AI 4 10 Water Pump Impeller Installation amp Seen 4 10 Water Pump Impeller Inspection M eese 4 11 Water Pump Leakage 0 3 4 11 Mechanical Seal Replacement ig Nene 4 11 Inizio ALO asma T MEHR Ve We Ane 4 13 Radiator Removal ient NM erret rite Ee pai ep 4 13 Eadiator Installallorr s teet RM On e Rino ete 4 14 Radiator Fan Removal 3 2 20 educar 4 14 Radiator Fan Installauon 2 eek bue xh cuoc 4 14 Radiator Inspection 4 15 Radiator 1 9 4 15 Radiator Cap Inspectton Qa 4 15 NCC NB e a e OO Rhet peteret 4 16 Thermostat Hagmnowgl a EEEE 4 16 Thermos
29. 13 Coolant Air Bleed Bolt Water Pump 7 0 0 71 62 14 Coolant Air Bleed Bolt Thermostat 7 8 0 80 69 in lb 15 KRF750 NBF PBF RBF SBF SBFA VBF Models G Apply grease R Replacement Parts RL Apply rubber lubricant DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 4 4 COOLING SYSTEM Coolant Flow Chart Permanenttype antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump coupled with the oil pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is below 67 C 153 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 69 5 72 5 C 157 163 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 100 212 F the radiator fan relay conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the temperature is below 90 194 F the fan rel
30. DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 15 Cable Wire and Hose Routing L efe 01 UR m NN WPA 1808224884 C 1 Filter 9 Clamp 2 Breather Hose 10 Cover 3 Vent Hose 11 Run the vacuum hose under the cover 4 2WD AWD Solenoid Valve 12 Run the hoses into the hole 5 Vacuum Hose 13 Band 6 Vacuum Hose 14 View A 7 Clamp 15 Vacuum Actuator 8 Vacuum Hose DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 16 APPENDIX Cable Wire and Hose Routing Pa Iv o Ds wl b j 9 ll FRY L P Ll 64 7 67 a DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 17 Cable Wire and Hose Routing LUE E N Water Pipes Lower Radiator Hose Upper Radiator Hose Cooling Hose Clamps Bracket Keep clearance of 20 mm 0 8 in between the cooling hose and the edge of bracket View A Align the white paint mark on the cooling hose with the index mark on the pump cover View B Tighten the clamp screw to the direction as shown in the figure Connect the cooling hoses with its white mark facing up
31. Do not over tighten them They could be damaged requiring replacement e Turn out the bypass screw until the vacuum enters the standard e Open and close the throttle valves after each measure ment and adjust the bypass screw as necessary x If both vacuums are within the standard finish the engine vacuum synchronization any vacuum cannot be adjusted within the standard remove the bypass screws 1 2 and clean them e Remove Bypass Screw A Spring B Washer C O ring D e Check the bypass screw and its hole for carbon deposits x lf any carbon accumulates wipe the carbon off the bypass screw and the hole using a cotton pad penetrated witha high flash point solvent e Replace the O ring with a new one e Check the tapered portion E of the bypass screw for wear or damage x If the bypass screw is worn or damaged replace it e Turn in the bypass screw until it seats fully but not tightly e Repeat the same procedure for other bypass screw e Repeat the synchronization adjustment 6505015851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 88 FUEL SYSTEM ISC Valve ISC Valve Removal e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Screws A and Resonator B Connector C e Remove ISC Valve Hose Front A ISC Valve Hose Rear B ISC V
32. ECU Removal e Remove Left Seat see Seat Removal in the Frame chapter Screws A Quick Rivet B e Pull out the electrical parts case C e Remove ECU Mounting Bolts A Connectors B ECU C ECU Installation e Connect the ECU connectors to the ECU e Install the ECU to the electrical parts case e Tighten Torque ECU Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib ECU Power Supply Inspection e Visually inspect the ECU connectors xIf the connector is clogged with mud or dust blow it off with compressed air e Visually inspect the terminals A of the ECU connectors x If the terminals of the main harness connectors are dam aged replace the main harness x lf the terminals of the ECU connectors are damaged re place the ECU DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 71 ECU e Turn the ignition switch OFF e Disconnect the ECU connectors A Main Harness e Set the hand tester B to the x 1 O range and check the following wiring for continuity Special Tool Hand Tester 57001 1394 Main Harness Grounding Inspection Connections BK Y leads 11 33 or 42 terminal gt Battery Terminal 15084881 6 Engine Ground lt Battery Terminal Criteria All 00 x If no continuity check the connectors the engine ground lead or main harness an
33. Front Axle Steering Knuckle Joint Boots 4408 Front Propeller Shaft Joint Boots Tie rod End Boots s Rear Propeller Shaft Joint Boots Te Rear Axle Stabilizer Joint Boots Inspection 8 General Lubrication cel er Nes ee eec T b ARS 1 e Va DOR INSPOCHON EE t koe Bolts and Nuts 2 A sue 5 gt EIER DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 2 45 2 45 2 46 2 46 2 46 2 47 2 47 2 47 2 47 2 48 2 48 2 48 2 48 2 48 2 49 2 49 2 49 2 49 2 50 2 50 2 51 2 51 DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition The initial maintenance is vitally important and must not be neglected FREQUENCY First Service Regular Service OPERATION ENGINE Throttle pedal play inspect
34. e Remove Allen Bolts A e Move the ratchet B and bracket C forward e Remove Shift Lever Assembly Nut D e Remove Tie rod End Bolt A Tie rod B Spring C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 19 Transmission e Remove Oil Seals A Collar B c mA US f ta Shift Lever Installation e Twist the tie rod end A and tie rod end locknut B to bottom of the screw and then turn back the tie rod end to dimension with 94 10 C as shown in the figure e Tighten the locknut against the tie rod end Torque Tie rod End Locknut 19 6 N m 2 0 kgf m 14 ft Ib 11096000841 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 20 CRANKSHAFT TRANSMISSION Transmission e Align the mark A on the shaft end with the slit B of the shift shaft lever e Position the shift shaft lever end C on the boss center D of the crankcase as shown in the figure e Tighten Torque Shift Shaft Lever Bolt E 13 5 N m 1 4 kgf m 10 ft Ib e Install Shift Lever Assembly F Spring G to Shift Lever Assembly Washer H Shift Lever Assembly Nut I Tighten Torque Shift Lever Assembly Nut 19 6 N m 2 0 kgf m 14 ft Ib e Install Ti
35. B Screw 6 L 25 mm 0 98 in e Connect the headlightdead connector A and install the champs B e After installation adjust the headlight aim see Headlight Beam Vertical Adjustment Tail Brake Light Bulb Replacement e Remove Rear Fender see Rear Fender Removal in the Frame chapter Tail Brake Light Mounting Nuts A and Washers Tail Brake Light Assembly B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 54 ELECTRICAL SYSTEM Lighting System e Remove Tail Brake Light Lens Mounting Screws A and Nuts Tail Brake Light Lens B e Push and turn the bulb A counterclockwise and remove it OTurn the bulb about 15 e Insert the new bulb by aligning its upper and lower pins A with the upper and lower grooves B in the socket and turn the bulb clockwise e Fit the projections A of the gasket and lens into the re cess B of the housing e Install Screws and Nuts Part No 92015 1550 A Olnstall the nuts so that the flat side faces to the housing B e Install Washers C Bracket D Washers E and Nuts Part No 311 0400 F e Install the removed parts 1013014BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 55 Lighting System L
36. DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 33 Cargo Bed e Remove Screw Rivets A Tail Gate Cover B e Remove Screws A Reinforce B Screws C Stoppers D e Remove Tail Gate A e Disconnect the taillight lead connectors A e Remove Bolt B and Nut Bolts C Taillight Bracket D e Remove Bolts A both sides Wires B both sides Dampers C both sides Collar both sides DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 34 FRAME Cargo Bed e Remove Bolts A and Collars both sides Screws B and Collars both sides Middle Rear Fenders C both sides e Remove Quick Rivets A Bolts B Bolt C and Nut Plate D e Remove Bolt A both sides Bolts B and Nuts both sides Plates C both sides e Remove Bolts A both sides Hook Lever Assembly B e Remove Bolts A both sides Brackets B both sides Spring C both sides Hook Lever D DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 35 Cargo Bed e Remove Bolts A and Nuts Plate B e Remove Quick Rivets A Flaps B e Remove Cargo Bed see Carg
37. DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Bleed the air from the cooling system as follows OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down x If the coolant level is lower than the L Low level line A add coolant to the F Full level line B Do not add more coolant above the full level line e Install the reserve tank cap Engine Top End Valve Clearance Inspection NOTE OCheck the valve clearance only when the engine is cold at room temperature e Remove Seat Lower Cover see Seat Lower Cover Removal the Frame chapter Air Cleaner Housing and Duct see Air Cleaner Housing and Duct Removal in the Fuel System DFI chapter Air Outer Duct see Torque Converter Cover Removal in the Converter System chapter Center Bracket see Center Bracket Removal in the Frame chapter Valve Adjusting Caps A e Remove Left Cover see Left Cover Removal in the Frame chap ter Bolts A and Engine Left Cover B DOCUMENT AVAILABL
38. GE16044BS1 C e Do not mix up the top ring and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN mark D faces up GE16060481 e The piston ring openings must be positioned as shown in D the figure The openings of the oil ring steel rails do not SS align Y Top Ring A i Second Ring B Oil Ring Steel Rails C Oil Ring Expander D F mark E must be faced toward Front Side for front and rear pistons Opening Positions F e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more e Apply engine oil to the cylinder bore and piston skirt HE14002BS1 C e Install Dowel Pins A New Cylinder Base Gasket B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 41 Cylinder and Piston e Install Cylinder e Tighten Torque Cylinder Bolts A 9 8 N m 1 0 kgf m 87 in Ib e Install Chain Guide B e Apply grease to the O rings on the oil pipe C and insert the pipe Cylinder Wear Inspection e Since there is a difference in cylinder wear in different di rect
39. 2 5 peto esee t urbes lets 3 19 Troubleshooting the DFI naf b 3 21 e Uu DCUM LUN T 3 21 Inquiries to Rc cm Ev PNIS 3 24 DFI System Troubleshooting Guide 2 2 torret ell NM cere nets 3 27 Selt DIagrioSiS tco Rmi 3 31 Self diagnosis Outline tecnico 3 31 Self diagnosis Procedures nci rtt o call e re i n tla oe e 3 31 How to Read Service 2 64 3 34 Service Code Erasing soccer obe WEL ca NR edi b ot eem eno fec 3 34 Service Code 2 3 34 izle Uoc C d MI 3 36 Throttle Sensor Service Code 11 4 99 98 3 38 Throttle Sensor 3 38 Throttle Sensor Input Voltage Inspection 3 38 Throttle Sensor Output Voltage 3 39 Throttle Sensor Resistance 3 40 Inlet Air Pressure Sensor 3 41 Inlet Air Pressure Sensor 3 41 Inlet Air Pressure Se sor Installation sseeeeeeeeemeene
40. DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 9 Shock Absorbers Other than KRF750S Model e Install the bushing A using a press e Install the front shock absorber so that the label side B faces outside C Needle Bearing D Collar E Grease Seals F New Nuts e Tighten Torque Front Shock Absorber Mounting Nuts 57 5 5 9 kgf m 42 ft Ib 1N04008BS2 C Front Shock Absorber Inspection e Check the bushing in the upper pivot x If bushing is worn cracked hardened or otherwise dam aged replace it e Check the needle bearing and grease seals in the lower pivot x lf they are damaged replace them Front Shock Absorber Scrapping A WARNING Since the front shock absorber contains nitrogen gas do not incinerate or disassemble the front shock absorber Before a front shock absorber is scrapped drill hole at a point about 15mm 0 59 in A up from the bottom of the cylinder to release the nitrogen gas completely Wear safety glasses when drilling the hole as the gas may blow out bits of drilled metal when the hole opens DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 10 SUSPENSION Shock Absorbers Other than KRF750S Model Rear Shock Absorber Spring Preload Adjus
41. DOCUMENT AVAILABLE FOR MILITARY USE ONLY _ 4 750 FI 4x4 LE am Kawasaki TERYX 750 FI 4x4 SPORT TERYX 750 FI 4x4 Recreation Utility Vehicle Service Manual DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Quick Reference Guide 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 Electrical System 4 gt h h k N jd m This quick reference guide will assist you in locating a desired topic or pro cedure the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts
42. DOCUMENT AVAILABLE FOR MILITARY USE ONLY 4 10 COOLING SYSTEM Water Pump Water Pump Cover Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Left Cover see Left Cover Removal in the Frame chap ter Water Hose A Water Pump Cover Bolts B Water Pump Cover C Water Pump Cover Installation e Install Dowel Pins A New Gasket B e Tighten Torque Water Pump Cover Bolts 8 8 0 90 kgf m 78 in Ib Water Pump Impeller Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Water Pump Cover see Water Pump Cover Removal e Loosen the water pump impeller A counterclockwise Water Pump Impeller Installation e Apply a small amount of coolant on the sliding surface A of the mechanical seal and the sealing seat e Install the impeller on the water pump shaft and tighten the impeller Torque Water Pump Impeller 7 8 N m 0 80 kgf m 69 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY COOLING SYSTEM 4 11 Water Pump Water Pump Impeller Inspection e Visually inspect the impeller A xIf the surface is corroded or the blades are damaged re place the impeller Water Pump Leakage Inspection e Check the drainage tube A at the bottom of the water pump body for coolant leakage x If there is a cool
43. e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the delivery pipe B with the fuel hose C both ends connected with the clamps D as shown in the figure OApply soap and water solution to the areas E as shown in the figure OWatching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Injector Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi NOTICE During pressure testing do not exceed the maxi mum pressure for which the system is designed OWatch the gauge for at least 6 seconds x lf the pressure holds steady the fuel line is good x lf the pressure drops at once or if bubbles are found in the area the fuel line is leaking Replace the delivery pipe assy injectors and related parts e Repeat the leak test and check the fuel line for no leak age e Remove the vacuum pressure pump and install the fuel hose see Fuel Hose Replacement e Start the engine and check for fuel leakage DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 68 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Circuit gb W R BL R gt W R Fuel Injector 1 Fuel Injector 2 Ignition S
44. e Remove Bolt A and Nut Brake Cam Lever B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 78 FINAL DRIVE Rear Final Gear Case e Remove Rear Final Gear Case Front Cover Bolts A Rear Final Gear Case Front Cover B e Remove Gasket Screws A Gasket B e Remove Set Pins A Steel Plates B and Friction Plates C e Remove Brake Cam Plate A Brake Camshaft B e Remove St Is A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 79 Rear Final Gear Case e Remove Rear Final Gear Case Right Cover Bolts M10 A Rear Final Gear Case Right Cover Bolts M12 B Rear Final Gear Case Right Cover C e Using the pry points A remove the rear final gear case right cover B e Remove Shims A both sides Ring Gear B e Remove Pinion Gear Bearing Holder A OHold the rear final gear case A in a vise and remove the bearing holder using the socket wrench B Special Tool Socket Wrench Hex 50 57001 1478 Olf it is difficult to break free the holder apply the heat to it to softer the locking agent DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 80 FINAL DRIVE Rear
45. 10100118 F DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 43 Ignition System Ignition System Circuit ill 19010013884 C 1 Throttle Sensor 11 Engine Ground 2 Ignition Switch 12 Battery 3 Reverse Position Switch 13 Spark Plugs 4 Neutral Position Switch 14 Ignition Coils 5 Speed Sensor 15 Water Temperature Sensor 6 Frame Ground 1 16 Crankshaft Sensor 7 Fuse Box 17 Inlet Air Temperature Sensor 8 Main Fuse 30 A 18 Inlet Air Pressure Sensor 9 ECU Electronic Control Unit 10 Vehicle down Sensor DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 44 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Seat Lower Left Plate see Seat Lower Left Plate Re moval in the Frame chapter Air Inlet Duct A e Remove Joint Duct A Bolts and Collars e Remove Starter Motor Cable A and Nut Starter Motor Mounting Bolts B Starter Motor C NOTICE Do not tap the end of the starter motor shaft or the motor may be damaged Starter Motor Installation e Clean the starter motor lugs A and crankcase B where the starter motor is grounded e Replace the O
46. 16 20 ELECTRICAL SYSTEM Battery e Check that the damper A on the battery holder B is properly in place e Check that the damper A on the battery B is properly in place 1908020851 C e Check that the damper A on the battery bracket B is properly in place 1908024851 C e Install Battery Brackets A Battery Bracket Mounting Bolts B Battery C Collars D Battery Holder E e Tighten Torque Battery Holder Mounting Bolts F 16 1 6 kgf m 12 ft Ib e Connect the positive cable first and then negative cable Positive Terminal G e Puta light coat of grease on the terminals to prevent cor rosion e Install the terminal cap on the positive terminal 1908025851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Battery Battery Activation CA Model Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for KRF750N P R S KMX 14 BS NOTICE Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance
47. Battery 0 NKO MN DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 58 ELECTRICAL SYSTEM Meter Multifunction Meter Unit Removal e Tilt up the front fender front see Front Fender Front Re moval in the Frame chapter e Remove the cover see Front Fender Rear Removal in the Frame chapter e Disconnect Meter Lead Connector A e Remove Meter Bracket Bolts B Meter Assembly C and Upper Damper e Remove Multifunction Meter Mounting Nuts A and Washers Meter Bracket B Multifunction Meter Unit C Do not drop the meter unit Multifunction Meter Unit Installation e Install Multifunction Meter Unit A Upper Damper B Lower Dampers C Bracket D Washers E Multifunction Meter Mounting Nuts F 1919001851 C e Install Meter Assembly and Upper Damper Meter Bracket Screws e Connect Meter Lead Connector e Install Cover see Front Fender Rear Installation in the Frame chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 59 Meter Multifunction Meter Unit Inspection e Remove Multifunction Meter Unit see Multifunction Meter Unit Removal 1 2 3 4 s Le 7 8 Do not drop the meter unit A M
48. Fuel hoses and connections inspect Fuel hose replace Idle speed inspect Spark plug clean and gap inspect Air cleaner inspect First 2 000 km 1 200 mile thereafter Valve clearance inspect every 4 000 km 2 500 mile Spark arrester clean Engine oil change filter replace Front and rear final gear case oil change Radiator clean Water hoses and connections check Coolant change Converter drive beltwear inspect Converter drive belt deflection inspect Engine brake control lever inspect CHASSIS Rear brake plates replace every 10 000 km Front brake pad wear inspect Brake light switch inspect Brake fluid change 2 years Brake master cylinder cup and dust seal 2 years replace Rear brake master cylinder cup O ring and boot replace Front brake caliper piston seal and dust seal replace Brake hose replace 4 years 2 years 2 years Brake fluid level Specs Brake pedal play Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY First Service Regular Service After Every Every 20 h 100 h 200 h or See 200 2 000 4 000 Pape km 120 mile OPERATION of use of use of use of use Brake hose and pipe inspect 2 40 Parking brake pedal i
49. Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Charging System e Install the alternator rotor A while turning the starter clutch gear B e Apply molybdenum disulfide grease to the shaft of the torque limiter C e Install the torque limiter Alternator Stator Removal e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor A see Crankshaft Sensor Re moval Bolts B and Alternator Stator C Alternator Stator Installation e Tighten Torque Alternator Stator Bolts 13 5 1 4 kgf m 10 ft lb e Install Crankshaft Sensor see Crankshaft Sensor Installation e Fit the lead grommets into the notch on the alternator cover Grommets A for Alternator Leads Grommets B for Crankshaft Sensor Leads ORun the alternator stator leads under the crankshaft sen sor leads OFit the grommet for alternator leads first and then install the one of crankshaft sensor leads to the notch of the alternator cover Regulator Rectifier Output Voltage Inspection e Remove the left seat see Seat Removal in the Frame chapter e Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions ELECTRICAL SYSTEM 16 31 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 32 ELECTRICAL SYSTEM Charging
50. Ring Gear Example 2 Increase the thickness of the pinion gear shim s by 0 1 mm 0 004 In to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Heel Bottom booom DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 64 FINAL DRIVE Front Final Gear Case Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged Differential Gear Inspection e Visually check the differential gears A for scoring chip ping or other damage Replace the differential gears as a set if either gear is damaged e Also inspect the differential gear shaft B gear case C and cover D where the differential gears rub x f they are scored discolored or otherwise damaged re place them as a set 1L04046BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 65 Rear Propeller Shaft Rear Propeller Shaft Removal e Remove Right Rear Wheel see Wheel Removal in the Wheels Tires chapter e Slip the O rings A off the grooves on the rubber boot B e Slide the boot A forward and remove the circlip B with a suitable commercially circlip pliers C
51. and measure the disc runout x f the runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 25 mm 0 010 in or less 1012002881 0 Service Limit TIR 0 3 mm 0 012 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 18 BRAKES Brake Hoses and Pipes Brake Hose and Pipe Inspection e Refer to the Brake Hose and Pipe Connections Inspection in the Periodic Maintenance chapter Brake Hose Replacement e Refer to the Brake Hose Replacement in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 19 Parking Brake Pedal and Cables Parking Brake Pedal Inspection e Refer to the Parking Brake Pedal Inspection in the Peri odic Maintenance chapter Parking Brake Pedal Removal e Remove Control Panel see Control Panel Removal in the Frame chapter Cable Locknuts A e Remove the cable end from the pin B e Remove Spring C Circlip D Shim E Parking Brake Pedal F e When removing the parking release lever G remove the following parts Spring H Circlip and Washer I Parking Brake Pedal Installation e Apply grease Parking Brake Pedal Pivot A Parking Release Lever Pivot B e Install Parking Brake Pedal C New Bushings D press if in
52. e Remove Front Wheel see Wheel Removal in the Wheel Tires chapter Front Hub see Front Hub Removal in the Wheel Tires chapter Front Suspension Arms see Front Suspension Arm Re moval in the Suspension chapter e Remove the knuckle joint A from the suspension arm using a suitable joint remover B Steering Knuckle Installation e Clean the taper surfaces A of the knuckle B and shank of the knuckle joint or the tapers will not fit snugly e Install Knuckle A Washers B and Nuts Olnstall the washer as shown in the figure 1N05002BS1 C e Install Front Suspension Arm see Front Suspension Arm In stallation in the Suspension chapter Tie rod End see Steering Gear Assembly Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY STEERING 14 13 Steering Knuckles e Install New Cotter Pins A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole 07000851 e Bend the cotter pin A over the nut B HNO4001BS1 C e Install the removed parts see appropriate chapter Knuckle Bearing Removal e Remove Knuckle see Steering Knuc
53. e With the 2WD AWD shift cable disconnected at both ends the cable should move freely within the cable housing x lf the cable does not move freely A after lubricating if the cable is frayed B or if the housing is kinked C replace the cable Front Final Gear Case Removal e Drain the gear case oil see Front Final Gear Case Oil Change in the Periodic Maintenance chapter e Remove Front Bottom Guard Front Bottom Guard Removal in the Frame chapter Front Axles see Front Axle Removal Front Propeller Shaft Front Propeller Shaft Removal Differential Shift Cable Holder Bolts A and Cable Holder B Differential Shift Cable End C e Remove Cable Holder Bolts A and Cable Holder B 2WD AWD Shift Cable End C 2WD AWD Shift Position Switch Lead Connector D e Remove Front Final Gear Case Mounting Bolts A and Nuts Breather Hose B e Remove Front Final Gear Case Bracket Bolts A Brackets B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 42 FINAL DRIVE Front Final Gear Case e Remove front final gear case A from under the vehicle Front Final Gear Case Installation e Install Front Final Gear Case Front Side Bolts 2 and Nuts Front Final Gear Case Bracket and Bolts Rear Side Bolt and Nut e Tighten Torque Front Final Gear Case Bracket Bolts 90 5 N m 9 2 kgf m 67 16 Front Fi
54. grinding operation easier O When the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x f the outside diameter O D A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding After making the 32 grind return to the seat O D mea surement step above e Jo measure the seat width use vernier calipers to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat O D measurement step above GE15011881 C GE15012181 GE15012281 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Valves x lf the seat width is too wide make the 60 A grind de s
55. 530 57001 1123 Holder and Bar Valve Seat Cutter Holder 5 57001 1208 B Valve Seat Cutter Holder Bar 57001 1128 C the manufacturer s instructions are not available use the following procedure DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 8 15011752 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 35 Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve seat for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the
56. 617037381 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Troubleshooting the DFI System e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x lf the tester does not read 0 the lead is defective Re place the lead or the main harness or the sub harness Olf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harness OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring o
57. A Differential Shift Cable Rear End B Center Bracket Mounting Bolt C Differential Shift Lever Removal see Differential Shift Lever Removal in the Final Drive chapter Shift Lever see Shift Lever Removal in the Crank shaft Transmission chapter e Remove Band and Harnesses Rubber Cover A Center Bracket Mounting Bolts B Center Bracket C Center Bracket Installation e Install Center Bracket Assembly A Center Bracket Mounting Bolts B e Tighten Torque Center Bracket Mounting Bolts 22 N m 2 2 kgf m 16 ft Ib e Install the removed parts gt Ina Right Frame Pipe Removal e Remove Fuel Tank Fuel Tank Removal in the Fuel System chap ter Solenoid Valve Bracket Bolts A and Bracket Assembly B Vacuum Actuator Bracket Bolts C and Bracket Assem bly D DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 52 FRAME Covers e Remove Right Frame Pipe Mounting Bolt A and Nut Right Frame Pipe Mounting Bolt B Right Frame Pipe C Right Frame Pipe Installation e Install Right Frame Pipe and Bolts e Tighten Torque Right Frame Pipe Mounting Bolts 34 3 N m 3 5 kgf m 25 ft Ib Vacuum Actuator Bracket Bolts 8 8 0 90 kgf m 78 in Ib Solenoid Valve Bracket Bolts 8 8 N m 0 90 kgf m 78 e Install the removed parts Left Cover Removal e Remove Seat Lower C
58. A into the slit B on the joint lock e Twist the screwdriver to disconnect the joint lock A e Pull the fuel hose joint B out of the delivery pipe A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe Cover the hose connection with a clean shop towel to prevent fuel spillage e Install the new fuel hose e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C e Push and pull the fuel hose joint A back and forth more than two times and make sure it is locked and doesn t come off A WARNING Leaking fuel can cause a fire or explosion resulting in severe burns Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn t leak ici gi28 x If it comes off reinstall the hose joint e Start the engine and check the fuel hose for leaks DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Radiator Cleaning Clean the radiator screen and the radiator in ac cordance with the Periodic Maintenance Chart
59. B e Disconnect the fuel injector connector A e Remove the rear fuel injector B from the delivery pipe C Fuel Injector Installation e Replace the seals A with new ones DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 64 FUEL SYSTEM Fuel Injectors e Before installation blow away dirt or dust from the deliv ery pipe A by applying compressed air e Replace the O rings A with new ones e Install the rear fuel injector A into the delivery pipe B securely e Insert the rear fuel injector into the seal and tighten the rear delivery pipe mounting screws A Torque Delivery Pipe Mounting Screws 5 0 0 51 kgf m 44 in Ib e Install the front fuel injector B into the delivery pipe C securely e Insert the front fuel injector into the seal and tighten the front delivery pipe mounting screws A Torque Delivery Pipe Mounting Screws 5 0 0 51 kgf m 44 in Ib e Connect the fuel injector connectors B as follows BL R and W R Leads Connector Front Fuel Injector V and W R Leads Connector Rear Fuel Injector DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 65 Fuel Injectors Audible Inspection e Remove Engine Upper Cover see Engine Upper C
60. B Vacuum Hoses C Spark Plug Cap D Rocker Case see Rocker Case Removal Camshaft see Camshaft Removal e Remove Cylinder Head Bolt 6 A Cylinder Head Bolts M10 B and Washers Cylinder Head C Gasket OLift the cylinder head to clear the dowel pins in the cylin der Cylinder Head Installation e Apply grease to the O rings on the oil pipe A and insert the pipe e Install Camshaft Chain Guides B Dowel Pins C New Cylinder Head Gasket D e Tighten Torque Front Cylinder Camshaft Chain Guide Bolt 20 2 0 kgf m 15 ft Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Cylinder Head e Apply molybdenum disulfide oil to the threads and seating surface of the cylinder head bolts M10 and both sides of the washers e Tighten the cylinder head bolts A following the tightening sequence as shown First Torque Cylinder Head Bolts M10 25 N m 2 5 kgf m 18 ft lb Final Torque Cylinder Head Bolts M10 49 N m 5 0 kgf m 36 ft lb e Tighten the cylinder head bolt M6 B Torque Cylinder Head Bolt M6 9 8 1 0 kgf m 87 in Ib Cylinder Head Cleaning e Remove the cylinder head see Cylinder Head Removal e Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool e Wash the head with a high flash point solvent e Blow out any particles
61. DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 24 FINAL DRIVE Front Propeller Shaft Front Propeller Shaft Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter e Move the rubber boot A rearward e Push the front propeller shaft B forward and remove the rear end from the universal joint e Remove the front propeller shaft and spring from the ve hicle e Remove Universal Joint A Front Propeller Shaft Installation e Wipe off any old grease on the splines of the following parts Universal Joint of Front Final Gear Case Propeller Shaft Universal Joint Output Bevel Gear Shaft e Apply molybdenum disulfide grease to the splines A of the propeller shaft B and output bevel gear shaft C 1L06017BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 25 Front Propeller Shaft e Install Universal Joint A Boot B OAlign each yoke C with the other yoke as shown in the figure UN DN 106018892 C e Apply soap and water solution on the yoke A e Install Spring B Boot C Propeller Shaft D Olnstall the front end of the propeller shaft and then install the rear end as shown in the figure
62. E Bottom Drive Gear Heel Toe Bottom Driven Gear HK16003492 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 22 FINAL DRIVE Output Bevel Gears Example 1 Decrease the thickness of the drive bevel gear shim s by 0 1 mm 0 004 in and or increase the thickness of the driven bevel gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Example 2 Increase the thickness of the drive bevel gear shim s by 0 1 mm 0 004 in and or decrease the thick ness of the driven bevel gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Incorrect Tooth Contact Patterns 1 Bottom Ah Heel Top nn E Drive Gear Driven Gear 16003582 Incorrect Tooth Contact Patterns 2 Bottom Heel Top 2M Drive Gear Bottom Toe Heel N Toe Top Bottom Driven Gear HK160036S2 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 23 Output Bevel Gears Bevel Gears Inspection e Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged v
63. In dusty areas they should be cleaned more fre quently than the recommended interval After riding through muddy terrains the radiator screen and the radiator should be cleaned immediately e Remove the front fender front see Front Fender Front Removal in the Frame chapter e Remove Radiator Cover see Radiator Removal in the Cooling chapter Radiator Screen Mounting Screws A bothside Radiator Screen B e Clean the radiator screen in a bath of tap water and then dry it with compressed air or by shaking it e Clean the radiator When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 20 in B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction Water Hoses and Connections Inspection OThe high pressure inside the water hose can cause coolant to leak A or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly HUOG003BS1 Coolant Change A WARNING Coolant can be extremely hot and cause se
64. MAXXIS M990 Tubeless DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Wheels Nuts Tightness Inspection e Check the tightness of all the wheel nuts there are loose nut first loosen by 1 2 turn then re torque them to the specified torque Torque Wheel Nuts 137 14 kgf m 101 ft lb OTighten the wheel nuts 1 4 in a criss cross pattern Final Drive Differential Shift Lever Play Inspection e Check the differential shift lever travel by feeling clicks e Push the center of the damper B with 98 10 kof 22 lbf of force OThe differential shift lever travel should be about 5 notches clicks Differential Shift Lever Travel about 5 notches clicks at 98 N 10 Standard kgf 22 Ibf 1513000851 xIf the lever travel is more than 9 notches clicks at 98 N 10 kgf 22 Ibf adjust the cable Differential Shift Lever Play Adjustment e Loosen the differential shift cable locknuts A at the front final gear case e Turn the nuts to obtain the correct amount of travel e Tighten Torque Differential Shift Cable Locknuts 9 8 1 0 kgf m 87 in Ib Front Final Gear Case Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle e Park the
65. Speed Sensor Water Temperature Sensor Vehicle down Sensor Inlet Air Temperature Sensor Multifunction Meter Delivery Pipe Air Cleaner Housing Air Cleaner Element Air Flow Fuel Flow FUEL SYSTEM DFI 3 9 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 10 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram a 601 HH H1 H F a oo WI koni H A sad mt M LL li co I m AM IT T DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com BK Y 42 1615072885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY DFI System Part Name Throttle Sensor Fuel Injector 1 Fuel Injector 2 Ignition Switch Speed Sensor Fuse Box Fuel Pump Fuse 10 A Main Fuse 30 A Fuel Pump 10 Vehicle down Sensor 12 13 14 15 16 17 18 19 20 21 22 23 ECU Electronic Control Unit Fuel Pump Relay KDS Kawasaki Diagnostic System Connector ISC Valve Battery Spark Plugs Ignition Coils Water Temperature Sensor Crankshaft Sensor Multifunction Meter Inlet Air Temperature Sensor Inlet Air Pressure Sensor Frame Ground 1 FUEL SYSTEM
66. Speed Sensor Installation as sc 3 54 Speed Sensor Input Voltage 3 54 Speed Sensor Output Voltage 3 54 Vehicle down Sensor Service Code 31 7 22 0404 10004000000 3 56 Vehicle down Sensor Removal sss eene nennen nennen nnne nnn 3 56 Vehicle down Sensor 3 56 Vehicle down Sensor Input Voltage Inspection 3 56 Vehicle down SERE Guieutr Voliaged psreceting MIEITARY USE 3 57 Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 2 FUEL SYSTEM DFI Fuel Pump Relay Service Gode 1 i e BR rt ede OE QU Re NR ees 3 59 Fuel Pump Relay Removal eoe rauca te ia x 3 59 Fuel Pump Relay InspectlOfi oo operit te e doeet rre et das 3 59 Ignition Coils 1 2 Service Code 51 52 3 61 Ignition Gol Installation 3 61 Ignition Coil Winding Resistance 3 61 Ignition Coil Input Voltage IDSpeCllOh As eS de dass 3 61 PGA 2 DI 3 63 Fuel Injector REMOVAL ER 3 63 Fuel Injector Installation soe eate 3 63 Audible Inispectlo
67. Steering chapter e Disconnect Ignition Switch Lead Connector A 2WD AWD Shift Switch Lead Connector B Power Outlet Connector Lead Connectors C e Remove Quick Rivets A Cover B e Remove Plug A e Remove Screw A Knob B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 21 Control Panel e Remove Mounting Nut A Light Switch B e Remove Quick Rivets A e Remove Quick Rivets A e Open the cover A e Remove Screws B and Collars e Remove Screws A Washers and Collars B Screws C and Collars Control Panel D DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 22 FRAME Control Panel Control Panel Installation e Install Control Panel A Screws B L 16 mm 0 63 in Collars C L 2 4 mm 0 16 in Screws D L 56 mm 2 20 in Collars E L 2 40 mm 1 57 in Washers F Collars G 4 7 mm 0 19 in Quick Rivets H Quick Rivets I Cover J IPO8009BS2 C e Fit the projection A on the light switch B into the recess in the control panel e Install Mounting Nut Screw Knob Plug e Install removed parts Glove Compartment Removal Right Glove Compartment Cover e Remove Clips A Pins B Right Glove Compartm
68. Suspension Front Shock Absorber Mounting Nuts 57 5 5 9 42 R Front Suspension Arm Pivot Nuts 87 5 8 9 65 R Steering Knuckle Joint Nuts 46 5 4 7 34 Rear Shock Absorber Mounting Nuts 95 5 9 7 70 R Rear Suspension Arm Pivot Nuts 87 5 8 9 65 R Rear Knuckle Mounting Nuts 57 5 5 9 42 R Stabilizer Joint Nuts 57 5 5 9 42 R Stabilizer Holder Bolts 31 5 3 2 23 L Steering Steering Wheel Mounting Nut 54 5 5 40 R Steering Knuckle Joint Nuts 46 5 4 7 34 31 17 70 Main Shaft Mounting Bolts Intermediate Shaft Clamp Bolts Steering Gear Assembly Nuts Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Remarks Tie rod End Locknuts 44 Tie rod End Nuts 41 5 Frame Right and Left Bar Mounting Bolts 98 Upper Bar Mounting Bolts 46 5 Back Bar Mounting Bolts 46 5 Bottom Guard Bolts 8 8 78 in lb Front Guard Bolts 31 5 23 Seat Belt Case Mounting Nuts 46 5 34 Seat Belt Mounting Bolts 41 5 31 Seat Belt Buckle Mounting Bolts 46 5 34 Seat Plate Bolts 8 8 78 inelb L Bracket Mounting Bolts L 20 mm 34 3 25 L 1 Pedal Bracket Mounting Bolts L 30 mm 1 2 34 3 25 Center Bracket Mounting Bolts 22 16 Right Frame Pipe Mounting Bolts 34 3 25 Bracket Bolts 47 35 Heart Guard Bolts 8 8 Electrical System Starter Motor Mounting Bolts 8 8 0 90 78 Starter Motor Terminal Locknut 11 1 1 97 in l
69. e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubri cation Cables Lubricate with Cable Lubricant Rear Brake Inner Cable Throttle Inner Cable Variable Differential Shift Inner Cable 2WD AWD Shift Inner Cable e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant 6604011451 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Points Lubricate with Grease Throttle Inner Cable Ends A Brake Cable Upper End Variable Differential Control Cable Ends 2WD AWD Shift Cable Ends Slide Points Lubricate with Grease Brake Lever Brake Pedal Pivot Shaft Throttle Pedal Pivot Shaft Cables Inspection e With the cable disconnected at the both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004040381 C
70. e Connect a digital meter to the harness adapter leads Connections to Adapter Meter lead G Y lead of Main Harness Meter gt BK lead BR BK lead of Main Harness e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Inlet Air Pressure Sensor Output Voltage Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa 76 cmHg abs e Turn the ignition switch OFF x f the output voltage is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation x lf the output voltage is out of the usable range check the wiring for continuity see Inlet Air Pressure Sensor Circuit DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 43 Inlet Air Pressure Sensor Service Code 12 x If the wiring is good check the sensor for various vacuum e Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor e Connect an auxiliary hose B to the inlet air pressure sen Sor e Temporarily install the inlet air pressure sensor e Connect a digital meter C vacuum gauge D the fork oil level gauge E and the harness adapter to the inlet air pressure sensor
71. e Loosen the clamp screw A and duct B e Remove Snap Pin A Pin B and Washer e Loosen the nut C and remove the 2WD 4WD shift cable from the bracket e Remove 2WD AWD Vacuum Actuator Mounting Bolts D 2WD AWD Vacuum Actuator E DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 40 FINAL DRIVE Front Final Gear Case e Remove Lower Hose A 2WD 4WD Vacuum Actuator Installation e Install Lower Hose e Install the 2WD AWD vacuum actuator to the bracket and tighten the 2WD 4WD vacuum actuator mounting bolts Torque Vacuum Actuator Mounting Bolts 8 8 0 90 kgf m 78 in Ib e Install 2WD 4WD Shift Cable see 2WD 4WD Shift Cable In stallation e Install the duct A so that the projection B of the duct inserts the groove of the rubber duct C e Install the removed parts 2WD AWD Shift Cable Lubrication Whenever the 2WD AWD shift cable is removed lubricate the cable as follows e Apply a small amount of multi purpose grease to the cable both ends e Lubricate the cable with a penetrating aerosol cable lubri cant through the pressure cable luber 6604011451 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 41 Front Final Gear Case 2WD AWD Shift Cable Inspection
72. even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear O The checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are available at automotive supply stores for the purpose of checking gear tooth patterns and contact Use one of these for checking the bevel gears DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Rear Final Gear Case e Assemble the rear final gear case see Rear Final Gear Case Assembly e Turn the pinion gear for one revolution in the drive and reverse coast direction while creating drag on the ring gear e Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth OThe tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe x lf the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown see Front Final Gear Case Tooth Contact Adjustment e Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as nec essary NOTE Olf the backlash is out
73. f of this manual for service limits on individual parts Replace YS the parts if any damage has been found or if the part is be yond its service limit X 020098 5 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips cotter pins or self locking nuts must be replaced with new ones whenever disassembled gap 5 Assembly Order In most cases assembly order is the reverse of disassem Ste bly however if assembly order is provided in this Service ie d msn E Manual follow the procedures given f p C gt DP amp 1 gt f igo eo 08020118 5 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or
74. in a straight line out of the front final gear case Front Axle Installation e Wipe the old grease off the splines of the axle and the gear case oil seal e Visually inspect the splines of the axle x lf they are badly worn or chipped replace the axle with new one e Apply molybdenum disulfide grease to the axle splines e Apply grease to the gear case oil seal e Push A the end of the front axle straght and install it in the gear case NOTE OThe axle shaft must not come off easily Front Axle Joint Boot Inspection e Refer to the Front Axle Joint Boot Inspection in the odic Maintenance chapter Front Axle Joint Boot Replacement Outboard Joint Boot Removal e Remove Front Axle see FrontAxle Removal e Tap the joint portion of the boot bands A with a suitable tool e Scrap the removed boot bands e Slide the joint boot B toward the inboard joint 1107800 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 28 FINAL DRIVE Front Axle e Tapthe bearing housing A straight B with a plastic ham mer to separate it from the shaft Do not tap on the cage Be careful not get hurt when the housing comes out If the splined portion of shaft cracked or damaged during disassembling of outboard joint do not reuse the shaft e Remove Circlip A Boot B Outboard Joint
75. kgf m ft lb 1 Hose Banjo Bolts 23 5 2 4 17 2 Pipe Nipples 17 5 1 8 13 3 Rear Master Cylinder Bleed Valve 7 8 0 80 69 in lb 4 Rear Master Cylinder Mounting Bolts 27 2 8 20 L 5 Final Gear Case Front Cover Bolts 24 2 4 18 6 Spring Bracket Bolt 8 8 0 90 78 in lb L 7 Rear Final Gear Case Gasket Screws 1 3 0 13 12 1 1 8 Brake Pipe Joint 17 5 1 8 13 B Apply brake fluid G Apply grease L Apply a non permanent locking agent MF Apply gear oil MOBIL FLUID 424 or equivalent oil R Replacement Parts Si Apply silicone grease DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 6 BRAKES Specifications Item Brake Fluid Type Fluid Level Brake Pedal Brake Pedal Play Front Disc Brake Pad Lining Thickness Disc Thickness Disc Runout DOT3 Standard Between upper and lower level lines 2 10 mm 0 08 0 39 in 3 9 mm 0 15 in 4 6 5 0 mm 0 18 0 20 in TIR 0 25 mm 0 010 in or less Service Limit 1 mm 0 04 in 4 3 mm 0 17 TIR 0 3 mm 0 012 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 7 Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fl
76. nector noting the position of the lock D and the lead color before measurement Do not reverse connections of the digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Turn the ignition switch ON and measure the voltage with the connector joined Incorrect reverse connection or short circuit by needle adapters could damage the or electrical system parts OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Sealant Liquid Gasket TB1211 56019 120 e Always check battery condition before replacing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by Some other item or items they too must be repaired or replaced or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold at room temperature e Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying short etc Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system xIf any wiring is deteriorated replace the wiring 6017572681
77. or hitting the alternator by leaving it near an electromag netic field or just by aging will result in low output e To check the alternator output voltage perform the follow ing procedures ODisconnect the alternator lead connectors A OConnect a hand tester B as shown in the table OStart the engine ORun it at the rpm given in the table ONote the voltage readings total 3 measurements Alternator Output Voltage Reading Tester Range Tester to Tester to at 4 000 rpm 250 One black lead 52 78 xIf the output voltage is within the values in the table the alternator is operating correctly and the regulator rectifier is damaged A much lower reading indicates that the al ternator is defective DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 33 Charging System e Check the stator coil resistance as follows OStop the engine ODisconnect the alternator connector OConnect a hand tester as shown in the table ONote the readings total 3 measurement Stator Coil Resistance at 20 C 68 F Connections Tester Range Reading Tester to Tester to x10 One black lead 2 0 24 0 36 x If there is more resistance than shown the table no reading infinity for any two leads the stator has an open and must be r
78. 0 71 165 225 17 0 23 0 125 165 20 0 79 225 325 23 0 33 0 165 240 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 13 Specifications Item Standard Service Limit Fuel System Throttle Pedal Free Play 5 10 mm 0 20 0 39 in Idle Speed 1 100 50 r min rpm Air Cleaner Element High quality foam air filter oil enm Cooling System Coolant Type Recommended Permanent type of anitfreze soft water and ethylene glycol plus Q corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 Coolant 50 Freezing Point 35 C 31 Total Amount 4 4 L 4 7 US qt Valve Clearance Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in Converter System Belt Width 30 0 30 6 mm 1 181 1 205 in 28 6 mm 1 126 in Belt Deflection 22 31 0 87 1 22 in at checking 22 27 mm 0 87 1 06 in at adjusting Actuator Lever Guide Shoe 6 mm 0 24 in Engine Lubrication System Engine Oil Type SG SH SJ SL or SM with JASO MA 1 or 2 Viscosity SAE 10W 40 2 4 L 2 5 US qt When filter is not removed 2 5 L 2 6 US qt When filter is removed 2 6 L 2 7 US qt When engine is completely dry
79. 22 psi L x 2 113 05 cmHg x 1 333 L x 1 816 pint IMP mL x 0 03381 oz US mL x 0 02816 oz IMP Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N x 0 1020 kg kW x 1 360 5 0 2248 Ib kW x 1 341 kg x 9 807 N PS x 0 7355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Temperature o 5 F 40 F ta 68 60 104 176 212 248 284 80 100 120 140 160 180 200 220 240 260 280 300 1140 138 1120 116 i 100 93 3 20 i 267 40 48 9 0 E 44 DOCUMENT AVAIEABLE FOR MILITARY USE ONEY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic eoe xn RT M M Ee ER AER I ER IRR D PR 2 9 Torque and LOCKING 2 5 SPOCIICATIONS E aang 2 13 Special LOOMS RN 2 15 Periodic Maintenance 2 16 Fuel System 2 16 Throttle Pedal Free Play
80. 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal xIf the reading is out of the usable range replace thesen sor x If the reading is within the usable range check the ECU for its ground and power supply see EGU Power Supply Inspection x lf the ground and power supply good replace the ECU see ECU Removal Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 45 Inlet Air Pressure Sensor Service Code 12 76 80 90 cmHg Ps 1 1 101 32 120 lt gt abs HC110388W4 C ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 46 FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Circuit Q 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 gt N lt
81. 57001 135 Output Shaft Holder amp Spacer m1 25 57001 1479 Output Driven Bevel Gear Assembly e Press the new ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 e Hold the housing assembly A with the holder B in a vise Special Tool Holder amp Guide Arbor 57001 1476 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 19 Output Bevel Gears e Apply a non permanent locking agent to the threads of the bearing holder A and tighten it Special Tool Socket Wrench Hex 50 B 57001 1478 Torque Bearing Holder M75 250 25 5 kgf m 184 ft Ib e Hold the output shaft holder A vise and set the output shaft B on the holder Special Tool Output Shaft Holder 57001 1570 e Press the output driven bevel gear C using the steering stem bearing driver D until it is bottomed Special Tool Steering Stem Bearing Driver 57001 137 e Press the housing assembly A using the steering stem bearing driver B until it is bottomed Special Tool Steering Stem Bearing Driver 57001 137 e Apply a non permanent locking agent Three Bond TB2471 Blue to the threads of the output shaft holder nut A and tighten it so that the projection side B faces outward Special Tool Socket Wrench 57001 1482 Torque Output Shaft Holder Nut
82. 6004040381 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 83 Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment NOTE Oldle speed adjustment is best performed by ECU so idle speed cannot be adjusted Throttle Body Assy Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Air Cleaner Duct see Air Cleaner Housing and Duct Re moval Fuel Hose see Fuel Hose Replacement Fuel Injectors see Fuel Injector Removal ISC Valve Hose A e Disconnect Throttle Sensor Connector B Inlet Air Pressure Sensor Connector C e Remove Screws A and Washers Throttle Link Case Cover B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 84 FUEL SYSTEM Thr
83. BR W BR BK 2 G Y BR W r BR BK HC110528W2 1 ECU Electronic Control Unit 2 Inlet Air Pressure Sensor DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 47 Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Removal Installation Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Inlet Air Temperature Sensor Connector A Screw B Inlet Air Temperature Sensor C e Install a new O ring A e Put the inlet air temperature sensor into the air cleaner housing e Tighten the screw securely 10158101 P Inlet Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged OThe output voltage changes according to the inlet air temperature e Turn the ignition switch OFF e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter e Disconnect the inlet air temperature sensor connector and connect the measuring adapter A between these connectors Special Tool Measuring Adapter 57001 1700 e Connect a digital meter to the measuring adapter leads Connections to adapter Meter Y lead of Main Harness Meter BR BK lead of Main Harness e Measure the output voltage with the engine stopped and the connect
84. Battery Initial Charge e Newly activated sealed batteries require an initial charge Standard Charge 1 2 A 5 10 hours using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Battery Mate 150 9 OptiMate PRO 4 S PRO S PRO2 Yuasa MB 2040 2060 Christie C10122S xIf the above chargers are not available use equivalent one e Let battery sit 30 minutes after initial charge then check voltage using a voltmeter Voltage immediately after charging becomes temporarily high For accurate mea suring let the battery sit for given time NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used If voltage is not at least 12 8 V repeat charging cycle OTo ensure maximum battery life and customer satisfac tion 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 V repeat the charging cycle and load test If still below 12 8 V the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give ref
85. Beam Vertical Adjustment e Turn the adjusting screw A on each headlight rim in or out to adjust the headlight vertically NOTE OOn high beam the brightest point should be slightly be low horizontal with the vehicle on its wheels and the rider seated Adjust both headlights to the same an gle Headlight Bulb Replacement e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Remove Headlight Lead Connector A Clamps B e Remove Screws A e Remove Headlight Connector A Vertical Adjustment Screw B Spring and Nut Bolts C both sides e Turn the headlight bulb A counterclockwise and pull out the bulb from the headlight When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode 19138112 P NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 53 Lighting System e Replace the headlight bulb e Fit the projections A of the bulb in the hollows B of the headlight e Turn the headlight bulb A clockwise e Install the removed parts A Screw 5 L 10 mm 0 39 in
86. Bearing Remover Head 10 x 12 57001 1129 57001 1266 7571129ST C 875712665 C Bearing Remover Shaft 9 57001 1265 875712655 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Visually inspect the coolant in the reserve tank A whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system xIf the coolant gives off an abnormal smell check for cool ing system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank with the vehi cle held perpendicularly Reserve Tank A F full Mark B L low Mark C e If the coolant level is lower than the L mark A remove the reserve tank cap B then add coolant to the F mark A For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attach the aluminum engine parts
87. Boot Installation e Clean the axle shaft by wiping off the used grease on it e Wind the tape on the splines of the axle shaft in order to protect the joint boot e Install New Small Band A New Boot B OApply the special grease slightly on the inside of the new boot small diameter and install the boot on the axle shaft NOTICE Only the special grease that is included with the boot kit can be applied to the boots e Install New Circlip C e Place the special grease tube nozzle in the bore of the housing and squeeze the tube A until the grease comes out from the joint bearing DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 29 Front Axle e Tap the shaft end A straight with a plastic hammer until it is locked by the circlip e Pinch the small boot band A with a suitable tool B to install it Recommend Tool OETIKER 192 e Squeeze all of the special grease A into the new boot B and slide the boot onto the outboard joint C e Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot e Hold the axle at this setting Standard Length of Assembling Front Axle 206 mm 8 11 in A 1L07017BS1 C e Open the edge A of the boot in order to equalize the air pressures DOCUMENT A
88. Capacity Wheels Tires Tire Tread Depth Front 4 mm 0 16 in Rear 4 mm 0 16 in Standard tire Front 26 x 8 00 12 MAXXIS M989 Tubeless Rear 26 x 10 00 12 MAXXIS M990 Tubeless DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Front Final Gear Case Gear Case Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Oil Level Filler opening bottom Capacity 0 7 L 0 74 US qt Rear Final Gear Case Gear Case Oil Type MOBIL FLUID 424 CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Oil Level Filler opening bottom Capacity 1 0 L 1 06 US qt Brakes Brake Fluid Type DOT 3 Brake Pads Pad Lining Thickness 3 9 mm 0 15 in Brake Pedal Brake Pedal Play 2 10 mm 0 08 gt 0 39 in Steering Steering Wheel Free Play 0 20 mm 0 0 79 in Electrical System Spark Plug Gap 0 7 0 8 mm 0 028 0 031 Rear Brake Light Switch Timing ON after 10 mm 0 4 in of pedal travel DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 15 Special Tools Inside Circlip Pliers Pulley Holder Attachment 57001 143 57001 1472 7570143ST C 75714728T C Valve Adjuster Flywheel amp Pulley Holder 57001 1232 57001 1605 8757123
89. Check 1 e Connect terminal 6 to the battery terminal 1019033BS1 C OThe meter illumination A should go on lf the illumination does not go on replace the meter unit ao 1019049BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 66 ELECTRICAL SYSTEM Meter Meter Circuit ws R Y o BK Y 1 Multifunction Meter 10 Fuel Level Sensor 2 AWD Position Switch 11 ECU 3 Neutral Position Switch 12 Engine Ground 4 Reverse Position Switch 13 Battery 5 Speed Sensor 14 Oil Pressure Switch 6 Frame Ground 1 15 Lighting Switch 7 Parking Brake Light Switch 16 Ignition Switch 8 Fuse Box 9 Main Fuse 30 A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 1Q019050BW3 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 67 Actuator Control System Engine Brake Actuator Removal e Remove Torque Converter Cover see Torque Converter Cover Removal in the Converter System chapter Actuator Cover Bolt A Actuator Mounting Bolts B Actuator C Actuator Cover D Engine Brake Actuator Installation e Apply grease and Install O ring A e Apply molybdenum disulfide grease to the pin B e Apply grease to the trim seal A and install the cover B e Insert the pin into
90. Clockwise Softer 4 Harder STD 3 2 1 adjuster turned fully d 1N04006BS1 C Counterclockwise Clockwise Softer 4 Harder STD 20 12 1110 9 8 7 6 5 4 3 2 1 adjuster turned fully clockwise 1N04007BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 17 Shock Absorbers KRF750S Model Rear Shock Absorber Spring Preload Adjustment e Loosen the locknut A e Turn the adjusting nut B to the desired position Special Tool Hook Wrench R37 5 R42 57001 1101 Adjusting Length C from center of upper mounting bolt to lower surface of adjusting nut OThe standard adjusting nut setting for an average build rider of 68 kg 150 Ib with no passenger and no acces sories is 116 0 mm 4 567 in spring length Spring Preload Setting Standard Adjusting length 116 0 mm 4 567 in Usable Range Adjusting length 109 5 127 5 mm 4 311 5 020 in e Tighten the locknut x If the spring action feels too soft or too stiff adjust it Spring Preload Adjustment uA Damp ing Setting Load Road Speed Length Force 109 5 mm 4 811 in Weak Soft Light Good Low T T T ji T l l l l l 127 5 mm 5 020 in Strong Hard Heavy Bad High Rear Shock Absorber Removal Remove Rear Wheel see Wheel Removal in the Wheels Tires chapter Guard A Bolt
91. Contents Exploded VIGW Ma E tU i CS 11 8 Specification NR IER LTEM 11 10 erp e 11 11 Output Bevel eats 11 13 Output Drive Bevel Gear 11 13 Output Drive Bevel Gear Installation eese lg 11 13 Output Drive Bevel Gear 11 14 Output Drive Bevel Gear 11 16 Output Driven Bevel Gear 4560 25722 11 16 Output Driven Bevel Gear 0 11 17 Output Driven Bevel Gear Disassembly 2 44441 5 2 520 11 17 Output Driven Bevel Gear hes 11 18 Output Bevel Gears Adjustment I Fees 11 19 Bevel Gears 4 BELLES 11 23 Front Propeller Shaft ec a er trier ero Et tre pea 11 24 Front Propeller Shaft 11 24 Front Propeller Shaft Installation e 4 11 24 Front Propeller
92. Cover Bolt 8 8 0 90 78 S Belt Inspection Opening Cover Bolts 8 8 0 90 78 4 Converter Cover Bolts 8 8 0 90 78 S 5 Converter Cover Drain Bolt 20 2 0 15 6 Joint Duct Bolts 8 8 0 90 78 in lb G Apply grease M Apply molybdenum disulfide grease R Replacement Parts S Follow the specific tightening sequence DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 6 CONVERTER SYSTEM Specifications Item Torque Converter Actuator Lever Guide Shoe Actuator Lever Assembly Installation Length Drive Belt Belt Width Belt Deflection Standard 30 0 30 6 mm 1 181 1 205 22 31 mm 0 87 1 22 in at checking 22 27 mm 0 87 1 06 in at adjusting Service Limit 6 mm 0 24 in Drive Pulley Shoe Side Clearance Cover Bushing Inside Diameter Sheave Bushing Inside Diameter Spring Free Length Drive Pulley Installation Length Up to 0 20 mm 0 008 in in the text 27 985 28 085 mm 1 1018 1 1057 in 37 985 38 085 mm 1 4955 1 4994 in 60 0 mm 2 36 in 164 85 165 95 mm 6 490 6 533 in 28 12 mm 1 107 in 38 12 mm 1 501 in Driven Pulley Sheave Bushing Inside Diameter Spring Free Length 40 000 40 039 mm 1 5748 1 5763 in 99 mm 3 9 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militarya
