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2008-09 KRF750RAF Teryx -Service Manual

1. ay e O74 IN NES Q A A NS Wi Ces P sl SG Sy K r SE Wi Eo MUSS os AE d RS XE Uf Sy e d ei Z t 1808220884 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 clearance between the fuel tube and the water temperature sensor at least 5 mm 0 2 in MILITARY USE ONLY 17 10 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing e ol Bn S A A A 2 i alte G G d e ACT METTE Hf PS gd SEN SEY eis SN ui d EA Di A K H Se OM EC J KS Pd Ke eae W C27 v KE SR EZ oO SY JP ST X E 1808233885 C MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 11 Cable Wire and Hose Routing SE EEGEN 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 MILITARY USE ONLY MILITARY USE ONLY 17 12 APPENDIX Cable Wire and Hose Routing a CL EO VN PS E J 1808221884 C 1 Front Gear Ca
2. e Reese enne 9 19 Transmission Removal 2a Ss NW A 9 23 Transmission Installation e 9 24 Shift Fork Bending Inspec amp m af 9 26 Shift Fork Gear and Shifter Groove Wear Inspection ccccccccececeeeecceeeeeeeeeeeeeeeeeeees 9 26 Transmission and Shift Mechanism Inspechon 9 27 Ball Bearing Needle Bearing and Oil Gezai 9 29 Ball and Needle Bering P kolzfement AEN 9 29 Ball and NeedleBearing Wear Inspection eeeeeeeeeeeeeeenee nenne 9 29 Oil Seal See Se nnne nnne 9 29 MILITARY USE ONLY 9 2 CRANKSHAFT TRANSMISSIONNY USE ONLY 77 Exploded View MILITARY USE ONLY 77 MILITARY USE RANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Torgus Remarks N m kgf m ft Ib 1 Connecting Rod Big End Cap Nuts 34 3 3 5 25 MO 2 Engine Oil Drain Plug 20 2 0 15 3 Crankcase Bolts M8 L 75 mm 2 95 in 20 2 0 15 S 4 Crankcase Bolts M8 L 110 mm 4 33 in 20 2 0 15 S 5 Crankcase Bolt M8 L 110 mm 4 33 in 20 2 0 15 S L 1 6 Crankcase Bolts M6 L 40 mm 1 57 in 9 8 1 0 87 in lb 71 Crankcase 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 20 10 11 12 13 14 15 EO Apply grease Apply a non permanent locking agent LG Apply molybdenum disulfide grease MO About 12 mm 0 47 in Do not apply
3. 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 MILITARY USE ONLY 7T MILITARY USE ONLY ELECTRICAL SYSTEM 16 37 Ignition System Rear Side e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter
4. Starter Control Relay InSpection Starter Motor Glutch Removal Starter Motor Clutch Installation Starter Motor Clutch Inspection Torque Limiter Inspection Lighting lc EE Headlight Beam Vertical IBdii5tment Headlight Bulb Replacement Tail Brake Light Bulb Replacement Radiator Fan System Radiator Fan Circuit Inspection Radiator Fan Motor Inspection Radiator Fan Breaker Inspection Radiator Fan Breaker Installation Radiator Fan Relay Inspection Music Multifunction Meter Unit Removal Multifunction Meter Unit Installation Multifunction Meter Unit Inspection uuuuussse Actuator Control System Engine Brake Actuator Removal Engine Brake Actuator Installation Actuator Control System Outline Engine Brake Actuator Inspection Speed Sensor Circuit Inspection Controller Unit Inspection Forward Reverse Detecting Sensor Inspection 2WD 4WD Solenoid Valve 2WD AWD Solenoid Valve Inspechon pin Relay Inspection Switches and Sensor Brake Light Switch Adjustment Starter Motor Disassembly MIL fx S USE ONLY ee 16 2 ELECTRICAL SYSTEM MILITARY USE ONLY
5. 15 44 Floorboard Installation 15 63 Side Cover Remowval 15 44 MILITARY USE ONLY MILITARY USE ONLY 15 2 FRAME Exploded View MILITARY USE ONLY MILITARY USE ONLY FRAME 15 3 Exploded View 1 The seal ends should be at lower area and the gap is less than 3 mm 0 12 in 2 KRF750N T Models 3 KRF750P R S Models AD Apply adhesive agent R Replacement Parts MILITARY USE ONLY CS TX UR Nc MILITARY USE ONLY 15 4 FRAME Exploded View MILITARY USE ONLY MILITARY USE ONLY FRAME 15 5 Exploded View Remarks ft lb 72 10 Upper Bar Mounting Bolts 46 5 34 7 2 2 3 Back Bar Mounting Bolts 46 5 34 4 Bottom Guard Bolts 8 8 0 90 Fastener 1 Right and Left Bar Mounting Bolts 98 9 4 4 78 in lb Front Guard Bolts 31 5 23 5 R Replacement Parts MILITARY USE ONLY MILITARY USE ONLY 15 6 FRAME Exploded View NS Se WE IPO2062BW5 C MILITARY USE ONLY 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 grease MILITARY USE ONLY
6. 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 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 men P MILITARY USE ONLY 2 36 PERIODIC MAINTENANCE ILTARY USE ONLY 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 N m 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 finishe
7. 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 Calipers St Front Brake Caliper Removal Front Brake Caliper Installation Front Brake Caliper Disassembly Front Brake Caliper Assembly Caliper Piston Seal Damage Inspection 3 Brakes Table of Contents 12 2 12 6 12 7 12 7 Dust Seal and Friction Boot Damage Inspection Front Brake Caliper Piston and Cylinder Damage Inspections Front Brake Caliper Holder Shaft Wear Inspection css Brake Pads ssa Front Brake Pad Removwal Front Brake Pad Installations Front Brake ad Wear Inspection Brake Discs D En Front Brake Disc Cleaning Front Brake Disc Removal Front Brake Disc Installation Front Brake Disc Wear Inspection Front Brake Disc Runout Ipnspechon Brake Hoses and Pipes Brake Hose and Pipe Inspection Brake Hose Replacement Parking Brake Pedal and Cables
8. 99 9884 4 14 Radiator Fan Installation E eese nennen nennen enn nens 4 14 Radiator Inspection 9 Z 9897 4 15 Radiator Cleaning D a Eoo oO ERE eie tiet btts 4 15 Radiator Cap Inspechon nennen nne enne 4 15 Runen m 4 16 Thermostat REMowel iin e 4 16 Baue ECH vull D nn WT 4 16 Thermostat laspectien A9 4 16 Water Temperiureenzger nnn nnne nennen nnns nnn n sensn ense nns EEEE 4 17 Water Temperature Sensor Removal Installation eeeeeeeseeseessesessesssssss 4 17 Water Temperature Sensor Inspection eeeeeeesessessssssssssssesesene eene 4 17 MILITARY USE ONLY MILITARY USE ONLY 4 2 COOLING SYSTEM Exploded View 1p020158BW5 C MILITARY USE ONLY EE COOLING SYSTEM 4 3 Exploded View No Fastener Torque 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 in Ib 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 in lb 9 Water Pump Impeller 7 8 0 80 69 in Ib 10 Water Pump Cover Bolts
9. 5 31 Camshaft Chain Tensioner Valve Clearance Adjustment 5 31 HRemoval 5 13 Valve Removal 00 5 31 Camshaft Chain Tensioner Valve Installation 1 5 31 Installation 5 13 Valve Guide Removal 35 4 5 31 Rocker Case 5 15 Valve Guide Installation 5 32 Rocker Case Removal 5 15 Valve to Guide Clearance Rocker Case Installation 5 16 Meas rementh ee 5 32 Rocker Arm HRemoval 5 17 Valve Geatlnspechon 5 33 Rocker Arm Installation 5 18 Valve Seat Repair Valve Rocker Arm Inspection 5 18 oo oE 5 33 Rocker Shaft Diameter Cylindem and Piston 5 38 Measurement 5 18 Cylinder Remowval 5 38 Camshaft cninn e 5 19 Piston Hemoval 5 38 Camshaft Removal 5 19 Cylinder Piston Installation 5 38 Camshaft Installation 5 19 Cylinder Wear Inspection 5 40 Camshaft Assembly 5 20 Piston Wear Inspection 5 40 Cam Wear Inspection 5 20 Piston Cylinder Clearance Camshaft Bearing Wear Geer Le EE 5 40 Inspection e 5 21 Piston Ring Piston Ring Groove KACR Inspection 5 5 22 Wear Inspection 5 41 KACR Remowval
10. sssssssssssssssssssesseeeeeee eme eem Rear Knuckle Disassembly 5 o regeiert geed tse befete tuta A rte rgteiugeet Rear Knuckle Assembly niente eet roe RERO RR NIRE Lie RR ex EM DERE IO MR POM dud Bearing snd Oil Sal isco pci noc nodes eiie Last tet pice ratus ta AN Mei eon AR tns hoes Ball Bearing ee EE BUR a ee MILITARY USE ONLY MILITARY USE ONLY 13 2 SUSPENSION Exploded View MILITARY USE ONLY MILITARY USE ONLY SUSPENSION 13 3 Exploded View Torque No Fastener S kgf m ftlb Remarks 1 Front Shock Absorber Mounting Nuts 57 5 5 9 42 R 2 Front Suspension Arm Pivot 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 MILITARY USE ONLY 13 4 SUSPENSION MILITARY USE ONLY Exploded View MILITARY USE ONLY MILITARY USE ONLY Exploded View SUSPENSION 13 5 Torque No Fastener Nem kgf m ftlb 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
11. 15 8 FRAME MILITARY USE ONLY Exploded View 1P02078B8BW5 C MILITARY USE ONLY MILITARY USE ONLY FRAME 15 9 Exploded View Fastener Remarks Seat Belt Mounting Bolts Seat Belt Buckle Mounting Bolts Seat Plate Bolts in L L Apply a non permanent locking agent R Replacement Parts MILITARY USE ONLY MILITARY USE ONLY 15 10 FRAME Exploded View MILITARY USE ONLY MILITARY USE ONLY FRAME 15 11 Exploded View Fastener f Remarks Brake Pedal Bracket Mounting Bolts L 20 mm 0 79 in Brake Pedal Bracket Mounting Bolts L 30 mm 1 2 in Right Frame Pipe Mounting Bolts Bracket Bolts Heat Guard Bolts AD Apply adhesive agent L Apply a non permanent locking agent R Replacement Parts MILITARY USE ONLY 15 12 FRAME MILITARY USE ONLY Exploded View Canada Model 1P020808W5 C MILITARY USE ONLY MILITARY USE ONLY FRAME 15 13 Exploded View 1 Reflector Yellow 2 Reflector Red MILITARY USE ONLY MILITARY USE ONLY 15 14 FRAME Exploded View KRF750P R Models MILITARY USE ONLY MILITARY USE ONLY FRAME 15 15 Exploded View el mme eee 1 Upper Bar Mounting Bos 465 47 934 2
12. 4 M REENEN 14 12 Knuckle Bearing Removal MEIN 14 13 Knuckle Bearing Installation 48 A 14 13 MILITARY USE ONLY 14 2 STEERING MILITARY USE ONLY Exploded View MILITARY USE ONLY MILITARY USE ONLY STEERING 14 3 Exploded View Torque No Fastener Nam kok 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 MILITARY USE ONLY 14 4 STEERING MILITARY USE ONLY 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 MILITARY USE ONLY MILITARY USE ONLY STEERING 14 5 Special Tools Outside Circlip Pliers Bearing Driver Set 57001 144 57001 1129 7570144ST C ST571129ST C MILITARY USE ONLY 14 6 STEERING MILITARY USE ONLY Steering Wheel and Main Shaft Assembly St
13. 1007004BS1 C 16 18 ELECTRICAL SYSTEM MILITARY USE ONLY 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 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 TE Battery Holder F Battery G Battery Installation For US Model e Check that the damper A on the plate B is properly in place MILITARY USE ONLY WU USE ONLY ELECTRICAL SYSTEM 16 19 Batey 0000000000 T e Check that the damper A on the battery holder B is properly in place A e Check that the dampers A on the battery B are properly in place 18008019BS1 C e Install Battery A Collars B Battery Holder C e Tighten Torque Battery Holder Mounting Bolts D 16 N m 1 6 kgf m 12 ft lb 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 termi
14. 7571491ST C T5717218T MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 13 Output Bevel Gears Output Drive Bevel Gear Removal j 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 N m 2 7 kgf m 19 ft Ib 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 Woo po MILITARY USE ONLY 11 14 FINAL DRIVE MILITARY USE ONLY 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 Lubricatio
15. A S 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 surface C lt m a e Place the rear camshaft chain D onto the rear camshaft sprocket V n ES v Engage the camshaft and intermediate shaft chains on the intermediate shaft sprocket A and insert the inter gt mediate shaft left side view OFit the splines of the intermediate shaft B and grooves CT of the sprocket as shown e Align the punch mark D on the sprocket with the em bossed mark E on the crankcase MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 25 Camshaft 32 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 m 78 in Ib e Install Intermediate Shaft Chain e Tighten Torque Intermed Shaft 0 g 78 in uide A front in Guide Bolts B 8 8 N m N all In ediate Shaft Chain Guide A Rear sher B irclip C Special Tool Outside
16. I IR NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid ORemove 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 1814008BS1 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 gud ro the dust seal and install it into the cylinder by hand GL05040281 C MILITARY USE ONLY MILITARY USE ONLYBE RIODIC MAINTENANCE 2 45 Periodic Maintenance 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 1814009BS1 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 Dapp P Rear Brake Plates Replacement e Replace the steel plates and friction plates in accordance with the specified inter
17. MILITARY USE ONLY amp ER E z xxx gs a sf Dana ER Sa ul x amp Se oil ri Pressure S at Switch mos eS es Water Temperature Sensor Crankshaft Sensor Alternator Ignition Coils ng d d Spark Plugs W2L0482CW5 C 77 MILITARY USE ONLY ELECTRICAL SYSTEM 16 15 Wiring Diagram Fuse Box i Main Fuse 30A 2 Actuator Controller Fuse 10A 3 Fuel Pump Fuse 10A Mn EM 4 Accessory Fuse 10A rake ectifier Actuator Controller Actuator Fuse Box Fuel Level Sensor Pump EP Pos z H 2555 2 Frame E E Ground 2 28D 4WD Solenoid gees BEE Valve Se pare Zi D sit Brake TailpLight Right 12V 27 8 Li E v Brake Tail Light EN Leve 12 27 8W SS Be 7 Reverse Optional Light j Part ECU Electronic Control Unit ary BR W R W BL BL R w R L Le BR BK BK Y GY BR H Y w P LG Y amp G BK R BK W LG BK W BK G W BL BR Y Lid Y BK Y v LI ND vw KE P BL RZY Ii BK Y BL R HF E ak Ze Ee ZC z8 ll zz NEEN E 2m IR gee BEES ggg a353 SC Color Code BK Black Forward Wolz l BL Blue Reverse esse BR Brown Detecting ELI i Fuel Radiator Starter Vehicle Gray EES Pump Fan Control down Light Blue Diagnostic Relay Relay Relay Sensor System Light Green Connector CSC Orange Pink eatery 5 IGNITION SWITCH
18. O lead of Main Harness Meter CH 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 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 If 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 MILITARY USE ONLY 3 52 FUEL SYSTEM DFI MILITARY USE ONLY 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 tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil whi
19. No Fastener Torgus Remarks N m kgf m ft Ib 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 MILITARY USE ONLY 10 4 WHEELS TIRES MILITARY USE ONLY Specifications Item Standard Service Limit Wheel Alignment Caster 2 2 non adjustable Camber Front 0 7 non adjustable SSS Rear 0 4 non adjustable iei Toe in 20 40 mm 0 79 1 57 in at 1G c Wheels Rims Rims Size Front 12 x 6 0AT Rear 12 x 8 0AT dr Tires Standard Tire Front 26 x 8 00 12 MAXXIS M989 Tubeless Sr 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 kgficm 13 1 psi 250 kPa 2 5 kgf em 36 psi 4 mm 0 16 in 4 mm 0 16 in MILITARY USE ONLY 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 N N UY N f UY 7571216ST C T571326ST C Jack Brake Drum Pusher amp Washer 57001 1238 57001 1709 757
20. Water Temperature Switch Inspection suusss 16 76 Fuel Level Sensor Inspection 16 76 Speed Sensor Removal Installa ie PM E E atststehanese 16 76 Speed Sensor Inspection 16 77 Switch Inspection 16 77 FUSOS i sts b nim Ni 16 79 Fuse Removal 16 79 Fuse Installation 16 79 Fuse Inspection 16 80 MILITARY USE ONLY 7 MILITARY USE ONLY ELECTRICAL SYSTEM 16 3 Parts Location Ignition Switch A 2WD 4WD 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 PosSition 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 MILITARY USE ONLY 16 4 ELECTRICAL SYSTEM MILITARY USE ONLY 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
21. 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 54 3 B 57001 1488 A Rear Final Gear Case Ri B Ball Bearing e Press the oil seal C so t mm 0 14 in D as s Special Tool Bearing D e Apply Grease Oil SO Wi Front Cover Assembly e inal Gear Case Front Cover Bearing B until bottomed pecial Tool Bearing Driver Set 57001 1129 ress the faces of the oil seals C are flush with the ends of the housing Cl VY e Apply Grease Oil Seal Lips 1L08004881 C 1LO8003BS1 C MILITARY USE ONLY 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 Inside Circlip Pliers 57001 143 Lj ed Va B 1L08005BS1 C e Press Ball Bearing until bottomed Special Tool Baring Driver 5
22. 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 agent to the rear final gear case right cover bolts e Tighten Torque Rear Final Gear Case Right Cover B A 94 N m 9 6 kgf m 69 ft Ib Rear Final Gear Case Right Cover Bolts B 49 N m 5 0 kgf m 36 e Apply specified oil to RN of the brake camshaft NS amshaft A eel Balls B ror P MILITARY USE ONLY 41 84 FINAL DRIVE MILITARY USE ONLY Rear Final Gear Case e Install the 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 Steel Plate A P No 41080 1483 Olnsert the pins B into th th RG e Rear Final Gear Case Gasket Screws C 1 3 N m 0 13 kgf m 12 in Ib MILITARY USE ONLY 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 N m 2 4 kgf m 18 ft Ib e Install Spring Bracket C e Apply a non permanent locking agent to the spring bracket bol
23. 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 HK11002081 C 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 HK11006BS1 C disc and disc asse x If the width is not disc assembl e Install Inner cI N MILITARY USE ONLY 41 50 FINAL DRIVE MILITARY USE ONLY 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 e il to the differential control shift shaft A e th ring B as shown in the figure MILITARY USE ONLY iLoshioy P 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 Bo A 8 8 N m 0 90
24. Fuel Injector 2 Ignition Switch Fuse Box Fuel Pump Fuse 10 A Main Fuse 30 A ECH Electronic Control Unit Fuel Pump Relay Engine Ground Battery Frame Ground 1 MILITARY USE ONLY 1C15074BW3 C WITT 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 xIf the Fl indicator symbol LCD is abnormal replace the meter unit xIf 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 f Qema CRY 1019047BS1 C 1C15075BW2 C Multifunction Meter lgnition Switch Fuse Box Main Fuse 30 A EGU Electronic Control Unit Engine Ground Battery Frame Ground 1 ON OoOm P h A MILITARY USE ONLY 3 70 FUEL SYSTEM DFI WU USE ONLY 77 ECU NOTICE Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it 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 EC
25. Covers K Bands L Detail M IP04013BW3 C MILITARY USE ONLY MILITARY USE ONLY FRAME 15 39 Cargo Bei SSS e Install Tail Gate A Stoppers B Stoppers C Screws D Reinforce E Tail Gate Cover F Screw Rivets G Hook Levers H Brackets I Bolts J M6 L 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 18 mm 0 71 in Rear Fenders see Rear Fender Installation IP04007BW3 C MILITARY USE ONLY 15 40 FRAME MILITARY USE ONLY 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 9 Mounting Bolts A and Lower Seat Bracket B both sides Right Bar C Left Bar D gt Rigt NN ars Installation and Left Bar A ower Seat Bracket B both sides ounting Bolts C temporarily MILITARY USE ONLY MILITARY USE ONLY FRAME 15 41 Bars e Install Lower Back Bar
26. MILITARY USE ONLY ve 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 3281 ft mega M x 1000 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 4020 kgf m N m x 0 7376 ftlb N m x 8 851 in Ib kgf m x 9 807 N m Units of Mass kgf m x 7 233 ft lb kg x 2 205 Ib kgf m x 86 80 in Ib g x 0 03527 OZ Units of Pressure Units of Volume kPa x 0 01020 kgf cm L x 0 2642 gal US kPa x 0 1450 psi 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 22 psi L x 2 113 pint US cmHg x 1 333 kPa 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 z PS N x 0 2248 Ib kW x 1 341 HP kg x 94807 N PS x 0 7355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Temperature 68 60 20 i F 5 F 40 40 c 104 176 212 248 284 80 100 120 140 160 180 200 220 240 260 280 300 1440 138 i 420 116 i 400 93 3 40 48 9 26 7 MIEITARY USE ONEY 7 MILITARY USE ONLY BERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart e
27. MILITARY USE ONLY Teryx 750 Fl 4x4 Teryx 750 Fl 4x4 LE a Kawasaki Teryx 750 Fl 4x4 Sport Recreation Utility Vehicle Service Manual MILITARY USE ONLY 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 a l O CO N G Oj ol NI Oo O1 B Oo IND lech Appendix This quick reference guide will assist you in locating a desired topic or pro cedure send 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 MILITARY USE ONLY 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 Consumer Products amp Machinery Company Kawa
28. Starter Motor Clutch Inspection e 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 kk ELECTRICAL SYSTEM 16 51 WB P Pigs P WB P MILITARY USE ONLY 16 52 ELECTRICAL SYSTEM MILITARY USE ONLY Lighting System Headlight 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 Remo
29. TIR 0 3 mm 0 012 in 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 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 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 Bra
30. e w Vrew D ee LT Bee MILITARY USE ONLY 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 A Screws B and Collars C Tapping Screws D Front Bottom Guard Removal Remove Bottom Guard Bolts A and Collars Front Bottom Guard B MILITARY USE ONLY 15 58 FRAME MILITARY USE ONLY Guards Front Bottom Guard Installation e Install Front Bottom Guard A Bottom Guard Bolts B and Collars 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 Engine Bottom Guard Removal e Remove Bottom Guard Bolts A Ve A Engine Bottom Guar xD S MILITARY USE ONLY MILITARY USE ONLY FRAME 15 59 Guards Engine Bottom Guard Installation e Install Engine Bottom Guard A Bottom Guard Bolts B e When installing the following parts install them as shown in the figure Guard C Bottom Guard Bolts D Damper E Insulator F IP14005BS2 C Rear Bot
31. e Remove the front shock absorber B Front Shock Absorber Installation e Apply grease to the inside of needle bearing A and grease sedl lips B e Install the collar C MILITARY USE ONLY 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 N m 5 9 kgf m 42 ft lb 1N04008BS2 C Front Shock Absorber Inspection e Check the bushing in the upper pivot 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 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 a 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 whendrilling the hole as the gas may blow out bits of drilled metal when the hole opens MILITARY USE ONLY 13 10 SUSPENSION MILITARY USE ONLY Shock Absorbers Other than KRF750S Model Rear Shoc
32. e Tighten Torque Chain Tensioner Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install Pin A and Spring B Washer C and Chain Tensioner Cap Bolt D e Tighten Torque Chain Tensioner Cap Bolt 22 N m 2 2 kgf m 16 ft Ib MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 15 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 notch B in the inspection window and the cam lobes are pointing awaysfrom the rocker arms the end of the compression stroke A 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 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 MILITARY USE ONLY 5 16 ENGINE
33. 1T06000BW1 C MILITARY USE ONLY 9 20 CRANKSHAFT TRANSMISSION USE ONLY 7 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 lb e Install Shift Lever Assembly F Spring G to Shift Lever Assembly Washer H Shift Lever Assembly Nut I e Tighten Torque Shift Lever Assembly Nut 19 6 N m 2 0 kgf m 14 ft lb e Install Tie rod J e 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 MILITARY USE ONLY ITO6O01BHW2 C 7 7 MILITARY USECGR AN KSHAFT 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 N m 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 N d ges ITO6O002BHW2 C MILITARY USE ONLY 9 22 CRANKSHAFTITRANSMISSIONTT USE ONLY
34. 5 28 ENGINE TOP END MILITARY USE ONLY 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 0380 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 Incorrect 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
35. Assemble the final gear case completely MILITARY USE ONLY 11 58 FINAL DRIVE MILITARY USE ONLY Front Final Gear Case Front Final Gear Case Backlash related Parts ILO4015BW4 C OON DO AO hoy 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 MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 59 Front Final Gear Case 1 Ring Gear Right 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 92180 1428 1 2
36. Bolt B Speed Sensor C e Replace the O ring with a new one Apply grease to the O 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 MILITARY USE ONLY 7T 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 KO 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 x If 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 MILITARY USE ONLY GP18254BS1 C DC25V GP18255BS1 C 16 78 ELECTRICAL SYSTEM MILITARY USE ONLY 77 Switches and Sensor Neutral Position Switch Connection pS Terminal 7
