All Terrain Vehicle Assembly & Preparation Manual
Contents
1. Vv WP Jo NB02013BS1 C A Rear Upright B Socket e Repeat these steps for the other upright The front upright is shown in this example NC03014BS1 C A Front Upright B Diagonal Brace NC03015BS1 C A Front Upright B Diagonal Brace e The clevis pins 4 and hairpin clips 4 are already installed into the braces Notice that itis necessary to collapse one upright so that enough space exists for both uprights when laid down 6 UNCRATING NCO3016BS1 C A Rear Upright B Clevis Pins and Hairpin Clips C Front Upright e These items are discarded Outer Cover Inner Cover Tie downs Qty 2 e Now the empty RSC may be stacked maxi mum 12 high for return shipment Each empty RSC weighs about 97 kg 215 lbs so a stack of 12 is very heavy The empty crates interlock at each corner for stability No stack ing bands are needed Opening Crate Other than US and Canadian Models A WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury Always wear protective gloves boots and eye protection when uncrat ing to prevent injury MCO3003B S e Clear a space about 6 m 20 ft square to give yourself plenty of space to work e Place the crate upright on its base e Remove the outer cover and inspect the unit for concealed damage If concealed damage is evident document the damage as outlined in the Kawasa2. BRUTE FORCE 750 4x4iEPS BRUTE FORCE 750 4x4i p KVF750 4x4 EPS Kawasaki KVF750 4x4 All Terrain Vehicle Assembly amp Preparation Manual Foreword In order to ship Kawasaki vehicles as effi ciently as possible they are partially disassem bled before crating Since some of the most commonly removed parts have a direct bear ing on a vehicle s reliability and safety consci entious pre sale assembly and preparation be come extremely important Good setup pro cedures can prevent needless warranty claims and give customers a greater sense of confi dence in Kawasaki and their Kawasaki Dealers This Assembly and Preparation Manual ex plains step by step procedures of the following items for all Kawasaki BRUTE FORCE 750 4x4i EPS BRUTE FORCE 750 4x4i KVF750 4x4 EPS KVF750 4x4 1 Uncrating 2 Assembly 3 Preparation The selling dealer assumes sole responsibil ity for any unauthorized modifications prior to sale Refer to your Service Binder for any Ser vice Bulletins specifying Factory Directed Mod ifications Special Claims which must be per formed before the vehicle is ready for sale Whenever you see the following symbols heed their instructions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury 2011 Kawasaki Heavy Industries Ltd WARNING WARNING indicates a
3. 25 mm 0 6 1 0 in A Brake Pedal B 15 25 mm 0 6 1 0 in Brake Pedal Free Play Adjustment e To adjust the pedal free play turn the brake pedal adjuster at the rear end of the brake cable S A Brake Lever Adjuster B Brake Pedal Adjuster C Rear Wheel Left Side g BL21B055 P Rear Brake Parking Lever Free Play Inspection e Check the rear brake lever free play If the free play is incorrect adjust the free play Rear Brake Lever Free Play 1 2 mm 0 04 0 08 in Rear Brake Parking Lever Free Play Adjustment e Slide the rubber cover e Loosen the locknut and turn the adjuster at the brake lever in as far as it will go e Tighten the locknut e Turn the adjuster at the rear end of the brake cable so that the brake lever has 1 2 mm 0 04 0 08 in of free play PREPARATION 21 A 1 2 mm 0 04 0 08 in B Locknut C Adjuster NOTE OSince the above two free play adjustments pedal and lever affect each other make them at the same time e After adjustments check for brake drag there should be none and effectiveness Suspension Front and Rear Shock Absorber Spring Preload Adjustment e Check the position of the spring preload adjusting sleeves Turn here with a hook wrench on the front and rear shock ab sorbers STD Position Front No 2 Rear No 2 A Rear Shock Absorber B Spring Adjusting Sleeve 22 PREPARATION e Turn the ad
4. 8 in from the grip PREPARATION 25 HU12B041 P A Variable Differential Control Lever B Handlebar Grip C 20 mm 0 8 in Variable Differential Control Lever Posi tion Adjustment e Loosen the screws D 5 L 16 4 to re move bolt front handle cover ND06B023 P A Screws D 5 L 16 B Front Handle Cover e Loosen the locknut at the middle of differential control cable e Turn the adjuster until the cable has the proper amount of play e Tighten the locknut after adjustment 26 PREPARATION PAT NE28B000 P A Variable Differential Control Cable B Locknut C Adjuster e Reinstall the front handlebar cover with the screws D 5 L 16 4 and tighten them Rear Brake Switch Adjustment Light Rear Brake Light Switch Adjustment e Turn the ignition switch to ON position e Depress the brake pedal The brake light should go on after about 10 mm 0 4 in of pedal travel A Brake Pedal B 10 mm 0 4 in e To adjust the brake light switch located near the brake pedal move the switch forward or rearward by turning the adjusting nut NOTICE To avoid damaging the electrical con nections inside the switch be sure that the switch body does not turn during ad justment B Adjusting Nut C Lights later D Lights sooner Headlight Beam e The headlight beams can be adjusted verti cally e Turn the adjusting screw on e