93. DFI 3 11 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 12 FUEL SYSTEM DFI DFI System Terminal Numbers of ECU Connectors 35 3 4 3 3 3 2 3 1 3 0 2 9 2 8 27 oso 13 1211112 9 8 7 6 514131211 HC11046BW2 C Terminal Names Inlet Air Pressure Sensor G Y Inlet Air Temperature Sensor Y Power Supply to Sensors BR W Reverse Switch R W Brake Light Switch BL Crankshaft Sensor BL R Battery Monitor W R Power Supply from Battery W External Communication Line KDS Ground for Sensors BR BK Ground for Control System BK Y Ignition Switch GY Ignition Switch from Battery BR Water Temperature Sensor O Throttle Sensor Unused Speed Sensor P Neutral Switch LG Vehicle down Sensor Y G Parking Brake Switch Crankshaft Sensor BK R Unused Unused Unused Starter Button BK W Diagnosis Terminal LG BK ISC Valve 4 W BK 2WD AWD Shift Switch G ISC Valve 2 W BL Fuel Pump Relay BR Y Water Temperature Warning Indicator Symbol LCD W G Radiator Fan Relay Y Ground BK Y Injector 2 V lgnition Coil 42 BL W ISC Valve 1 V W 2WD 4WD Solenoid Valve W R ISC Valve 3 P BL Fl Indicator Symbol LCD R Y Drive Belt Ch
94. FINAL DRIVE 11 53 Front Final Gear Case e Install Spring A 2WD AWD Shift Shaft Lever B e Align the lines C of the shaft and lever e Install 2WD AWD Shift Shaft Lever Nut A Vs a NL e Tighten AF gt Torque 2WD AWD Shift Shaft Lever Nut 20 N m 2 0 b 74 kgf m 15 ft Ib wr e Apply grease to the oil seal lip A e Press the oil seal B in the coupling C as shown in the figure 1 1 5 mm 0 039 0 059 in D e Install Coupling A Washer B e Install Coupling Nut A e Push B and hold the 2WD AWD shift shaft lever C e Hold the coupling D with a wrench E e Tighten Torque Coupling Nut 35 N m 3 6 kgf m 26 ft Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 54 FINAL DRIVE Front Final Gear Case e Press the plug A into the yoke B as shown in the figure 10 5 1 mm 0 413 0 039 C e Install Yoke A Caps B New Snap Rings C 1L04037BS1 C e Install Differential Control Shift Shaft Lever A e Align the punch marks B of the shaft and lever e Install Differential Control Shift Shaft Lever Bolt C and Nut D e Tighten Torque Differential Control Shift Shaft Lever Nut 8 8 0 90 kgf m 78 in Ib Ring Gear Disassembly e Remove Ring Gear Assembly See Front Final Gear Case Disas sembly Ring
95. Filler Cap 29 3 0 21 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Fastener Torgus Remarks N m kgf m ft lb Rear Final Gear Case Right Cover Bolts M10 49 5 0 36 L Rear Final Gear Case Right Cover Bolts M12 94 9 6 69 L Rear Final Gear Case Mounting Nuts 90 5 9 2 67 R Rear Final Gear Case Bracket Bolts 90 5 9 2 67 Heat Guard Bolts 8 8 0 90 78 in lb Brakes Front Master Cylinder Reservoir Cap 3 4 0 35 30 in lb Reservoir Clamp Bolt 6 2 0 63 55 in lb Piston Stop Bolt 8 8 0 90 78 in lb Brake Pipe Nipples 17 5 1 8 13 Brake Pipe Joint 17 5 1 8 13 Brake Hose Banjo Bolts 23 5 2 4 17 Front Master Cylinder Mounting Bolts 23 5 2 4 17 Master Cylinder Bolt 23 5 2 4 14 Push Rod Locknut 17 2 1 8 13 Parking Brake Pedal Assy Mounting Bolts 41 5 4 2 31 Front Brake Pad Mounting Bolts 17 2 1 8 13 Caliper Bleed Valves 7 8 0 80 69 in lb Brake Hose Clamp Bolts 8 8 0 90 78 in lb L Caliper Holder Shaft 17 2 1 8 13 Brake Caliper Mounting Bolts 33 3 4 24 L Front Brake Disc Mounting Bolts 41 5 4 2 31 L Parking Brake Position Switch Screws 0 4 0 04 4 in lb Rear Master Cylinder Bleed Valve 7 8 0 80 69 in lb Rear Master Cylinder Mounting Bolts 27 2 8 20 L Rear Final Gear Case Front Cover Bolts 24 2 4 18 Spring Bracket Bolt 8 8 0 90 78 L Rear Final Gear Gase Gasket Screws 1 3 0 13 12 in lb
96. Gear Bolts A Ring Gear B e Remove Differential Gear Case Cover A Right Side Gear 16T B Spider Gear Shaft C Spider Gears 10T D Left Side Gear 16T E Left Differential Gear Case F 1L04045BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 55 Front Final Gear Case Ring Gear Assembly e Press the bearing A on the left differential gear case B until it is bottomed e Apply engine oil to the teeth C of the gears e Apply molybdenum disulfide grease to the diagonal line parts D e Install Left Side Gear 16T E Spider Gears 10T F Spider Gear Shaft G 1LO4039BS1 C e Apply engine oil to the teeth A of the gear e Apply molybdenum disulfide grease to the diagonal line parts B e Install Right Side Gear 16T C Pin D Differential Gear Case Cover E Ring Gear F e Apply a non permanent locking agent Three Bond TB2471 Blue to the ring gear bolts G and tighten them Torque Ring Gear Bolts 57 N m 5 8 kgf m 42 ft lb 1L04040BS1 C LSD Clutch Torque Inspection x If the vehicle has the following symptoms check the LSD Limited Slip Differential clutch torque The steering wheel is hard to turn The front final gear case overheats Abnormal noises come from the front final gear case when rounding a curve e Ensure 2WD mode e Su
97. In an emergency soft water can be added CEU AM But the diluted coolant must be returned to the cor rect mixture ratio within a few days If coolant must be added often or the reserve tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY COOLING SYSTEM 4 9 Coolant Pressure Testing e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Remove the radiator cap and install a cooling system pressure tester A on the radiator filler neck NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leakage e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds x lf the pressure holds steady the system is alright x If the pressure drops soon check for leaks DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com
98. Inspection 16 56 Radiator Fan Breaker Installation 16 57 Radiator Fan Relay Inspection 16 57 Niger 16 58 Multifunction Meter Unit Removal 16 58 Multifunction Meter Unit Installation Multifunction Meter Unit In Spector d Actuator Control System Engine Brake Actuator Removal 16 67 Engine Brake Actuator Installation 16 67 Actuator Control System Outline 16 68 Engine Brake Actuator Inspection 16 68 Speed Sensor Circuit Inspection 16 69 Controller Unit Inspection 16 70 Forward Reverse Detecting Sensor Inspection 16 71 2WD AWD Solenoid Valve 16 73 2WD AWD Solenoid Valve Inspector 16 73 Gli 16 75 Relay Inspection 16 75 Switches and Sensor 16 76 Brake Light Switch Adjustment 16 76 Starter Motor DissegermalNT AVAIL BIA9 FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 2 ELECTRICAL SYSTEM Water Temperature Switch Inspection e etie 16 76 Fuel Level Sensor Inspection 16 76 Speed Sensor Removal Installa 16 76 Speed Sensor Inspection 16 77 Switch Inspection 16 77 ESOS ite tb 16 79 Fuse Remowval 16 79 Fuse Installat
99. MILITARY USE ONLY 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Brake Caliper Piston Seal and Dust Seal Replacement e Remove Caliper see Front Brake Caliper Removal in the Brakes chapter Pads see Brake Pad Removal in the Brakes chapter Anti rattle Spring e Using compressed air remove the piston OCover the caliper opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to where the brake line fits into the caliper WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston 15140101 P NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid O Remove the pads see Brake Pad Removal and anti rattle spring OPump the brake pedal to remove the caliper piston e Remove Dust Seals A Piston Seals B 1514008851 C e Replace the piston seal A with a new one OApply silicone grease to the piston seal and install it into the cylinder by hand e Replace the dust seal B with a new one OApply brake fluid to the dust seal and install it into the cylinder by hand 6105040251 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 45 Periodic Main
100. NOTICE Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge 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 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 the electrolyte container ELECTRICAL SYSTEM 16 21 8 08020451 ME02112BS1 ME02113BS1 8 09000751 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 22 ELECTRICAL SYSTEM Battery e Check the electrolyte flow If no air bubbles A are coming
101. Nl oo A 80904020152 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures Bolts and Nuts Tightening Tightness Inspection e Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition xIf there are loose fasteners retorque them to the speci fied torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not listed in the appropriate chapter see the Basic Torque Table see Torque and Locking Agent For each fastener first loosen it by 1 2 turn then tighten it x lf cotter pins are damaged replace them with new ones Bolts Nuts and Fasteners to be checked Engine Engine Mounting Bolts Engine Bracket Pipe Mounting Bolts Exhaust Pipe Nuts Muffler Mounting Bolts Muffler Clamp Bolt Spark Arrester Mounting Bolts Throttle Pedal Pivot Clip Fuel Tank Band Bolts Transmission Final Drive Shift Lever Assembly Nut Shift Shaft Lever Bolt Tie rod End Bolt and Nut Tie rod End Locknuts Differential Shift Lever Pivot Clip Final Gear Case Mounting Bolts Final Gear Case Bracket Bolts Wheels Axle Nuts and Cotter Pins Wheel Nuts Brakes Front Master Cylinder Mounting Bolts
102. OAlign the T F mark A with the notch B in the inspection window HE10001BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Camshaft Face the arrow A of the front camshaft sprocket upward right side view e Engage the front camshaft chain with the front camshaft sprocket Align the marks B on the weights with the front cylinder head upper surface e Install Rocker Cases see Rocker Case Installation Camshaft Chain Tensioners see Camshaft Chain Ten sioner Installation e Check the valve clearance see Valve Clearance Inspec tion Camshaft Assembly e Install the KACR unit A sprocket on the camshaft so that the unit fits onto the camshaft pins B e Apply a non permanent locking agent to the camshaft sprocket bolts C e Tighten Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 106 in Ib Cam Wear Inspection e Remove the camshaft e Measure the height A of the cam with a micrometer xIf the cams are worn past the service limit replace the camshaft Cam Height Standard Exhaust 35 363 35 477 mm 1 3922 1 3967 in Inlet 35 622 35 736 mm 1 4024 1 4069 Service Limit Exhaust 35 26 mm 1 388 in Inlet 35 52 mm 1 398 in ENGINE TOP END 5 21 HEO9010BS1 00006 P GE11012281 DOCUMENT AVAILABLE FOR MILITARY USE
103. ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE O Whenever the belt is replaced inspect the drive and the driven pulleys e Install the air outlet duct see Torque Converter Cover In stallation in the Converter System chapter Drive Belt Deflection Inspection e Put the transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Bolts A Clamp B Cover C e Set the cover plate A on the torque converter cover B with two bolts C Special Tool Belt Deflection Gauge 57001 1713 e Putthe belt deflection gauge A along with the semi circle cutout B in the cover plate and let the flat end of the gauge contact at right angle to the belt C NOTE O Take care not to drop the gauge in the converter cover 1808004BS1 C e Press A the gauge head until the 59 N 6 kgf 13 Ib scale line B aligns with the top end of the stopper C e Make a line mark D on the gauge at the upper surface of the cover plate E SIRF753081 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 29 Periodi
104. Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 10 16 WHEELS TIRES Rear Hub ORemove the brake drum pusher and install one spacer A in the brake drum pusher set to the pusher OTighten the brake drum pusher B until the pusher stops ORemove the brake drum pusher and install two spacers A in the brake drum pusher set to the pusher OTighten the brake drum pusher B until the pusher stops ORemove the brake drum pusher and spacers e Install Washer A Axle Nut B e Using the brake drum holder C hold the rear hub D Special Tool Brake Drum Holder 57001 1325 e Tighten Torque Rear Axle Nut 266 27 1 kgf m 196 ft lb e Insert a new cotter pin A e Bend the cotter pin over the axle shaft end B and install the cap A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin e Install the rear wheel see Wheel Installation Rear Hub Disassembly Assembly e Do not remove the hub bolts A xIf any hub bolt is damaged replace the hub B and bolts as a unit e When installing the hub bolt press in it using a press DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 1K08000BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 1 Final Drive Table of
105. Output Voltage Inspection xIf the reading is out of the range check the wiring for continuity see Vehicle down Sensor Circuit x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace ECU see ECU Removal Installation Vehicle down Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the vehicle down sensor see Vehicle down Sensor Removal e Disconnect the vehicle down sensor connector A and connect the measuring adapter B between the main har ness connector and vehicle down sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter to the measuring adapter leads Connections to Adapter Meter Y G lead of Main Harness Meter BR BK lead of Main Harness e Hold the sensor vertically e Measure the output voltage with the engine stopped and with the connectors joined DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 58 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 e Turn the ignition switch ON e Tilt the sensor 55 75 or more A right or left then hold the sensor almost vertical with the arrow mark B pointed up and measure the output voltage Vehicle down Sensor Output Volta
106. P DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 26 SUSPENSION Suspension Arms Stabilizer Installation e Install the stabilizer A so that the recess side B faces to lower side 05011881 C e Install Stabilizer A Dampers B both sides Stabilizer Holders C and Bolts both sides e Apply a non permanent locking agent to the stabilizer holder bolts e Tighten Torque Stabilizer Holder Bolts D 31 5 3 2 kgf m 23 ft lb e Install Stabilizer Joints E both sides New Stabilizer Joint Nuts F OHold the joint bolt with an Allen wrench and tighten the nut Torque Stabilizer Joint Nuts F 57 5 N m 5 9 kgf m 42 ft Ib e Install Rear Wheels see Wheel Installation in the Wheels Tires chapter Stabilizer Joint Inspection e Remove Stabilizer Joint see stabilizer Removal e Inspect each spherical bearing A x f roughness excessive play or seizure is found replace the stabilizer joint e Inspect each boot B x If damage wear or deterioration is found replace the sta bilizer joint Rear Knuckle Removal e Remove Rear Wheel see Wheel Removal in the Wheels Tires chapter Rear Hub see Rear Hub Removal in the Wheels Tires chapter e Remove Rear Knuckle Mounting Bolts A washers and Nuts Rear Knuckle B DOCUMENT AVAILABLE FOR MIL
107. Pulley Driven Pulley Removal e Remove Torque Converter Cover see Torque Converter Cover Removal Drive Pulley see Drive Pulley Removal Drive Belt see Drive Belt Removal e Using the flywheel amp pulley holder A and attachments B remove the driven pulley nut C and washers Nut has R H threads Special Tools Flywheel amp Pulley Holder 57001 1605 Pulley Holder Attachment 57001 1472 e Remove Driven Pulley Driven Pulley Disassembly e Hold the drive amp driven pulley holder A in a vise Special Tool Drive amp Driven Pulley Holder 57001 1473 e Screw the guide bar B into the holder Special Tool Spring Holder Set 57001 1483 e Put the driven pulley C on the guide bar e Install the two bolts D so that the bolts protrude from the spring holder E about 7 mm 0 28 in F e Tighten the nut G and compress the spring with the EAS spring holder Special Tool Spring Holder Set 57001 1483 e Remove the circlip A with circlip pliers B Special Tool Outside Circlip Pliers 57001 144 e Remove the nut and spring holder C The spring seat A may not lift even if the nut B loosens OThen tap the spring seat with a plastic mallet C lightly to release the stuck spring DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 23 Driven Pulley e Remove Spri
108. Removal 15 30 Front Guard Installation Cargo Bed Installation 15 30 Front Bottom Guard Removal Cargo Bed Disassembly 15 32 Front Bottom Guard Installation Cargo Bed Assembly 15 35 Middle Bottom Guard Removal 15 40 Middle Bottom Guard Installation 15 58 Right and Left Bars Removal 15 40 Engine Bottom Guard Removal 15 58 Right and Left Bars Installation 15 40 Engine Bottom Guard Installation 15 59 TO a 15 43 Rear Bottom Guard Removal 15 59 Engine Upper Cover Removal 15 43 Rear Bottom Guard Installation 15 59 Engine Upper Cover Installation 15 43 FIOOI DOANE ceu tonno tetto 15 60 Center Cover Removal 15 44 Floorboard Removal 15 60 Center Cover Installation 15 44 Floorboard Installation 15 63 Side Cover Removal 15 44 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 2 FRAME Exploded View IP02105BW5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 3 Exploded View 1 The seal ends should be at lower area and the
109. Removal e8 994 3 78 Fuel Filter 1 uw UTR 3 79 Throttle Pedal and 6 7 3 80 Throttle Pedal Free Play 3 80 Throttle Pedal Free _____ 3 80 Throttle 2 26 reatu to reina neuter eve 3 80 Throttle Pedal Hemego een erbe i EC 3 80 Throttle Pedal NS ie c e te tx 3 81 Throttle 211 3 81 Throttle Cable Lubrication and Inspection 0 3 82 Throttle Body 3 83 Idle Speed Inspection vetet 3 83 PERS E w Vg Cm 3 83 Throttle Body Assy 2 3 83 Throttle Body Assy InstallattOfk 542 de erae 3 84 Throttle Body Assy Disassembly 0040244000 0000 3 85 Body Assy Assembly odere ee rU EDU bec Ph ius iad ae
110. Rod A and Shift Fork Ear B Needle Bearing C e Install Shift Rod with Shift Fork Spacer D Needle Bearing e Install Reverse Drive Gear A Spacer B e Install Reverse Shaft A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 26 CRANKSHAFT TRANSMISSION Transmission e Apply molybdenum disulfide oil to the shift shaft A e Install Shift Shaft Spring Bolt B Spring C Guide D e Apply a non permanent locking agent Three Bond TB2471 Blue to the shift shaft spring bolt e Tighten Torque Shift Shaft Spring Bolt 25 2 5 kgf m 18 ft Ib e When an oil seal A is installed in the shift shaft cover B press and insert the oil seal so that its surface is flush with the end of the hole HI10028BS1 C e Install Shift Shaft Cover e Tighten Torque Shift Shaft Cover Bolts 8 8 0 90 kgf m 78 in Ib Shift Fork Bending Inspection e Visually inspect the shift fork xIf the fork is bent replace the shift rod with a new one A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power A 90 HI10002281 Shift Fork Gear and Shifter Groove Wear Inspection e e Measure the thickness of the shift fork ears A and mea NS sure the width B of the shifter groove Shift F
111. Shaft Inspection t E Front Axle Front Axle Installation eine Pede adel Front Axle Joint Boot Inspection Front Axle Joint Boot Replacement 5 11 27 Front Final Gear Case Ne et ae ente 11 34 Front Final Gear Case Oil Level nspection 11 34 Front Final Gear Case oue ete rete eh eed 11 34 Differential Shift Lever Play Inspection 11 34 Differential Shift BevemPlay 444 11 34 Differential SaL Removal 11 34 Differential Shif Lever Installation 11 35 Differential Shift Gable nennen nnne 11 35 Differential ShiftCable TristallatiOp ctm repr o 11 36 Differential Shift Cable 11 37 Differential Shift Cable 44424 nnne 11 37 2WD 4AWD Shift Cable 11 37 2WD 4WD Shift C
112. Slowly pump the brake pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir OBleed the air completely from the front master cylinder by this operation NOTE OStart with the rear master cylinder and finish with the front left or right caliper e Remove the r bber cap from the bleed valve on the rear master cylinder e Connect a clear plastic hose A to the bleed valve on the rear master cylinder and run the other end of the hose into a container DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 9 Brake Fluid e Bleed the brake line and the rear master cylinder as fol lows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake pedal until it becomes hard and apply the brake pedal and hold it A 2 Quickly open and close B the bleed valve while holding the brake pedal applied 3 Release the brake pedal C NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time dur ing bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Remove the clear plastic hose e Tighten Torque Rear Master Cylinder Bleed Valve 7 8
113. Special Tool Nut Holding Bolts 57001 1481 D Output Drive Bevel Gear Housing E Outer Ball Bearing F Inner Ball Bearing G Bearing Holder H Output Drive Bevel Gear 16001652 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 15 Output Bevel Gears e Hold the output drive bevel gear housing A in a vise e Loosen the bevel gear B using an Allen wrench about four rotations e Remove one nut holding bolt and look at through the hole xIf the groove of the bevel gear holder nut is not seen loosen the other three bolts e Drive the gear shaft end using a copper mallet until the grooves of the bearing holder nut can be seen again e Retighten the nut holding bolts 4 securely into the groove of the bevel gear holder nut in the output drive bevel gear housing Special Tool Nut Holding Bolts 57001 1481 e Repeat the above procedure and remove the bevel gear from the housing e Remove the bearing holder A using the hexagon wrench B Special Tool Hexagon Wrench Hex 41 57001 1491 Olf it is difficult to break free the holder apply the heat to it to softer the locking agent e Remove Outer Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 e Remove Output Drive Bevel Gear Holder Nut Inner Ball Bearing A Special Tool Oil Seal amp Be
114. Steering Shafts Removal e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Lift and hold the front fender rear see Front Fender Rear Removal in the Frame chapter e Remove Control Panel see Control Panel Removal in the Frame chapter Steering Wheel see Steering Wheel Removal Washer Intermediate Shaft Clamp Bolt A Main Shaft Mounting Bolts B and Nut Main Shaft C Rubber Seal D e Remove Intermediate Shaft Clamp Bolt A Intermediate Shaft B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 14 8 STEERING Steering Wheel and Main Shaft Assembly Steering Shafts Installation e Apply grease to the dust cover lips A e Connect the intermediate shaft A to the main shaft B and the steering gear pinion C in any position e Tighten Torque Intermediate Shaft Clamp Bolts D 21 5 N m 2 2 kgf m 16 16 e Install the main shaft mounting bolts E and nut F e Tighten Torque Main Shaft Mounting Bolts 41 5 N m 4 2 kgf m 31 ft lb e Install the washer G e Install the rubber seal H so that the recess side faces to front side 1004007852 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY STEERING 14 9 Steering Gear Assembly Steering Gear Assembly Remo
115. THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM US MODEL only To minimize the noise emissions from this product Kawasaki has equipped it with effective inlet and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise level Please do not remove these systems or alter them in any way which results in an increase in noise level TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal regulations and California State law prohibit the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Do not tamper with the original emission related parts e Throttle body and internal parts e Spark plugs e Alternator or electronic battery ignition system e Fuel filter Fuel injector Fuel pump e Air cleaner element e ECU Electronic Control Unit DOCUMENT AVAI
116. Through Bolts A 5 0 0 51 kgf m 44 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 48 ELECTRICAL SYSTEM Electric Starter System Brush Inspection e Measure the length of each brush A If any is worn down to the service limit replace the brush assy Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 6 5 mm 0 26 in Commutator Cleaning and Inspection e Clean the metallic debris off the between commutator segments A NOTE ODo not use emery or sand paper on the commutator e Check the commutator for damage or abnormal wear Replace the starter motor with a new one if there is any damage or wear e Visually inspect the commutator segments for discol guam oration Replace the starter motor with a new one if discoloration is noticed Armature Inspection e Using the x 1 O hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between two segments a winding is open and the starter motor must be replaced AIA e Using the highest hand tester range measure the resis a XA tance between the segments and the shaft B B Wa x If there is any reading atall the armature has a short and the starter motor must be replaced
117. When using the plural spacers install the thick spacer to the movable sheave side and thin spacer to the fixed sheave side Spacers Part No Thickness 92026 0034 0 3 mm 0 012 in 92026 1569 0 6 mm 0 024 in 92026 1617 0 8 mm 0 031 92026 1565 1 0 mm 0 039 in 92026 1570 1 4 mm 0 055 in e Assemble the driven pulley see Driven Pulley Assembly in the Converter System chapter e With the transmission in neutral rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection e Measure the belt deflection again and repeat the above procedures until it is within the standard range e Using the flywheel amp pulley holder and pulley holder at tachment tighten the new driven pulley nut Special Tools Flywheel amp Pulley Holder 57001 1605 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Nut 93 N m 9 5 kgf m 69 ft Ib Actuator Lever Engine Brake Control Lever Assembly Inspection e Remove the torque converter cover see Torque Con verter Cover Removal in the Converter System chapter e Measure the width A of the plastic guide shoe B of the actuator lever assembly x f the guide contact area width is greater than the service limit replace the actuator lever assembly da il Actuator Lever Guide Shoe Service Limit 6 mm 0 24 in H 04005BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Onl
118. and initiates fail safe function In case of serious troubles the ECU stops the injection ignition starter motor operation Dealer Mode The ECU generate service code s to show the prob lem s which the DFI system and ignition system have at the moment of diagnosis Self diagnosis Procedures OWhen problem occurs with the DFI system and ignition system the Fl indicator symbol A LCD flashes NOTE OUse a fully charged battery when conducting self diagnosis OKeep the self diagnosis terminal grounded during self diagnosis with an auxiliary lead OEREIN 1919047851 C e Remove Left Seat see Seat Removal in the Frame chapter e Remove the cap A from the KDS connector B white e Connect an auxiliary lead A into the self diagnosis ter minal B LG BK in the KDS connector C for grounding e Turn on the ignition switch DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 32 FUEL SYSTEM Self Diagnosis e To enter the self diagnosis dealer mode ground the self diagnosis terminal to the battery terminal A for more than 2 seconds and then keep it grounded continuously e Count the blinks of the FI indicator symbol to read the Service code e Keep the auxiliary lead ground until you finish reading the service code DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Onl
119. are checked good replace the ECU Engine Won t Turn Over Symptoms or possible Causes Actions chapter Neutral switch trouble Inspect neutral switch see chapter 16 Crankshaft sensor trouble Inspect see chapter 16 Ignition coil shorted or not in good contact Inspect or Reinstall see chapter 16 Ignition coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor Running at Low Speed Spark weak Eee eR Ignition coil shorted or not in good contact Inspect or reinstall see chapter 16 Ignition coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 Air duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump
120. bottomed OWhen install the crankshaft bearing the stepped side faces engine inside Special Tool Bearing Driver Set 57001 1129 e Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole B Needle Bearing C Needle Bearing Insert it from outside e Apply engine oil to the bearings e Install Plates A Bearing Position Plate Screws B e Tighten Torque Bearing Position Plate Screws 4 9 N m 0 50 kgf m 43 in Ib 17104001851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 11 Crankcase e Be sure the following parts are in place in the right crankcase half Crankshaft Transmission Shafts and Shift Rod A Spacers B Oil Tube C Oil Screen D O ring E Apply Grease Dowel Pins F e Apply liquid gasket A to mating surface of the left crankcase half Sealant Liquid Gasket TB1216 92104 1063 e Apply a non permanent locking agent to the area C 12 mm 0 47 in except for the tip D 2 3 mm 0 08 0 12 in Left Crankcase Bolt M8 3 e Tighten the right and left crankcase bolts M8 following the tightening sequence 1 8 Torque Crankcase Bolts M8 20 2 0 kgf m 15 ft lb 1 2 5 6 L 75 mm 2 95 in 54 3 4 7 8 L 110 mm 4 33 ins HI04008BS1 e Tighten Torque Cran
121. com DOCUMENT AVAILABLE FOR MILITARY USE ONLY TERYX 750 FI 4x4 TERYX 750 FI 4x4 LE TERYX 750 FI 4x4 SPORT Kawasaki Recreation Utility Vehicle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2009 Kawasaki Heavy Industries Ltd Fourth Edition 0 Oct 15 2010 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY LIST OF ABBREVI
122. con tact Spark plug incorrect Crankshaft sensor trouble ECU trouble Ignition coil trouble Battery voltage low Ignition switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release KAGR cam sticks open Engine stalls when moving off Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect ECU trouble Crankshaft sensor trouble Ignition coil trouble Battery voltage low Fuel air mixture incorrect Bypass screw maladjusted Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble Throttle body holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent
123. e Set the rest position of the throttle pedal by adjusting the throttle pedal position bolt I so that the throttle vale is not open e Tighten Torque Throttle Pedal Position Bolt Locknut J 10 8 1 1 kgf m 96 in Ib 10040038853 C Throttle Pedal Removal e Remove Spring A Snap Pin B and Washer e Remove the throttle pedal from the bracket DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 81 Throttle Pedal and Cable e Remove the throttle cable end A from the throttle pedal B Throttle Pedal Installation e Apply grease Throttle Cable End Pin A of Throttle Pedal e Install Throttle Cable End Throttle Pedal B Snap Pin C and Washer D Spring E e Do not use a needle nose pliers for the damage preven 10040048581 C tion of the spring e Install the spring A as shown in the figure Downward B 104001851 C Throttle Cable Installation e Lubricate the throttle cable before installation A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Be sure the cables are routed correctly and properly adjusted e Apply grease to the cable ends A e Install the front end of the throttle cable B as shown in the figure e Install the end C of the boot D to the groo
124. e When removing the roller bracket A remove the screws B e When removing the plate A remove the tapping screws B both sides DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 25 Control Panel e When removing the guide A remove the rivets B the rivets and remove them DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 26 FRAME Control Panel Cupholder Installation KRF750P R S V Models e Install Cupholder Case A Cupholder B Trim C Rivets D Washers E Guides F Damper G Plate H Tapping Screws lI L 8 mm 0 31 in Roller Brackets J Screws K Rollers L Bolts M L 2 13 mm 0 51 in IP08004BW3 C e Install the cupholder case to the cupholder bracket N e Install Holder O Bolts P L 2 10 mm 0 39 in e Install the cupholder assembly to the control panel e Tighten the tapping screws both sides L 12 mm 0 47 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 27 Fenders Front Fender Front Removal e Remove Band A both sides e Clear the four hook portions from the slots lift up the front fender
125. engine e With the transmission in neutral operate the throttle pedal a few times to make sure that the idle speed does not change xIf the idle speed does change the throttle cable may be improperly adjusted incorrectly routed or it may be dam aged e Correct any of these conditions before operation A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Idle Speed Inspection e Start the engine and warm it up thoroughly e Check the idle speed with a suitable tachometer x lf the idle speed is out of the specified range check the ISC valve see ISC Valve Inspection and vacuum hoses Idle Speed Standard 1 100 50 r min rpm Idle Speed Adjustment NOTE Oldle speed adjustment is best performed by ECU so idle speed cannot be adjusted Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or muddy terrains the element should be cleaned immediately OAlso if there is a break in the element material or any other damage to the element replace the el
126. front A e Support it in the tilted position with the supporting rod B e Disconnect Headlight Lead Connector A both sides e Remove the harness B from the clamps C both sides e Remove Snap Pin D both sides Front Fender Front Mounting Pin E and Washer F both sides Front Fender Front G Front Fender Front Installation e Installation is the reverse of removal e Insert the front fender front hooks A into the receivers B in the front fender rear both sides Front Fender Rear Removal e Remove Tilt up and hold the front fender front see Front Fender Front Removal Quick Rivets A Cover B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 28 FRAME Fenders e Remove Quick Rivets A both sides Screws B both sides e Remove Screws A and Collars e When holding the front fender rear A at upper position lift and hold it with a suitable belt B firmly e When removing the front fender rear from the frame re move the right and left bar see Right and Left Bars Re moval e Remove the front fender rear Front Fender Rear Installation e Installation is the reverse of removal Rear Fender Removal e Remove Screw Rivets A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILIT
127. if necessary Wheel Rim Replacement e Remove the wheel see Wheel Removal e Disassemble the tire from the rim see Tire Removal ORemove the air valve and discard it Replace the air valve whenever the tire is replaced Do not reuse the air valve Plastic Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F e Install a new air valve in the new rim ORemove the valve cap lubricate the stem with a soap and water solution and pull A the stem through the rim from the inside out until it snaps into place NOTICE Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber e Mount the tire on the new rim see Tire Installation e Install the wheel see Wheel Installation e Install the air valve cap HJ05022BS1 6J05010881 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com HJ05036BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY 10 10 WHEELS TIRES Tires Tire Removal e Remove the wheel e Unscrew the valve core to deflate the tire OUse a proper valve core tool A e Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges NOTICE Do not lubricate the tire beads and rim flanges with eng
128. in Service Limit 17 94 mm 0 706 in Camshaft Journal Diameter 22 Standard 21 959 21 980 mm 0 8645 0 8654 in Service Limit 21 93 mm 0 863 in the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again x lf the clearance still remains out of the limit replace the cylinder head and the rocker case The cylinder head and rocker case are machined as a set and must be replaced as a set DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 23 Camshaft KACR Inspection The Kawasaki Automatic Compression Release KACR momentarily opens the exhaust valves on the compression stroke at very low speeds This allows some of the com pression pressure to escape making it easy to turn over the engine during starting Due to the simplicity of the mechanism no periodic main tenance is needed There are only two symptoms of prob lems with the KACR mechanism A compression is not re leased during starting and compression is released during running 1 If compression is not released during starting the weights are not returning to their rest position e Remove the camshaft see Camshaft Removal e Remove the KACR unit e Visually inspect the spring If damaged deformed or missing replace the spring e Remove the spring a
129. inspect sealing see chapter 2 Air duct loose Reinstall see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel injector clogged Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI Fuel pump bearings may wear Replace the fuel fuse blows pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 30 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Inlet air temperature sensor trouble Throttle sensor trouble Knocking Fuel poor quality or incorrect Spark plug incorrect Ignition coil trouble ECU trouble Actions chapter Inspect see chapter 3 Inspect see chapter 3 Fuel change Use the gasoline recommended in the Owner s Manual Replace it with the correct plug see chapter 2 Inspect see chapter 16 Inspect see chapter 3 Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Inspect see chapter 3 Inspect see chap
130. into the ignition timing at opened throttle position and sets the DFI in the a N method 1 Inlet Air nici Air Pressure Sensor If the inlet air pressure sensor system fails the 12 Pressife Output Voltage signal Pv is out of the usable range wiring sot 02 48V short or open the ECU sets the DFI in the a N method Inlet Air Inlet Air Temperature If the inlet air temperature sensor fails the 13 Temperature Sensor Output Voltage signal is out of the usable range wiring short Sensor 0 2 46V or open the ECU sets Ta at 30 C Water Water Temperature If the water temperature sensor system fails 14 Temperature Sensor Output Voltage lt the signal is out of the usable range wiring Sensor 0 2 4 85 V shortor open the ECU sets Tw at 80 C Crankshaft sensor must 21 Crankshaft send 22 signals output If crankshaft sensor does not generate signals Sensor signal to the ECU at the the engine stops by itself one cranking Speed sensor must send 21 signals output signal If the speed sensor system fails no signal 24 Speed Sensor to the ECU at the one wiring short or open the speedometer shows rotation of the output 0 driven bevel gear If the vehicle down sensor system has failures Vehicle down Sensor Vehicle down the output voltage Vd is more than usable 31 Output Voltage v Sensor Vd 02 46 V range wiring open the ECU shuts off the fuel pump When the relay ON Fuel Pump M 46 Relay condition batt
131. kgf m 18 ft Ib e Apply engine oil to the journal A and teeth B e Insert the shim C and pinion gear unit D in the front final gear case right cover E e Apply a non permanent locking agent to the pinion gear bearing holder A but do not apply a non permanent lock ing agent to one pitch B from the tip e Install the pinion gear bearing holder so that the no coat ing side C faces the bearing e Tighten Torque Pinion Gear Bearing Holder 250 N m 25 5 kgf m 184 ft lb e Install Dowel Pins A Steel Balls B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 49 Front Final Gear Case e Install Cam Lever A Needle Bearing B e Apply engine oil to the needle bearing e Check the wear of the disc assembly as follows OMeasure the width A of the disc assembly B at three locations and calculate average for three points NOTE OBe careful not to damage the facing surface C on the outer plates e Select the inner disc in accordance with the width of the disc assembly refer to the below table Thickness of Inner Disc A Part Number Width of Disc Assembly 16 7 17 3 mm 0 6675 0 6811 in 17 31 17 9 mm 0 6815 0 7047 in 17 91 18 5 mm 0 7051 0 7283 in 2 4 mm 0 0945 in 41080 1501 1 8 mm 0 0709 in 41080 1500 1 2 mm 0 0472 in 4108
132. legs 57001 1712 A and plate B on the crankcase C Special Tools Drive Pulley Measurement Tool 57001 1498 Leg 57001 1712 OMeasure the length D between the plate and collar E with vernier calipers F or a depth gauge Measurement Length D Standard 14 55 15 65 mm 0 573 0 616 in x f the measurement is not within the specified range ad just it according to following table Status Quo Replacement Part Measurement Paint Color Replace Part Paint Color Length of Cover Part Number of Cover Pulley Cover 14041 0037 No Paint toss Pulley Cover 14 55 mm No Paint 14041 0035 Red 0 573 in Drive Pulley Assembly 49093 0029 Red Drive Pulley Assembly Blug 49093 0029 mers nan Pulley Cover 15 65 mm No Paint 14041 0036 Blue 0 616 in ane ulley Cover Red 14041 0037 No Paint Drive Pulley Covers Part Number Paint Color A Length B 14041 0035 Red 240mm 0 945 in 14041 0036 25 4 mm 1 000 in 14041 0037 24 7 mm 0 972 in e Measure the length again after the drive pulley cover is replaces x lf the length is not within the specified length replace the drive pulley assembly HS06010BS2 C IF06039BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 22 CONVERTER SYSTEM Driven
133. light LED A should go on x lf the LED light does not go on replace the meter unit Check 12 Oil Pressure Warning Light Check e Connect the wires in the same manner as Check 1 e Connect terminal 11 to the battery terminal OThe oil pressure warning light EED A should flash x If the LED light does not flash replace the meter unit Check 13 FI Indicator Light Check e Connect the wires in the same manner as Check 1 e Connect terminal 14 R Y to the battery terminal 1019029BS1 C 777 1819045881 C 1019030BS1 C 75 tiens 1019046BS1 C 1919031851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 65 Meter OThe Fl indicator symbol LCD A should go on for 3 sec onds and flash after that x lf the symbol does not flash replace the meter unit Qema EN 1019047BS1 C Check 14 Parking Brake Indicator Symbol Check e Connect the wires in the same manner as Check 1 e Connect terminal 13 to the battery terminal 1019032BS1 C OThe parking brake indicator symbol P LCD A should appear x If the symbol does not appear replace the meter unit 1019048BS1 C Check 15 Meter Illumination Check e Connect the wires in the same manner as
134. m 115 in Ib Olnstall the cover clamp screws F as shown in the figure e Replace the exhaust pipe gaskets G with new ones Install New Exhaust Pipe Gaskets Front Exhaust Pipe H and Exhaust Pipe Nuts lightly Rear Exhaust Pipe I and Exhaust Pipe Nuts lightly e Replace and muffler gasket with new ones e Install the new muffler gasket J collar K and clamp L to the front side inlet pipe of the muffler as follows Olnstall the new muffler gasket more deeply than the first wide ditch M of the inlet pipe and contact the clamp claws N to the bottom O of the ditch e Install the new muffler gasket P collar K and clamp Q to the rear side inlet pipe of the muffler as follows Olnstall the new muffler gasket to the bottom of the inlet pipe OThe distance between the inlet pipe end and gasket end is 8 0 5 mm 0 31 0 02 in Olnstall the collar more deeply than the firstwwide ditch S of the rear side inlet pipe and contact the clamp claws T to the bottoms U of the ditch e Install the muffler to the exhaust pipes e Install the muffler bracket V to the bracket W of the frame side e Install Washer and Muffler Mounting Bolts X lightly e Tighten Torque Exhaust Pipe Nuts Y 17 1 7 kgf m 13 ft Ib e Push the mufflerto front and then confirm that the gasket entered into the muffler e Tighten the muffler clamp bolts Z in the direction of the figure Torque Muffle
135. mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x lf the bearing is noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x f there is any doubt as to the condition of a needle bear 6114010151 ing replace it Oil Seal Inspection e Inspect the oil seals Replace it if the lips misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY WHEELS TIRES 10 1 Wheels Tires Table of Contents Explodeu VI BW sociae tton cupiditate lta m nde topi SDSGITOSTOTS iio bees NEUE d I dene jM pe Ht HE E Wheel Alignment m m Toe in WIS DS CHOU nM E quim
136. mm 1 5742 1 57449 O 39 993 40 000 mm 1 57452 1 5748 Crankpin Diameter Mark B O mark or no mark e Measure the connection rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the big end nuts to the specified torque Torque Connecting Rod Big End Cap Nuts 34 3 N m 3 5 kgf m 25 16 NOTE O The mark already on the big end should almost coincide with the measurement because of little wear Connecting Rod Big End Inside Diameter Marks None 43 000 43 008 mm 1 6929 1 69322 in O 43 009 43 016 mm 1 69326 1 6935 in Diameter Mark A or no mark e Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Big End Bearing Insert Selection Con rod Big Bearing Insert Crankpin isse Diameter Mark i Diameter Mark Size Color Part Number None Brown 92028 1963 None Yellow 92028 1962 92028 1961 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 105021881 HIOS002BS1 6105041781 DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 17 Crankshaft Connection Rod Cran
137. negative terminal to terminal 11 see Check 12 The hour meter cannot be reset DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 60 ELECTRICAL SYSTEM Meter Check 2 MODE and TIME SET Buttons Operation Check e Connect the wires in the same manner as Check 1 e Check that when the MODE button A is pushed and held continuously the display B cycles through the three modes ODO TRIP A TRIP B gt Hour ODO x lf the display function does not work replace the meter unit e Cycle the meter to TRIP A or TRIP B mode e Check that when the SET RESET button A is pushed the display turns to 0 0 x lf the display function does not indicate 0 0 B replace the meter unit e Check that when the TIME SET A and SET RESET B buttons are pushed the time C will reset x If the meter function does not work replace the meter unit e Indicate the ODO mode e Check that the display A change to the mile and km dis play each time by pushing the SET RESET B bottom while MODE C bottom pushed in NOTE OMile Km Display can alternate between English and metric modes mile and km in the digital meter Make sure that km or mile according to local regulations is correctly displayed before riding x If the display function does not work and adjust replace the meter unit f
138. power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation x If the input voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation Ignition Coil Circuit i 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 gt SON 24 ea ta e G W ICis06i1BW3 C 1 ECU Electronic Control Unit 7 Spark Plug Front 2 Engine Ground 8 Frame Ground 1 3 Battery 9 Fuse Box 4 Ignition Coil 42 Rear 10 Main Fuse 30 A 5 Ignition Coil 1 Front 11 Ignition Switch 6 Spark Plug Rear DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 63 Fuel Injectors Fuel Injector Removal e Remove Air Cleaner Duct see Air Cleaner Housing and Duct Re moval Fuel Hose Joint A see Fuel Hose Replacement Front Delivery Pipe Mounting Screws B e Remove the front fuel injector C from the throttle body e Disconnect the fuel injector connector A e Remove the front fuel injector B from the delivery pipe C e Remove Rear Delivery Pipe Mounting Screws A Rear Fuel Injector
139. resulting in serious injury or death Do not operate the vehicle until any water or soap solution applied to the bead has com pletely dried Tire Inspection e Refer to the Tire Inspection in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 10 12 WHEELS TIRES Front Hub Front Hub Removal e Remove Cap A Cotter Pin B e Loosen the axle nut C while applying the brake e Remove the front wheel see Wheel Removal e Remove the caliper by taking off the mounting bolts A and let the caliper B hang free e Remove Axle Nut A and Washer B Front Hub C with Brake Disc x If the front hub seems too difficult to remove use the fol lowing special tools OMount the brake drum remover A on the hub bolt with the remover nuts B and washers C parts in the remover set Special Tools Brake Drum Remover 57001 1260 Brake Drum Remover Nut 57001 1326 OTighten the rotor puller D and remove the front hub Special Tool Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 e Separate the brake disc from the front hub see Disc Re moval in the Brakes chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Front Hub Front Hub Installation e Install Brake Disc see Disc Insta
140. ring B Push Rod End C e Install Spring D as shown in the figure Piston E New Cup and O ring New Circlip F Special Tool Inside Circlip Pliers 57001 143 e Install New O ring Push Rod New Boot H ODo not apply oil or grease to the seal part I of the boot b Ow 00 E es EE EE AY MON 18 7 zu e Install the rear master cylinder see Rear Brake Master Cylinder Installation in the Brakes chapter 1514006892 C Brake Hose and Pipe Inspection e The high pressure inside the brake line can cause fluid to leak A orthe hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it x Replace it if any cracks B or bulges C are noticed e The metal pipe will rust if the plating is damaged x Replace the pipe if it is rusted cracked especially check the fittings or if the plating is badly scratched DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 1 14000BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Brake Hose Replacement e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Lift and hold the front fender rear see Front Fender Rear Removal in the Frame chapter e Drain the brake fluid e Remove Front Wheels see Wheel Removal in the Wh
141. screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Locking Agent For applications that require Liquid Gasket or a Non Permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent Do not apply them excessively Exces sive application can clog oil passages and cause serious damage 2 19 ad a A 4 UA Cy A oo r d E Q KX ee 7 LJ y T a WS J ARN t E 1020138 5 a 1 Ay Su AK Y EX T gt AA 060720148 5
142. see Drive Pulley Removal in the Converter System chapter Plate Bolts A Plate B Remove Oil Pipe Bolt A Oil Pipe B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 7 14 ENGINE LUBRICATION SYSTEM Cil Pipe Engine Inside Oil Pipe e Remove Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Oil Pipe A Oil Pipe Installation e Replace the O rings A with new ones if they are dam aged e Apply engine oil to the O rings before installation e Tighten Torque Oil Pipe Bolts 8 8 0 90 kgf m 78 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents 8 2 Engine Hemoval InstallatiOn 8 4 Engine 8 4 Engine Installation 8 6 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 8 2 ENGINE REMOVAL INSTALLATION Exploded View QNS MR 7 7 A J E y k M e X ANS AU
143. shaft mounting bolts A e Adjust the steering wheel position e Tighten Torque Main Shaft Mounting Bolts 41 5 N m 4 2 kgf m 31 ft lb Steering Wheel Free Play Inspection e Refer to Steering Wheel Free Play Inspection in the Peri odic Maintenance chapter Steering Wheel Centering e Test ride the vehicle x If the steering wheel is not straight when the vehicle is traveling in a straight line do the following e Check the tie rod length and adjust it if necessary see Toe in Adjustment in the Wheels Tires chapter e Remove Wheel Cap A e Loosen the steering wheel mounting nut A e Push the vehicle in a straight line with no one aboard and stop it without turning the steering wheel e Remount the steering wheel so that it is straight ahead e Tighten Torque Steering Wheel Mounting Nut 54 N m 5 5 kgf m 40 ft Ib e Install Wheel Cap Steering Wheel Removal e Remove Wheel Cap A Steering Wheel Mounting Nut B and Spring Washer Steering Wheel C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY STEERING 14 7 Steering Wheel and Main Shaft Assembly Steering Wheel Installation e Install Steering Wheel A Spring Washer B New Steering Wheel Mounting Nut C 1004005BS1 C e Install the steering wheel cap A so that the Kawasaki mark parallel to the line B 1004006BS1 C
144. side of parking brake cable D as follows e Install the following parts in the lever E temporarily Rear End of Parking Brake Cable Washer and Pin Adjuster F e Push the lever toward cable as shown until the lever is stopped without lever return spring Setting Position G e Then tighten the adjuster until the pin touches the lever and return the adjuster 3 5 rotations e Install the return spring to the lever e Check the parking brake for good braking power and when the parking brake released no brake drag 1M09002BS2 C Parking Brake Cable Lubrication Whenever the brake cable is removed lubricate the cable as follows e ubricate the cable with a penetrating aerosol cable lubri cant through the pressure cable luber 6604011451 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 21 Internal Wet Brake Internal Wet Brake Disassembly e Refer to Rear Final Gear Case section in the Final Drive chapter Internal Wet Brake Assembly e Refer to Rear Final Gear Case section in the Final Drive chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 1
145. softened rotted or swollen replace it x lf fluid leakage is noted at the push rod D the cup of the piston should be replaced e Check the boot E for damage x lf it is damaged replace it e Check the piston return springs F for any damage x lf the spring is damaged replace it DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com BRAKES 12 13 1 05001851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 14 BRAKES Calipers Front Brake Caliper Removal e Remove the front wheel see Wheel Removal in the Wheels Tires chapter e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper NOTICE Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Front Brake Caliper Piston Seal and Dust Seal Replacement Front Brake Caliper Installation e Install the caliper and brake hose lower end OReplace the washers that are on each side of hose fitting with new ones e Touch the stopper of the brake hose to the stopper on the caliper Tighten Torque Brake Caliper Mounting Bolts 33 N m 3 4 kgf m 25 ft lb Brake H
146. switch OFF x If the output voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation xIf the output voltage is out of the standard check the wiring for continuity See Water Temperature Sensor Cir cuit x If the wiring is good check the water temperature sensor resistance see Water Temperature Sensor Resistance Inspection DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 52 FUEL SYSTEM Water Temperature Sensor Service Code 14 Water Temperature Sensor Resistance Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded portion are submerged e Suspend an accurate thermometer B with heat sensitive portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con trainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using the hand tester measure the internal resistance of the sensor across the terminal and the body at the tem peratures shown in the table x I
147. the brake hose clasp C to the stopper D e Tighten Torque Brake Hose Banjo Bolts 23 5 2 4 kgf m 17 ft lb e Install Retainer E Brake Pipe F Nipple e Tighten Torque Brake Pipe Nipple 17 5 1 8 kgf m 13 ft Ib e Fill the reservoir with new brake fluid see Brake Fluid Change e Check that the brake line has proper fluid pressure and no fluid leakage e Install the removed parts 1 14005BS1 C Parking Brake Pedal Inspection e Push down the parking brake pedal A until it is stopped OThe vehicle should not roll while parked e Pull the parking release lever B above and return the pedal to its rest position x If the pedal does not work correctly adjust it see Parking Brake Cable Installation in the Brakes chapter 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 adjusted to the specification Front Brake Pad Wear Inspection e Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard 3 9 mm 0 15 in Service Limit 1 mm 0 04 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR
148. the collar A of the engine brake lever assembly B e Wipe off any protruding grease e Install the clamp A in this area B about 30 mm 1 2 in e Tighten the actuator mounting bolts following the tighten ing sequence 1 4 Torque Engine Brake Actuator Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Engine Brake Actuator Cover Bolt 8 8 0 90 kgf m 78 in Ib 1920004851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 68 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Outline The actuator controller has a microprocessor that detects vehicle speed ignition switch and the forward reverse movement of the vehicle in order to control the engine brake actuator Actuator Control System P Wiring Diagram e 8 n o ee 4 16 DC 12V Gmund 10 Ll Ground 4 77 TS lt W er Vacant Terminal Spoed Sensor Puise Sigua j ro 11 Fonwardffivorse 1 Detecting Sensor z oo p Vacant Terminal Vacant Termina 1 controlior Note Tha circled figures indicata tho pin kiyout of the contrer 5 Red Y y c Siam 1 14 v Omn9e 2 Vey A Yellow Vout hem 5 4 GND y E Engine Brake Actuator 3
149. the marks on the tires are at the front side and at the level of the axle height e Ground the front wheels IK04001B 5 e Set the steering wheel straight ahead e At the level of the axle height measure the distance be tween the scribed lines with a measure 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 e Subtract the measurement of the front from the measure ment of the rear to get the toe in Toe in of Front Wheels Standard 20 40 mm 0 79 1 57 in at 1G x lf the toe in is not the specified range go on to the Toe in Adjustment procedure Toe in Adjustment e Loosen the locknuts A on each tie rod and turn the ad justing rods B the same number of turns and the same direction on both sides to achieve the specified toe in 4 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY WHEELS TIRES 10 7 Wheel Alignment NOTE OThe toe in will be near the specified range if the length of the tie rod distance between the dust boot end A of steering gear assembly and the locknut B is 80 mm 3 15 in C on both the left and right tie rods e Tighten Torque Tie rod End Locknuts 44 4 5 kgf m 32 ft lb e Check the toe in again e Test drive the vehicle 1K0400
150. the reservoir runs completely out any time during fluid changing air bleeding must be done since air will have entered the line e Remove the reservoir cap B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the rubber cap from the bleed valve on the rear master cylinder e Connect a clear plastic hose A to the bleed valve run the other end of the hose into a container NOTE OStart with the rear master cylinder and finish with the front left or right caliper e Fill the reservoir with new brake fluid e Change the brake fluid as follows 1 Open bleed valve 2 Pump brake pedal and hold it 3 Close bleed valve 4 Release brake pedal e Repeat the previous step until fresh brake fluid comes out into the plastic hose or the color of the fluid changes e Remove the clear plastic hose e Tighten Torque Rear Master Cylinder Bleed Valve 5 4 0 55 kgf m 48 in Ib e Install the rubber cap on the bleed valve e Repeat the previous step for front calipers A e After changing the fluid tighten the caliper bleed valves Torque Caliper Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e When brake fluid changing is finished add the fluid to the upper level in the reservoir e Tighten Torque Front Master Cylinder Reservo
151. the trip meter A or B CN E e Raise the input frequency of the oscillator to see the result is 20 of this inspection x lf the value indicated by the trip meter A or B does not increase replace the meter unit NOTE O The integrated value of the odometer cannot be reset Check 6 Belt Check Indicator Light Check e Connect the wires in the same manner as Check 1 e Connect terminal 2 to the battery terminal 1019024BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 62 ELECTRICAL SYSTEM Meter OThe belt check indicator light LED A should go on x lf the LED light does not go on replace the meter unit e Connect the wires in the same manner as Check 1 e Connect terminal 3 to the battery terminal 1019025BS1 C OThe water temperature warning symbol LCD A should flash x lf the symbol does not flash replace the meter unit ZWD ure 1919040851 C Check 7 Water Temperature Warning Symbol Check Check 8 2WD AWD Indicator Symbols Check e Connect the wires in the same manner as Check 1 OThe 2WD indicator Symbol LCD A should appear 1S 19019041851 C e Connect terminal 4 to the battery terminal 1019026BS1 C DOCUMENT AVAILABLE FOR MILITARY USE
152. then the positive cable B NOTICE Be sure to disconnect the negative cable first US Model C CA Model D e Remove Battery Holder Mounting Nuts E Battery Holder F Battery G Battery Installation For US Model e Check that the damper A on the plate B is properly in place DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Battery e Check that the damper A on the battery holder B is properly in place e Check that the dampers A on the battery B are properly in place e Install Battery A Collars B Battery Holder C e Tighten Torque Battery Holder Mounting Bolts D 16 1 6 kgf m 12 ft Ib e Connect the positive cable first and then negative cable Positive Terminal E e Do not run the positive cable between the left cover and collar see Cable Wire and Hose Routing in the Ap pendix chapter e Put a light coat of grease on the terminals to prevent cor rosion e Install the terminal cap on the positive terminal For CA Model e Check that the dampers A on the plate B and bracket C are properly in place ELECTRICAL SYSTEM 16 19 1908019851 C 1908023851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY
153. trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Inspect see chapter 3 Fuel pressure regulator trouble Fuel line clogged Poor acceleration Fuel pressure too low Water or foreign matter in fuel Fuel filter or pump screen clogged Fuel pump trouble Fuel injector trouble Throttle sensor trouble Inlet air pressure sensor trouble Water temperature sensor trouble Inspect fuel pressure and replace fuel pump see chapter 3 Inspect and repair see chapter 3 Inspect see chapter 3 Change fuel Inspect and clean fuel system see chapter 3 Replace fuel pump see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Ignition coil trouble Inspect see chapter 16 Stumble Fuel pressure too low Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Throttle sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble KS J SS Inspect see chapter 3 Surge