37. 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 in Second 0 03 0 07 mm 0 0012 0 0028 in 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 GE16020881 C 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 in Second 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 Second 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 xIf any of the measurements is less than the service limit on either of the rings repla
38. MICITARY USE ONLY en mmm 2 2 PERIODIC MAINTENANCE MIHTARY USE ONLY 7 Steering Steering Inspection Steering Joint Dust Boot InSpectODi n cucoo testo teh Pato h tzt Frame noaei Seat Belt Inspection Electrical System Spark Plug Cleaning MMS een EE Spark Plug Gap Inspection cccccccccceccceeceeeeeeeeeceeeaeceaeeceeceeeeeaeecaeeeaeceaeseaaeseeeeaeseneeaas Brake Light Switch Ne Ee EE Brake Light Timing Adjustment EE Joint Boots Inspection Front Axle Steering Knuckle Joint Boots Inspection esssssssssssd Front Propeller Shaft Joint Boots Inspechon EE Tie rod End Boots In Rear Propeller Shaft Rear Axle Stabilizer General Lubrication Lubrication Cables Inspection ee TEEN es Joint Boots Inspection EE Joint Boots Inspection EE Bolts and We TRL Ei e DE WE E Tightness Inspection MILITARY USE ONLY 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 7 MILITARY USE ONLY GERIODIC 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 OPERATION First Service Regular Service ENGINE Thro
39. MILITARY USE ONLY 6 2 CONVERTER SYSTEM Exploded View OLS INS M IFO2030BWS C MILITARY USE ONLY MILITARY USE ONLY CONVERTER SYSTEM 6 3 Exploded View Torque No Fastener RE kafim ft Ib Remarks 1 Drive Pulley Bolt 93 9 5 69 Lh 2 Drive Pulley Cover Bolts 12 5 1 3 111 in Ib 3 Ramp Weight Nuts 7 0 0 71 62 mb R 4 Spider 275 28 203 Lh 5 Driven Pulley Nut 93 9 5 69 R G Apply grease Lh Left hand Threads Replacement Parts Apply grease WR500 No2 KYODO YUSHI POWER LITE WR 2 KYODQ YUSHI on SERAN HV TOTAL FINA MILITARY USE ONLY MILITARY USE ONLY 6 4 CONVERTER SYSTEM Exploded View MILITARY USE ONLY MILITARY USE ONLY CONVERTER SYSTEM 6 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Engine Brake Actuator Mounting Bolts 8 8 0 90 78 in lb S 2 Engine Brake Actuator Cover Bolt 8 8 0 90 78 in lb S 3 Belt Inspection Opening Cover Bolts 8 8 0 90 78 in lb 4 Converter Cover Bolts 8 8 0 90 78 in lb 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 MILITARY USE ONLY 6 6 CONVERTER SYSTEM MILITARY USE ONLY 77 Specifications Item Standard Ser
40. 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 and Spacer Shifter D Shift Rod E MILITARY USE ONLY 9 24 CRANKSHAFT TRANSMISSION USE ONLY 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 us 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 gs and install them e Install the following he Needle Bearings B Spacer C SS gear A 6 1599 48 2 x 54 3 x 1 0 MILITARY USE ONLY WU USECRIANKSHAFT 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 Circ
41. b g A on the pinion gear until it is permanent locking agent Three Bond e to the pinion gear bearing holder nut B pinion gear bearing holder nut so that the pro n C faces outward 1L0404iBS1 C MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 57 Front Final Gear Case e Hold the pinion gear unit A with the socket wrench B in i 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 N m 20 4 kgf m 148 ft lb Front Final Bevel Gear Adjustment The backlash distance one gear will move back and forth without moving the mate gear and tooth 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
42. e Visually inspect the coolant in the reserve tank A If 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 x If 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 th 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 In an emergency soft water can be added 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 Referto the Coolant Change in the Periodic Maintenance chapter Coolant Filling Refer to the Coolant Change in the Periodic Maintenance chapter MI
43. seseesssese c E messes 3 31 Self diagnosis ProOCedufes o esie te chop ausac ad ede dtd uas NR e 3 31 How to Read Service Codes sss es emen 3 34 Service Code Erasing tm A Noe 3 34 Service Code Table A A ccc cece ccecccecceeecseceeecseeseeeenaees 3 34 Backups nece eere rh Nectar tenete hem Ee eret 3 36 Throttle Sensor Service Code 11 4 9M 3 38 Throttle Sensor RemovalAdiustmment A 2 EEN 3 38 Throttle Sensor Input Voltage Inspechon 0c cceeececceneceaeeeaeecaeeeaeeeaeeeaaeeaeeeaeeeaeeeaeeeas 3 38 Throttle Sensor Output Voltage INSPECTION M cceceeeceeeceeeeeeeeeeeeeaeesaeeaeeeeaeeeaneaes 3 39 Throttle Sensor Hesistancelnspechopn enne 3 40 Inlet Air Pressure Sensor SerWice Qede 12 3 41 Inlet Air Pressure Sensor R amp mowVal 7 eene 3 41 Inlet Air Pressure Sensor Installation ccecc cece cece cee e cece cece tees eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 3 41 Inlet Air Pressure Sensor Input Voltage Inspection 3 41 Inlet Air Pressure Sensor Output Voltage Inspechon nnr nnnnneeeen nnn 3 42 Inlet Air Temperatur Sensor Service Code 131 3 47 Inlet Air Temperature Sensor Removal Installation esses 3 47 Inlet Air Temperature Sensor Output Voltage Inspection seesesssesessesss 3 47 Inlet AirsTemperature Sensor Resistance Inspechon 3 48 Water TemperatlitesSensor
44. 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 1F04023BS2 C 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 4mm 0 039 0 004 in 13236 0124 Green 1 6 0 1 mm 0 063 0 004 in H 04003BS1 C MILITARY USE ONLY T 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
45. x lf 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 HIO5000BS1 6105040881 C 6105040781 C MILITARY USE ONLY T MILITARY USECRIANKSHAFT TRANSMISSION 9 15 Crankshaft Connection Rod Connecting Rod Big End Side Clearance i 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 Cap Nuts 34 3 N m 3 5 kgf m 25 ft lb NOTE ODo not move the connecting rod and crankshaft during clearance measurement 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 x lf the clearance is within the standard no bearing inse
46. 0 2323 0 2362 in Service Limit 5 8 mm 0 2283 in 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 HI10028BS1 C HI10002281 C i 7 c Wo P MILITARY USE ONLY T MILITARY USECRRIANKSHAFT 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 MILITARY USE ONLY 9 28 CRANKSHAFT TRANSMIS SION Y USE ONLY 7 Transmission OOGO WOCO DEDIDA 1 HI10000BN4 C n sch OOAOAND UAB WN Driven Shaft Spacer 17 3 x 30 x 2 0 Reverse Gear 12T 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 Drive Low Gear 20T Reverse Idle Shaft Reverse Driven Gear 16T Reverse Driven Output 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 MILITARY USE ONLY MILITARY USECGRIANI KSHAFT TRANSMISSION 9 29 Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing Replacement Do not remove t
47. 4 14 32 50 68 86 104 F NOTE IU liuos002881 6 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 Front 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 oil will 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 r ar 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 n 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 e oilhascompletely drained out install the oil drain plug with a new O ring OApply grease to the O ring e Tighten Torque Rear Final Gear Case Oil Drain Plug 15 N m 1 5 kgf m 11 ft Ib 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 ODo not use mixing the above oils MI
48. 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 57 N m 5 8 kgf m 42 ft lb 5 000 r min rpm Fuel Injection Mikuni 34 x 2 Electric Starter eee Coil transistorized MILITARY USE ONLY 1 12 GENERAL INFORMATION MILITARY USE ONLY General Specifications Items 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 Front Final Gear Case Oil Type Viscosity Capacity Rear Final Gear Case Oil Type Capacity KRF750NAF PAF RAF SAF TAF Electronically advanced digital 10 BTDC 1 110 r mi rpm NGK CR7E or DENSO U22ESR N Front to rear 1 2 1 2 20 BTDC 44 ABDC 244 44 BBDC 20 ATDC 244 Forced lubrication wet sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 2 6 L 2 7 US df Belt drive torque converter 3 200 0 721 9 549 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 API SG SH SJ SL or SM with
49. 7571454ST C Valve Guide Reamer 5 Liquid Gasket TB1216 57001 1204 92104 1063 p z 7571204ST C 7921063ST Valve Seat Cutter Holder 5 57001 1208 7571208ST C MILITARY USE ONLY 1 MILITARY USE ONLY ENGINE TOP END 5 13 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE 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 Cap 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 pushrod B into the tensioner body MILITARY USE ONLY 5 14 ENGINE TOP END MILITARY USE ONLY Camshaft Chain Tensioner
50. A Upper Back Bar B Back Bar Mounting Bolts C temporarily IPOSO005BS1 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 N m 10 kgf m 72 ft Ib Back Bar Mounting Bolts 46 5 N m 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 MILITARY USE ONLY 15 42 FRAME MILITARY USE ONLY Bars 1P05004BW2 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 Upper Bar Mounting Bolts MILITARY USE ONLY 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 K e Remove Small Quick Rivets A Quick Riv
51. A and Collars Screws B and Collars Quick Rivets C Right Floorboard D MILITARY USE ONLY 1P150010 P IP P MILITARY USE ONLY FRAME 15 63 Floorboard Floorboard Installation e Install Right Floorboard A Left Floorboard B Tapping Screws C and Collars D L 4 mm 0 16 in Screws E and Collars D L 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 gege SE SS Z EZ e IP15001BS1 C MILITARY USE ONLY 15 64 FRAME MILITARY USE ONLY 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 IP15002BS1 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 N m 3 5 kgf m 25 ft Ib IP15003BS1 C e Install Throttle Cable see Throttle Cable
52. 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 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 Omespecially 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 Diff rential Shift Inder 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 6004011481 C MILITARY USE ONLY 2 50 PERIODIC MAINTENANCE ILTARY USE ONLY Periodic Maintenance Procedures Points Lubricate with Grease Throttle Inner Cable Ends A Brake Cable Upper End Variable Differential Control Cable Ends 2WD 4WD Shift Cable Ends 6004040381 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 n
53. 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 ORemove the piston assembly two pistons by lightly tap the master cylinder on a wooden block Pistons E Springs F Secondary Cups G Primary Cups H Master Cylinder I MILITARY USE ONLY 2 38 PERIODIC MAINTENAN CE ILTARY USE ONLY 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 NOTICE 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 scre and install the piston stop bolt Use a new washer OTighten Torque Piston Stop Bolt 8 8 N m 0 90 Reservo
54. D Fuel Pump Relay E Battery F Frame Ground 1 G MILITARY USE ONLY 3 14 FUEL SYSTEM DFI MILITARY USE ONLY 7 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 MILITARY USE ONLY MILITARY USE ONLY Specifications FUEL SYSTEM DFI 3 15 Item Standard Digital Fuel Injection System Idle Speed Throttle Body Assy Type Bore ECU Electronic Control Unit Make Type Fuel Pressure 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 MILITAR 1 100 x50 r min rpm Two barrel type 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
55. Frame Ground 1 3 Battery 9 Fuse Box 4 Ignition Coil 2 Rear 10 Main Fuse 30 A 5 Ignition Coil 1 Front 11 Ignition Switch 6 Spark Plug Rear MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DFI 3 63 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 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 fi D E P MILITARY USE ONLY 3 64 FUEL SYSTEM DFI MILITARY USE ONLY 7 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 Torque Delivery Pipe kgf m 44 i e Install the front fu securely AKA t fuel injector into the seal and tighten the e pipe mounting screws A elivery Pipe Mounting Screws 5 0 N m 0 51 kgf m 44 in Ib onnect the fuel injector connec
56. 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 metento 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 connector 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 lf the wiring is good check the sensor resistance see Inlet Air Temperature Sensor Resistance MILITARY USE ONLY 3 48 FUEL SYSTEM DFI MILITARY USE ONLY Inlet Air Temperature Sensor Service Code 13 x If the output voltage is within the standard 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 Inlet Air Temperature Sensor Resi
57. Le cO Section A A 18082388W5 C MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 23 Cable Wire and Hose Routing Parking Brake Cable Differential Shift Cable Band Secure the differential shift cable and the throttle cable 2WD 4WD Shift Cable Throttle Cable Clamp Brake Pipe Main Harness Clamp Clamp the parking brake cable at the white mark SE EEGEN MILITARY USE ONLY MILITARY USE ONLY 17 24 APPENDIX Cable Wire and Hose Routing e CO nite 2 V v S E Geer y ZS E Y K d H Fey p Z lt lt ba Sw I Wd a E Aki S Bast S GC Ces V d ee NS AM f e en e Xd wey Yd SP gt A A RA d Sech Ose 3 b N WNY PN Detail A Taping 1 2 3 4 5 MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 25 Cable Wire and Hose Routing 1808228884 C t 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 MILITARY USE ONLY 17 26 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing Front ENT d 2 mAT y ee J pr LU 8 AN l AN D a ee ee ji PATE Bie 2s 6 Lr
58. 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 in 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 MILITARY USE ONLY 2 24 PERIODIC MAINTENANCE TARY USE ONLY 7 Periodic Maintenance Procedures e Remove the timing inspection plug A Special Tool Filler Cap D
59. OThe procedure to bleed the brake line is as follows e Remove the reservoir cap A and fill the reservoir with new brake fluid e 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 thesfront master cylinder by this operation NOTE OStart with the rear master cylinder and finish with the front left or right caliper 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 on the rear master cylinder and run the other end of the hose into a container MILITARY USE ONLY 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 Tighte
60. 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 Adjustin Damp 9 ing Setting Load Road Speed Length Force 109 5 mm 4 311 in Weak Soft Light Good Low T T T T D T l l l L l l 127 5 mm 5 020 in 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 eRemove Rear Shock Absorber Mounting Bolts A and Nuts Reap Shock Absorber B MILITARY USE ONLY 13 18 SUSPENSION MILITARY USE ONLY 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 B C Grease Seals D Collars E New Nuts F Needle Bearing s 95 e Tighten Torque Rear Shock Absorber Mountin 1N04010BS2 C sorber Inspection t all bearing and grease seals in the u
61. Oknocking fuel poor quality or incorrect Obrake dragging DIclutch slipping Oengine overheating Hengine oil level too high Hengine oil viscosity too high DIother MILITARY USE ONLY IT USE ONLY FUEL SYSTEM DFI 3 27 DEI 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 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 Symptoms or Possible Causes Actions chapter Spark weak a M Ignition coil shorted or not in good co
62. Operate only in a well ventilated area e 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 c lculated as 20 km 13 mi per day or 1 1 hours More frequent inspection is necessary if the vehicle is subjected to hard usage A 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 or death Maintain ac cording to periodic maintenance chart e Remove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Bands A cut Air Outlet Duct B MILITARY USE ONLY MILITARY USE ONLYBERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Check the belt A for breaks x If necessary replace the belt e Push the drive belt A between the driven sheaves and check the belt position in the driven sheaves EN xIf the upper surface B of the drive belt is lower
63. 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 in the assembled state so the crankcase halves must be replaced as a set NOTE Be 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 result MILITARY USE ONLY 1 9 10 CRANKSHAFT TRANSMISSION USE ONLY 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 be
64. Starter Relay Installation 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 kk ELECTRICAL SYSTEM 16 49 1011025BS1 C MILITARY USE ONLY 16 50 ELECTRICAL SYSTEM MILITARY USE ONLY Electric Starter System Electric Starter Circuit BL BK W BL 1011027BW3 C lgnition Switch Neutral Position Switch Brake Light Switch Fuse Box Main Fuse 30A 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 Oc JO Om P ob A MILITARY USE ONLY MILITARY USE ONLY Electric Starter System e Take out the one way clutch A 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 Ib
65. Tie rod End Nut 19 6 2 0 14 R Shift Shaft Lever Bolt 13 5 1 4 10 Shift Shaft Gover Bolts 8 8 0 90 78 mb Shift Shaft Positioning Bolt 25 2 5 18 Neutral Position Switch 15 1 5 11 Reverse Position Switch 15 1 5 11 Shift Shaft Spring Bolt 25 2 5 18 LB Wheel Tires Front Axle Nuts 266 27 1 196 Front Wheel Nuts 110 11 2 81 S Rear Wheel Nuts 110 11 2 81 S Tie rod End Locknuts 44 4 5 32 Rear Axle Nuts 266 27 1 196 Final Drive Output Bevel Gears Rotor Mounting Bolts 12 1 2 106 in Ib Output Driven Bevel Gear Housing Bolts 26 2 7 19 Bevel Gear Bearing Holder Nut 200 20 4 148 LB MILITARY USE ONLY 2 8 PERIODIC MAINTENANCE MILITARY USE ONLY 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 Ee Bevel Gear Cover Bolt L 65 mm 8 8 0 90 78 in Ib cas Bevel Gear Cover Bolts L 20 mm 8 8 0 90 78 mb 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 Bolt 8 8 0 90 78 in Ib Front Final Gear Case Oil Filler Cap 29 30 21 Front Final Gear Case Oil Drain Plug 15 1 5 11 2WD 4WD Shift Cable Holder Bolts 8 8 0 90 78 in lb L 2WD 4WD Shift Shaft Cover Bolts 88 0 90 78 in lb L 2WD 4WD Shift Shaft Lever Nut 20 2 0 15 R Pinion Gear Bearing Holder Nut 200 20 4 148 LB Pinion Gear Bearing Hold
66. 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 N m 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 OThe front locknut has left hand threads OThe thread length B of the front and rear are almost same ODo 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 H does not scrub the ditch of guide excessively when the lever leaned to right side I 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 andthe 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 R 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 fe op hold nut Torque Grip Hold Nut lt 9 8 N m 1 0 kgf m 87 in Ib MILITARY USE ONLY v MILITARY USCRANIKCSHAFT TRANSMISSION 9 23 Transmission 1IT06005BW2 C
67. When a fast charge is inevitably requir d 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 hot 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 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 using 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 ey
68. and rotate the driven pul ley to allow the belt to return to the top A ofthe 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 Maintenance chapter Drive Belt Inspection e Refer to the Drive Belt Inspection in the Periodic Mainte nance chapter MILITARY USE ONLY 6 14 CONVERTER SYSTEM MILITARY USE ONLY 7 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 e 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 Hold
69. e Remove the cable tension adjusting tool e Confirm the 2WD 4WD shift shaft lever A return to 2WD position B AWD 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 Removakin the Frame chapter Vacuum Hose A 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 MILITARY USE ONLY 41 40 FINAL DRIVE MILITARY USE ONLY Front Final Gear Case e Remove Lower Hose A 2WD 4WD Vacuum Actuator Installation e Install Lower Hose e Install the 2WD 4WD vacuum actuator to the bracket and tighten the 2WD 4WD vacuum actuator mounting bolts Torque Vacuum Actuator Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install 2WD AWD Shift Cable see 2WD AWD Shift Cable In stallation e Install the duct A so that the projection B of thesduct inserts the groove of the rubber duct C e Install the removed parts 2WD 4WD Shift Cable Lubrication Whenever the 2WD AWDsshiftcable is removed lubricate the cable as follows e Apply a small amountof multi purpose grease to the cable both ends e Lubricate t
70. e Tighten Torque Tie rod End Nuts 41 5 N m 4 2 kgf m 31 ft Ib e Install New Cotter Pin E NOTE OWhen inserting the cotter pin 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 C 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 MILITARY USE ONLY 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 MILITARY USE ONLY 14 12 STEERING MILITARY USE ONLY Steering Knuckles Steering Knuckle Removal 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
71. e When replacing the ball bearing A install the new cir B C Grease Seals D Collars E New Nuts F Needle Bearing e Tighten Torque Rear Shock Absorber Mo Nu 95 5 N m 1N04001BS2 C k Absorber Inspection h the ball bearing and grease seals in the upper If they are damaged replace them Check the needle bearing and grease seals in the lower pivot xIf they are damaged replace them MILITARY USE ONLY 13 12 SUSPENSION MILITARY USE ONLY Shock Absorbers Other than 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 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 MILITARY USE ONLY MILITARY USE ONLY 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 tu
72. from possible sharp edges on the parts 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 foreignamaterials entering into sealed areas during ve hicledisassembly can cause excessive wear and decrease performance of the vehicle MILITARY USE ONLY U8 MILITARY USE ONLY GENERALI 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 ERE V oration or other damage Refer to the appropriate s ctions E of this manual for service limits on individual parts Replace Y WS A the parts if any damage has been found or if the partis be N yond its service limit a 6020098 S Replacement Parts Replacement Parts must be KAWASAKI genuine or x
73. 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 wremg B gx Special Tool Hexagon Wrench Hex 41 57001 Olf it is difficult to break free the holder apply tf to softer the locking agent e Remove Outer Ball Bearing A Special Tool Oil S g Remover B 57001 1058 xO ut Drive Bevel Gear Holder Nut er Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 MILITARY USE ONLY 41 16 FINAL DRIVE MILITARY USE ONLY 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 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 be holder nut A and tighten it so that the projection sid faces outward Special Tool Socket Wrench C 57001 148
74. 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 HK160035S2 C Lncorrect Tooth Contact Patterns 2 Bottom Heel Top e Drive Gear Bottom Toe Heel N Toe Top Bottom Driven Gear HK160036S2 C MILITARY USE ONLY 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 x Replace the bevel gears as a set if either gear is dam aged MILITARY USE ONLY 41 24 FINAL DRIVE MILITARY USE ONLY 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 foll parts Universal Joint of Front Final Gear Case Propeller Shaft Universa
75. prevent it front coming off e Install Front Fender Rear see Front Fender Rear Installation in the Frame chapter MILITARY USE ONLY 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 ft Ib 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 Nm 1 8 kgf m 13 ft lb e Bleed the brake line aftermaster cylinder installation 1 e Adjust the brake pedal play see Brake Pedal Play Inspec ee tion e Check that the brake line has proper fluid pressure and no fluid leakage Front Master Cylinder Disassembly Assembly e Refer to the Front Brake Master Cylinder Cup and Dust Seal Replacement in th