5. ae d me 99 Engine 10 Engine oil drain plug 20 2 0 15 11 Front final gear case oil drain plug 15 1 5 11 12 Front final gear case oil filler cap 29 3 0 22 13 Rear final gear case oil drain plug 15 1 5 11 14 Rear final gear case oil filler cap 29 3 0 22 Cotter pin or Circlip 15 Tie rod end nut cotter pins Left and Right 16 Steering knuckle joint nut cotter pins Left and E 7 B Right 17 Rear brake cable cotter pin S1 Tighten the upper clamp bolt first and then the lower clamp bolt S2 Tighten the nuts in a criss cross pattern to the first and final specified torques 34 PREPARATION Standard Torque Table This table relating tightening torque to thread diameter lists the basic torque for 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 General Fasteners Threads Torque dia mm N m kgf m ft lb 5 3 4 4 9 0 35 0 50 30 43 in Ib 6 5 9 7 8 0 60 0 80 52 69 in Ib 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 33 165 240 Test Ride e Complete the test ride checklist Control Cables The control cables must work without binding in any steering position Steering Action is free from lock to lock Suspension C
6. container from the battery the battery re quires all the electrolyte from the container for proper operation Removal of the container before it is completely empty can shorten the ser vice life of the battery 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 e Make sure that the container cells have emp tied completely and remove the container from the battery e Place the strip of caps 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 battery LI LJ LJ LJ LJ L3 e o GPO8012BS1 C A Strip of Caps PREPARATION 15 GPOS8010BS1 C Once the strip of caps is installed onto the battery never remove the caps nor add water or electrolyte to the battery NOTE OCharging the battery immediately after filling can shorten service life Initial Charge e Newly activated sealed batteries require an initial charge Standard Charge 1 2 A x 5 10 hours e f using a recommended battery charger fol low the charger s instructions for newly acti vated sealed battery Kawasaki recommended chargers Battery Mate 150 9 OptiMate PRO 4 S PRO S PRO 2 Yuasa MB 2040 2060 Christie C10122S e If the above chargers
7. e Install the air cleaner element to the element frame e Insert and tighten the screw to the specified torque Torque 3 5 N m 0 36 kgf m 31 in Ib e Reinstall the air cleaner housing cap Seat Installation e Align the front hooks with the front receivers and slide the seat forward Make sure that the rear hooks align to their rear receivers Push the seat with both hands around the rear hooks and make sure there is a click sound of the latches engaging PREPARATION 17 NE26B014 P A Front Hooks B Front Receivers C Rear Hooks D Rear Receivers E Latches F Latch Lever e Pull up the rear end of the seat to make sure it is securely locked Front Final Gear Case Oil Front Final Gear Case Oil Level Inspec tion e With the vehicle level front to rear and side to side remove the filler cap from the front final gear case BLO4BO03 P A Front Final Gear Case B Filler Cap C Front Axle Shaft NOTICE Be careful not to allow any dirt or for eign materials to enter the front final gear case e Check the oil level The oil level should come to the bottom thread of the filler opening If it is insufficient add oil through the oil filler opening as necessary 18 PREPARATION BL04B004 P A Front Final Gear Case B Filler Opening C Bottom Thread Front Final Gear Case Oil Equivalent to engine oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capac
8. hazardous situa tion which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a hazardous situa tion which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to personal injury NOTE OThis note symbol indicates points of particular interest for more efficient and convenient op eration Kawasaki Heavy Industries Ltd accepts no liability for any inaccuracies or omissions in this publication although every possible care has been taken to make it as completely and accu rately as possible All procedures and specifi cations subject to change without prior notice Jan 2011 Table of Contents WG RACING eee EE 3 Opening Crate US and Canadian Models only 3 Opening Crate Other than US and Canadian Models 6 Parts GCheck eei e te eee eee eet deest eo d tenet 7 Assembly unco etis tac INDEM Ec EL LEE 10 Handlebars re a RT e A erts 10 PLEAD M yesveactartheeca a cen lias AA EARE AE aa aaa 11 French Labels aenea ete ei A AAEE 11 Owner s Mari dl 2 m x A AA T ARANA 12 Preparation ei ro SR n Pe XR HER TH ERE aA 13 tenue M rindneiegaus 13 Alf Glearner ze eR ER MEER et 16 Front Final Gear Case Oil eeseeen ee 17 Rear Final Gear Case Oil eeeecenm eene 18 Front Brake ots cc rr ree pde eee tees euet ee e etas 19 Rear Bra
9. to remove the front handlebar cover NDO6B023 P A Screws B Front Handlebar Cover e Remove the screws D 5 L 14 3 to remove the rear handlebar cover Zr SS NDO6B024 P A Rear Handlebar Cover B Screws C Well Nuts NOTE OBe careful not to drop the well nuts when you removing the rear handle cover e Loosen the handlebar clamp bolts and lift the handlebar up e Set the handlebar to match its punched mark to the upper edge of the gap between the handlebar clamp NDO6B025 P A Handlebar Clamp Bolts B Handlebar C Punched Mark D Clamp Handlebar Clamp Bolt Tightening e Tighten the front clamp bolts first and then the rear clamp bolts to the specified torque If the handlebar clamps are correctly installed there will be no gap at the front and a gap at the rear after tightening Handlebar Clamp Bolt Torque 29 N m 3 0 kgf m 22 ft Ib A Front Clamp Bolts B Rear Clamp Bolts C No Gap D Gap NOTE Olt is recommended that the front handlebar cover should be installed after completing the steps in the Throttle Lever and Cable and Differential Control Lever and Cable sec tions in the PREPARATION chapter Olt is recommended that the rear handlebar cover should be installed after completing the step in the Throttle Lever Free Play Adjust ment in the PREPARATION chapter ASSEMBLY 11 Hangtag Exhaust Emission Air Index Hangtag In