154. vehicle so that it is level both side to side and front to rear e Place an oil pan beneath the front final gear case and remove the oil drain plug A A WARNING Oil on tires can cause loss of traction and an ac cident resulting in serious injury or death When draining or filling the final gear case do not spill oil the tire or rim Clean any oil that may spill with a high flash point solvent e After the oil has completely drained out install the oil drain plug with a new O ring OApply grease to the O ring e Tighten Torque Front Final Gear Case Oil Drain Plug 15 N m 1 5 AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Fill the gear case up to the bottom of filler opening with s SAE 208 50 gt the oil specified below SAE 208 40 Front Final Gear Case Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 0 7 L 0 74 US qt 20 10 0 10 20 30 40 C 4 14 32 50 68 86 104 NOTE liuosop2B81 ODepending on the atmospheric temperature of your rid ing area the engine oil viscosity should be changed ac cording to the chart e Be sure the O ring A is in place and tighten the filler cap B OApply grease to the O ring Torque Fr
155. within certain rpm limits Disas sembly assembly and servicing procedures of the pulley assemblies must be followed closely Modi fications to the engine or pulleys that increase rpm may cause failure Torque Converter Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Right Frame Pipe see Right Frame Pipe Removal in the Frame chapter Band A cut Air Outlet Duct B e Remove Actuator Lead Connector A Torque Converter Cover Bolts B Clamp C Torque Converter Cover D Torque Converter Cover Installation e Check the actuator lever assembly installation length see Torque Converter Cover Assembly e Fit the trim seal A into the converter cover 1 04020851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 10 CONVERTER SYSTEM Torque Converter Cover e Tighten the two cover bolts following the tightening se quence 1 2 and tighten the other bolts A in arbitrary order B Clamp Torque Converter Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the clamp C in this area D about 30 mm 1 2 1 04029852 C e Install the rubber duct A to the converter cover B OFit the projection C of the converter cover into the slit of the rubber duct ODo not run up D the rubber duct onto the converter cover e Install t
156. worn or carbon accumulation on the seating surface Compression release KACR cam sticks open Engine stalls when moving off Other Engine oil viscosity too high Brake dragging ECU trouble Front or rear final gear case oil viscosity too DOCUMENT AVAILABLE FOR MillgPARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 3 Troubleshooting Guide Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect Crankshaft sensor trouble ECU trouble Ignition coil trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Water or foreign matter in fuel Throttle body holder loose Air cleaner duct loose Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston rings bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Knocking Carbon built up in combustion chamber Fuel
157. www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 7 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 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 2 6 L 2 7 US qt when engine is completely dry Oil Pressure Measurement Oil Pressure 515 kPa 5 3 kgf cm 74 7 psi at 4 000 r min rpm Oil Temperature 120 C 248 F DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart Ys y V d Ks 22 NS 2 M N 4 KS TA SA z N N N UN T NN YS 1608001884 C 1 Front Camshaft 2 Filter 3 Crankshaft 4 Oil Pressure Switch 5 Oil Pipes 6 Oil Pump 7 Relief Valve 8 Transmission Idle Shaft 9 Oil Screen 10 Transmission Driven Shaft 11 Rear Camshaft 12 Breather Hose 13 To Air Cleaner DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 7 6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Liquid Gasket TB1211 57001 164 56019 120 7570164ST C 875601205
158. 0 0008 0 0023 in 17 966 17 984 mm 0 7073 0 7080 in 21 959 21 980 mm 0 8645 0 8654 in 18 000 18 018 mm 0 7087 0 7094 22 000 22 018 mm 0 8661 0 8668 35 26 mm 1 388 in 35 52 mm 1 398 0 14 0 0055 in 0 15 mm 0 0059 in 17 94 mm 0 706 in 21 93 mm 0 863 in 18 08 mm 0 712 in 22 08 mm 0 869 in TIR 0 02 mm 0 0008 in orless TIR 0 1 mm 0 0039 in 760 30 r min rpm 251 456 kPa 2 56 4 65 kgf cm 36 66 psi 9380 r min rpm Cylinder head warp 0 05 0 002 Valve Valve Clearance Exhaust 0 20 0 25 mm 0 0079 0 0098 Inlet 0 10 0 15 mm Valve Head Thickness Exhaust Inlet Valve Stem Bend 0 0039 0 0059 in 0 8 mm 0 031 in 0 5 mm 0 020 in 0 4 mm 0 016 in 0 3 mm 0 012 in TIR 0 01 mm 0 0004 in orless TIR 0 05 mm 0 002 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 10 ENGINE TOP END Specifications Item Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve Valve Guide Clearance Wobble Method Exhaust Inlet Valve Seat Cutting Angle Valve Seating Surface Outside Diameter Exhaust Inlet Width Exhaust Inlet Valve Spring Free Length Exhaust Inlet Cylinder Piston Cylinder Inside D
159. 0 1499 x f the width is within the specified range install the inner disc and disc assembly x lf the width is not within the specified range replace the disc assembly e Install Inner Disc A HK11002081 HK11006BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 50 FINAL DRIVE Front Final Gear Case e Install Disc Assembly A e Install Housing A e Apply engine oil to the needle bearing A e Install Needle Bearing e Install Outer Disc A New Gasket B gine oil to the differential control shift shaft A spring B as shown in the figure DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 51 Front Final Gear Case e Install the shaft A and spring in the front final gear case as shown in the figure Olnsert the spring end into the slit B and insert the tab of the shift shaft into the groove C of the cam plate e Install Front Final Gear Case Left Cover A OTo fix the cover turn the shaft B counterclockwise e Tighten Torque Front Final Gear Case Left Cover Bolts M6 A 8 8 N m 0 90 kgf m 78 in Ib L 2 35 mm 1 4 in e Apply grease to t
160. 0 2 0 15 S L 1 6 Crankcase Bolts M6 L 40 mm 1 57 in 9 8 1 0 87 in lb 7 Bolts M6 L 65 mm 2 56 in 9 8 1 0 87 in lb 8 Bearing Position Plate Screws 4 9 0 50 43 in lb L 20 10 11 12 13 14 15 Apply grease Apply a non permanent locking agent LG Apply molybdenum disulfide grease MO About 12 mm 0 47 in Do not apply a non permanent locking agent to this area 2 3 mm 0 08 0 12 in Face the seal of the bearing to the left side outward White Mark Align the white mark with the crankcase mark Left Crankcase Right Crankcase Apply engine oil Apply liquid gasket Liquid Gasket TB1216 92104 1063 Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 Replacement Parts Follow the specific tightening sequence DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 4 CRANKSHAFT TRANSMISSION Exploded View 1T020058BW5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 5 Exploded View No Fastener Remarks kgf m ft Ib 1 Grip Hold Nut 9 8 1 0 87 in lb 2 Tie rod End Locknut 19 6 2 0 14 Shift Lever Assembly Nut
161. 1104029851 C e Press the following parts in the left cover A until they are bottomed Ball Bearing B Oil Seal C e Press the oil seal D so that the surface is flush with the end of the hole e Apply grease to the oil seal lips E e Press the fitting pipe A in the left cover B as shown in the figure 14 mm 0 55 in C FN 11040318581 C e Visually check the pinion gear and ring gear for scoring chipping or other damage Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact e Refer to the gear backlash and tooth contact pattern see Front Final Bevel Gear Adjustment e Apply engine oil to the teeth of the ring gear e Install Shim s A both sides Ring Gear Assembly B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 48 FINAL DRIVE Front Final Gear Case e Apply grease to the O ring A on the front final gear case center cover e Install Front Final Gear Case Center Cover A e Apply a non permanent locking agent Front Final Gear Case Center Cover Bolts M10 B Front Final Gear Case Center Cover Bolts M8 C e Tighten Torque Front Final Gear Case Center Cover Bolts M10 49 N m 5 0 kgf m 36 ft lb gt Front Final Gear Case Center Cover Bolts 8 24 2 4
162. 12 V 12 Ah Semi sealed beam 12V 35 35 W 2 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 1 14 GENERAL INFORMATION General Specifications KRF750NAF NBF PAF PBF RAF RBF SAF nems SBF TAF VBF Brake Tail Light 12 V 27 8 W x 2 Alternator Type Three phase AC Max Output 28 A 14 V Load Capacity Maximum Vehicle Load Including Occupants and 422 kg 931 Ib Cargo Maximum Cargo Bed Load 227 kg 500 Ib Specifications subject to change without notice and may not apply to every country DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY GENERAL INFORMATION 1 15 Unit Conversion Table Prefixes for Units Units of Length km x 0 6214 mile Symbol Power m x 3 281 ft mega M x 1 000 000 mm x 0 03937 in kilo k x 1000 centi C x 0 01 milli m x 0 001 Units of Torque micro u x 0 000001 N m x 0 1020 kgf m N m x 0 7376 16 N m x 8 851 in Ib 9 807 Units of Mass kgf m x 7 233 ft lb kg x 2 205 Ib 86 80 in Ib g x 0 08527 OZ Units of Pressure Units of Volume kPa x 0 01020 kgf cm L x 0 2642 05 0 1450 L x 0 2200 gal IMP kPa x 0 7501 cmHg L x 1 057 qt US kgf cm x 98 07 kPa L x 0 8799 qt IMP kgf cm x 14
163. 1216ST C 875713255 Jack Brake Drum Pusher amp Washer 57001 1238 57001 1709 7571238ST C 875717095 6 Brake Drum Remover Brake Drum Pusher 57001 1260 57001 1714 T571260ST 875717145 6 Brake Drum Holder 57001 1325 7571325ST C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 10 6 WHEELS TIRES Wheel Alignment Toe in is the difference between the distance of front and the one of rear atthe axle height position in the front wheels When there is toe in the distance A Rear is the 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 slip ping or scuffing action between the tires and the ground If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are build in and require no adjust 040008 5 ment A Rear B Front Amount of Toe in Distance A and B are measured at axle height with the vehicle sitting on the ground or at 1G Toe in Inspection 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
164. 19 6 2 0 14 R 4 Tie rod End Bolt 9 8 1 0 87 in lb 5 Tie rod End Front Locknut 9 8 1 0 87 in lb Lh 6 Tie rod End Rear Locknut 9 8 1 0 87 in lb Tie rod End Nut 19 6 2 0 8 Shift Shaft Lever Bolt 13 5 1 4 14 Do not apply a non permanent locking agent to this end EO Apply engine oil G Apply grease L Apply a non permanent locking agent LB Apply a non permanent locking agent Three 2471 Blue Lh Left hand Threads M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist 0 2 100 0 008 3 94 Connecting Rod Big End Side Clearance 0 16 0 46 mm 0 7 mm 0 0063 0 0181 in 0 028 in Connecting Rod Big End Bearing Insert Crankpin 0 028 0 052 mm 0 09 mm Clearance 0 0011 0 0020 in 0 0035 in Crankpin Diameter 39 984 40 000 mm 39 97 mm 1 5742 1 5748 in 1 5736 in Marking None 39 984 39 992 mm 1 5742 1 57449 in O 39 993 40 000 mm 1 57452 1 5748 in Connecting Rod Big End Inside Diamete
165. 200 N m 20 4 kgf m 148 ft lb e Apply grease to the oil seal and press it so that it is flush with the end surface of the housing Output Bevel Gears Adjustment backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged When replacing any one of the backlash related parts be sure to check and adjust the backlash and tooth contact First adjust the backlash and then tooth contact by replac ing shims These two adjustments are of critical importance and must be carried out in the correct sequence using the procedures shown MOMS Output Bevel Gear Adjustment Procedure Adjust gear backlash Adjust tooth contact pattern Assemble the output bevel gear completely HK16005BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 20 FINAL DRIVE Output Bevel Gears Output Bevel Gear Backlash related Parts HK08008BW3 C 1 Ball Bearings 4 Bearing Housings 6 Output Driven Shaft 2 Drive Bevel Gear Shims 5 Output Driven Bevel Gear 7 Driven Bevel Gear Shims 3 Output Drive Bevel Gear Drive Bevel Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1311 0 2 mm 0 008 in 92180 1312 0 5 mm 0 020 in 92180 1313 0 8 mm 0 031 in 92180 1314 1 0 mm 0 0
166. 297 6 875716055 C Oil Filter Wrench Belt Deflection Gauge 57001 1249 57001 1713 7571249ST C 8 5717135 6 Filler Cap Driver 57001 1454 7571454ST C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Pedal Free Play Inspection e Check that the throttle pedal moves smoothly from full open to close x If the throttle pedal does not return properly lubricate the throttle cable see Throttle Cable Lubrication in the Fuel System chapter e Check the throttle pedal play A Throttle Pedal Play Standard 5 10 mm 0 20 0 39 in x If the play is incorrect adjust the throttle cable Throttle Pedal Free Play Adjustment e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Throttle Link Case Cover e Loosen the locknut A and turn the adjusting nut B on the throttle cable until the cable has proper amount of play e Tighten the locknut securely after adjustment e Install Throttle Link Case Cover Engine Upper Cover see Engine Upper Cover Installa tion in the Frame chapter x lf the free play cannot be adjusted by using the rear cable adjusting nut use the cable adjusting nuts A at front of the floorboard and make the necessary free play OMove the rubber seat B e Start the
167. 2BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 10 8 WHEELS TIRES Wheels Rims Wheel Removal e Loosen the wheel nuts A e Lift the wheels off the ground Special Tool Jack 57001 1238 e Remove Wheel Nuts Wheel Figure is the aluminium wheel KRF750S Model Wheel Installation e Check the tire rotation mark A on the tire and install the tire on the rim accordingly NOTE O The direction of the tire rotation B is Shown by an arrow on the tire sidewall e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Bolt Threads Portion A Wheel Nut Threads Portion B e Position the wheel so that the air valve A is toward the outside of the vehicle e Tighten the wheel nuts in a criss cross pattern Torque Wheel Nuts 110 N m 11 2 81 ft lb Figure is the aluminium wheel KRF750S Model Wheel Rim Inspection e Examine both sides of the rim for dents A If the rim is dented replace it HJ05035BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY WHEELS TIRES 10 9 Wheels Rims x If the tire is removed inspect the air sealing surfaces A of the rim for scratches or nicks Smooth the sealing sur faces with fine emery cloth
168. 3 seconds ORepeat this operation several times e Turn the ignition switch OFF x lf the fuel flow is much less than the specified replace the fuel pump see Fuel Pump Removal Installation e After inspection connect the fuel hose see Fuel Hose Replacement e Start the engine and check for fuel leakage DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 76 FUEL SYSTEM Fuel Pump Fuel Pump Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it e Remove Right Seat see Seat Removal in the Frame chapter Fuel Hose A see Fuel Hose Replacement Connector B e Remove Fuel Pump Mounting Bolts A Plate B Fuel Pump C O ring Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air DOCUMENT
169. 39 in 92180 1351 1 2 mm 0 047 in 92180 1352 Driven Bevel Gear Shims for Backlash Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1307 0 2 mm 0 008 in 92180 1308 0 5 mm 0 020 in 92180 1309 0 8 mm 0 031 in 92180 1310 1 0 mm 0 039 in 92180 1349 1 2 mm 0 047 in 92180 1350 UMENT AVAIEABEE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 21 Output Bevel Gears Bevel Gear Backlash Adjustment OThe amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position e Remove the output drive idle gear see Output Drive Bevel Gear Removal e Set up a dial gauge A against the output drive shaft spline groove to check gear backlash OTo measure the backlash turn the shaft clockwise and counterclockwise slightly so as not to move the mate gear The difference between the highest and lowest gauge reading is the amount of backlash x lf the backlash is not within the limit replace the shim s at the driven bevel gear Change the thickness little at a time e Recheck the backlash and readjust as necessary Output Bevel Gear Backlash Standard 0 05 0 11 mm 0 002 0 004 in at output drive shaft spline Tooth Contact Adjustment OTooth contact location is influenced by drive gear position more than by driven gear position e Clean any dirt and oil
170. 474 in Rocker Shaft Diameter Measurement e Measure the diameter A of the rocker shaft where the rocker arm pivots on it with a micrometer xf the rocker shaft diameter is smaller than the service limit replace it Also check the rocker arm inside diameter see Rocker Arm Inspection Rocker Shaft Diameter Standard 11 983 11 994 mm 0 4718 0 4722 in Service Limit 11 96 mm 0 471 in ENGINE TOP END 5 19 HE10011BS2 C 100017 P DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 20 ENGINE TOP END Camshaft Camshaft Removal e Remove Camshaft Chain Tensioners see Camshaft Chain Ten sioner Removal Rocker Cases see Rocker Case Removal Camshafts A e Support the chain using a suitable tool Camshaft Installation e Using a wrench on the alternator bolt turn the crankshaft clockwise until mark A is aligned with the notch B in the inspection window HE10002BS1 C e The rear camshaft A has a groove B e First install the rear camshaft e Face the arrow A of the rear camshaft sprocket upward left side view e Engage the rear camshaft chain with the rear camshaft sprocket e Align the marks B on the weights with the rear cylinder head upper surface e Using wrench on the alternator bolt turn the crankshaft clockwise 270
171. 57001 1394 Needle Adapter Set 57001 1457 Connections Meter W R lead Meter gt Battery terminal e Measure the power source voltage with the engine stopped e Turn the ignition switch ON Fuel Injector Power Source Voltage Standard Battery Voltage for 3 seconds and then 0 V e Tum the ignition switen RIENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 66 FUEL SYSTEM Fuel Injectors xIf the reading stays on battery voltage and never shows 0 V check the fuel pump relay see Relay Inspection in the Electrical System chapter xIf the fuel pump relay is normal check the ECU for its ground and power supply see ECU Power Supply In spection x lf the ground and power supply are good replace the ECU see ECU Removal Installation x If there is still no battery voltage check the fuel pump relay see Relay Inspection in the Electrical System chapter x If the fuel pump relay is normal check the power source wiring see Fuel Injector Circuit xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is in specification check the output voltage see Fuel Injector Output Voltage Inspection Fuel Injector Output Voltage Inspection NOTE OBe sur
172. 6 Frame Clamp DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 13 Cable Wire and Hose Routing Py S NA AE Mir IGA EN y eut er pL li 7 DES all H 6 7 n 1808222884 C 1 Fan Motor Lead Connector 2 Band 3 Fan Motor Breather Hose 4 Front Gear Case Breather Hose 5 Reserve Tank Hose 6 Reserve Tank Overflow Hose 7 Bands 8 Clamps 9 Frame Clamp 10 Run the radiator fan motor lead between the bracket and the radiator hose 11 to Radiator DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 14 APPENDIX Cable Wire and Hose Routing h qe SA ORAN les d NY 1808223894 C 1 Clamp Of Insert the breather hose to outside lower fitting Band Install the band so that the position is about middle the area C and it must avoid the damper of the cargo bed Rear Gear Case Breather Hose Damper of Cargo Bed Direction of Breather Hose Installation to Gear Case 10 Frame View A View B
173. 7001 144 e Slide the cage B on the inner race and install the steel balls C HKI28044 P DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 32 FINAL DRIVE Front Axle e Apply the special grease A to the steel balls and cage e Squeeze about half a tube of the special grease A into the bearing cup B Bo 11078101 P e Install the bearing cup A onto the balls and cage assem bly e Install the new retaining ring A so that the opening B is aligned with one of the projections C HK10004BS1 C e Squeeze the remaining special grease A into the bearing cup B and inboard joint boot C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 33 Front Axle e Pinch the small boot band A with a suitable tool B to install it Recommend Tool OETIKER 192 e Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot e Hold the axle at this setting Standard Length of Assembling Front Axle 162 2 mm 6 39 in A e Open the edge A of the boot in order to the air pressures e Pinch the boot band A with a suitable tool B to install it Recommend Tool 192 e Be sure the out
174. 8 V or over than DC 4 8 V at Ignition Switch ON and 0 km h Magnetic flux detection method more than 55 75 for each bank DC 4 75 5 25 V with sensor arrow mark pointed up DC 0 4 1 4 V with sensor tilted 55 75 or more DC 3 7 4 4 V Q N AQ ABLE MI RB gt Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 16 FUEL SYSTEM DFI Specifications Item Standard Engine Vacuum 29 6 1 3 kPa 222 9 8 mmHg at Idle Speed Throttle Pedal and Cable Throttle Pedal Free Play Air Cleaner Air Cleaner Element Oil 5 10 mm 0 20 0 39 in High quality foam air filter oil DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 17 Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 875701255 C Jack 57001 1238 7571238ST C Pilot Screw Adjuster A 57001 1239 815712395 Fork Oil Level Gauge 57001 1290 7571290ST C Vacuum Gauge 57001 1369 225 222 875713695 C Hand Tester 57001 1394 875713945 Needle Adapter Set 57001 1457 T571457ST C Sensor Harness Adapter 57001 1561 875715615 6 Fuel Pressure Gauge Adapter 57001 1593 875715935 Fuel Hose 57001 1607 7571607ST C DOCUMENT AVAI
175. 94 in Service Limit 38 12 mm 1 501 in M 000013 P x lf the spider shoes A are damaged replace them e Check the spider shoe side clearance see Spider i Side Clearance Inspection x If the ramp weights A in the movable sheave are dam aged or worn replace them If the pins B are damaged or worn replace them x If the rollers A are damaged or worn replace the spider B x If the washers C are damaged or worn replace the spi der DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 17 Drive Pulley x If the spring is worn or damaged replace the spring Spring Free Length A Standard 60 0 mm 2 36 in Spider Shoe Side Clearance Inspection Adjust ment e Remove Drive Pulley see Drive Pulley Removal Drive Pulley Cover and Spring see Drive Pulley Disas sembly e Set the drive pulley A without the spring onto the pulley holders see Drive Pulley Disassembly Special Tools Drive amp Driven Pulley Holder 57001 1473 Drive amp Driven Pulley Holder 57001 1412 e Temporarily install the following parts on the movable sheave Dowel Pins 2 Drive Pulley Cover B Two Bolts C at dowel pins ODo not install the spring DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ON
176. A1 or MA2 SAE 10W 40 2 6 2 7 US Belt drive torque converter 3 200 0 721 3 549 30 26 x 29 18 x 21 11 5 536 36 20 x 29 18 x 21 11 4 614 16 12 x 18 16 x 29 18 x 21 11 Shaft 4WD 2WD 4 375 35 8 11 195 17 464 14 553 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY General Specifications GENERAL INFORMATION 1 13 Items KRF750NAF NBF PAF PBF RAF RBF SAF SBF TAF VBF Front Final Gear Case Oil Type Viscosity Capacity Rear Final Gear Case Oil SG SH SJ SL or SM with JASO MA 1 or MA2 SAE 10W 40 0 7 L 0 74 US at Type MOBIL FLUID 424 CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Capacity 1 0 L 1 06 US qt Frame Type Steel tube Ladder Caster Rake Angle Camber Front Rear King Pin Angle Trail Tire Front Type Size Rear Type Size Rim Size Front Rear Steering Type Suspension Front Type Wheel Travel Rear Type Wheel Travel Brake Type Front Rear Parking Brake Type Electrical Equipment Battery Headlight Type Bulb 2 2 0 7 0 49 11 49 11 mm 0 43 in Tubeless 26 x 8 00 12 Tubeless 26 x 10 00 212 12 x 6 0AT 12 x 8 0AT Rack and pinion Double Wishbone 190 mm 7 48 in Double Wishbone 190 mm 7 48 in Disc x 2 Enclosed wet multi plate Enclosed wet multi plate US 12 V 14 Ah CA
177. AILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 8 ENGINE TOP END Exhaust System Exhaust System EXHAUST PIPE Non Catalyst P No 18088 0466 18088 0490 Mark Non MUFFLER BODY SPECIFICATION PIPE Type Catalyst USA P No 18087 0205 Mark Non CANADA DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com MODEL KRF750NAF KRF750PAF KRF750RAF KRF750SAF 5 5 KRF750TAF KRF750VBF KRF750NAF KRF750PAF KRF750RAF KRF750SAF KRF750SAFA 1E110098 F DOCUMENT AVAILABLE FOR MILITARY USE ONLY Specifications ENGINE TOP END 5 9 Item Standard Service Limit Rocker Case Rocker Arm Inside Diameter Rocker Shaft Diameter 12 000 12 018 mm 0 4724 0 4731 in 11 983 11 994 mm 0 4718 0 4722 in 12 05 mm 0 474 in 11 96 mm 0 471 in Camshafts Cam Height Exhaust Inlet Camshaft Bearing Clearance 18 22 Camshaft Journal Diameter 18 22 Camshaft Bearing Inside Diameter 18 22 Camshaft runout KACR Kawasaki Automatic Compression Release KACR Operating Engine Speed Cylinder Head Cylinder Compression Usable Range Electric Starter 35 363 35 477 mm 1 3922 1 3967 in 35 622 35 736 mm 1 4024 1 4069 0 016 0 052 mm 0 0006 0 0020 in 0 020 0 059 mm
178. ARY USE ONLY FRAME 15 29 Fenders e Remove Screw A and Collar Screw Rivets B Rear Fender C Rear Fender Installation e Install Rear Fender A Screw B and Collar C Screw Rivets D Rear Flap Removal e Remove Rear Wheel see Wheel Removal in the Wheels Tires chapter Quick Rivets A Tapping Screws B and Collars Rear Flap C Rear Flap Installation e Install Rear Flap A Tapping Screws B and Collars C e Install Quick Rivets A Rear Wheel see Wheel Installation in the Wheels Tires chapter IP12003BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 30 FRAME Cargo Bed Cargo Bed Removal e Remove Rear Fenders see Rear Fender Removal Tail Brake Light Lead Connectors A e Remove Tail Brake Light Lead Connectors A e Remove the harness B from the clamps e Remove the gas spring dampers A following procedure as follows OLift up the cargo bed Olnsert the standard tip screwdriver B between thexclamp C and recess and pry the clamp OLift up stronger and hold the cargo bed at full position ORemove the gas spring damper from the stud ORepeat the same procedure for other side and remove the gas spring damper e Remove Snap Pins A both sides Cargo Bed Mounting Pins B and Washers C both sides Cargo Bed D Cargo Bed Installa
179. ATIONS A ampere s Ib pounds s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s COUNTRY AND AREA CODES CA Canada US United States 750 FI 4x4 TERYX 750 FI 4x4 LE TERYX 750 FI 4x4 SPORT KRF750N T Models KRF750P R V Models KRF750S Model DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 exhaust emission 2 and evaporative emission 3 control systems in compliance with applicable regulations of the United States Environmental Protection Agency Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of t
180. AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 77 Fuel Pump e Replace the O ring A with a new one e Install the plate A so that the projections B of the fuel tank and fuel pump fit to the hollows of the plate e Tighten the fuel pump bolts to a snug fit tighten them alternating diagonally e Tighten Torque Fuel Pump Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install Fuel Hose see Fuel Hose Replacement Connector e Start the engine and check the fuel hose for leaks Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged OJust listen to the pump sound in the fuel tank to confirm pump operation e Turn the ignition switch ON and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Turn the ignition switch OFF x Ifthe pump does not operate as described above inspect the operating voltage see Fuel Pump Operating Voltage Inspection Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Right Seat see Seat Removal in the Frame chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 78 FUEL SYSTEM Fuel Pump e Disconnect the fuel pump lead connector and
181. Adjustment 13 13 Front Shock Absorber Spring Preload 13 14 Front Shock Absorber Remowval 43 5989 98 13 14 Front Shock Absorber 1 7 7 13 14 Front Shock Absorber Inspection M 13 15 Front Shock Absorber Scrapping e me 13 15 Rear Shock Absorber Rebound Damping Force 13 16 Rear Shock Absorber Compression Damping Force 13 16 Rear Shock Absorber Spring Preload Rear Shock Absorbef Hamovaa gf ren e ict Rr Sacerdos eie dee Pearce ede Rear Shock Absorber Installation Rear Shock cote RE e ep cem Qe censet Rear Shock AbsorbebScrapping 2 2 4040 nnne nnne SuUSpensiori AIMS sins IRE e eU E UAE Front SuspensionArm Rerrov al ucc ee tiere te Pg tie Rae ort ente leta tpa Front Suspension Arm Installatiori Front Suspensi n Arm Disasserbly n oe puce e erre EE Arm
182. Adjustment m Pd ik Setting Load Road Speed iudex RET Light Good Low i 94 44 High 1 4005881 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 14 SUSPENSION Shock Absorbers KRF750S Model Front Shock Absorber Spring Preload Adjustment e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Loosen the locknut A e Turn the adjusting nut B to the desired position Special Tool Hook Wrench R37 5 R42 57001 1539 Adjusting Length C from center of upper mounting bolt to lower surface of adjusting nut OThe standard adjusting nut setting for an average build rider of 68 kg 150 Ib with no passenger and no acces sories is 82 5 mm 3 248 in spring length Spring Preload Setting Standard Adjusting length 8 25 mm 3 248 in Usable Range Adjusting length 75 5 95 5 mm 2 972 3 760 in e Tighten the locknut x If the spring action feels too soft or too stiff adjust it Spring Preload Adjustment eH Damp dm ing Setting Load Road Speed Length Force 75 5 mm 2 972 in Weak Soft Light Good Low 95 5 mm 3 760 Strong Hard Heavy Bad High Front Shock Absorber Removal e Support the vehicle on a stand or a jack so that the front wheels are
183. B Vacuum Hose C e Remove the drain tube D if necessary Throttle Body Assy Assembly e Install the drain tube A if removed e Install the inlet air pressure sensor B e Tighten Torque Inlet Air Pressure Sensor Mounting Screw C 5 0 0 51 kgf m 44 in Ib e Connect the vacuum hose D Engine Vacuum Synchronization Inspection e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter e Check idle speed see Idle Speed Inspection e Remove the plug A and connect the hose B of the vac uum gauge Special Tool Vacuum Gauge 57001 1369 e Remove the vacuum hose A and connect the hose B of the vacuum gauge e Connect the vacuum gauge C e Start the engine and read the intake vacuum when idling x lf the vacuum is out of the specified range check the ISC valve see ISC Valve Inspection lf the ISC valve is good adjust the vacuum see Engine Vacuum Synchronization Adjustment Engine Vacuum Standard 29 6 1 3 kPa 222 9 8 mmHg at Idle Speed DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 87 Throttle Body Assy Engine Vacuum Synchronization Adjustment e Turn in the bypass screws A until it seats fully but not tightly Special Tool Pilot Screw Adjuster A B 57001 1239
184. B e When installing the following parts install them as shown in the figure Guard C Bottom Guard Bolts D Damper E Insulator F 14005 52 C Rear Bottom Guard Removal e Remove Bottom Guard Bolts A and Collars Rear Bottom Guard B Rear Bottom Guard Installation e Install Rear Bottom Guard Bottom Guard Bolts B and Collars C 1IP14004BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 60 FRAME Floorboard Floorboard Removal Left Floorboard e Remove Control Panel see Control Panel Removal Steering Shafts see Steering Shafts Removal in the Steering chapter Seat Lower Cover see Seat Lower Cover Removal Front Brake Master Cylinder see Front Brake Master Cylinder Removal in the Brakes chapter e Remove Parking Brake Cable A Parking Brake Light Switch Lead Connectors B e Remove Throttle Cable A e Remove Brake Light Switch Lead Connectors A Brake Pedal Bracket Mounting Bolts B e Remove Brake Pedal Bracket Mounting Bolts A Brake Pedal Bracket B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 61 Floorboard e Remove Plate Bolts A and Washers e Remove Bracket Bolts A Bracket B and Plate e Remove Tapping Screws A and C
185. BLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 1 Exploded View Specifications Rina Rada Brake Fluid Front Brake Fluid Recommendation Front Brake Fluid Level Front Brake Fluid Change Brake Line Air Bleeding Brake Pedal and Master Cylinder Brake Pedal Play Inspection Brake Pedal Removal Brake Pedal Installation Front Master Cylinder Removal Front Master Cylinder Installation Front Master Cylinder Disassembly Assembly Front Master Cylinder Inspection Rear Master Cylinder Removal Rear Master Cylinder Installation Rear Master Cylinder Disassembly Assembly Rear Master Cylinder Inspection aa Front Brake Caliper Removal Front Brake Caliper Installation Front Brake Caliper Disassembly Front Brake Caliper Assembly Caliper Piston Seal Damage Inspection X 9 Brakes Table of Contents 12 2 12 6 12 7 12 7 Dust Seal and Friction Boot Damage Inspection Front
186. Bolt 8 8 0 90 78 in lb Front Final Gear Case Oil Filler Cap 29 3 0 21 Front Final Gear Case Oil Drain Plug 15 1 5 11 2WD AWD Shift Cable Holder Bolts 8 8 0 90 78 in lb L 2WD AWD Shift Shaft Cover Bolts 8 8 0 90 78 1 1 L 2WD AWD Shift Shaft Lever Nut 20 2 0 15 R Pinion Gear Bearing Holder Nut 200 20 4 148 LB Pinion Gear Bearing Holder 250 25 5 184 LO Coupling Nut 35 3 6 26 R Front Final Gear Case Center Cover Bolts 8 24 2 4 18 L Front Final Gear Case Center Cover Bolts M10 49 5 0 36 L Ring Gear Bolts 57 5 8 42 LB Front Final Gear Case Left Cover Bolts M6 35 mm 8 8 0 90 78 in lb Front Final Gear Case Left Cover Bolts M6 40 mm 8 8 0 90 78 in lb Front Final Gear Case Mounting Nuts 90 5 9 2 67 R Front Final Gear Case Bracket Bolts 90 5 9 2 67 Differential Shift Cable Locknuts 9 8 1 0 87 2WD AWD Shift Gable Locknuts 4 4 0 45 39 in Ib 4WD Position Switch 15 1 5 11 Vacuum Actuator Bracket Bolts 8 8 0 90 78 in lb Solenoid Valve Bracket Bolts 8 8 0 90 78 in lb Vacuum Actuator Mounting Bolts 8 8 0 90 78 Rear Final Gear Case Rear Master Cylinder Mounting Bolts 27 2 8 20 L Rear Master Cylinder Bleed Valve 7 8 0 80 69 in lb Rear Final Gear Case Front Cover Bolts 24 2 4 18 Spring Bracket Bolt 8 8 0 90 78 L Rear Final Gear Case Gasket Screws 1 3 0 13 12 in lb Pinion Gear Bearing Holder 450 45 9 332 L Pinion Gear Bearing Holder Nut 200 20 4 148 LB Rear Final Gear Case Oil Drain Plug 15 1 5 11 Rear Final Gear Case Oil
187. Brake Caliper Piston and Cylinder Damage Inspection Front Brake Caliper Holder Shaft Wear Inspection Brake 5 122 Front Brake Pad Removal Front Brake Pad Installation Front Brake Pad Wear Inspection Brake Discs 2 Front Brake Disc Cleaning Front Brake Disc Removal Front Brake Disc Installation Front Brake Disc Wear Inspection Front Brake Disc Runout MISPCCHON Brake Hoses and Pipes Brake Hose and Pipe Inspection Brake Hose Replacement Parking Brake Pedal and Cables Parking Brake Pedal Inspection Parking Brake Pedal Removal Parking Brake Pedal Installation Parking Brake Cable Removal Parking Brake Cable Installation Parking Brake Cable Lubrication Internal Wet Internal Wet Brake Disassembly Internal Wet Brake Assembly DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 12 16 12 17 12 17 12 17 12 17 12 17 12 17 12 18 12 18 12 18 12 19 12 19 12 19 12 19 12 20 12 20 12 20 12 21 12 21 12 21 12 DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 2 BRAKES Exploded View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY
188. CUMENT AVAILABLE FOR MILITARY USE ONLY 16 74 ELECTRICAL SYSTEM 2WD AWD Solenoid Valve eq P X Jo AND 9 0 BK Y BK Y 2WD jo A BR BR o 1022005BW3 C 2WD 4WD Shift Switch Frame Ground 1 Fuse Box Main Fuse 30 A 2WD 4WD Solenoid Valve ECU Engine Ground Battery Ignition Switch DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 75 Relay Relay Inspection e Remove Left Seat see Seat Removal in the Frame chapter Starter Control Relay A Radiator Fan Relay B Fuel Pump Relay C OThe relays are identical e Connect the hand tester A and a 12 V battery B to the relay C as shown Special Tool Hand Tester 57001 1394 xIf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Criteria When battery is connected gt 0 Q When battery is disconnected gt Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 1923000851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 76 ELECTRICAL SYSTEM Switches and Sensor Brake Light Switch Adjustment e Refer to the Brake Light Switch Inspection
189. Charging Method 1 2 A x 20h NOTE v B the charging voltage to a maximum voltage of d 25 V ifthe battery will not accept current initially Charge PN forno more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current D decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C 8 08011351 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 26 ELECTRICAL SYSTEM Battery e Determine battery condition after refreshing charge ODetermine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below US model Criteria Judgement 12 6 V or higher Good 12 0 12 5 V or lower Charge insufficient Recharge 12 0 V or lower Unserviceable Replace CA model Criteria Judgement 12 8 V or higher Good 12 0 12 7 V or lower Charge insufficient Recharge 12 0 V or lower Unserviceable Replace DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTE
190. Control Shift Shaft Spring e Remove Outer Disc A Needle Bearing e Remove Housing A and Differential Disc Assembly B Inner Disc Needle Bearing DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 46 FINAL DRIVE Front Final Gear Case e Remove Cam Plate A e Remove Steel Balls A Dowel Pins B e Remove Front Final Gear Case Center Cover Bolts M8 A Front Final Gear Case Center Cover Bolts M10 B Front Final Gear Case Center Cover C OUsing the pry points D remove the cover e Remove Ring Gear Assembly A Shim s B Front Final Gear Case Coupling Inspection xIf the coupling bushing A is damaged or worn replace the front final gear case coupling Front Final Gear Case Coupling Bushing Inside Diameter B Standard 20 000 20 021 mm 0 7874 0 7882 in Service Limit 20 051 mm 0 7894 in 1L04027BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 47 Front Final Gear Case Front Final Gear Case Assembly e Press the following parts in the right cover A until they are bottomed Ball Bearing B Needle Bearing C Oil Seal D e Apply grease to the oil seal lips E e Install Circlip F Special Tool Inside Circlip Pliers 57001 143
191. DOCUMENT AVAILABLE FOR MILITARY USE ONLY Radiator Radiator Inspection e Check the radiator core x lf there are obstructions to air flow remove the radiator and remove obstructions the corrugated fins A are deformed carefully straighten them xIf the air passages of the radiator core are blocked more than 2096 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one Radiator Cleaning e Refer to the Radiator Cleaning in the Periodic Mainte nance chapter Radiator Cap Inspection e Check the condition of the top and bottom valve seals of the radiator cap x If any one of them shows visible damage replace the cap Top and Bottom Valve Seals A Valve Spring B e Install the cap A on a cooling system pressure tester B NOTE O Wet the cap sealing surfaces with water or coolant to prevent pressure leakage e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The relief valve opens indicated by the gauge hand flicks downward OThe relief valve mustopen within the relief pressure range in the table below and the gauge hand must remain within the specified range atleast 6 second Radiator Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi x If the cap cannot hold the specified pressure or if it holds too much pressure replace it with a new one COOLING SYSTEM 4 15 6007010451
192. DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 18 APPENDIX Cable Wire and Hose Routing 1808225B8W4 C Rear Ignition Coil Run the rear ignition coil lead over the shift lever tie rod Front Ignition Coil Clamps Run the front ignition coil lead over the center bracket pipe Harness Black Connector White Connector Black Terminal Green Terminal WD DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 19 Cable Wire and Hose Routing ute P 1808226884 C 1 Front Master Cylinder 2 Brake Hose 3 Clamps 4 Brake Pipes 5 Brake Pipe Joint DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 20 APPENDIX Cable Wire and Hose Routing E NN 0 Z A SQ hi Vie efc mt ii Se RY Wi 4 57 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 21 Cable Wire and Hose Routing la ol
193. Drive amp Driven Pulley Holder 57001 1473 Drive amp Driven Pulley Holder 57001 1412 e Set the pulley onto the pulley holder e Remove Drive Pulley Cover Bolts A Drive Pulley Cover B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 15 Drive Pulley e Remove Spring A Spacer e Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1474 e Turn the wrench clockwise and remove the spider with the movable sheave NOTE OThe spider has left hand threads the wrench clockwise for loosening e Remove Spider A Shoes B Nuts C Ramp Weight Pin D Ramp Weight E Movable Sheave F Fixed Sheave G HS06000BS2 C Drive Pulley Inspection xIf the sheave surfaces A appear damaged replace the sheaves DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 16 CONVERTER SYSTEM Drive Pulley x If the cover bushing is damaged or worn replace the drive pulley cover Cover Bushing Inside Diameter A Standard 27 985 28 085 mm 1 1018 1 1057 in Service Limit 28 12 mm 1 107 in x lf the sheave bushing is damaged or worn replace it Sheave Bushing Inside Diameter A Standard 37 985 38 085 mm 1 4955 1 49
194. E Front Brake Fluid Recommendation Use extra heavy duty brake fluid only from a container marked DOTS Recommended Disc Brake Fluid Type DOT 3 Front Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Front Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 8 BRAKES Brake Fluid Brake Line Air Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake pedal is transmit ted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately NOTE O The procedure to bleed the brake line is as follows e Remove the reservoir cap A and fill the reservoir with new brake fluid e
195. E FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the timing inspection plug A Special Tool Filler Cap Driver B 57001 1454 e Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until T R mark A on the alter nator rotor aligns with the notch B as shown the end of the compression stroke in the rear cylinder head HE10002BS1 C e Measure the clearance for all four valves one at a time between the end of the valve stem and the adjusting screw A with the thickness gauge B Valve Clearance when cold Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 xIf the valve clearance is not correct adjust it see Valve Clearance Adjustment wrench on the alternator rotor bolt until T F mark A on the alternator rotor aligns with the notch B as shown the end of the compression stroke in the front cylinder head e Measure the clearance for all four valves one at a time between the end of the valve stem and the adjusting screw with the thickness gauge Then turn the crankshaft counterclockwise with a Valve Clearance when cold HE10001881 Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in xIf the valve clearance is n
196. E ONLY ELECTRICAL SYSTEM 16 51 Electric Starter System e Take out the one way clutch A Wwnew F Starter Motor Clutch Installation e Apply engine oil to around the cams of the one way clutch e Install the one way clutch so that the flange A fits on the recess B of the race e Apply a non permanent locking agent Starter Motor Clutch Bolts e Tighten Torque Starter Motor Clutch Bolts 34 N m 3 5 kgf m 25 ft lb Starter Motor Clutch Inspection Remove Alternator Rotor see Alternator Rotor Removal e Fit the starter clutch gear into the starter motor clutch xIf the alternator rotor turns counterclockwise A freely from the starter clutch gear but not clockwise B the clutch is operating correctly xIf the clutch does not operate correctly or if it makes noise disassemble it and examine each part visually Re place any worn or damaged parts NOTE OExamine the starter clutch gear A Replace it if it is worn or damaged Torque Limiter Inspection e Remove Alternator Rotor see Alternator Rotor Removal e Remove the torque limiter A and visually inspect it xIf the limiter has wear discoloration or other damage replace it as a unit WB DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 52 ELECTRICAL SYSTEM Lighting System Headlight
197. EM DFI DFI Servicing Precautions OTo maintain the correct fuel air mixture F A there must be no inlet air leaks in the DFI system Be sure to install the oil filler cap A after filling the engine oil DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 21 Troubleshooting the DFI System Outline When an abnormality in the DFI system occurs the FI indicator symbol A LCD flashes on the meter panel to alert the driver In addition the condition of the problem is stored in the memory of the ECU electronic control unit OEREIN 19019047851 C With the engine stopped and turned in the self diagnosis mode the service code A is indicated by the number of times the Fl indicator symbol LCD blinks When due to a malfunction the Fl indicator symbol LCD remains flashed first ask the rider about the conditions B of trouble and then determine the cause C of problem First conduct a self diagnosis inspection and then a non self diagnosis inspection non self diagnosis items are not indicated by the FI indicator symbol LCD Do not rely solely on the DFI self diagnosis function use common sense 1015048BS1 C 1015049BS1 C Even when the DFI system is operating normally the FI indicator symbol LCD may appear under strong electrical interference No repair
198. Final Gear Case e Remove Pinion Gear Unit A Shim s B e Drill out the spring pin A with a drill bit of the 3 mm 0 12 in diameter and remove it e Remove the needle bearing B Rear Final Gear Case Right Cover Assembly A Rear Final Gear Case Right Cover e Press Ball Bearing until bottomed Special Tool Bearing Driver 554 3 B 57001 1488 A Rear Final Gear Case Right Cover B Ball Bearing e Press the oil seal C so that the projecting distance is 3 5 mm 0 14 in D as shown in the figure Special Tool Bearing Driver Set 57001 1129 e Apply Grease Oil Seal Lips E Rear Final Gear Case Front Cover Assembly A Rear Final Gear Case Front Cover e Press Ball Bearing B until bottomed Special Tool Bearing Driver Set 57001 1129 Press the faces of the oil seals C are flush with the ends of the housing e Apply Grease Oil Seal Lips 1LOB004BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 81 Rear Final Gear Case Rear Final Gear Case Assembly e Apply specified oil to the bearings e Press Ball Bearing A until bottomed Special Tool Bearing Driver Set 57001 1129 OWhen pressing the bearing support the face B of the rear final gear case C with a suitable block or press the bearing with less than 5 ton e Install New Circlip D Special Tool I
199. G SYSTEM 4 5 Coolant Flow Chart 7 Lh Wie fi A WA j KAZAT Y it NOS N LAG SANN o gt 1245 cand 25 ARS AN e PA i N iN PINK ASIDE cios 5 1 Radiator 2 Radiator Cap 3 Radiator Fan 4 Water Temperature Sensor 5 Thermostat 6 Cylinder Head 7 Cylinder 8 Water Pump 9 Reserve Tank Black Painted Arrow Hot Coolant White Painted Arrow Cold Coolant DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 4 6 COOLING SYSTEM Specifications Item Coolant Provided when Shipping Type Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure Thermostat Valve Opening Temperature Valve Full Opening Lift Standard Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 F 4 4 L 4 7 US qt reserve tank full level including radiator and engine 93 123 kPa 0 95 1 25 kgf cm 13 18 psi 69 5 72 5 157 163 F 8 mm 0 31 or more 85 C 1852F DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com Service Limit DOCUMENT AVAILABLE FOR MILITARY USE ONLY COOLING SYSTEM 4 7 Special Tools Bearing Driver Set
200. GD07000BS1 C GD07001BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 4 16 COOLING SYSTEM Thermostat Thermostat Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Thermostat Housing Cover Bolts A Thermostat Housing Cover B Thermostat Thermostat Installation e Install Thermostat A e Be sure to install the O ring B on the housing cover e Tighten Torque Thermostat Housing Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib e Add coolant see Coolant Change in the Periodic Mainte nance chapter Thermostat Inspection e Remove the thermostat and inspect the thermostat valve A at room temperature x If the valve is open replace the valve with a new one e To check valve opening temperature suspend the ther mostat A and an accurate thermometer B in a container of water with the heat sensitive portions C in almost the same depth NOTE OThe thermostat must be completely submerged and the thermostat and thermometer must not touch the con trainer sides or bottom e Gradually raise the temperature of the water while stirring the water gently for even temperature x lf the measurement is out of t
201. Hose A Water Hose B e Remove Radiator Bolts A Radiator B NOTICE Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 4 14 COOLING SYSTEM Radiator Radiator Installation e Install Dampers A Collars B e Tighten Torque Radiator Mounting Bolts C 8 8 0 90 kgf m 78 in Ib e Connect Radiator Fan Motor Lead Connector e Install the fan motor breather hose NOTE ODo not apply lubricant at fitting hose region e Install Water Hoses Reserve Tank Hose e Run the hoses according to the Cable Wire and Hose Routing section in the Appendix chapter Radiator Fan Removal e Remove Radiator Cover see Radiator Removal Radiator Screen Mounting Bolts A both side Radiator Screen and Radiator Cover Bracket Mounting Bolts B both side Radiator Screen C Radiator Cover Bracket Mounting Bolts D both side Radiator Cover Bracket E both side e Remove Radiator see Radiator Removal Radiator Fan Assembly Bolts A Fan Assembly B Radiator Fan Installation e Install Radiator Fan Assembly e Tighten Torque Radiator Fan Assembly Bolts 8 3 N m 0 85 kgf m 73 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com
202. ITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 27 Suspension Arms Rear Knuckle Installation e Install the rear knuckle A so that the TOP mark B faces upward e Tighten Torque Rear Knuckle Mounting Nuts 57 5 N m 5 9 kgf m 42 ft lb Rear Knuckle Disassembly e Remove Rear Knuckle see Rear Knuckle Removal Oil Seals A Sleeve B e Remove Bushings A OUsing a suitable bearing remover B Remove Circlip A Special Tool Inside Circlip Priers B 57001 143 e Remove the ball bearing using a press A Special Tool Bearing Driver Set B 57001 1129 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 28 SUSPENSION Suspension Arms Rear Knuckle Assembly e Install Ball Bearing until bottomed Special Tool Bearing Driver Set A 57001 1129 e Install New Circlip A Special Tool Inside Circlip Priers 57001 143 e Apply grease Chevron Black Pearl Grease EP NLGI 2 Sleeves B Lips of Oil Seals C e Install Bushings D until bottomed Special Tool Bearing Driver Set 57001 1129 IN0SOT3B81 e Install Sleeve Oil Seals DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPE
203. LABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest l
204. LABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 18 FUEL SYSTEM Special Tools and Sealant Measuring Adapter Liquid Gasket TB1211 57001 1700 56019 120 875717005 6 875601205 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 19 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis DFI system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OWhen charging remove the battery from the vehicle This is to prevent ECU damage by excessive voltage ODo not turn the ignition switch ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes not spray water on the electrical parts DFI parts con nect
205. LE FOR MILITARY USE ONLY 2WD AWD Solenoid Valve 2WD AWD Solenoid Valve Inspection e Remove Right Bracket see Right Bracket Removal in the Frame chapter 2WD AWD Solenoid Valve Lead Connector A Bracket Bolts B Bracket C with 2WD 4WD Solenoid Valve D Hose Ends from each part e Set the hand tester A to x 10 O range and connect the tester leads to the terminals in the 2WD AWD solenoid valve connector B Special Tool Hand Tester 57001 1394 2WD AWD Solenoid Valve Resistance Standard 37 43 at 20 C 68 F the reading is out of the standard replace the 2WD AWD solenoid valve x If the reading is standard resistance check the operation of the 2WD 4WD solenoid valve as follows e Connect the 12 V battery A to the terminals in the 2WD AWD solenoid valve connector as shown in the figure e When the battery is connected check that the 2WD 4WD solenoid valve makes a clicking sound operating sound x lf the 2WD AWD solenoid valve does not click replace it e When the battery is connected check that the 2WD AWD solenoid valve operates the air flow arrows as shown in the figure A Battery is connected B Battery is disconnected x lf the 2WD AWD solenoid valve does not work replace it ELECTRICAL SYSTEM 16 73 1922001851 C 1822003B 2 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DO
206. LE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 35 Self Diagnosis Service FI Indicator Light Problems 51 be Ignition coil 1 malfunction wiring open or short 52 Ignition coil 2 malfunction wiring open or short Notes OThe ECU may be involved in these problems If all the parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 36 FUEL SYSTEM Self Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles Service Output Signal Usable Codes rang Range or Criteria Backups by ECU If the throttle sensor system fails the signal is out of the usable range wiring short or open the ECU locks ignition timing into the ignition Throttle Sensor Output timing at opened throttle position and sets the 11 Throttle Voltage DFI in the D J method 1 Sensor 02 48V Also the throttle sensor system and inlet air pressure sensor fails the ECU locks ignition timing
207. LE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 7 12 ENGINE LUBRICATION SYSTEM Oil Pump e Install the oil pump drive chain A with the oil pump as sembly B e Tighten Torque Oil Pump Cover Bolts C 8 8 N m 0 90 kgf m 78 in Ib e Install Chain Guide A and Collar B Tighten Torque Chain Guide Bolt 8 8 N m 0 90 kgf m 78 in Ib HG06002BS1 e Apply grease to the O ring A e Install Pin B Spring C O ring Oil Pump Drive Chain Tensioner Bolt D Tighten Torque Oil Pump Drive Chain Tensioner Bolt 25 2 5 kgf m 18 ft lb HG06001BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE LUBRICATION SYSTEM 7 13 Cil Pipe Oil Pipe Removal Engine Left Side Oil Pipe Engine Outside e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Left Cover see Left Cover Removal in the Frame chap ter Engine Bottom Guard see Engine Bottom Guard Re moval in the Frame chapter Oil Pipe Bolts A Oil Pipe B Engine Left Side Oil Pipe Engine Inside e Remove Alternator Cover see Alternator Cover Removal in the Electrical System chapter Oil Pump see Cil Pump Removal Oil Pipe Bolts A Oil Pipe B Engine Right Side Oil Pipe e Remove Drive Pulley
208. LITARY USE ONLY GENERAL INFORMATION 1 7 Model Identification KRF750NAF TAF Left Side View Frame Number A Frame Number A Engine Number B Right Front Axle B Engine Oil Drain Plug DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 1 8 GENERAL INFORMATION Model Identification KRF750PAF Left Side View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY GENERAL INFORMATION 1 9 Model Identification KRF750RAF VBF Left Side View The KRF750RAF VBF is identical to the KRF750PAF in every aspect controls features and Specifications except for the camouflage surface treatment The gun case is an optional part DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 1 10 GENERAL INFORMATION Model Identification KRF750SAF Left Side View 18030097 KRF750SAF Right Side View 18038038 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY General Specifications GENERAL INFORMATION 1 11 KRF750NAF NBF PAF PBF RAF RBF SAF nem SBF TAF VBF Dimensions Overall Length 2 955 mm 116 3 i
209. LY 15 54 FRAME Covers Windshield Removal KRF750P R V Models e Remove Bolts A and Washers Brackets B Dampers and Collars Windshield C Windshield Installation KRF750P R V Models e Install Windshield A Trim B Collars C Washers D OThick side E is front side F e Install Dampers G Brackets H Bolts I J Fit the trim on the front fender rear IPi3022BW3 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 55 Covers Sun Top Cover Removal KRF750P R V Models e Remove Screws A and Collars Sun Top Cover B Sun Top Cover Installation KRF750P R V Models e Install Sun Top Cover A Screws B and Collars C e When installing the brackets install them with the upper bar mounting bolts D Small Bracket E Large Bracket F Front Side G OTighten Torque Upper Bar Mounting Bolts 47 N m 4 8 kgf m 35 ft Ib IPi3010BW3 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 56 FRAME Covers e When installing the pads A install them on the rib of the front fender as shown in the figure Sun Top Cover B 49 mm 1 93 in C 0 View D IPis019BW2 C DOCUMENT AVAILABLE FOR MILITARY USE ON
210. LY 6 18 CONVERTER SYSTEM Drive Pulley e Turn the spider clockwise e Measure the resulting clearance A between the shoe B and the post C on the movable sheave at two positions as shown D Arrow Mark Shoe Side Clearance Standard up to 0 20 mm 0 008 in and there must be kept a clearance which the movable sheave E moves smoothly until it touches the fixed sheave F with its own weight xIf the clearance is not the specified range adjust it using the following shoes Part Number Thickness Standard Shoe 49048 1090 7 5 mm 0 295 in 49048 1087 7 2 mm 0 283 in 49048 1088 7 3 mm 0 287 in 49048 1089 7 4 mm 0 291 in 49048 1091 7 6 mm 0 299 in Adjustment Shoes 49048 1092 7 7 mm 0 303 in 49048 1093 7 8 mm 0 307 in 49048 1094 7 9 mm 0 311 in 49048 1095 8 0 mm 0 815 in xIf the clearance is not the specified range after the above shoes are replaced use the spacer A 92026 0038 of the option part B Shoe C Spider D Post E Clearance H 06030BS1 Drive Pulley Assembly e When installing the bushing A press B the bushing into the movable sheave C so that the bushing end is flush with the boss D of the sheave IF06029BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER
211. LY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 57 Guards Front Guard Removal e Remove Tapping Screws A and Collars Screws B and Collars Front Guard Cover C e Remove Bolts A both sides Front Guard B Front Guard Installation e Install Front Guard A Bolts B e Install Front Guard Cover Screws B and Collars C Tapping Screws D Front Bottom Guard Removal e Remove Bottom Guard Bolts A and Collars Front Bottom Guard B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 58 FRAME Guards Front Bottom Guard Installation e Install Front Bottom Guard A Bottom Guard Bolts B and Collars C 14002881 C Middle Bottom Guard Removal e Remove Bottom Guard Bolts A and Collars Middle Bottom Guard B Middle Bottom Guard Installation e Install Middle Bottom Guard A Bottom Guard Bolts B and Collars C IP14003BS1 C Engine Bottom Guard Removal e Remove Bottom Guard Bolts A Engine Bottom Guard B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 59 Guards Engine Bottom Guard Installation e Install Engine Bottom Guard A Bottom Guard Bolts
212. M 16 27 Charging System Alternator Cover Removal e Drain Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Torque Converter Cover see Torque Converter Cover Removal in the Converter System chapter e Remove the three bolts of the drive pulley cover A e Install the drive pulley holder B tightening the removed three bolts C Special Tool Drive Pulley Holder 57001 1620 e Remove Left Cover see Left Cover Removal in the Frame chap ter Water Pump Impeller see Water Pump Impeller Re moval in the Cooling System chapter Bolts A and Left Engine Cover B e Holding the drive pulley with the drive pulley holder re move the alternator rotor bolt A e Remove Collar A Olnstall a M6 bolt B to the collar and remove it DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 28 ELECTRICAL SYSTEM Charging System e Remove Engine Ground Terminal Bolt A e Remove the main harness B from the clamp C e Disconnect Alternator Lead Connectors A Crankshaft Sensor Lead Connector B e Remove Alternator Cover Bolts A Alternator Cover B Alternator Cover Installation e When installing the oil seals A press the oil seals in the alternator cover so that each oil seal surface is flush
213. MENE TEA 1528 0050 IWD 2WD TES mtr B p EBBES 1919051851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 61 Meter Check 3 Speedometer Check e Connect the wires in the same manner as Check 1 e The speed equivalent to the input frequency is indicated in the oscillator A if the square wave is input into terminal 1 Olndicates approximately 40 mph if the input frequency is approximately 789 Hz Olndicates approximately 40 km h if the input frequency is approximately 526 Hz x If the meter function does not work replace the meter unit NOTE OThe input frequency of the oscillator adds the integrated value of the odometer OThe integrated value of the odometer cannot be reset 9V 959 OV Duty 50t255 1019023BS2 Check 4 Odometer Check e Connect the wires in the same manner as Check 3 e Pushing the MODE button A cycle the odometer B 2 B 4WD e Raise the input frequency of the oscillator to seethe result 4022 ra of this inspection I x lf the value indicated by the odometer does not increase replace the meter unit NOTE OThe integrated value of the odometer cannot be reset Check 5 Trip Meter A B Check e Connect the wires in the same manner as Check 3 e Pushing the MODE button A cycle
214. Master Cylinder Push Rod Clevis Pin Clip Rear Master Cylinder Mounting Bolts Brake Pedal Pivot Shaft Cotter Pin Brake Caliper Mounting Bolts Parking Brake Lever Assembly Mounting Bolts Suspension Stabilizer Holder Bolts Suspension Arm Pivot Nuts Shock Absorber Mounting Nuts Steering Steering Wheel Mounting Nut Intermediate Shaft Clamp Bolts Main Shaft Mounting Bolts and Nuts Tie rod End Nuts and Cotter Pins Tie rod End Locknuts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Frame Bars Mounting Bolts and Nuts Front Guard Mounting Nuts Cargo Bed Mounting Pin Clips Seat Belt Mounting Bolts Battery Holder Nuts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents 3 4 DF 3 8 Locations seisena a a 3 13 3 15 Special 0 6 956 la eater n rto e cr 3 17 DFI Servicing Precautions eerte Mg 3 19 DFI Servicing PrecauliOris