76. 0 10 20 30 40 2 5 L 2 6 US at 4 14 33 50 8 36 TOMC HU0O9002BS1 C When filter is removed 2 6 L 2 7 US qt hen 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 to accommodate atmospheric conditions in yo r riding area e Install Bottom Guard see Engine Bottom Guard Installation in the Frame chapter MILITARY USE ONLY 2 32 PERIODIC MAINTENANGE TARY USE ONLY 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 Ib OPour in the specified type and amount of oil e Install Engine Bottom Guard see Engine Bottom Guard Instal eed 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 replaceme
77. 052 mm 0 0006 0 0020 in Service Limit 0 14 mm 0 0055 in Camshaft Bearing Clearance 022 Standard 0 020 0 059 mm 0 0008 0 0023 in Service Limit 0 15 mm 0 0059 in xIf any clearance exceeds thelservice limit measure the diameter of the camshaft journal Camshaft Journal Diameter 18 Standard 17 966 17 984 mm 0 7073 0 7080 in Service Limit 1794 mm 0 706 in Camshaft Journal Diameter 22 Standard 21 959 gt 21 980 mm 0 8645 0 8654 in ServiceLimit 21 93 mm 0 863 in x If 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 NOTICE The cylinder head and rocker case are machined as a set and must be replaced as a set MILITARY USE ONLY ENGINE TOP END 5 21 5 22 ENGINE TOP END MILITARY USE ONLY 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 compre
78. 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 ssseeseeeseesseeesee 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 SO 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 Control EE 15 20 Right and Left Brackets Removal 15 49 Control Panel Removal 15 20 Right and Left Brackets Control Panel Installation 15 22 Installation ee 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 Models 15 23 Right Frame Pipe Installation 15 52 Cupholder Installation Left Cover Removal 15 52 KRF750P R S Models 15 26 Left Cover Installation 15 53 Fenders I ts acta eia tat 15 27 Windshield Removal KRF750P R Front Fender Front Removal 15 27 M
79. 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 Actuator B 2WD AWD Solenoid Valve C Fuel Pump and Fuel Level Sensor D Speed Sensor A MILITARY USE ONLY WU 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 H 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 iB Ji 1804001B 2 C MILITARY USE ONLY 16 6 ELECTRICAL SYSTEM MILITARY USE ONLY 7 Exploded View a 39 A RS O 1902042BW5 C MILITARY USE ONLY V8 MILITARY USE ONLY ELECTRICAL SYSTEM 16 7 Exploded View Torque No Fastener em kgf m ftlb 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 Ib 4 Starter Motor Through Bolts 5 0 0 51 44 in lb 5 Starter Motor Clutch Bolts 34 3 5 25 L 6 Left
80. 35 36 37 38 39 40 41 42 43 44 HC110518W2 C 1 ECU Electronic Control Unit 2 Throttle Sensor MILITARY USE ONLY WU USE ONLY FUEL SYSTEM DEI 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 N m 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 dir pressure sensor Special Tool Sensor Harness Adapter 57001 1561 e Connect a digital meter to the harness adapter leads Connections to Adapter Meter G W lead BR W lead of Main Harness Meter 4 BK lead BR BK lead of Main Harness e Measure the input voltage with the engine stopped and with theyconnectors
81. 4 5 22 Piston Ring Groove Width KACR Installation 2 5 23 Inspechon 5 41 Camshaft Chain Hemoval 5 23 Piston Ring Thickness Inspection 5 41 Camshaft Chain Installation 5 24 Piston Ring End Gap Inspection 5 42 Camshaft Chan Guide Wear Exhaust System 5 43 Inspection Zeie 5 27 Spark Arrester Cleaning 5 43 Cylinder Hea Z 9 5 28 Muffler and Exhaust Pipe Cylinder Compression Removal crater tes 5 43 Kiefer 5 28 Exhaust System Inspection 5 45 Cylinder Head Removal 5 29 Muffler and Exhaust Pipe Oylinder Head Installation 5 29 Installation a e 5 45 MILITARY USE ONLY 5 2 ENGINE TOP END MILITARY USE ONLY Exploded View 1E020248W85 C MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 3 Exploded View No Fastener Lorine Remarks N m kgf 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 in lb 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 i
82. 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 Ib 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 MILITARY USE ONLY 1N05007BS1 C 1NOS008BS1 C 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 NLGI 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 EO ge EC UNE MILITARY USE ONLY 13 26 SUSPENSION MILITARY USE ONLY S
83. 57001 1239 7T571239ST C Fork Oil Level Gauge 57001 1290 7571290ST C Vacuum Gauge 57001 1369 ey E 7571369ST C Hand Tester 57001 1394 T571394ST C Needle Adapter Set 57001 1457 T571457ST C Sensor Harness Adapter 57001 1561 ST571561ST Fuel Pressure Gauge Adapter 57001 1593 ST571593ST C Fuel Hose 57001 1607 7571607ST C MILITARY USE ONLY 3 18 FUEL SYSTEM DFI MILTARY USE ONLY Special Tools and Sealant Measuring Adapter Liquid Gasket TB1211 57001 1700 56019 120 ST571700ST T5601208T C MILITARY USE ONLY WITT 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
84. 78 mb S Converter Cover Drain Bolt 20 2 0 15 Joint Duct Bolts 8 8 0 90 78 mb Engine Lubrication System Oil Filter 17 5 1 8 13 R Oil 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 IHNEN 1 5 11 L T MILITARY USE ONLY BERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Torque Remarks N m kgf m ft Ib Oil Pump Cover Bolts 8 8 0 90 78 in Ib Chain Guide Bolt 8 8 0 90 78 in lb Oil Pump Drive Chain Tensioner Bolt 25 2 5 18 Oil Filter Mounting Bolt 25 2 5 18 L 15 mm Plate Bolts 8 8 0 90 78 in Ib Engine Removal Installation Engine Bracket Pipe Mounting Nuts 41 5 4 2 31 R Engine Mounting Bolt 60 1 6 1 44 Engine Mounting Nut 60 1 6 1 44 R Crankshaft Transmission Connecting Rod Big End Cap Nuts 34 3 3 5 25 MO Engine Oil Drain Plug 20 2 0 15 Crankcase Bolts M8 L 75 mm 2 95 in 20 2 0 15 S Crankcase Bolts M8 L 110 mm 4 33 in 20 2 0 15 S Crankcase Bolt M8 L 110 mm 4 33 in 20 2 0 15 S L 1 Crankcase Bolts M6 L 40 mm 1 57 in 9 8 1 0 87 in lb Crankcase Bolts M6 L 65 mm 2 56 in 9 8 1 0 87 in lb Bearing Position Plate Screws 4 9 0 50 43 in Ib Rear Cylinder Camshaft Chain Guide Bolt 20 2 0 15 Grip Hold Nut 9 8 1 0 87 in lb Tie rod End Locknut 19 6 2 0 14 Shift Lever Assembly Nut 19 6 2 0 14 R Tie rod End Bolt 9 8 1 0 87 in Ib Tie rod End Front Locknut 9 8 1 0 87 mb Lh Tie rod End Rear Locknut 9 8 1 0 87 in Ib
85. 8 8 0 90 T8 in Ib 11 Coolant Drain Plug Water Pump 7 0 0 74 62 in lb 12 Coolant Drain Plugs Cylinder 7 0 0 71 62 in lb 13 Coolant Air Bleed Bolt Water Pump 7 0 0 71 62 in Ib 14 Coolant Air Bleed Bolt Thermostat 7 8 0 80 69 in lb G Apply grease R Replacement Parts RL Apply rubber lubricant MILITARY USE ONLY 4 4 COOLING SYSTEM MILITARY USE ONLY Coolant Flow Chart Permanent type 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 C 212 F the radiator fan relay conducts to operate the radiator fan The radiator fan draws air through the radiator core when there isnot sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the temperature is below 90 C 194 F the fan relay opens and the r
86. A on the fuel tank xIf the dampers are damaged or deteriorated replace them e When 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 1C11011BS1 C e Check the mats A on the fuel tank xIf the mat is damaged or deteriorated replace it 1C11013BS1 C e Install Fuel Tank Bands A Fuel Tank Band Bolts4B 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 1C11010BS2 C MILITARY USE ONLY 7T MILITARY USE ONLY FUEL SYSTEM DEI 3 95 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 F F of the check valve 1C11005BS1 C 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 poi
87. Assembly e Do not remove the hub bolts A If 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 MILITARY USE ONLY 1K08000BS1 C MILITARY USE ONLY FINAL DRIVE 11 1 Final Drive Table of Contents leie e WEE 11 3 ellene de EE 11 10 Seer ccs 11 11 Quiput Bevel G6ars e ee E ee ri vt a itc teet retail lm 11 13 Output Drive Bevel Gear Removal E 11 13 Output Drive Bevel Gear Installaton ANERER 11 13 Output Drive Bevel Gear Disassembly Abbe ssa 11 14 Output Drive Bevel Gear Assembly eee NM A 11 16 Output Driven Bevel Gear Removal EE 11 16 Output Driven Bevel Gear Installatton EE 11 17 Output Driven Bevel Gear Disassembly A M uf e 11 17 Output Driven Bevel Gear Assembly BI OL 11 18 Output Bevel Gears Adjustment Akkuen TT 11 19 Bevel Gears Inspechon EE 11 23 Front Propeller haft AAA EE R o eeaeee eaea 11 24 Front Propeller Shaft Removal sss eem emnes 11 24 Front Propeller Shaft Installation 45 s semen 11 24 Front Propeller Shaft Inspection Front Axle iste tete tnlit erbe Front Axle Removal AA 098mm Front Axle Installation nenn A NB mmm mmm Front Axle Joint Boot Inspection Front Axle Joint Boot Replacement y ieee cec
88. Bolt C Joint D e Remove B njo Bolt A Washers and Brake Hose B 4811 P MILITARY USE ONLY 2 42 PERIODIC MAINTENANCE TARY USE ONLY 7 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 N m 2 4 kgf m 17 ft Ib 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 MILITARY USE ONLY MILITARY USE ONLYBERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Install New Brake Hose A Banjo Bolts B and New Washers OTouch the brake hose clasp C to the stopper D e Tighten Torque Brake Hose Banjo Bolts 23 5 N m 2 4 kgf m 17 ft Ib e Install Retainer E Brake Pipe F Nipple e Tighten Torque Brake Pipe Nipple 17 5 N m 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 1814005BS1 C Parking Brake Pedal Inspection e Push down the parking brake pedal A until it is stopped OThe vehicle should
89. Brake Disc x If the front hub seems too difficult to remove use the f l lowing special tools OMount the brake drum remover A onthe hub bolt with the remover nuts B and washers C parts in the remover set Special Tools Brake Dr m Remover 57001 1260 Brake Drum Remover Nut 57001 1326 OTighten the rotor puller TD 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 MILITARY USE ONLY MILITARY USE ONLY WHEELS TIRES 10 13 Front Hub Front Hub Installation e Install Brake Disc see Disc Installation 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 th pusher OTighten the hub pusher B until the pusher stops ORemove the brake drum pusher and spacer Special Tool Brake Drum Pusher amp Washet 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 N m 27 1 kgf
90. C Rear Master Cylinder Installation e Apply specified oil to the rod end A e Apply grease to the O ring B e Install Heart 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 N m 2 8 kgf m 20 ft Ib Brake Pipe Nipple 17 5 N m 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 MILITARY USE ONLY 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 If the cylinder or piston shows any damage replace them e Inspect the cup C xIf a cup is worn damaged softened rotted or swollen replace it x If fluid leakage is noted at the push rod D the cup of the piston should be replaced e Check the boot E for damage xIf it is damaged replace it e Check the piston return springs F for any damage xIf the spring is damaged
91. C ST5714158T C Flywheel Holder Needle Adapter Set 57001 1313 5700121457 T571313ST C T571457ST C Hand Tester Drive Pulley Holder 57001 1394 57001 1620 7571394ST C T5716208T MILITARY USE ONLY 16 14 ELECTRICAL SYSTEM MILITARY USE ONLY Wiring Diagram Inlet Air Inlet Air Temperature Pressure Sensor Sensor Y BR BK BR W BR BK Ed Throttle Sensor Fuel Fuel Injector Injector 2 ges S m 83 Ss ZS Radiator BL BL R Fan Motor ox 7 2WD 4WD Shift Switch o BK Y BK Y o D D AWD Position Switch a 3 Parking Brake Reverse Brake Light Position Speed Position Switch Switeh Sensor Switch M gt Neutral i ez 36 Mes Ed S a Position 5 eg Switch Radiator Fan Breaker Frame 12A Ground 1 5555 77 ux oe EEEG AE a NICI TI Headlight Left Headlight Right PESTE 12V35 35W R Y R Y R Y BK Y BK Y BK Y G R a R l 8L BL LG L D D n H o Multifunction P P Meter w a LO R R D Y BR BR BL R BL R BK Y BK Y R Y R Y 8 8 R BK R BK R BK R Y R Y R Y BK Y BK Y BK Y 12V35 35W Accessory Connector 12V120W Power Outlet pe BR SC eR BK Y d jeJ eK Y LIGHTING SWITCH CONNECTIONS Color R BK R Y OFF a BK Y Ignition weak sa BK W Sr D D ay av E t Lighti Switch
92. CONNECTIONS punia 12V14Ah Engine Color IA EE BK W urp s US Model Ground R Red Starter e ON V Violet Motor Other than US Model White stare Beams Y Yellow BEEN W2RO482CH5 C MILITARY USE ONLY 16 16 ELECTRICAL SYSTEM MILITARY USE ONLY 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 check 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 dete
93. Case Bolts L 30 mm 1 2 in 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 mb Valve Adjusting Screw Locknuts 12 1 2 106 in Ib Rocker Shaft Bolts 22 2 2 16 Rear Rocker Case Clamp Bolt 8 8 0 90 78 in Ib Camshaft Sprocket Bolts 12 1 2 106 inb L Chain Tensioner Cap Bolts 22 2 2 16 Chain Tensioner Mounting Bolts 8 8 0 90 48 in Ib Front Cylinder Camshaft Chain Guide Bolt 20 2 0 15 Position Plate Bolts 8 8 0 90 78 in Ib Intermediate Shaft Chain Guide Bolts 8 8 0 90 78 in lb Intermediate Shaft Chain Tensioner Bolts 8 8 0 90 78 mb Rear Cylinder Camshaft Chain Guide Bolt 20 2 0 15 Cylinder Bolts L 30 mm 1 2 in 9 8 1 0 87 in lb Cylinder Bolts L 40 mm 1 6 in 9 8 1 0 87 in Ib Coolant Drain Plugs Cylinder 7 0 0 71 62 in Ib 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 ml Ramp Weight Nuts 7 0 0 71 62 in Ib R 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 mb Converter Cover Bolts 8 8 0 90
94. 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 Wiring Diagram Ignition Switch CO 1 2 5 Red t p Lgi Coach 1 14 2 VII ick DC Ca Oranga LAT M d f Yellow T Ground j d t Ki Blue E Ground GND i a el Oo Engine Brake Actuator Vacant Teqrilpai Senso sor Pulse AEN j Signal UJ e o PN Vacant Terminal 5 LA fan el N2 du Vacant Terminal Forward Reverse cting Senor dh ow e 4 j o dMicant Terminal Vacant Terminal Vacant Terminal controller Note The circled figures indicato the pin layout of the controller 10200006 Engine Brake Actuator Inspection e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Actuator Lead Connector A MILITARY USE ONLY 77 MILITARY USE ONLY ELECTRICAL SYSTEM 16 69 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 KQ 2 Yellow 3 Blue 630 5 330 Q xIf any reading is not within
95. 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 se 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 If 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 bigend arbor A still on the V block C hold the connecting rodyhorizontally and measure the amount that the arbor B varies from being parallel with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist
96. E m Rear View Inside of Seat Lower Cover G e Stick the insulator E so that the press line matches the corner H IP13013BS3 C MILITARY USE ONLY MILITARY USE ONLY 15 48 FRAME Covers e Install A Seat Lower Cover A Quick Rivets B Collar C L 4 mm 0 16 in Screw D L 16 mm 0 63 in A chy 4 a VAC W Ai N Kai Sa e Seat Lower Right Plate Removal e Remove Seat Lower Cover see Seat Lower Cover Removal Bolts A and Brackets Bolts B Seat 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 MILITARY USE ONLY 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 I Olnstall the clamp in the right angle direction
97. 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 0907 78inb EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum dislfide grease R Replacement Parts MILITARY USE ONLY MILITARY USE ONLY 16 8 ELECTRICAL SYSTEM Exploded View MILITARY USE ONLY V7 MILITARY USE ONLY ELECTRICAL SYSTEM 16 9 Exploded View Torque No Fastener Nm kaim ftlb Remarks 1 Ignition Coil Mounting Bolts 5 9 0 60 52 in Ib 2 Spark Plugs 13 1 3 115 in lb 3 Vacuum Actuator Bracket Bolts 8 8 0 90 78 inb 4 Solenoid Valve Bracket Bolts 8 8 0 90 78 inb 5 ECU Mounting Bolts 6 9 0 70 61 in lb 6 Engine Brake Actuator Mounting Bolts 8 8 0 90 78 inb S 7 Engine Brake Actuator Cover Bolt 8 8 0 90 78 in Ib S 8 Forward Reverse Detecting Sensor Mounting 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 4 5 11 4WD Position Switch 2WD 4WD Solenoid Valve Lighting Switch Ignition Switch 2WD 4WD Shift Switch Acces
98. 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 ft lb Front Final Gear Case Mounting Nuts 90 5 N m 9 2 kgf m 67 ft lb e Install Breather Hose 2WD AWD Shift Cable End see 2WD AWD 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 AWD Shift Cable Holder Bolts 8 8 N m 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 MILITARY USE ONLY 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 N m 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 F
99. Front Master Cylinder Mounting Bolts Master Cylinder Push Rod Clevis Pin Clip Rear Master Oylinder 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 MILITARY USE ONLY 2 52 PERIODIC MAINTENAN CE ILTARY USE ONLY 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 MILITARY USE ONLY U8 MILITARY USE ONLY FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents Exploded EE 3 4 DEI Kn EE 3 8 DEI Parts Location wisn oie t aa e a dari Sg ee ANE 3 13 Specifications 5 rte ERT vg 3215 Special Tools and Sealant iste e e a e ee E Ee e ER e e dece 3 17 DFI Servicing Precautions Akku atl m H 3 19 DFI Reie ee EE EE AARC oes 3 19 Troubleshooting the DFI System eese es MQ A 3 21 eiu EE nr dE 3 21 Inquiries to Rider ea hee 3 24 DFI System Troubleshooting Guide Me ff AN e cece eee 3 27 Ee Ile CEET TIT IT TT 3 31 Self diagnosis Outline
100. Gap Inspection e Measure the gap A with a wire type thickness gauge xIf 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 GP100108S1 C 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 xIf it does not as specified adjust the brake light timing Brake Light Timing Standard On after about 10 mm 0 4 in of pedal travel A MILITARY USE ONLY 2 48 PERIODIC MAINTENANCE TARY USE ONLY 7 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 Fina
101. Inlet Air Pressure Sensor Mounting Screw C 5 0 N m 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 in the Frame chapter the Frame chapter e Check idle speed see Idle Speed Inspecti of the vac uum gauge Special Tool Vacuum Gauge 57 S e Rem eet and connect the hose B co gauge C e and read the intake vacuum when idling sein out of the specified range check the ISC e ISC Valve Inspection e Remove the plug A and connect the hose 0 Vacuum Synchronization Adjustment ngine Vacuum Standard 29 6 1 3 kPa 222 9 8 mmHg at Idle Speed MILITARY USE ONLY Um USE ONLY FUEL SYSTEM DFI 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 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 lf 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
102. JASO MA MA1 or MA2 SAE 10W 40 0 7 L 0 74 US qt MOBIL FLUID 424 CITGO TRANSGARD TRACTOR HYDRAULIC FLUID EXXON HYDRAUL 560 1 00 L 1 06 US qt MILITARY USE ONLY General Specifications VY MILITARY USE ONLY ENERAL INFORMATION 1 13 Items KRF750NAF PAF RAF SAF TAF Frame Type Steel tube Ladder Caster Rake Angle 2 2 Camber Front 0 7 Rear 0 4 King Pin Angle 11 4 Trail 11 mm 0 43 in Tire Front Type Tubeless Size 26 x 8 00 12 Rear Type Tubeless Size 26 x 10 00 12 Rim Size Front 12 x 6 0AT Rear 12 x 8 0AT Steering Type Rack and pinion Suspension Front Type Double Wishbone Wheel Travel 190 mm 7 48 in Rear Type Double Wishbone Wheel Travel 190 mm 7 48 in Brake Type Front Disc x 2 Rear Enclosed wet multi plate Parking Brake Type Electrical Equipment Battery Headlight Type Bulb Brake Tail Light Alternator Type Max Output Enclosed wet multi plate US 12 V 14 Ah CA 12 V 12 Ah Semi sealed beam 12 V 35 35 W x 2 12 V 27 8 W x2 Three phase AC 24 A 14 V MILITARY USE ONLY 1 14 GENERAL INFORMATION MILITARY USE ONLY General Specifications Items KRF750NAF PAF RAF SAF TAF Load Capacity Maximum Vehicle Load Including Occupants and Cargo Maximum Cargo Bed Load 422 kg 931 Ib 227 kg 500 Ib Specifications subject to change without notice and may not apply to every country
103. L Ignition Coil Mounting Bolts 5 9 0 60 52 mb Spark Plugs 13 1 3 115 in Ib Vacuum Actuator Bracket Bolts 8 8 0 90 78 in lb Solenoid Valve Bracket Bolts 8 8 0 90 78 in lb ECU Mounting Bolts 6 9 0 70 61 in Ib 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 Forward Reverse Detecting Sensor Mounting Bolt 14 9 1 5 11 Speed Sensor Mounting Bolt 8 8 0 90 78 mb MILITARY USE ONLY MILITARY USE ONLYBERIODIC MAINTENANCE 2 11 Torque and Locking Agent Torque Fastener Nem kgfm ftlb 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 Ib Radiator Fan Assembly Bolts 8 3 0 85 73 mb Oil Pressure Switch 15 1 5 11 SS Battery Holder Mounting Nuts 16 1 6 12 Regulator Rectifier Mounting Bolts 8 8 0 90 78 in lb MILITARY USE ONLY 2 12 PERIODIC MAINTENANCE TARY USE ONLY 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 MILITARY USE ONLY Threads dia
104. L 5 Rear Final Gear Case Gasket Screws 1 3 0 13 12 in Ib 6 Pinion Gear Bearing Holder 450 45 9 332 L 1 Pinion Gear Bearing Holder Nut 200 20 4 148 LB 8 Rear Final Gear Case Oil Drain Plug 15 1 5 11 10 Rear Final Gear Case Right Cover Bolts M10 36 L T sq 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 MILITARY USE ONLY 11 10 FINAL DRIVE MILITARY USE ONLY 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 EE at output drive shaft spline API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 Filler opening bottom 0 7 L 0 74 US qt 20 051 mm 0 7894 in 20 000 20 021 mm 0 7874 0 7882 in 300 N m 31 kgf m 221 ft lb or more 0 08 0 16 mm 0 003 0 006 in at pinion gear spline MOBIL FLUID 424 CITG
105. Meter OThe 4WD indicator Symbol LCD A should appear xIf the display function does not work replace the meter unit Check 9 Fuel Level Gauge Check e Connect the wires in the same manner as Check 1 OThe first segment LCD A should flash xIt 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 ini 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 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 OThe reverse indicator light LED A should go on Alf the LED light does not go on replace the meter unit ELECTRICAL SYSTEM 16 63 B AWD 2WD SR 0 000 E 1019027BS1 C 1019028BS1 C HBE a TT 0919044881 C MILITARY USE ONLY 16 64 ELECTRICAL SYSTEM MILITARY USE ONLY 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 light LED A should go on x If 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
106. Mounting Bolts 34 3 N m 3 5 kgf m 25 ft lb Vacuum Actuator Bracket Bolts 8 8 N m 0 90 kgf m 78 in Ib Solenoid Valve Bracket Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the removed parts Left Cover Removal e Remove e 4 Seat Lower Cover see Seat Lower Cover Removal Left Bracket see Right and Left Brackets Removal Battery see Battery Removal in the Electrical System chapter Weg u Vehicle down Sensor A see Vehicle down Sensor Re moval in the Fuel System DEI chapter ly Quick Rivet B and Cover C Dd Tapping Screws D and Collars Electric Parts Case E A e Remove aF Bolts A B Battery MountingyPlate B MILITARY USE ONLY 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
107. 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 Brake Internal Wet Brake Disassembly Internal Wet Brake Assembly MILITARY USE ONLY 12 15 12 17 12 17 12 18 12 18 12 18 12 19 12 19 12 19 12 2 BRAKES MILITARY USE ONLY Exploded View MILITARY USE ONLY MILITARY USE ONLY BRAKES 12 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Front Master Cylinder Reservoir Cap 3 4 0 35 30 in Ib 2 Reservoir Clamp Bolt 6 2 0 63 55 in lb 3 Piston Stop Bolt 8 8 0 90 78 in Ib 4 Brake Pipe Nipples 17 5 1 8 13 5 Brake Hose Banjo Bolts 23 5 2 4 17 6 Front Master Cylinder Mounting Bolts 23 5 2 4 17 7 Master Cylinder Bolt 23 5 24 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 in Ib Brake Hose Clamp Bolts 8 8 78 in Ib 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