10. type Also the two different oil types for the rear gear case oil must not be mixed in use A Rear Final Gear Case B Filler Opening C Bottom Thread e Install the filler cap Oil Filler Cap Torque 29 N m 3 0 kgf m 22 ft Ib Front Brake Front Brake Fluid Level Inspection e Position the front brake reservoir horizontal and check that the fluid level in the reservoir is higher than the lower level line BL21000BM2 C A Lower Level Line e f the fluid level in the reservoir is lower than the lower level line check for fluid leaks in the front brake lines and fill the reservoir e Loosen the screws to remove the front brake fluid reservoir cap and diaphragm e Fill the reservoir to the upper level line with DOT4 brake fluid Inside the front brake reservoir is a stepped line showing the upper level line PREPARATION 19 m BL21001BM2 C A Upper Level Line WARNING When working with the disc brake ob serve the precautions listed below 1 Never reuse old brake fluid 2 Do not use fluid 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 deterio rate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contam ination of the
11. ET17BOI5 P A Locknut Left hand Threads B Locknut Wheel Side C Tie rod NOTE OThe toe in will be near the specified value if the tie rod length A is 388 5 mm 15 30 in on each tie rod NOTICE Adjust the tie rod length so that the visi ble thread length is even on both ends of the tie rod Uneven thread length could cause tie rod damage HJ04014BS1 C A Visible Thread Length e Check the toe in e Tighten the tie rod locknuts to the specified torque Torque 36 N m 3 7 kgf m 27 ft lb e Test ride the vehicle Multifunction Meter Check the km h mph Display in the Mul tifunction Meter The km h mph display can alternate between metric and English modes km h and mph in the meter unit Make sure that km h or mph is correctly displayed according to local regu lations before riding If the measurement unit displayed in the multifunction meter is not cor rect switch it to the correct unit as follows BG04102B G A km h mph Display e Turn the ignition key to ON e Check to see if the ODO is displayed in the multifunction meter NOTE OThe km h or mph display can be switched over only when the meter is in the ODO display mode PREPARATION 29 NE30000B G A ODO Display e If the ODO is not displayed switch the me ter display mode by pushing the left button several times to shift the display mode to the ODO NE30001B G A ODO Display B TR
12. IP A Display C TRIP B Display D HR Display E Push Left Button NE30002B G A Left Button B Right Button 30 PREPARATION e The km h mph display is shifted by pushing the Right button for less than two seconds while pushing in the Left button during the odometer is displayed e Turn the ignition key to OFF PREPARATION 31 This page intentionally left blank 32 PREPARATION Fastener Check e The torque values listed are for assembly and preparation items only see the appropriate Service Manual for a more comprehensive list Check tightness of all fasteners that are in the table before retail delivery Also check to see that each cotter pin or circlip is in place NE19B052 P ada ae PREPARATION 33 Torque No Fastener Nem kgf m ftlb Remarks Frame Steering 1 Tie rod locknuts Left and Right 36 3 7 27 Brake 2 Front master cylinder clamp bolts 8 8 0 90 78 in lb S1 3 Front brake bleed valves Left and Right 7 8 0 80 69 in Ib 4 Front brake caliper mounting bolts Left and Right 25 2 5 18 Wheel 5 Front and rear wheel nuts First Torque 15 1 5 11 S2 Front and rear wheel nuts Final Torque 76 7 8 56 S2 Suspension 6 e al shock absorber mounting nuts Left 34 3 5 25 7 E suspension arm pivot nuts Left and 59 6 0 44 8 Aus vd suspension arm pivot nuts Left and 47 48 35 9 Rear upper and lower suspension arm pivot nuts Left and Right j i
13. Pump the brake lever a few times until it becomes hard and then holding the lever squeezed quickly open turn counterclock wise and close the bleed valve Then release the lever Repeat this operation until no more air can be seen coming out into the plastic hose NE0O9005BS1 C A Hold the brake lever applied B Release the brake lever NEO9BO16 P A Quickly open and close the bleed valve e Repeat the previous step one more time for the other front disc brake e When air bleeding is finished check that the fluid is between the upper and lower level lines e Install the diaphragm and the reservoir cap e Tighten the bleed valve s to the specified torque Torque 7 8 N m 0 8 kgf m 69 in Ib e Apply the brake lever forcefully for a few sec onds and check for fluid leakage around the fittings Rear Brake Brake Pedal Position Inspection e Measure the adjusting bolt length It should be 5 mm 0 20 in B Locknut C 5 mm 0 20 in Brake Pedal Position Adjustment e To adjust the pedal position loosen the lock nut turn the adjusting bolt and make the bolt length 5 mm 0 20 in and then tighten the locknut Now adjust the brake pedal free play Brake Pedal Free Play Inspection e Release the parking brake e Measure the distance the brake pedal moves before the brake starts to take hold Pedal free play should be 15 25 mm 0 6 1 0 in Brake Pedal Free Play 15