215. NE TOP END Cylinder and Piston Piston Ring Piston Ring Groove Wear Inspection e Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 04 0 08 mm 0 0016 0 0031 Second 0 03 0 07 mm 0 0012 0 0028 Service Limit Top 0 18 mm 0 0071 in Second 0 17 mm 0 0067 in x If the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both Piston Ring Groove Width Inspection e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top 1 03 1 05 mm 0 0406 0 0413 in Second 1 02 1 04 mm 0 0402 0 0409 in Service Limit Top 1 13 mm 0 0445 1 12 mm 0 0441 in xIf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Inspection e Measure the piston ring thickness OUse a micrometer to measure at several points around the ring Piston Ring Thickness Standard Top 0 97 0 99 mm 0 0382 0 0390 in Sec
216. NLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Rocker Case Bolts L 30 mm 1 2 in 9 8 Rocker Case Bolts L 25 mm 1 0 in 9 8 S Cylinder Head Bolts M10 first torque 25 S MO Cylinder Head Bolts M10 final torque 49 5 0 36 S Cylinder Head Bolts M6 9 8 1 0 87 in lb Water Pipe Mounting Bolts 8 8 0 90 78 Valve Adjusting Screw Locknuts 12 1 2 106 in lb Rocker Shaft Bolts 22 2 2 16 Rear Rocker Case Clamp Bolt 8 8 0 90 78 in lb Camshaft Sprocket Bolts 12 1 2 106 in lb L Chain Tensioner Cap Bolts 22 2 2 16 Chain Tensioner Mounting Bolts 8 8 0 90 78 inelb Front Cylinder Camshaft Chain Guide Bolt 20 2 0 15 Position Plate Bolts 8 8 0 90 78 in lb Intermediate Shaft Chain Guide Bolts 8 8 0 90 78 Intermediate Shaft Chain Tensioner Bolts 8 8 0 90 78 in lb Rear Cylinder Camshaft Chain Guide Bolt 20 2 0 15 Cylinder Bolts L 30 mm 1 2 in 9 8 1 0 87 Cylinder Bolts L 40 mm 1 6 in 9 8 1 0 87 Coolant Drain Plugs Cylinder 7 0 0 71 62 in lb Exhaust Pipe Nuts 17 1 7 13 Exhaust Pipe Cover Bolts 13 1 3 115 in Ib Muffler Clamp Bolts 15 1 5 11 Muffler Mounting Bolts 28 2 9 21 Spark Arrester Mounting Bolts 13 1 3 115 in Ib Converter System Drive Pulley Bolt 93 9 5 69 Lh Drive Pulley Cover Bolts 12 5 1 3 111 in Ib Ramp Weight Nuts 7 0 0 71 62 R
217. NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Electric Starter System Brush Lead Inspection e Using the x 1 O hand tester range measure the resis tance as shown Terminal Bolt and Positive Brushes A Right hand End Cover and Negative Brushes B Special Tool Hand Tester 57001 1394 x If there is not close to zero ohms the brush lead has an open Replace the brush plate assy Right hand End Cover Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Right hand End Cover A Terminal Bolt and Negative Brushes B Special Tool Hand Tester 57001 1394 x If there is any reading the brush assy and or terminal bolt assy have a short Replace the starter motor Starter Relay Inspection e Remove Left Seat see Seat Removal in the Frame chapter Battery Negative Cables e Disconnect Starter Motor Cable A Battery Positive Cable B Connector C e Remove Starter Relay D e Connect the hand tester A and a 12 V battery B to the starter rela
218. NOTICE Brake fluid quickly ruins painted surface spilled fluid should be completely washed away immediately e Remove Rear Master Cylinder Mounting Bolts B Rear Master Cylinder Rear Master Cylinder Installation e Apply specified oil to the rod end A Apply grease to the O ring B e Install Rear Master Cylinder C e Apply a non permanent locking agent to the rear master cylinder mounting bolts e Tighten Torque Rear Master Cylinder Mounting Bolts 27 2 8 kgf m 20 ft Ib Brake Pipe Nipple 17 5 1 8 kgf m 13 ft lb e Bleed the brake line after master cylinder installation e Check that the brake line has proper fluid pressure and no fluid leakage Rear Master Cylinder Disassembly Assembly e Refer to the Rear Brake Master Cylinder Cup O ring and Boot Replacement in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Brake Pedal and Master Cylinder Rear Master Cylinder Inspection e Disassemble the rear master cylinder see Rear Brake Master Cylinder Cup O ring and Boot Replacement in the Periodic Maintenance chapter e Check that there are no scratches rust or pitting on the inside of the cylinder A and on the outside of the pistons B x lf the cylinder or piston shows any damage replace them e Inspect the cup C xlf a cup is worn damaged
219. NSION 13 29 Bearing and Oil Seal Ball Bearing Inspection Since the bearings are made to extremely close toler ances the clearance cannot normally be measured Do not remove any bearings for inspection e Turn each bearing back and forth A while checking for plays roughness or binding bearing play roughness or binding is found replace the bearing 6114010151 Oil Seal Inspection e Inspect the oil seals Replace any if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY STEERING 14 1 Steering Table of Contents Exploded VIGW 14 2 5 14 4 Special E ERR dll 14 5 Steering Wheel and Main Shaft 2444244440 0 0 14 6 Steering Wheel Position 1 14 6 Steering Wheel Free Play 4 n cad 14 6 Steering Wheel Genternntg icono bete ee tall eee 14 6 Steering Wheel
220. No Fastener Nm kaim ft Ib Remarks 1 Steering Wheel Mounting Nut 54 5 5 40 R 2 Steering Knuckle Joint Nuts 46 5 4 7 34 3 Main Shaft Mounting Bolts 41 5 4 2 31 4 Intermediate Shaft Clamp Bolts 21 5 2 2 16 5 Steering Gear Assembly Nuts 95 5 9 7 70 R 6 Tie Rod End Locknuts 44 4 5 32 7 Tie Rod End Nuts 41 5 4 2 31 G Apply grease LB Apply a non permanent locking agent Three Bond TB2471 Blue R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 14 4 STEERING Specifications Item Standard Steering Wheel Steering Wheel Free Play Steering Gear Assembly Tie Rod Length distance between boot end and locknut 0 20 mm 0 0 79 in 80 mm 3 15 in Service Limit DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY STEERING 14 5 Special Tools Outside Circlip Pliers Bearing Driver Set 57001 144 57001 1129 7570144ST C 875711295 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 14 6 STEERING Steering Wheel and Main Shaft Assembly Steering Wheel Position Adjustment e Remove Control Panel see Control Panel Removal in the Frame chapter e Loosen the steering main
221. ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 22 ENGINE TOP END Camshaft Camshaft Bearing Wear Inspection OThe journal wear is measured using plastigage press gauge which is inserted into the clearance to be mea sured The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft with the camshaft installed in the correct position so that the plastigage will be compressed between the journal and rocker case e Install the rocker case tightening the bolts in the correct sequence to the specified torque see Rocker Case In stallation NOTE ODo not turn the camshaft when the plastigage is be tween the journal and rocker case e Remove the rocker case and measure the plastigage width A to determine the clearance between the journal and the rocker case Measure the widest portion of the plastigage Camshaft Bearing Clearance 018 Standard 0 016 0 052 mm 0 0006 0 0020 in Service Limit 0 14 mm 0 0055 in Camshaft Bearing Clearance 22 Standard 0 020 0 059 mm 0 0008 0 0023 in Service Limit 0 15 mm 0 0059 in x If any clearance exceeds the service limit measure the diameter of the camshaft journal Camshaft Journal Diameter 18 Standard 17 966 17 984 mm 0 7073 0 7080
222. ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 63 Meter OThe 4WD indicator Symbol LCD A should appear x lf the display function does not work replace the meter unit 2WD alg 0005 Check 9 Fuel Level Gauge Check e Connect the wires in the same manner as Check 1 OThe first segment LCD A should flash the segment LCD does not flash replace the meter unit e Connect terminal 5 to the battery terminal OWhen terminal 5 is connected one segment in the fuel gauge should appear every 15 seconds When all segments appeared disconnect the termi nal 5 xIf the display function does not work replace the meter unit 1019027881 Check 10 Reverse Indicator Light Check e Connect the wires in the same manner as Check 1 e Connect terminal 7 to the battery terminal 1019028BS1 C OThe reverse indicator light LED A should go on xIf the LED light does not go on replace the meter unit HBE 019044 81 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 64 ELECTRICAL SYSTEM Meter Check 11 Neutral Indicator Light Check e Connect the wires in the same manner as Check 1 e Connect terminal 8 to the battery terminal OThe neutral indicator
223. Outside Circlip Pliers 57001 144 ide the cage B on the inner race and install the steel balls C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 73 Rear Axle e Apply the special grease A to the steel balls and cage e Squeeze about half a tube of the special grease A into the bearing cup B e Insert the balls and cage assembly in the bearing cup strongly e Install the new retaining ring A so that the opening B is aligned with one of the projections C e Tighten the small band e Squeeze the remaining special grease A into the inboard joint boot B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 74 FINAL DRIVE Rear Axle e Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot e Hold the axle at this setting Standard Length of Assembling Left Rear Axle 244 3 mm 9 62 in A 1L07013BS1 C Right Rear Axle 193 8 mm 7 63 in A 11070148581 C e Open the edge of the boot in order to egalize the air pres sures e Tighten the large band A and tap down the tangs se curely to hold down the end of the band e Be sure outside diameter of the band A is less than the max
224. Pin Puller Adapter 14 57001 1199 57001 1211 875711995 C 875712115 C Valve Spring Compressor Adapter 22 Compression Gauge Adapter M10 x 1 0 57001 1202 57001 1317 CIS Y 875712025 C 7571317ST C Valve Guide Arbor 5 Filler Cap Driver 57001 1203 57001 1454 CR 875714545 Valve Guide Reamer 5 Liquid Gasket 1216 57001 1204 92104 1063 7571204ST C 879210635 6 Valve Seat Cutter Holder 5 57001 1208 7571208ST C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal This is a non return type cam chain tensioner The push rod does not return to its original position once it moves out to take up cam chain slack Ob serve all the rules listed below When removing the tensioner do not take out the mounting bolts only partway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the cam chain timing and damage the valves e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Ca
225. Pivot Nuts 87 5 N m 8 9 kgf m 65 ft Ib Rear Knuckle Mounting Nuts 57 5 N m 5 9 kgf m 42 ft lb Rear Shock Absorber Mounting Nuts 95 5 N m 9 7 kgf m 70 ft lb e Install Stabilizer Joint see Stabilizer Installation Rear Wheel see Wheel Installation in the Wheels Tires chapter Rear Suspension Arm Disassembly e Remove Upper Suspension Arm A Caps B Bushings C Sleeve D O rigs E 1N05007BS1 C 1NOS008BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 25 Suspension Arms e Remove Lower Suspension Arm A Caps B Bushings C Sleeve D O rigs E Rear Suspension Arm Assembly e Apply adhesive Three Bond 1215 to outside of the bushing A and install it into the suspension arm B e Wipe off any extra adhesive e Apply grease Chevron Black Pearl Grease EP 2 to the inside C of the bushing and cap D 1N05003BS1 C e Apply grease Chevron Black Pearl Grease EP NLGI 2 to the sleeves A and New O rings B of the upper and lower suspension arms Stabilizer Removal e Remove Rear Wheels see Wheel Removal in the Wheels Tires chapter Stabilizer Joint A OHold the joint bolt with an Allen wrench B and remove the nut C e Remove Stabilizer Holder Bolts A Stabilizer Holders B Dampers and Stabilizer C impio
226. RY USE ONLY 17 6 APPENDIX Cable Wire and Hose Routing 1808107884 C Align the white paint mark on the tube with the adjustment mark on the crankcase Starter Motor Starter Motor Cable about 20 cy DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 7 Cable Wire and Hose Routing 1 Clamps 2 about 45 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 8 APPENDIX Cable Wire and Hose Routing Ef Ci DNA LS 1808219884 C 1 1SC Valve 2 SC Valve Tube Front 3 Resonator 4 Fuel Hose 5 Breather Hose 6 ISC Valve Tube Rear 7 Clamp 8 Position the clamp so that its edge must not contact to adjacent tube DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 9 Cable Wire and Hose Routing lo aye GIAN WTS M 2 CJ lay 2 i 74 AL SSW 2x 1808220894 C 1 Fuel Hose 2 Clamp Bend the end of clamp to secure the tube 3 Fuel Pump 4 Harness 5 Water Temperature Sensor 6 Keep the clearan
227. Refer to the Ignition Coil Inspection in the Electrical Sys tem chapter x lf the resistance is within the standard check the input voltage see Ignition Coil Input Voltage Inspection Ignition Coil Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Left Seat see Seat Removal in the Frame chapter e Connect a digital voltmeter as shown using two needle adapters Special Tool Needle Adapter Set 57001 1457 Connections for Ignition Coil 1 Front Meter G W lead terminal 44 Meter gt Battery Terminal Connections for Ignition Coil 2 Rear Meter BL W lead terminal 35 Meter gt Battery Terminal Measure the input voltage to each primary winding of the ignition coils with the engine stopped and with the con nectors joined e T rn the ignition switch ON Ignition Coil Input Voltage Standard 12 V or more FUEL SYSTEM DFI 3 61 HC11083BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 62 FUEL SYSTEM DFI Ignition Coils 1 2 Service Code 51 52 e Turn the ignition switch OFF x lf the input voltage is out of the standard check the wiring for continuity see Ignition Coil Circuit Special Tool Hand Tester 57001 1394 x If the wiring is good check the ECU for its ground and
228. S S 7 V N cw NP A ANA i 1 5 e SN DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener Nam kgf m Remarks 1 Engine Bracket Pipe Mounting Nuts 41 5 4 2 31 R 2 Mounting Bolt 60 1 6 1 44 60 1 6 1 44 R 3 Mounting Nut R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter e Remove Bars If required see Bars Removal in the Frame chap ter Air Cleaner Housing and Duct see Air Cleaner Housing and Duct Removal in the Fuel System chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Right Frame Pipe see Right Frame Pipe Removal in the Frame chapter Shift Lever see Shift Lever Removal in the Crank shaft Transmission chapter Center Bracket see Center Bracket Removal in the Frame chapter Muffler and Exhaust Pipe see Muffler and Exhaust Pipe Removal in the Engine Top End chapter Front Propeller Shaft see Front Propell
229. SE ONLY FINAL DRIVE 11 71 Rear Axle e Compress the axle assembly to the specified length while relieving the air pressure inside the outboard boot e Hold the axle at this setting Standard Length of Assembling Outboard 228 9 mm 9 01 in A 1107012851 e Open the edge of the boot in order to equalize the air pressures e Tighten the large band A and tap down the tangs se curely to hold down the end of the band e Be sure outside diameter of the band is less than the max imum diameter Maximum Outside Diameter of Band 85 3 mm 3 36 in Inboard Joint Boot Removal e Remove Rear Axle see Rear Axle Removal Boot Bands A e Scrap the removed boot bands e Slide the joint boot toward the outboard joint e Remove the retaining ring A e Separate to the axle shaft e Remove the steel balls A e Slide the cage B toward the outboard joint DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 72 FINAL DRIVE Rear Axle e Remove Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Remove Inner Race A Cage B Inboard Joint Boot C Boot Band D Inboard Joint Boot Installation e Install New Small Band A New Inboard Joint Boot B Cage C e Install the inner race A so that the fl rration side B faces outboard joint N e Install Ci p Tool
230. SYSTEM 6 19 Drive Pulley e Install the ramp weight A as shown e Replace the ramp weight nuts with new ones e Tighten Torque Ramp Weight Nuts B 7 0 N m 0 71 kgf m 62 in Ib e Check that the ramp weights swing smoothly e Hold the fixed sheave A with the drive pulley holder B in a vise Special Tool Drive amp Driven Pulley Holder 57001 1473 e Clean the threads of the fixed sheave and spider e Install Movable Sheave Spider A and Shoes B OAlign the arrow C on the spider with the arrow D on the movable sheave Olnsert the shoes so that the rubber side black small di ameter faces inward e Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1474 e Turn the wrench counterclockwise for tightening Torque Spider left hand threads 275 28 kgf m 203 e Remove the drive pulley wrench e Install the spacer e Put the spring A in the groove of the spider e Align the arrows B on the drive pulley cover and spider e Install Dowel Pins C Drive Pulley Cover e Tighten Torque Drive Pulley Cover Bolts 12 5 N m 1 3 kgf m 111 in Ib e Clean the surface of the sheaves with an oil less cleaning fluid DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 20 CONVERTER SYSTEM Drive Pulley Drive Pu
231. Screw 4 5 0 46 40 in lb Element Cover Screw 45 0 46 40 in lb Air Cleaner Mounting Bolts 8 8 0 90 78 in lb L ISC Valve Mounting Bolts 8 8 0 90 78 in lb Delivery Pipe Mounting Screws 5 0 0 51 44 in lb Inlet Air Pressure Sensor Mounting Screw 5 0 0 51 44 in lb Throttle Cable Locknuts 4 4 0 45 39 in lb Throttle Pedal Position Bolt Locknut 10 8 1 1 96 in lb Fuel Pump Mounting Bolts 4 0 0 41 35 Fuel Tank Band Bolts 11 1 1 97 ECU Mounting Bolts 6 9 0 70 61 in lb Water Temperature Sensor 12 1 2 106 in Ib Cooling System Radiator Screen Mounting Bolts 8 8 0 90 78 in lb Radiator Cover Bracket Mounting Bolts 8 8 0 90 78 in lb Radiator Mounting Bolts 8 8 0 90 78 6 Radiator Fan Assembly Bolts 8 3 0 85 73 Thermostat Housing Cover Bolts 8 8 0 90 78 Water Temperature Sensor 12 1 2 106 in lb Water Pipe Mounting Bolts L 20 mm 0 79 in 8 8 0 90 78 in lb Water Pipe Mounting Bolt L 12 mm 0 47 in 8 8 0 90 78 in lb Water Pump Impeller 7 8 0 80 69 in Ib Water Pump Cover Bolts 8 8 0 90 78 in lb Coolant Drain Plug Water Pump 7 0 0 71 62 in lb Coolant Drain Plugs Cylinder 7 0 0 71 62 in lb Coolant Air Bleed Bolt Water Pump 7 0 0 71 62 in lb Coolant Air Bleed Bolt Thermostat 7 8 0 80 69 in lb Engine Top End Valve Adjusting Cap Bolts 8 8 0 90 78 in lb Rocker Case Bolts L 55 mm 2 2 in 8 8 0 90 78 in lb 5 Rocker Case Bolts L 130 mm 5 1 in 9 8 1 0 87 in lb S DOCUMENT AVAILABLE FOR MILITARY USE O
232. Shift Shaft Lever Bolt A and Nut B Differential Control Shift Shaft Lever C e Remove Snap Rings A both sides Special Tool Outside Circlip Pliers B 57001 144 e Remove Caps A Yoke B e Push A and hold the 2WD AWD shift shaft lever B e Hold the coupling C with a wrench D e Remove Coupling Nut E DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 44 FINAL DRIVE Front Final Gear Case e Remove Washer A Coupling B e Remove 2WD AWD Shift Shaft Lever Nut A 2WD AWD Shift Shaft Lever B Spring C e Remove Washer A 2WD AWD Shift Shaft Cover Bolts B 2WD AWD Shift Shaft Cover C 2WD AWD Shift Shaft D e Remove Oil Seal A e Remove Shifter A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 45 Front Final Gear Case e Hold the front final gear case in a vise and remove the bearing holder using the socket wrench A Special Tool Socket Wrench Hex 50 57001 1478 x If the holder seems too difficult to break free apply heat to softer the locking agent e Remove Pinion Gear Bearing Holder e Remove Pinion Gear Unit A Shim s B e Remove Front Final Gear Case Left Cover Bolts A Front Final Gear Case Left Cover B Differential
233. Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connections to Adapter Meter G W sensor G Y lead Meter BK sensor BR BK lead e Turn the ignition switch ON e Measure the output voltage from various vacuum read ings while pulling the handle of the fork oil level gauge x f the output voltage for various vacuum is normal check the ECU for its ground and power supply see ECU Power Supply Inspection e Check the output voltage using the following formula and chart 0017119852 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 44 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Suppose Pg Vacuum Pressure gauge to Sensor PI Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum Pressure absolute to Sensor Vv Sensor Output Voltage V then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg Vacuum gauge reading 70 cmHg Barometer reading Vv 3 2 V Digital meter reading then Pv 70 8 62 cmHg Abs Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 04 3 49 V Plot Vv
234. Spider 275 28 203 Lh Driven Pulley Nut 93 9 5 69 R Engine Brake Actuator Mounting Bolts 8 8 0 90 78 in lb S Engine Brake Actuator Cover Bolt 8 8 0 90 78 in lb S Belt Inspection Opening Cover Bolts 8 8 0 90 78 in lb Converter Cover Bolts 8 8 0 90 78 S Converter Cover Drain Bolt 20 2 0 15 Joint Duct Bolts 8 8 0 90 78 in lb Engine Lubrication System Filter 17 5 1 8 13 Pressure Switch 15 1 5 11 SS Oil Pipe Bolts 8 8 0 90 78 in lb Engine Oil Drain Plug 20 2 0 15 Oil Pressure Relief Valve 15 1 5 11 L DOCUMENT AVAILAB OR ARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Torgus Remarks kgf m ft Ib Oil Pump Cover Bolts 0 90 78 Chain Guide Bolt 0 90 78 in lb Oil Pump Drive Chain Tensioner Bolt 2 5 18 Oil Filter Mounting Bolt 2 5 18 L 15 mm Plate Bolts 0 90 78 Engine Removal Installation Engine Bracket Pipe Mounting Nuts 4 2 31 R Engine Mounting Bolt 6 1 44 Engine Mounting Nut 6 1 44 R Crankshaft Transmission Connecting Rod Big End Cap Nuts 3 5 25 MO Engine Oil Drain Plug 2 0 15 Crankcase Bolts M8 L 75 mm 2 95 2 0 15 S Crankcase Bolts M8 L 110 mm 4 33 in 2 0 15 S Crankcase Bolt M8 L 110 mm 4 33 in 2 0 15 S L 1 Crankcase Bolts M6 L 40 mm 1 57 in 1 0 87 Crankcase Bolts M6 L 65 mm 2 56 1 0 87 in lb Be
235. Sus pension chapter Upper Suspension Arm B see Rear Suspension Arm Removal in the Suspension chapter e Pull the rear axle A in a straight line out of the rear final gear case Rear Axle Installation e Wipe off any old grease Splines A of Axle Gear Case Oil Seal B e Visually inspect the splines of the axle xIf they are badly worn or chipped replace the axle with new one e Apply molybdenum disulfide grease to the axle splines e Apply grease to the gear case oil seal lips e Push A the end of the rear axle straight and install the rear axle NOTE OThe axle shaft must not come off easily Rear Axle Joint Boot Inspection e Refer to the Axle Joint Boot Inspection in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 69 Rear Axle Rear Axle Joint Boot Replacement Outboard Joint Boot Removal e Remove Rear Axle see Rear Axle Removal Boot Bands A e Scrap the removed boot bands e Slide the joint boot B toward the inboard joint e Tap the bearing housing A straight B with a plastic ham mer to separate it from the shaft NOTICE Do not tap on the cage Be careful not get hurt when the housing comes out If the splined portion of shaft cracked or damaged during disassembling of outboard joint do not reuse the shaft e Remove Cir
236. Suspension Table of Contents Exploded VOW m 13 2 Specifications E 13 6 lores nr 13 7 Shock Absorbers Other than KRF750S Model 13 8 Front Shock Absorber Spring Preload 13 8 Front Shock Absorber FIem wvalas orem em 13 8 Front Shock Absorber Installation ttal qe 13 8 Front Shock Absorber 13 9 Front Shock Absorber 13 9 Rear Shock Absorber Spring Preload Adjustment nsns 13 10 Rear Shock Absorber 606556 Nn nn n nnne 13 10 Rear Shock Absorber Installation ur AR 7 13 11 Rear Shock Absorber Inspection 38 EL M 13 11 Rear Shock Absorber Scrapping 5 777 13 12 Shock Absorbers KRFE750S Model 5 nente Nee 13 13 Front Shock Absorber Rebound Damping Force 13 13 Front Shock Absorber Compression Damping Force
237. Suspension Arm Disassembly e Remove Upper Suspension Arm A Caps B Bushings C Sleeve D O rigs E 1N05004BS1 C e Remove Lower Suspension Arm A Caps B Bushings C Sleeve D O rigs E e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove the knuckle joint B using a press Front Suspension Arm Assembly e Press the new knuckle joint using a press Special Tool Knuckle Joint Driver A 57001 1640 e Install New Circlip Special Tool Outside Circlip Pliers 57001 144 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 23 Suspension Arms e Apply adhesive Three Bond 1215 to outside of the bushing A and install it into the suspension arm B e Wipe off any extra adhesive e Apply grease Chevron Black Pearl Grease EP NLGI 2 to the inside C of the bushing and cap D INOSO03BS1 C e Apply grease Chevron Black Pearl Grease EP NLGI 2 to the sleeves A and new O rings B Rear Suspension Arm Removal e Remove Rear Wheel see Wheel Removal in the Wheels Tires chapter Axle Guard A Stabilizer Joint B see Stabilizer Removal e Support the rear hub using a suitable jack or block A e Remove Rear Shock Absorber Bolt Washer and Nut lower Rear Knuckle Mounting Bolt B Washers Shim and Nut Rear Upper Susp
238. System e Check that the ignition switch is turned off and connect a hand tester A to the battery terminals Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off The readings should show nearly battery voltage when the engine speed is low and as the engine speed in creases the readings should also increase Regulator Rectifier Output Voltage Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 15 e Turn off the ignition switch and disconnect the hand tester x f the regulator rectifier output voltage is between the val ues given in the table the charging system is working nor mally x If the output voltage is much higher than the values spec ified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open xIf the battery voltage does not increase as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective Alternator Inspection There are three types of alternator failures short open or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping
239. T AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 73 Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove the fuel hose see Fuel Hose Replacement WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses B Special Tool between the fuel pump outlet pipe and the delivery pipe e Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 A WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death Do not try to start the engine with the fuel hoses disconnected e Turn the ignition switch ON The fuel pump will turn for 3 seconds and then stop NOTE OTurn the ignition Switch ON and inspect the fuel line leakage after installing the special tools NOTICE Do not drive the fuel pump without the fue
240. TARY USE ONLY 9 8 CRANKSHAFT TRANSMISSION Special Tools and Sealant Outside Circlip Pliers Crankshaft Jig 57001 144 57001 1174 7T5701448T C ST571174ST C Bearing Driver Set Liquid Gasket TB1216 57001 1129 92104 1063 7571129ST C 879210635 6 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 9 Crankcase Crankcase Disassembly e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter Cylinder Blocks and Pistons see Cylinder and Piston Removal in the Engine Top End chapter Intermediate Shaft and Chains see Camshaft Chain Re moval in the Engine Top End chapter Right Crankcase Bolt M6 A Right Crankcase Bolts M8 B e Remove Shift Shaft Positioning Bolt A Washer Spring and Steel Ball Left Crankcase Bolts M6 B Left Crankcase Bolts M8 C e Wrap the teeth on the sprockets A by taping for protect ing the bushing in the crankcase e Using the pry points B split the crankcase halves e Lift off the left crankcase half Crankcase Assembly The right and left crankcase halves are machined at the factory inthe assembled state so the crankcase h
241. TARY USE ONLY GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing ale cet cann Satins Model IdentifiCatiOri General SDOcITIGatlOriS eb x qeu ta Fi e dax es d rci Unit Conversion Tab lO DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper ation on a vehicle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the vehicle disconnect the battery wires from the battery to prevent the engine from accidentally turning over Disconnect the ground wire first and then the positive When completed with the service first connect the positive wire to the positive terminal of the battery then the negat
242. TENANCE Periodic Maintenance Procedures Oil Filter Replacement e Remove Engine Bottom Guard see Engine Bottom Guard Re moval in the Frame chapter e Drain the engine oil e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 e Replace the filter with a new one e When installing the oil filter be careful of the following OApply oil to the gasket A before installation OTighten the filter with the oil filter wrench Special Tool Oil Filter Wrench 57001 1249 Torque Oil Filter 17 5 N m 1 8 kgf m 13 ft lb OPour in the specified type and amount of oil e Install Engine Bottom Guard see Engine Bottom Guard Instal es lation in the Frame chapter Wheels Tires Tire Inspection e Examine the tire for damage and wear x lf the tire is cut or cracked replace it OLumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement ORemove any foreign objects from the tread After re moval check for leaks with a soap and water solution e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurements at several places any measurements are less than the service limit re place the tire Tire Tread Depth Service Limit Front 4 mm 0 16 in Rear 4 mm 0 16 in Standard Tire Front 26 x 8 00 12 MAXXIS M989 Tubeless Rear 26 x 10 00 12
243. UMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 7 Exploded View No Fastener Torque Remarks N m kgf m ft lb 1 Fuel Pump Mounting Bolts 4 0 0 41 35 in lb 2 Fuel Tank Band Bolts 11 1 1 97 in lb 3 ECU Mounting Bolts 6 9 0 70 61 4 Water Temperature Sensor 12 1 2 106 in lb 5 Fuel Pump 6 ECU Electronic Control Unit 7 Fuel Pump Relay 8 Vehicle down Sensor 9 Ignition Coils 10 Speed Sensor 11 CrankShaft Sensor Apply grease Replacement Parts 20 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 8 FUEL SYSTEM DFI DFI System DFI System 7 ja Y D 5 34 m Ze WW j NS XN na D EZ qv 2 EL a S Ne lt NE E A ene 10615079885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DFI System E cL Battery ECU Electronic Control Unit Inlet Air Pressure Sensor Throttle Sensor Fuel Injectors Crankshaft Sensor ISC Valve Fuel Pump
244. USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 44 ENGINE TOP END Exhaust System This vehicle is equipped with a spark arrester approved for off road use by the United States Forest Service It must be properly maintained to ensure its efficiency In accor dance with the Periodic Maintenance Chart clean the spark arrester Spark Arrester Cleaning e Refer to the Spark Arrester Cleaning in the Periodic Main tenance chapter Muffler and Exhaust Pipe Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Engine Bottom Guard see Engine Bottom Guard Re moval in the Frame chapter e Loosen Muffler Clamp Bolts A both sides e Remove Muffler Mounting Bolts A and Washers Bracket B Muffler C e Remove Rear Exhaust Pipe Nuts A Rear Exhaust Pipe B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 45 Exhaust System e Remove Front Exhaust Pipe Nuts A Front Exhaust Pipe B e Remove Circlips A and Washers B both sides Special Tool Inside Circlip Pliers 57001 143 e Remove Damper C 1 110000 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 46 ENGINE TOP END Exhaust Syst
245. USPENSION 13 21 Suspension Arms Front Suspension Arm Installation e Clean the taper surface A of the knuckle B and shank of the knuckle joint or the tapers will not fit snugly e Apply grease Chevron Black Pearl Grease EP NLGI 2 to the inside of the caps e Install Front Upper Suspension Arm Front Lower Suspension Arm Suspension Arm Pivot Bolts Caps and Nuts temporary Front Shock Absorber Mounting Bolt and Nut lower e Install Knuckle A Washers B and Nuts Olnstall the washer as shown in the figure INO5002BS1 C e Tighten Torque Front Suspension Arm Pivot Nuts 87 5 N m 8 9 kgf m 65 ft Ib Steering Knuckle Joint Nuts 46 5 N m 4 7 kgf m 34 ft lb Front Shock Absorber Mounting Nut 57 5 5 9 kgf m 42 ft lb e Install New Cotter Pins A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole 1807000881 C e Bend the cotter pin A over the nut B zT HNO4001BS1 C e Install the removed parts see appropriate chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 22 SUSPENSION Suspension Arms Front
246. VAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 30 FINAL DRIVE Front Axle e Pinch the boot bands A with a suitable tool B to install it Recommend Tool OETIKER 192 e Be sure outside diameter of the band A is less than the maximum diameter Maximum Outside Diameter of Band 82 9 mm 3 26 in Inboard Joint Boot Removal e Remove Front Axle see Front Axle Removal e Tap the joint portion of the boot bands A with aSuitable tool e Scrap the removed boot bands e Slide the joint boot B toward the outboard joint e Remove the retaining ring A e Separate the bearing cup B from the axle shaft e Remove the steel balls A e Slide the cage B toward the outboard joint DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 31 Front Axle e Remove Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Remove Inner Race A Cage B Inboard Joint Boot C Inboard Joint Boot Installation e Install New Small Band A New Inboard Joint Boot B Cage C 28070 P e Install the inner race A so that the flat serration side B faces outboard joint 11079077 P e Install New Circlip A Special Tool Outside Circlip Pliers 5
247. VAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 13 Shock Absorbers KRF750S Model Front Shock Absorber Rebound Damping Force Adjustment e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e To adjust the rebound damping force turn the rebound damping force adjuster A to the desired position OThe standard adjuster setting for an average build rider of 68 kg 150 Ib with no passenger and no accessories is the 1 turn out from the fully clockwise position Rebound Damping Force Adjustment Adjuster Damping Position Force Setting Load Road Speed Counterclockwise Clockwise Softer w Harder Weak Soft Light Good Low i 1 1 1 1 1 2 1 0 Strong Hard Heavy Bad High adjuster turned fully clockwise 1N04004BS1 C Front Shock Absorber Compression Damping Force Adjustment e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e To adjust the compression damping force turn the com pression damping force adjuster A to the desired posi tion OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 3 5 turns out from the fully clockwise position Compression Damping Force
248. Washer B Collar C viv o gt e Pull out the brushes from the brush holder A e Remove Brush Springs B Starter Motor Terminal C Positive Brush Assy D and O ring Screw E Negative Brush Assy F Brush Holder Starter Motor Assembly e Align the hole A of the brush holder B to the boss Cl of the end cover D 2 M Ni e Install the negative brush assy Alto e Tighten the screw C securely e Install the positive brush assy D the brush holder e Install the starter motor terminal e brush holder B Replace the ring A with a new one install the following parts to the starter motor terminal B Starter Motor Terminal Locknut E Olnstall the collar so that stepped side faces outward e Tighten Torque Starter Motor Terminal Locknut 11 1 1 kgf m 97 in Ib GP11104BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 47 Electric Starter System e Install the brush springs A e Insert the brushes B to the brush holder e Apply thin coat of grease to the oil seal A WHD e Replace the O rings A with new ones e Insert the armature B so that commutator side i hollow side D of the yoke 2 e Align the marks A to ass mbly the yoke and the end cover B as SO UN que Starter Motor
249. When the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 00 4 75 lt 5 002 0 95 V 1 24 x 4 75 5 00 1 18 V Thus the valid range is 0 95 1 18 V e Turn the ignition switch OFF xIf the output voltage is out of the standard inspect the throttle sensor resistance see Throttle Sensor Resis tance Inspection x lf the output voltage is normal check the wiring for conti nuity see Throttle Sensor Circuit xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 40 FUEL SYSTEM Throttle Sensor Service Code 11 Throttle Sensor Resistance Inspection e Turn the ignition switch OFF e Disconnect the harness connector A e Connect a digital meter to the throttle sensor lead con nector ODo not connect the main harness connector Connections BR W lead BR BK lead Measure the throttle sensor resistance Throttle Sensor Resitance Standard 4 6 x f the reading is out of the range replace the throttle body assy xIf the reading is within the range but the problem still exists replace the ECU see ECU Removal In
250. Y USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 27 Cable Wire and Hose Routing 2a oL RONDO Main Harness View Bands to 2WD AWD Shift Switch Apply grease to the terminals Clamps Side View Section A A Push the pre installed clamp into the hole of frame Band Clamp the wire harnesses at the taped areas to Radiator Fan Motor 20 40 mm 0 8 1 6 in Right and Left side 40 60 mm 1 6 2 4 in Right and Left side 70 90 mm 2 8 3 5 in 140 160 mm 5 5 6 3 in 30 mm 1 2 in maximum DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 28 APPENDIX Cable Wire and Hose Routing US model 1808229895 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 29 Cable Wire and Hose Routing npo ok Inlet Air Pressure Sensor Inlet Air Temperature Sensor Forward Reverse Detecting Sensor Connector Neutral Position Switch Reverse Position Switch Apply grease Chevron Black Pearl Grease EP NLGI 2 to the connectors Battery Positive Cabl
251. a digital meter to the harness adapter leads Connections to Adapter Meter G W lead BR W lead of Main Harness Meter gt BK lead BR BK lead of Main Harness e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Inlet Air Pressure Sensor Input Voltage Standard DC 4 75 5 25 V x If the reading is within the standard range check the out put voltage see Inlet Air Pressure Sensor Output Voltage Inspection x If the reading is less than the standard check the wiring for continuity see Inlet Air Pressure Sensor Circuit x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 42 FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Output Voltage Inspection NOTE The output voltage changes according to the local at mospheric pressure e Measure the output voltage at the input air pressure in the same way as input voltage inspection Note the following e Disconnect the inlet air pressure sensor connector and connect the harness adapter A between these connec tors Special Tool Sensor Harness Adapter 57001 1561
252. able Installation 11 38 2WD AWD Vacuum Actuator Removal 11 39 2WD AWD Vacuum Actuator 11 40 PWD AWD Shift Cable LubriCalloni s o e eer ERE eH ORE 11 40 2WD AWD Shift Cable Inspection 11 41 Front Final Gear Case Removal vec ede n ree etd 11 41 Front Final Gear Case Installation 11 42 Front Final Gear Case 1 5 11 43 Front Final Gear Case Coupling Inspection 11 46 Front Final Gear Gase ASsetribly c 11 47 Ring Gear Disassembly usd one ee tet spas E E 11 54 Ring Gear C 11 55 LSD Clutch Torque Inspection 11 55 Pinion Gear Unit Disassembly oe t or i Rete exa PER UR DU xk xar e 11 56 Pinion Gear Unit ASSembly i csset ect 11 56 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 2 FINAL DRIVE Front Final Bevel Gear Adjustment etre ede E EU REOR ERN 11 57 Front Final Gear Case Backlash
253. aintenance chapter Drive Belt Inspection e Refer to the Drive Belt Inspection in the Periodic Mainte nance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 14 CONVERTER SYSTEM Drive Pulley Drive Pulley Removal e Remove the torque converter cover see Torque Con verter Cover Removal e Remove the three cover bolts A and install the drive pul ley holder B Special Tool Drive Pulley Holder 57001 1620 e Tighten the three cover bolts Torque Drive Pulley Cover Bolts 12 5 N m 1 3 kgf m 111 in Ib e Loosen the drive pulley bolt C left hand threads hold ing the drive pulley with the drive pulley holder NOTE OThe drive pulley bolt has left hand threads Turn the wrench clockwise for loosening e Remove the drive pulley bolt two washers and the stepped washer but do not remove the drive pulley holder yet Remove the drive pulley A from the crankshaft by screw ing the drive pulley puller bolt B clockwise while holding the drive pulley with the drive pulley holder C Special Tools Puller Bolt 57001 1711 Drive Pulley Holder 57001 1620 Drive Pulley Disassembly e Hold the drive amp driven pulley holder 57001 1473 A and the tapered guide of the holder 57001 1412 B in a vise so that the upper surface on the holder is 7 mm 0 28 in C above the vise Special Tools
254. ak Voltage 5 16 39 Crankshaft Sensor Removal 16 39 Crankshaft Sensor Installation 16 40 Crankshaft Sensor Inspection 16 40 Crankshaft Sensor Peak Voltage IriSpecliOrtes sace recu 16 40 Alternator Rotor Inspection 16 41 Ignition Timing 16 41 Electric Starter System 16 44 Starter Motor Removal 16 44 Starter Motor Installation 16 44 Starter Motor Assembly 16 46 Brush Inspection 16 48 Commutator Cleaning and 16 48 Armature Inspection 16 48 Brush Lead Inspection 16 49 Right hand End Coverdnspection 16 49 Starter Relay Inspection 16 49 Starter Relay Installation 16 49 Starter Control Relay Inspection 16 49 Starter Motor Clutch Removal 16 50 Starter Motor Clutch Installation 16 51 Starter Motor Inspection 16 51 Torque Limiter Inspection 16 51 Lighting System 16 52 Headlight Beam Vertical 16 52 Headlight Bulb Replacement 16 52 Tail Brake Light Bulb Replacement 16 53 Radiator Fan 16 56 Radiator Fan Circuit Inspection 16 56 Radiator Fan Motor Inspection 16 56 Radiator Fan Breaker
255. akes overheat OThere is a large difference in inner and outer pad wear OThe seal is stuck to the pistons xlf the piston seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed 06011 851 6 Dust Seal and Friction Boot Damage Inspection e Replace the dust seals A in accordance with the Peri odic Maintenance Chart or check that the dust seals and friction boots B are not cracked worn swollen or other wise damaged x lf they show any damage replace them HLOG012BS1 C Front Brake Caliper Piston and Cylinder Damage Inspection e Visually inspect the piston A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scored or rusty Front Brake Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts A alf the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber boots B are not damaged x lf the rubber boot is damaged replace the rubber boot caliper holder shaft is damaged replace the caliper holder shaft and rubber boot as a unit HLOG014BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvpart
256. aladjustment Suspension arm bent or twisted Steering shaft bent Steering gear assembly damaged Front or rear tire air pressure unbalanced Shock absorber unbalanced Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber damaged Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber damaged Brake Doesn t Hold Front brake Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Pad overworn or worn unevenly Oil grease on pads and disc Disc worn or warped Brake overheated Rear Brake Brake not properly adjusted Plates worn Brake parts worn or damaged Kawasaki Engine Brake Control System Malfunction Actuators failed Speed sensor short or open Forward Reverse detecting sensor short or open Actuator controller failed Controller 10 A fuse blown Battery disconnected Battery Discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator rectifier trouble Alternator trouble Wiring faulty Battery Overcharged Regulator rectifier trouble Battery trouble DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITA
257. allation e Install the spring seat e Replace the valve stem oil seal xIf a new valve is to be used check the valve to guide clearance see Valve to Guide Clearance Measurement x lf there is too little clearance ream the valve guide see Valve Guide Installation x lf there is too much clearance install a new valve guide see Valve Guide Removal and Valve Guide Installation e Check the valve seat see Valve Seat Inspection e Apply a thin coat of molybdenum disulfide grease to the valve stem e Install each spring so that the closed coil end faces down wards OThe white paint on the spring faces upwards Valve Stem A Oil Seal B Spring Seat C Spring D Retainer E Split Keepers F Closed Coil End G HE13000BS2 C Valve Guide Removal e Remove Valve see Valve Removal Valve Stem Oil Seal e Hammer lightly on the valve guide arbor A to remove the guide from the top of the head Special Tool Valve Guide Arbor 5 57001 1203 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 33 Valves Valve Guide Installation e Lightly oil the valve guide outer surface e Using the valve guide arbor A drive the valve guide B until its flange touches the cylinder head Special Tool Valve Guide Arbor 5 57001 1203 e Ream the valve guide with the valve guide reamer A it may be ne
258. alve Hose Primary C Bolts D ISC Valve E p ISC Valve Installation e Install the ISC valve e Tighten Torque ISC Valve Mounting Bolts 8 8 0 90 kgf m 78 in Ib ISC Valve Inspection e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter ISC Valve Connector A Connect the hand tester to the following pair of terminals Special Tool Hand Tester 57001 1394 e Set the hand tester to the x 1 range Connections Terminal A B Terminal B C Terminal D E Terminal E F Standard Resistence 28 8 31 2 Q at 20 C 68 F x lf the tester does not read as specified replace the ISC valve HC11086BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 89 Air Cleaner Air Cleaner Element Removal e Remove Quick Rivets A both sides Air Cleaner Top Cover B e Remove Clips A Air Cleaner Housing Cap B e Remove Element Holder Screw A Element Assembly B e After removing the element stuff pieces of lint free clean cloth into the air cleaner ducts to keep dirt out of the car buretor and engine A WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident Replace the air cleaner element according to the maintenance chart If dirt gets throug
259. alves must be replaced as a set NOTE OBe certain that all parts are cleaned thoroughly before assembly OBlow through all oil passages with compressed air to clear any blockage in the crankcase halves and crank shaft A WARNING Clean the engine parts in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or low flash point solvents to clean parts A fire or ex plosion could MENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 10 CRANKSHAFT TRANSMISSION Crankcase e Press and insert the new ball bearings until they are bot tomed Special Tool Bearing Driver Set 57001 1129 A Ball Bearing B Ball Bearing sealed side towards crankcase e Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole C Needle Bearing D Needle Bearing Insert it from outside e Apply engine oil to the bearings e Install Oil Pressure Relief Valve E see Oil Pressure Relief Valve Installation in the Engine Lubrication System chapter LI PN e Install Rear Cylinder Camshaft Chain Guide A e Tighten Torque Rear Cylinder Camshaft Chain Guide Bolt B 20 2 0 kgf m 15 ft Ib e Press and insert the new ball bearings A until they are
260. anada Model IP02080BW5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 13 Exploded View 1 Reflector Yellow 2 Reflector Red DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 14 FRAME Exploded View KRF750P R V Models IP02081BW5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 15 Exploded View 1 Upper Bar Mounting Bos 465 47 934 2 Sun Top Cover DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 16 FRAME Seat and Seat Belts Seat Removal e Pull the seat lock lever A upward e Lift the front edge of the seat B and then slide the seat forward and up Seat Installation e Insert the projections A at the rear of the seat into the seat holders B e Push down on the seat at the front and insert the pin A into the seat lock OThe seat lock clicks A WARNING A loose seat could cause the operator to lose con trol or the passenger to fall out of the vehicle dur ing operation causing severe injury or death Make sure the seat is securely la
261. and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 39 Throttle Sensor Service Code 11 Throttle Sensor Output Voltage Inspection e Measure the output voltage in the same way as input volt age inspection Note the following e Connect a digital meter to the connector A with the nee dle adapter set Special Tool Needle Adapter Set 57001 1457 Connections to Adapter Meter Y W lead Meter BR BK lead e Start the engine and warm it up thoroughly e Check idle speed to ensure the throttle opening is correct Idle Speed Standard 1 100 50 r min rpm xIf the idle speed is out of the specified range adjust it see Idle Speed Inspection in the Periodic Maintenance chapter e Turn the ignition switch OFF e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Throttle Sensor Output Voltage Standard DC 1 00 1 24 V at idle throttle opening DC 4 0 4 4 V at full throttle opening for reference NOTE OOpen the throttle confirm the output voltage will be raise OThe standard voltage refers the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly O
262. and Adjust ment in the Periodic Maintenance chapter Water Temperature Switch Inspection e Refer to the Water Temperature Sensor Inspection in the Fuel System DFI chapter Fuel Level Sensor Inspection e Remove Fuel Pump see Fuel Pump Removal in the Fuel System DFI chapter e Check that the float moves up and down smoothly without binding It should go down under its own weight x lf the float does not move smoothly replace the fuel pump assembly e Using a hand tester A measure the resistance across the terminals in the fuel pump lead connector B Special Tool Hand Tester 57001 1394 NOTE Oln contrast to the normal measuring method the current that flows through the gauge when measuring it with a tester is very low thus making the measurement easily affected by the oxidized film of the resistance plate and resulting in excessive resistance Therefore make sure to wipe the resistance plate with alcohol before taking a measurement x If the readings are not as specified replace the fuel pump assembly Fuel Level Sensor Resistance Standard Full Level Position 10 Q Empty Level Position D 120 O Speed Sensor Removal Installation e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance Chapter e Disconnect the speed sensor Connector A e Remove Bolt B Speed Sensor C e Replace the O ring with a new one e Apply grease to the O
263. and Spacer Shifter D Shift Rod E M IL LLL DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 24 CRANKSHAFT TRANSMISSION Transmission e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove Spacer A Idle Gear Assembly B Washers and Spacer C Low and High Gears D e Remove Needle Bearings A e Remove the driven shaft B from the crankcase using a press Transmission Installation e Insert the driven shaft in the crankcase until it is bottomed using a press e Apply engine oil to the needle bearings and install them e Install the following parts on the low gear Needle Bearings B Spacer C P No 92026 1599 48 2 x 54 3 x 1 0 High Gear D DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 25 Transmission e Apply engine oil to the journal of the idle shaft A e Install Idle Shaft with Gear Assembly B Spacer C Spacer D P No 92026 1599 48 2 x 54 3 x 1 0 e Apply engine oil to the inner surface of the spacer E e Install the spacer E so that the rounded side F faces outward G e Install Spacer A Toothed Washer B Circlip Special Tool Outside Circlip Pliers 57001 144 e Apply engine oil Shift
264. ant leak the mechanical seal in the pump could be damaged Replace the mechanical seal with a new one see Mechanical Seal Replacement Mechanical Seal Replacement e Remove Water Pump Impeller see Water Pump Impeller Re moval Alternator Cover see Alternator Cover Removal in the Electrical System chapter e Take the bearing A out of the alternator cover using the bearing remover Special Tools Bearing Remover Shaft 9 B 57001 1265 Bearing Remover Head 10 x 012 C 57001 1266 e Press out the mechanical seal A and oil seal B from the inside of the alternator cover with the bearing driver set C Special Tool Bearing Driver Set 57001 1129 NOTICE If either the mechanical seal oil seal or the ball bearing is removed make sure to replace all of them simultaneously with a new one Be careful not to block the inspection hole with the oil seal If the inspection hole is blocked the coolant may pass through the oil seal and flow into the crankcase HD06000781 06000851 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 4 12 COOLING SYSTEM Water Pump e Apply heat resistance grease on the oil seal lip e From outside the alternator cover press and insert the oil seal A so that its surface is flush with the step portion B of the cover as s
265. ar case Abnormal Frame Noise Shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Rear brake noise Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc not properly mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged DOCUMENT AVAILABLE FOR eet teg high gt Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 5 Troubleshooting Guide Black Smoke Air cleaner clogged Brown smoke Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Steering wheel hard to turn Tire air pressure too low Steering shaft damaged Steering shaft lubrication inadequate Steering shaft bent Steering gear assembly damaged Steering knuckle joint damaged Tie rod end damaged LSD clutch maladjusted front final gear case Noise when turning Side gear or pinion damaged front final gear case LSD clutch friction plates damaged Front final gear case Steering wheel shakes or excessively vibrates Tire worn Wheel rim warped Suspension arm bushing worn Tie rod joint worn Axle shaft bearing worn Steering wheel mount loose Steering bolt or nut loose Steering wheel pulls to one side Frame bent Wheel m
266. ar case see Front Final Gear Case Assembly Olt is not necessary to install the variable front differential control unit OWhen installing the pinion gear bearing holder non permanent locking agent is not used OUse the following two spare bolts when installing the front final gear case center cover A M10 Bolt B L 2 35 mm 1 38 in P 1 25 mm 0 049 in M8 Bolt C L 40 mm 1 57 in P 1 25 mm 0 049 in 1L04017BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 61 Front Final Gear Case e Temporarily install the right front axle in the gear case and hold it in a vise e Mount a dial gauge A so that the tip of the gauge is against the splined portion B of the pinion gear shaft e To measure backlash turn the pinion gear shaft right and left C while holding the front axle steady The differ ence between the highest and lowest gauge reading is the amount of backlash OMeasure backlash at three locations equally spaced on the splines Front Final Bevel Gear Backlash Standard 0 08 0 16 mm 0 003 0 006 in at pinion gear spline x If the backlash is not within the standard replace the ring gear shims according to the below NOTE To increase backlash increase the thickness of the shim s 1 and decrease the thickness of the shim s 2 To decrease backlash decrease th
267. aring Position Plate Screws 0 50 43 in lb L Rear Cylinder Camshaft Chain Guide Bolt 2 0 15 Grip Hold Nut 1 0 87 in lb Tie rod End Locknut 2 0 14 Shift Lever Assembly Nut 2 0 14 R Tie rod End Bolt 1 0 87 Tie rod End Front Locknut 1 0 87 Lh Tie rod End Rear Locknut 1 0 87 Tie rod End Nut 2 0 14 R Shift Shaft Lever Bolt 1 4 10 Shift Shaft Gover Bolts 0 90 78 in lb Shift Shaft Positioning Bolt 2 5 18 Neutral Position Switch 1 5 11 Reverse Position Switch 1 5 11 Shift Shaft Spring Bolt 2 5 18 LB Wheel Tires Front Axle Nuts 27 1 196 Front Wheel Nuts 11 2 81 S Rear Wheel Nuts 11 2 81 S Tie rod End Locknuts 4 5 32 Rear Axle Nuts 27 1 196 Final Drive Output Bevel Gears Rotor Mounting Bolts 1 2 106 in lb Output Driven Bevel Gear Housing Bolts 2 7 19 Bevel Gear Bearing Holder Nut 20 4 148 LB DOCUMENT AVAILABLE FOR MIL ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Bearing Holder M64 Bearing Holder M75 250 184 L Output Shaft Holder Nut 200 148 LB Output Drive Bevel Gear Housing Bolts 26 2 7 19 Bevel Gear Cover Bolt L 65 mm 8 8 0 90 78 inlb REO Bevel Gear Cover Bolts L 20 mm 88 0 90 78 in lb Forward Reverse Detecting Sensor Mounting Bolt 14 9 1 5 11 Front Final Gear Case Differential Control Shift Shaft Lever Nut 8 8 0 90 78 in lb R Differential Shift Cable Holder
268. aring Remover B 57001 1058 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 16 FINAL DRIVE Output Bevel Gears Output Drive Bevel Gear Assembly e Press the new inner ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 e Apply a non permanent locking agent to the threads of the bearing holder A and tighten it so that the deep side B faces outward Torque Bearing Holder M64 120 N m 12 2 kgf m 89 ft lb e Press the output drive bevel gear until it is bottomed e Apply a non permanent locking agent Three Bond TB2471 Blue to the threads of the bevel gear bearing holder nut A and tighten it so that the projection side B faces outward Special Tool Socket Wrench C 57001 1482 Torque Bevel Gear Bearing Holder Nut 200 N m 20 4 kgf m 148 ft Ib e Press the new outer ball bearing until it is bottomed Output Driven Bevel Gear Removal e Remove Engine Engine Removal in the Engine Removal Instal lation chapter Output Driven Bevel Gear Housing Bolts A Output Driven Bevel Gear Housing B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 17 Output Bevel Gears OTap lightly the front end A of the output driven bevel gear shaft usin
269. aryatvparts com 6 2 6 7 6 9 6 9 6 9 6 10 6 11 6 11 6 13 6 13 6 13 6 13 6 13 6 13 6 14 6 14 6 14 6 15 6 17 6 18 6 20 6 22 6 22 6 22 6 23 6 24 6 26 DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 2 CONVERTER SYSTEM Exploded View IFO2030BWS C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Exploded View CONVERTER SYSTEM 6 3 Torque No Fastener Nm kafi itib Remarks 1 Pulley Bolt 93 9 5 69 Lh 2 Pulley Cover Bolts 12 5 1 3 111 in lb 3 Ramp Weight Nuts 7 0 0 71 62 in lb R 4 Spider 275 28 203 Lh 5 Driven Pulley Nut 93 9 5 69 R G Apply grease Lh Left hand Threads R Replacement Parts WR Apply grease WR500 No2 KYODO YUSHI POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 4 CONVERTER SYSTEM Exploded View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com IFO2029BW5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 5 Exploded View No Fastener zoe Remarks N m kgf m ft Ib 1 Engine Brake Actuator Mounting Bolts 8 8 0 90 78 in lb 5 2 Brake Actuator
270. ase DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 8 FRAME Exploded View 1 02078885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 9 Exploded View Fastener Right and Left Bar Mounting Bolts Seat Belt Case Mounting Nuts Seat Plate Bolts L Apply a non permanent locking agent R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com Remarks DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 10 FRAME Exploded View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 11 Exploded View Fastener Remarks Brake Pedal Bracket Mounting Bolts L 20 mm 0 79 in Brake Pedal Bracket Mounting Bolts L 30 mm 1 2 in Center Bracket Mounting Bolts Right Frame Pipe Mounting Bolts Bracket Bolts Heat Guard Bolts AD Apply adhesive agent L Apply a non permanent locking agent R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 12 FRAME Exploded View C
271. ase to the grease seal lips A e Install the collars B e When replacing the ball bearing A install the new circlip B C Grease Seals D Collars E New Nuts F Needle Bearing e Tighten Torque Rear Shock Absorber Mounting Nuts 95 5 9 7 kgf m 70 ft Ib e Install the removed parts see appropriate chapters 1N04001BS2 C Rear Shock Absorber Inspection e Check the ball bearing and grease seals in the upper pivot xIf they are damaged replace them e Check the needle bearing and grease seals in the lower pivot x lf they are damaged replace them DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 12 SUSPENSION Shock Absorbers Other than KRF750S Model Rear Shock Absorber Scrapping WARNING Pressurized nitrogen may explode when heated The rear shock contains nitrogen gas To avoid an explosion do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Drill the hole A of the reservoir tank using about 2 mm 0 08 in drillbit A WARNING Drilling will release high pressure gas that may blow metal shavings at high speed and cause eye injury Wear safety goggles or face shield when drilling the reservoir tank DOCUMENT A
272. at Lower Right Plate C Seat Lower Right Plate Installation e Install Seat Lower Right Plate A Bolts B and Brackets C Seat Lower Left Plate Removal e Removal Seat Lower Cover see Seat Lower Cover Removal Tapping Screw A Bolts B and Bracket C Clamp D e Removal Bolt A Seat Lower Left Plate B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 49 Covers Seat Lower Left Plate Installation e When installing the insulators and damper on the seat lower left plate A install them as shown in the figure Damper B P No 92161 0273 15 mm 0 59 in C Insulator D P No 16073 0112 Insulator E P No 16073 0113 OMatch the center of the hole to the center of the nut F OMatch the edges of the insulators G e Install Bracket H Clamp 1 Olnstall the clamp in the right angle direction of the pipe J e Install Bolts K Tapping Screw L Right and Left Brackets Removal Right Bracket e Remove Seat Lower Cover see Seat Lower Cover Removal Right Side Cover see Side Cover Removal Center Bracket Mounting Bolt A Bracket Bolts B Right Bracket C Left Bracket e Remove Seat Lower Cover see Seat Lower Cover Removal Left Side Cover see Side Cover Removal Seat Lower Left Plate see Seat Lower Left Plate Re moval Ignition Coil A Center Bracket Mou
273. ay opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contract and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 13 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 13 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY COOLIN
274. b Starter Motor Cable Mounting Nut 6 8 0 69 60 in lb Starter Motor Through Bolts 5 0 0 51 44 in lb Starter Motor Clutch Bolts 34 3 5 25 L Left Engine Cover Bolts 5 9 0 60 52 L Alternator Rotor Bolt 127 13 0 94 Alternator Cover Plugs 17 5 1 8 13 Crankshaft Sensor Mounting Bolts 5 9 0 60 52 in lb Alternator Stator Bolts 13 5 1 4 10 Alternator Cover Bolts L 55 mm 2 17 in 8 8 0 90 78 Alternator Cover Bolts L 30 mm 1 18 in 8 8 0 90 78 Breather Plate Screws 2 9 0 30 26 in lb L Ignition Coil Mounting Bolts 5 9 0 60 52 inrlb Spark Plugs 13 1 3 115 in Ib Vacuum Actuator Bracket Bolts 8 8 0 90 78 Solenoid Valve Bracket Bolts 8 8 0 90 78 ECU Mounting Bolts 6 9 0 70 61 in lb Engine Brake Actuator Mounting Bolts 8 8 0 90 78 in lb S Engine Brake Actuator Cover Bolt 8 8 0 90 78 S Forward Reverse Detecting Sensor Mounting Bolt 14 9 1 5 11 Speed Sensor Mounting Bolt 8 8 0 90 78 in lb DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 11 Torque and Locking Agent Torque Fastener Nm kgf m ft Ib Remarks Reverse Position Switch 15 1 5 11 Neutral Position Switch 15 1 5 11 4WD Position Switch 15 1 5 11 Water Temperature Sensor 12 1 2 106 in lb Radiator Fan Assembly Bolts 8 3 0 85 73 Oil Pressure Switch 15 1 5 11 56 Battery Holde