108. Pulley Disas sembly in the Converter System chapter x If 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 x lf the adjustment cannot be done within the specified range even if the shim is removed replace the drive belt x If 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 OWhen 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 in 92026 1565 1 0 mm 0 039 in 92026 1570 1 A 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 t the top of the sheaves before measuring the belt deflection e Measure the belt deflection again and repeat the above procedures until itis within the standard range e Using the flywheel amp pulley holder and pulley holder at tachment tighten the n w driven pulley nut Special Tools Flywheel amp Pulley Holder 57001 1
109. 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 4A 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 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 MILITARY USE ONLY 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 It also precedes the text of a NOTE x 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 the
110. 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 HP10039B51 C BR Lead Terminal B Black Rear Side BL W Lead Terminal A Green BR Lead Terminal B Black MILITARY USE ONLY 16 38 ELECTRICAL SYSTEM MILITARY USE ONLY 7 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 If the distance reading is less than the specified value the ignition coil or spark plug cap is defective e To determine 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 HP10040
111. Service Code 12 76 80 90 cmHg Ps l l L L 101 32 120 kPa Ps Set Pv abs HC110388W4 C ID Idling Ps Standard Atmospheric Pressure Absolute Py 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 MILITARY USE ONLY 3 46 FUEL SYSTEM DFI MILITARY USE ONLY Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Circuit Q gt N e 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 EA 2 gt e BR W BR BK G Y HC110528W2 C 1 ECU Electronic Control Unit 2 Inlet Air Pressure Sensor MILITARY USE ONLY UUOMUTARYUSEONLY 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 ICH P Inlet Air Temperature Sensor Output Voltage
112. Service Code 14 3 50 Water Temperature Sensor HRemoval neret 3 50 Water Temperature Sensor Installaton ene 3 50 Water Temperature Sensor Output Voltage Inspechon 3 51 Water Temperature Sensor Resistance JInspechon nt 3 52 CNksnhart Sensor Service Code 2 1 ui eee ut Sonore qu de ert gm Ludis sedo 3 53 Crankshaft Sensor Removal lnstallatton esses 3 53 Crankshaft Sensor Inspection neis 3 53 Speed Sensor Service Code 24 esses inen seen nennen nannte nnn h ada ana n in nnecn 3 54 Speed Sensor Removal nennen nnne nennen nennen senes n esr asida 3 54 Speed Sensor Installation nnne nnnn nnns 3 54 Speed Sensor Input Voltage Inspection ssseeeereesrrrrrtrrrrrrrrrrrrrrrrrrrrrrtrrrrrrrrrrrrrrerrrn 3 54 Speed Sensor Output Voltage Inspection 3 54 Vehicle down Sensor Service Code 31 cceccceeccneteeeneeeeeeeeeeeeeeeeeseessneebeceeeeteesseceenneeeeeene 3 56 Vehicle down Sensor Remowval sse eene nennen 3 56 Vehicle down Sensor Installation sse 3 56 Vehicle down Sensor Input Voltage Inspechon eneen nennen nren n rennene 3 56 Vehicle down Sensor Output Voktagiertrrggealiep ONLY 55 3 57 3 2 FUEL SYSTEM DFI MILITARY USE ONLY 77 Fuel Pump Relay Service Code 46 aoreet reticere aei pe EE e Uo bee d eee Fuel Pump Relay Removal rre ER pareri totae aed dek dee REESEN r b edad Fuel Pump Relay Inspection senem Igniti
113. 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 spring holder Special Tool Spring Holder Set 57001 1483 e Remove the circlip A with circlip pliers B Special Tool Outside Circlip Pliers 57 144 e Remove the nut and spring A x The spring seat A OThen tap th ring S y Not lift even if the nut B loosens t with a plastic mallet C lightly to MILITARY USE ONLY Ip P T MILITARY USE ONLY CONVERTER SYSTEM 6 23 Driven Pulley e Remove Spring 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 driver B e Remove the movable sheave from the fixed sheave e Remove Spacer s A for SS ection Adjustment x fei ey Inspection t heave surfaces A appear damaged replace the aves MILITARY USE ONLY 6 24 CONVERTER SYSTEM MILITARY USE ONLY Driven Pulley e Replace the sheave with uneven wear on the belt con tacting surfaces A Sheave Surface B Straight Edge x If the sheave bushings A are damaged or worn replace the movable sh
114. Sun Top Cover MILITARY USE ONLY 15 16 FRAME MILITARY USE ONLY 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 n IA into the seat lock OThe seat lock clicks AA WARNING in B as shown in the figure W Washers C e Nut D New Self Lock Nut E ee Seat Removal late Bolts A Seat Plate B Dampers C MILITARY USE ONLY 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 MILITARY USE ONLY 15 18 FRAME MILITARY USE ONLY 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 N m 0 90 kgf m 78 in Ib IP03007BS2 C Seat Belt Removal e Open the cover A e Remove Seat Belt
115. USE ONLY 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 xIf the backlash is not within the limit replace the shim s at the driven bevel gear x Change the thickness a 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 Correct Tooth Contact Patterns No adjustment is required Tooth Contact Adjustment OTooth contact location is influenced by drive gear position more than by driven gear position e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the output driven bevel gear Bottom Toe Bottom Toe Drive Gear Bottom Heel NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brushs If painted too thickly the exact tooth pattern may no appear OThe checking compound must
116. USE ONLY 15 46 FRAME MILITARY USE ONLY 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 4 mm 0 16 in Screws D M6 L 16 mm 0 63 in Collars E L 7 2 mm 0 28 in b a Screws F M6 L 22 mm 0 87 in Guard G aa Screws H M5 aa e Install the left side cover according to the same procedure as the right side cover 1 e Install Pw Fuel Tank Cap Right Side IP13003BS2 C Seat Lower Cover Removal e Remove Engine Upper Cover see Engine Upper Cover Re moval Center Cover see Center Cover Removal Screw A and Collar MILITARY USE ONLY NK ER 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 P ODo 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 lt Insulator D P No 1607340121 Insulator E P No 16073 0122 Standard Line to Stick F Frame
117. 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 If the output voltage is within the usable range 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 lf the output voltage is out of the usable range check the wiring for continuity see Inlet Air Pressure Sensor Circuit MILITARY USE ONLY MILITARY USE ONLY 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 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 If the output voltage for various vacuum is normal check
118. V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 00 4 75 5 00 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 Alf the output voltage is out of the standard inspect the throttle sensor resistance see Throttle Sensor Resis tance Inspection x If 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 MILITARY USE ONLY 3 40 FUEL SYSTEM DFI MILITARY USE ONLY 77 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 e Measure the throttle sensor resistance Throttle Sensor Resitance Standard 4 6kQ x If the reading is out of the range replace the throttle body assy x lf the reading is within the range but the problem still exists replace the ECU see ECU Removal Installation Throttle Sensor Circuit D 1 2 3 4 5 6 7 8 9 10 ii 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
119. 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 n 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 fuel in the fuel tank If the fuel pump is driven without the fuel itmay 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 MILITARY USE ONLY 3 74 FUEL SYSTEM DFI MEITARY USE ONEY Fuel Line NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications e Turn the ignition s
120. and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals MILITARY USE ONLY 3 20 FUEL SYSTEM DFI MILITARY USE ONLY 77 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 MILITARY USE ONLY U8 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 1Q19047BS1 C With the engine stopped and turned in the self diagnosis e 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 AX 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 The non self diagnosis items are not indicated by the Fl indicator symbol LCD Do not rely solely on the DFI self diagnosis function us common sense 1015048BS1 C 1015049BS1 C Even when the DFI system is operating normally the FI indic
121. 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 If the 2WD AWD solenoid valve does not work replace it 1822003B 2 C MILITARY USE ONLY 16 74 ELECTRICAL SYSTEM MILITARY USE ONLY 2WD 4WD Solenoid Valve eq P X Jo AND Q 0 BK Y r BK Y 2WD o a G A BR BR o D 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 SE EEGEN MILITARY USE ONLY 7T 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 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Q Criteria When battery is connected gt 0 Q 1023000BS1 C When battery is disconnected gt O Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 MILITARY USE ONLY 16 76 ELECTRICAL SYSTEM MILITARY USE ONLY 77 Switches an
122. collar K and clamp TQ 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 R 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 first wide 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 N m 1 7 kgf m 13 ft Ib e Push th muffler to front and then confirm that the gasket entered int the muffler e Tighten the muffler clamp bolts Z in the direction of the figur Torque Muffler Clamp Bolts 15 N m 1 5 kgf m 11 ft lb e Tighten Torque Muffler Mounting Bolts 28 N m 2 9 kgf m 21 ft Ib 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 MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 47 Exhaust System Detail a CO out CN S EL e A LS H d A 1E110058W4 C MILITARY USE ONLY 7 MILITARY USE ONLY CONVERTER SYSTEM 6 1 Converter System Table of Contents Exploded E 6 2 een
123. disassembled and itanust be inspected in the assembled state GG08060281 C x If the valve movement is not smooth wash he relief valve with high flash point solvent and use compressed air to remove any foreign particles from it AWARNING Gasoline and low flash point 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 itreplace the relief valve The oil pressure relief valve is precision made with no allowance for replacement of individual parts MILITARY USE ONLY UT MILITARY URINE 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 Oil 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 am Oil Pump Dri
124. 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 C 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 NN 1L04059BS2 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 2 0 08 in D 40 mm 1 57 in E Cap F Differential Shift Cable Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter e Loosen the locknut A MILITARY USE ONLY 41 36 FINAL DRIVE MILITARY USE ONLY 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 A WARNING Operation with an improperly adjusted incorrectly routed or damaged cables could result in an un safe riding Conditi
125. 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 life out ofyyour 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 ual 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 products 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
126. fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease MILITARY USE ONLY 12 4 BRAKES MILITARY USE ONLY Exploded View MILITARY USE ONLY 1M020438W5 C MILITARY USE ONLY BRAKES 12 5 Exploded View No Fastener Torgus Remarks N m kgf m ft Ib 1 Brake Hose Banjo Bolts 23 5 24 17 2 Brake Pipe Nipples 17 5 1 8 13 3 Rear Master Cylinder Bleed Valve 7 8 0 80 69 in Ib 4 Rear Master Cylinder Mounting Bolts 27 2 8 20 L 5 Rear 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 in Ib 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 MILITARY USE ONLY 12 6 BRAKES MILITARY USE ONLY Specifications Item Brake Fluid Type Fluid Level Brake Pedal Brake Pedal Play Front Disc Brake Pad Lining Thickness Disc Thickness Disc Runout Standard DOT3 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 MILITARY USE ONLY Service Limit 1 mm 0 04 in 4 3 mm 0 17 in
127. gears MILITARY USE ONLY 41 62 FINAL DRIVE MILITARY USE ONLY 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 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 If the tooth contact pattern is incorrect replace the pinion e 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 Olf the backlash is out of the standard rang changing the pinion gear shim s change the ring ge shim s to correct the backlash before checking the tooth contact pattern NOTE MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 63 Front Final Gear Case Correct Tooth Contact Pattern No adjustment is required Heel Si Bott om C Bottom Bottom Pinion Gedr Incorrect Tooth Contact Patterns Example 1 Decre
128. grommet for the one of crank alternator cove leads first and then install leads to the notch of the Regulator Recti Output Voltage Inspection see Seat Removal in the Frame hapter ck the ry condition see Battery section up the engine to obtain actual alternator operating ditions MILITARY USE ONLY 16 32 ELECTRICAL SYSTEM MILITARY USE ONLY Charging 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 15V e Turn off the ignition switch and disconnect the hand tester x If 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 alter
129. is damaged or worn replace it Sheave Bushing Inside Diameter A Standard 37 985 38 085 mm 1 4955 1 4994 in Service Limit 38 12 mm 1 501 in x lf the spider shoes A are damaged replace them e Check the spider shoe side clearance see Spider Side Clearance Inspection xIf the ramp weights A in the aged or worn replace them x lf the pins B are damag x If the washers C are damaged or worn replace the spi MILITARY USE ONLY WITT USE ONLY CONVERTER SYSTEM 6 17 Drive Pulley xIf 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 141 e Temporarily install the following parts on the vable sheave Dowel Pins 2 Drive Pulley Cover B Two Bolts C at dowel pins ODo not install the spring MILITARY USE ONLY 6 18 CONVERTER SYSTEM MILITARY USE ONLY 77 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 M
130. 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 ODo not spray water on the electrical parts DFI parts con nectors leads and wiring OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch anddisconnect the battery terminal Do not pull the lead only the con nector Conversely make sure that all the DEL electrical connections are firmly reconnected before starting the en gine OConnect these connectors until theyclick A 617036881 C Olf a transceiver is installed on the vehicle make sure that the operation of the DEI system is not influenced by elec tric wave radiated from the antenna Check operation of the system with the engine atidle 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 ignition 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
131. joined e urn 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 xIf the reading is less than the standard check the wiring for continuity see Inlet Air Pressure 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 MILITARY USE ONLY 3 42 FUEL SYSTEM DFI MILITARY USE ONLY Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Output Voltage Inspection NOTE OThe 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 e Connect a digital meter to the harness adapter leads Connections to Adapter Meter G lead G Y lead of Main Harness Meter CH 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
132. m 0 90 kgf m 78 in Ib 1011021BS1 C e Fit the projection A of the air inlet duct into the groove B of the rubber duct and tighten the Q P e Qu ud he armature A out of the yoke B NOTE not remove the circlip C from the shaft Lal ir P MILITARY USE ONLY 16 46 ELECTRICAL SYSTEM MILITARY USE ONLY Electric Starter System e Remove Starter Motor Terminal Locknut A Washer B Collar C 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 bo of the end cover D e Install the negative brush assy e Tighten the screw C securely e Install the positive brush e Install the starter moto brush holder B brush holder the O ring A with a new one llowing parts to the starter motor terminal B her D tarter Motor Terminal Locknut E Olnstall the collar so that stepped side faces outward e Tighten Torque Starter Motor Terminal Locknut 11 N m 1 1 GP11104BS1 C kgf m 97 in Ib MILITARY USE ONLY 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 oi
133. mm 0 047 in MILITARY USE ONLY 11 60 FINAL DRIVE MILITARY USE ONLY 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 Robi Cover e Assemble the front final gear 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 a non permanent locking agent is not used OUse the following twoSpare bolts when installing the front final gear cas center cover A M10 Bolt B L 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 MILITARY USE ONLY 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 b
134. mm 0 08 0 39 in Steering 0 20 mmm 0 79 in Electrical System Spark Plug Gap Rear Brake Light Switch Timing 0 7 0 8 mm 0 028 0 031 in ON after 10 mm 0 4 in of pedal travel MILITARY USE ONLY 77 MILITARY USE ONLYBERIODIC MAINTENANCE 2 15 Special Tools Inside Circlip Pliers Pulley Holder Attachment 57001 143 57001 1472 7570143ST C ST57T1472ST C Valve Adjuster Flywheel amp Pulley Holder 57001 1232 57001 1605 8757123297 7571605ST C Oil Filter Wrench Belt Deflection Gauge 57001 1249 5700121713 T571249ST C T5717138T Filler Cap Driver 57001 1454 7571454ST C MILITARY USE ONLY 2 16 PERIODIC MAINTENANGE TARY USE ONLY 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 xIf 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 u
135. not roll while parked e Pull the parking release lever B above andereturn the pedal to its rest position x If the pedal does not work correctly adjust it SeeParking Brake Cable Installation in the Brakes chapter A WARNING Insufficient free play can cause brake heating and drag resulting in skidding nd 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 MILITARY USE ONLY 2 44 PERIODIC MAINTENANGE TARY USE ONLY 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 A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston
136. of the knuckle B and shank of the knuckle joint or the tapers will not fit snugly P e Install Knuckle A Washers B and Nuts Olnstall the washer as shown in the fig re 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 MILITARY USE ONLY 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 1807000BS1 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 Knuckle Removal Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Drive the bearing A out using a 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 MILITARY USE ONLY MILITARY USE ONLY FRAME 15
137. on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 8 volts repeat charging cycle MILITARY USE ONLY 08 MILITARY USE ONLY ELECTRICAL SYSTEM 16 23 Battery e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery NOTICE Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery GPO90005S1 C NOTE 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 volts repeat the charging cycle and load test If still below 12 8 volts 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 orlamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge
138. pumpdmpeller by turning the bolt clock wise Torque Water Pump Impeller 7 8 N m 0 80 kgf m 69 in Ib MILITARY USE ONLY 17 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 A Y Reserve Tank Hose A s t Water Hose B d e Remove l fa gt Radiator Bolts ai pmo NOTICE Do nottouch the radiator core This could damage the radiator fins resulting in loss of cooling effi MILITARY USE ONLY 4 14 COOLING SYSTEM MILITARY USE ONLY Radiator Radiator Installation e Install Dampers A Collars B e Tighten Torque Radiator Mounting Bolts C 8 8 N m 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 M
139. 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 milf according to local regulations is correctly displayed before riding 1019051BS1 C t the display function does not work and adjust replace theymeter unit MILITARY USE ONLY 7T 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 5V 959 OV Duty 50425 1019023BS2 C 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 e Raise the input frequency of the oscillator to see the result B ODD of this inspection OUT 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 Con
140. relief valve must open within the relief pressure range in the table below and the gauge hand must remain within the specified range at least 6 second Radiator Cap Relief Pressure Standard 934 123 kPa 0 95 1 25 kgf cm 13 18 psi x lf the cap cannot hold the specified pressure or if it holds too much pressure replace it with a new one MILITARY USE ONLY COOLING SYSTEM 4 15 6GD07010481 C GD07000BS1 C GD07001BS1 C 4 16 COOLING SYSTEM MILITARY USE ONLY 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 accuratethermometer B in a container of water with the heat
141. replace it MILITARY USE ONLY BRAKES 12 13 1M0500i1BS1 C 12 14 BRAKES MILITARY USE ONLY 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 e Tighten Torque Brake Caliper Mounting Bolts 33 N m 3 4 kgfm 25 ft lb Brake Hose Banjo Bolt 23 5 N m 2 4 kgfm 17 ft lb 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 A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could resul
142. the ECU for its ground and power supply see ECU Power Supply Inspection e Check the output voltage using th following formula and chart MILITARY USE ONLY FUEL SYSTEM DFI 3 43 GC1I7119BS2 C 3 44 FUEL SYSTEM DFI MILITARY SEIT 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 PI 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 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal x If the reading is out of the usable range replace the sen Sor xIf the reading is within the usable range check the ECU for its ground and power supply see ECU Power S pply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DFI 3 45 Inlet Air Pressure Sensor
143. 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 MILITARY USE ONLY 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 OThe direction of the tire rotation B is shown by an arrow on the tire sidewall e Install the tire on the rim using a 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 si
144. the electrolyte flow xIf no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation GPO90008S1 Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery e Let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 60 minutes after filling Initial Charge e Place the strip A of caps loosely over the filler ports e Newly activated sealed batteries require an initial charge Standard Charge 1 2 A x 5 10 hours xIf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate Ill GPOS018BS1 C Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 xIf the above chargers are not available use equivalent one NOTE OCharging rates will vary depending
145. 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 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 repeat from to 5 V x If the reading is not standard check the wiring x If the wiring is good check the speed sensor see Speed Sensor Inspection MILITARY USE ONLY HP23001BS1 C HP23003BS1 C 16 70 ELECTRICAL SYSTEM MILITARY USE ONLY 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 HP23002BS1 0 Tester Connector BR Terminal 9 Tester Connector BK Y Terminal 10 Olnstall the needle adapters on the tester leads Special Tools Hand Tester 57001 13
146. the witingis good check the ECU for its ground and powefisupply See ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation MILITARY USE ONLY WU 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 confirmethe output voltage will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5