14. Stallation For US Model e There is an exhaust emission air index hang tag included into the removed parts Hang it to the left handlebar as shown EXE TEILE St ND26000BS1 C A Exhaust Emission Air Index Hangtag 49007 0706 B Left Grip NOTE O This hangtag is not to be removed before sale General Hangtag Installation For US and Canadian Models e There is a general hangtag included into the removed parts Hang it to the right handlebar as shown ND26002BS1 C A General Hangtag 56030 0194 US and Canada English Models 56030 0197 Canada French Model B Right Grip NOTE OThis hangtag is notto be removed before sale French Labels For Canadian Model NOTE OStick the French labels onto the English labels on the front fender rear fender or the seat only when required e Wipe off any oil or grease from the English labels Refer to the following photographs in the label locations e Peel each French label off the backing sheet and apply it over the English label A 3 3 f zh j TJ ND258005 P Air Cleaner Information 56033 0308 2 Age Recommendation Warning 56040 1325 General Warning 56071 0059 Shifting Caution 56070 0092 Protective Cover Warning 56070 1271 S d 12 ASSEMBLY ND25B006 P 6 Passenger Warning 56071 0097 7 Tire Pressure amp Maximum Loading Warning 56071 0074 8 Transmission Warning 56070 0039 9 Vehicle Em
15. Terminal C Negative Terminal D Red Tape E About 30 e Reinstall the battery cover bolt screws 2 and collars 3 in the reverse order of removal Air Cleaner Air Cleaner Element Inspection The foam air cleaner element on ATV models is oiled prior to shipping However over time the filter will dry and filtration performance will diminish e Pull release the snaps and remove the air cleaner housing cap and inspect the foam air cleaner element for proper oiling is BLO9B033 P A Air Cleaner Housing Cap B Snaps e f the air cleaner element is dry remove the screw D 6 L 5 and washer and pull out the air cleaner element and the element frame from the air cleaner housing A Air Cleaner Element B Air Cleaner Housing C Screw and Washer D Element Frame e Remove the air filter element from the ele ment frame NE26B007 P A Air Cleaner Element B Element Frame e Saturate the air cleaner element with a high quality foam air filter oil ex Kawachem Foam Filter Oil Bel Ray Foam Filter Oil Maxima FFT Foam Filter Treatment or equivalent cohesive type and make sure that the oil is evenly applied throughout the air cleaner element Squeeze out the excess oil but do not wring the air cleaner element as this could cause tearing In this case too much oil is better than too little Finally pat the inside of the air cleaner element with a paper towel to remove any excess oil
16. a with liberal amounts of water and seek medical attention for more severe burns 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 ME02112BS1 C A Sealing Sheet B Filler Ports e Remove the electrolyte container from the vinyl bag e Detach the strip of caps 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 of the electrolyte container Do not at tempt to separate individual cells GP08139BS1 C A Strip of Caps B Sealed 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 SETS I r fote GPO80105S1 C e Check the electrolyte flow e If no air bubbles are coming up from the filler ports or if the container cells have not emp tied completely tap the container a few times NOTE OBe careful not to have the battery fall down ME02114BS1 C A Air Bubbles B Tap the Container e Keep the container in place Don t remove the
17. ach headlight rim in or out to adjust the headlight vertically o A Adjusting Screw B Headlight Body Front Wheel Alignment Toe in is the amount that the front wheels are closer together in front than at the rear at the axle height When there is toe in the distance A Rear is greater than B Front as shown If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are built in and require no adjustment A Rear B Front Amount of Toe in Dis tance A and B are measured at axle height with the vehicle sitting on the ground or at 1G HJ04011BS1 C PREPARATION 27 Steering Centering Inspection e Test ride the vehicle If the handlebar is straight when the vehicle is traveling in a straight line go on to the Toe in Inspection procedure Otherwise go on to the Steering Centering Adjustment procedure Steering Centering Adjustment e Hold a straightedge against the rear wheel rim on one side at axle height NE17B014 P A Straightedge e With the handlebar straight ahead loosen the locknuts A B and turn the tie rod until the front wheel on that side is parallel to the straightedge NOTE OThe locknut A on the tie rod has left hand threads Turn the wrench clockwise for loos ening A Locknut Left hand Threads B Locknut Wheel Side C Tie rod NOTICE Adjust the tie rod so that the visible thread len