275. bon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guides worn Alternator rotor loose Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mountJoose Driven pulley shoe worn Drive pulley weight or roller side washer worn Drive pulley weight or roller worn Wear guides worn Transmission noise Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Front or rear final gear case noise Insufficient lubricant Incorrect oil Front final gear case Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Worn LSD clutch friction plate Front final gear case Damaged side gears or pinions Front final ge
276. c Maintenance Procedures e Remove the gauge and measure the distance L between the mark D and the gauge bottom end e Calculate the belt deflection H H L mm 82 4 mm or H L in 3 24 in Belt Deflection Belt Deflection Standard 22 31 mm 0 87 1 22 in at checking SIRF7581S1 For reference The 82 4 mm 3 24 in is the distance be tween the top surface of cover plate and the design base point of the drive belt for measuring x lf the belt deflection is not within the specified range ad just the deflection by adding or removing spacers on the fixed sheave of the driven pulley NOTE OThis is timesaving preliminary drive belt deflection mea suring method When recheck the belt deflection after deflection adjustment follow the standard method de scribed below Olf the belt deflection is not within the standard adjustit by adding or removing spacers on the fixed sheave of the driven pulley NOTE OFor easy drive belt deflection judgment puta9mm wide tape A at the position on the belt deflection gauge as shown in the figure With this tool the technician can judge the deflection directly by checking the position of the tape against the cover plate Standard Drive Belt Deflection Measurement e After deflection adjustment check the belt deflection be fore installing the cover following the method de scribed below e Measure the belt deflection A at the
277. cal shock Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and igniter Use the standard regulator rectifier or the igniter will be damaged Spark Plug Removal e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Rubber Covers Spark Plug Cap A e Using a spark plug wrench remove the spark plug B Spark Plug Installation e Tighten Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib e Fit the spark plug caps securely e Pull up the spark plug caps lightly to make sure of the installation of the spark plug caps Spark Plug Cleaning Inspection e Refer to the Spark Plug Cleaning Inspection in the Peri odic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter Ignition Coil Removal Front Side e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Rubber Cover Clamps A and B Spark Plug Cap C Primary Lead Connectors D Bolts E Ignition Coil F DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 37 Ignition System R
278. carbon particles are purged from the muffler DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures A DANGER Exhaust gas contains carbon monoxide a color less odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area Stop the engine e Apply grease to the new gasket A and install it on the muffler e Install the spark arrester B so that the opening C of the pipe faces downward e Tighten Torque Spark Arrester Mounting Bolts 13 N m 1 3 kgf m 115 in Ib Converter System Converter Drive Belt Wear Inspection Inspection of the drive belt is required at least every 200 hours 6 months of vehicle use or 4 000 km 2 500 mi whichever comes first An average day of use is calculated as 20 km 13 mi per day or 1 1 hours More frequent inspection is necessary if the vehicle is subjected to usage WARNING Neglect abuse or failure to maintain the transmis sion can result in a severely worn or damaged drive belt locking up the transmission and wheels This can cause the operator to lose control and have an accident resulting in injury death Maintain ac cording to periodic maintenance chart e Remove Engin
279. ce C e Place the rear camshaft chain D onto the rear camshaft sprocket e Engage the camshaft and intermediate shaft chains on the intermediate shaft sprocket A and insert the inter mediate shaft left side view OFit the splines of the intermediate shaft B and grooves C of the sprocket as shown e Align the punch mark D on the sprocket with the em bossed mark E on the crankcase DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 26 ENGINE TOP END Camshaft Front Camshaft Chain e Install the circlip A Special Tool Outside Circlip Pliers 57001 144 e Rotate the crankshaft clockwise 270 e Align the key grooves B on the crankshaft with the em bossed line C on the crankcase e Move the intermediate shaft A to the left side of the en gine e Engage the front camshaft chain B with the sprocket on the intermediate shaft e Install left side view Position Plate A e Tighten Torque Position Plate Bolts B 8 8 N m 0 90 kgf m 78 in Ib e Install Intermediate Shaft Chain Guide A front e Tighten Torque Intermediate Shaft Chain Guide Bolts B 8 8 0 90 kgf m 78 in Ib e Install Intermediate Shaft Chain Guide A Rear Washer B Circlip C Special Tool Outside Circlip Pliers 57001 144 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online a
280. ce between the fuel tube and the water temperature sensor at least 5 mm 0 2 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 10 APPENDIX Cable Wire and Hose Routing u 40 RIES 9 e I MOSS f AO Ne T eX 48 5 CG SQ SS RNV EL 17 INS Jid u Y ns ELT N L C 7 dx RN 2 9 e on 7 1808255885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 11 Cable Wire and Hose Routing ISC Valve ISC Valve Tube Front ISC Valve Tube Primary ISC Valve Tube Rear Breather Hose Clamp Clamp the ISC valve tube Primary and breather hose White Marks Clamp Main Harness Clamps Drain Tube Drain Plug View P 1 o N O DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 12 APPENDIX Cable Wire and Hose Routing 1808221884 C 1 Front Gear Case Breather Hose 2 Bands 3 Clamp 4 Reserve Tank Overflow Hose 5 Fan Motor Breather Hose
281. cessary to ream the guide even if the old guide is reused Special Tool Valve Guide Reamer 5 57001 1204 Valve to Guide Clearance Measurement If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move C the stem back and forth to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x lf the reading exceeds the service limit replace the guide HE13002BS1 P NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 17 mm 0 0035 0 0067 in Inlet 0 03 0 11 mm 0 0012 0 0043 in Service Limit Exhaust 0 37 mm 0 0146 in Inlet 0 31 mm 0 0122 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 34 ENGINE TOP END Valves Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OCoat the valve seat with machinist s dye OPush the valve into the guide ORotate the valve a
282. ch B in the inspection window and the cam lobes are pointing away from the rocker arms the end of the compression stroke Be sure to position the crankshaft at of the end of the compression stroke when removing or installing the rocker case The rocker arms could bend the valves HE10001BS1 C e Remove Rocker Case Bolts A e Lift the rocker case to clear of the dowel pins in the cylin der head and remove the front rocker case B HE10000BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 17 Rocker Case Rear Rocker Case e Remove Front Rocker Case Air Cleaner Housing and Duct see Air Cleaner Housing and Duct Removal in the Fuel System DFI chapter Clamp Bolts A e Using a wrench on the alternator bolt turn the crankshaft counterclockwise 270 until T R mark A is aligned with the notch B in the inspection window and the cam lobes are pointing away from the rocker arms the end of the compression stroke Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case The rocker arms could bend the valves e Remove Rear Camshaft Chain Tensioner see Camshaft Chain Tensioner Removal Rocker Case Bolts A Rear Rocker Case B e Lift the rocker case to clear of the dowel pins in
283. ck Absorbers Other than KRF750S Model Front Shock Absorber Spring Preload Adjustment e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Using the nut wrench turn the adjusting sleeve A to ad just the spring preload Special Tool Steering Stem Nut Wrench 57001 1100 OThe standard adjuster setting for average build rider of 68 kg 150 Ib with no passenger and no accessories is 2th position Spring Preload Setting Standard Position 2th position Adjustable Range 1st 5th position e f the compression of the spring is not suited to the op erating conditions adjust it to an appropriate position by referring to the table below Spring Preload Adjustment Shock Adjuster Damping Absorb t Position Force Road Driving Hardness Conditions Speed 151 Weak Soft Good Front Shock Absorber Removal e Support the vehicle on a stand or a jack so that the front wheels are off the ground Special Tool Jack 57001 1238 e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e While holding the front wheels remove the lower and up per shock absorber mounting bolts A and nuts e Remove the front shock absorber B Front Shock Absorber Installation e Apply grease to the inside of needle bearing A and grease seal lips B e Install the collar C e z X M A ag E s
284. clip A Boot B Small Band C Outboard Joint Boot Installation e Clean the axle shaft wiping off the used grease on it e Wind the tape on the splines of the axle shaft in order to protect the joint boot e Install New Small Band A New Boot B OApply the special grease slightly on the inside of the new boot small diameter and install the boot on the axle shaft Only the special grease that is included with the boot kit can be applied to the boots e Install New Circlip C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 70 FINAL DRIVE Rear Axle e Apply the special grease slightly on the part A of the band installation in order to make easy to install the boot band e Tighten the small boot band B OTighten the boot band A and bend the tangs B securely to hold down the end of the band e Place the special grease tube nozzle in the bore of the housing and squeeze the tube A until the grease comes out from the joint bearing e Tap the shaft end A straight with a plastic hammer until it is locked by the circlip amp e Squeeze all of the special grease A into the new boot B and slide the boot onto the outboard joint C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY U
285. completely wiped up immediately e Turn the ignition switch OFF e Wait until the engine cools down e Prepare a fuel hose Special Tool and a measuring cylin der Special Tool Fuel Hose 57001 1607 e Remove the fuel hose see Fuel Hose Replacement A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 75 Fuel Line e Connect the prepared fuel hose A to the fuel pump outlet pipe e Secure the fuel hose with a clamp e Insert the fuel hose into the measuring cylinder B A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop NOTICE Do not drive the fuel pump without the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Measure the discharge for 3 seconds Amount of Fuel Flow Standard 50 mL 1 7 US oz or more for
286. connect the measuring adapter A between the connectors of the fuel pump and harness Special Tool Measuring Adapter 57001 1700 e Connect the hand tester B to the measuring adapter leads Special Tool Hand Tester 57001 1394 Connections to Adapter Meter W R lead of Main Harness Meter BK Y lead of Main Harness e Confirm the color of the lead by opening the cap A of the connector W R B BK Y C e Measure the operating voltage with engine stopped with the connector joined e Turn the ignition switch ON Fuel Pump Operating Voltage Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch OFF x f the reading is not the standard check the fuel pump re lay see Relay Inspection in the Electrical System chap ter xIf the fuel pump relay is normal check the wiring for con tinuity see Fuel Pump Circuit xIf the wiring is good check the for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump B and cannot be removed Viae v DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 79 Fuel Pump Fuel Filter Cleaning OThe fuel filter A and fuel
287. cribed below x f the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B e Lap the valve to the seat once the seat width and O D are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound A Lapper B Valve Seat C Valve e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If itis it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter ENGINE TOP END 5 37 8 15012351 GE15012081 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at ww
288. d Inspection in the Periodic Maintenance chapter Air Cleaner Housing and Duct Removal e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter e Loosen the clamp screw A e Remove Air Cleaner Mounting Bolts B both sides Air Cleaner Housing C e Remove Breather Hose A and Clamp ISC Valve Hose B e Disconnect Inlet Air Temperature Sensor Connector A e Loosen Clamp Screws B e Remove Hose C Air Cleaner Duct D Air Cleaner Housing and Duct Installaion e Install Hose A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 92 FUEL SYSTEM DFI Air Cleaner e Install the air cleaner duct assembly A to the throttle body assy e Tighten the clamp screws e Connect Inlet Air Temperature Sensor Connector B e Tighten Clamp Screws A e When tighten the clamp screws install the clamp as shown in the figure Front B Out Side C 30 D View A E 1C08009BS2 C e Install Breather Hose A and Clamp B ISC Valve Hose C e Install the air cleaner housing A to the rubber duct B e Apply a non permanent locking agent Air Cleaner Mounting Bolts C both sides e Tighten Torque Air Cleaner Mounting Bolts 8 8 N m 0 90 kgf m 78 1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militar
289. d repair or replace them xIf the wiring is good check the power source voltage of the ECU NOTE OBe sure the battery is fully charged e Connect the ECU connectors e Connect the hand tester A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 1015085BS1 C Battery C ECU Power Supply Inspection Connections Tester Terminal 8 W Tester gt Battery Terminal Tester Terminal 13 BR Tester Battery Terminal Ignition Switch OFF 1 Battery Voltage I 0 V Ignition Switch ON 1 Battery Voltage Battery Voltage If the reading is out of the specification check the follow ing Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 10 A see Fuse Inspection Electrical System chapter Power Source Wiring see ECU Power Source Circuit DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 72 FUEL SYSTEM DFI ECU ECU Power Source Circuit i 2 3 4 8 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3i 32 33 34 35 36 37 38 39 40 41 42 43 44 e t e Cu 1615076892 C ECU Electronic Control Unit Frame Ground 1 Engine Ground Battery Ignition Switch Fuse Box Main Fuse 30 A OD DOCUMEN
290. del Beginning Frame No 2010 KRF750NAF JKARFDN10AB500001 2010 KRF750PAF JKARFDP10AB500001 2010 KRF750RAF JKARFDR10AB500001 2010 KRF750SAF JKARFDS1 AB500001 2010 KRF750SAFA JKARFDS10AB500001 2010 KRF750 TAF JKARFDT1GAB500001 2011 KRF750NBF JKARFDN10BB502601 2011 KRF750PBF JKARFDP101BB501801 2011 KRF750RBF JKARFDR10BB501001 2011 KRF750SBF JKARFDS10BB501401 2011 KRF750SBFA JKARFDS10BB501401 2011 KRF750VBF JKARFDV10BB500001 O This digit in the frame number changes from one machine to another Order Online at www militaryatvparts com Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company DOCUMBKETNGA9924r 340 USE ONLY Printed in Japan
291. des IP13001BS1 C Side Cover Removal Right Side Cover e Remove Right Seat see Seat Removal Screws A Quick Rivet B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 45 Covers e Remove Screw A and Collar e Remove Screws A and Collars Screws B Guard C Quick Rivets D e Remove Screw A and Collar Quick Rivets B Fuel Tank Cap C Right Side Cover D Left Side Cover e Remove Left Seat see Seat Removal Screws A Quick Rivet B e Remove Screw A and Collar 1 128010 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 46 FRAME Covers e Remove Screws A and Collars Screws B Guard C Quick Rivets D e Remove Screw A and Collar Quick Rivets B Left Side Cover C Side Cover Installation e Install Right Side Cover A Quick Rivets B Collars C L 2 4 mm 0 16 in Screws D M6 L 16 mm 0 63 in Collars E L 7 2 mm 0 28 in Screws F M6 L 22 mm 0 87 in Guard G Screws H M5 e Install the left side cover according to the same procedure as the right side cover e Install Fuel Tank Cap Right Side IP13003BS2 C Seat Lower Cover Removal e Remove Engine Upper Cover see Engine Upper Cover Re moval Cent
292. e BL BL BK Y BK Y R BL BL BK Y BK Y R R 4 W R BR i BR SO Reverse Optional Light j Part ECU Electronic Control Unit Brake Tail Light Right 12V 27 8W Brake Tail Light Left 12V 27 8W El me m 28 zi Bos zer Fak 5355 ESS Forward S6 Xalve 1 gt Reverse Slee Detecting ELI Sensor p K ki Fuel Radiator Starter Vehicle ae Pump Fan Control down Diagnostic Relay Relay Relay Sensor System Connector IGNITION SWITCH CONNECTIONS Motor Other than US Model Battery vavta Engine Color BK W BR W av US Model Ground OFF a o Starter B o Start 98052 04826 Color Code Blue Green Orange 8 Red V Violet Y Yellow W2RO482CW5 C BK BR 6 Li O0 Orange P PU Lv Y DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that should be taken when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery lead connections This will burn out the diodes in the electrical parts OAlways chec
293. e Battery Negative Cable Clamp the alternator lead crankshaft sensor lead and oil pressure sensor lead with clamps Clamp the main harness with clamp as shown Engine Ground Clamp the alternator lead crankshaft sensor lead oil pressure sensor lead battery negative cable and starter cable with band Clamp the connector so that the connector does not touch to the engine Clamp Main Harness Engine DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 30 APPENDIX Cable Wire and Hose Routing CA model Q3 d 9297 E Arie CES rt UA D K gt j 18082308485 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 31 Cable Wire and Hose Routing npo ok Inlet Air Pressure Sensor Inlet Air Temperature Sensor Forward Reverse Detecting Sensor Connector Neutral Position Switch Reverse Position Switch Apply grease Chevron Black Pearl Grease EP NLGI 2 to the connectors Battery Positive Cable Battery Negative Cable Clamp the alternator lead crankshaft sensor lead and oil pressure sensor lead with clamps Clamp the main harn
294. e Apply a non permanent locking agent to the pinion gear bearing holder A but do not apply a non permanent lock ing agent to one pitch B from the tip e Install the pinion gear bearing holder so that the no coat ing side C faces the bearing e Tighten Torque Pinion Gear Bearing Holder 450 45 9 kgf m 332 ft lb 1L08007BS1 C e Apply molybdenum disulfide grease to the spline A in the ring gear B e Apply specified oil to the journal and teeth C e Install Shim D Ring Gear DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 83 Rear Final Gear Case e Install Shim A e Apply specified oil to the journal B e Apply grease to the O ring A and install the rear final gear case right cover B e Apply a non permanent locking agentto the rear final gear case right cover bolts e Tighten Torque Rear Final Gear Case Right Cover Bolts qna A 94 N m 9 6 kgf m 69 ft Ib Rear Final Gear Case Right Cover Bolts M10 B 49 N m 5 0 kgf m 36 ft Ib e Apply specified oil to the journal A of the brake camshaft e Install i Brake Camshaft A Steel Balls B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 84 FINAL DRIVE Rear Final Gear Case e Install th
295. e The left shaft A of the crankshaft is longer than the right shaft B e Apply engine oil to the both main journals e Insert the right crankshaft tapered end the shorter end into the right crankcase using a press and two crankshaft jigs Special Tools Crankshaft Jig 57001 1174 x 2 1040014 P Connecting Rod Removal e Remove the crankshaft see Crankshaft Removal e Remove the connecting rods A from the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps B so that they can be installed in their original positions ORemove the connecting rod big end nuts and take off the rod and cap with the bearing inserts 040015 Connecting Rod Installation NOTICE If the connecting rods bearing inserts or crank shaft are replaced with new ones select the bearing insert and check clearance with a plastigage before assembling the engine to be sure the correct bear ing inserts are installed e Apply molybdenum disulfide oil Inner Surface A of Bearing Inserts e Face the OUT marks B of both connecting rods to wards the outsides of the crankshaft e Fit the connecting rod cap so that the grooves C of the cap and connecting rod are on the same side DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 14 CRANKSHAFT TRANSMISSION Crankshaft Con
296. e Upper Cover see Engine Upper Cover Removal in the Frame chapter Bands A cut Air Outlet Duct B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Check the belt A for breaks x f necessary replace the belt e Push the drive belt A between the driven sheaves and check the belt position in the driven sheaves xIf the upper surface B of the drive belt is lowered 1 5 mm 0 059 in C or more from the edge D of sheaves B check the belt wear as follows 1508003851 C e Remove the torque converter cover see Torque Con verter Cover Removal in the Converter System chapter e Measure the width A of the belt at several locations with a pair of suitable straightedges B as shown x If any measurements exceed the service limit replace the belt Belt Width Standard 30 0 30 6 mm 1 181 1 205 in Service Limit 28 6 mm 1 126 in e Check the belt A for abnormal wear B OMeasure the width C of the beltat abnormal wear point any measurements exceed 0 5 mm 0 02 in replace the belt H 05003BS1 e Check the belt for cracks breaks or peeling If necessary replace the belt Belt A Crack B Broken C Peeling D H 05002BS1 DOCUMENT AVAILABLE FOR MILITARY USE
297. e brake cam plate A so that the recess side faces to steel balls e Install Steel Plate A P No 41080 1483 two holes as shown in the gigure Set Pins B and Springs C e Install alternately Friction Plates A Steel Plates P No 41080 1484 without hole e Install x 7 Steel Plate A P No 41080 1483 two holes Olnsert the pins B into the holes of the steel plate e Install _DowelPins A New Gasket B 5 Tighten Torque Rear Final Gear Case Gasket Screws C 1 3 N m 0 13 kgf m 12 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 85 Rear Final Gear Case e Install Rear Final Gear Case Front Cover A e Tighten Torque Rear Final Gear Case Front Cover Bolts B 24 2 4 kgf m 18 ft lb e Install Spring Bracket C e Apply a non permanent locking agent to the spring bracket bolt D e Tighten Torque Spring Bracket Bolt 8 8 N m 0 90 kgf m 78 in Ib IL08008BS1 C e Install Brake Cam Lever A OAlign the punch mark B of the brake cam lever with the punch mark C of the brake camshaft e Install Bolt D and Nut e Install Spring A Pinion Gear Unit Disassembly e Remove Pinion Gear Unit A See Rear Final Gear Case Disas sembly e Hold the pinion gear bearing holder nut B with the socket wrench C in vise and lo
298. e rim using suitable commercially available tire changer e Lubricate the tire beads again and center the tire on the rim e Support the wheel rim A on a suitable stand B to pre vent the tire from slipping off e Inflate the tire until the tire beads seat on the rim Maximum Tire Air Pressure to seat beads when cold Front and Rear 250 kPa 2 5 kgf cm 36 psi A WARNING Overinflating a tire can cause it to explode causing serious injury or death Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than maximum pressure e Check to see that rim lines A on both sides of the tire are parallel with the rim flanges B x lf the rim lines and the rim flanges are not parallel deflate the tire lubricate the sealing surfaces again and reinflate the tire e After the beads are properly seated check for air leaks OApply a soap and water solution around the tire bead and check for bubbles e Deflate the tire to the specified pressure e Check the tire pressure using an air pressure gauge Tire Air Pressure when cold Front 60 kPa 0 6 kgf cm 8 7 psi Rear 90 kPa 0 9 kgf cm 13 1 psi e Install the air valve cap e Install the wheel see Wheel Installation e Wipe off the soap and water solution on the tire and dry the tire before operation A WARNING Water or soap solution on the tire bead can cause tire separation and an accident
299. e ring gear e Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth OThe tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe x If the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown e Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as nec essary NOTE Olf the backlash is out of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before checking the tooth contact pattern DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 63 Front Final Gear Case Correct Tooth Contact Pattern No adjustment is required Bottom Sk Bottom Pinion Gear Heel Vie i ee Incorrect Tooth Contact Patterns Example 1 Decrease the thickness of the pinion gear shim s by 0 4mm 0 004 to correct the pattern shown below Repeat 0 1 mm 0 004 steps if necessary Bottom Heel Bottom Toe Pinion Gear Toe Heel x 4 ed i
300. e rod J Tighten Torque Tie rod End Nut K 19 6 N m 2 0 kgf m 14 ft Ib e Turn the tie rod until the upper tie rod end L will be ad justed to hole M of the shift lever assembly as shown in the figure OThe connection length of the upper and lower tie rod end N should be equal DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 1706001892 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 21 Transmission e Apply molybdenum disulfide grease to the collar A e Install the following parts to the shift lever assembly B Oil Seals C Tie rod End Bolt D e Tighten Torque Tie rod End Bolt 9 8 1 0 kgf m 87 in Ib e Turn the tie rod E and align the lever F with neutral position of the guide G as shown in the figure Mo Le 225 Ne 1706002892 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 22 CRANKSHAFT TRANSMISSION Transmission e Tighten the tie rod end rear locknut A so that the thread length is 6 mm 0 24 in B Torque Tie rod End Rear Locknut 9 8 1 0 kgf m 87 in Ib e Holding the rear tie rod end C and tighten the front lock nut D so that the thread length is 6 mm 0 24 in B Torque Tie rod End Front Locknut 9 8 N m 1 0 kgf m 87 in Ib NOTE O The front
301. e the battery is fully charged e Turn the ignition switch OFF e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter e Connect the hand tester to the connector A with the nee dle adapter set Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Connections Meter BL R lead or V lead Meter Battery terminal e Measure the output voltage with the engine stopped e Turn the ignition switch ON Fuel Injector Output Voltage Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch OFF xIf the reading is in specification check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf the reading is out of the specification check the wiring for continuity see Fuel Injector Circuit x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 67 Fuel Injectors Fuel Injector Fuel Line Inspection e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Fuel Hose see Fuel Hose Replacement
302. e the drain plug DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove Overflow Hose A and Clamp Screw B e Remove the reserve tank cap C and pour the coolant into a container e Install the water hoses to the water pipes and tighten the clamp screw e Install Overflow Hose and Clamp Reserve Tank A Olnsert the projection B into the grommet C e Tighten the screws e Fil the radiator up to the radiator filler neck A with coolant NOTE O Pour in the coolant slowly so that the air in the engine and radiator can escape e Fil the reserve tank up to the F Full level line with coolant NOTE O Pour in the coolant slowly so that the air in the engine and radiator can escape Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages considerably reducing the efficiency of the cooling system Water and Coolant Mixture Ratio when shipping Soft Water 5096 Coolant 5096 Freezing Point 35C 31 F Total Amount 4 4 L 4 7 US qt NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s directions DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com
303. e thickness of the shim s 1 and increase the thickness of the shim s 2 NOTE OThe total of the ring gear shims 1 and 2 should be less than D the clearance between the ring gear as sembly and gear case covers OExample D 2 34 mm 1 2 2 30 mm D 2 26 mm 1 2 2 25 mm OThe second decimal of the total of 1 and 2 should be X0 or x5 nearest of D e Recheck the backlash and readjust if necessary Front Final Gear Case Tooth Contact Adjustment e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the pinion gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear OThe checking compound must be smooth and firm with of tooth paste OSpecial compounds are available at automotive supply Stores for the purpose of checking differential gear tooth patterns and contact Use one of these for checking the bevel gears DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 62 FINAL DRIVE Front Final Gear Case e Assemble the front final gear case see Front Final Gear Case Backlash Adjustment e Turn the pinion gear shaft A for one revolution in the drive and reverse coast direction while creating a drag on th
304. ear Side e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Rubber Cover Spark Plug Cap A e Open the clamp B e Remove Primary Lead Connectors C Bolts D Ignition Coil E Ignition Coil Installation e Install Ignition Coil Torque Ignition Coil Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Connect the primary leads to the ignition coil terminals as shown Front Side G W Lead Terminal A Green 10039851 BR Lead Terminal B Black Rear Side BL W Lead Terminal A Green BR Lead Terminal B Black DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 38 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection e Remove the ignition coil e Measure the arcing distance with a coil tester A to check the condition of the ignition coil B e Connect the ignition coil with the spark plug cap left at tached at the end of the spark plug lead to the tester in the manner prescribed by the manufacturer and measure the arcing distance Ignition Coil 3 Needle Arcing Distance 7 mm 0 28 in or more A WARNING To avoid extremely high voltage shocks do not touch the coil body or leads x lf the distance reading is less than the specified value the ignition coil or spark plug cap is defective e To determi
305. eck Indicator Light LED O R Starter Relay BL Ground BK Y Injector 1 BL R Ignition Coil 1 G W DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 13 DFI Parts Location FI Indicator Symbol LCD A Inlet Air Pressure Sensor A Fuel Injectors B Inlet Air Temperature Sensor C Spark Plug Front A Ignition Coil 1 Front B Engine Ground A Crankshaft Sensor B Fuse Box A Vehicle down Sensor B ECU Electronic Control Unit C KDS Kawasaki Diagnostic System Connector D Fuel Pump Relay E Battery F Frame Ground 1 G DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 14 FUEL SYSTEM DFI Parts Location Spark Plug Rear A ISC Idle Speed Control Valve B Throttle Sensor C Water Temperature Sensor D Ignition Coil 2 Rear A Fuel Pump B Speed Sensor A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Specifications FUEL SYSTEM DFI 3 15 Item Standard Digital Fuel Injection System Idle Speed Throttle Body Assy Throttle Valve Bore ECU Electronic Control Unit Make Type Fuel Pres
306. ed parts be sure to check and adjust the backlash and tooth contact of the bevel gears First adjust backlash and then tooth con tact by replacing shims OThe amount of backlash is influenced by the ring gear position more than by the pinion gear position OTooth contact locations is influenced by the pinion gear position more than by the ring gear position DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 87 Rear Final Gear Case Rear Final Gear Case Backlash related Parts gt 11098009883 C Ring Gear Shim s Ring Gear Shim s Pinion Gear Shim s Pinion Gear Bearing Holder Ball Bearings Gear Case Right Cover Pinion Gear Ring Gear DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 88 FINAL DRIVE Rear Final Gear Case 1 Ring Gear Shims for Backlash Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 0248 0 2 mm 0 008 in 92180 0247 0 5 mm 0 020 in 92180 0246 0 8 mm 0 031 in 92180 0245 1 0 mm 0 039 in 92180 0244 1 2 mm 0 047 in 92180 0243 2 Ring Gear Shims for Backlash Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1417 0 2 mm 0 008 in 92180 1418 0 5 mm 0 020 in 92180 1419 0 8 mm 0 031 i
307. eels Tires chapter e Unscrew the nipple A and remove the brake pipe B e Immediately wipe up any brake fluid that spills Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove Retainer A Banjo Bolt B Washers and Brake Hose C e Remove Nipple A unscrew Brake Pipe B Bolt C Joint D e Remove Banjo Bolt A Washers and Brake Hose B 15140112 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove Clamp Bolts A and Clamp B both sides Grommets C both sides e Install New Brake Hose A Clamp Bolts B and Clamp C both sides Grommets D both sides Banjo Bolts E and New Washers e Touch the stopper of the brake hose to the stopper on the calliper e Tighten Torque Brake Hose Banjo Bolts 23 5 2 4 kgf m 17 ft lb e Install Joint A Bolt B Brake Pipe C Nipple D e Tighten Torque Brake Pipe Nipple 17 5 N m 1 8 kgf m 13 ft Ib 1814004BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Install New Brake Hose A Banjo Bolts B and New Washers OTouch
308. elt Case B Rear Bar Mounting Bolt C Lower Seat Bracket D and Seat Belt DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 19 Seat and Seat Belts e Remove Seat Belt Buckle Mounting Bolt A Seat Belt Buckle B Seat Belt Installation e Install Seat Belt Buckle A as shown in the figure e Tighten Torque Seat Belt Buckle Mounting Bolt B 46 5 N m 4 7 kgf m 34 ft lb e Fit the projection A on the recess of the frame and install the seat belt case B e Install Seat Belt Case Mounting Bolts C and Nuts e Tighten Torque Seat Belt Case Mounting Nuts 46 5 N m 4 7 kgf m 34 ft lb e Fit the cover in the case securely e Install Lower Seat Bracket A as shown in the figure Bar Mounting Bolt B e Tighten Torque Right Left Bar Mounting Bolts 98 10 kgf m 72 ft lb e Install Upper Seat Bracket A Seat Belt Mounting Bolt B e Tighten Torque Seat Belt Mounting Bolt 41 5 4 2 kgf m 31 ft lb e Fit the cover on the bracket securely DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 20 FRAME Control Panel Control Panel Removal e Lift and hold the front fender rear see Front Fender Rear Removal e Remove Steering Wheel see Steering Wheel Removal in the
309. em Exhaust System Inspection e Before removing the exhaust system check for signs of leakage at the exhaust pipe gasket in the cylinder head and at the muffler clamp x lf there are signs of leakage around the exhaust pipe gas ket it should be replaced If the muffler to exhaust pipe joint leaks tighten the clamp e Remove the exhaust pipe and muffler see Muffler and Exhaust Pipe Removal e Inspect the gasket for damage and signs of leakage x If the gasket is damaged or has been leaking replace it e Check the exhaust pipe and muffler for dents cracks rust and holes xIf the exhaust pipe or muffler is damaged or has holes it should be replaced for best performance and least noise Muffler and Exhaust Pipe Installation e When installing the muffler bracket dampers A do as follows e Install the following parts in the muffler bracket B Muffler Bracket Damper Washers C New Circlips D Special Tool Inside Circlip Pliers 57001 143 e Install the muffler brackets to the muffler DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com IEO06005BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Exhaust System e When installing the exhaust pipe covers A do as follows Olnstall Exhaust Pipe Covers Collars B Dampers C Washers D Exhaust Pipe Cover Bolts E OTighten Torque Exhaust Pipe Cover Bolts 13 N m 1 3 kgf
310. emarks 1 Rear Master Cylinder Mounting Bolts 27 2 8 20 L 2 Rear Master Cylinder Bleed Valve 7 8 0 80 69 in lb 3 Final Gear Case Front Cover Bolts 24 2 4 18 4 Spring Bracket Bolt 8 8 0 90 78 L 5 Rear Final Gear Case Gasket Screws 1 3 0 13 12 in lb 6 Pinion Gear Bearing Holder 450 45 9 332 L 7 Gear Bearing Holder Nut 200 20 4 148 LB 8 Rear Final Gear Case Oil Drain Plug 15 1 5 11 5 F G Apply grease L Apply a non permanent locking agent LB Apply a non permanent locking agent Three Bond TB2471 Blue M Apply molybdenum disulfide grease MF Apply gear oil MOBIL FLUID 424 or equivalent oil R Replacement Parts Si Apply silicone grease DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 10 FINAL DRIVE Specifications Item Output Bevel Gear Case Output Bevel Gear Backlash Front Final Gear Case Gear Case Oil same engine oil Type Viscosity Oil Level Capacity Coupling Bushing Inside Diameter LSD Clutch Torque When differential shift lever is locked position 5 notches Bevel Gear Backlash Rear Final Gear Case Gear Case Oil Type Oil Level Capacity Rear Final Bevel Gear Backlash Standard Service Limit 0 05 0 11 mm 0 002 0 004 in at output drive shaft spline API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 Fill
311. ement with a new one A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the element e Remove the air cleaner element see Air Cleaner Element Removal in the Fuel System chapter e Clean the element A in a bath of high flash point solvent DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged e Inspect the element for damage x If it is torn punctured or hardened replace it e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess oil then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the element e Install the air cleaner element Air Cleaner Element Instal lation in the fuel system chapter Air Cleaner Draining e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter e Lift up the cargo bed x If any water or oil accumulates in the drain boots A drain it by removing the boots Aft
312. ension Arm Pivot Bolts C Caps and Nuts Rear Upper Suspension Arm D e Remove Rear Lower Suspension Arm Pivot Bolts A Washers Shim and Nut Rear Lower Suspension Arm Pivot Bolts B Caps and Nuts Rear Lower Suspension Arm C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 24 SUSPENSION Suspension Arms Rear Suspension Arm Installation e Apply grease Chevron Black Pearl Grease EP NLGI 2 to the inside of the caps A e Install Rear Lower Suspension Arm B Rear Lower Suspension Arm Pivot Bolts C Caps and New Nuts D temporary Rear Knuckle Mounting Bolt E Washers F Shim G and New Nuts H temporary there are over 0 5 mm 0 02 gap between the knuckle and lower suspension arm add the shim G to front side e Support the rear hub using a suitable jack or block e Apply grease Chevron Black Pearl Grease EP NLGI 2 to the inside of the caps A e Install Rear Upper Suspension Arm B Rear Upper Suspension Arm Pivot Bolts C Caps and New Nuts D temporary Rear Knuckle Mounting Bolt E Washers F Shim G and New Nuts H temporary there are over 0 5 mm 0 02 gap between the knuckle and upper suspension arm add the shim G to front side e Install Rear Shock Absorber Mounting Bolt Washer lower e Tighten Torque Rear Suspension Arm
313. ent Cover C Center Glove Compartment KRF750N T Models e Remove Control Panel see Control Panel Removal Screws A Center Glove Compartment B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 23 Control Panel Glove Compartment Installation Right Glove Compartment Cover e Install Right Glove Compartment Cover A Pins B e Install the clips C as shown in the figure Up D Forward E e When installing the cover F install the following parts Pin G and Bracket H Screws I e When installing the trim seal J the seal ends K should be at lower area and the gap is less than 3 mm 0 12 in Center Glove Compartment KRF750N T Models e Install Center Glove Compartment A Screws B Cupholder Removal KRF750P R S V Models e Remove Control Panel see Control Panel Removal Tapping Screws A Cupholder Assembly B e Remove Bolts A Holder B e Pull out the cupholder case C from the cupholder bracket D DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 24 FRAME Control Panel e Remove Rivets A ODrill the rivets and remove them e Remove the cupholder A from the cupholder case B e When removing the roller A remove the bolt B
314. ential Mode 2WD Locked Axle Mode 4WD Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower 4 2 m 13 8 ft 5 0 m 16 4 ft 4 stroke SOHC V2 cylinders Liquid cooled 85 0 x 66 0 mm 3 35 x 2 60 in 749 cm 45 7 cu in 8 8 1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 1 12 GENERAL INFORMATION General Specifications Items Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Engine Oil Type Viscosity Capacity Drive Train Primary Reduction System Type Reduction Ratio Transmission Gear Ratio Forward High Low Reverse Final Drive System Type Reduction Ratio Overall Drive Ratio Forward High Low Reverse KRF750NAF NBF PAF PBF RAF RBF SAF SBF TAF VBF 57 5 8 kgf m 42 ft lb 95 000 r min rpm Fuel Injection Mikuni 34 x 2 Electric Starter Battery and Coil transistorized Electronically advanced digital 10 BTDC 91 110 r mi rpm NGK CR7E or DENSO U22ESR N Front to rear 1 2 1 2 20 BTDC 44 ABDC 2449 44 BBDC 20 244 Forced lubrication wet sump API SG SH SJ 51 SM with JASO MA M
315. epeat from 0 to 5 V x If the reading is not standard check the wiring x lf the wiring is good check the speed sensor see Speed Sensor Inspection ELECTRICAL SYSTEM 16 69 HP23001BS1 HP23003BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 70 ELECTRICAL SYSTEM Actuator Control System Controller Unit Inspection NOTE OBe sure the battery is fully charged e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter e Connect Controller Connector A Hand Tester B range DC 25 V 2 002881 6 Tester Connector BR Terminal 9 Tester Connector BK Y Terminal 10 Olnstall the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch i Es pra 11 9 7 5 3 1 pre 4 12 10 8 8 3 2 Controller Power Supply Voltage Standard near Battery Voltage xIf the reading is not battery voltage check the wiring har ness 30 A fuse or ignition switch e Connect Controller Connector A Hand Tester B range DC 10 V Tester Connector Terminal 2 Tester Connector BK Y Terminal 10 Olnstall the needle adapters on the tester leads
316. eplaced Much less resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any reading less than infinity gt indicates a short neces sitating stator replacement x lf the stator coils have normal resistance but the voltage check shows the alternator to be defective then the rotor magnetism has probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 Regulator Rectifier Removal e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Remove Regulator Rectifier Mounting Bolts A Regulator Rectifier B e Disconnect the regulator rectifier lead connector C Regulator Rectifier Installation e Connect the regulator rectifier lead connector e Install Regulator Rectifier Tighten Torque Regulator Rectifier Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib 1909020851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 34 ELECTRICAL SYSTEM Charging System Regulator Rectifier Inspection e Remove Regulator Rectifier see Regulator Rectifier Removal e Set the hand tester to the x 1 kO range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Con
317. er Brake Cable Rear End B Breather Hose C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 76 FINAL DRIVE Rear Final Gear Case e Remove Rear Final Gear Case Bolt A and Nut e Remove Rear Final Gear Case Bracket Bolts A Rear Final Gear Case Brackets B e Support the rear final gear case with a suitable jack and or stand A e Remove Rear Final Gear Case Bolts B and Nuts e Remove Rear Final Gear Case A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 77 Rear Final Gear Case Rear Final Gear Case Installation e Install Rear Final Gear Case Bracket A Bracket Bolts B e Apply a non permanent locking agent to the rear final gear case bolts e Install Rear Final Gear Case Bolts C L 120 mm 4 72 in Rear Final Gear Case Bolts D L 70 mm 2 76 in e Tighten Torque Rear Final Gear Case Bracket Bolts 90 5 9 2 kgf m 67 ft Ib Rear Final Gear Case Mounting Nuts E 90 5 N m 9 2 kgf m 67 16 F Front e Install Removed Parts see applicable chapters NS KE Rear Final Gear Case Disassembly e Remove Rear Final Gear Case see Rear Final Gear Case Re moval Spring A e Remove Master Cylinder Mounting Bolts A Master Cylinder B
318. er 10 mm 0 4 in of pedal travel 18 80 2 37 at 20 C 4 F about 6 544 at 0 C 32 1 136 0 095 at 40 104 F 0 1553 0 0070 at 100 212 Reference Information Order Online at www militaryatvparts com 6 5 mm 0 26 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 13 Special Tools Bearing Driver Set Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1129 57001 1405 C e 7571129ST C 875714055 C Timing Light Peak Voltage Adapter 57001 1241 57001 1415 875712415 C 875714155 C Flywheel Holder Needle Adapter Set 57001 1313 57001 1457 875713135 C 8 5714575 C Hand Tester Drive Pulley Holder 57001 1394 57001 1620 7571394ST C 875716205 6 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 14 ELECTRICAL SYSTEM Wiring Diagram Throttle Sensor Fuel Fuel Injector Injector GG Inlet Air Inlet Air MN M Parking Brake Temperature Pressure 252 ES E Reverse Brake Light Sensor Sensor 5a Position Speed Position Switch LJ E Switch Sensor Switch M r3 ee gt ias Neutral 38 5 iss ft a aM Position See xr LEE z 5 zs zE x ag A Switch Radiator 7 Breaker 2 Frame 124 Ground 1 IR 1 Rad
319. er Cover see Center Cover Removal Screw A and Collar Pix DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 47 Covers e Remove Quick Rivets A both sides Seat Lower Cover B Seat Lower Cover Installation e Insert the projection A of the cover into the hole B both sides e When installing the insulators install them as shown in the figure OWipe the seat lower cover by alcohol before sticking the insulators not protrude the insulators beyond the edge of the seat lower cover A Insulator B P No 16073 0119 Insulator C P No 16073 0120 Insulator D P No 16073 0121 Insulator E P No 16073 0122 Standard Line to Stick F Frame E Rear View Inside of Seat Lower Cover G e Stick the insulator E so that the press line matches the corner H ZN NY RY NN IP13013BS3 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 48 FRAME Covers e Install Seat Lower Cover A Quick Rivets B Collar C L 2 4 mm 0 16 in Screw D L 16 mm 0 63 in JUN 7776 ED FJ i fj E NIE EEN JA Seat Lower Right Plate Removal e Remove Seat Lower Cover see Seat Lower Cover Removal Bolts A and Brackets Bolts B Se
320. er Cover see Seat Lower Cover Removal in the Frame chapter e Loosen the locknut A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 36 FINAL DRIVE Front Final Gear Case e Loosen the locknuts A e Remove the cable B from the bracket C e Remove both cable ends Differential Shift Cable Installation e Lubricate the differential shift cable before installation e Apply grease to the end of the cable e Route the cable correctly the according to the Cable Wire and Hose Routing in the Appendix chapter WARNING Operation with an improperly adjusted incorrectly routed or damaged cables could result in an un safe riding Condition Follow the service manual to make sure to correct any of these conditions e When installing the new cable set the cable as shown in the figure Differential Shift Cable A Differential Shift Cable Locknuts B 6 0 5 mm 0 24 50 02 in C o gt a 72 o e Tighten Torque Differential Shift Cable Locknut A 9 8 N m 1 0 kgf m 87 in Ib e Check the differential shift lever play see Differential Shift Lever Play Inspection in the Periodic Maintenance chap ter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 37 Fron
321. er Shaft Re moval in the Final Drive chapter Rear Propeller Shaft see Rear Propeller Shaft Removal in the Final Drive chapter Torque Converter Outlet Duct see Torque Converter Cover Removal in the Converter System chapter e Remove Neutral Switch Lead Connector A Reverse Switch Lead Connector B Forward Reverse Detecting Sensor Lead Connector C e Remove Alternator Lead Connectors A Cranksh ft Sensor Lead Connector B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation e Remove Engine Ground Lead Terminal A Oil Pressure Switch Lead Connector B Starter Motor Cable C Water Hose D e Remove Water Pipes A and Thermostat Housing Torque Converter Inlet Duct B Engine Brake Actuator Lead Connector C e Remove Speed Sensor Connector A e Remove Bolts A Plate B e Hold the engine with a lifter A e Remove Engine Mounting Bolt and Nut B Engine Mounting Bolt C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Engine A Engine Installation e When installing the engine bracket pipes A note the fol lowing e Install the red painted damp
322. er draining be sure to install the drain boots and clamps firmly Fuel Hose and Connections Inspection e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter e Check the fuel hose Replace the fuel hose if any fraying leaks cracks B or bulges C are noticed Replace the hose if it has been sharply bent or kinked Hose Joints A Fuel Hose B HUOSO06BS1 C e Check that the fuel hose joints are securely connected OPush and pull A the fuel hose joint B back and forth more than two times and make sure it is locked does not locked reinstall the hose joint A WARNING Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in stalled correctly on the delivery pipe by sliding the Joint HU0S007BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Fuel Hose Replacement A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Be sure to place a piece of cloth around the fuel hose joint e Insert a thin standard tip screwdriver
323. er opening bottom JA 0 7 L 0 74 US qt ans 20 051 mm 0 7894 in 20 000 20 021 mm 0 7874 0 7882 in 300 N m 31 221 ft lb or more 0 08 0 16 mm 0 003 0 006 at gear spline MOBIL FLUID 424 CITGO TRANSGARD E TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Filler opening bottom 1 01 1 06 US qt 0 05 gt 0 11 mm 0 002 0 004 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 11 Special Tools Bearing Puller Bearing Driver Set 57001 135 57001 1129 875701355 C 875711295 C Steering Stem Bearing Driver Pinion Gear Holder m1 0 57001 137 57001 1281 875701375 875712818 Inside Circlip Pliers Socket Wrench 57001 143 57001 1363 7570143ST C Outside Circlip Pliers Holder amp Guide Arbor 57001 144 57001 1476 875701445 875714765 Oil Seal amp Bearing Remover Socket Wrench Hex 50 57001 1058 57001 1478 7571058ST C 7571478ST C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 12 FINAL DRIVE Special Tools Output Shaft Holder amp Spacer m1 25 57001 1479 uw 7571479ST C Nut Hold
324. ers B part number stamped 92161 0571 and cover C at the front left position OTouch the projection of the cover to the bracket of front side e Install No Painted Dampers D e Replace the engine bracket pipe mounting nuts A with new ones e Tighten Torque Engine Bracket Pipe Mounting Nuts A 41 5 N m 4 2 kgf m 31 ft Ib Front Engine Bracket Pipe B Rear Engine Bracket Pipe C 1H04003BS1 C e Install Engine Rear Engine Mounting Bolt A Front Engine Mounting Bolt and Nut B Olnsert the front engine mounting bolt from right side e Tighten Torque Engine Mounting Bolt and Nut 60 1 N m 6 1 kgf m 44 ft Ib e Install the removed parts e Adjust Throttle Cable see Throttle Pedal Free Play Adjustment in the Periodic Maintenance chapter Differential Control Cable see Differential Control Lever Free Play Adjustment in the Periodic Maintenance chap ter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Paese DSC CANONS d ad Special Tools and Sealant zs eant queden deis seti ren c r N Crankcase Disassembly 4
325. ery monitor If the relay fails battery monitor voltage 12 V voltage 5 V or more The ignition coil primary If the ignition primary winding 1 has failures winding must send no signal wiring short or open the ECU signals output voltage shuts off the injector 1 to stop fuel to the continuously to the ECU cylinder 1 though the engine keeps running The ignition coil primary If the ignition primary winding 2 has failures winding must send no signal wiring short or open the ECU signals output voltage shuts off the injector 2 to stop fuel to the continuously to the ECU cylinder 2 though the engine keeps running 51 Ignition Coil 1 52 Ignition Coil 2 Note 1 D J Method and a N Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum inlet air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 37 Self Diagnosis method low speed mode As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method hig
326. ess Top Second Piston Ring End Gap Top Second Oil 0 0402 0 0409 in 0 97 0 99 mm 0 0382 0 0390 in 0 97 0 99 mm 0 0382 0 0390 in 0 15 0 25 mm 0 0059 0 0098 in 0 30 0 45 mm 0 0118 0 0177 in 0 20 0 70 mm 0 0079 0 0276 in 0 90 mm 0 0354 0 90 mm 0 0354 in 0 55 mm 0 0217 in 0 75 mm 0 0295 in 1 00 mm 0 0394 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 12 ENGINE TOP END Special Tools and Sealant Inside Circlip Pliers Valve Seat Cutter 45 27 5 57001 143 57001 1114 7570143ST C ST571114ST C Outside Circlip Pliers Valve Seat Cutter 32 28 57001 144 57001 1119 7570144ST C ST571119ST C Compression Gauge 20 kgf cm Valve Seat Cutter 60 30 57001 221 57001 1123 7570221ST C 875711235 C Valve Spring Compressor Assembly Valve Seat Cutter Holder Bar 57001 241 57001 1128 875702415 C ST571128ST Piston Pin Puller Assembly Valve Seat Cutter 45 530 57001 910 57001 1187 7570910ST C 8 5711875 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 13 Special Tools and Sealant Valve Seat Cutter 32 633 Piston
327. ess with clamp as shown Engine Ground Clamp the alternator lead crankshaft sensor lead oil pressure sensor lead battery negative cable and starter cable with band Clamp the connector so that the connector does not touch to the engine Clamp Main harness Engine DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 32 APPENDIX Cable Wire and Hose Routing Detail L Detail M 18082388W5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 33 Cable Wire and Hose Routing la lla ISC Valve Harness Water Temperature Sensor 2WD AWD Solenoid Valve Connector Clamp the fuel hose and harness with clamp Fuel Pump Fuel Level Sensor Clamp the engine brake actuator harness with the clamp Engine Bake Actuator Clamp the main harness with clamp Throttle Position Sensor Fuel Injector 2 Rear Fuel Injector 1 Front Breather Hoses Clamp the harnesses and breather hoses with the clamp Run the branched harnesses under the pipe Bands Secure the main harness to the pipe Secure the main harness at the front of pipe within this area with the bands DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www mili
328. eter Unit Lead Connectors 1 Speed Sensor Pulse 2 Belt Indicator Light LED 3 Water Temperature Warning Symbol 4 2WD 4WD Position Indicator Symbols LCD 5 Fuel Level Gauge Segments LCD 6 Meter Illumination 7 Reverse Indicator Light LED 8 Neutral Indicator Light LED 9 Ignition 10 Battery 11 Pressure Warning Indicator Light LED 12 Battery 13 Parking Brake Indicator Symbol LED 14 Fl Indicator Symbol LCD 15 Unused 16 Unused LED Light Emitting Diode LCD Liquid Crystal Display Check 1 LCD Segments Check e Using auxiliary wires connect a 12 V battery to the meter unit connector as follows e Connect the battery positive terminal to terminal 10 e Connect the battery negative terminal to terminal 12 e Connect terminal 9 to the battery terminal OWhen the terminal 9 is connected all the LCD segments appear for one second OWhen the terminal 9 is disconnected all the LCD seg ments disappear xIf the display function does not work replace the meter 101902iBS1 C ZI N maala fae 0111 1919022851 C unit NOTE OWhen the oil switch is turned off the hour meter begins count Therefore when connecting the check 1 circuit the hour meter begins count because the circuit of the oil switch is opened stop the count of the hour meter connect the battery
329. ey e Check that the O rings A are in good condition xIf any of the O rings are damaged replace them e Apply grease to the O rings e Hold the drive amp driven pulley holder in a vise Special Tool Drive amp Driven Pulley Holder 57001 1473 e Screw the guide bar into the holder Special Tool Spring Holder Set 57001 1483 e Put the driven pulley A onto the guide bar 529 e Put the thrust plate B so that the alloy side gray faces E 2 the movable sheave o e Install Spring Seat C 18 5 mm 0 728 7 0 Spring Seat 23 3 mm 0 917 Circlip F e Tighten the nut A and compress the spring with the spring holder B Special Tool Spring Holder Set 57001 1483 e Install a new circlip C with circlip pliers D Special Tool Outside Circlip Pliers 57001 144 e Remove the driven pulley from the spring holder set e Clean the surface of the sheaves with an oil less cleaning fluid Driven Pulley Installation e Clean the transmission driven shaft A e Install Driven Pulley NOTE OWhen engaging the spline on the driven pulley with the spline B on the shaft do not damage the pulley s spline If any damage occurs remove it with a file DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 27 Driven Pulley e Clean the thread
330. f breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Front Brake Disc Removal e Remove Front Hub see Front Hub Removal in the Wheels Tires chapter Brake Disc Mounting Bolts A Brake Disc B Front Brake Disc Installation e The disc must be installed with the marked side A facing A toward the steering knuckle O e Apply a non permanent locking agent to the brake disc O mounting bolts O O A O e Tighten O MIN TH 4 3MM O Torque Front Brake Disc Mounting Bolts 41 5 N m 4 2 kgf m 31 ft lb e After installing the discs check the disc runout Com 112000881 pletely clean off any grease that has gotten either side of the disc with a high flash point solvent Do not use one which will leave an oily residue Front Brake Disc Wear Inspection e Measure the thickness of each disc at the point A where it has worn the most Replace the disc if it has worn past the service limit 59226 COLO LOE MS TH 4 34 460 f 2 D ON NM SS ANS NN 65555255 SENSUS S Disc Thickness Standard 4 6 5 0 mm 0 18 0 20 in Service Limit 4 3 mm 0 17 in 1M12001BS1 C Front Brake Disc Runout Inspection e Jack up the vehicle so that the wheels are off the ground e Remove the front wheels and turn the handlebar fully to one side e Set up a dial gauge against the disc A
331. f m ft Ib 1 Valve Adjusting Cap Bolts 8 8 0 90 78 in lb 2 Rocker Case Bolts L 55 mm 2 2 in 8 8 0 90 78 in lb S 3 Rocker Case Bolts L 130 mm 5 1 in 9 8 1 0 87 in lb S 4 Rocker Case Bolts L 30 mm 1 2 in 9 8 1 0 87 in lb S 5 Rocker Case Bolts L 25 mm 1 0 in 9 8 1 0 87 S 6 Cylinder Head Bolts M10 first torque 25 2 5 18 S MO 6 Cylinder Head Bolts M10 final torque 49 5 0 36 S 7 Cylinder Head Bolts M6 9 8 1 0 87 8 Water Pipe Mounting Bolts 78 in lb 9 Valve Adjusting Screw Locknuts 106 in Ib 10 Rocker Shaft Bolts 16 711 RearRoWerCaseClampBol 0 Tib 12 13 14 15 EO G LG M MO R S Rocker Case Cylinder Head Front Rear Apply engine oil Apply grease Apply liquid gasket Liquid Gasket TB1216 92104 1063 Apply molybdenum disulfide grease Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 Replacement Parts Follow the specific tightening sequence DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 4 ENGINE TOP END Exploded View 1E02018885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 5 Exploded View
332. f the ground and power supply are good replace the ECU see ECU Removal Installation Crankshaft Sensor Circuit Q 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 BL R B BK R BK W 2 BL R BL 16150818842 C 1 ECU Electronic Control Unit 2 Grankshaft Sensor DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 54 FUEL SYSTEM DFI Speed Sensor Service Code 24 Speed Sensor Removal e Refer to the Speed Sensor Removal in the Electrical Sys tem chapter Speed Sensor Installation e Refer to the Speed Sensor Installation in the Electrical System chapter Speed Sensor Input Voltage Inspection e Remove Right Rear Wheel see Wheel Removal in the Wheels Tires chapter NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Disconnect the speed sensor connector A e Connect the measuring adapter A between the harness connector B and speed sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter to the measuring adapter leads Connections to Adapter Meter BR lead of Main Harness Meter BK Y lead of Main Harness e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Speed Senso
333. f the measurement is out of the range replace the sensor Water Temperature Sensor Resistance 8 18055 52 C Temperature Resistance kQ 20 C 4 F 18 80 2 37 0 C 32 F about 6 544 40 C 104 F 1 136 0 095 100 C 212 F 0 1553 0 0070 Reference Information xIf the resistance is within the standard replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit 0 12 3 4 56 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 BR BK 0 0 BR BK 2 1 ECU Electronic Control Unit 2 Water Temperature Sensor DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 1Cc150788W2 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 53 Crankshaft Sensor Service Code 21 Crankshaft Sensor Removal Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals e Refertothe Crankshaft Sensor Inspection in the Electrical System e Check the wiring for continuity see Crankshaft Sensor Circuit x lf the crankshaft sensor and the wiring are good check the ECU for its ground and power supply see ECU Power Supply Inspection x I
334. fferential Shift Lever Play Adjustment in the Periodic Maintenance chapter Differential Shift Lever Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Differential Shift Cable Rear End see Differential Shift Cable Removal Cap A Damper B Bolts C e Remove the double stick tape for damper e Remove Bolts A Bracket B Ratchet C Snap Pin D Pin E Differential Shift Lever Assembly F DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 35 Front Final Gear Case Differential Shift Lever Installation e Install Lever Assembly A Spring B Coil Length 16 mm 0 63 in Spring C Coil Length 20 mm 0 79 in Rod D Lever E Washers F New Circlip G e Apply grease Chevron Black Pearl Grease EP NLGI 2 or equivalent grease Teeth A of Ratchet Pin B e Install Lever Assembly C Bushings D Bracket E Ratchet F Bolts G Pin B Snap Pin H Bolts I Damper J Cap K e Tighten the bolts I with bracket E pushed to the arrow L direction OThe line M shall be parallel to line N 1104059852 C e Install the damper A to the rod B of lever assembly as shown in the figure Double Stick Tape C 1 2 mm 0 04 0 08 D 40 mm 1 57 in E Cap F Differential Shift Cable Removal e Remove Seat Low