147. 001 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 h b 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 MILITARY USE ONLY 10 16 WHEELS TIRES MILITARY USE ONLY 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 N m 27 1 kgfm 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
148. 003BS1 C Coolant Change A WARNING Coolant can be extremely hot and cause severe 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 MILITARY USE ONLY MILITARY USE ONCYBERIODIC 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 re
149. 1 1100 57001 1539 4 ST5711008T C T5715398T C Hook Wrench R37 5 R42 Knuckle Joint Driver 57001 1101 57001 1640 ST571101ST C ST571640ST MILITARY USE ONLY 13 8 SUSPENSION MILITARY USE ONLY Shock 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 Adjuster Damping Pee Road Driving Position Force Conditions Speed Hardness 1st Soft Good T 5th 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
150. 1238ST C 75717098T Brake Drum Remover Brake Drum Pusher 57001 1260 5700141714 T5741260ST C ST5717148T Brake Drum Holder 57001 1325 7571325ST C MILITARY USE ONLY 10 6 WHEELS TIRES MILITARY USE ONLY Wheel Alignment Toe in is the difference between the distance of front and the one of rear at the 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 1K040008 S 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 the marks on the tires are at the front side and at the level of the axle height e Ground the front wheels IK04001B S e Set the steering wheel straight ahead e At the level o
151. 2 Torque Bevel Gear Bearing Holder N kgf m 148 ft Ib Press the new outer ball bearing until it is ut Driven Bevel Gear Housing Bolts A utput Driven Bevel Gear Housing B MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 17 Output Bevel Gears OTap lightly the front end A of the output driven bevel gear shaft using 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 N m 2 7 kgf m 19 ft Ib Output Driven Bevel Gear Disassembly e Remove Output Driven Bevel Gear Housing Asse put Driven Bevel Gear Removal Oil Seal e Hold the output shaft holder A in a vise housing assembly B on the hold Special Tool Output Shaft Holder 01 1 e Remove Output Shaft Holder Nut A Special Tool Soc B 57001 1482 Oe the output shaft A from the housing B using a re MILITARY USE ONLY 41 18 FINAL DRIVE MILITARY USE ONLY 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 s
152. 2 33 34 35 36 37 38 39 40 41 42 43 44 i BK Y ekz gt ta 1 ECU Electronic Control Unit 2 Fuel Pump Relay 3 Engine Ground 4 Battery 5 Frame Ground 1 1C15077BW3 C 6 Ignition Switch 7 Fuse Box 8 Fuel Pump Fuse 10 A 9 Main Fuse 30 A 10 Fuel Pump MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DFI 3 61 Ignition Coils 1 2 Service Code 51 52 Ignition Coil 1 Ignition Coil for Front Cylinder Service Code 51 Ignition Coil 2 Ignition Coil for Rear Cylinder Service Code 52 Ignition Coil Removal Installation NOTICE 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 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 shownusing two needle adapters Special Tool Needle Adapter Set 57001 1457 Connections for Ignition Coil 1 Front Meter G W lead
153. 3 50 FUEL SYSTEM DFI WU USE ONLY 77 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 chapter 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 e 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 MILITARY USE ONLY 08 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
154. 3 Seconds INP 250 One spray type with 4 holes About 11 7 12 3 Q t 20 C 68 F Non adjustable and non removable DC 4 75 5 25 V between BR W and BR BK leads DO 1 00 1 24 V between Y W and BR BK leads DC 4 0 4 4 V between Y W and BR BK leads 4 6 kQ 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 F in the text About 2 24 2 48 V at 20 C 68 F Battery Voltage at Ignition Switch ON less than DC 0 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 28di o8 2 Q at 20 C 68 F 3 16 FUEL SYSTEM DFI MILITARY USE ONLY 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 MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DFI 3 17 Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 7570125ST C Jack 57001 1238 7571238ST C Pilot Screw Adjuster A
155. 3 ft Ib AWARNING 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 toride 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 MILITARY USE ONLY 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 if 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 e Apply a non permanent locking agent to the brake disc O mounting bolts O O ff O e Tighten O MIN TH 4 3MM O Torque Front Brake Disc Mounting Bolts 44 5 N m 4 2 kgf m 31 ft Ib e After installing the discs check the disc runout Com 412000
156. 37381 C MILITARY USE ONLY IT USE ONLY FUEL SYSTEM DFI 3 23 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 If the tester does not read 0 Q the lead is defective Re place the lead or the main harness or the sub harness 1C15080BS1 C OIf 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 circ it open one end B and check the continuity between the other end C and ground D If there is continuity th harness has a short circuit to ground and it must be repaired or re placed 6017029281 C e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts ar
157. 4 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 cas 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 1LO8002BS2 C MILITARY USE ONLY 41 82 FINAL DRIVE MILITARY USE ONLY 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 x 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 rea gear case E e Tighten Torque Pi 1L08007BS1 C num disulfide grease to the spline A in the ear B ecified oil to the journal and teeth C MILITARY USE ONLY MILITARY USE ONLY
158. 40 in Ib Air Cleaner Mounting Bolts 8 8 0 90 78 in lb L ISC Valve Mounting Bolts 3 8 0 90 78 in Ib Delivery Pipe Mounting Screws 5 0 0 51 44 in lb Inlet Air Pressure Sensor Mounting Screw 5 0 0 51 44 in Ib Throttle Cable Locknuts 4 4 0 45 39 in Ib Throttle Pedal Position Bolt Locknut 10 8 1 1 96 in Ib Fuel Pump Mounting Bolts 4 0 0 41 35 in Ib Fuel Tank Band Bolts 11 1 1 97 in Ib ECU Mounting Bolts 6 9 0 70 61 in Ib Water Temperature Sensor 12 1 2 106 in Ib Cooling System Radiator Screen Mounting Bolts 8 8 0 90 78 in Ib Radiator Cover Bracket Mounting Bolts 8 8 0 90 78 mb Radiator Mounting Bolts 8 8 0 90 78 mb Radiator Fan Assembly Bolts 8 3 0 85 73 in Ib Thermostat Housing Cover Bolts 8 8 0 90 78 in Ib Water Temperature Sensor 12 1 2 106 in Ib 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 mb Coolant Drain Plug Water Pump 7 0 0 71 62 in Ib Coolant Drain Plugs Cylinder 7 0 0 71 62 in Ib Coolant Air Bleed Bolt Water Pump 7 0 0 71 62 in Ib Coolant Air Bleed Bolt Thermostat 7 8 0 80 69 in Ib Engine Top End Valve Adjusting Cap Bolts 8 8 0 90 78 mb Rocker Case Bolts L 55 mm 2 2 in 8 8 0 90 78 mb S Rocker Case Bolts L 130 mm 5 1 in 98 1 0 87 in lb S 2 6 PERIODIC MAINTENANCE MILITARY USE ONLY Torque and Locking Agent Fastener Rocker
159. 45 mm 0 0118 0 0177 in 0 20 0 70 mm 0 0079 0 0276 in Service Limit 1 13 mm 0 0445 in 1 12 mm 0 0441 in 0 90 mm 0 0354 in 0 90 mm 0 0354 in 0 55 mm 0 0217 in 0 75 mm 0 0295 in 1 00 mm 0 0394 in MILITARY USE ONLY 77 MILITARY USE ONLY ENGINE TOP END 5 11 Special Tools and Sealant Inside Circlip Pliers Valve Seat Cutter 45 27 5 57001 143 57001 1114 7570143ST C ST57Tit1i4ST C Outside Circlip Pliers Valve Seat Cutter 32 028 57001 144 57001 1119 7570144ST C ST571119ST C Compression Gauge 20 kgf cm Valve Seat Cutter 60 530 57001 221 5700121123 7570221ST C 7571123ST C Valve Spring Compressor Assembly Valve Seat Cutter Holder Bar 57001 241 57001 1128 7T5702418T C 7T5711288T C Piston Pin Puller Assembly Valve Seat Cutter 45 530 57001 910 57001 1187 7570910ST C 7571187ST C MILITARY USE ONLY 5 12 ENGINE TOP END MILITARY USE ONLY Special Tools and Sealant Valve Seat Cutter 32 633 Piston Pin Puller Adapter 14 57001 1199 57001 1211 7571199ST C ST5712118T C Valve Spring Compressor Adapter 22 Compression Gauge Adapter M10 x 1 0 57001 1202 57001 1317 CIS C S T5712028T C ST5713178T C Valve Guide Arbor 5 Filler Cap Driver 57001 1203 57001 1454 d A 7571203ST
160. 57001 1620 oO 7571474ST C 8757162097 MILITARY USE ONLY 6 8 CONVERTER SYSTEM MILITARY USE ONLY Special Tools Rod Leg 57001 1710 57001 1712 ST571710ST T5717428T C Puller Bolt 57001 1711 ST571711ST C MILITARY USE ONLY MILITARY USEONPY 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 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 leverassembly installation length see Torque Converter Gover Assembly e Fit the trim seal A into the converter cover 1IF04020BS1 C MILITARY USE ONLY 6 10 CONVERTER SYSTEM MILITARY USE ONLY Tor
161. 605 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 If the guide contact area width is greater than the service limit replace the actuator lever assembly da i Actuator Lever Guide Shoe Service Limit 6 mm 0 24 in H 04005BS1 C MILITARY USE ONLY MILITARY USE ONCYBERIODIC 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 it is 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 e Pour in the specified type and amount of oil SAE 208 50 gt Engine Oil SAE 208 40 SAE 10W SAE 10 Type API SG SH SJ SL or SM with JASO MA 50 MA1 or MA2 Viscosity SAE 10W 40 Amount 2 4L 2 5 US qt W 40 When filter is not removed 20 10
162. 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 ID Reservoir Clamp Bolt 6 2 0 63 55 in Ib 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 24 17 Master Cylinder Bolt 23 5 2 4 17 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 Ib Brake Hose Clamp Bolts 8 8 0 90 78 in Ib 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 ml Rear Master Cylinder Bleed Valve 7 8 0 80 69 in Ib Rear Master Cylinder Mounting Bolts 27 2 8 20 L Rear Final Gear Case Front Cover Bolts 24 24 18 Spring Bracket Bolt 8 8 0 90 78 mb L Rear Final Gear Case Gasket Screws 1 3 0 13 12 in Ib 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 Main S
163. 7 3 77 3 78 3 79 3 80 3 80 3 80 3 80 3 80 3 81 3 81 3 82 3 83 3 83 3 83 3 83 3 84 3 85 3 86 3 86 3 87 3 88 3 88 3 88 3 88 3 89 3 89 3 90 3 91 3 91 T7 MILITARY USE ONLY FUEL SYSTEM DFI 3 3 Air Cleaner Housing and Duct Installaion ENEE 3 91 Fuel Tank and Fuel Hose nnne nennen en nn en nn en ner en nennen nene nnns 3 93 Fuel Tank ue E LEE 3 93 Fuel Tank Installation sssssssssss mm mme nennen nnns 3 93 F el Tank Cleanih giei EE 3 95 Fuel Hose INSP CON enrere r e etna eet P ce E E EER 3 95 Fuel Hose Replacement esanian raiek aK EE REEE EEE A EEE E aE EAEE EEE EEE 3 MILITARY USE ONLY MILITARY USE ONLY 3 4 FUEL SYSTEM DFI Exploded View 1C02041BW5 C MILITARY USE ONLY T7 MLIARYUSEONLY FUEL SYSTEM DFI 3 5 Exploded View Torque No Fastener Nm kgf m ftlb Remarks 1 Element Holder Screw 45 0 46 40 in Ib 2 Element Cover Screw 4 5 0 46 40 in Ib 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 Ib 6 Inlet Air Pressure Sensor Mounting Screw 5 0 0 51 44 in lb 7 Throttle Cable Locknuts 4 4 0 45 39 in Ib 8 Throttle Pedal Position Bolt Locknut 10 8 1 1 96 in Ib 9 Inlet Air Temperature Sensor 10 ISC Valve 11 Inlet Air Pressure Sensor 12 Fuel Injectors CL Apply cable lub
164. 7 8 L 110 mm 4 33 in e Tighten Torque Crankcase 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 mmr 0 12 in C inwards from the end of the boss HIO4015BS1 C MILITARY USE ONLY 9 12 CRANKSHAFTITRANSMISSIONTT USE ONLY 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 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 N m 2 5 kgf m 18 ft lb e Check Crankshaft and driven shaft turn freely xIf any of the shafts do not turn freely split the crankcase to locate the problem 1T04000BS1 C MF E Ka HI04001281 C MILITARY USE ONLY MILITARY USECGRIAAIKSHAFT 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 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 crank
165. 7 11 Oil Pump Installation 98 amp amp 8 7 11 elm di UE 7 13 Oil Pipe Removal et c etre ient denter terres 7 13 Oil Pipe Installation a Mme Nem 7 14 MILITARY USE ONLY 7 2 ENGINE LUBRICATION SYS EWRY USE ONLY Exploded View MILITARY USE ONLY WUTIA USERWIGINE LUBRICATION SYSTEM 7 3 Exploded View No Fastener Torgus Remarks N m kgf m ft Ib 1 Oil Filter 17 5 1 8 13 R 2 Oil Pressure Switch 15 1 5 11 Ss 3 Oil Pipe Bolts 8 8 0 90 78 in lb 4 Engine 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 in lb 8 Oil Pump Drive paan Tensioner Bolt 2 5 18 EE 10 Plate Bolts 0 90 T8 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 MILITARY USE ONLY 7 4 ENGINE LUBRICATION SYSTEWRY USE ONLY 77 Specifications Item Standard Engine Oil Type API SG SH SJ SL or SM with JASO MA MAT 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 Oi
166. 77 Men transnission is in neutral ommo When transmission is not in neutral t Q1S5009BN3 C A Neutral Position Switch Reverse Position Switch Connection When transmission is in reverse oot When transmission is not in reverse aa aes B Reverse Position Switch AWD Position Switch Connection Bieri 77 mb Position 4WD Position Ges 1015010BN3 C 2WD AWD Shift Switch Connection Ls eer Das Position NN 4WD Position 1Q015011BN3 C Brake Light Switch Connection A When brake pedal is pushed down NE When brake pedal is released 1015012BN3 C Parking Brake Position Switch Connection bA Leg BEY fen parking brake pedalis pushed dom oe When parking brake pedal is released Q15013BN3 C Oil Pressure Switch Connection When engine is SURE Engine lubrication system is in good condition MILITARY USE ONLY T 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 nose pliers Q Fuse Installation x lf a fuse fails during operation inspect the electrical sys tem to determine t then replace it with a new fuse of prop e Install the fus the fuse bo e projection A of the cover B under the el
167. 851 0 pletely clean off any grease thathas gotten on 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 x Replace the disc if it has worn past the service limit 7 BA WL 15697 7 Ce LS 7 0 Ke PA ZEN 44 MIN HAAN NAS Rs ANS Ne ANGE SUN SS NN N N E 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 and measure the disc runout x If the runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 25 mm 0 010 in or less IM12002881 Service Limit TIR 0 3 mm 0 012 in MILITARY USE ONLY 12 18 BRAKES MILITARY USE ONLY 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 MILITARY USE ONLY MILITARY USE ONLY BRAKES 12 19 Parking Brake Pedal and Cables Parking B
168. 94 Needle Adapter Set 57001 1457 e Turn ON the ignition switch RE Es pra p 9 C71 8 31 pre r3 r2 r9 8 8 3 2 A Controller Power Supply Voltage Standard near Battery Voltage x If 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 O Terminal 2 Tester Connector BK Y Terminal 10 Olnstall the needle adapters on the tester leads Bm Special Tools Hand Tester 57001 1394 Es E31 22 E Ce Ce E Needle Adapter Set 57001 1457 e Turn ON the ignition switch A HP23005851 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 MILITARY USE ONLY 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 whe
169. 98 P MILITARY USE ONLY General Specifications MILITARY USE ONLY GENERAL INFORMATION 1 11 Items KRF750NAF PAF RAF SAF TAF Dimensions Overall Length Overall Width Overall Height KRF750N S T KRF750P R Wheelbase Tread Front Rear Ground Clearance Seat Height Curb Mass KRF750N KRF750P R KRF750S KRF750T Front KRF750N KRF750P R KRF750S KRF750T Rear KRF750N T KRF750P R KRF750S Fuel Tank Capacity Cargo Bed L x W x H Seating Capacity 2 955 mm 116 3 in 1485 mm 58 46 in 1 925 mm 75 79 in 2 020 mm 79 53 in 1 930 mm 75 98 in 1 225 mm 48 23 in 1 200 mm 47 24 in 295 mm 11 6 in 780 mm 30 7 in 633 kg 648 kg 630 kg 634 kg 1 396 Ib CA 630 kg 1 389 Ib 1 429 Ib CA 645kg 1 422 Ib 1 389 Ib CA 627 kg 1 383 Ib 1 398 Ib 280 kg 6117 1b CA 279 kg 615 Ib 291 kg 642 Ib CA 289 kg 637 Ib 279 kg 615 Ib GA 278 kg 613 Ib 281 kg 620 Ib 353 kg 778 Ib CA 351 kg 774 Ib 357 kg 787 Ib CA 356 kg 785 Ib 351 kg 774 Ib CA 349 kg 770 Ib 28 L 7 9 US gal 830 x 1 120 x 280 mm 32 68 x 44 09 x 11 10 in 2 Performance Minim m Turning Radius Differential Mode 2WD Locked Axle Mode 4WD Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System 4 2 m 13 8 ft
170. ARY USE ONLY 77 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 N m 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 O range Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance 110 140 Q x If the tester does not read as specified replace the crank shaft sensor Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery isfully charged e Disconnect Crankshaft Sensor Lead Connector A Set the hand tester B to the 10 V DC range e Connect 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 Lead Adapter Hand Tester Black White Red gt Blue Black gt e Turn the ignition switch on and rotate the engine
171. 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 Enginetalls when moving off Knocking Carbon built up in combustion chamber Fuel 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 of incorrect Fro
172. BS2 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 lf 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 OThe 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 O ange 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 Lk range Ignition Coil Winding Resistance HP10041881 C Primary Windings 1 84 2 76 Q Secondary Windings 10 4 15 6 kO x If the hand tester does not read as specified replace the coil OTo install the plug cap turn it clockwise MILITARY USE ONLY MILITARY USE ONLY Ignition System Ignition Coil Primary Peak Voltage Inspection NOTE OBe 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 pe
173. C ZI N maala fae d s Iro r 1019022BS1 C unit NOTE OWhen the oil switch is turned off the hour meter begins count OTherefore when connecting the check 1 circuit the hour meter begins count because the circuit of the oil Switch is opened OTo stop the count of the hour meter connect the battery negative terminal to terminal 11 see Check 12 OThe hour meter cannot be reset MILITARY USE ONLY 16 60 ELECTRICAL SYSTEM MILITARY USE ONLY 7 Meter Check 2 MODE and TIME SET Buttons Operation Check e Connect the wires in the same manner as Check 1 f jesse SEH e Check that when the MODE button A is pushed and ee held continuously the display B cycles through the three Zo modes ODO TRIP A TRIP B Hour ODO xIf 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 xIf the display function does not indicate 0 0 B replace the meter unit A 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 B 4WD 2WD Ck Tes Q0 00 U s 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
174. Check the bypass screw and its hole for carbon deposits x If any carbon accumulates wipe the carbonoff the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent e Replace the O ring with a new one e Check the tapered portion E of th bypass screw for wear or damage x If the bypass screw is worn or damaged r place it e Turn in the bypass screw until it seats fully but not tightly e Repeat the same procedure for ther bypass screw e Repeat the synchronization adjustment GSO5015BS1 C MILITARY USE ONLY 3 88 FUEL SYSTEM DFI MILITARY USE ONLY 77 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 Valve Hose Primary C Bolts D ISC Valve E SC Valve Installation e Install the ISC valve e Tighten Torque ISC Valve Mounting Bolts 8 8 N m 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 e Connect th hand tester to the following pair of terminals Special Tool Hand Tester 57001 1394 e Set the hand tester to the x 1 Q 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
175. Circlip Pliers 57001 144 e MILITARY USE ONLY 5 26 ENGINE TOP END MILITARY USE ONLY 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 N m 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 B on the crankcase e Face the arrow mark A upwa e Align the marks B on the weights the front cylinder head upper surface C e Place the front cams cha the front camshaft sprocket gt N De o the O ring A and install the cover B into h e of the crankcase so that the tapped hole C S Outward MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 27 Camshaft e Install Rocker Cases see Rocker Case Installation Camshaft Chain Tensioners see Camshaft Chain Ten sioner Installation e Check the valve clearances see Valve Clearance Inspec tion Camshaft Chain Guide Wear Inspection e Visually inspect the rubber on the guides x If the rubber is damaged cut or is missing pieces replace the guide MILITARY USE ONLY
176. Connect terminal 11 to the battery terminal OThe oil pressure warning light ED A should flash x If the LED light does not flash replace the meter unit Check 13 Fl 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 rt Genk Hz 777 1819045881 C 1019030BS1 C Hos His 1019046BS1 C 1019031BS1 C MILITARY USE ONLY tT MILITARY USE ONLY ELECTRICAL SYSTEM 16 65 Meter OThe FI indicator symbol LCD A should go on for 3 sec onds and flash after that x If the symbol does not flash replace the meter unit E SECH 1019047BS1 C Check 14 Parking Brake Indicator Symbol Check e Connect the wires in the same manner as Check 1 e Connect terminal 13 G 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 Check 1 e Connect terminal 6 fo the battery terminal 1019033BS1 C OThe meter illumination A should go on xf the illumination does not go on replace the meter unit Gell LG ao 1019049BS1 C MILITARY USE ONLY 16 66
177. D Bolts E e Install the removed parts IP1302i1BS1 C MILITARY USE ONLY 15 54 FRAME MILITARY USE ONLY Covers Windshield Removal KRF750P R Models e Remove Bolts A and Washers Brackets B Dampers and Collars Windshield C Windshield Installation KRF750P R 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 MILITARY USE ONLY MILITARY USE ONLY FRAME 15 55 Covers Sun Top Cover Removal KRF750P R Models e Remove Screws A and Collars Sun Top Cover B bs P Sun Top Cover Installation KRF750P R 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 MILITARY USE ONLY 15 56 FRAME MILITARY USE ONLY 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 sa So ss 3 m d f M hl Ok dk M WM A Ah ER Rr C d Ger S
178. D OK gio MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 19 Cable Wire and Hose Routing 1808226884 C 1 Front Master Cylinder 2 Brake Hose 3 Clamps 4 Brake Pipes 5 Brake Pipe Joint MILITARY USE ONLY 17 20 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing le pum li g d d WE 4 SNA He _ LA SET Vie SA L Il o 2 i Kaes wy JA z 7 Ge od fe o d d Zt 99 j Na fe Se AL EG YW J V S ZK He df d o4 Ka bd o S S US 6 D d MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 21 Cable Wire and Hose Routing 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 no gap between brake hose and steerifig knuckle Steering Knuckle No gap ONNATDRWNA ak Ze Af AR y cx aRWN O MILITARY USE ONLY 17 22 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing Le EE JI B j Front a PERSE L 2 e ldem e Au gy S SSS
179. E IEEE NE Lge B a ec Li IL 5 MILITARY USE ONLY 1808237885 C MILITARY USE ONLY APPENDIX 17 27 Cable Wire and Hose Routing eA At ek X RONDO SE EEGEN Main Harness Top 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 MILITARY USE ONLY 17 28 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing US model 1808229885 C MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 29 Cable Wire and Hose Routing SE EEGEN A N gt O on OO Om PS W 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 harness with clamp as shown
180. ELECTRICAL SYSTEM MILITARY USE ONLY 7 Meter Meter Circuit SEKR Multifunction Meter 4WD Position Switch Neutral Position Switch Reverse Position Switch Speed Sensor Frame Ground A Parking Brake Light Switch Fuse Box Main Fuse 30 A 1019050BW3 C 10 Fuel Level Sensor 11 ECU 12 Engine Ground 13 Battery 14 Oil Pressure Switch 15 Lighting Switch 16 Ignition Switch MILITARY USE ONLY 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 E e Insert the pin into the coll assembly B e Wipe off any protrudi e clamp A in this area B about 30 mm 1 2 ten 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 N m 0 90 kgf m 78 in Ib 1Q20004BS1 C MILITARY USE ONLY 16 68 ELECTRICAL SYSTEM MILITARY USE ONLY Actuator