18. are not available use equivalent one e Let battery sit 30 minutes after initial charge then check voltage using a voltmeter Volt age immediately after charging becomes tem porarily high For accurate measuring let the battery sit for given time 16 PREPARATION NOTE OCharging rates will vary depending on how long the battery has been stored tempera ture and the type of charger used If voltage is not at least 12 8 volts repeat charging cy cle OTo ensure maximum battery life and customer satisfaction it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 volts repeat the charging cycle and load test f still below 12 8 volts the battery is defective Battery Installation e Turn the ignition switch to OFF e Check that the rubber dampers on the battery holder and the battery case are properly in place e Put the battery in place e Securely connect the red cable with protec tive cap and the black cable with the round terminal and the red tape to the terminal and then securely connect the black cable to the terminal On the battery terminal make sure the round terminal cable is on the red cable mak ing about 30 degree angle with the red cable e Put a light coat of grease on the terminals to prevent corrosion e Cover the terminal with its protective cap NEO2BO31 P A Battery B Positive
19. e search Octane Number RON and the Motor Octane Number MON as shown in the table For US and Canadian Models f Minimum Octane Rating Method l Rating RON MON AARON P MON E vi Antiknock Index 2 For Other than US and Canadian Models Minimum Rating Research Octane Number RON 91 Octane Rating Method e Close the fuel tank cap and check for any leaks and correct them Coolant Coolant Reservoir Tank Level Check e Situate the vehicle on level ground e Check the coolant level through the coolant level gauge on the reserve tank The coolant level should be between the F Full and L Low marks NOTE OCheck the level when the engine is cold room or atmospheric temperature PREPARATION 23 BLO6BO16 P Reserve Tank F Full Mark L Low Mark Cap Front Shock Absorber Right Side moou r e f the amount of coolant is insufficient un screw the cap from the reserve tank and add coolant through the filler opening to the F Full mark Install the cap Recommended Coolant Solution Coolant Mixture Ratio Water 50 Coolant 50 1 1 Recommended Coolant Permanent type coolant ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiator NOTE OA permanent type of antifreeze is installed in the cooling system when shipped It is col ored green and contains ethylene glycol It is mixed at 50 and has the freezing po
20. fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Brake fluid quickly ruins painted sur faces any spilled fluid should be com pletely wiped up immediately T If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE e Operate the front brake lever several times e f it feels spongy there might be air in the brake line e f necessary bleed the air in the rear brake line e Also check for fluid leakage around the fit tings and bleed the air in the front brake lines Brake Line Air Bleeding e With the front brake reservoir horizontal re move the front brake reservoir cap and di aphragm and check that there is plenty of fluid in the reservoir 20 PREPARATION 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 during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the front brake master cylinder end of the line e
21. g a syringe or some other suitable device e If the oil level is too low add the oil to reach the correct level e Screw the plug in finger tight Recommended Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 1 9 L 2 0 US qt when filter is not removed 2 0 L 2 1 US qt when filter is removed Although 10W 40 engine oil is the recom mended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area SAE 10W 50 pe d SAE 10W 40 20 10 0 10 20 30 40 b 4 14 32 50 68 86 104 F aa e es a E S BLO3006BM2 C Throttle Lever and Cable Throttle Lever Free Play Inspection e Check the throttle lever free play If the free play is incorrect adjust the throttle cable Throttle Lever Free Play 2 3 mm 0 08 0 12 in e Check that the throttle lever moves smoothly from full open to close and the throttle closes quickly and completely in all steering posi tions by the return spring If the throttle lever does not return properly check the throttle lever free play cable routing and for possi ble cable damage Then lubricate the throttle cable BL11000BM2 C A 2 3 mm 0 08 0 12 in e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change If the idle speed increases c
22. gth is even on both ends of the tie rod or the threads could be dam HJ04013BS1 C A Visible Thread Length e Repeat the straightedge procedure on the other side of the vehicle Now the front wheels are parallel to each other and to the center line of the vehicle e Go on to the Toe in Inspection procedure 28 PREPARATION HJ04016BS1 C A Front Wheels B Vehicle Center Line C Parallel each other D Straightedges E Rear Wheels Toe in Inspection e Apply a heavy coat of chalk or a paint line 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 NE17003BS1 C e With the front wheels on the ground set the handlebar straight ahead e At the level of the axle height measure the distance between the scribed or painted lines for both front and rear of the front tires NE17B016 P e Subtract the measurement of the front from the measurement of the rear to get the toe in If the toe in is not in the specified range go on to the Toe in Adjustment procedure Toe in of Front Wheels Standard 5 15 mm 0 20 0 59 in at 1G Toe in Adjustment e Loosen the locknuts A B and turn the tie rod the same number of turns on both sides to achieve the specified toe in NOTE OThe locknut A on the tie rod has left hand threads Turn the locknut clockwise for loos ening mU N