335. following Cutter angle B S Outer diameter of cutter C 8 15011851 C Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth NOTICE Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 36 ENGINE TOP END Valves Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with vernier calipers x lf the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE O Remove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60
336. ft sprocket bolts C and tighten them Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 106 in Ib Camshaft Chain Removal e Remove left side view Rear and Front Camshafts see Camshaft Removal Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Oil Pumpx see Oil Pump Removal in the Engine Lubri cation System chapter Intermediate Shaft Chain Tensioner A Circlip B and Washer Special Tool Outside Circlip Pliers 57001 144 e Remove Intermediate Shaft Chain Guides C Position Plate Bolts D and Position Plate DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 25 Camshaft e Remove right side view Torque Converter Cover see Torque Converter Cover Removal in the Converter System chapter e Using a M6 bolt A pull out the cover B e Remove left side view Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove Intermediate Shaft Sprocket B Intermediate Shaft Drive Chain C Rear Camshaft Chain D Front Camshaft Chain right side Camshaft Chain Installation Rear Camshaft Chain e Align the key grooves A on the crankshaft with the em bossed line B on the crankcase left side view e Face the arrow A of the rear camshaft sprocket upward e Align the marks B on the weights with the rear cylinder head upper surfa
337. g all codes the display is repeated until the self diagnosis terminal is opened OFor example if two problems occurred in the order of 21 12 the service codes are displayed from the lowest number in the order listed 12 21 125 21 repeated Olf there is no problem or when the repair has been done no service code is shown Self Diagnosis Terminal Grounded Open AH ON n 1C15052BW1 C Fl Indicator Symbol ON OFF Service Code Erasing OWhen repair has been done FI indicator light will not show service codes any more But the service codes stored in memory of the ECU not erased to preserve the problem history In this model the problem history cannot be erased Service Code Table service FI Indicator Light Problems Code ON Throttle sensor malfunction wiring open or 11 OFF short Inlet air pressure sensor malfunction wiring 12 open or short Inlet air temperature sensor malfunction 19 wiring open or short 14 RUP Water temperature sensor malfunction wiring open or short 21 Crankshaft sensor malfunction wiring open or short 24 Speed sensor malfunction wiring open or short 31 Vehicle down sensor malfunction wiring open or short 46 Fuel pump relay malfunction relay is stuck DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILAB
338. g Bolt 14 9 1 5 11 9 Speed Sensor Mounting Bolt 8 8 0 90 78 in lb 10 Reverse Position Switch 15 1 5 11 11 Neutral Position Switch 15 1 5 11 2WD 4WD Solenoid Valve Lighting Switch Ignition Switch 2WD AWD Shift Switch Accessory Connector 12 V 120 W Power Outlet Actuator Controller Air Temperature Sensor Brake Light Switch Apply grease Follow the specific tightening sequence DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 10 ELECTRICAL SYSTEM Exploded View 1902050895 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 11 Exploded View Torque No Fastener Nam kgf m ft Ib Remarks 1 Water Temperature Sensor 12 1 2 106 2 Radiator Fan Assembly Bolts 8 3 0 85 73 3 Pressure Switch 15 1 5 11 55 4 Battery Holder Mounting Bolts 16 1 6 12 5 Regulator Rectifier Mounting Bolts 8 8 0 90 78 in lb 6 Fuse Box 7 Radiator Fan Breaker 12 A 8 Fuse Pump Relay 9 Radiator Fan Relay 10 Starter Control Relay 11 Multifunction Meter 12 US Model 13 CA Model SS Apply silicone sealant Liquid Gasket TB1211 56019 120 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts c
339. g a plastic mallet OThe output driven bevel gear shaft assembly comes off with the housing Output Driven Bevel Gear Installation e Apply grease O ring A e Install the output driven bevel gear shaft assembly e Tighten Torque Output Driven Bevel Gear Housing Bolts 26 2 7 kgf m 19 ft Ib Output Driven Bevel Gear Disassembly e Remove Output Driven Bevel Gear Housing Assembly see Out put Driven Bevel Gear Removal Oil Seal e Hold the output shaft holder A in a vise and set the housing assembly B on the holder Special Tool Output Shaft Holder 57001 1570 e Remove Output Shaft Holder Nut A Special Tool Socket Wrench B 57001 1482 e Remove the output shaft A from the housing B using a press DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 18 FINAL DRIVE Output Bevel Gears e Hold the housing assembly A with the holder B in a vise Special Tool Holder amp Guide Arbor 57001 1476 e Remove Bearing Holder C Special Tool Socket Wrench Hex 50 D 57001 1478 Olf the holder seems too difficult to break free apply heat to softer the locking agent e Remove Ball Bearing Special Tool Oil Seal amp Bearing Remover 57001 1058 e Remove the output driven bevel gear A from the output shaft B using the bearing puller C and spacer D Special Tools Bearing Puller
340. g situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by the sensor brackets e Insert the projection A of the bracket into the hole of the frame e Tighten the bolt B securely Vehicle down Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Left Seat see Seat Removal in the Frame chapter Vehicle down Sensor see Vehicle down Sensor Re moval DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 57 Vehicle down Sensor Service Code 31 e Disconnect the vehicle down sensor connector A and connect the measuring adapter B between the main har ness connector and vehicle down sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter to the measuring adapter leads Connections to Adapter Meter BR W lead of Main Harness Meter BR BK lead of Main Harness e Install the vehicle down sensor temporarily e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Vehicle down Sensor Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch OFF xIf the reading is good check the output voltage see Ve hicle down Sensor
341. gainst the seat with a lapping tool OPull the valve out and check the seating pattern on the valve head It must be the correct width and even all the way around e Measure the outside diameter D of the seating pattern on the valve seat x lf the outside diameter of the valve seating pattern is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Exhaust 25 2 25 4 mm 0 992 1 000 in Inlet 29 4 29 6 mm 1 157 1 165 in NOTE The valve stem and guide must be in good condition or this check will not be valid xIf the valve seating pattern is not correct repair the seat see Valve Seat Repair e Measure the seat width E of the portion where there is no build up carbon white portion of the valve seat with vernier calipers x f the width is too wide too narrow or uneven repair the seat see Valve Seat Repair F Good G Too Wide H Too Narrow J Uneven Valve Seating Surface Width Exhaust 0 5 1 0 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 Valve Seat Repair Valve Lapping e Using the valve seat cutters A repair the valve seat Special Tools Valve Seat Cutters Exhaust Valves Valve Seat Cutter 45 27 5 57001 1114 Valve Seat Cutter 32 628 57001 1119 Valve Seat Cutter 60 030 57001 1123 Inlet Valves Valve Seat Cutter 45 530 57001 1187 Valve Seat Cutter 32 033 57001 1199 Valve Seat Cutter 60
342. gap is less than 3 mm 0 12 in 2 KRF750N T Models 3 KRF750P R S V Models 4 KRF750NAF PAF RAF SAF TAF Models AD Apply adhesive agent R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 4 FRAME Exploded View 4 15 NS AN V Say S S SAX NZ ij 9 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 5 Exploded View Fastener Remarks m kgm feib 1 Right and Left Bar Mounting Bolts 98 72 2 Upper Bar Mounting Bolts 46 5 34 3 Bar Mounting Bolts 46 5 4 7 34 4 Guard Bolts 8 8 0 90 78 in Ib 5 Front Guard Bolts 31 5 23 R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 6 FRAME Exploded View 1 02062885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 7 Exploded View 1 Apply sealing material to the hatched area and holes 2 For the square dampers install them so that the UP mark faces to upper side AD Apply adhesive agent G Apply gre
343. ge Standard with sensor arrow mark pointed up DC 0 4 1 4V with sensor tilted 55 75 or more right or left DC 3 7 4 4 V e Turn the ignition switch OFF xIf the reading is out of the standard replace the vehicle down sensor x lf the reading is within the standard check the wiring for continuity see Vehicle down Sensor Circuit xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation 1C15059BS2 C Vehicle down Sensor Circuit 12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 lt BR BK LL BR W BR W BR BK HC110578W2 C 1 ECU Electronic Control Unit 2 Vehicle down Sensor DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 59 Fuel Pump Relay Service Code 46 Fuel Pump Relay Removal e Remove Left Seat see Seat Removal in the Frame chapter Fuel Pump Relay A Fuel Pump Relay Inspection e Refer to the Relay Inspection in the Electrical System chapter x If the fuel pump relay is normal check the wiring for con tinuity see Fuel Pump Relay Circuit Special Tool Hand Tester 57001 1394 xIf the wiring is go
344. ge or other suitable device x f the level is too low add oil through the filler hole Use the same type and make of oil that is already in the engine Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Change e Refer to the Oil Filter Change in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Removal e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Pull the oil screen A out of the crankcase Oil Screen Cleaning e Clean the oil screen A thoroughly whenever it is removed for any reason e Clean the oil screen with high flash point solvent and remove any particles stuck to it WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the screen in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the screen NOTE O While cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes broken wires or gasket
345. h contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged Above two adjustments are of critical importance and must be carried out following the correct sequence and method e When any one of the backlash related parts are replaced check and adjust the bevel gear backlash and tooth con tact by replacing shims OThe amount of backlash is influenced by the ring gear position more than by the pinion gear position OTooth contact location is influenced by the pinion gear po sition more than by the ring gear position Front Final Bevel Gear Adjustment Procedure Adjust gear backlash Adjust tooth contact pattern Assemble the final gear case completely DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 58 FINAL DRIVE Front Final Gear Case Front Final Gear Case Backlash related Parts ILO4015BW4 C NO Ring Gear Right Shim s Ring Gear Left Shim s Pinion Gear Shim s Front Final Gear Case Center Cover Front Final Gear Case Right Cover Ball Bearings Ring Gear Ring Gear Assembly Pinion Gear DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 59 Front Final Gear Case 1 Ring Gear Rig
346. h into the engine excessive en gine wear and possibly engine damage will occur e Remove Element Cover Screw A Element Cover B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 90 FUEL SYSTEM DFI Air Cleaner e Remove Element A Element Holder B Air Cleaner Element Installation e Install Element A Element Holder B e Install the element cover C so that the wider side D faces projection E of the holder and fit the slits F onto the projections NOTE OBe sure that the edge of the element A fits completely in the groove and does not rest on the edge of the el ement holder B or become folded the groove as shown in the figure e Tighten Torque Element Cover Screw A 4 5 0 46 kgf m 40 e the element holder A until it is bottomed into the housing B as shown in the figure Correct Not Correct 1C08003BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 91 Air Cleaner e Tighten Torque Element Holder Screw 4 5 N m 0 46 kgf m 40 in Ib e Install the air cleaner housing cap and fit the clips Air Cleaner Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning an
347. h speed mode DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 38 FUEL SYSTEM Throttle Sensor Service Code 11 Throttle Sensor Removal Adjustment Do not remove or adjust the throttle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter e Connect a digital meter to the connector A with the nee dle adapter set Special Tool Needle Adapter Set 57001 1457 Connections Meter gt BR W lead Meter BR BK lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Throttle Sensor Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch OFF xIf the input voltage is normal check the output voltage see Throttle Sensor Output Voltage Inspection the input voltage is less than the standard check the wiring for continuity see Throttle Sensor Circuit xIf the wiring is good check the ECU for its ground
348. hapter e Disconnect the switch lead connector A e Remove the water temperature sensor B Water Temperature Sensor Installation e Apply grease to new O ring on the water temperature sen sor Tighten Torque Water Temperature Sensor 12 N m 1 2 kgf m 106 in Ib e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 51 Water Temperature Sensor Service Code 14 Water Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged OThe output voltage changes according to the coolant temperature in the engine e Turn the ignition switch OFF e Remove Engine Upper Cover see Engine Upper Cover Re moval e Disconnect the water temperature sensor connector and connect the measuring adapter A between these con nectors Special Tool Measuring Adapter 57001 1700 e Connect a digital meter to the measuring adapter leads Connections to Adapter Meter lead of Main Harness Meter gt BR BK lead of Main Harness e Measure the output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Water Temperature Sensor Output Voltage Standard About 2 24 2 48 V at 20 C 68 F e Turn the ignition
349. he V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being parallel with the surface plate over 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in HIOS000BS1 C 6105040881 C 6105040781 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 15 Crankshaft Connection Rod Connecting Rod Big End Side Clearance Inspection e Measure the side clearance of the connecting rod big end A Olnsert a thickness gauge B between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 16 0 46 mm 0 0063 0 0181 in Service Limit 0 7 mm 0 028 in x If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Bearing Crankpin Wear Inspection e Measure the bearing insert crankpin A clearance with plastigage B OTighten the big end cap nuts to the specified torque Torque Connecting Rod Big End Ca
350. he breather chamber from the crankcase and then returned back to the bottom of crankcase Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a catalytic converter in the muffler US and CA models a fuel injection and ignition system having optimum ignition timing characteristics The fuel injection system has been calibrated to provide lean air fuel mixture characteristics and opti mum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inopera
351. he duct E to the rubber duct OFit the projection F of the duct into the slit of the rubber duct OPush the duct until the rib G of the duct touches the rubber duct Right H Wrong I e Tighten the bands on the rubber duct 1 04028852 Torque Converter Cover Disassembly e Remove Torque Converter Cover see Torque Converter Cover Removal Engine Brake Actuator see Engine Brake Actuator Re moval in the Electrical System chapter Circlip A Spring B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 11 Torque Converter Cover e Remove Bushing A Washer B Actuator Lever Assembly C Actuator Lever Engine Brake Control Lever Assembly Inspection e Refer to the Actuator Lever Engine Brake Control Lever Assembly Inspection in the Periodic Maintenance chap ter Torque Converter Cover Assembly e When installing the bushing A into the cover B press it until itis stopped as shown in the figure IF04015BS1 C e Install Actuator Lever Assembly Washer Bushing Spring New Circlip Engine Brake Actuator see Engine Brake Actuator In stallation in the Electrical System chapter Torque Engine Brake Actuator Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib e Measure the installation length A of the actuator lever assembly between the cover end B and resin
352. he guides x If the rubber is damaged cut or is missing pieces replace the guide DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 29 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly and stop the engine e Remove the spark plug see Spark Plug Removal in the Electrical System chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 e Hold the throttle wide open and crank the engine with the electric starter or the recoil starter several times OWhen the gauge stops rising stop cranking and read the gauge Cylinder Compression Usable Range Electric Starter 251 456 kPa 2 56 4 65 kgf cm 36 66 psi 2380 r min rpm The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston Remove the carbon deposits and replace compression cylinder head and in combustion damaged parts if necessary is higher than chamber possibly due to damaged usable range valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Incor
353. he piston and remove the piston pin snap rings A from the outside of each pis ton Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall GE16020381 e Using the piston pin puller assembly special tool re move the piston pins Special Tools Piston Pin Puller Assembly A 57001 910 Piston Pin Puller Adapter 14 B 57001 1211 e Remove the piston GE16060581 C e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner GE16060881 C Cylinder Piston Installation NOTE Olf a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance and use new piston rings DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 40 ENGINE TOP END Cylinder and Piston NOTE O The oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove UE
354. he shifter splines and groove e Install Shifter A OFace the dogs side B to outside e Press the oil seal A in the front final gear case so that the oil seal surface is flush with the case end Special Tool Oil Seal Driver 57001 1715 e Apply grease to the oil seal lip B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 52 FINAL DRIVE Front Final Gear Case e Apply grease to the shaft A and pin B of the 2WD AWD shift shaft lever e Insert the 2WD AWD shift shaft lever so that the pin B is opposite side of the 2WD AWD shift switch C e Insert the pin into the groove D of the shifter e Apply grease to the oil seal lip A e Press the oil seal B in the 2WD AWD shift shaft cover C as shown in the figure 0 5 1 5 mm 0 020 0 059 in D e Apply grease to the O ring A e Install 2WD AWD Shift Shaft Cover B OWhen installing the cover use the oil seal guide A for protecting the oil seal Special Tool Oil Seal Guide 57001 1721 e Apply non permanent locking agent to the threads of the shift shaft cover bolts A and tighten them Torque 2WD 4WD Shift Shaft Cover Bolts 8 8 0 90 kgf m 78 in Ib e Install Washer B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY
355. he specified range replace the thermostat Thermostat Valve Opening Temperature 69 5 72 5 C 157 163 F 6009020252 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY COOLING SYSTEM 4 17 Water Temperature Sensor Water Temperature Sensor Removal Installation The water temperature sensor should never be al lowed to fall on a hard surface Such a shock to water temperature sensor can damage it e Refer to the Water Temperature Sensor Removal Instal lation in the Fuel System DFI chapter Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Fuel System DFI System chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded VIew ntes 5 2 Cylinder Head Cleaning 5 31 Exhaust Systelm 5 8 Cylinder Head Warp Inspection 5 31 Specifications 5 9 4 5 32 Special Tools and Sealant 5 12 Valve Clearance Inspection 5 32 Camshaft Chain Te
356. he throttle cable 2WD 4WD Shift Cable Throttle Cable Clamp Brake Pipe Main Harness Clamp Clamp the parking brake cable at the white mark DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 24 APPENDIX Cable Wire and Hose Routing 1808227884 C 2 N uv 7 B 1 AC m eu 5 lt lt PN p aK a lt 5 5 96 OO x oF S o SA lt E D GS x 20 gt 1 2 3 4 5 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 25 Cable Wire and Hose Routing 1808228884 C 1 Grommet 2 Parking Brake Cable 3 Main Harness 4 Bands Secure the differential shift cable and the throttle cable 5 Differerntial Shift Cable 6 Throttle Cable 7 Clamp DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 26 APPENDIX Cable Wire and Hose Routing il 8 B b a 25 7 cw EV DOCUMENT AVAILABLE FOR MILITAR
357. hown Special Tool Bearing Driver Set 57001 1129 e From inside the alternator cover press and insert the ball bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 HD06001081 C e Using a suitable socket A and the bearing driver B press and insert a new mechanical seal C until its flange stops at the step D of the hole Special Tool Bearing Driver Set 57001 1129 e Clean the sliding surface new mechanical seal with a high flash point solvent and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica tion e Apply coolant to the surfaces of the rubber seal and seal ing seat A and press the rubber seal B and sealing seat into the impeller by hand until the seat bottoms out e Tighten the water pump impeller by turning the bolt clock wise Torque Water Pump Impeller 7 8 N m 0 80 kgf m 69 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY COOLING SYSTEM 4 13 Radiator Radiator Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the front fender front see Front Fender Front Removal in the Frame chapter e Remove Radiator Cover Mounting Screws A Radiator Cover B e Remove Radiator Fan Motor Lead Connector A Water Hose B e Remove Reserve Tank
358. ht Shims for Backlash Adjustment Thickness Parts Number 0 15 mm 0 006 in 92180 0260 0 2 mm 0 008 in 92180 0261 0 5 mm 0 020 in 92180 1207 0 8 mm 0 031 in 92180 0259 1 0 mm 0 039 in 92180 1205 1 2 mm 0 047 in 92180 0262 2 Ring Gear Left Shims for Backlasht Adjustment Thickness Parts Number 0 15 mm 0 006 in 92180 1390 0 2 mm 0 008 in 92180 1391 0 5 mm 0 020 in 92180 1392 0 7 mm 0 028 in 92180 1393 0 8 mm 0 031 in 92180 1394 0 9 mm 0 035 in 92180 1395 1 0 mm 0 039 in 92180 1396 1 1 mm 0 043 in 92180 1397 1 2 mm 0 047 in 92180 1398 3 Pinion Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1423 0 2 mm 0 008 in 92180 1424 0 5 mm 0 020 in 92180 1425 0 8 mm 0 031 in 92180 1426 1 0 mm 0 039 in 92180 1427 1 2 mm 0 047 in 92180 1428 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 60 FINAL DRIVE Front Final Gear Case Front Final Gear Case Backlash Adjustment e Clean dirt and oil off bevel gear teeth e Measure length A B and C and calculate the clear ance D between the ring gear assembly and gear case covers D A B C 1L040168W2 C E Front Final Gear Case Center Cover F Ring Gear Assembly G Front Final Gear Case Right Cover e Assemble the front final ge
359. iameter Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Top Second Standard 4 955 4 970 mm 0 1951 0 1957 in 4 975 4 990 mm 0 1959 0 1965 in 5 000 5 012 mm 0 1969 0 1973 5 000 5 012 mm 0 1969 0 1973 0 09 0 17 mm 0 0035 0 0067 in 0 03 0 11 mm 0 0012 0 0043 in 45 32 60 25 2 25 4 mm 0 992 1 000 in 29 4 29 6 mm 1 157 1 165 0 5 1 0 mm 0 02 0 04 0 5 1 0 mm 0 02 0 04 in 41 3 mm 1 626 in 41 3 mm 1 626 in 84 994 85 006 mm 3 3462 3 3467 in 84 964 84 979 mm 3 3450 3 3456 in 0 015 0 042 mm 0 0006 0 0017 in 0 04 0 08 mm 0 0016 0 0031 in 0 03 0 07 mm 0 0012 0 0028 in Service Limit 4 94 mm 0 1945 in 4 96 mm 0 1953 in 5 08 mm 0 20 in 5 08 mm 0 20 in 0 37 mm 0 0146 0 31 mm 0 0122 in 39 5 mm 1 555 in 39 5 mm 1 555 in 85 09 mm 3 3500 in 84 81 mm 3 3390 in 0 18 mm 0 0071 in 0 17 mm 0 0067 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Specifications ENGINE TOP END 5 11 Item Standard Service Limit Piston Ring Groove Width Top 1 03 1 05 mm 1 13 mm 0 0445 in 0 0406 0 0413 in Second 1 02 1 04 mm 1 12 mm 0 0441 in Piston Ring Thickn
360. iator BL BL R 2222 a Fan Motor s dL 2WD 4WD o BK Y BK Y Shift Switoh 4WD Position Switch 1 3l H H Er E Headlight Right R BK R BK R BK 12V35 35W R Y R Y R Y BK Y BK Y BK Y G R G R BL BL LG 16 R W R v 1 9 9 Multifunction Meter R Y BR BI BL R BL R BK Y BK Y R Y R Y 6 Headlight Left R BK R BK R BK R Y R Y RZY 12V35 35W BK Y BK Y BK Y Accessory Connector BR Li BR 12V1208 Power Outlet EI eU BK Y Ignition Switch v ay av LIGHTING SWITCH CONNECTIONS Color R BK BR R Y R a OFF RENE a eco 011 Pressure Switch Water Temperature Sensor Crankshaft Sensor Alternator Ignition Coils Lighting Switch 7 2 Spark Plugs W2L0482CW5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 15 Wiring Diagram Fuse Box 1 Fuse 30A 2 Actuator Controller Fuse 10 3 Fuel Pump Fuse 10 F or 4 Accessory Fuse 10 rake ectifier Actuator Controller Actuator Fuse Box Fuel Level Sensor Pump 5 amp 2 ER MEE SEES P Frams ZEEE 2 Ground 2 2WD 4WD Solenoid Valv
361. ib Remarks 1 Front Axle Nuts 266 27 1 196 2 Front Wheel Nuts 110 11 2 81 S Rear Wheel Nuts 110 11 2 81 S 3 Tie rod End Locknuts 44 4 5 32 4 Rear Axle Nuts 266 27 1 196 5 KRF750S Model R Replacement Parts S Follow the specified tightening sequence W Apply water or soap and water solution DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheel Alignment Caster 2 2 non adjustable Camber Front 0 7 non adjustable zen Rear 0 4 non adjustable Es Toe in 20 40 mm 0 79 1 57 in at 1G Wheels Rims Rims Size Front 12 x 6 0AT 12 8 0 Standard Tire Front 26 x 8 00 12 MAXXIS 989 Tubeless SiS Rear 26 x 10 00 12 Tire Air Pressure when cold Front Rear Maximum Tire Air Pressure to seat beads when cold Tire Tread Depth Front Rear MAXXIS M990 Tubeless 60 kPa 0 6 kgf cm 8 7 psi 90 kPa 0 9 kgf cm 13 1 psi 250 kPa 2 5 kgf cm 36 psi 4 mm 0 16 in 4 mm 0 16 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY WHEELS TIRES 10 5 Special Tools Rotor Puller M16 M18 M20 M22 x 1 5 Brake Drum Remover Nuts 57001 1216 57001 1326 757
362. ie rod end joint A and the tapered hole of the steering knuckle B or the tapers will not fit snugly Install Washers C both sides as shown in the figure Tie rod End Nuts D both sides Tighten Torque End Nuts 41 5 N m 4 2 kgf m 31 ft lb e Install New Cotter Pin E NOTE O When inserting the cotter A if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole HJ07007BS1 e Bend the cotter pin A over the nut B HNO4001BS1 C e Install the removed parts see appropriate chapter e Check the toe in of front wheels see Toe in Adjustment in the Wheels Tires chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY STEERING 14 11 Steering Gear Assembly Tie rod Length Adjustment e Refer to Toe in Adjustment in the Wheels Tires chapter Tie rod Length A Steering Joint Dust Boot Inspection e Refer to Steering Joint Dust Boot Inspection in the Peri odic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 14 12 STEERING Steering Knuckles Steering Knuckle Removal
363. ife out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Vehi cle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man uak Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want engine oil informa tion use the Quick Reference Guide to locate the Engine lubrication System chapter Then use the Table of Contents on the first page of the chapter to find the Engine Oil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious
364. ighting System Circuit R BK Y R Y R BK R Y BK Y 1Q13016BW3 C Lighting Switch Brake Light Switch lgnition Switch Fuse Box Main Fuse 30 A Headlight Right 12 V 35 35 W Headlight Left 12 V 35 35 W Brake Tail Lights 12 V 27 8 W Battery Engine Ground Frame Ground 1 O i DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 56 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit Inspection e Remove Left Seat see Seat Removal in the Frame chapter Radiator Fan Relay A e Disconnect the 4 pin connector B e Using an auxiliary leads A connect BL R and BL W ter minals in the relay lead connector of the harness side NOTE O The ignition switch need not be turned on x If the fan does not rotate inspect the following Main Fuse 30 A Radiator Fan Breaker see Radiator Fan Breaker In spection Fan Motor see Fan Motor Inspection xWhen the fan system is abnormal even if the above in spection is normal check the following items Water Temperature Sensor see Water Temperature Sensor Inspection Radiator Fan Relay see Relay Circuit Inspection Wiring see Wiring Inspection xIf their parts are normality replace the ECU see ECU Removal Installation in the Fuel System chapter Radiator Fan Motor Inspection e Lift a
365. imum diameter Maximum Outside Diameter of Band 94 6 mm 3 72 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 75 Rear Final Gear Case Rear Final Gear Case Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Remove the filler cap NOTICE Be careful not to allow any dirt or foreign materials to enter the gear case e Check the oil level The oil level should come to the bot tom of the filler opening A x If it is insufficient first check the rear final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case e Apply grease to the O ring B e Be sure the O ring is in place Torque Rear Final Gear Case Oil Filler Cap 29 3 0 kgf m 21 ft Ib Rear Final Gear Case Oil Change e Refer to the Rear Final Gear Case Oil Change in the Pe riodic Maintenance chapter Rear Final Gear Case Removal e Remove Rear Bottom Guard see Rear Bottom Guard Removal in the Frame chapter Rear Suspension Arm see Rear Suspension Arm in the Suspension chapter Rear Axles see Rear Axle Removal Rear Propeller Shaft see Rear Propeller Shaft Re moval e Remove Rear Brake Master Cylinder A see Rear Brake Master Cylinder Removal in the Brakes chapt
366. ine Upper Cover see Engine Upper Cover Removal in the Frame chapter e Disconnect forward reverse detecting sensor lead con nector A e Measure the forward reverse detecting sensor resis tance OConnect the hand tester between the BK lead and the W lead OSet the tester to the x 10 O range Special Tool Hand Tester 57001 1394 Forward Reverse Detecting Sensor Resistance Standard 1 2 1 6 kO x lf the reading is not within the specified range replace the forward reverse detecting sensor e Using the highest resistance measure the resistance be tween forward reverse detecting sensor leads and chas Sis ground the tester reading is less than infinity indicates a short replace the forward reverse detecting sensor ELECTRICAL SYSTEM 16 71 HP23006BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 72 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Circuit Ca a 1 2000SBH3 1 Engine Brake Actuator 7 Actuator Controller Fuse 10 A 2 Actuator Controller 8 Main Fuse 30 A 3 Speed Sensor 9 Frame Ground 1 4 Forward Reverse Detecting Sensor 10 Engine Ground 5 Ignition Switch 11 Battery 6 Fuse Box DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILAB
367. ine at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 33 Self Diagnosis Self Diagnosis Flow Chart Turn the ignition switch OFF Turn the ignition switch ON Connect the self diagnosis terminal LG BK in the KDS connector to the ground for more than 2 seconds using an auxiliary lead Then self diagnosis mode starts Fl indicator symbol blinks to display all the service codes Turn the ignition switch OFF Locate the problem with the service code table and inspect and repair DFI or ignition system according to inspection procedure on all the service codes Turn the ignition switch ON Make sure the Fl indicator symbol LCD does not flash Run the engine for several minutes at idling and run the vehicle at 20 km h 12 mph or above in order to confirm no problem 1 15051 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 34 FUEL SYSTEM DFI Self Diagnosis How to Read Service Codes OService codes are shown by a series of long and short blinks of the Fl indicator symbol as shown below ORead 10th digit and unit digit as the Fl indicator symbol blinks OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order Then after completin
368. ine at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change e Remove Bottom Guard Bolts A Bottom Guard B e Support the vehicle so that itis level both side to side and front to rear after warming up the engine e Remove the engine oil drain plug A to drain the oil OThe oil in the filter can be drained by removing the filter see Oil Filter Change e Replace the oil drain plug gasket with a new one e Tighten Torque Engine Oil Drain Plug 20 N m 2 0 kgf m 15 ft Ib 15000011 P e Pour in the specified type and amount of oil SAE 208 50 Engine Oil SAE 20 40 Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Amount 2 41 2 5 US qt When filter is not removed 20 10 0 10 20 20 100 2 5 L 2 6 US qt ee When filter is removed 2 6 L 2 7 US qt When engine is completely dry NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed io accommodate atmospheric conditions in your riding area 100 50 e Install Bottom Guard see Engine Bottom Guard Installation in the Frame chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 32 PERIODIC MAIN
369. ine oil or petroleum distillates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer 08005861 c cially available tire changer NOTE O The tires cannot be removed with hand tools because they fit the rims tightly Tire Installation e Inspect the rim see Wheel Rim Inspection e Replace the air valve with a new one Replace the air valve with whenever the tire is re placed Do not reuse the air valve e Check the tire for wear damage see Tire Inspection in the Periodic Maintenance chapter e Lubricate the tire beads and rim flanges with a soap and water solution or water A WARNING Lubricants other than water or a water and soap so lution can cause the bead to separate from the rim and cause an accident resulting in serious injury or death Use only water or a water and soap solution to lubricate the bead when installing the tire DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY WHEELS TIRES 10 11 Tires e Check the tire rotation mark A on the tire and install the tire on the rim accordingly OThe tires should be installed on the rims so that each air valve is toward the outside of the vehicle NOTE O The direction of the tire rotation B is shown by an arrow lt lt ROTATION on the tire sidewall e Install the tire on th
370. ing Torque Rear Final Gear Case Oil Filler Cap 29 3 0 kgf m 21 ft Ib Brakes Brake Fluid Level Inspection e With the vehicle on level ground check that the fluid level in the reservoir A is between the upper and lower level lines Upper Level ine MAX B Lower Level ine MIN C If the fluid level is lower than the lower level line check for fluid leaks in the brake lines and fill the reservoir to the upper level line A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake pedal has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately Brake Fluid Change e Level the brake fluid reservoir A NOTE OThe fluid level must be checked several times during the fluid changing and replenished as necessary If the fluid in
371. ing Bolts 57001 1481 Socket Wrench 57001 1482 Bearing Driver 54 3 57001 1488 Q o 875714815 C 7571482ST C 7571488ST C Hexagon Wench Hex 41 57001 1491 875714915 C Output Shaft Holder 57001 1570 ST571570ST C Pinion Gear Holder 57001 1708 875717085 Oil Seal Driver 57001 1715 8 5717155 6 Cable Tension Adjusting Tool 57001 1716 T5717168T 6 Oil Seal Guide 57001 1721 875717215 6 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 13 Output Bevel Gears Output Drive Bevel Gear Removal e Remove Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Left Cover see Left Cover Removal in the Frame chap ter Engine Left Side Oil Pipe Engine Outside see Oil Pipe Removal in the Engine Lubrication System chapter Output Drive Bevel Gear Cover Bolts A Output Drive Bevel Gear Cover B e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove Output Drive Idle Gear B e Remove Output Drive Bevel Gear Housing Bolts A Output Drive Bevel Gear Housing B Output Drive Bevel Gear Installation e Install the output drive bevel gear housing e Tighten Torque Output Drive Bevel Gear Housing Bolts 26 2 7 kgf m 19 ft lb
372. ing a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water and seek medial at tention for more severe burns Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electri cal system Therefore replace a sealed battery only on a vehicle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage e Remove the battery see Battery Removal NOTICE Be sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE GP08070381 OMeasure with a digital voltmeter A which can be read to one decimal place voltage x lf the reading is below the specified refreshing charge is 13 0 required M Battery Terminal Voltage US model 5 Standard 12 6 V gt 42 0 0 25 50 75 100 Battery Charge X le gt Refreshing i i Good is required 1908015851 C
373. injury A CAUTION CAUTION indicates a hazardous situa tion which if not avoided could result in minor or moderate injury NOTICE NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows lt also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILI
374. installing the dampers A install them so that the distance to the damper end from the bottom of the fuel tank is 10 mm 0 39 in B Right Side View C 1011011851 C e Check the mats A on the fuel tank x If the mat is damaged or deteriorated replace it 1011013851 C e Install Fuel Tank Bands A Fuel Tank Band Bolts B and Washers e Tighten the bolts until the brackets C of the bands touch the frame e Tighten Torque Fuel Tank Band Bolts 11 N m 1 1 kgf m 97 in Ib 16011010852 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Fuel Tank and Fuel Hose e When installing the check valve A install it so that the arrow B faces fuel tank Black Color C Blue Color D e Fit the hose edge E E to the line of the check valve e Install Fuel Hose see Fuel Hose Replacement Breather Hoses and Clamps Fuel Tank Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank and drain it e Remove Fuel Pump see Fuel Pump Removal e Pour some high flash point solvent into the fuel tank and shake the tank to
375. ion 2 30 Actuator Lever Engine Brake Control Lever Assembly Inspection 2 30 Engine E bricatiorfie v SMR TW esee tei petet eme nnter te eol lae vase Pe RE EPA 2 31 Engine 1 Nee ee reete teme e adr Fi eee re hen erbe 2 31 Oil Filter IS DARE 752 sce ceed OT T D 2 32 Wheels oT rama 2 32 SHIPS HTS DS CIMA 2 32 Wheels Nuts Tightness 2 33 p eg am cM t 2 33 Differential Shift Lever Play 44 4 4 404000 2 33 Differential Shift Lever Play nennen 2 33 Front Final Gear Case Change easet ER reset 2 33 Rear Final Gear Case 2 4442 2 34 NS acon Fate Resets D MEE ML T 2 35 Brake Fluid Level Inspection oett oe rem e n ex RR ERE 2 35 Brake Flut Change d to et p eroe tob aet Eten taped lese b 2 35 Brake Pedal Play Inspection 22 cab alates detur dom del cea tuae go 2 37 Brake Master Cylinder Cup and Dust Seal 2 37 Rear Brake Master Cylinder Cup O ring and Boot Replace
376. ion 16 79 Fuse Inspection 16 80 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 3 Parts Location Ignition Switch A 2WD AWD Shift Switch B Multifunction Meter C Accessory Connector 12 V 120 W Power Outlet D Lighting Switch A Parking Brake Position Switch A Brake Light Switch B Starter Motor A Engine Ground B Crankshaft Sensor C Alternator D Forward Reverse Detecting Sensor E Reverse Position Switch F Neutral Position Switch G Battery A Fuse Box B Starter Relay C Actuator Controller D Vehicle down Sensor E Starter Control Relay F Radiator Fan Relay G Fuel Pump Relay H Frame Ground 1 I Radiator Fan Breaker J ECU Electronic Control Unit K DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 4 ELECTRICAL SYSTEM Parts Location Regulator Rectifier A Frame Ground 2 B Radiator Fan C 4WD Position Switch D Spark Plug Front Cylinder A Starter Motor B Oil Pressure Switch C Ignition Coil 1 Front Cylinder D Spark Plug Rear Cylinder A ISC Valve B Throttle Sensor C Water Temperature Sensor D Ignition Coil 2 Rear Cylinder A Engine Brake Actua
377. ions take a side to side and a front to back measure ment at each of the three locations total of six measure ments shown in the figure xIf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 4 in A 60 mm 2 4 in B 20 mm 0 8 in C HE14003BS1 Cylinder Inside Diameter Standard 84 994 85 006 mm 3 3462 3 3467 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 85 09 mm 3 3500 in or more than 0 05 mm 0 0020 in difference between any two measurements SS SSSSSSSXS Sad SX Piston Wear Inspection e Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the measurement is under service limit replace the pis ton Piston Diameter Standard 84 964 84 979 mm 3 3450 3 3456 in Service Limit 84 81 mm 3 3390 in 14004881 Piston Cylinder Clearance Inspection e Subtract the piston diameter from the cylinder inside di ameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 015 0 042 mm 0 0006 0 0017 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 42 ENGI
378. ipes Fuel Hose INSP SCHON Pec Fuel Hose DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 3 91 3 93 3 93 3 93 3 95 3 95 3 95 DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 4 FUEL SYSTEM DFI Exploded View 10602041885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 5 Exploded View Torque No Fastener Nm kati itib Remarks 1 Element Holder Screw 4 5 0 46 40 in Ib 2 Element Cover Screw 4 5 0 46 40 in lb 3 Air Cleaner Mounting Bolts 8 8 0 90 78 in lb L 4 ISC Valve Mounting Bolts 8 8 0 90 78 in lb 5 Delivery Pipe Mounting Screws 5 0 0 51 44 in lb 6 Inlet Air Pressure Sensor Mounting Screw 5 0 0 51 44 in lb 7 Throttle Cable Locknuts 4 4 0 45 39 in lb 8 Throttle Pedal Position Bolt Locknut 10 8 1 1 96 in lb 9 Inlet Air Temperature Sensor 10 ISC Valve 11 Inlet Air Pressure Sensor 12 Fuel Injectors CL Apply cable lubricant G Apply grease L Apply a non permanent locking agent O Apply high quality foam air filter oil R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 6 FUEL SYSTEM DFI Exploded View DOC
379. ir Cap 3 4 0 35 kgf m 30 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the brake lines see Blake Line Air Bleeding in the Brakes chapter A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake pedal has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately Brake Pedal Play Inspection e Check the brake pedal play A Brake Pedal Play Standard 2 10 mm 0 08 0 39 x lf the play is not correct adjust it e Loosen the locknut A and turn the push rod B to obtain the correct amount of free play e Tighten Torque Push Rod Locknut 17 2 N m 1 8 kgf m 13 ft Ib e Check the brake for good braking power and no brake drag 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 adjusted to the specification 518109 p
380. itaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 5 Exploded View Torque No Fastener Nm kgm ft lb Remarks 1 Rotor Mounting Bolts 12 1 2 106 2 Output Driven Bevel Gear Housing Bolts 26 2 7 19 3 Bevel Gear Bearing Holder Nut 200 20 4 148 LB 4 Bearing Holder M64 120 122 89 L 5 Bearing Holder M75 250 25 5 184 L 6 Output Shaft Holder Nut 200 20 4 148 LB 7 Output Drive Bevel Gear Housing Bolts 26 2 7 19 8 Output Drive Bevel Gear Cover Bolt L 65 mm 2 56 8 8 0 90 78 in lb 9 Output Drive Bevel Gear Cover Bolts L 20 mm 0 79 in 8 8 0 90 78 10 Forward Reverse Detecting Sensor Mounting Bolt 14 9 1 5 11 Apply engine oil Apply grease Apply a non permanent locking agent Apply a non permanent locking agent Three Bond TB2471 Blue Apply molybdenum disulfide grease Replacement Parts Apply soap and water solution m 5 2 0 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 6 FINAL DRIVE Exploded View AN 4 uM 11020358485 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 7 Exploded View
381. itches and Sensor Neutral Position Switch Connection Bieri When transmission is in neutral oo When transmission is not in neutral meu 1015009BN3 A Neutral Position Switch Reverse Position Switch Connection When transmission is in reverse 0 40 When transmission is not in reverse Bo ESSI B Reverse Position Switch 4WD Position Switch Connection O 77 mb Position Position gt 1015010 3 2WD AWD Shift Switch Connection Ls er mp Position WS Position 1015011BN3 Brake Light Switch Connection 0 970 When brake pedal is pushed down When brake pedal is released 1015012BN3 Parking Brake Position Switch Connection NS When parking brake pedalis pushed down OO When parking brake pedal is released 1015013 3 Oil Pressure Switch Connection Engine lubrication system is in good condition DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 79 Fuses Fuse Removal e Remove Left Seat see Seat Removal in the Frame chapter e Push the central pin A of the quick rivet and remove it e Slide the cover B rearward and remove it e Remove Fuse Box Lid A e Pull the fuses A straight out of the fuse box with needle nose
382. ive wire to the 1 negative terminal DISASSEMBLY ASSEMBLY Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 6 SNIMNMB E Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle 0020018 5 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol EN oration or other damage Refer to the appropriate sections
383. ive Belt Installation ss te etn Drive Belt Deflection Inspection 22 6 2 Drive Belt Deflection Adjustment 5 Drive Belt Inspection t tt tette ettet tenes gcc EOM Uu IR Drive Pulley Remowval 999 A M Drive Pulley Disassembly lili NR Drive Pulley Inspecuor ue ce NC e ree ceret d inea Spider Shoe Side Clearance Inspection Adj stment Drive Pulley Assembly Drive Pulley Installatiori 5 Roda Ent rers Driven NM qu TEX Driven Pulley Driven Pulley Disassemgly 9 2 1 Driven Pulley InspecffeneW Driven Pulley Driven Pulley lgstallaW M enm reet re teni rrt bene tinte es DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www milit
384. k battery condition before condemning other parts of an electrical system A fully charged battery is required for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damaging electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the high current never keep the ignition switch key turned START position when the starter motor will not turn over or the current may burn out the starter motor windings OTake care not to short the leads that are directly con nected to the battery positive terminal to chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc De fective wires and bad connections will affect electrical sys tem operation OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black GY Gray R Red BL Blue LB Light blue V Violet BR Brown LG Lightgreen White CH Chocola
385. kcase Bolts M6 9 8 N m 1 0 kgf m 87 in Ib A L 40 mm 1 57 in B L 65 mm 2 56 in e Grease the lip A of the oil seal B and press the seal 3 mm 0 12 in C inwards from the end of the boss HIO4015BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 12 CRANKSHAFT TRANSMISSION Crankcase e Install the breather tube A on the crankcase fitting OAlign the white line on the tube with the mark B on the crankcase OFace the open end of the clamp C towards the left side D as shown 1704000851 C e Apply grease to the steel ball A and spring B e Install Steel Ball Spring Washer C Shift Shaft Positioning Bolt D e Tighten Torque Shift Shaft Positioning Bolt 25 2 5 kgf m 18 ft Ib MEE HI04001281 e Check Crankshaft and driven shaft turn freely any of the shafts do not turn freely split the crankcase to locate the problem DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 13 Crankshaft Connection Rod Crankshaft Removal e Split the crankcase see Crankcase Disassembly e Remove the crankshaft A from the crankcase using a press Crankshaft Installation
386. kle Removal Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Drive the bearing A out using suitable bearing driver Special Tool Bearing Driver Set 57001 1129 Knuckle Bearing Installation e Press in the bearing until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Replace the circlip with a new one Special Tool Outside Circlip Pliers 57001 144 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 1 Frame Table of Contents Exploded View 15 2 Side Cover Installation 15 46 Seat and Seat Belts 15 16 Seat Lower Cover Removal 15 46 Seat Removal 15 16 Seat Lower Cover Installation 15 47 Seat Installation 15 16 Seat Lower Right Plate Removal 15 48 Seat Disassembly 15 16 Seat Lower Right Plate Seat Assembly 15 17 Installation M 15 48 Seat Belt Removal 15 18 Seat Lower Left Plate Removal 15 48 Seat Belt Installation 15 19 Seat Lower Left Plate Installation 15 49 Co
387. kshaft Runout Inspection e Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 04 mm 0 0016 in or less Service Limit TIR 0 10 mm 0 0039 in HI05022BS1 Crankshaft Main Bearing Journal Wear Inspection e Measure the diameter A of the crankshaft main journal Crankshaft Main Journal Diameter Standard 41 984 42 000 mm 1 6529 1 6535 in Service Limit 41 96 mm 1 6520 in If any journal has worn past the service limit replace the crankshaft with a new one HIOS023BS1 e Measure the main bearing bore diameter A in the crankcase halves Crankcase Main Bearing Bore Diameter Standard 42 025 42 041 mm 1 6545 1 6552 Service Limit 42 07 mm 1 6563 in there is any signs of seizure damage or excessive wear replace the crankcase halves as a set HIOS003BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 18 CRANKSHAFT TRANSMISSION Transmission Shift Lever Removal e Set the shift lever in the neutral position e Remove Seat Lower Cover see Seat Lowe Cover Removal in the Frame chapter Shift Shaft Lever Bolt A e Remove the shift shaft lever B from the shift shaft e Remove Grip A Grip Hold Nut B 17008007 P e Remove Spring A Ratchet Assembly Bolts B
388. l 2WD AWD Shift Cable Rear End 2WD AWD Shift Cable Front End Pin and Washer Snap Pin e Support the vehicle on a stand or a jack so that the all wheels are off the ground e Shift the transmission in neutral position e Remove Vacuum Hose A e Tighten Torque 2WD 4WD Shift Cable Locknut A 4 4 N m 0 45 kgf m 39 in Ib e Install the cable tension adjusting tool A on the cable and between the brackets as shown in the figure Special Tool Cable Tension Adjusting Tool 57001 1716 1L04049BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 39 Front Final Gear Case e Push the 2WD 4WD shift shaft lever A rearward 4WD position and make the engagement of the shifter maxi mum while turning the propeller shaft by hand e Turn the nut B with fingers and pull slightly the inner cable e Tighten Torque 2WD 4WD Shift Cable Locknut C 4 4 0 45 kgf m 39 in Ib e Remove the cable tension adjusting tool e Confirm the 2WD 4WD shift shaft lever A return to 2WD position B 4WD Position C e Install the vacuum hose to the actuator e Install the removed parts 2WD 4WD Vacuum Actuator Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Right Bracket see Right Bracket Removal in the Frame chapter Vacuum Hose A
389. l Rebound Damping Force Adjustment Out from the fully tightened position Front Rear Compression Damping Force Adjustment Out from the fully tightened position Front Rear Spring Preload Setting Position Front Rear Standard No 2 111 5 mm 4 390 in 1 turn out 1 turn out 3 5 turns out 12 clicks out 82 5 mm 3 248 in 116 0 mm 4 567 in Service Limit Usable Range 1 5 109 5 127 5 mm 4 311 5 020 in Usable Range 0 2 5 turns out 1 3 turns out Usable Range 0 5 turns out 1 20 clicks Usable Range 75 5 95 5 mm 2 972 3 760 in 109 5 127 5 mm 4 311 5 020 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 7 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C 875711295 C Outside Circlip Pliers Jack 57001 144 57001 1238 lt LHZ 6 EK 875701445 E 875712385 Steering Stem Nut Wrench Hook Wrench 3 2 R37 57001 1100 57001 1539 875711905 T5715398T C Hook Wrench R37 5 R42 Knuckle Joint Driver 57001 1101 57001 1640 I Ge ST571101ST C 875716405 6 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 8 SUSPENSION Sho
390. l in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure Idling Standard 294 kPa 3 0 kgf cm 43 psi DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 74 FUEL SYSTEM DFI Fuel Line NOTE O The gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications e Turn the ignition switch OFF x If the fuel pressure is much higher than specified the fuel pressure regulator in the fuel pump has been clogged or stuck Replace the fuel pump see Fuel Pump Removal xIf the fuel pressure is much lower than specified check the following Fuel Line Leakage see Fuel Injector Fuel Line Inspec tion Amount of Fuel Flow see Fuel Flow Rate Inspection e Remove the fuel pressure gauge hoses and adapter e Install the removed parts Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be
391. l the piston stop bolt Use a new aluminum washer OTighten Torque Piston Stop Bolt 8 8 0 90 kgf m 78 in Ib Reservoir Clamp Bolt 6 2 N m 0 63 kgf m 55 in Ib e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter Rear Brake Master Cylinder Cup O ring and Boot Replace e Remove Rear Brake Master Cylinder see Rear Brake Master Cylinder Removal in the Brakes chapter Push Rod A Boot B 15148115 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Remove Circlip A Special Tool Inside Circlip Pliers 57001 143 e Remove Piston A Cup B Spring C O rings D e Assemble the master cylinder e Clean all the parts including the master cylinder with b fluid or alcohol and apply brake fluid to the remo and the inner wall of the cylinder NOTICE cohol for cleaning brake parts D fluid for cleaning these parts ration of the rubber par 1 on any part will be difficult to wash o Be careful of th lirection B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply silicone grease New Cup A New O
392. llation in the Brakes chapter e Apply grease to the spline A of the front axle e Install Front Hub B xIf the front hub seems too difficult to install use the fol lowing special tool OUsing the brake drum pusher A and tighten it until the pusher stops Special Tool Brake Drum Pusher 57001 1714 ORemove the brake drum pusher and install one spacer A in the brake drum pusher set 57001 1709 to the pusher OTighten the hub pusher B until the pusher stops ORemove the brake drum pusher and spacer Special Tool Brake Drum Pusher amp Washer 57001 1709 e Install Washer A Axle Nut B e Using the brake drum holder C hold the front hub D Special Tool Brake Drum Holder 57001 1325 e Tighten Torque Front Axle Nut 266 27 1 kgf m 196 ft Ib e Insert a new cotter pin A e Bend the cotter pin over the axle shaft end B and install the cap A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin e Install Brake Caliper see Brake Caliper Installation in the Brakes chapter Front Wheels see Wheel Installation WHEELS TIRES 10 13 08001851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 10 14 WHEELS TIRES Front Hub Front Hub Disassembly A
393. lley Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Fixed Sheave Tapered Portion A Crankshaft Tapered Portion B A WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings H 04000881 C e Install the drive pulley stepped waster and two washers on the drive pulley bolt as shown Crankcase Side A Stepped Washer B Two Washers C Bolt Head Side D H 06024BS1 e Remove the three cover bolts A and install the drive pul ley holder B Special Tool Drive Pulley Holder 57001 1620 e Tighten Torque Drive Pulley Cover Bolts 12 5 1 3 kgf m 111 in Ib Drive Pulley Bolt C new left hand threads 93 9 5 kgf m 69 ft lb e Remove the drive pulley holder and install three drive pul ley cover bolts to the specified torque e Adjust the installation length A of the drive pulley be tween the surface of the crankcase B and the collar C on the drive pulley as followings Drive Pulley Installation Length A Standard 164 85 165 95 mm 6 490 6 533 in H 06004BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 21 Drive Pulley Olnstall the drive pulley measurement tool
394. locknut has left hand threads OThe thread length B of the front and rear are almost same not lean the tie rod rear end after tightening the front locknut Right E Wrong F e Install the lower end of the spring G to the bracket e Confirm the lever does not scrub the ditch of guide excessively when the lever leaned to right side 1 Clearance J 0 mm 0 in 8 mm 0 31 in K 18 mm 0 71 in L Lighting Range M of Neutral Indicator Light e f the excessive friction N occurs to the lever and the ditch of guide readjust the thread length of the tie rod Good O Readjustment P e Tighten the grip hold nut Q lightly by finger until it is stopped e Twist the grip to bottom of the screw and then turn back in accordance with the direction of figure Oln view of S the mark T becomes the position of figure e Hold the grip and tighten the grip hold nut Torque Grip Hold Nut 9 8 1 0 kgf m 87 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 23 Transmission 1706005892 C Transmission Removal e Split the crankcase see Crankcase Disassembly e Remove Shift Shaft Cover Bolts A Shift Shaft Cover B e Remove Shift Shaft Spring Bolt A Shift Shaft B e Remove Reverse Idle Shaft A Spacer B Reverse Drive Gear C Needle Bearing
395. ltage Standard less than DC 0 8 V or over than DC 4 8 V e Turn the ignition switch OFF x If the reading is out of the standard replace the sensor If the reading is within the standard check the wiring for continuity see Speed Sensor Circuit xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Speed Sensor Circuit 123 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1615070892 C 1 ECU Electronic Control Unit 3 Power Source 5 Multifunction Meter 2 Speed Sensor 4 Frame Ground 1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 56 FUEL SYSTEM Vehicle down Sensor Service Code 31 Vehicle down Sensor Removal Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Left Seat see Seat Removal in the Frame chapter Bolt A Vehicle down Sensor B Connector C Vehicle down Sensor Installation e The UPPER mark A of the sensor should face upward A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain ridin
396. mbly Installation in the Steering chapter Steering Gear Assembly Mounting Rubber Dampers Tie rod End Nuts see Steering Gear Assembly Installa tion in the Steering chapter x lf the inspections above are good but the free play is out of the specified the steering gear assembly is damaged and should be replaced as a unit DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Joint Dust Boot Inspection e Visually inspect the dust boots A at both the ends of the steering gear assembly Front B xIf there is any signs of deterioration cracks or damage replace the steering gear assembly together with these boots 1516001851 C Frame Seat Belt Inspection e Check the belt A for damage or tear x If necessary replace the belt with a new one OCheck the tightness torque of the seat belt mounting bolts both sides Torque Right and Left Bar Mounting Bolts A 98 N m 10 kgf m 72 ft lb Seat Belt Case Mounting Nuts B 46 5 4 7 kgf m 34 ft Ib Torque Seat Belt Mounting Bolt A 41 5 N m 4 2 kgf m 31 ft lb DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Torque Seat Bel
397. middle of two pulleys with a straightedge the belt deflection gauge and a ruler e Place a straightedge B on top of the belt between the drive pulley C and the driven pulley D e Push the belt away from the straightedge with the belt deflection gauge Press the gauge head until the 59 N scale line aligns with the top end of the stopper HSO5000BS1 Belt Deflection Standard 22 27 mm 0 87 1 06 in at adjusting x lf the belt deflection is not within the specified range ad just the deflection again DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Converter Drive Belt Deflection Adjustment e Disassemble the driven pulley see Driven Pulley Disas sembly in the Converter System chapter x f the belt deflection is more than 31 mm 1 22 in remove the spacers to decrease it OThe rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 3 mm 0 051 in change in belt deflection xIf the adjustment cannot be done within the specified range even if the shim is removed replace the drive belt x f the belt deflection is less than 22 mm 0 87 in add the spacers A to increase it OThe rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 6 mm 0 063 in change in belt deflection NOTE O
398. mm 0 4 in of pedal travel A 9 0 0 0 9 0 9 0 9 MHW ING SAWN 5555555 SS 22 gt 8 10010851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Timing Adjustment e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Lift and hold the front fender rear see Front Fender Rear Removal in the Frame chapter e Adjust the brake light switch A up or down To change the switch position turn the adjusting nut B Light sooner C Light later D To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment Joint Boots Inspection Front Axle Steering Knuckle Joint Boots Inspection e Visually inspect the front axle joint boots A x If the joint boot is torn worn deteriorated or leaks grease replace the joint boot or front axle assembly see Front Axle Joint Boot Replacement in the Final Drive chapter e Visually inspect the knuckle joint boots B x If the joint boot is torn worn deteriorated or leaks grease replace the knuckle see Steering Knuckle section in the Steering chapter Front Propeller Shaft Joint Boots Inspection e Remove Center Cover