181. 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 MILITARY USE ONLY 17 30 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing CA model iv S Kg B 9 Ke Get i e TC ec 1808230885 C MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 31 Cable Wire and Hose Routing SE EEGEN A N gt O on OO Om PS W 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 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 MILITARY USE ONLY MILITARY USE ONLY 17 32 APPENDIX Cable Wire and Ho
182. FUEL SYSTEM DFI MILITARY USE ONLY 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 completing 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 12 21 gt repeated Olf there is no problem or when the repair has been done no service code is shown Self Diagnosis Terminal Grounded Open 10th digit a digit DL XN n 1G15052BW1 C Service Code Erasing OWhen repair has been done FI indicator light will mot show service codes any more x But the service codes stored in memory of the ECU are not erased to preserve the problem history In this model the problem history cannot be erased Service Code Table Service Code Fl Indicator Symbol ON OFF FI Indicator Light Problems ON Throttle sensor malfunction wiring open or Hn SS short Inlet air pressure sensor malfunction wiring T open or short Inlet air temperature sensor malfunction 2 wiring open or
183. Free Length Exhaust Inlet Cylinder Piston Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Top Second 0 1959 0 1965 in 5 000 5 012 mm 0 1969 0 1973 in 5 000 5 012 mm 0 1969 0 1973 in 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 4 25 4 mm 0 992 gt 1 000 in 29 4 29 6 mm 4 157 1 165 in 0 5 1 0 mm 0 02 0 04 in 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 5 08 mm 0 20 in 5 08 mm 0 20 in 0 37 mm 0 0146 in 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 MILITARY USE ONLY 5 10 ENGINE TOP END MILITARY USE ONLY Specifications Item Piston Ring Groove Width Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil Standard 1 03 1 05 mm 0 0406 0 0413 in 1 02 1 04 mm 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
184. ITARY USE ONLY 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 a tool e Scrap the removed boot bands e Slide the joint boot B toward the outboar e Remove the retaining ring A e Separate the bearing cup B from the axle shaft A XO teel balls A e h ge B toward the outboard joint MILITARY USE ONLY 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 WR P Inboard Joint Boot Installation e Install New Small Band A New Inboard Joint Boot B Cage C WK138070 P e Install the inner race A so thatthe flat serration side B faces outboard joint LOTR P e Install New Circlip A Special Tool Outside Circlip Pliers 57001 144 e Slide the cage B on the inner race and install the steel balls C MILITARY USE ONLY 41 32 FINAL DRIVE MILITARY USE ONLY Front Axle e Apply the special grease A to
185. Installation in the Fuel System chapter Parking Brake Cable see Parking Brake Cable Installa 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 MILITARY USE ONLY 7 MILITARY USE ONLY ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Parts Location 16 3 Exploded View 16 6 Specifications ssssss 16 12 Special Tools 16 13 lge Tu EE 16 14 PreCautiOns ccceeceeeceeeeeeeeeeeeeeeeees 16 16 Electrical Wiring 16 17 Wiring Inspection 16 17 Battery cere door IET 16 18 Battery Removal 16 18 Battery Installation 16 18 Battery Activation CA Model 16 21 Precautions cccceeeeeeeeeeeeeeeeees 16 23 IrtercDiangesausedenstiocesebee dees Ae 16 23 Charging Condition Inspection 16 24 Refreshing Charge 16 24 Charging System 16 27 Alternator Cover Removal 16 27 Alternator Cover Installation 16 28 Alternator Rotor Removal 16 30 Alternator Rotor Installation 16 30 Al
186. LITARY USE ONLY MILITARY USE ONCYBERIODIC 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 ring Torque Rear Final Gear Case Oil Filler Cap 29 N m 3 0 kgf m 21 ft lb 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 xIf 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 fl id 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 itis 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
187. LITARY USE ONLY WEE 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 cm7 18 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is alright x If the pressure drops soon check for leaks MILITARY USE ONLY 4 10 COOLING SYSTEM MILITARY USE ONLY 7 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 N m 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 i
188. Mark of bolt head pone mm in N m kgf m ft lb 5 0 20 AT 2 2 2 6 0 22 0 27 19 23 mb 6 0 24 9T 12 15 1 2 1 5 104 130 in Ib 6 0 24 7T 7 8 9 8 0 8 1 0 69 87 inlb 6 0 24 4T 3 9 4 9 0 4 0 5 35 43 in Ib 8 0 31 7T 18 22 1 8 22 13 16 8 0 31 4T 10 14 1 0 1 4 87 122 in lb 10 0 39 7T 39 44 4 0 4 5 29 33 10 0 39 4T 20 24 20 24 44 17 Basic Torque for General Fasteners of Frame Parts Threads dia mm in Torque N m kgf m ft Ib 5 0 20 3 4 4 9 0 35 040 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 115s 155 11 5 16 0 83 115 18 0 71 165 225 17 0 23 0 125 165 20 0 79 225 325 23 0 33 0 165 240 OO MILITARY USE ONFYBERIODIC 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 Oil High quality foam air filter oil EE Cooling System Coolant Type Recommended Permanent type of anitfreze soft water and ethylene glycol plus di corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft water 5096 Coolant 5096 Freezing Point 35 C 31 F Total Amount 4 4 L 4 7 US qt En
189. 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 Belt Case B Rear Bar Mounting Bolt C Lower Seat Bracket D and Seat Belt MILITARY USE ONLY 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 instal p the seat belt case B e Install Seat Belt Case Mounting Bolts C and Nits e Tighten Torque Seat Belt Case Mounting Nuts As Nan 4 7 kgf m 34 ft Ib D e Fit the cover in the case securely e Install Lower Seat Bracket A as shown i in the figure Bar Mounting Bolt P e Tighten Torque Right and Left Bar Mounting Bolts 98 N m 10 ey 72 ft lb ii e Msta Upper Seat Bracket A Seat Belt Mounting Bolt B Tighten Torque Seat Belt Mounting Bolt 41 5 N m 4 2 kgf m 31 ft Ib e Fit the cover on the bracket securely MILITARY USE ONLY 45 20 FRAME MILITARY USE ONLY Control Panel Control Panel Removal e Lift and hold the front fender rear see Front Fender Rear Removal e Remove Ste
190. N Speed Sensor Input Voltage Standard Battery Voltage e Turn the ignition switch OFF xIf the reading is good check the output voltage see Speed Sensor Output Voltage Inspection xIf the reading is out ofthe range 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 gr und 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 MILITARY USE ONLY T7 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 CH 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 Voltage Standard less than DC 0 8 V or over than DC 4 8 V e Turn t
191. Nut lower Rear Knuckle Mounting Bolt B Washers Shim and Nut Rear Upper Suspension 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 MILITARY USE ONLY 13 24 SUSPENSION MILITARY USE ONLY 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 xIf there are over 0 5 mm 0 02 in gap between the knuckle and lower suspension arm add the shim C 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 xIf there are over 0 5 mm 0 02 in gap between the knuckle and upper suspension arm add the shim4G to front side e Install Rear Shock Absorber Mounting Bolt Washer and Nut lower e Tighten Torque Rear Suspension Arm Pivot Nuts 87
192. O TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Fill r opening bottom 1 0 L4 1 06 US qt 0 05 0 11 mm 0 002 0 004 in at pinion gear spline MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 11 Special Tools Bearing Puller Bearing Driver Set 57001 135 57001 1129 7570135ST C ST57i129ST C Steering Stem Bearing Driver Pinion Gear Holder m1 0 57001 137 57001 1281 7570137ST C T5712818T Inside Circlip Pliers Socket Wrench 57001 143 57001 1363 7570143ST C 7571363ST C Outside Circlip Pliers Holder amp Guide Arbor 57001 144 57001 1476 7570144ST C 7571476ST C Oil Seal amp Bearing Remover Socket Wrench Hex 50 57001 1058 57001 1478 a J 7571058ST C 7571478ST C MILITARY USE ONLY 11 12 FINAL DRIVE MILITARY USE ONLY Special Tools Output Shaft Holder amp Spacer m1 25 Output Shaft Holder 57001 1479 57001 1570 P d 75714798T C ST571570ST C Nut Holding Bolts Pinion Gear Holder 57001 1481 57001 1708 7T5714818T C T5717088T C Socket Wrench Cil Seal Driver 57001 1482 57001 1715 1571482ST T5717158T C Bearing Driver 54 3 Cable Tension Adjusting Tool 57001 1488 57001 1716 ST571488ST C T5717168T C Hexagon Wench Hex 41 Cil Seal Guide 57001 1491 57001 1721 g
193. O YUSHI or SERAN HV TOTAL FINA NOTE ODo not heap up the grease out of the openings MILITARY USE ONLY 6 26 CONVERTER SYSTEM MILITARY USE ONLY Driven Pulley 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 e Put the thrust plate B so that the alloy side gray faces the movable sheave e Install Spring Seat C 18 5 mm 0 728 in Spring D Spring Seat E 23 3 mm 0 917 in Circlip F e Tighten the nut A and compress the spring spring holder B Special Tool Spring Holder Set 57001 1483 e Install a new circlip C with circlip plier Special Tool Outside Circlip Pliers 570 4 older se e Remove the driven pulley from th t e Clean the surface of the sheaves oi s cleaning fluid Driven Pulley Installation e Clean the transmission en shaft A e Install Driven Pu NOTE i e spline on the driven pulley with n the shaft do not damage the pulley s damage occurs remove it with a file MILITARY USE ONLY T MILITARY USE ONLY CONVERTER SYSTEM 6 27 Driven Pulley e Clean the threads of the driven shaft and driven pulley end
194. OS80109S1 C Refreshing Charge e Remove the battery A see Battery Removal e Refresh charge by following method according to the bat tery terminal voltage AA 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 GP080705S1 MILITARY USE ONLY T MILITARY USE ONLY ELECTRICAL SYSTEM 16 25 Battery US model Terminal Voltage 11 8 less than 12 6 V e Standard Charge see following chart ae 2A x4 12h charger 6Ax2 6h s 2A e charger 0 l l f 1 1 L 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltag V 1008016BS1 C CA model A Terminal Voltage 11 5 less than 12 8 V Standard Charge 1 2 A x 5 10 h see following chart Quick Charge 60Ax1 0h Charge Time h H 1 1 1 1196 11 8 1270 12 2 12 4 12 6 12 8 13 0 Battety Terminal Vol tage 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 Charging Method 1 2 A x 20h NOTE Olncrease the charging voltage to maximum voltage of 25 V if the battery will not accept currentinitially Charge for no more than 5 minutes atthe increased voltage then check if the battery is drawingcurrent If the battery will accept current D decrease the v
195. OTE OThe ignition switch need not be turned on xIf 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 Jas When 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 x lf their parts are normality replace the ECU see ECU Removal Installation in the Fuel System DFT chapter Radiator Fan Motor Inspection e Lift and 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 x If the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Motor Leads BL gt gt Battery BK Battery Radiator Fan Breaker Inspection e Remove Left Seat see Seat Removal in the Frame chapter Connectors A disconnect Radiator Fan Breaker B MILITARY USE ONLY 77 MILITARY USE ONLY ELECTRICAL SYSTEM 16 57 e Inspect the breaker for operation zi NEE BR 1 20A R 0 60 12 V Battery A 0 6 O Resistance B Radiator Fan Breaker C Switch D x If the circuit in the breaker will not open within 60 seconds replace the breaker e When resetting
196. Pulley Cover Blue 14041 0037 No Paint o Tan Pulley Cover 14 55 mm No Paint 14044 0035 Red 0 573 in Drive Pulley Assembly SES 49093 0029 Drive Pulley Assembly ia 49093 0029 more than aig core 15 65 mm No Paint Blue 0 616 in ulley Cover Red 14041 0037 V Ratt HS06010BS2 C Drive Pulley Covers Part Number Paint Color A Length B 14041 0035 4 Red 240 mm 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 If be length isnot within the specified length replace the drive pulley assembly IF06039BS1 C MILITARY USE ONLY 6 22 CONVERTER SYSTEM MILITARY USE ONLY Driven 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
197. 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 MILITARY USE ONLY 4 6 COOLING SYSTEM MILITARY USE ONLY 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 C 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 C 157 163 F 8 mm 0 31 in or more 85 C 185 F MILITARY USE ONLY Service Limit MILITARY USE ONLY COOLING SYSTEM 4 7 Special Tools Bearing Driver Set Bearing Remover Head 10 x 12 57001 1129 57001 1266 7571129ST C ST571266ST C Bearing Remover Shaft 9 57001 1265 7571265ST C MILITARY USE ONLY 4 8 COOLING SYSTEM MILITARY USE ONLY Coolant Coolant Deterioration Inspection e Tilt up and hold the front fender front see Front Fender Front Removal in the Frame chapter
198. Removal in the Frame chap ter Water Pump Impeller see Water Pump Jmpeller 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 Remove Collar A Olnstall a M6 bolt B to the collar and remove it kk ELECTRICAL SYSTEM 16 27 MILITARY USE ONLY 16 28 ELECTRICAL SYSTEM MILITARY USE ONLY 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 ol seal surface is flush with the cover end as showniin the figure e Apply grease to the oil seal lips e When installing th 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 MILITARY USE ONLY CC MILITARY USE ONLY ELECTRICAL SYSTEM 16 29 Charging System e Fit the
199. Sensor If the vehicle down sensor system has failures Vehicle down the output voltage Vd is more than usable 31 Output Voltage et Sensor Vd 02 46V range wiring open the ECU shuts off the fuel i pump D POM When the relay ON 46 Rela P condition battery monitor If the relay fails battery monitor voltage 12 V y voltage 5 V or more The ignition coil primary If the ignition primary winding 1 has failures P winding must send no signal wiring short or open the ECU A ignition oils 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 ve winding must send no signal wiring short or open the ECU SS SES signals output voltage shuts off the injector 2 to stop fuel to the continuously to the ECU cylinder 2 though the engine keeps running 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 MILITARY USE ONLY 7T MILITARY USE ONLY FUEL SYSTEM DFI 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
200. TARY USE ONLY FINAL DRIVE 11 67 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 xIf it 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 x If the splines are twisted or damaged in any 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 MILITARY USE ONLY 41 68 FINAL DRIVE MILITARY USE ONLY 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 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 Ax
201. TE 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 O or no mark HIOS002BS1 C e Select the proper bearing insert A inaccordance with the combination of the connecting rod and crankshaft coding Size Color B Big End Bearing Insert Selection Con rod Big Bearing Insert 6105041781 C Crankpin Fna Bojs Diameter Mark i Diameter Mark Size Color Part Number None N ne Yellow 92028 1962 O O O None Green 92028 1961 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage MILITARY USE ONLY T MILITARY USECGRIANI KSHAFT TRANSMISSION 9 17 Crankshaft Connection Rod Crankshaft 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 C 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 repla
202. TOP END MILITARY USE ONLY 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 NOTICE 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 HE10002BS1 C 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 imthe cylin der head and remove the rocker case HE10003BS1 C Rocker Case Installation e Check that the crankshaftis positioned at TDC and at the end of the compression stroke Be sure to position the crankshaft is at TDC of the end of the compression stroke The rocker arms could benrd 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 HE10008BS1 C MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 17 Rocker Ca
203. U 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 xIf the tefminals of the ECU connectors are damaged re place the ECU MILITARY USE ONLY 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 Q 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 77 Battery Terminal b U Engine Ground Battery Terminal Criteria All 0 Q x If no continuity check the connectors the engine ground lead or main harness and 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 Adapt
204. USE ONLY MILITARY USE ONLY FINAL DRIVE 11 5 Exploded View Torque No Fastener Nm kgfm ftib Remarks 1 Rotor Mounting Bolts 12 1 2 106 in Ib 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 in 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 in lb 10 Forward Reverse Detecting Sensor Mounting Bolt 14 9 1 5 11 EO Apply engine oil G 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 zzgUr MILITARY USE ONLY 11 6 FINAL DRIVE MILITARY USE ONLY Exploded View ILO2035BW5 C MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 7 Exploded View No Fastener Nam kgf m ftlb Remarks 1 Differential Control Shift Shaft Lever Nut 8 8 0 90 78 in Ib R 2 Differential Shift Cable Holder Bolt 8 8 0 90 78 inb 3 Front Final Gear Case Oil Filler Cap 29 3 0 21 4 Front Final Gear Case Oil D
205. USE ONLY 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 N m 5 9 kgf m 42 ft Ib 1N04009BS2 C Front Shock Absorber Inspection e Check the bushing in the upper pivot 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 hole A of the reservoir tank using about 2 mm 0 08 ind 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 MILITARY USE ONLY 13 16 SUSPENSION MILITARY USE ONLY 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
206. Y 41 74 FINAL DRIVE MILITARY USE ONLY 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 1L07013BS Right Rear Axle 193 8 mm 7 63 in A 1L07014BS1 C e Open the edge of the boot in order to eqalize the air pres sures e Tighten the large band A and tap down the tang curely to hold down the end of the band e Be sure outside diameter of the ba is less than the maximum diameter Maximum Outside Dia nd 94 6 mm 3 72 in XO MILITARY USE ONLY 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 N m 3 0 kgf m 21 f
207. a US United States Teryx 750 FI 4x4 Teryx 750 FI 4x4 LE Teryx 750 FI 4x4 Sport KRF750N T Models KRF750P R Models KRF750S Model MILITARY USE ONLY 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 the 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 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
208. 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 MILITARY USE ONLY 9 4 CRANKSHAFT TRANSMISSIONNY USE ONLY 77 Exploded View MILITARY USE ONLY WU USE RANKSHAFT TRANSMISSION 9 5 No Fastener Torgus Remarks N m 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 3 Shift Lever Assembly Nut 19 6 2 0 14 R 4 Tie rod End Bolt 9 8 1 0 87 in Ib 5 Tie rod End Front Locknut 9 8 1 0 87 in Ib Lh 6 Tie rod End Rear Locknut 9 8 1 0 87 in Ib Tie rod End Nut 19 6 8 Shift Shaft Lever Bolt 13 5 2 0 1 4 Do not apply a non permanent locking agent to this end Apply engine oil Apply grease Apply a non permanent locking agent Apply a non permanent locking agent Three Bond TB247 1 Blue Left hand Threads Apply molybdenum disulfide grease Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 Repl
209. acement Parts MILITARY USE ONLY 9 6 CRANKSHAFT TRANSMISSIONNY USE ONLY 77 Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend EE TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist SE TIR 0 2 100 mm 0 008 3 94 in 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 Diameter 43 000 43 016 mm 1 6929 1 6935 in Marking None 43 000 43 008 mm 466929 1 69322 in O 43 009 43 016 mm 1 69326 1 6935 in Connecting Rod Big End Bearing Insert Thickness Brown 1 482 1 486 mm 0 05835 0 05850 in Yellow 1 486 1 490 mm SE 0 05850 0 05866 in Green 1 490 1 494 mm 0 05866 0 05882 in Connecting Rod Big End Bearing Insert Selection Con rodyBig End Bore Crankpin Diameter Bearing Insert Diameter Marking Marking Size Color Part Number None O Brown 92028 1963 None None Yellow 92028 1962 O O O None Green 92028 1961 Crankshaft Runout TIR 0 04 mm 0 0016 in TIR 0 10 mm or less 0 0039 in Crankshaft Main Jour
210. acklash 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 the 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 ringsgear as sembly and gear case covers OExample D 2 34mm 1 2 2 2 30 mm D 2 26mm 1 2 2 25 mm OThe second decimal of the total of 1 and 2 should be xO or x5 nearest of D e Recheck the backlash and readjustiif 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 thesexachtooth 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 one of these for checking the bevel
211. acturer 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 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Apply specified grease togthe lip of seal before installing the seal Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation MILITARY USE ONLY kx GENERAL INFORMATION 1 5 68020198 S Grease GB02046BS1 C GB02026B S 1 6 GENERAL INFORMATION MILITARY USE ONLY Before Servicing Lubrication It is important to lubricate rotating or sliding parts during m assembly to minimize wear during initial operation Lubri LAM oi Y cation points are called out throughout this manual apply rk Wo Via l the specific oil or grease as specified N T 3 65020218 NS Direction of Engine Rotation When rotating the crankshaft by hand the free play W amount of rotating direction will affect the adjustment Ro To ed XY tate the crankshaft to positive dir
212. adiator 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 oubbles 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 MILITARY USE ONLY MILITARY USE ONLY COOLING SYSTEM 4 5 Coolant Flow Chart Sy Li Dii N ENA RKL VR I SIY SOS I A ONE 1
213. aft 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 adapter is removed e Apply silicone sealant to the oil pressure switch and tighten it Sealant Liquid Gasket TB1211 56019 120 Torque il Pressure Switch 15 N m 1 5 kgf m 11 ft Ib MILITARY USE ONLY 7 10 ENGINE LUBRICATION SYSTENI USE ONLY Oil 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 lb Oil Pressure Relief Valve Inspection e 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 O NOTE O The relief valve cannot be
214. ak 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 F 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 toymeasure 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 Coil 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 Removal e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor Mounting Bolts A Plate B Crankshaft Sensor C k k ELECTRICAL SYSTEM 16 39 t 1010010BS1 C MILITARY USE ONLY 16 40 ELECTRICAL SYSTEM MILIT
215. amp Bolt A e Remove Cotter Pins Tie rod End Nuts A and Washers both sides NOTICE 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 svit 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 MILITARY USE ONLY 14 10 STEERING MILITARY USE ONLY Steering Gear Assembly e Apply a non permanent locking agent Three Bond TB2471 Blue Steering Gear Assembly Bolts A M12 L 60 mm 2 36 in Steering Gear Assembly Bracket Bolts B M12 L 25 LEA L d RG e D mm 2 36 in UT Wen e Install Steering Gear Assembly C E ON Damper D Om 1005007BS1 C Washer E and Steering Gear Assembly Bolts Bracket F and Steering Gear Assembly Bracket Bolts New Steering Gear Assembly Nuts G e Tighten Torque Steering Gear Assembly Nuts G 95 5 N m 9 7 kgf m 70 ft Ib e Clean the tapered portion of the tie rod end joint A and the tapered hole of the steering knuckle B or the tapers will not fit snugly e Install Washers C both sides as shown in the figure Tie rod End Nuts D both sides