23. he battery holder bolt D 6 L 16 with collar D 6 3 to and screws D 6 L 18 2 with collars D 7 6 3 2 remove the battery cover e Take the battery out of the battery case Be careful that any rubber dampers are not pulled out of position PREPARATION 13 j P 4 y F IA 1 ve SEE A AM Ce A Bolt with Collar B Screws with Collars C Battery Cover Battery Activation Electrolyte Filling e Make sure that the model name of the elec trolyte container matches the model name of the battery These names must be the same Battery Model Name KVF750G H J L KMX14 BS GP08135BS1 C A Model Name of the Electrolyte B Model Name of the Battery Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and spe cific gravity vary with the battery type This is to prevent overfilling of the elec trolyte shorting the battery life and de terioration of the battery performance Do not remove the aluminum sealing sheet from the filler ports until just prior to use Be sure to use the dedicated electrolyte container for correct elec trolyte volume 14 PREPARATION A WARNING The electrolyte contains sulfuric acid which can cause severe burns To avoid sulfuric acid burns wear protec tive clothing and safety glasses when handling electrolyte If the electrolyte touches the skin or eyes wash the are
24. heck operation front and rear Engine Electric starter works properly and engine starts promptly Good throttle response and return Belt Drive Torque Smooth operation Converter Differential Smooth operation Forward Reverse Smooth operation Shift Hi Low Shift Smooth operation 2WD 4WD Shift Smooth operation Brakes Adequate smooth stopping power Do not drag Multifunction Meter Speedometer check operation Fuel Level Gauge check operation Clock check operation Odo Trip Hour Meters check operation Electrical System Headlight check operation Taillight check operation Brake Light check operation Instrument Lights and Indicator Lights check operation European and UK Models only Reverse Light check operation Other than US and Canadian Models Horn check operation Engine Stop Switch Works No Unusual Noises No Fuel Oil Brake Fluid or Coolant Leaks PREPARATION COMPLETE A amp P Check List e Complete the A amp P Check List MODEL APPLICATION BRUTE FORCE 750 4x4i EPS 2012 KVF750GCF KVF750 4x4 EPS 2012 KVF750HCF BRUTE FORCE 750 4x4i EPS 2012 KVF750JCF BRUTE FORCE 750 4x4i EPS BRUTE FORCE 750 4x4i 2012 KVF750LCF KVF750 4x4 H Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99931 1524 02
25. heck the throttle lever free play and the cable routing A WARNING Operation with incorrectly routed or im properly adjusted cables could result in an unsafe riding condition Be sure the cables are routed correctly and properly adjusted Throttle Lever Free Play Adjustment e Slide the rubber cover off of the adjuster at the throttle case e Loosen the locknut and turn the throttle ca ble upper adjuster to obtain the specified free play e Tighten the locknut and reinstall the rubber cover BL11001BM2 C A Adjuster B Locknut e Reinstall the rear handlebar cover with the screws D 5 L 14 3 and tighten them A A N E y f d A A Rear Handlebar Cover B Screws C Well Nuts Variable Differential Control Lever and Cable By pulling the control lever toward the handle bar the driving force of the front wheels can be equalized to provide more traction If the differ ential control lever has excessive play adjust the differential control cable Variable Differential Control Lever Posi tion Inspection e Pull the variable differential control lever to wards the handlebar grip with a spring scale until it reads 30 N 3 kgf 7 Ib of force The clearance between the control lever and grip should be 20 mm 0 8 in If the clearance is not within specification adjust the cable Variable Differential Control Lever Posi tion 20 mm 0
26. int of 35 C 31 F Engine Oil Engine Oil Level Inspection NOTE OThis vehicle s engine is filled with 10W 30 oil from the factory DO NOT DRAIN and refill the crankcase before use Check oil level and drain plug tightness Engine Oil Drain Plug Torque 20 N m 2 0 kgf m 15 ft Ib A Oil Drain Plug e Park the vehicle so that it is level both side to side and front to rear e Before starting the engine check that the en gine has oil e Unscrew the oil filler plug on the lower left side of the engine and wipe the dipstick dry Then screw it in again Unscrew the plug and check that the engine has oil BLO3BO31 P A Oil Filler Plug e When replacing the plug be sure the O ring is in place and screw the plug in finger tight NOTICE If the engine is run without oil it will be severely damaged e Start the engine and run it for several minutes at idle speed Stop the engine then wait sev eral minutes until the oil settles e Unscrew the oil filler plug wipe its dipstick dry and screw it in again e Unscrew the plug and check the oil level The oil level should be between the H High and L Low lines on the dipstick 24 PREPARATION BLO3026B G A Oil Filler Plug and Dipstick B Screw in the oil filler plug fully to inspect the oil level C H High Line D L Low Line e f the oil level is too high remove the excess oil through the oil filler opening usin