399. mow Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch 1 22005851 6 e Measure the controller output voltage for the actuators Controller Output Voltage to Actuators Standard 4 8 0 2 V xIf the reading is not standard replace the actuator con troller unit DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Actuator Control System e Support the vehicle on a stand or a jack so that the wheels are off the ground e Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector W R Terminal 15 Tester Connector BK Y Terminal 10 Olnstall the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Spin a rear wheel as forward rotation e After the wheels stop and one second elapses turn OFF the ignition switch e After two seconds elapses measure the controller output voltage for the engine brake actuator until the actuator stops Controller Output Voltage to engine brake actuator Standard 5 12V x If the reading is not standard check the forward reverse detecting sensor x If the forward reverse detecting sensor is normal replace the actuator controller unit Forward Reverse Detecting Sensor Inspection e Remove Eng
400. n Overall Width 1 485 mm 58 46 in Overall Height KRF750N S T 1 925 mm 75 79 in KRF750P R V 2 020 mm 79 53 in Wheelbase 1 930 mm 75 98 in Tread Front 1 225 mm 48 23 in Rear 1 200 mm 47 24 in Ground Clearance 295 mm 11 6 in Seat Height 780 mm 30 7 in Curb Mass KRF750N 633 kg 1 396 Ib CA 630 kg 1 389 Ib KRF750P R V CA KRF750SAF SBF KRF750SAFA SBFA KRF750T Front KRF750N KRF750P R V KRF750SAF SBF KRF750SAFA SBFA KRF750T Rear KRF750N T KRF750P R V KRF750SAF SBF KRF750SAFA SBFA Fuel Tank Capacity Cargo Bed L x W x Seating Capacity P CUP J 648 kg 1 429 Ib 630 kg 1 389 Ib 631 kg 1 391 Ib 634 kg 1 398 Ib 280 kg 617 Ib 291 kg 642 Ib CA 279 kg 615 CA CA CA a c DH 280 kg 617 Ib 281 Kg 620 Ib 353 kg 778 Ib 357 kg 787 Ib 351 kg 774 Ib 351 kg 774 Ib 28 L 7 4 US gal CA CA CA CA cl 830 x 1 120 x 280 mm 32 68 x 44 09 x 11 10 in 2 CA 627 kg 1 383 Ib CA 628 kg 1 385 Ib 279 kg 289 kg 278 kg 279 kg 351 kg 356 kg 349 kg 349 kg 645 1 422 Ib 615 Ib 637 Ib 613 Ib 615 Ib a 774 lb 785 Ib 770 Ib 770 Ib we Fae Da DW Performance Minimum Turning Radius Differ
401. n 92180 1420 1 0 mm 0 039 in 92180 1421 1 2 mm 0 047 in 92180 1422 3 Pinion Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1423 0 2 mm 0 008 in 92180 1424 0 5 mm 0 020 in 92180 1425 0 8 mm 0 031 in 92180 1426 1 0 mm 0 039 in 92180 1427 1 2 mm 0 047 in 92180 1428 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 89 Rear Final Gear Case Rear Final Gear Case Backlash Adjustment e Clean dirt and oil off bevel gear teeth e Measure length A B and C and calculate the clear ance D between the ring gear assembly and gear case covers D A B C ILOsO10BW2 C E Rear Final Gear Case F Ring Gear Assembly G Rear Final Gear Case Right Cover e Assemble the rear final gear case see Rear Final Gear Case Assembly OWhen installing the pinion gear bearing holder non permanent locking agent is not used OUse the following two spare bolts when installing the rear final gear case right cover A M12 Bolt B L 2 35 mm 1 38 in P 1 25 mm 0 049 in M10 Bolt C L 2 35 mm 1 38 in P 2 1 25 mm 0 049 in 1LO801i1BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 90 FINAL DRIVE Rear Final Gear Case
402. n 3 41 Inlet Air Pressure Sensor Input Voltage 40000 0 3 41 Inlet Air Pressure Sensor Output Voltage 3 42 Inlet Air Temperat re Sensor Service Code 13 3 47 Inlet Air Temperature Sensor 1 3 47 Inlet Air Temperature Sensor Output Voltage 3 47 Inlet Air Temperature Sensor Resistance 3 48 Water Temperature Sensor Service Code 14 40000 3 50 Water Temperature Sensor nnne 3 50 Water Temperature Sensor 3 50 Water Temperature Sensor Output Voltage 3 51 Water Temperature Sensor Resistance 3 52 Crankshaft Sensor Service Code 21 nennen enne 3 53 Crankshaft Sensor 3 53 Crankshaft Sensor INSpection 3 53 Speed Sensor Service Code 24 mete eie ditte rie LN RED re EE EE Ru ean gn 3 54 Speed Sensor ASMOVAl 3 54
403. n the figure e Hold the pinion gear unit and remove the pinion gear bear ing holder nut e Remove the ball bearing if required Special Tool Bearing Puller 57001 135 Pinion Gear Unit Assembly e Visually inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a bearing re place the bearing e Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Front Final Bevel Gear Adjustment e Press the ball bearing A on the pinion gear until it is bottomed e Apply non permanent locking agent Three Bond 1B2471 Blue to the pinion gear bearing holder nut B e Install the pinion gear bearing holder nut so that the pro jection C faces outward 1L0404iBS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 57 Front Final Gear Case e Hold the pinion gear unit A with the socket wrench B in a vise see Pinion Gear Unit Disassembly Special Tools Socket Wrench 57001 1363 Pinion Gear Holder C 57001 1708 e Turn the wrench D counterclockwise and tighten the nut Torque Pinion Gear Bearing Holder Nut 200 20 4 kgf m 148 ft Ib Front Final Bevel Gear Adjustment The backlash distance one gear will move back and forth without moving the mate gear and toot
404. nal Gear Case Mounting Nuts 90 5 9 2 kgf m 67 ft lb e Install Breather Hose 2WD AWD Shift Cable End see 2WD 4WD Shift Cable Installation 2WD 4WD Shift Cable Holder and Bolts 2WD 4WD Shift Position Switch Lead Connector e Apply a non permanent locking agent to the holder bolts e Tighten Torque 2WD 4WD Shift Cable Holder Bolts 8 8 0 90 kgf m 78 in Ib e Install Differential Shift Cable End see Variable Shift Cable In stallation Differential Shift Cable Holder and Bolts e Tighten Torque Front Final Gear Case Left Cover Bolts M6 8 8 N m 0 90 kgf m 78 in Ib Differential Shift Cable Holder Bolt 8 8 N m 0 90 kgf m 78 in Ib e Install the differential shift cable so that the distance A between the nut and casing cap is 6 mm 0 24 in 1L04028BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 43 Front Final Gear Case e Install the drain plug and a new O ring OApply grease to the O ring e Tighten Torque Front Final Gear Case Oil Drain Plug 15 1 5 kgf m 11 ft lb e Install the removed parts e Fill the front final gear case with the specified oil see Front Final Gear Case Oil Change in the Periodic Main tenance chapter Front Final Gear Case Disassembly e Remove Front Final Gear Case see Front Final Gear Case Re moval Differential Control
405. nd hold the front fender see Front Fender Removal in the Frame chapter e Disconnect the connector A in the fan lead e Using two auxiliary wires supply battery B voltage to the fan motor xIf the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Motor Leads BL Battery BK gt Battery Radiator Fan Breaker Inspection e Remove Left Seat see Seat Removal in the Frame chapter Connectors A disconnect Radiator Fan Breaker B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 57 Radiator Fan System e Inspect the breaker for operation e Connect 12 V Battery A 0 6 O Resistance B Radiator Fan Breaker C BR 1 20 R 0 60 Switch D 12VD0 x lf the circuit the breaker will not open within 60 seconds replace the breaker e When resetting the breaker push the reset button after D HP13002BS1 ten seconds or more pass Radiator Fan Breaker Installation e Connect the radiator fan breaker lead connector e Install Radiator Fan Breaker Radiator Fan Relay Inspection e Refer to the Relay Inspection Radiator Fan Circuit 1014013882 C Radiator Fan Motor Frame Ground 1 Radiator Fan Breaker Fuse Box Main Fuse 30 A ECU Radiator Fan Relay Engine Ground
406. nd move the weights back and forth x If the weights do not move smoothly replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary A Rest Position compression is released B Weights C Spring 2 If compression is released while the engine is running the weights are not swinging out e Remove the spring and move the weights back and forth x lf the weights do not move easily from the retracted po sition replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary A Running Position Compression is not released B Weights C Spring KACR Removal e Remove Camshaft see Camshaft Removal Camshaft Sprocket Bolts A Unit B HEOSOOOBS1 HE09001BS1 C HE09002BS1 C 090028 P DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 24 ENGINE TOP END Camshaft e Remove Circlips A Weights B Spring C NOTE ODo not remove the shaft A and pin B Olf the parts are removed they cannot be reinstalled KACR Installation e Install Weights Circlips Spring A OHook the spring from the outside with the open side of the hook inwards Install KACR Unit Hook the arms B on the pins e Apply a non permanent locking agent to the camsha
407. nd npe nes ea mae tU l Oil Screen GClearnirig ei e qne dero e Mi cider Pressure Measurement uide roi cel Nehme Gs UEM Air M Oil Pipe Rermoval i etm n Rete a tsp etes Pipe Installation t ND Et DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 7 2 7 5 7 6 7 7 7 7 7 7 7 7 7 8 7 8 7 10 7 10 7 10 7 10 7 11 7 11 7 11 7 13 7 13 7 14 DOCUMENT AVAILABLE FOR MILITARY USE ONLY 7 2 ENGINE LUBRICATION SYSTEM Exploded View DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque No Fastener Nam kgf m ft Ib Remarks 1 Oil Filter 17 5 7 9 13 R 2 Oil Pressure Switch 15 1 5 11 SS 3 Oil Pipe Bolts 8 8 0 90 78 in lb 4 Oil Drain Plug 20 2 0 15 5 Oil Pressure Relief Valve 15 1 5 11 L 6 Oil Pump Cover Bolts 8 8 0 90 78 in lb 7 Chain Guide Bolt 8 8 0 90 78 8 Oil cump Drive Tensioner Bolt 2 5 18 10 Plate Bolts 0 90 78 in lb EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant Liquid Gasket TB1211 56019 120 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at
408. ne which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil Remove the cap by turning it counterclock wise HP10040BS2 C xIf the arcing distance is as before the trouble is with the ignition coil If the arcing distance is normal the trouble is with the spark plug cap x If a coil tester is not available the coil can be checked for a broken or badly shorted winding with a hand tester Special Tool Hand Tester 57001 1394 NOTE O The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage e Measure the primary winding resistance A as follows OConnect the tester between the coil terminals OSet the tester to the x 1 0 range e Measure the secondary winding resistance B as follows ORemove the plug cap by turning it counterclockwise OConnect the tester between the spark plug lead and ter minal OSet the tester to the x 1 range Ignition Coil Winding Resistance HP10041881 0 Primary Windings 1 84 2 76 Secondary Windings 10 4 15 6 xIf the hand tester does not read as specified replace the OTo install the plug cap turn it clockwise DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Ignition System Ignition Coil Primary Peak Voltage Inspection NOTE OBe
409. nect the hand tester to the regulator rectifier x lf the tester readings are not as specified replace the regulator rectifier HP09037BS1 Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resistance Unit kQ Tester Lead Connection Terminal A B C D E A EIE S D 2 26 eo 2 50 2 26 2 26 2 26 Tester Lead Connection DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 35 Charging System Charging System Circuit 1909019882 C Ignition Switch Fuse Box Main Fuse 30 A Regulator rectifier Engine Ground Battery Alternator Loads Frame Ground 2 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 36 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electri
410. nection Rod e Apply molybdenum disulfide oil Threads A of Connecting Rod Big End Cap Bolts Seating Surface B of Connecting Rod Big End Cap Nuts C e Tighten Torque Connecting Rod Big End Cap Nuts 34 3 N m 3 5 kgf m 25 16 Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend Inspection e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on a V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend x f connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist Inspection e With the big end arbor A still on t
411. needed Turn the ignition switch OFF to stop the indicator symbol When the FI indicator symbol LCD flashes and the ve hicle is brought in for repair check the service codes When the repair has been done the symbol disappears But the service codes stored in memory of the ECU are not erased to preserve the problem history can be referred using the KDS Kawasaki Diagnostic System when solving unstable problems Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 22 FUEL SYSTEM Troubleshooting the DFI System e When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors A have seals B including the ECU e When measuring the input or output voltage with the con nector joined use the needle adapter set C Special Tool Needle Adapter Set 57001 1457 e Insert the needle adapters inside the seals from behind the connector until the adapter reaches the terminal NOTICE Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals e Make sure that measuring points are correct in the con
412. ng Groove 5 22 Wear Inspection 5 42 KACR 4 21 0 5 23 Piston Ring Groove Width KACR 5 23 5 42 KACR Installation d a 5 24 Piston Ring Thickness Inspection 5 42 Camshaft Chain Removal 5 24 Piston Ring End Gap Inspection 5 43 Camshaft Chain Installation 5 25 Exhaust 5 44 Camshaft Chain Guide Wear Spark Arrester Cleaning 5 44 Inspection me 5 28 Muffler and Exhaust Pipe Cylinder 27 5 29 Removal ote 5 44 Cylinder Compression Exhaust System Inspection 5 46 Measurement 5 29 Muffler and Exhaust Pipe Oylinder Head Remowval 5 30 Installation eim t pr en 5 46 Cylinder Head Installation 5 30 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 2 ENGINE TOP END Exploded View 1E02024885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 3 Exploded View No Fastener Remarks kg
413. ng Seats A Spring B Thrust Plate C e Confirm the paint mark 0 A on the movable sheave B in alignment with the point C on the fixed sheave D for phase fit of the sheaves e Wipe off the molybdenum disulfide grease e Remove the four pins A with a thin standard tip screw driver B e Remove the movable sheave from the fixed sheave e Remove J Spacer s A for Drive Belt Deflection Adjustment Driven Pulley Inspection x Ifthe sheave surfaces A appear damaged replace the Sheaves DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 24 CONVERTER SYSTEM Driven Pulley e Replace the sheave with uneven wear on the belt con tacting surfaces A Sheave Surface B Straight Edge xIf the sheave bushings A are damaged or worn replace the movable sheave Sheave Bushing Inside Diameter Standard 40 000 40 039 mm 1 5748 1 5763 in Service Limit 40 07 mm 1 578 in e Inspect seals for damage x If seals are damaged replace the movable sheave x If the splines A are damaged or worn replace the fixed cU x If the spring is damaged or worn e spring Spring Free Length A Standard 99 mm 3 9 in x If the spring coils are UN replace the spring Driv Assembly any grease or dirt on the movable and fixed s and dry them with a clean cl
414. ng broken or weak Converter engagement speed too low Drive pulley spring broken or weak Converter engagement speed too high Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly Drive pulley spring weak Air cleaner poorly Gea RAE RT ASHNGABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 4 APPENDIX Troubleshooting Guide Driven pulley spring weak or incorrectly in stalled too loose Shifting too slowly Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive pulley spring incorrect installed too tight Driven pulley movable sheave doesn t move smoothly Gear Shifting Faulty Doesn t go into gear Shift fork bent or seized Gear stuck on the shaft Shift tie rod maladjusted Shift tie rod damaged Jumps out of gear Shifter groove worn Gear dogs worn Shift fork worn bent Shift arm positioning bolt spring weak or broken Shift tie rod maladjusted Drive shaft output shaft and or gear splines worn Overshifts Shift arm positioning bolt spring weak or broken Shift tie rod maladjusted Abnormal Engine Noise Knocking ECU trouble Car
415. ni oo eee E eR reete ae dada anid n tu hes Recens 3 65 Fuel Injector Resistance 3 65 Fuel Injector Power Source Voltage 3 65 Fuel Injector Output Voltage 14 0 3 66 Fuel Injector Fuel Line Inspection 00 1 1m 3 67 FI Indicator Symbol eit cot t oet Titre ber 3 69 Fl Indicator Symbol LCD 42 06 2 9E 3 69 0 p ada WEM We MES 3 70 ECU Removal Pr REN dh Wh IPIS 3 70 ECU InistallatiOrk us a o NN e 3 70 ECU Power Supply 8 3 70 3 73 Fuel ressurednspecliol ote p e pet acca tS 3 73 Fuel Flow Rate Inspection een Ne 3 74 E E DUREE ue n 3 76 Fuel Pump VI 3 76 Fuel Pump Installation un etel No p Rs 3 76 Fuel Pump Operation Inspection 2 2 2222222222 22 3 77 Fuel Pump Operating Voltage Inspection 3 77 Pressure Regulator
416. nnect the peak voltage adapter C to the hand tester and crankshaft sensor leads in the connector Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connections Crankshaft Sensor Adapter Hand Tester Black White lt Red gt Blue lt Black e Turn the ignition switch on and rotate the engine for 4 5 seconds with the transmission gear in neutral to measure the crankshaft sens r degOWM amp deT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 41 Ignition System e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 2 V or more x If the peak voltage is lower than the standard inspect the crankshaft sensor Alternator Rotor Inspection e Check the timing projection A for damage such as chip ping or grooving xIf the timing projection on the rotor is visibly damaged replace the alternator rotor Ignition Timing Test e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Ignition Timing Inspection Plug A e Attach a timing light A and a tachometer in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the timing mark on the alternator rotor e Runthe engine atthe speeds specified and note the align ment
417. ns eui eee tus 16 12 Special Tools 16 13 Wiring Diagram 16 14 Precautions 16 16 Electrical Wiring ees 16 17 Wiring Inspection 16 17 Battery s cheats Caec pedea 16 18 Battery Removal 16 18 Battery Installation 16 18 Battery Activation CA Model 16 21 Precautions 16 23 Interchange re e trees 16 24 Charging Condition Inspection 16 24 Refreshing Charge 16 25 Charging System 16 27 Alternator Cover Removal 16 27 Alternator Cover Installation 16 28 Alternator Rotor Removal 16 30 Alternator Rotor Installation 16 30 Alternator Stator Removal 16 31 Alternator Stator Installation 16 31 Regulator Rectifier Output Voltage Inspection 16 31 Alternator Inspections ds e 16 32 Regulator Rectifier Removal e 16 33 Regulator Rectifiernstallation 16 33 Regulator Rectifier Inspection 16 34 Ignition System 54 16 36 Spark Plug Removal 16 36 Spark Plug Installation 16 36 Spark Plug Cleaning Inspection 16 36 Spark Plug Gap Inspection 16 36 Ignition Coil Removal 16 36 Ignition Coil Installation 16 37 Ignition Coil Inspection 16 38 Ignition Coil Primary Pe
418. nside Circlip Pliers 57001 143 ILO8005BS1 C e Press Ball Bearing until bottomed Special Tool Baring Driver 54 3 A 57001 1488 B Rear Final Gear Case e Press the needle bearing A in the rear final gear case B so that the surface is flush with the case end C e Press the pin D in the rear final gear case so that the surface is flush with the case end E e Press the oil seal F so that the projecting distance is 3 5 mm 0 14 in G as shown in the figure e Apply grease Oil Seal Lip Section H H 1108002852 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 82 FINAL DRIVE Rear Final Gear Case e Press the fitting A so that the projecting distance is 14 mm 0 55 in B as shown in the figure C Rear Final Gear Case e Visually check the pinion gear A and ring gear B for scoring chipping or other damage Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact e Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Rear Final Bevel Gear Adjustment e Apply specified oil to the journal A and teeth B e Insert the shim C and pinion gear unit D in the rear final gear case E
419. nsioner 5 14 Valve Clearance Adjustment 5 32 Camshaft Chain Tensioner Valve Removal 4 5 32 Removal 5 14 Valve Installation Camshaft Chain Tensioner Valve Guide Removal Installation i etes 5 14 Valve Guide Installation Rocker C Ss0 temen 5 16 Valve to Guide Clearance Rocker Case Removal 5 16 5 33 Rocker Case Installation 5 17 Valve Seat Inspection 5 34 Rocker Arm Removal 5 18 Valve Seat Repair Valve Rocker Arm Installation 5 19 5 34 Rocker Arm Inspection 5 19 Cylinder and Piston 5 39 Rocker Shaft Diameter Cylinder Removal 5 39 Measurement 5 19 Piston Removal 5 39 Camshaft uo Gch nesta deed iota dest on rais 5 20 Cylinder Piston Installation 5 39 Camshaft Removal 5 20 Cylinder Wear Inspection 5 41 Camshaft Installation 5 20 Piston Wear Inspection 5 41 Camshaft Assembly 5 21 Piston Cylinder Clearance Cam Wear Inspection 5 21 WES POCHOM cs i 5 41 Camshaft Bearing Wear Piston Ring Piston Ri
420. nspect 2 43 Tire wear inspect 2 32 Wheel nuts tightness inspect 2 33 Joint boots inspect 2 48 Steering inspect 2 45 Steering joint dust boots inspect 2 46 General lubrication perform KIJ Tx Bolts nuts and fasteners tightness 2 51 inspect Seat belt inspect e 2 46 Cables inspect e 2 50 Service more frequently when operated mud dust other harsh riding conditions or when carrying heavy loads or pulling a trailer e Clean adjust lubricate torque or replace parts as necessary DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent LB Apply a non permanent locking agent Three Bond TB2471 Blue LO Apply a non permanent locking agent Three Bond TB2440B Orange Lh Left hand Threads MO Apply molybdenum disulfide oil mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specific tightening sequence S SS Apply silicone sealant Liquid Gasket TB1211 56019 120 Fastener s ds Remarks kgf m ft lb Fuel System Element Holder
421. nt Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 30 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Ball Bearing A D gt SA m i C v SS 6 M e Screw the flywheel puller A onto the alternator rotor Special Tool Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 e Holding the flywheel puller turn the rotor puller bolt until the alternator rotor is forced off the end of the crankshaft If the rotor is difficult to remove turn the puller while tapping the end of the puller Do not strike the alternator rotor Striking the rotor can cause the magnets to lose magnetism Alternator Rotor Installation e When installing the starter clutch gear A apply molyb denum disulfide grease to the crankshaft B e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Alternator Rotor Tapered Portion B e Fit the rotor onto the crankshaft so that woodruff key C fits into the groove D in the hub of the rotor DOCUMENT AVAILABLE FOR MILITARY USE ONLY
422. nting Bolt B Bracket Bolts C Left Bracket D e Remove the leads A from the clamp DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 50 FRAME Covers Right and Left Brackets Installation e Install Right and Left Brackets Bracket Bolts e Tighten Torque Bracket Bolts 47 4 8 kgf m 35 ft Ib Center Bracket Mounting Bolts 22 2 2 kgf m 16 ft lb e Install the removed parts Center Bracket Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Seat Lower Left Plate see Seat Lower Left Plate Re moval in the Frame chapter Seat Lower Right Plate see Seat Lower Right Plate Re moval in the Frame chapter Right Bracket see Right and Left Brackets Removal in the Frame chapter For Center Bracket Assembly Removal e Remove Throttle Cable Rear End A Center Bracket Mounting Bolt B e Remove ISC Valve A ISC Valve Removal in the Fuel System DFI chapter Breather Hoses B e Remove Spring A Shift Lever Tie rod End B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Covers e Remove Rubber Cover A Center Bracket Mounting Bolts B Center Bracket C FRAME 15 51 For Center Bracket Unit Removal e Remove Throttle Cable Rear End
423. ntrol 15 20 Right and Left Brackets Removal 15 49 Control Panel Removal 15 20 Right and Left Brackets Control Panel Installation 15 22 Installation 15 50 Glove Compartment Removal 15 22 Center Bracket Removal 15 50 Glove Compartment Installation 15 23 Center Bracket Installation 15 51 Cupholder Removal Right Frame Pipe Removal 15 51 KRF750P R S V Models 15 23 Right Frame Pipe Installation 15 52 Cupholder Installation Left Cover 15 52 KRF750P R S V Models 15 26 Left Cover Installation 15 53 Fenders esses 15 27 Windshield Removal Front Fender Front Removal 15 27 KRF750P R V Models 15 54 Front Fender Front Installation 15 27 Windshield Installation Front Fender Rear Removal 15 27 KRF750P R V Models 15 54 Front Fender Rear Installation 15 28 Sun Top Cover Removal Rear Fender Removal 15 28 KRF750P R V Models 15 55 Rear Fender Installation 15 29 Sun Top Cover Installation Rear Flap Remowval 15 29 KRF750P R V Models Rear Flap Installation 15 29 UNOS seed sen T Cargo Bed 15 30 Front Guard Removal Cargo Bed
424. o Bed Removal Bolts A Tapping Screws B Heat Guard Plate C Cargo Bed Assembly e Install Heat Guard Plate A Tapping Screws B Bolts C IP04015BS1 C e When installing the insulators A to the heat guard plate B install them as shown in the figure 1 04016851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 36 FRAME Cargo Bed e Apply adhesive agent to the cargo bed rubber dampers A e Install Cargo Bed Rubber Dampers Clamps B e Install the hook lever following procedure as follows Olnstall Hook Lever A Bracket B both sides Spring C as shown in the figure both sides DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 37 Cargo Bed Olnstall Hook Lever A Springs B Brackets C Bolts D Bolts E OWhen installing the hook F position it as shown in the figure and tighten the bolts G Upper Side H Front Side I IP04012BW3 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 38 FRAME Cargo Bed e Install Cargo Bed Base A Front Plate B Side Plates C both sides Bolts D M6 L 16 mm 0 63 in Nuts E Cargo Ne
425. od check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 60 FUEL SYSTEM DFI Fuel Pump Relay Service Code 46 Fuel Pump Relay Circuit 12 34 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Jl 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 gt gt M Ww 10150778833 1 ECU Electronic Control Unit 6 Ignition Switch 2 Fuel Pump Relay 7 Fuse Box 3 Engine Ground 8 Fuel Pump Fuse 10 A 4 Battery 9 Main Fuse 30 A 5 Frame Ground 1 10 Fuel Pump DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Ignition Coils 1 42 Service Code 51 52 Ignition Coil 1 Ignition Coil for Front Cylinder Service Code 51 Ignition Coil 42 Ignition Coil for Rear Cylinder Service Code 52 Ignition Coil Removal Installation Never drop the ignition coils especially on a hard surface Such a shock to the ignition coil can dam age it e Refer to the Ignition Coil Removal and Installation in the Electrical System chapter Ignition Coil Winding Resistance e
426. ody without first releasing the nitrogen and removing the shraeder valve e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Drill the hole A of the reservoir tank using about 2 mm 0 08 in drillbit A WARNING Drilling will release high pressure gas that may blow metal shavings at high speed and cause eye injury Wear safety goggles or face shield when drilling the reservoir tank DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 20 SUSPENSION Suspension Arms Front Suspension Arm Removal e Remove Front Wheels see Wheel Removal in the Wheels Tires chapter Front Hub A see Front Hub Removal in the Wheels Tires chapter Brake Caliper and Hose B from Suspension Arm Front Shock Absorber Mounting Bolt C and Nut lower e Remove Cotter Pins Tie rod End Nut A Knuckle Joint Nuts B e Remove the tie rod end A from the knuckle using a suit able joint remover B e Remove Front Lower Suspension Arm Pivot Bolts Caps and Nuts A Front Upper Suspension Arm Pivot Bolt Caps and Nut B Knuckle C and Front Suspension Arms Assembly e Remove the knuckle joints A from the knuckle using a suitable joint remover B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY S
427. of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before checking the tooth contact pattern FINAL DRIVE 11 91 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 92 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Inspection Since the bearings are made to extremely close toler ances the clearance cannot normally be measured NOTICE Do not remove any bearings for inspection except the right rear axle bearing e Turn each bearing in the case or hub back and forth A while checking for plays roughness or binding bearing play roughness or binding is found replace the bearing e Check the needle bearings A OThe rollers in the needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x lf the bearing is damaged replace the bearing DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FINAL DRIVE 11 93 Bearing and Oil Seal Oil Seal Inspection e Inspect the oil seals A x Replace any if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged DOCUMENT AVAILA
428. of the timing marks A F or R mark 6 Ignition Timing Engine speed r min rpm Slot B aligned with e 22 1 100 nd below mark C on alternator NOTE ODo not mix up the timing marks with mark A C HP10086BS1 C x If the ignition timing is incorrect replace the ECU and the crankshaft sensor DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 42 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition No spark Battery Inspection Charge or replace battery No good Repair or replace damaged part Ignition system wiring and connector inspection Spark plug inspection Replace spark plug Plug cap inspection Replace plug cap Nin Voltage is less than the Ignition coil primary peak voltage inspection specified value Good No good Ignition coil is Voltage is zero or Inspect defective almost zero 1 Lower resistance in a Replace ignition coil hand tester Use KAWASAKI Hand No good Tester 2 Crankshaft sensor peak voltage Inspect 1 Adapter connection is incorrect or adapter is defective No good 2 Ignition switch 3 Crankshaft sensor peak voltage Good Good Replace bad parts ECU is defective Replace ECU Replace bad parts or inspect them with KAWASAKI Hand Tester
429. off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the output driven bevel gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear OThe checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact Use this for checking the bevel gears e Turn the output driven shaft for or 4 turns in the drive and reverse coast directions while creating a drag on the drive bevel gear shaft e Check the drive pattern and coast pattern of the bevel gear teeth The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth and a little closer to the toe of the tooth x lf the tooth contact pattern is incorrect replace the shim s at the drive bevel gear and shim s at the driven bevel gear following the examples shown Then erase the tooth contact patterns and check them again Also check the backlash every time the shims are replaced Repeat the shim change procedure as necessary NOTE Olf the backlash is out of the standard range after chang ing shims correct the backlash before checking the tooth contact pattern Correct Tooth Contact Patterns No adjustment is required Bottom
430. off the ground Special Tool Jack 57001 1238 e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e While holding the front wheels remove the lower and up per shock absorber mounting bolts A and nuts e Remove the front shock absorber B Front Shock Absorber Installation e Apply grease to the inside of needle bearing A and grease seal lips B e Install the collar C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 15 Shock Absorbers KRF750S Model e Install the bushing A using a press B Needle Bearing C Collar D Grease Seals E New Nuts e Tighten Torque Front Shock Absorber Mounting Nuts 57 5 5 9 kgf m 42 ft Ib 1N04009BS2 C Front Shock Absorber Inspection e Check the bushing in the upper pivot x If bushing is worn cracked hardened or otherwise dam aged replace it e Check the needle bearing and grease seals in the lower pivot xIf they are damaged replace them Front Shock Absorber Scrapping A WARNING Pressurized nitrogen may explode when heated The rear shock contains nitrogen gas To avoid an explosion do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve e Remove the front shock absorber see Front Shock Ab sorber Removal e Drill the h
431. ole A of the reservoir tank using about 2 mm 0 08 drillbit A WARNING Drilling will release high pressure gas that may blow metal shavings at high speed and cause eye injury Wear safety goggles or face shield when drilling the reservoir tank DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 16 SUSPENSION Shock Absorbers KRF750S Model Rear Shock Absorber Rebound Damping Force Adjustment e To adjust the rebound damping force turn the rebound damping force adjuster A to the desired position OThe standard adjuster setting for an average build rider of 68 kg 150 Ib with no passenger and no accessories is the 1 turn out from the fully clockwise position Rebound Damping Force Adjustment Adjuster Damping Position Force 3 Turns Out Weak Rear Shock Absorber Compression Damping Force Adjustment e To adjust the compression damping force turn the com pression damping force adjuster A to the desired posi tion until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 12th click from the 1st click of the fully clockwise position Compression Damping Force Adjustment Adjuster Damping Position Force Setting Load Road Speed Counterclockwise
432. ollars e Remove Screws A and Collars e Remove Tapping Screws A and Collars Screws B and Collars Quick Rivets C Left Floorboard D DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 62 FRAME Floorboard Right Floorboard e Remove Left Floorboard Coolant Reserve Tank see Coolant Change in the Cool ing System chapter Tapping Screws A and Collars Clamp B e Remove Grommet A e Remove Tapping Screws A and Collars Screws B and Collars Quick Rivets C Right Floorboard D 1 58011 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 63 Floorboard Floorboard Installation e Install Right Floorboard A Left Floorboard B Tapping Screws C and Collars D L 2 4 mm 0 16 in Screws E and Collars D L 2 4 mm 0 16 in Screws F and Collars G L 7 2 mm 0 28 in Quick Rivets H Well Nuts I Caps J IPi5000BW2 C e Install Coolant Reserve Tank see Coolant Change in the Cool ing System chapter e Install the grommet A to the right floorboard B so that the large diameter C side faces forward Harness D Front Side E OO gt SS Z 2 2 IP15001BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online a
433. om DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 12 ELECTRICAL SYSTEM Specifications Item Battery Type Model Name Capacity Charging System Alternator Type Charging Voltage Regulator Rectifier Output Voltage Alternator Output Voltage Stator Coil Resistance Standard Sealed Battery KMX14 BS CA Model 12 V 12 Ah CA Model 12 V 14 Ah US Model Three phase AC 14 15 V 52 78 V at 4 000 r min rpm 0 24 0 36 O Service Limit Ignition System Spark Plug Spark Plug Gap Spark Plug Cap Resistance Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage 0 7 0 8 mm 0 028 0 031 3 75 6 25 7 mm 0 28 in or more 1 84 2 76 Q 10 4 15 6 160 V or more 110 1400 2 V or more Electric Starter System Starter Motor Brush Length Fuel Level Sensor Fuel Level Sensor Resistance Full Level Position Empty Level Position Actuator Control System Actuator Resistance Forward Reverse Detecting Sensor Resistance 2WD AWD Solenoid Valve Solenoid Valve Resistance Switches Brake Light Switch Timing Water Temperature Sensor Resistance 12 mm 0 47 in 10 Q 120 Q 15 between R and BK leads 3 5 6 5 between and BL leads 630 5 330 O between Y and BL leads 1 2 1 6 KQ 37 43 at 20 C 68 F ON aft
434. ond 0 97 0 99 mm 0 0382 0 0390 in Service Limit Top 0 90 mm 0 0354 in Second 0 90 mm 0 0354 in any of the measurements is less than the service limit on either of the rings replace all the rings NOTE When using new rings a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com GE16020881 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Cylinder and Piston Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top Second Cil 0 15 0 25 mm 0 0059 0 0098 in 0 30 0 45 mm 0 0118 0 0177 in 0 20 0 70 mm 0 0079 0 0276 in Service Limit Top Second Cil 0 55 mm 0 0217 in 0 75 mm 0 0295 in 1 00 mm 0 0394 in xIf the end gap of either ring is greater than the service limit replace all the rings ENGINE TOP END 5 43 NEN AN SSN N SXXXSSXN SXXSXX SS SSSSSSAX NS N A HE14005BS1 DOCUMENT AVAILABLE FOR MILITARY
435. ont Final Gear Case Oil Filler Cap 29 N m 3 0 kgf m 21 ft Ib Rear Final Gear Case Oil Change e Warm up the oil by running the vehicle so that the oilwill pick up any sediment and drain easily Then stop the vehicle e Park the vehicle so that it is level both side to side and front to rear e Place an oil pan beneath the rear final gear case and remove the oil drain plug A WARNING Oil on tires can cause loss of traction and an ac cident resulting injury or death When draining or filling the final gear case do not spill oil the tire or rim Clean any oil that may spill with a high flash point solvent e After the oil has completely drained out install the oil drain plug with a new O ring OApply grease to the O ring Tighten Torque Rear Final Gear Case Oil Drain Plug 15 N m 1 5 kgf m 11 ft lb e Fill the final gear case up to the bottom of filler opening with the oil specified below Rear Final Gear Case Oil Type MOBIL FLUID 424 CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Capacity 1 0 L 1 06 US qt OD t ixing the above oils not use mixing S DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures e Be sure the O ring A is in place and tighten the filler cap B OApply grease to the O r
436. or joined e Turn the ignition switch ON Inlet Air Temperature Sensor Output Voltage Standard About 2 25 2 50 V at inlet air temperature 20 C 68 F e Turn the ignition switch OFF x lf the output voltage is out of the standard check the wiring for continuity see Inlet Air Temperature Sensor Cir cuit x If the wiring is good check the sensor resistance see Inlet Air Temperature Sensor Resistance DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 48 FUEL SYSTEM Inlet Air Temperature Sensor Service Code 13 x lf the output voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation Inlet Air Temperature Sensor Resistance Inspection e Remove the inlet air temperature sensor see Inlet Air Temperature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tions C located in almost the same depth with the sen sor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even tempe
437. ork Ear Thickness x If the thickness of a shift fork ear is less than the service limit the shift rod must be replaced 8 Standard 5 9 6 0 mm 0 2323 0 2362 Service Limit 5 8 mm 0 2283 We v x If the groove is worn over the service limit the shifter must be replaced Shifter Groove Width Standard 6 05 6 15 mm 0 2382 0 2421 in Service Limit 6 25 mm 0 2461 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 27 Transmission Transmission and Shift Mechanism Inspection e Visually inspect Gears Dogs of Gear and Shifter x If they are damaged or worn excessively replace them DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 9 28 CRANKSHAFT TRANSMISSION DOCUMENT AVAILABLE FOR MILITARY USE ONLY Transmission OOGO WOCO DEDIDA 1 HI10000BN4 C WD Driven Shaft Spacer 17 3 x 30 x 2 0 Reverse Gear 12 Spacer 21 2 x 29 x 1 6 Shifter Circlip Toothed Washer T 1 5 Spacer 28 2 x 34 5 x 1 6 Spacer Hi and Low Spacer 48 2 x 54 3 x 1 0 Drive Hi Gear 26T 12 13 14 15 16 17 18 19 20 21 Drive Low Gear 20T Reverse Idle Shaft Reverse Driven Gear 16T Reverse Driven Out
438. ors leads and wiring OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery terminal Do not pull the lead only the con nector Conversely make sure that all the DFl electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A 6617036851 Olf a transceiver is installed on the vehicle make sure that the operation of the DFI system is not influenced by elec tric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage OWhen any fuel hose is disconnected do not turn on the ighition switch Otherwise the fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 20 FUEL SYST
439. ose Banjo Bolt 23 5 2 4 kgf m 17 ft Ib e Check the fluid level in the brake reservoir e Bleed the brake line see Brake Line Air Bleeding e Check the brake for good braking power no brake drag and no fluid leakage AWARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Front Brake Caliper Disassembly e Refer to the Front Brake Caliper Piston Seal and Dust Seal Replacement in the Periodic Maintenance chapter Front Brake Caliper Assembly e Refer to the Front Brake Caliper Piston Seal and Dust Seal Replacement in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 15 Calipers Caliper Piston Seal Damage Inspection The piston seals A around the piston maintain the proper pad disc clearance If the seals are not satisfactory pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Replace the piston seals in accordance with the Periodic Maintenance Chart or under any of the following condi tions OBrake fluid leakage around the pad OBr
440. osen the pinion gear shaft using the pinion gear holder D Special Tools Socket Wrench 57001 1363 Pinion Gear Holder m1 0 57001 1281 e Remove the ball bearing E as necessary Special Tool Bearing Puller 57001 135 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 86 FINAL DRIVE Rear Final Gear Case Pinion Gear Unit Assembly e Visually inspect the bearing for abrasion color change or other damage xIf there is any doubt as to the condition of a bearing re place the bearing e Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Rear Final Bevel Gear Adjustment e Press the bearing A on the pinion gear until it is bot tomed e Install the pinion gear bearing holder nut B so that the projection C faces outward HK14020BS1 C e Apply a non permanent locking agent Three Bond TB2471 Blue to the pinion gear bearing holder nut A and tighten it Special Tools Socket Wrench B 57001 1363 Pinion Gear Holder m1 0 C 57001 1281 Torque Pinion Gear Bearing Holder Nut 200 N m 20 4 kgf m 148 ft Ib Rear Final Bevel Gear Adjustment OThe backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged e After replacing any of the backlash relat
441. ot correct adjust it see Valve Clearance Adjustment DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Valve Clearance Adjustment e Remove the valve adjusting caps e Loosen the locknut and turn the adjusting screw until the clearance is correct e Using the valve adjuster A hold the adjusting screw from turning and tighten the locknut Special Tool Valve Adjuster 57001 1232 Torque Valve Adjusting Screw Locknuts 12 1 2 kgf m 106 in Ib Recheck the clearance x f the clearance is incorrect repeat the adjustment proce dure xIf the clearance is correct perform the adjustment proce dure on the other valve Spark Arrester Cleaning A WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Since the engine must be running during this procedure wear heat resistant gloves while cleaning the spark ar rester e Remove Bolts A Spark Arrester B e Clean the spark arrester A in a bath of high flash point solvent and if necessary use a fine wire brush to gently remove any particles in the screen e n an open area away from combustible materials start the engine with the transmission in neutral e Raise and lower engine speed while tapping on the muf fler with a rubber mallet until
442. oth tall acers A see Converter Drive Belt Deflection Adjust ment in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 25 Driven Pulley e Apply grease to the oil seal lips A e Press the oil seals B in the movable sheave assembly so that the oil seal surface is flush C with the sleeve end eApply D grease WR500 No 2 KYODO YUSHI POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA to the inner surfaces of the busings HS07006BS1 0 e Align the paint mark 0 A on the movable sheave B with the point C on the fixed sheave D for phase fit of the sheaves Oln that case the opening A and hole B will be matched easily e Apply grease WR500 No 2 KYODO YUSHI POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA to the seating surface A of the pins and insert them into the holes in the movable sheave e Draw the movable sheave onto the fixed sheave and ap ply grease of 1 g 0 035 oz to all openings A Grease WR500 No 2 KYODO YUSHI or POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA NOTE ODo not heap up the grease out of the openings DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 26 CONVERTER SYSTEM Driven Pull
443. ottle Body Assy e Remove Throttle Cable End A e Loosen the throttle cable locknut B and remove the throt tle cable C from the throttle link case e Loosen the clamp screws A fully e Remove the throttle body assy B from the throttle body assy holders e Remove ISC Valve Hose A Vacuum Hose B e After removing the throttle body assy stuff pieces of lint free clean cloth into the throttle body assy holders NOTICE If dirt gets into the engine excessive engine wear and possible engine damage will occur Throttle Body Assy Installation e Turn the throttle pulley to check that the throttle valve move smoothly and return by spring force xIf the throttle valve do not move smoothly replace the throttle body assy e Open the butterfly valves A and wipe any carbon off the throttle bores B around the valve using a piece of lint free cloth penetrated with a high flash point solvent e Blow away dirt or dust from the throttle body by applying compressed air Do not immerse the throttle body in a high flash point solvent for cleaning This could damage the throttle sensor on the throttle body DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 85 Throttle Body Assy e Be sure to groove A of the throttle body assy holder fits on the projection B of the cylinder head e In
444. outing 1808240884 C 1 Left Headlight Cover 2 Left Headlight Lead 3 Clamps 4 Holder Hold headlight lead to the headlight cover 5 Frame 6 Right Headlight Cover 7 Right Headlight Lead 8 Run the radiator fan motor harness between the bracket and the radiator hose 9 Run the right headlight harness above the radiator reserve tank hose DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 37 Cable Wire and Hose Routing b Front ANTT TTE deere ear H3 OA 5 Tert EAT Top View 4 Bottom View 1808232884 C Band Right and Left sides Clamp the tail light lead each sides and reverse light lead right side only to the bar Clamp Clamp the tail light lead Reverse Light Lead Connector Cover Band Installation of Cover NDN RS DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 38 APPENDIX Cable Wire and Hose Routing DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 39 Cable Wire and Hose Routing 2a N O Kawasaki Diagnostic System Connecto
445. ove Rocker Arm C Washers D OMark and record the rocker arm location so it can be in stalled in the original position OThe rocker arms come off with the rocker shafts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Rocker Case Rocker Arm Installation e Apply engine oil Rocker Shafts A Hole in Rocker Arms B e Replace the copper washers C with new ones e Install Wave Washers D as shown Rocker Arms as shown Rocker Shafts and Copper Washers e Tighten Torque Rocker Shaft Bolts E 22 2 2 kgf m 16 ft Ib Rocker Arm Inspection e Inspect the area A on the rocker arm where the cam rubs x If the rocker arm is scored discolored or otherwise dam aged replace it Also inspect the camshaft lobes e Inspect the end of the valve clearance adjusting screws B where it contacts the valve stem x If the end of the adjusting screw is mushroomed or dam aged any way or if the screw will not turn smoothly replace it Also inspect the end of the valve stem e Measure the inside diameter C of the rocker arm with a dial bore gauge x If the rocker arm inside diameter is larger than the service limit replace it Also check the rocker shaft diameter see Rocker Shaft Diameter Measurement Rocker Arm Inside Diameter Standard 12 000 12 018 mm 0 4724 0 4731 in Service Limit 12 05 mm 0
446. over see Seat Lower Cover Removal Left Bracket see Right and Left Brackets Removal Battery see Battery Removal in the Electrical System chapter Vehicle down Sensor A see Vehicle down Sensor Re moval in the Fuel System DFI chapter Quick Rivet B and Cover C Tapping Screws D and Collars Electric Parts Case E e Remove Bolts A Battery Mounting Plate B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 53 Covers e Remove Tapping Screws A and Washers Tapping Screws B Left Cover C ORemove the bolts D and plate if necessary Left Cover Installation e When installing the trim seal A to the left cover B apply adhesive to the trim seal and install it as shown in the figure 24 1 mm 0 94 0 04 in C e Install Left Cover Tapping Screws D Washers E For US Model e Install Battery Mounting Plate A Bolts B e When the following part is removed install it Damper C e Install the removed parts For CA Model e Install Battery Mounting Plate A Bolts B e When the following parts are removed install them as shown in the figure Dampers C Brackets D Bolts E e Install the removed parts IP1302i1BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ON
447. over Removal in the Frame chapter e Start the engine e Apply the tip of a screwdriver A to the fuel injector B Put the grip end onto your ear and listen whether the fuel injector is clicking or not OA sound scope can also be used e Do the same for the other fuel injector x If all the fuel injectors click at a regular intervals the fuel injectors are good The trouble may be related to the fuel line requiring fuel pressure inspection see Fuel Pressure Inspection OThe click interval becomes shorter as the engine speed rises x If any fuel injector s does not click check the fuel injector resistance see Fuel Injector Resistance Inspection Fuel Injector Resistance Inspection e Remove Fuel Injector see Fuel Injector Removal e Connect a digital meter A to the terminals in the fuel injector e Measure the fuel injector resistance Fuel Injector Resistance Standard About 11 7 12 3 Q at 20 C 68 F e If the reading is out of the standard replace the fuel in jector e If the reading within the standard check the power source voltage see Fuel Injector Power Source Voltage Inspec tion Fuel Injector Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter e Gonnect the hand tester to the connector A with the nee dle adapter set Special Tools Hand Tester
448. p Bolt A and Washer Pin and Spring e Remove Tensioner Mounting Bolts A Camshaft Chain Tensioner B Camshaft Chain Tensioner Installation e Push the stopper A to release the ratchet and push the push rod B into the tensioner body DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 15 Camshaft Chain Tensioner e Tighten Torque Chain Tensioner Mounting Bolts 8 8 0 90 kgf m 78 in Ib e Install Pin A and Spring B Washer C and Chain Tensioner Cap Bolt D Tighten Torque Chain Tensioner Cap Bolt 22 N m 2 2 kgf m 16 ft lb DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 16 ENGINE TOP END Rocker Case Rocker Case Removal Front Rocker Case e Remove Center Bracket see Center Bracket Removal in the Frame chapter Right Water Pipe Bolts A e Remove Left Cover see Left Cover Removal in the Frame chap ter Bolts A and Engine Left Cover B e Remove Timing Inspection Plug A Special Tool Filler Cap Driver B 57001 1454 e Remove Front Camshaft Chain Tensioner see Camshaft Chain Tensioner Removal Valve Adjusting Caps e Using a wrench on the alternator bolt turn the crankshaft counterclockwise until T F mark A is aligned with the not
449. p Nuts 34 3 N m 3 5 kgf m 25 ft Ib NOTE ODo not move the connecting rod and crankshaft during clearance measurement 105056851 Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 028 0 052 mm 0 0011 0 0020 in Service Limit 0 09 mm 0 0035 in xIf the clearance is within the standard no bearing insert replacement is required xIf the clearance is between 0 052 mm 0 0020 in and the service limit 0 09 mm 0 0035 in replace the bear ing inserts A with inserts painted green B Check in sert crankpin clearance with plastigage The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter the crankpin 6105041751 Crankpin Diameter Standard 39 984 40 000 mm 1 5742 1 5748 in Service Limit 39 97 mm 1 5736 in x f the crankpin has worn past the service limit replace the crankshaft with a new one DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 9 16 CRANKSHAFT TRANSMISSION Crankshaft Connection Rod x lf the measured crankpin diameter A is not less than the service limit but does not coincide with the original diameter marking on the crankshaft make a new mark on it Crankpin Diameter Marks None 39 984 39 992
450. per Bar Mounting Bolts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 43 Covers Engine Upper Cover Removal e Remove Seats see Seat Removal Small Quick Rivet A Quick Rivet B Screw C and Collar OWhen removing the small rivet insert thin driver A be tween the pin B and socket ORemove the pin A and socket B from the cover e Remove Small Quick Rivets A Quick Rivet B Screw C and Collar Engine Upper Cover D Engine Upper Cover Installation e Install Engine Upper Cover A Small Quick Rivets B Quick Rivets C both sides Collars D both sides Screws E L 22 mm 0 87 in IP13000BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 44 FRAME Covers e When installing the insulators install them as shown in the figure ODo not protrude the insulators beyond the edge of the engine upper cover A Insulator B P No 16073 0118 Insulator C P No 16073 0117 Insulator D P No 16073 0116 Air Cleaner Housing Cap E Insulator F P No 16073 0115 Center Cover Removal e Remove Quick Rivets A Quick Rivets B both sides Center Cover C Center Cover Installation e Install Center Cover A Quick Rivets B Quick Rivets C both si
451. pliers Fuse Installation xIf a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage e Install the fuses on the original position as specified on the fuse box lid A e Insert the projection A of the cover B under the electric parts case C and install the cover DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 80 ELECTRICAL SYSTEM Fuses Fuse Inspection e Inspect the fuse element is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C GP19040181 C Blown Element D When replacing fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 1 Appendix Table of Contents QUIC 17 2 Cable Wire and Hose
452. poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous Throttle valve won t fully open Brake dragging Engine overheating Engine oil level too high Engine oil viscosity too high Front or rear final gear case oil viscosity too high Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Fuel air mixture incorrect Throttle body holder loose Air cleaner duct loose Air cleaner clogged Fuel pump trouble Compression high Carbon built up in combustion chamber Engine load faulty Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Front or rear final gearcase overheating Insufficient oil Bevel gears maladjusted LSD clutches in frontfinal gear case malad justment Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble ECU trouble Water temperature sensor trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Cooling system component incorrect ECU trouble Water temperature sensor trouble Thermostat trouble Converter Operation Faulty Belt slipping Belt dirty worn or wetted Drive or driven pulley sheave dirty or worn Drive pulley spri
453. pport the vehicle so that the front wheels are off the ground e Remove Left Front Wheel see Wheel Removal in the Wheels Tires chapter Front Axle Nut Cotter Pin e Secure the right front wheel from rotating e Pull the differential shift lever 5 notches and shift to the differential lock position e Measure the clutch torque using a torque wrench A Turn the wrench evenly OThe clutch torque is the mean torque reading during about a quarter turn of the wrench LSD Clutch Torque Standard 300 31 kgf m 221 ft lb or more x If the clutch torque is out of the specified range check the width of the disc assembly see Front Final Gear Case Assembly NOTE OThe correct type of oil must be installed DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 56 FINAL DRIVE Front Final Gear Case Pinion Gear Unit Disassembly e Remove Pinion Gear Unit see Front Final Gear Case Disassem bly e Hold the pinion gear unit A with the socket wrench B in a vise and put the rubber mat C 1 mm or more at the bottom of the unit Special Tool Socket Wrench 57001 1363 e Loosen the pinion gear bearing holder nut a little with the pinion gear holder A Special Tool Pinion Gear Holder 57001 1708 OTurn the wrench B clockwise a little e Setthe pinion gear unit A upside down in a vise as shown i
454. pulling off xIf the screen is damaged replace it Oil Pressure Measurement e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Engine Bottom Guard see Engine Bottom Guard Re moval in the Frame chapter Water Pipe Bolts A e Remove Oil Pressure Switch Lead A disconnect Oil Pressure Switch B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE LUBRICATION SYSTEM 7 9 Engine Oil and Oil Filter e Attach the oil pressure gauge adapter A and gauge hose B to the engine Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge A Cil Pressure Standard 515 kPa 5 3 kgf cm 74 7 psi 24 000 r min rpm Oil Temperature 120 248 F x If the oil pressure is much lower than the standard inspect the relief valve oil pump and or crankshaft bearing insert wear xIf the oil pressure is much higher than the standard in spect the oil filter oil screen and other areas of the lubri cation system for clogging e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Hot oil can cause severe burns Beware of hot en gine oil that will drain through the oil passage when the gauge adapte
455. put Gear 16T Idle Shaft Spacer 20 3 x 33 x 2 0 Driven Output Gear 18T Driven Hi Gear 30T Driven Low Gear 36T Needle Bearing DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 29 Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing Replacement Do not remove the ball or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or three needle bearings NOTE the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 200 F max and tapping the bearing in or out NOTICE Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing OThree new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 6114060551 Ball and Needle Bearing Wear Inspection Do not remove the bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made close toler ances the wear must be judged by feel rather than
456. r Clamp the frame and main harness with band Place the frame ground 1 terminal horizontally as shown Clamp the ignition coil lead with clamp Ignition Coil 1 Front Front Crankshaft Sensor Connector Grease to the inside of the connector Alternator Lead Connectors Free Location Oil Pressure Switch Lead Connector Starter Relay 30 45 Detail T View W DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 40 APPENDIX Cable Wire and Hose Routing 7 gt Pa a DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 41 Cable Wire and Hose Routing Ll ll lll Rubber Cover Rubber Cover Rubber Cover Bands Bands for Bracket for Breather Hose for Fuel Hose for CVT Duct Frame Pipe for Harness for Harness Clamp for Drain Tube for Engine Inlets for Clamp Pass the clamp through the cover Clamp Seat Rail Harness DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY MODEL APPLICATION Year Mo
457. r 43 000 43 016 mm eedem 1 6929 1 6935 in Marking None 43 000 43 008 mm 1 6929 1 69322 43 009 43 016 mm 1 69326 1 6935 Connecting Rod Big End Bearing Insert Thickness Brown 1 482 1 486 mm 0 05835 0 05850 Yellow 1 486 1 490 mm uicem 0 05850 0 05866 in Green 1 490 1 494 mm e 0 05866 0 05882 in Connecting Rod Big End Bearing Insert Selection Con rod Big End Bore Crankpin Diameter Bearing Insert Diameter Marking Marking Size Color Part Number None Brown 92028 1963 None None Yellow 92028 1962 92028 1961 Crankshaft Runout TIR 0 04 mm 0 0016 in TIR 0 10 mm or less 0 0039 in Crankshaft Main Journal Diameter 41 984 42 000 mm 41 96 mm 1 6529 1 6535 in 1 6520 in Crankshaft Main Bearing Bore Diameter 42 025 42 041 mm 42 07 mm 1 6545 1 6552 in 1 6563 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Transmission Shift Fork Ear Thickness 5 9 6 0 mm 5 8 mm 0 2323 0 2362 in 0 2283 in Shifter Groove Width 6 05 6 15 mm 6 25 mm 0 2382 0 2421 in 0 2461 in DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILI
458. r Clamp Bolts 15 N m 1 5 kgf m 11 ft Ib e Tighten Torque Muffler Mounting Bolts 28 N m 2 9 kgf m 21 ft lb e After installation thoroughly warm up the engine wait un til the engine cools down and then retighten the exhaust pipe nuts muffler clamp bolts and muffler mounting bolts ENGINE TOP END 5 47 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 48 ENGINE TOP END Exhaust System IE11006884 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 1 Converter System Table of Contents q elo le AVAE a Specification Special oro I T Torque Converter COVE M X Torque Converter Cover Torque Converter Cover Installation 4 4 6 5000000 24 Torque Converter Cover Disassembly 4 0000000 Actuator Lever Engine Brake Control Lever Assembly 1 5 Torque Converter Cover OMM CE ge Toa Drive Belt Removal E up Dr
459. r Input Voltage Standard Battery Voltage e Turn the ignition switch OFF xlf the reading is good check the output voltage see Speed Sensor Output Voltage Inspection xIf the reading is out of the range check the wiring for continuity see Speed Sensor Circuit the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Speed Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 55 Speed Sensor Service Code 24 e Disconnect the speed sensor connector and connect the measuring adapter A between the harness connector B and speed sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter to the measuring adapter leads Connections to Adapter Meter P lead of Main Harness Meter BK Y lead of Main Harness e Measure the output voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON e Rotate the rear wheel by hand and confirm whether the output voltage rises or lowers Speed Sensor Output Vo
460. r Mounting Nuts 16 1 6 12 Regulator Rectifier Mounting Bolts 8 8 0 90 78 in lb DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 2 12 PERIODIC MAINTENANCE Torque and Locking Agent The tables below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners of Engine Parts Threads dia ark of bolt head To due mm N m kgf m ft lb 5 0 20 4T 2 2 2 6 0 22 0 27 19 23 in lb 6 0 24 9T 12 15 12 1 5 104 130 indb 6 0 24 7 7 8 9 8 0 8 1 0 69 87 in lb 6 0 24 4 3 9 4 9 0 4 0 5 35 43 in lb 8 0 31 7 18 22 1 8 2 2 13 16 8 0 31 4 10 14 10 1 4 87 122 in lb 10 0 39 7T 39 44 4 0 4 5 29 33 10 0 39 4 20 24 2 0 2 4 14 17 Basic Torque for General Fasteners of Frame Parts Torque Threads dia mm in Km ftlb 5 0 20 3 4 4 9 0 35 5 0 50 2 5 3 6 6 0 24 5 9 7 8 0 60 0 80 4 3 5 8 8 0 31 14 19 1 40 1 90 10 13 10 0 39 25 34 2 60 3 50 19 25 12 0 47 44 61 4 50 6 20 33 45 14 0 55 73 98 7 40 10 0 54 72 16 0 63 115 155 11 5 16 0 83 115 18