216. ance 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 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 4 ditions and can cause severe burns B prepared i d for fuel spillage any spilled fuel must be completely wiped up immediately When the f el hose is dis connected fuel spills out from the hose and the e pipe Cover the hose connection withja clean shop towel to prevent fuel spillage 10158126 P 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 15 172 P 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 Lip P x If it comes off reinstall the hose joint e Start the engine and check the fuel hose for leaks MILITARY USE ONLY 2 20 PERIODIC MAINTENANCE ILTARY USE ONLY Periodic Maintenance Procedures Cooling System Radiator Cleaning Clean th
217. apter Breather Hoses B e Rem ve Spring A Shift Lever Tie rod End B MILITARY USE ONLY MILITARY USE ONLY FRAME 15 51 Covers e Remove Rubber Cover A Center Bracket Mounting Bolts B Center Bracket C For Center Bracket Unit Removal e Remove Throttle Cable Rear End 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 39 P Center Bracket Installation e Install Center Bracket Ass mbly A Center Bracket Mounting Bolts B e Tighten Torque Center Bracket Mounting Bolts 22 N m 2 2 kgf m 16 ft lb e Install the removed parts 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 MILITARY USE ONLY 45 52 FRAME MILITARY USE ONLY 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
218. ar Final Gear Case Mounting Nuts E 90 5 N m 9 2 kgf m 67 ft lb F Front e Install Removed Parts see applicable chapters Rear Final Gear Case Disassembly e Remove Rear Final Gear Case see Rear Final moval Spring A Master Cylinder w i ke Cam Lever B e Remove Master Cylinder Mounting Bolts A MILITARY USE ONLY 41 78 FINAL DRIVE MILITARY USE ONLY 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 Q e Remove Brake Cam Plate A Brake Camshaft B MILITARY USE ONLY 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 W s Wi final gear case A in a vise and remove the older using the socket wrench B cial Tool Socket Wrench Hex 50 57001 1478 f itis difficult to break free the holder apply the heat to it to softer the locking agent ipeo P MILITARY USE ONLY 41 80 FINAL DRIVE MILITARY USE ONLY Rear Final Gear Case
219. aring housing A straight B with a plastic ham mer to separate it from the shaft Do nottap 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 Boot Installation e Clean the axle shaft by wiping off the used grease o 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 insi boot small diameter and install theybo e Install New Circlip C e Place the special gr be nozzle in the bore of the housingan uee tube A until the grease comes out fr AN bearing SS MILITARY USE ONLY 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 boo B and slide the boot onto the outboard Q relieving the air pressure i e Hold the axle at thi Standard Length Front Axle 1L07017BS1 C H n edge A of the boot in order to equalize the air ressures MILITARY USE ONLY 41 30 FINAL DRIVE MIL
220. arings e Install Oil Pressure Relief Valve E see Oil Pressure Relief Valve Installation in the Engine Lubrication System chapter 1040004 e Install Rear Cylinder Camshaft Chain Guide A e Tighten Torque Rear Cylinder Camshaft Chain Guide Bolt B 20 N m 2 0 kgf m 15 ft Ib Press and insert the new ball bearings A until they are bottomed OWhen install the crankshaft bearing side faces engine inside bearing surfaces are flush wit B Needle Bearing C Needle Bearing In e Apply engine oil to the e Install Plates A Bearing P n crews B e Tighten a the osition Plate Screws 4 9 N m 0 50 AN fM 43 in Ib 1TO4001BS1 C MILITARY USE ONLY WUTr USEGRANKSHAFT 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 N m 2 0 kgf m 15 ft Ib 1 2 5 6 L 75 mm 2 95 in 3 4
221. ark 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 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 0 315 in IF06031BS2 C Adjustment Shoes x If 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 C 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 MILITARY USE ONLY 77 MILITARY USE ONLY CONVERTER 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
222. ary lead Aj into the self diagnosis ter minal B LG BK in the KDS connector C for grounding e Turn on the ignition Switch MILITARY USE ONLY 3 32 FUEL SYSTEM DFI MILITARY USE ONLY 77 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 Fl indicator symbol to read the service code e Keep the auxiliary lead ground until you finish reading the service code MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DEI 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 ignitiongswitch OFF Locate the problem with the service code table and inspect and repair DEI or ignition system according to inspection procedure on all the service codes Turn the ignition switch ON Make sure the FI indicator symbol LCD does not flash Runithe engine for several minutes at idling and run the vehicle at 20 km h 12 mph or above in order to confirm no problem C15051B F MILITARY USE ONLY 3 34
223. ase the thickness of the pinion gear shim s by 0 1 mm 10 004 In Lite Correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Heel Top Bottom Bottom Toe oo Pinion Gear Heel x F s l 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 Top Toe Bottom ILO4047B8 S MILITARY USE ONLY 11 64 FINAL DRIVE MILITARY USE ONLY 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 lf they are scored discolored or otherwise damaged re place them as a set 1L04046BS1 C MILITARY USE ONLY 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 su
224. ater temperature sensor trouble Inspect see chapter 3 MIEITARY USE ONLY 77 3 30 FUEL SYSTEM DFI MILITARY USE ONLY DEI 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 Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 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 sensomtrouble see Overheating of Troubleshootin
225. ather 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 MILITARY USE ONLY 17 16 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing JTE Sg de Se lt 7 YVA Y REFER H T SX S 74 d D MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 17 Cable Wire and Hose Routing A N gt oO SE EEGEN 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 MILITARY USE ONLY 17 18 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing d K eRe N E 7 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 O v oN
226. ator symbol LCD may appear under strong electrical interference No repair 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 MILITARY USE ONLY 3 22 FUEL SYSTEM DFI MILITARY USE ONLY 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 nector n
227. ature 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 mr good contact Inspect or Reinstall see chapter 16 Ignition coil trouble Inspect see chapter 16 Spark plug difty 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 Air cleaner clogged poorly sealed or missing Clean element or 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 W
228. aust 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 MILITARY USE ONLY ENGINE TOP END 5 45 1EO06005BS1 C 5 46 ENGINE TOP END 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 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 e 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
229. 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 3 or 4 turns in the drive and reverse coast directions while creating a drag on the drive bevel gear shaft e Che k 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 If 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 Driven Gear HK16003492 C MILITARY USE ONLY 11 22 FINAL DRIVE MILITARY USE ONLY 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
230. 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 MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 33 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 against 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 If 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 OThe valve stem and guide must be in good condition or this check will not be valid GE15011782 C 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 If the width is
231. ce all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston MILITARY USE ONLY 5 42 ENGINE TOP END 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 N SSN XX AN Lo SSES lt SSSSSSSS SY SESS ESS ear De SSESSS SSSSSSAX NS N Ka A Piston Ring End Gap Standard Top 0 15 0 25 mm 0 0059 0 0098 in HE14005BS1 0 Second 0 30 0 45 mm 0 0118 0 0177 in Oil 0 20 0 70 mm 0 0079 0 0276 in Service Limit Top 0 55 mm 0 0217 in Second 0 75 mm 0 0295 in Oil 1 00 mm 0 0394 in xIf the end gap of either ring is greater than the service limit replace all the rings MILITARY USE ONLY MILITARY USE ONLY 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 Refe
232. ce the crankshaft with a new one HIOS023BS1 C 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 14 6552 in Service Limit 42 07 mm 1 6563 in xIf there is any signs of seizure damage or excessive wear replace the crankcase halves as a set HIOS003BS1 C MILITARY USE ONLY 9 18 CRANKSHAFT TRANSMISSION USE ONLY 7 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 oom P e Remove Spring A Ratchet Assembly Bolts B 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 MILITARY USE ONLY T MILITARY USECRIANKSHAFT TRANSMISSION 9 19 Transmission e Remove Oil Seals A Collar B 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 lb
233. ch torque is the mean torque reading during about a quarter turn of the wrench LSD Clutch Torque Standard 300 N m 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 MILITARY USE ONLY 41 56 FINAL DRIVE MILITARY USE ONLY 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 gearunit A upside down in a vise as shown in the figure e Hold the pinion gear unit and remove the pinion ge 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 other damage xIf there is any doubt a place the bearing rasion color change or the ition of a bearing re e Be sure to check ju e bevel gear backlash and tooth conta he backlash related parts are replaced s ron Bevel Gear Adjustment
234. 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 NW 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 MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 29 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 B Vacuum Hoses C Spark Plug Cap D Rocker Case see Rocker Case Removal Camshaft see Camshaft Removal e Remove Cylinder Head Bolt M6 A Cylinder Head Bolts M10 B and Washers Cylinder Head C and Gasket OLift the cylinder head to clear the dowel pins in the cyli
235. d add the fluid to the upper level in the reservoir e Tighten Torque Front Master Cylinder Reservoir Cap 3 4 N m 0 35 kgf m 30 in Ib MILITARY USE ONLY MILITARY USE ONLYBERIODIC 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 in xIf 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
236. d Sensor Brake Light Switch Adjustment e Refer to the Brake Light Switch Inspection 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 asily affected by the oxidized film of the resistance plate and resulting in excessive resistance Therefore make s re to wipe the resistance plate with alcohol before taking a measurement D x If the readings are not as specified replace the fuelpump assembly Fuel Level Sensor Resistance Standard Full Level Position C 10 O 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 spe d sensor Connector A e Remove
237. d 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 MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 31 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 Installation e Install the spring seat e Replace the valve stem oil seal xIf a new valve is to be used check the valve to guid Valve Guide Installation x lf there is too much clearance install a ne see Valve Guide Removal and Valve Guid e Check the valve seat see Valve Sea e Apply a thin coat of molybdenum Ifide valve stem e Install each spring so that th il end faces down wards OThe white paint on the spring faces upwards Val
238. 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 xIf the end of the adjusting screw is mushroomed or dam aged in 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 th 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 Insid Diameter Standard 12 000 12 018 mm 0 4724 0 4731 in Service Limit 12 059mm 0 474 in Rocker Shaft Diameter Measurement e Measure the diameter A of the rocker shaft where the rocker arm pivots on it with a micrometer x Ifthe 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 ame gen HE10011BS2 C WE108017 MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 19 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 U
239. des ofth tire are parallel with the rim flanges B x If 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 4nstall 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 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 MILITARY USE ONLY 10 12 WHEELS TIRES MILITARY USE ONLY 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 ikossoos P e Remove Axle Nut A and Washer B Front Hub C with
240. 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 t D 0 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 Counterclockwise Clockwise Softer te Ha rider STD 3 2 1 adjuster turned fully d 1N04006BS1 C Counterclockwise Clockwise Softer Harder STD 20 12 1110 9 8 7 6 5 4 3 2 1 adjuster turned fully clockwise 1N04007BS1 C MILITARY USE ONLY 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
241. e Bolts A and Nuts Plate B e Remove Quick Rivets A Flaps B e Remove Cargo Bed see Cargo Bed Removal Bolts A Tapping Screws B Heat Guard Plate C Cargo Bed Assembly e Install Heat Guard Plate em I ANN EE RS S X YS SW Tapping Screws Bolts C RN e When installing the insulators A to the heat guard plate install them as shown in the figure MILITARY USE ONLY IP04015BS1 C 1IP04016BS1 C 15 36 FRAME MILITARY USE ONLY 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 MILITARY USE ONLY 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 MILITARY USE ONLY 15 38 FRAME MILITARY USE ONLY 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 Net F Bolts G M6 L 14 mm 0 55 in Hooks H Stopper I Bolts J M6 L 14 mm 0 55 in
242. 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 C e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails do not align Top Ring A 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 HE14028BS1 C 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 pingsholes 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 MILITARY USE ONLY 5 40 ENGINE TOP END MILITARY USE ONLY 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 rections take a side to side and a front to back measure ment at each of the three locations total of six measure ments sho
243. e Periodic Maintenance chapter MILITARY USE ONLY 12 12 BRAKES MILITARY USE ONLY 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 If 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 xIf it is damaged replace it e Check that the relief F and supply G ports are not plugged x If 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 xIf 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 NOTICE Brake fluid quickly ruins painted Surface any spilled fluid should be completely washed away immediately e Remove Rear Master Cylinder Mounting Bolts B Rear Master Cylinder
244. e 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 N m 1 2 kgf m 106 in Ib e Recheck the clearance x If the clearance is incorrect repeat the adjustment proce dure x If 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 intthe screen en 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 carbon particles are purged from the muffler MILITARY USE ONLY 2 26 PERIODIC MAINTENANCE TARY USE ONLY 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
245. e ceeccee cece cece eeeeeeeeeeeeeeeeeeeeeeeeeseeteeeeeeeeeeeeeeees 11 27 Front Final Gear Case Sep A 11 34 Front Final Gear Case Oil Level Inspection ccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeees 11 34 Front Final Gear Gase e Ke e 11 34 Differential Shift Lever Play IrNlipection seeeeeeeeeeeeeeeeeee nene 11 34 Differential Shift LevepPlay AdBetrment Akku 11 34 Differential Shift Lever FRemgouzal Re 11 34 Differential Shift Lever Installation ssssssssmmRRRReeRRHeHeB 11 35 Differential Shifb Cable Hemgval nennen enne 11 35 Differential Shift Gable Installation kee EEN 11 36 Differential Shift Cable Lubricatton nnnm 11 37 Diff renti h Shift Cable Inspection ke 11 37 2WD AWD Shift Cable Hemoval nanan neern EEEa 11 37 2WD AWD Shift Cable Installation c ccccecceeececeeceeeeeeeeaeeaaeeaaeeaaeeaaaeaaeeaaeeaaeeaaeasaasaas 11 38 2WD 4WD Vacuum Actuator Removal cccccccscssssssseccecsecessssnsesececeeeessssseaeeeeeeeessessees 11 39 2WD AWD Vacuum Actuator Installation eeeeeeesseessessessssesssseee eene 11 40 2WD AWD Shift Cable Lubrtcaton esent 11 40 2WD AWD Shift Cable Inspection eese 11 41 Front Final Gear Case Remova eme ene emere 11 41 Front Final Gear Case Installation sssssssssssssssssseeemm emen 11 42 Front Final Gear Case Disassembly esee eeneeeeeee ener ann neenne ttn 11 43 Front F
246. e de 6 6 Special TOONS EE 6 7 Torque Converter Cover 6 9 Torque Converter Cover Removal E 6 9 Torque Converter Cover Installation EE Tene 6 9 Torque Converter Cover Disassembly seeeseeeee Meee 4S3 6 10 Actuator Lever Engine Brake Control Lever Assembly Inspection 5 6 11 Torque Converter Cover Assembly eee gig nennen nnn 6 11 BI Hil RAE Lr LU Gam ENET 6 13 Drive Belt Removal M A 6 13 Drive Belt Installation AA EE aad sss 6 13 Drive Belt Deflection Inspection NEE 6 13 Drive Belt Deflection Adjustment a acne 6 13 Drive Belt Inspection sssssseeeeeeee een 6 13 D vePulley ie etait ime cA tens 6 14 Drive Pulley Removal M Wu 6 14 Drive Pulley Disassembly EE WEE em eee 6 14 Drive Pulley Inispectlan ert Mg e eit eri e ertet 6 15 Spider Shoe Side Clearance Inspection Adjustment esses 6 17 Drive Pulley Assembly oo Ne EE Echt egbenEeb eg geed 6 18 Drive Pulley Installation 94 98984 eeeeessseeeeneeeeewe 6 20 Driven Pulley reco licent lere rei atre t E core dens 6 22 Driven Pulley Removal 4 m Lees 6 22 Driven Pulley Disassembly D a NIC EE 6 22 Driven Pulley Inspection E dert rtg oh c RR eterne Rd 6 23 Driven Pulley Assembly E WE 6 24 Driven Pulley ET WE 6 26 MILITARY USE ONLY
247. e 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 onpetroleum distillates to lu bricate the stem because they will deteriorate the rubber HJ05036BS1 C e Mount the tire on the new rim see Tire Installation e Install the wheel see Wheel Installation e Install the air valve cap MILITARY USE ONLY 10 10 WHEELS TIRES MILITARY USE ONLY 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 engine oil or petroleum distillates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer 08005851 0 cially available tire changer NOTE OThe 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 and damage see Tire Inspection in
248. e radiator screen and the radiator in ac cordance with the Periodic Maintenance Chart 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 insid 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 andsbrittle 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 HUOG
249. e th next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself xIf an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DEI parts replace the ECU MILITARY USE ONLY 3 24 FUEL SYSTEM DFI MILTARY USE ONLY Troubleshooting the DEI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider The ignition switch is turned on and the state ofthe 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 throttle assy air cleaner fuel tank etc End 1C15050B 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 areas and will help you decide if it is a DFl system problem or a general engine problem MILITARY USE ONLY IT ITT FUEL SYSTEM DFI 3 25 Troubleshooting the DFI System Sample Diagno
250. eave 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 lf seals are damaged replace the movable sheave x lf the splines A are damaged or worn replace the fixed sheave x lf the spring is damaged or wo ce the spring Spring Free Length A Standard 99 mm 3 x lf the spring coils are di ed replace the spring cers A see Converter Drive Belt Deflection Adjust ent in the Periodic Maintenance chapter MILITARY USE ONLY UT MILITARY USE ONLY CONVERTER SYSTEM 6 25 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 e Apply 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 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 matc easily e Apply grease WR500 N DO YUSHI POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA to the seati A of the pins and insert them into the hol e Ww movable sheave onto the fixed sheave and ap ly grease of 1 g 0 035 oz to all openings A se WR500 No 2 KYODO YUSHI or POWER LITE WR 2 KYOD
251. ection clockwise viewed aid SN from right side J eg vd d e A 9 C 6GB020278 S Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise el ctrical Y R wires must be connected to those of the same color IC Ss 6B020238 S 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 C MILITARY USE ONLY 1T MILITARY 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 MILITARY USE ONLY 1 8 GENERAL INFORMATION MILITARY USE ONLY Model Identification KRF750PAF Left Side View 18088093 P 18089804 P MILITARY USE ONLY 1T MILITARY USE ONLY GENERAL INFORMATION 1 9 Model Identification KRF750RAF Left Side View ee The KR Z50RAF is identical to the KRF750PAF in every aspect controls features and specifications except for the camouflage surface treatment Theygun case is an optional part MILITARY USE ONLY 1 10 GENERAL INFORMATION MILITARY USE ONLY Model Identification KRF750SAF Left Side View 16038097 P 180000
252. ectric a ase C and install the cover position as specified on MILITARY USE ONLY 16 80 ELECTRICAL SYSTEM MILITARY USE ONLY Fuses Fuse Inspection e Inspect the fuse element xIf it 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 Blown Element D NOTICE When replacing a 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 MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 1 Appendix Table of Contents Troubleshooting REI EE 2 Cable Wire and Hose Routing EE 1 MILITARY USE ONLY 17 2 APPENDIX MILITARY USE ONLY 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 Starte
253. ed 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 maladjustment Suspension arm bent or twisted Steering shaft bent Steering gear a sembly damaged Front or reafetire 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 op
254. ed 1 5 mm 0 059 in C or more from the edge D of sheaves B check the belt wear as follows 1808003BS1 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 1 426 in e Check the belt A for abnormal wear B OMeasure the width C of the belt at abnormal wear point xIf any measurements exceed 0 5 mm 0 02 in replace the belt H 05003BS1 C e Check the belt for cracks breaks or peeling xf necessary replace the belt Belt A Crack B Broken C Peeling D H 05002BS1 C MILITARY USE ONLY 2 28 PERIODIC MAINTENANCE ILTARY USE ONLY Periodic Maintenance Procedures NOTE OWhenever 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 Putthe 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 Co
255. eel 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 criss eross pattern Torque Wheel Nuts 110 N m 11 2 kgf m 81 ft Ib Figure is the aluminium wheel KRE750S Model Wheel Rim Inspection e Examine both sides of the rim for dents A If the rim is dented replace it HJ05035BS1 C MILITARY USE ONLY MILITARY USE ONLY WHEELS TIRES 10 9 Wheels Rims x lf 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 if necessary HJ05022BS1 C 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 6J05010881 C e Install a new air valv
256. eering Wheel Position Adjustment e Remove Control Panel see Control Panel Removal in the Frame chapter e Loosen the steering main 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 xIf 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 MILITARY USE ONLY 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 pa