27. ission Control Information French Label for KVF750GCF Canadian Model only 59465 0046 French Label for KVF750HCF Canadian Model only 59465 0627 French Label for KVF750JCF Canadian Model only 59465 0629 French Label for KVF750LCF Canadian Model only 59465 0604 e Stick the label cover 14092 0127 onto the vehicle emission control information label 59465 xxxx Attached in the back of the seat at WERT 10 Trailer Towing Warning 56071 0080 For European Model 1 Important Air Cleaner Information 56033 0308 2 Shifting Caution 56071 0092 3 Protective Cover Warning 56070 1271 ND25B00 4 Transmission Warning 56070 0039 5 Passenger Warning 56071 0097 Owner s Manual e The storage box is located on the left side front fender Keep this Owner s Manual and other light items in this storage box e Keep the cover securely fastened with the strap when driving the vehicle ND28B000 P A Owner s Manual B Cover C Strap D Storage Box Preparation Battery Service Battery Removal The battery used in this vehicle is a sealed type and never needs to be refilled Follow the procedures for activating a new battery to en sure the best possible battery performance Seat Removal e Remove the seat by pulling up the seat latch lever located at the left rear end of the seat and then pull the seat up and to the rear NEO2B030 P E A Seat Latch Lever e Remove t
28. ity 0 40 L 0 42 US qt Although 10W 40 engine oil is the recom mended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area SAE 20W 50 ee a ay AE 20W 40 EE SAE 10W 50 EEEE SS p SAE 10W 40 1 I SAE 10W 30 0 4000 6 104 F HUOS002BS1 C 20 10 0 10 2 0 3 8 8 e Install the filler cap Oil Filler Cap Torque 29 N m 3 0 kgf m 22 ft Ib Rear Final Gear Case Oil Rear Final Gear Case Oil Level Inspec tion e With the vehicle level front to rear and side to side remove the filler cap from the rear final gear case BLO5BO12 P A Rear Final Gear Case B Filler Cap Be careful not to allow any dirt or for eign materials to enter the rear final gear case e Check the oil level The oil level should come to the bottom thread of the filler opening If it is insufficient add oil through the oil filler opening as necessary NOTE OFront and rear final gear cases use different types of oils Use the specified type and brand of oil in each final gear case Rear Final Gear Case Oil Type Mobil Fluid 424 CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Capacity 0 72 L 0 76 US qt NOTE ODo not apply front final gear case oil into the rear final gear case Apply only the specified oil The rear final gear case contains brake plates which require a special oil
29. justing sleeve on the shock ab sorbers to the standard position with a hook wrench e Check to see that each pairs of adjusting sleeves are turned to the same relative posi tion A WARNING If a pair of adjusting sleeves are not adjusted equally handling may be im paired and a hazardous condition may result Adjust the sleeves equally Tire Air Pressures Tire Air Pressure Adjustment e Adjust the pressures to the specified values in the front and rear and make sure to tighten the caps securely Tire Air Pressures when cold Normal Use Front 35 kPa 0 35 kgf cm 5 psi Rear 35 kPa 0 35 kgf cm 5 psi NE14B006 P A Air Pressure Gauge NOTE OTo accurately measure the pressure use a low air pressure gauge included in the tool kit of ATV Do not use an automotive air pressure gauge because the specified tire air pressures of ATV is too low Fuel A WARNING Gasoline is extremely flammable and can be explosive under certain condi tions creating the potential for serious burns When filling the tank turn the ignition switch to 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 Fill the fuel tank with one gallon or four liters of unleaded gasoline Use gasoline with a min imum octane rating indicated in the following table The antiknock index is an average of the R
30. ke c o eL Ae hio fen x ea as aie ie ada 20 SUSPENSIONS m 21 Tire Air PIreSSUF eS Linien meiibirt t ease inn Lini iiml 22 Fuel tete ett ep b ettet EE Eb ebat ete un 22 COOGAN orte dide ces fal e de uf Lou dla tita enis 22 Engine Oil e 23 Throttle Lever and Cable eeenm ee 24 Variable Differential Control Lever and Cable 25 Rear Brake Light Switch Adjustment 26 Headlight Beatn iu Sp m bc E EE 26 Front Wheel Alignment eene 26 Multifunction Meter lseeeeeeen eene 29 Fastener Check n i RT Ati eee tee nee redet 32 Standard Torque Table cccccccccccccceeeeeeeeceeceeeeeeeeeeeeeeeeeeeeeeeess 34 Test RAE kronante a Er eee Eie Ee oo 34 PP E SE a a aE a a Apea a a eaaa aiai 34 UNCRATING 3 Uncrating Returnable Steel Crate RSC EUER UU TIER EE NOTICE Openmg Crate To avoid damagi i A ging the front plastic US and Canadian Models only guard fold down the front end of the steel crate before removing the tie downs A WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury Always wear protective gloves boots and eye protection when uncrat ing to prevent injury NBO2000BS1 C A Outer Cover e Remove the inner cover MCO3003B S WARNING The steel crate panel plates and fasten ers have sharp edges Always wear pro tective gloves boots and eye