461. r connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself an abnormality is found replace the affected DFI part xf no abnormality is found in the wiring connectors and parts replace the ECU FUEL SYSTEM DFI 3 23 1C15080BS1 C 6017029281 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 24 FUEL SYSTEM DFI Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider The ignition switch is turned on and the state of the Fl indicator symbol LCD is seen Does the symbol go off after 1 2 seconds Conduct non self diagnosis inspection Conduct self diagnosis Conduct general fuel inspection System inspection General fuel system tlirottle assy air cleaner fuel tank etc End 10150508 F Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe following sample diagnosis sheet will help prevent you from overlooking any a
462. r is removed e Apply silicone sealant to the oil pressure switch and tighten it Sealant Liquid Gasket TB1211 56019 120 Torque Oil Pressure Switch 15 1 5 kgf m 11 ft Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 7 10 ENGINE LUBRICATION SYSTEM Cil Pressure Relief Valve Oil Pressure Relief Valve Removal e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e See crankcase assembly see Crankcase Assembly in the Crankshaft Transmission chapter e Apply a non permanent locking agent to the threads of oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft Ib Oil Pressure Relief Valve Inspection Remove the relief valve e Using a wooden stick push the inner valve to make sure B that the valve A moves smoothly and that it returns to its original position by the force of the spring B OThe relief valve cannot be disassembled and it must be inspected in the assembled state 6008060251 x If the valve movement is smooth wash the relief valve with high flash point solvent and use compressed air to remove any foreign particles from it A WARNING Gasoline and low flash poin
463. rature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the following Inlet Air Temperature Sensor Resistance Standard 5 4 6 6 at 0 C 32 F 0 29 0 39 at 80 C 176 F x lf the measurement is out of the standard replace the sensor x lf the measurement is within the specified replace the ECU see ECU Removal Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com 9017608652 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 49 Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Circuit 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 BR BK Y 1 ECU Electronic Control Unit 2 Inlet Air Temperature Sensor HC110538W2 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 50 FUEL SYSTEM Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal NOTICE Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame c
464. reas and will help you decide if it is a DFl system problem or a general engine problem DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 25 Troubleshooting the System Sample Diagnosis Sheet Registration No license plate No Year of initial registration Date p oben Environment when problem occurred Ocloudy Orain Osnow Oalways Oother Temperature Owarm Ocold Overy cold Oalways Problem Ooften frequency Listreet mountain road Cuphill downhill Opebble Altitude Onormal Dhigh about 1 000 m or more Vehicle conditions when problem occurred Fl indicator appears immediately after ignition switch and disappear after 1 2 symbol LCD seconds normal Osymbol blinks after ignition switch ON DFI problem LIsymbol does not appear multifunction meter ECU or its wiring fault o i iri SE flooded do not crank engine with throttle opened which promotes engine flooding Engine stops L1 sometimes symbol appears probably wiring fault Ewhen cruising Hother Poor running Overy low idle speed Overy high idle speed Orough idle speed atlow speed Obattery voltage is low charge the battery Ospark plug loose tighten it pl
465. rect cylinder head gasket Replace the gasket with a standard part thickness Damaged or missing compression Replace the spring release cam spring Compression release weights do Replace the compression release unit not move smoothly Cylinder Gas leakage around cylinder head Replace damaged gasket and check compression is cylinder head warp lower than usable Bag condition of valve seating Repair if necessary Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and liner and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or Replace the piston and or the piston rings piston ring grooves Compression release weights do Replace the compression release unit not move smoothly DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 30 ENGINE TOP END Cylinder Head Cylinder Head Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Throttle Body Assy see Throttle Body Assy Removal in the Fuel System chapter Exhaust Pipe see Muffler and Exhaust Pipe Removal Spark Plug Cap Water Pipe Bolt A Front Water Pipe B e Remove Water Pipe Bolt A for Rear Water Pipe e Remove Bolt A Rear Water Pipe
466. reen 1 6 0 1 mm 0 063 0 004 in 1 04023 52 H 04003BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 13 Drive Belt Drive Belt Removal e Remove the drive pulley A see Drive Pulley Removal NOTE OBefore removing observe the direction the belt s printed information B such as manufacturer s name is facing so that it may be reinstalled on the pulleys to rotate in the same direction as originally installed e Lift the drive belt C off the driven pulley D Drive Belt Installation NOTE OBe sure the printed information faces the same direc tion so the belt rotates in the same direction as origi nally installed When installing a new belt install it so the printed information A can be read from beside the vehicle e Installation is basically the reverse of removal e Loop the belt B over the drive and driven pulleys e Install the drive pulley see Drive Pulley Installation e Put the transmission in neutral and rotate the driven pul ley to allow the belt to return to the top A of the sheaves before measuring belt deflection Drive Belt Deflection Inspection e Refer to the Drive Belt Deflection Inspection in the Peri odic Maintenance chapter Drive Belt Deflection Adjustment e Refer to the Drive Belt Deflection Adjustment in the Peri odic M
467. remove dirt and fuel deposits e Draw the solvent out of the fuel tank e Dry the tank with compressed air e Install Fuel Pump see Fuel lt Pump Installation Fuel Tank see Fuel Tank Installation Fuel Hose Inspection e Refer to the Fuel Hose and Connections Inspection in the Periodic Maintenance chapter Fuel Hose Replacement Refer to the Fuel Hose Replacement in the Periodic Main tenance chapter FUEL SYSTEM DFI 3 95 1C11005BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY COOLING SYSTEM 4 1 Cooling System Table of Contents ExXDlOded 4 2 Coolant Flow Ghart ente eee ecd ere diese ease riu m teeny 4 4 Specifications ERR I T 4 6 lere A 4 7 COGAN 4 8 Coolant Deterioration n cad 4 8 Coolant Level Inspectores eso eet tette e eei e ual 2 4 8 CoolanbDr millgu sso M ME 4 8 eC ee 4 8 Pressure Testing uae t Ge ertet Meo Ni eos 4 9 Water ulucm e
468. resh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal caps during refresh charge If by chance an excessive amount of gas is generated due to overcharging the safety valve operates to keep the battery safe 3 When you do not use the vehicle for months Give a refresh charge before you store the vehicle and store it with the negative cable removed Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 24 ELECTRICAL SYSTEM Battery A DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri ous injury and burns if ignited Keep the battery away from sparks and open flames during charging When us
469. ring e Install the speed sensor to the fully seated position before tightening the mounting bolt NOTE Olf the sensor is not fully seated before tightening the bolt the O ring can be damaged and oil may leak e Tighten Torque Speed Sensor Mounting Bolt 8 8 N m 0 90 kgf m 78 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 77 Switches and Sensor Speed Sensor Inspection e Remove the speed sensor see Speed Sensor Removal e Connect the speed sensor connector A with the battery B 10 resistor C and hand tester D as shown e Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 e Trace A each side of the speed sensor surface with the screw driver OThen the tester indicator should flick B xlf the tester indicator does not flick replace the speed sensor Switch Inspection e Using the hand tester check to see that only the connec tions shown in the table have continuity OFor the ignition switch and headlight switch refer to tables in the Wiring Diagram x If the switch has an open or short repair or replace it with a new one GP18254BS1 DC25V GP18255BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 78 ELECTRICAL SYSTEM Sw
470. ring A with a new one e Apply grease to the O ring e Install the starter motor NOTICE Do not tap the end of the starter motor shaft or the motor may be damaged DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 45 Electric Starter System e Install the starter motor cable A at the angle as shown in the figure B about 20 e Tighten Torque Starter Motor Mounting Bolts 8 8 0 90 kgf m 78 Starter Motor Cable Mounting Nut 6 8 0 69 kgf m 60 in Ib e Apply grease to the O ring A in the joint duct B e Install Joint Duct and Collars C e Tighten Torque Joint Duct Bolts D 8 8 N m 0 90 kgf m 78 in Ib 1911021851 C e Fit the projection A of the air inlet duct into the groove B of the rubber duct and tighten the clamp screw Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Take off the starter motor through bolts A and remove the both end covers B e Pull out the armature A out of the yoke B NOTE ODo not remove the circlip C from the shaft P DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 46 ELECTRICAL SYSTEM Electric Starter System e Remove Starter Motor Terminal Locknut A
471. s Take care not to open the clip excessively when in stalling to prevent deformation 68020268 5 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during Een assembly to minimize wear during initial operation Lubri E oY cation points are called out throughout this manual apply A Yei 4 jh the specific oil or grease as specified LESE A mone amp Direction of Engine Rotation s When rotating the crankshaft by hand the free play Xx amount of rotating direction will affect the adjustment Ro E tate the crankshaft to positive direction clockwise viewed ro 724 from right side gt vA N ff 020228 5 Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R wires must be connected to those of the same color Dci Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GB02082BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MI
472. s and Washer e Remove Rear Shock Absorber Mounting Bolts A and Nuts Rear Shock Absorber B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 18 SUSPENSION Shock Absorbers KRF750S Model Rear Shock Absorber Installation e Apply grease to the inside of needle bearing A and grease seal lips B e Install the collars C e Apply grease to the grease seal lips A e Install the collars B e When replacing the ball bearing A install the new circlip 822 e C Grease Seals oe D Collars E New Nuts F Needle Bearing Tighten Torque Rear Shock Absorber Mounting Nuts 95 5 N m 9 7 kgf m 70 ft Ib e Install the removed parts see appropriate chapters 1N04010BS2 Rear Shock Absorber Inspection e Gheck the ball bearing and grease seals in the upper pivot x If they are damaged replace them e Check the needle bearing and grease seals in the lower pivot xIf they are damaged replace them DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 19 Shock Absorbers KRF750S Model Rear Shock Absorber Scrapping A WARNING Pressurized nitrogen may explode when heated The rear shock contains nitrogen gas To avoid an explosion do not incinerate the shock b
473. s com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 16 BRAKES Brake Pads Front Brake Pad Removal e Remove the caliper with the hose installed see Front Brake Caliper Removal e Remove the pad mounting bolts A e Remove the brake pads A 18118001 P Front Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Be sure that the anti rattle spring is in place e Install Brake Pads Pad Mounting Bolts e Tighten Torque Front Brake Pad Mounting Bolts 17 2 N m 1 8 kgf m 13 16 WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Front Brake Pad Wear Inspection e Refer to the Front Brake Pad Wear Inspection in the Pe riodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 17 Brake Discs Front Brake Disc Cleaning Poor braking can be caused by oil on a disc Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone A WARNING These cleaning fluids are usually highly flammable and harmful i
474. s of the driven shaft and driven pulley ends to open the air vent passage Wipe off any extra grease OWipe off any protruding grease A e Install two washers A on the shaft as shown Crankcase Side B Bolt Head Side C e Using the flywheel amp pulley holder A and attachments B tighten the new driven pulley nut C Special Tools Flywheel amp Pulley Holder 57001 1605 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Nut 93 N m 9 5 kgf m 69 ft Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents M Specifications C Emig diea Special Tools Engine Oll and eret e sr itt Oil Level Inspection im epe tees tere e re rd re PN Engine OIL GhangB si eo Qoae dou estote tasses urea En do to al Oil Filter Gange c semet ettet pt Ie tete M M Screen Removal trees pe
475. see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 DOCU B OH ARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 28 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Inlet air temperature sensor trouble Throttle sensor trouble Unstable rough idling Fuel pressure too low or too high Fuel injector trouble Throttle sensor trouble Inlet air pressure sensor trouble Water temperature sensor trouble Actions chapter Inspect see chapter 3 Inspect see chapter 3 Inspect Inspect Inspect Inspect Inspect see chapter 3 see chapter 3 see chapter 3 see chapter 3 see chapter 3 Inlet air temperature sensor trouble S KS JH J SY SY Saar Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Ignition coil trouble Inspect see chapter 16 Throttle sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Fuel pump trouble Inspect see chapter 3 Fuel injector
476. see Center Cover Removal in the Frame chapter e Visually inspect the boot A of the front propeller shaft x If damage tear or deterioration is found replace the boots see Front Propeller Shaft section in the Final Drive chap ter Tie rod End Boots Inspection e Visually inspect the tie rod end boots A of the tie rods xIf the boot is torn worn deteriorated or leaks grease replace the tie rod end see Tie Rod End Removal in the Steering chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures Rear Propeller Shaft Joint Boots Inspection e Visually inspect the boots A of the rear propeller shaft x If the joint boot is torn worn or deteriorated replace the joint boot and check the propeller shaft see Rear Pro peller Shaft section in the Final Drive chapter Rear Axle Stabilizer Joint Boots Inspection e Visually inspect the rear axle joint boots A x If the joint boot is torn worn deteriorated or leaks grease replace the joint boot or rear axle assembly see Rear Axle Joint Boot Replacement in the Final Drive chapter e Visually inspect the stabilizer joint boots B x If the joint boot is torn worn deteriorated or leaks grease replace the stabilizer joint see Stabilizer Removal in the Suspension chapter General Lubrication Lubrication
477. side diameter of the band A is less than the maximum diameter Maximum Outside Diameter of Band 73 4 mm 2 89 in N AAA AWA 11070188581 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 34 FINAL DRIVE Front Final Gear Case Front Final Gear Case Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Remove the filler cap Be careful not to allow any dirt or foreign materials to enter the gear case e Check the oil level The oil level should come to the bot tom of the filler opening A is insufficient first check the front final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case e Be sure the O ring is in place e Apply grease to the O ring and tighten the filler cap Torque Front Final Gear Case Oil Filler Cap 29 N m 3 0 kgf m 21 ft Ib Front Final Gear Case Oil Change e Refer to the Front Final Gear Case Oil Change in the Pe riodic Maintenance chapter Differential Shift Lever Play Inspection e Refer to the Differential Shift Lever Play Inspection the Periodic Maintenance chapter Differential Shift Lever Play Adjustment e Refer to the Di
478. ssembly e Do not remove the hub bolts A xlf any hub bolt is damaged replace the hub B and bolts as a unit e When installing the hub bolt press in it using a press 1K08000BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY WHEELS TIRES 10 15 Rear Hub Rear Hub Removal e Remove Cap A Cotter Pin B e Loosen the axle nut C while applying the brake e Remove the rear wheel see Wheel Removal e Remove Axle Nut A and Washer B Rear Hub C x If the rear hub seems too difficult to remove use the fol lowing special tools OMount the brake drum remover A on the hub bolt with the remover nuts B and washers C parts in the remover set Special Tools Brake Drum Remover 57001 1260 Brake Drum Remover Nut 57001 1326 OTighten the rotor puller D and remove the rear hub Special Tool Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Rear Hub Installation e Apply grease to the spline A of the rear axle e Install the collar B so that the small diameter side C faces to knuckle e Install Rear Hub x If the rear hub seems too difficult to install use the follow ing special tool OUsing the brake drum pusher A and tighten it until the pusher stops Special Tool Brake Drum Pusher amp Washer 57001 1709 DOCUMENT AVAILABLE FOR MILITARY USE ONLY
479. stall Vacuum Hose ISC Valve Hoses Throttle Body Assy e Tighten the throttle body assy holder clamp screw se curely e Apply a thin coating of grease to the throttle cable rear end e Fit the throttle cable rear end into the throttle pulley B e Tighten the adjusting nut C and locknut D see Throttle Cable Installation e Be sure to install the seal A on the throttle link case cover e Install the removed parts e Check the throttle pedal free play see Throttle Pedal Free Play Inspection A WARNING Operation with an incorrectly routed cable could re sult in an unsafe riding condition Be sure the cable is routed correctly WHOSE e Adjust Idle Speed see Idle Speed Adjustment Throttle Body Assy Disassembly NOTICE Do not remove disassemble or adjust the throttle sensor A and throttle body assy because they are adjusted or set at the manufacturer Adjustment of these parts could result in poor performance re quiring replacement of the throttle body assy NOTICE Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 86 FUEL SYSTEM Throttle Body Assy e Remove Throttle Body Assy see Throttle Body Assy Removal Screw A Inlet Air Pressure Sensor
480. stallation Throttle Sensor Circuit D 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 HC110518W2 C 1 ECU Electronic Control Unit 2 Throttle Sensor DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 41 Inlet Air Pressure Sensor Service Code 12 Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Inlet Air Pressure Sensor Removal e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Screw A e Disconnect the inlet air pressure sensor connector B and the vacuum hose C e Remove the inlet air pressure sensor D Inlet Air Pressure Sensor Installation e Installation is the reverse of removal Torque Inlet Air Pressure Sensor Mounting Screw 5 0 0 51 kgf m 44 in Ib Inlet Air Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter e Disconnect the inlet air pressure sensor connector A e Connect the measuring adapter A between the main har ness connector and inlet air pressure sensor Special Tool Sensor Harness Adapter 57001 1561 e Connect
481. stalled bend the spring ends B to prevent it from coming off e Install Front Fender Rear see Front Fender Rear Installation in the Frame chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY BRAKES 12 11 Brake Pedal and Master Cylinder Front Master Cylinder Removal e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Remove Brake Hose Banjo Bolts A Brake Pipe Nipple B unscrew e Immediately wipe up any brake fluid that spills Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately e Remove Front Master Cylinder Mounting Bolts C Front Master Cylinder D Front Master Cylinder Installation e Install Front Master Cylinder Front Master Cylinder Mounting Bolts e Tighten Torque Front Master Cylinder Mounting Bolts 23 5 N m 2 4 kgf m 17 16 e Replace the washers on each side of the hose fitting with new ones OTouch the brake hose clasp A to the stopper B e Tighten Torque Brake Hose Banjo Bolts 23 5 N m 2 4 kgf m 17 ft lb Brake Pipe Nipple 17 5 N m 1 8 kgf m 13 ft lb Bleed the brake line after master cylinder installation e Adjust the brake pedal play see Brake Pedal Play Inspec tion e Check that the brake line has proper fluid pressure and no fluid leakage Front Mas
482. stalling Pin E Shim F New Circlip G Spring H Parking Release Lever I Washer J New Circlip K Spring L xIf there is the excess play in right and left directions on the parking brake pedal replace the shim F to one in the following shims Shims Part Number Thickness MATURE 92180 0279 0 8 mm 0 031 in 92180 0281 1 0 mm 0 039 in 92180 0279 1 2 mm 0 047 in e When installing the parking brake indicator light switch M install the washer N and tighten the parking brake indicator light switch screws Torque Parking Brake Indicator Light Switch Screws 0 4 0 04 kgf m 4 in Ib DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 20 BRAKES Parking Brake Pedal and Cables Parking Brake Cable Removal e Remove Control Panel see Control Panel Removal in the Frame chapter Cable Locknuts A e Loosen the cable mounting nuts B and remove the cable C from the bracket e Remove Adjuster A Pin B Washer Spring C e Remove the cable from the bracket and remove it from the frame Parking Brake Cable Installation e Run the 2WD AWD shift cable according to the Cable Wire and Hose Routing section in the Appendix chapter e Install the front side of parking brake cable A as shown in the figure Cable Mounting Nut B 10 mm 0 39 in C e Install the rear
483. strainer B are built into the pump and cannot be cleaned or checked x lf the fuel filter is suspected of clogging or being damaged replace the fuel pump Fuel Pump Circuit 12 34 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Jl 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 gt 10150778833 ECU Electronic Control Unit Fuel Pump Relay Engine Ground Battery Frame Ground 1 lgnition Switch Fuse Box Fuel Pump Fuse 10 A Main Fuse 30 A Fuel Pump DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 80 FUEL SYSTEM Throttle Pedal and Cable Throttle Pedal Free Play Inspection e Refer to the Throttle Pedal Free Play Inspection in the Periodic Maintenance chapter Throttle Pedal Free Play Adjustment e Refer to the Throttle Pedal Free Play Adjustment in the Periodic Maintenance chapter Throttle Pedal Position Adjustment e Depress the throttle pedal A until the pedal stopper B touches to the floorboard C e Then adjust the gap between the stopper D of the link lever and stopper E of the throttle body to 1 mm 0 04 in F by adjusting the adjusting nut G e Tighten Torque Throttle Cable Locknut 4 4 0 45 kgf m 39 in Ib
484. sure High Pressure Line Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Throttle Sensor Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Inlet Air Pressure Sensor Input Voltage Output Voltage Inlet Air Temperature Sensor Resistance Output Voltage at ECU Water Temperature Sensor Resistance Output Voltage at ECU Speed Sensor Input Voltage Output Voltage Vehicle down Sensor Detection Method Detection Angle Input Voltage Output Voltage ISC Valve Resistance DO MENT AVA 1 100 50 r min rpm Dual throttle valve 34 mm 1 34 in Mitsubishi Electric Digital memory type with built in IC igniter sealed with resin 294 kPa 3 0 kgf cm 43 psi with engine idling In tank friction pump 50 mL 1 7 US oz or more for 3 seconds INP 250 One spray type with 4 holes About 11 7 12 3 at 20 C 68 F Non adjustable and non removable DC 4 75 5 25 V between BR W and BR BK leads DC 1 00 1 24 V between Y W and BR BK leads DC 4 0 4 4 V between Y W BR BK leads 4 6kO DC 4 75 5 25 V between BR W and BR BK leads DC 3 80 4 20 V at standard atmospheric pressure see this text for details 5 4 6 6 kQ at 0 C 32 F 0 29 0 39 kQ at 80 C 176 F About 2 25 2 50 V at 20 C 68 in the text About 2 24 2 48 V at 20 C 68 F Battery Voltage at Ignition Switch ON less than DC 0
485. sure the battery is fully charged e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter e Remove the spark plug cap see Spark Plug Removal but do not remove the spark plug e Measure the primary peak voltage as follows OConnect a commercially peak voltage adapter A to the hand tester B 1 000 V DC range Install the needle adapter C on the peak voltage adapter leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Olnsert the needle adapter into the terminal of the G W front or BL W rear primary lead D Olnstall a new spark plug E into the spark plug cap and ground it to the engine Ignition Coil A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch ON rotate the engine for 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one ignition coil Ignition Coil Primary Peak Voltage Standard 160 V or more e Repeat the test for the other ignition coil xIf the reading is less than the specified value check the following Ignition Coils see Ignition Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection x If the ignition coils and crankshaft sensor are normal see the Ignition System Troubleshooting chart on page 16 42 Crankshaft Sensor Remo
486. t F Bolts M6 L 14 mm 0 55 in Hooks H Stopper 1 Bolts J M6 L 2 14 mm 0 55 in Covers K Bands L Detail M IP04013BW3 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 39 Cargo Bed e Install Tail Gate A Stoppers B Stoppers C Screws D Reinforce E Tail Gate Cover F Screw Rivets G Hook Levers H Brackets Bolts J M6 L 2 65 mm 2 56 in Grommet K Taillight Bracket L both sides Bolts M M6 L 14 mm 0 55 in Nuts N Hooks O both sides Dampers P both sides Wires Q both sides Collars R Bolts S M6 L 2 18 mm 0 71 in Rear Fenders see Rear Fender Installation IP04007BW3 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 40 FRAME Bars Right and Left Bars Removal e Remove Seats see Seat Removal e Open the cover A e Remove Seat Belt Mounting Bolt B Upper Seat Bracket C e Remove Upper Bar Mounting Bolts A Front Upper Bars B Rear Upper Bars C e Remove Breather Hoses Back Bar Mounting Bolts A Back Bar Mounting Bolts B Upper Back Bar C Back Bar Mounting Bolts D Lower Back Bar E e Remove Mounting Bolts A and Lower Seat Bracket B both sides Right Bar C Left Bar D
487. t I and oil seal J 1L060218W2 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Rear Propeller Shaft e Fit the boots into the grooves of the yoke and shaft e Fit the O rings into the grooves of the boot Rear Propeller Shaft Inspection e Remove Rear Propeller Shaft see Rear Propeller Shaft Re moval e Check that the universal joint A works smoothly without rattling or sticking does rattle or stick the universal joint is damaged Replace the universal joint e Check the splines of the propeller shaft B and universal joint xIf the splines are twisted or damaged in way replace the damaged parts e Also inspect the splines of output bevel gear shaft and pinion gear shaft of the rear final gear case xIf the splines are badly worn chipped or loose replace the damaged parts FINAL DRIVE 11 67 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 68 FINAL DRIVE Rear Axle Rear Axle Removal e Drain the rear final gear case oil see Rear Final Gear Case Oil Change in the Periodic Maintenance chapter e Remove Rear Wheels see Wheel Removal in the Wheels Tires chapter Stabilizer Joint see Stabilizer Removal in the Suspen sion chapter Rear Knuckle A see Rear Knuckle Removal in the
488. t Buckle Mounting Bolts A 46 5 N m 4 7 kgf m 34 ft lb e Check the operation of the buckle A OSet the plate B in the buckle and confirm the plate does not come off when pulling it OSet the plate in the buckle and confirm the plate comes off when the buckle button C is pushed x If operation is not correct visually inspect the plate xIf the plate is damaged replace the plate assembly with a new one xIf the plate is not damaged replace the buckle assembly Electrical System Spark Plug Cleaning Inspection e Remove the spark plug see Spark Plug Removal in the Electrical System chapter e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a wire brush or other suitable tool xIf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Inspection e Measure the gap A with a wire type thickness gauge x If the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in Brake Light Switch Inspection e Turn on the ignition switch e Check the operation of the rear brake light switch by de pressing the brake pedal x If it does not as specified adjust the brake light timing Brake Light Timing Standard after about 10
489. t Final Gear Case Differential Shift Cable Lubrication Whenever the differential shift cable is removed lubricate the cable as follows e Apply a small amount of multi purpose grease to the cable both ends e Lubricate the cable with a penetrating aerosol cable lubri cant through the pressure cable luber 6604011451 Differential Shift Cable Inspection e With the differential shift cable disconnected at both ends the cable should move freely within the cable housing x If the cable does not move freely A after lubricating if the cable is frayed B or if the housing is kinked C replace the cable 6004020281 2WD AWD Shift Cable Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Right Bracket see Right Bracket Removal in the Frame chapter e Remove Snap Pin A Pin B and Washer e Loosen the nut C and remove the 2WD 4WD shift cable from the bracket D e Remove 2WD AWD Shift Cable Locknuts A 2WD AWD Shift Cable End B e Remove the 2WD AWD shift cable from the frame DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 11 38 FINAL DRIVE Front Final Gear Case 2WD AWD Shift Cable Installation e Apply grease to the front end of the cable e Run the 2WD AWD shift cable according to the Cable Wire and Hose Routing section in the Appendix chapter e Instal
490. t Nuts 87 5 8 9 65 R 3 Steering Knuckle Joint Nuts 46 5 4 7 34 4 KRF750S Model G Apply grease LG Apply liquid gasket Liquid Gasket TB1215 92104 1065 R Replacement Parts CG Apply grease Chevron Black Pearl Grease EP NLGI 2 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 4 SUSPENSION Exploded View 4 d 4 8 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 5 Exploded View Torque No Fastener Nm kati itib Remarks 1 Rear Shock Absorber Mounting Nuts 95 5 9 7 70 R 2 Rear Suspension Arm Pivot Nuts 87 5 8 9 65 R 3 Rear Knuckle Mounting Nuts 57 5 5 9 42 R 4 Stabilizer Joint Nuts 57 5 5 9 42 R 5 Stabilizer Holder Bolts 31 5 3 2 23 L 6 KRF750S Model G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Liquid Gasket TB1215 92104 1065 R Replacement Parts CG Apply grease Chevron Black Pearl Grease EP NLGI 2 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 13 6 SUSPENSION Specifications Item Shock Absorbers Oher than KRF750S Model Spring Preload Setting Position Front Rear Shock Absorbers KRF750S Mode
491. t solvents can be flammable and or explosive and cause severe burns Clean the oil pressure relief valve in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the oil pressure relief valve x If the valve does not move smoothly even after washing it replace the relief valve The oil pressure relief valve is precision made with no allowance for replacement of individual parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE LUBRICATION SYSTEM 7 11 Oil Pump Oil Pump Removal e Remove Alternator Rotor and Starter Clutch Gear see Alternator Rotor Removal in the Electrical System chapter Oil Pump Drive Chain Tensioner Bolt A Chain Guide Bolt B and Collar Chain Guide C e Remove Oil Pump Bolts A Oil Pump Drive Chain B and Cil Pump Assembly C e Remove Circlip A Inner Rotor B Outer Rotor C Oil Pump Drive Shaft D Oil Pump Cover E Oil Pump Installation e Apply engine oil Oil Pump Drive Shaft Inner and Outer Rotors e Install Oil Pump Drive Shaft Oil Pump Cover Inner Rotor Outer Rotor New Circlip e Check to see that the dowel pins A are in place e Apply engine oil in the oil pump housing DOCUMENT AVAILAB
492. t www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 64 FRAME Floorboard e Apply sealing material to the mating surface of the floor board and plate A e Install Plate Bracket B Bolts C M6 L 18 mm 0 71 in Washers D Outside Diameter 15 mm 0 59 in 15002881 C e Apply a non permanent locking agent to the brake pedal bracket mounting bolts A e Install Brake Pedal Bracket B Washers C Thickness 1 6 mm 0 063 in Washers D Thickness 3 2 mm 0 126 in e Tighten Torque Brake Pedal Bracket Mounting Bolts 34 3 3 5 kgf m 25 ft Ib IP15003BS1 C e Install Throttle Cable see Throttle Cable Installation in the Fuel System chapter Parking Brake Cable see Parking Brake Cable nstalla tion in the Brakes chapter Parking Brake Light Switch Lead Connectors Front Brake Master Cylinder see Front Brake Master Cylinder Installation in the Brakes chapter Steering Shafts see Steering Shafts Installation in the Steering chapter Control Panel see Control Panel Installation Seat Lower Cover see Seat Lower Cover Installation DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Parts LOCATON uoo rif e ttes 16 3 Exploded View 16 6 Specificatio
493. t www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 27 Camshaft e Install the intermediate shaft chain tensioner A as fol lows e Release the stopper B and push the push rod C into the tensioner body e Insert a wire D into the rod hole to hold the rod in place e Install Intermediate Shaft Chain Tensioner A e Tighten Torque Intermediate Shaft Chain Tensioner Bolts B 8 8 0 90 kgf m 78 in Ib e Remove the wire C to free the push rod e Confirm that the punch mark A on the intermediate shaft sprocket Right Side is aligned with the embossed mark B on the crankcase e Face the arrow mark A upward e Align the marks B on the weights with the front cylinder head upper surface C e Place the front camshaft chain on the front camshaft sprocket e Apply grease to the O ring A and install the cover B into the right side of the crankcase so that the tapped hole C faces outward DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 28 ENGINE TOP END Camshaft e Install Rocker Cases see Rocker Case Installation Camshaft Chain Tensioners see Camshaft Chain Ten sioner Installation Check the valve clearances see Valve Clearance Inspec tion Camshaft Chain Guide Wear Inspection e Visually inspect the rubber on t
494. taryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 34 APPENDIX Cable Wire and Hose Routing Right Side View 9 P PA 16 Kel A ais Sea FUN 5 ag 49 09 View Front DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY APPENDIX 17 35 Cable Wire and Hose Routing Regulator Rectifier Cover the regulator rectifier connector with cover Band Secure the regulator rectifier lead with the front gear case breather tube and the fan motor breather tube to the Left Headlight Speed Sensor Ignition Switch 2WD AWD Shift Switch Multifunction Meter Harness Bands Secure the ignition switch 2WD 4WD shift switch and mutifunction meter harnesses 10 11 12 13 14 15 16 17 18 19 20 Run the brake line and the harnesses above the frame Clamps Lighting Switch Bands Secure the lighting switch harness to the brake bracket Accessory Connector Clamps Grommet Large Diameter Floorboard Brake Light Switch Lead Parking Brake Light Switch Lead Frame Ground 2 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 17 36 APPENDIX Cable Wire and Hose R
495. tat Inm a We 4 16 Thermostat qn tm 4 16 Water Sensor gae 4 17 Water Temperature Sensor Removal Installation sese 4 17 WaterTemperature Sensor 4 17 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 4 2 COOLING SYSTEM Exploded View 1p020188W5 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY COOLING SYSTEM 4 3 Exploded View No Fastener poraue Remarks N m kgf m ft Ib 1 Radiator Screen Mounting Bolts 8 8 0 90 78 in lb 2 Radiator Cover Bracket Mounting Bolts 8 8 0 90 78 in lb 3 Radiator Mounting Bolts 8 8 0 90 78 in lb 4 Radiator Fan Assembly Bolts 8 3 0 85 73 in lb 5 Thermostat Housing Cover Bolts 8 8 0 90 78 in lb 6 Water Temperature Sensor 12 1 2 106 7 Water Pipe Mounting Bolts L 20 mm 0 79 in 8 8 0 90 78 in lb 8 Water Pipe Mounting Bolts L 12 mm 0 47 in 8 8 0 90 78 9 Water Pump Impeller 7 8 0 80 69 in Ib 10 Water Pump Cover Bolts 8 8 0 90 78 in lb 11 Coolant Drain Plug Water Pump 7 0 0 71 62 in lb 12 Coolant Drain Plugs Cylinder 7 0 0 71 62
496. tched before operating vehicle e When installing the pin A set the length 24 5 mm 0 965 in B as shown in the figure Washers C Nut D New Self Lock Nut E Seat Disassembly e Remove Seat see Seat Removal Seat Plate Bolts A Seat Plate B Dampers C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 17 Seat and Seat Belts e Remove Pipe Bolts A Washers and Nuts Pipe B Seat Lock Bolts and Nuts C Seat Lock D Seat Assembly e Install Seat Lock A Seat Lock Bolts B and New Nuts C Dampers D IPO3005BS1 C e Install Pipe A Pipe Bolts B Washers C and New Nuts D IP03006BS2 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 18 FRAME Seat and Seat Belts e Install Seat A Seat Plate B e Apply a non permanent locking agent to the seat plate bolts C e Tighten Torque Seat Plate Bolts 8 8 0 90 kgf m 78 IP03007BS2 Seat Belt Removal e Open the cover A e Remove Seat Belt Mounting Bolt B Upper Seat Bracket C e Lift up the cargo bed e Remove Seat see Seat Removal e Open the cover A upward e Remove Seat Belt Case Mounting Bolts and Nut A Seat B
497. te Orange Y Yellow DG Darkgreen P Pink G Green PU Purple DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc xIf any wiring is defective replace the damaged wiring e Pull each connector A apart and inspect for corrosion dirt and damage xIf the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x1 O range x If the tester does not read 0 Q the lead is defective Re place the lead or the wiring harness B if necessary ELECTRICAL SYSTEM 16 17 1007004BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 18 ELECTRICAL SYSTEM Battery Oln this model two batteries are prepared Pre charged Sealed Type Battery A US model Sealed Type Battery A CA model Battery Removal e Turn off the ignition switch e Remove Left Seat see Seat Removal in the Frame chapter e Disconnect the battery negative cable A first and
498. tenance Procedures e Apply brake fluid to the outside of the pistons A and in side of the cylinder e Push the seals into the cylinder by hand Take care that neither the cylinder nor the piston skirt gets scratched e Replace the rubber boots B if they are damaged e Apply a thin coat of silicone grease to the caliper holder shafts C Silicone grease is a special high temperature water resistant grease e Install Caliper Holder D 1 14009BS1 C e Install the anti rattle spring A in the caliper as shown e Install the pads see Brake Pad Installation in the Brakes chapter Isun Rear Brake Plates Replacement e Replace the steel plates and friction plates in accordance with the specified interval see Rear Final Gear Case sec tion in the Final Drive chapter Steering Steering Inspection e Check steering wheel free play A OSet the front wheels straight ahead Gently turn B 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 Standard 0 20 mm 0 gt 0 79 in steering wheel free play is not correct inspect the fol dios ds lowing Steering Wheel Mounting Nut see Steering Wheel Cen tering in the Steering chapter Intermediate Shaft Clamp Bolts see Steering Shaft In stallation in the Steering chapter Steering Gear Assembly Bracket Bolts see Steering Gear Asse
499. ter 3 Inspect see chapter 3 Miscellaneous Speed sensor trouble Inspect see chapter 3 Throttle valves will not fully open Inspect throttle cables and lever linkage see chapter 3 Engine overheating Water temperature sensor crankshaft sensor or speed sensor trouble Exhaust Smokes Excessively Black smokes Air cleaner element clogged Fuel pressure too high Fuel injector trouble Water temperature sensor trouble Inlet air temperature sensor trouble Brown smoke Air duct loose Fuel pressure too low Water temperature sensor trouble Inlet air temperature sensor trouble see Overheating of Troubleshooting Guide in chapter 17 Clean element see chapter 2 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Reinstall see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 31 Self Diagnosis Self diagnosis Outline The self diagnosis system has two modes and can be switched to another mode by grounding the self diagnosis terminal LG BK in the KDS connector User Mode The ECU notifies the rider of troubles in DFI system and ignition system by flashing the Fl indicator symbol when DFI system and ignition system parts are faulty
500. ter Cylinder Disassembly Assembly e Refer to the Front Brake Master Cylinder Cup and Dust Replacement in the Periodic Maintenance chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 12 12 BRAKES Brake Pedal and Master Cylinder Front Master Cylinder Inspection e Disassemble the front master cylinder see Front Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter e Check that there are no scratches rust or pitting on the inside of the cylinder A and on the outside of the pistons B x lf the cylinder or piston shows any damage replace them e Inspect the primary cups C and secondary cups D xIf a cup is worn damaged softened rotted or swollen replace it x If fluid leakage is noted at the brake push rod the sec ondary cup of the rear piston should be replaced e Check the dust cover E for damage x If it is damaged replace it e Check that the relief F and supply G ports are not plugged x f the small relief port becomes plugged the brake shoes will drag on the drum Blow the ports clean with com pressed air e Check the piston return springs H for any damage If the spring is damaged replace it 1M05000BS2 C Rear Master Cylinder Removal e Remove Brake Pipe Nipple A unscrew e Immediately wipe up any brake fluid that spills
501. the cylin der head and remove the rocker case Rocker Case Installation e Check that the crankshaft is positioned at TDC and at the end of the compression stroke NOTICE Be sure to position the crankshaft is at TDC of the end of the compression stroke The rocker arms could bend the valves e Apply liquid gasket to the outer surface of the cap A and the cylinder head upper surface B as shown in the figure Sealant Liquid Gasket TB1216 92104 1063 HE10002BS1 C HE10003BS1 C 27 HE10008BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 18 ENGINE TOP END Rocker Case e Tighten the rocker case bolts following the tightening se quence as shown in the figure Torque Rocker Case Bolts 8 8 0 90 kgf m 78 1 2 3 4 L 55 mm 2 2 in with washers Rocker Case Bolts 9 8 N m 1 0 kgf m 87 in Ib 5 6 L 130 mm 5 1 in A L 30 mm 1 2 in B L 25 mm 1 0 in e Check the valve clearance and adjust it if necessary e Apply grease to the O rings A e Install Bracket B e Tighten Torque Valve Adjusting Cap Bolts C 8 8 N m 0 90 kgf m 78 in Ib 1EO8000BS1 C Rocker Arm Removal e Remove Rocker Case see Rocker Case Removal Rocker Shaft Bolts A e Using a 8 bolt A remove the rocker shaft B e Rem
502. tion e When installing the dampers A apply an adhesive B and install them so that the UP mark C faces upward Frame D Left Side View E 1IP04014BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FRAME 15 31 Cargo Bed e When replacing the studs A do the following proce dures ORemove Studs Bolts B and Bracket C for both Upper Sides Olnstall Bracket A and Bolts B for Upper Side Studs C Nuts D P040118W2 C e Grease to the cargo bed mounting pins A e Install Cargo Bed Cargo Bed Mounting Pins Washers B and Snap Pins C 1 04005851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 15 32 FRAME Cargo Bed e Install the gas spring dampers following procedure as fol lows OPush the both clamps A of the gas spring damper until they are bottomed as shown in the figure OPosition the cylinder A to upper side OPush and fit the gas spring damper B on the stud C e Install the harness into the clamps e Install Tail Brake Light Lead Connectors Rear Fenders see Rear Fender Installation Cargo Bed Disassembly e Remove Rear Fenders see Rear Fender Removal Bolts A Hook Lever B Bracket e Remove Screws A
503. tips C on the actuator lever assembly as follows Actuator Lever Assembly Installation Length Standard 164 63 165 77 mm 6 481 6 526 in 1 04022851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 12 CONVERTER SYSTEM Torque Converter Cover ORemove the trim seal Olnstall the actuator lever measurement tool plate A and rods 57001 1710 B on the torque converter cover C and tighten the two cover bolts Special Tools Actuator Lever Measurement Tool 57001 1499 Rod 57001 1710 OSet the rod ends on the resin tips D OMeasure the recess length E between the plate and rods with Vernier calipers F or depth gauge Measurement Length E Standard 1 33 2 47 mm 0 052 0 097 in x lf the measurement is less than 1 33 mm 0 052 use the actuator lever assembly 13236 0123 of yellow paint x If the measurement is more than 2 47 mm 0 097 in use the actuator lever assembly 13236 0124 of green paint xIf the length is not within the specified length after the actuator lever assembly is replaced replace the torque converter cover and install the actuator lever assembly 13236 0125 Actuator Lever Assemblies Part Number Paint Color A Length B 13236 0123 Yellow 0 4 0 1 mm 0 016 0 004 in 13236 0125 None 1 0 0 1 mm 0 039 0 004 in 13236 0124 G
504. tive any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OjThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle c Addition of components or accessories that result in the vehicle exceeding the stan daras DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW
505. tment e Loosen the locknut A e Turn the adjusting nut B to the desired position Special Tool Hook Wrench T z 3 2 R37 57001 1539 Adjusting Length C from center of upper mounting bolt to lower surface of adjusting nut OThe standard adjusting nut setting for an average build rider of 68 kg 150 Ib with no passenger and no acces sories is 111 5 mm 4 390 in spring length Spring Preload Setting Standard Adjusting length 111 5 mm 4 390 in Usable Range Adjusting length 109 5 127 5 mm 4 311 5 020 in e Tighten the locknut x If the spring action feels too soft or too stiff adjust it Spring Preload Adjustment Damp Aalustng ing Setting Load Road Speed Length Force 109 5 mm 4 311 in Weak Soft Light Good Low T 1 T 127 5 5 020 Strong Hard Heavy Bad High Rear Shock Absorber Removal e Remove Rear Wheel see Wheel Removal in the Wheels Tires chapter Guard A Bolts and Washer e Remove Rear Shock Absorber Mounting Bolts A and Nuts Rear Shock Absorber B DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY SUSPENSION 13 11 Shock Absorbers Other than KRF750S Model Rear Shock Absorber Installation e Apply grease to the inside of needle bearing A and grease seal lips B e Install the collars C e Apply gre
506. tor B 2WD AWD Solenoid Valve C Fuel Pump and Fuel Level Sensor D Speed Sensor A DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 5 Parts Location Multifunction Meter A SET RESET Button B Belt Check Indicator Light C Neutral Indicator Light D Reverse Indicator Light E Oil Pressure Warning Indicator Light F AWD Indicator Symbol G 2WD Indicator Symbol Water Temperature Warning Symbol I FI Indicator Symbol J Fuel Level Gauge K TIME SET Button L Clock M Speedometer P Parking Brake Symbol N Trip Meter Odometer Hour Meter O MODE Button P 1804001B 2 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 6 ELECTRICAL SYSTEM Exploded View 5001 9 1002042885 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 7 Exploded View Torque No Fastener Nam kain itib Remarks 1 Starter Motor Mounting Bolts 8 8 0 90 78 in lb 2 Starter Motor Terminal Locknut 11 1 1 97 in lb 3 Starter Motor Cable Mounting Nut 6 8 0 69 60 in lb 4 Starter Motor Thro
507. tvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 7 Special Tools Outside Circlip Pliers Spring Holder Set 57001 144 57001 1483 875701445 C 5757148357 C Drive amp Driven Pulley Holder Drive Pulley Measurement Tool 57001 1412 57001 1498 Vd 875714125 C 7571498ST C Pulley Holder Attachment Actuator Lever Measurement Tool 57001 1472 57001 1499 BB 512499526 Drive amp Driven Pulley Holder Flywheel amp Pulley Holder 57001 1473 57001 1605 875714735 C 875716055 C Drive Pulley Wrench Drive Pulley Holder 57001 1474 57001 1620 875714745 C 875716205 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 6 8 CONVERTER SYSTEM Special Tools Rod Leg 57001 1710 57001 1712 8 5717108 8 5717125 Puller Bolt 57001 1711 8 5717115 6 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY CONVERTER SYSTEM 6 9 Torque Converter Cover A WARNING Excessive imbalance or operating rpm could cause torque converter pulley failure resulting in severe injury or death The pulleys of the belt drive torque converter are precision balanced components de signed to operate
508. ug dirty broken or gap maladjusted remedy it Obackfiring Dafterfiring when acceleration Hengine oil viscosity too high dragging overheating DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 26 FUEL SYSTEM DFI Troubleshooting the DFI System high speed Poor running plug loose tighten it or no power at Ospark plug dirty broken or gap maladjusted remedy it Ospark plug incorrect replace it Oknocking fuel poor quality or incorrect Obrake dragging Oclutch slipping overheating Hengine oil level too high Hengine oil viscosity too high DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM 3 27 DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply
509. ugh Bolts 5 0 0 51 44 in lb 5 Starter Motor Clutch Bolts 34 3 5 25 L 6 Left Engine Cover Bolts 5 9 0 60 52 in lb L 7 Alternator Rotor Bolt 127 13 0 94 8 Alternator Cover Plugs 17 5 1 8 13 9 Crankshaft Sensor Mounting Bolts 5 9 0 60 52 in lb 10 Alternator Stator Bolts 13 5 1 4 10 11 Alternator Cover Bolts L 55 mm 2 17 in 8 8 0 90 78 in lb Alternator Cover Bolts L 30 mm 1 18 in 88 090 78inlD EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum dislfide grease R Replacement Parts DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 8 ELECTRICAL SYSTEM Exploded View 1902049895 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 9 Exploded View Torque No Fastener Nm kgfm Remarks 1 Ignition Coil Mounting Bolts 5 9 0 60 52 2 Spark Plugs 13 1 3 115 6 3 Actuator Bracket Bolts 8 8 0 90 78 in Ib 4 Solenoid Valve Bracket Bolts 8 8 0 90 78 in lb 5 Mounting Bolts 6 9 0 70 61 in lb 6 Brake Actuator Mounting Bolts 8 8 0 90 78 in lb 5 7 Brake Actuator Cover Bolt 8 8 0 90 78 in lb 5 8 Forward Reverse Detecting Sensor Mountin
510. uid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t add or change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LIN
511. up from the filler ports or if the container cells have not emptied completely tap the container B a few times NOTE OBe careful not to have the battery fall down e Keep the container in place Don t remove the container from the battery the battery requires all the electrolyte from the container for proper operation sto 114881 6 Removal of the container before it is completely empty can shorten the service life of the battery e After filling let the battery sit for 20 60 minutes with the electrolyte container kept in place which is required for the electrolyte to fully permeate into the plates Make sure that the container cells have emptied com pletely and remove the container from the battery e Place the strip of caps A loosely over the filler ports press down firmly with both hands to seat the strip of caps into the battery don t pound or hammer When properly installed the strip of caps will be level with the top of the ooo battery B ue NOTICE Once the strip of caps is installed onto the battery never remove the caps nor add water or electrolyte to the battery GPO8012BS1 C NOTE OCharging the battery immediately after filling can shorten service life 8 08010851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 23
512. val e Remove Front Wheel see Wheel Removal in the Wheel Tires chapter Intermediate Shaft Clamp Bolt A e Remove Cotter Pins Tie rod End Nuts A and Washers both sides Do not loosen the tie rod end locknuts B or the toe in of the front wheels will be changed e Remove the tie rod end A from the knuckle using a suit able joint remover B e Remove Steering Gear Assembly Bracket Bolts A Steering Gear Assembly Bolts B Washers and Nuts Steering Gear Assembly C Steering Gear Assembly Installation e Adjust if necessary Tie rod Length Adjustment see Toe in Adjustment in the Wheels Tires chapter DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 14 10 STEERING Steering Gear Assembly e Apply a non permanent locking agent Three Bond 2471 Steering Gear Assembly Bolts A M12 L 60 mm 2 36 5 i XS PR Steering Gear Assembly Bracket Bolts B M12 L 25 6 AN mm 2 36 in it ey AN e Install Steering Gear Assembly C E ON Damper D Om Washer E and Steering Gear Assembly Bolts Ae di Bracket F and Steering Gear Assembly Bracket Bolts New Steering Gear Assembly Nuts G e Tighten Torque Steering Gear Assembly Nuts G 95 5 9 7 kgf m 70 ft lb e Clean the tapered portion of the t
513. val e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor Mounting Bolts A Plate B Crankshaft Sensor C ELECTRICAL SYSTEM 16 39 1910010851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation e Install Stator Coil Leads A Crankshaft Sensor B Plate C e Tighten Torque Crankshaft Sensor Mounting Bolts 5 9 0 60 kgf m 52 in Ib e Fit the lead grommets into the notch on the alternator cover Grommets A for Alternator Leads Grommets B for Crankshaft Sensor Leads OPosition the blue lead of the crankshaft sensor to outside Crankshaft Sensor Inspection e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the crankshaft sensor lead connector A e Measure the crankshaft sensor resistance OConnect a hand tester B between the BK W lead and the BL lead OSet the tester to the x 10 range Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance 110 1400 x If the tester does not read as specified replace the crank shaft sensor Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect Crankshaft Sensor Lead Connector A e Set the hand tester B to the 10 V DC range e Co
514. ve of the joint 4 8 mm 0 15 0 31 in E Bracket F Front G e Tighten Torque Throttle Cable Locknuts H 4 4 N m 0 45 kgf m 1015087BS1 C 39 in Ib e Adjust the full throttle pedal position see Full Throttle Pedal Position Adjustment e Check the throttle cable see Throttle Pedal Free Play Inspection _ DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 82 FUEL SYSTEM Throttle Pedal and Cable Throttle Cable Lubrication and Inspection e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubri cation e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant 6604011451 C e With the cable disconnected at the both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 80904020152 C e Lubricate the inner cable ends A with grease
515. vere burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Left Cover see Left Cover Removal in the Frame chap ter Engine Bottom Guard see Engine Bottom Guard Re moval in the Frame chapter e Place a container and a suitable paper A or plate under the drain plug B at the bottom of the water pump cover C and then remove the drain plug e Remove the radiator cap A in two steps First turn the cap counterclockwise to the first step Then push and turn it further in the same direction and remove the cap e The coolant will drain from the radiator and engine e Remove Torque Converter Inlet Duct e Place a container under the drain plug A at the front cylinder then remove the drain plug e Place a container under the drain plug A at the rear cylin der then remov
516. w militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 38 ENGINE TOP END Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec Too small Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose increase O D of Seat area to spec 32 Grind Tool 32 Cutter Purpose Measure Seating Width p reduce GB ST Seat area to spec Tool Vernier Caliper Purpose check seat width against spec Results 45 Grind Machinist s dye Tool 45 Cutter Purpose increase width of seat on seat area beyond spec to increase O D 60 Sand Tool 60 Cutter Purpose reduce seat Tool Valve Lapper Grinding Compound Purpose perfectly match inlet valve and inlet valve FINISHED seat are check valve head for damage 0 15061 F DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ENGINE TOP END 5 39 Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Oil Pipe A Chain Guide B Cylinder Bolts C Cylinder D Cylinder Base Gasket Piston Removal e Remove the cylinder block see Cylinder Removal e Place a piece of clean cloth under t
517. which may obstruct the oil passage in the cylinder head using compressed air Cylinder Head Warp Inspection e Clean the cylinder head see Cylinder Head Cleaning e Lay a straightedge across the lower surface of the cylinder head e Use a thickness gauge A to measure the space between the straightedge B and the head at several locations Cylinder Head Warp Service Limit 0 05 mm 0 002 in x If the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by lapping the lower surface with emery paper secured to a surface plate first No 200 then No 400 ENGINE TOP END 5 31 HE12006BS1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 5 32 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal OMark and record the valve location so it can be installed in the original position e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 22 B 57001 1202 Valve Inst
518. witch Fuse Box Fuel Pump Fuse 10 Main Fuse 30 A ECU Electronic Control Unit Fuel Pump Relay Engine Ground Battery Frame Ground 1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com BK Y BR Y BK Y BK Y BL R 161507483 DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 69 FI Indicator Symbol LCD FI Indicator Symbol LCD Inspection e Refer to the Multifunction Meter Unit Inspection in the Electrical System chapter for Fl indicator symbol A LCD Inspection x If the FI indicator symbol LCD is abnormal replace the meter unit x If the FI indicator symbol LCD is normal the wiring or ECU has trouble Check the wiring see FI Indicator Sym bol LCD Circuit If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection FI Indicator Symbol LCD Circuit Qema 18919047851 C 16150758842 C Multifunction Meter Ignition Switch Fuse Box Main Fuse 30 A ECU Electronic Control Unit Engine Ground Battery Frame Ground 1 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 70 FUEL SYSTEM DFI ECU NOTICE Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it
519. with the cover end as shown in the figure e Apply grease to the oil seal lips e When installing the ball bearing B press the ball bearing until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Be sure all of the old gasket has been removed from the alternator cover and the left crankcase sealing surfaces e Check that the dowel pins A are in place and fit a new gasket B on the crankcase e Check that the bearing C is in place DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY ELECTRICAL SYSTEM 16 29 Charging System e Fit the grommets A into the notch in the cover see Crankshaft Sensor Installation e Apply grease to the alternator cover oil seal e Install the alternator cover e Tighten Torque Alternator Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib e Replace the O ring A with a new one e Apply grease to the O ring e Install the collar B and O ring on the alternator cover e Hold the drive pulley with the drive pulley holder A Special Tool Drive Pulley Holder 57001 1620 e Tighten Torque Alternator Rotor Bolt A 127 N m 13 0 kgf m 94 ft lb e Apply a non permanent locking agent to the left engine cover bolts e Tighten Torque Left Engine Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the removed parts see appropriate chapter e Pour Coolant see Coola
520. y as shown x lf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 10 range Criteria When battery is connected gt 0 Q When battery is disconnected gt Q Starter Relay Installation e Connect the cables to the starter relay A as follows Starter Motor Cable B Battery Positive Cable C Damper D 30 45 E Starter Control Relay Inspection e Refer to the Relay Inspection ELECTRICAL SYSTEM 16 49 1011025BS1 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 16 50 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit BL BK W BL 1011027BW3 C lgnition Switch Neutral Position Switch Brake Light Switch Fuse Box Main Fuse 30 A Frame Ground 1 ECU Electronic Control Unit Starter Control Relay Engine Ground 10 Battery 11 Starter Relay 12 Starter Motor Starter Motor Clutch Removal e Remove the alternator rotor see Alternator Rotor Re moval e Hold the rotor with the flywheel holder and take out the starter motor clutch bolts A Special Tool Flywheel Holder 57001 1313 DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY US
521. yatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY FUEL SYSTEM DFI 3 93 Fuel Tank and Fuel Hose Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Right Side Cover see Side Cover Removal in the Frame chapter Right Bracket see Bracket Removal in the Frame chap ter Fuel Hose A see Fuel Hose Replacement Breather Hoses B Fuel Pump Connector C e Remove Fuel Tank Band Bolts A and Washers Bands B Fuel Tank C Fuel Tank Installation e Check the dampers A on the frame B the dampers are damaged or deteriorated replace them e When installing the dampers install them as shown in the figure 44 mm 1 7 in C 15 mm 0 6 in D 82 mm 3 2 E Front F 1011012851 C DOCUMENT AVAILABLE FOR MILITARY USE ONLY Order Online at www militaryatvparts com DOCUMENT AVAILABLE FOR MILITARY USE ONLY 3 94 FUEL SYSTEM Fuel Tank and Fuel Hose e Check the dampers A on the fuel tank the dampers are damaged or deteriorated replace them e When

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