31. ki Warranty Policies and Pro cedures Manual before proceeding to uncrate the unit e Remove the cardboard cover Removing Panels e Using a BPS3 square drive bit ex IM PORT APEX Square Recess Power Bits 1 4 Hex size 3 or MAGNA Insert Bits size 3 with quick change holder remove the screws from the sides and ends PCO3023BS1 C A Power Bit APEX A WARNING Staples nails and other fasteners have sharp points that can cause injury Re move or bend into the wood all staples nails or other fasteners in the crate base MCO3004B S Disposable Wooden Crate e Take out all the fasteners and remove the top and sides of the crate e Remove the top and side panels of the wood crate e Remove the inner cover Be careful not to puncture a tire with sharp fasteners when rolling off the ve hicle from the crate base e Remove the tie downs 2 which secure the vehicle to the crate pallet and roll off the vehi cle A Tie downs Parts Check e Remove the parts including Owner s Manual from the parts bag on the footboard e Remove the battery electrolyte from the rear end of the chassis A Electrolyte UNCRATING 7 NCO5B010 _ P 8 UNCRATING e Check the parts against the illustrations There may be minor differences between these illustrations and the actual vehicle parts NC05027BW3 C UNCRATING 9 No Part Name Remark
32. protection when uncrating to prevent injury NC03000BS1 C A Inner Cover To work efficiently start work at the rear of the crate e Remove the hairpin clips 2 then push out the clevis pins 2 to disconnect the rear diag onal braces 2 from the rear upright MCO3004B S e Clear a space about 6 m 20 ft square to give yourself plenty of space to work e Place the crate upright on its base e Remove the outer cover and inspect the unit for concealed damage If concealed damage is evident document the damage as outlined in the Kawasaki Warranty Policies and Pro cedures Manual before proceeding to uncrate the unit e Remove the cardboard cover 4 UNCRATING NCO3001BS1 C A Rear Upright B Hairpin Clip C Diagonal Brace e Allow the diagonal braces to pivot out and down to the ground They remain attached to the pallet e Install the hairpin clips 2 back into the braces for return shipment to KMM NC03002BS1 C A Hairpin Clip B Clevis Pin C Diagonal Brace e Remove the LH side rear diagonal brace again allowing it to pivot down At this time the rear upright may be pivoted down but it may not be necessary to do so Only one upright must be pivoted down before rolling off the vehicle In this example the vehicle will be rolled out the front which is shown later e Moving to the front disconnect the front diag onal braces 2 from the front upright Pull o
33. s 1 French Label and Instruction for KVF750GCF Canadian Model only Instruction Label 1 56030 0403 Label Vehicle Emission Information 1 59465 0046 KVF750HCF Canadian Model only Instruction Label 1 56030 0730 Label Vehicle Emission Information 1 59465 0627 KVF750JCF Canadian Model only Instruction Label 1 56030 0731 Label Vehicle Emission Information 1 59465 0629 KVF750LCF Canadian Model only Instruction Label 1 56030 0717 Label Vehicle Emission Information 1 59465 0604 French Labels for Canadian Model only Label Age 1 56040 1325 Label General 1 56071 0059 Label Passenger 1 56071 0097 Label Tire Pressure 1 56071 0074 Label Trailer Towing 1 56071 0080 Label Shifting 1 56071 0092 Label Transmission 1 56070 0039 Label Protective Cover 1 56070 1271 Label with Band General for English 1 56030 0194 Label with Band General for French 1 56030 0197 Label Air Cleaner Information 1 56033 0308 Cover Label 1 14092 0127 French Labels and Instruction for European Model Instruction Label 1 56030 0337 Label Protective Cover 1 56070 1271 Label Shifting 1 56071 0092 Label Transmission 1 56070 0039 Label Passenger 1 56071 0097 Label Air Cleaner Information 1 56033 0308 For US Model only Label with Band General 1 56030 0194 Label with Band Exhaust Emission Air Index 1 49007 0706 5 lgnition Key 2 7 Owner s Manual 10 ASSEMBLY Assembly Handlebar Handlebar Installation e Remove the screws D 5 L 16 4
34. ut the hairpin clips 2 push out the clevis pins 2 and allow each diagonal brace to pivot down to the ground Install all pins and hairpin clips back into the braces for return shipment to KMM NCO3005BS1 C A Front Upright B Hairpin Clip C Diagonal Brace NOTE ONote that the front upright is collapsible The rear upright is not collapsible e Hold it up while removing the second pin Af ter pin removal allow the upright to collapse NC03007BS1 C A Front Upright B Diagonal Brace e Lay down the front upright To do so lift up on the front upright lower section to disengage its sockets from the pallet NC03008BS1 C A Front Upright B Lower Section e Working down the sides remove the tie downs 2 which secure the vehicle to the crate pallet NC03004BS1 C A Tie down e Now the upright may be pivoted down to the ground It remains attached to the pallet Be careful not to drop it on anyone e Roll off the vehicle NCO3011BS1 C RETURN SHIPMENT RSC e Prepare the crate for return shipment In this example we will begin at the rear of the crate e Swing around the diagonal braces so that they will lay on the crate pallet NC03012BS1 C A Rear Upright B Diagonal Brace UNCRATING 5 e Pick up slightly on the rear upright to disen gage its sockets Pivot it down onto the crate pallet Be careful not to drop on anyone We Lc LX j 4 NI
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