257. el 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 After 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 R moval in the Frame chapter e Check the fuel hose x Replace the fuel hose if any fraying leaks A cracks B or bulges C are noticed Replace the hose if it has beengsharply bent or kinked Hose Joints A Fuel Hose B 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 eh does not locked reinstall the hose joint AA 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 C MILITARY USE ONLY MILITARY USE ONLYBERIODIC 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 appli
258. els 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 xIf the reading is not standard check the forward reverse detecting sensor xIf the forward reverse detecting sensor is normal replace the actuator controller unit Forward Reverse Detecting Sensor Inspection e Remove Engine 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 lfithe reading isinot 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 x If the tester reading is less than infinity lt indicates a short replace the forward reverse detecting sensor kk ELECTRICAL SYSTEM 16 71 HP23006BS1 C e EN t E im Y MILITARY USE ONLY 16 72 ELECTRICAL SYSTEM MILITARY USE ONLY Actuat
259. ely e Apply a thin coating of grease to the throttle cable rear end A 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 ThrottlePedal 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 mide Jd 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 setat 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 MILITARY USE ONLY 3 86 FUEL SYSTEM DFI MILITARY USE ONLY 77 Throttle Body Assy e Remove Throttle Body Assy see Throttle Body Assy Removal Screw A Inlet Air Pressure Sensor 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
260. ement Air Flow Fuel Flow MILITARY USE ONLY FUEL SYSTEM DFI 3 9 3 10 FUEL SYSTEM DFI MIITARY USE ONLY DFI System DFI System Wiring Diagram e3 Fes te KEE e G RIES du a A wT We EE BK Y ud tte ttt Y 1615072885 C MILITARY USE ONLY 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 ECU Electronic Control Unit Vehicle down Sensor 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 MILITARY USE ONLY FUEL SYSTEM DFI 3 11 3 12 FUEL SYSTEM DFI MILITARY USE ONLY DFI System Terminal Numbers of ECU Connectors 35 3 4 3 3 3 2 3 1 3 0 2 9 2 8 27 alelos 13 12 11 10 9 8 7 6 8 4 feel 201 epsjrspspep rfe frs pi shi 4 HC110468W2 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 Bat
261. emove Engine Upper Cover see Engine Upper Cover Removal in the Frame chapter Fuel Hose see Fuel Hose Replacement 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 If 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 MILITARY USE ONLY 3 68 FUEL SYSTEM DFI MILTARY USE ONLY Fuel Injectors Fuel Injector Circuit n BK Y O GOOD JO Om P Gobh A BR Y BK Y BK Y BL R Fuel Injector 1
262. emove all grinding compound before assem bly e When the engine is assembled be sure io adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter MILITARY USE ONLY GE15012381 GE15012081 C EE USE ONLY S47 ENGINE TOP END 5 37 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 OD 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 odie D ot 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 Grind 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 GE15061B F MILITARY USE ONLY 5 38 ENGINE TOP END MILITARY USE ONLY Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Oil Pipe A Chain Guide B Cylinder Bolts C Cyl
263. en 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 MILITARY USE ONLY 17 6 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing 1808107884 C 1 Tube 2 Clamp 3 Align the white paint mark on the tube with the adjustment mark on the crankcase 4 Starter Motor 5 Starter Motor Cable 6 about 20 MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 7 Cable Wire and Hose Routing LL Clamps 2 about 45 MILITARY USE ONLY 17 8 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing e 4 7 Y GF V X K E FNY D s Js VE KS EA SS JIN SSS Ey 1808219884 C IC Valve ISC Valve Tube Front Resonator Fuel Hose Breather Hose ISC Valve Tube Rear Clamp Position the clamp so that its edge must not contact to adjacent tube CON O 014 Qo NAA MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 9 Cable Wire and Hose Routing
264. en 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 e Remove Circlip A TA Special Tool Inside Cirelip Priers B 57001 143 e Remove the ball bearing using a press A Special Tool Bearing Driver Set B 57001 1129 MILITARY USE ONLY 13 28 SUSPENSION MILITARY USE ONLY 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 MILITARY USE ONLY MILITARY USE ONLY SUSPENSION 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 xIf bearing play roughness or binding is found replace the bearing 6114010181 C Oil Seal Inspectio
265. eplace 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 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 Connect the hand tester to the connector A 4with 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 sl 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 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 MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DFI 3 67 Fuel Injector Fuel Line Inspection e R
266. eplacement Parts MILITARY USE ONLY 8 4 ENGINE REMOVAL INSTALMATIONUSE ONLY 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 Propeller 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 Crankshaft Sensor Lead Connector B MILITARY USE ONLY VT MILITARY ER GINE REMOVAL INSTALLATION 8 5 Engine Removal Installatio
267. er 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 Drive amp Driven Pulley Holder 57001 1473 Drive amp Driven Pulley Holder 57001 1412 e Get the pulley onto the pulley holder e Remove Drive Pulley Cover Bolts A Drive Pulley Cover B MILITARY USE ONLY 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 Turn 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 ey Inspection the sheave surfaces A appear damaged replace the ves MILITARY USE ONLY 6 16 CONVERTER SYSTEM MILITARY USE ONLY 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 If the sheave bushing
268. er 7 0 0 71 62 in lb EO Apply engine oil G Apply grease for oil seal and O ring L Apply a non permanent locking agent R Replacement Parts MILITARY USE ONLY 5 6 ENGINE TOP END MILITARY USE ONLY Exploded View MILITARY USE ONLY MILITARY USE ONLY Exploded View ENGINE TOP END 5 7 No Fastener pone Remarks N m kgf m ft Ib 1 Exhaust Pipe Nuts 17 1 7 13 2 Exhaust Pipe Cover Bolts 13 1 3 115 in Ib 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 MILITARY USE ONLY 5 8 ENGINE TOP END MILITARY USE ONLY Specifications Item Rocker Case Rocker Arm Inside Diameter Rocker Shaft Diameter Camshafts Cam Height Exhaust Inlet Camshaft Bearing Clearance 18 22 Camshaft Journal Diameter 18 22 18 22 Camshaft runout KACR Kawasaki Automatic Compression Release KACR Operating Engine Speed Camshaft Bearing Inside Diameter Standard 12 000 12 018 mm 0 4724 0 4731 in 11 983 11 994 mm 0 4718 0 4722 in 35 363 35 477 mm 1 3922 1 3967 in 35 622 35 736 mm 1 4024 1 4069 in 0 016 0 052 mm 0 0006 0 0020 in 0 020 0 059 mm 0 0008 0 0023 in 17 966 17 984 mm 0 7073 0 7080 in 21 959 24 980 mm 0 8645 0 8654
269. er 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 Adjustin Damp Gelee ing Setting Load Road Speed Length Force 75 5 mm 2 972 in Weak Soft Light Good Low 95 5 mm 3 760 in Stong Hard Healy Bad High Front Shock Absorber Removal e Support the vehicle on agstandhor 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 nstall the collar C MILITARY
270. er 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 MILITARY USE ONLY 41 70 FINAL DRIVE MILITARY USE ONLY Rear Axle EE e Apply the special grease slightly on the part A of the band installation in order to make easy to install the boot M band is e Tighten the small boot band B EE ILON Y B D 9 HK10003BS1 C 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 c out from the joint bearing e Tap the shaft end A straight with stic hammer until it is locked by the circlip gt e all of the special grease A into the new boot d slide the boot onto the outboard joint C MILITARY USE ONLY MILITARY USE 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 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 d
271. er 250 25 5 184 LO Coupling Nut 35 3 6 26 R Front Final Gear Case Center Cover Bolts M8 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 mb 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 CasesBracket Bolts 90 5 9 2 67 Differential Shift Cable Locknuts 9 8 1 0 87 mb 2WD 4WD Shift Cable Rocknuts 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 mb 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 Ib Rear Final Gear Case Front Cover Bolts 24 2 4 18 Spring Bracket Bolt 8 8 0 90 78 in Ib L Rear Final Gear Case Gasket Screws 1 3 0 13 12 in Ib 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 Filler Cap 29 3 0 21 MILITARY USE ONLY T MILITARY USE ONLY BERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener Nem kgfm ftlb Remarks 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
272. er Glove Compartment B MILITARY USE ONLY 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 Models e Remove Control Panel seesControl Panel Removal Tapping Screws A Cupholder Assembly B e Remove Bolts A Holder B Pull out the cupholder case C from the cupholder bracket D MILITARY USE ONLY 15 24 FRAME MILITARY USE ONLY 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 e When removing the roller bracket A remove the screws B e When removing the plate A remove the tapping screws B both sides MILITARY USE ONLY MILITARY USE ONLY FRAME 15 25 Control Panel e When removing the guide A remove the rivets B ODril
273. er Nut A e Tighten Torque 2WD AWD Shift Shaft Lever Nut 20 N m 2 0 kgf m 15 ft Ib Apply grease to the oil seal lip A Press the oil seal B in the coupling C as s i figure 1 1 5 mm 0 039 0 059 in D e Install Coupling A Washer B ling Nut A h B and hold the 2WD 4WD shift shaft lever C Hold the coupling D with a wrench E ighten Torque Coupling Nut 35 N m 3 6 kgf m 26 ft Ib MILITARY USE ONLY 11 54 FINAL DRIVE MILITARY USE ONLY 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 in 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 N t 8 8 N m 0 90 kgf m 78 in Ib Ring Gear Disassembly e Remove Ring Gear Assembly see Front Final Gear Case Disas sembly Ring 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 MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 55 F
274. er Set 57001 1457 1015085BS1 C Battery C ECU Power Supply Inspection Connections I Tester Terminal 8 W Tester CH Battery Terminal Il Tester Terminal 13 BR Tester Battery Terminal Ignition Switch OFF I Battery Voltage I OV Ignition Switch ON I Battery Voltage Il Battery Voltage x lf 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 MILITARY USE ONLY 3 72 FUEL SYSTEM DFI WU USE ONEY 7 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 ec 1C15076B8W2 C ECU Electronic Control Unit Frame Ground 1 Engine Ground Battery lgnition Switch Fuse Box Main Fuse 30 A zl OO P Gabi A MILITARY USE ONLY MILITARY USEONLY 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 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
275. er 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 Rem Bolts A Hook Lever B Bracket Ve e Remove ch Screws A MILITARY USE ONLY 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 conflectors AL e Remove Bolt B and Nut a A Bolts C ai Taillight Bracket 1 ES v M N GH Remove Bolts A both sides N Wires B both sides Dampers C both sides Collar both sides MILITARY USE ONLY 15 34 FRAME MILITARY USE ONLY 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 oth sides s B both sides ing C both sides Lever D MILITARY USE ONLY MILITARY USE ONLY FRAME 15 35 Cargo Bed e Remov
276. erates make light sounds for 3 seconds and then stops e Turn the ignition switch OFF xf the 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 MILITARY USE ONLY 3 78 FUEL SYSTEM DFI WU USE ONLY 77 Fuel Pump e Disconnect the fuel pump lead connector and 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 WIR 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 and 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 If the reading is not the standard check the fuekpump re lay see Relay Inspection in the Electrical System chap ter x If the fuel pump relay is normal check the wiring for con tinuity see Fuel Pump Circuit xIf the wiring is good c
277. ering Wheel see Steering Wheel Removal in the 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 TA ANN MILITARY USE ONLY 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 V Screws B and Colas A e A Washers and Collars B Screws C and Collars ontrol Panel D MILITARY USE ONLY 45 22 FRAME MILITARY USE ONLY Control Panel Control Panel Installation e Install Control Panel A Screws B L 16 mm 0 63 in Collars C L 4 mm 0 16 in Screws D L 56 mm 2 20 in Collars E L 40 mm 1 57 in Washers F Collars G L 4 7 mm 0 19 in Quick Rivets H Quick Rivets I Cover J IP08007BS2 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 Compartment Cover C Center Glove Compartment KRF750N T Models e Remove Control Panel see Control Panel Removal Screws A Cent
278. ers x If 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 ORemove 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 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x If the outside diameter O D A of the seating s rface 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 432 Cutter into the holder and slide it into the valve guide OTurn the holder one fum 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 To 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 xIf the seat width is too narrow repeat the 45 grind until the seat
279. es 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 MILITARY USE ONLY 16 24 ELECTRICAL SYSTEM MILITARY USE ONLY 77 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 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 If the reading is below the specified refreshing charge is E 13 0 required ce Battery Terminal Voltage US model D e Standard 12 6 V or more SEN E 1125 0 25 50 75 100 Battery Charge i le kel Refreshing Charge g Good is required 1 08015BS1 C Battery Terminal Voltage CA model Standard 12 8 V or more 0 25 50 75 100 Battery Charge le kel Terminal Voltage V Refreshing Charge i Good is required GP
280. essure Cover the hose connection with a piece of clean cloth to prevent fuel spillage MILITARY USE ONLY MILITARY USEONLY FUEL SYSTEM DEI 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 3 seconds ORepeat this operation several times e Turn the ignition switch OFF x If 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 MILITARY USE ONLY 3 76 FUEL SYSTEM DFI MILITARY USE ONLY Fuel Pump Fuel Pump Removal AWARNING 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 inc
281. et B Screw C and ar Engine Upper Cover D h e Qu i per Cover Installation stall gine 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 MILITARY USE ONLY 15 44 FRAME MILITARY USE ONLY 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 sides IP13001BS1 C Side Cover Removal Right Side Cover e Remove Right Seat see Seat Removal Screws A Quick Rivet B MILITARY USE ONLY 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 EC Quick Rivet B e Remove Screw A and Collar 10138010 P MILITARY
282. et Air Pressure Sensor 9 ECU Electronic Control Unit 10 Vehicle down Sensor MILITARY USE ONLY 16 44 ELECTRICAL SYSTEM MILITARY USE ONLY 77 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 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 MILITARY USE ONLY 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 N m 0 90 kgf m 78 in Ib Starter Motor Cable Mounting Nut 6 8 N m 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
283. everse light lead right side only to the bar 3 Clamp Clamp the tail light lead 4 Reverse Light Lead Connector 5 Cover 6 Band 7 Installation of Cover MILITARY USE ONLY MILITARY USE ONLY 17 38 APPENDIX Cable Wire and Hose Routing ke 42 o c MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 39 Cable Wire and Hose Routing Kawasaki Diagnostic System Connector 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 Cover the terminals with cover after connecting the connectors Crankshaft Sensor Connector Grease to the inside of the connector Alternator Lead Connectors Free Location Oil Pressure Switch Lead Connector Starter Relay 90 45 A OO DO d OO P Gabi A MILITARY USE ONLY 17 40 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing or ee P GE y 2 LS as So D MEN QRZ o H yw e A fs ee LF W 2 e EI AD ASS A Z 24 za gi MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 41 Cable Wire and Hose Routing X 23 a Se 2X OO OO JO Om P Go A OH SE EEGEN Rubber Cover Rubber Cover Rubber Cover Bands Ba
284. f 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 thessame levelas 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 If 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 IK045014 P MILITARY USE ONLY 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 N m 4 5 kgf m 32 ft lb e Check the toe in again e Test drive the vehicle 1K04002BS1 C MILITARY USE ONLY 10 8 WHEELS TIRES MILITARY USE ONLY 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 wh
285. f the boot b xu m CT ANT ct a uem AN s e Install the rear master cylinder see Rear Brake Master Cylinder Installation in the Brakes chapter 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 Ow 00 ias 1 140068W2 C 1 14000BS1 MILITARY USE ONLY MILITARY USE ONCYBERIODIC 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 Wheels 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
286. for 4 5 seconds with the transmission gear in neutral to measure rn the crankshaft sensor peak voltage MILITARY USE ONLY 77 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 timinglightat the timing mark on the alternator rotor e Run the engine at the speeds specified and note the align ment of the timing marks AN CLOSE A F or R mark A B Ignition Timing Engine speed r min rpm Slot B aligned with e E be A 4 100and below a mark C on alternator NOTE ODo not mix up the timing marks with mark A HP10086BS1 C x If the ignition timing is incorrect replace the ECU and the crankshaft sensor MILITARY USE ONLY 16 42 ELECTRICAL SYSTEM MILITARY USE ONLY Igniti
287. g 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 MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DEI 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 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 a problem occurs with the DFI system and ignition system the FI 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 f p EAN 1019047BS1 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 a xili
288. gine Top End Valve Clearance Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mam 0 0039 0059 in SE Converter System Belt Width 30 0 30 6 mm 1 181 1 205 in 28 6 mm 1 126 in Belt Deflection 22 31 mm 0 87 1 22 in at checking 22 27 mm 0 87 1 06 in at adjusting Actuator Lever Guide Shoe Wear 6 mm 0 24 in Engine Lubrication System Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 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 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 2 14 PERIODIC MAINTENANCE TARY USE ONLY Specifications Steering Wheel Free Play Item Standard Service Limit Final Drive Front Final Gear Case Gear Case Oil Type API SG SH SJ SL or SM with JASO MA MAT 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 Imp Brake Pedal Brake Pedal Play 2 10
289. 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 MILITARY USE ONLY 13 6 SUSPENSION MILITARY USE ONLY Specifications Item Shock Absorbers Oher than KRF750S Model Spring Preload Setting Position Front Rear Shock Absorbers KRF750S Model 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 MILITARY USE ONLY 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 D 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 MILITARY USE ONLY SUSPENSION 13 7 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C ST57i129ST C Outside Circlip Pliers Jack 57001 144 57001 1238 el se e Vy ud d mer e 75701448T C b 5i 7571238ST C Steering Stem Nut Wrench Hook Wrench T 3 2 R37 5700
290. 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 S H oO GW O B 19009017BS1 C 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 Ib 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 Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter MILITARY USE ONLY 16 30 ELECTRICAL SYSTEM MILITARY USE ONLY Charging System Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Ball Bearing A 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
291. h baee recommended by KAWASAKI Gaskets O rings Oil seals P X Grease seals circlips cotter pins or self locking nuts must be replaced with new ones whenever disassembled GB020108 S Assembly Order D In most cases assembly order is the reverse of disassem T gen T bly however if assembly order is provided in this Service c Tea ge Manual follow the procedures given c p C i 3 8 AE OO NN a Wu WA j SEN MILITARY USE ONLY 1 4 GENERAL INFORMATION MILITARY USE ONLY 77 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 68020128 8 Tightening Torque Incorrect torque applied to a bolt nut or screw may 7A e lead to serious damage Tighten fasteners to the specified Oe ZS torque using a good quality torque wrench d rr Gank Often the tightening sequence is followed twice initial SX tightening and final tightening with torque wrench ut 1 3 2 bd GB020138 S Force E Use common sense dur
292. h contact pattern MILITARY USE ONLY FINAL DRIVE 11 91 41 92 FINAL DRIVE MILITARY USE ONLY 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 x lf 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 If the bearing is damaged replace the bearing MILITARY USE ONLY MILITARY USE ONLY 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 MILITARY USE ONLY FINAL DRIVE 11 93 MILITARY USE ONLY BRAKES 12 1 Exploded View Specifications ssseess Brake Flug Front Brake Fluid Recommendation Front Brake Fluid Level Inspechon Front Brake Fluid Change Brake Line Air Bleeding
293. haft Mounting Bolts 41 5 4 2 31 Intermediate Shaft Clamp Bolts 21 5 2 2 17 Steering Gear Assembly Nuts 95 5 9 7 70 R 2 10 PERIODIC MAINTENANCE ILTARY USE ONLY Torque and Locking Agent Fastener Remarks N m 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 Ib 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 3 34 Seat Plate Bolts 8 8 48 in Ib E reno Bracket Mounting Bolts L 20 mm 34 3 25 L E Pedal Bracket Mounting Bolts L 30 mm 1 2 34 3 l 25 Center Bracket Mounting Bolts 22 16 Right Frame Pipe Mounting Bolts 34 3 i 25 Bracket Bolts 47 35 Heart Guard Bolts 8 8 Electrical System Starter Motor Mounting Bolts 8 8 0 90 78 in lb Starter Motor Terminal Locknut 11 1 1 97 in lb Starter Motor Cable Mounting Nut 6 8 0 69 60 in Ib Starter Motor Through Bolts 5 0 0 51 44 in Ib Starter Motor Clutch Bolts 34 3 5 25 L Left Engine Cover Bolts 5 9 0 60 52 mb 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 mb Alternator Stator Bolts 13 5 1 4 10 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 8 8 0 90 78 in lb Breather Plate Screws 2 9 0 30 26 in lb
294. he 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 Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 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 6114060581 C 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 to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do notispin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the bearing iS noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings Ohe rollerin a needle bearing normally wear very little and wear is difficult to measure Instead of meas
295. he 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 puta 9 mm 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 CVT cover following the method de scribed below e Measure the belt deflection A at the middle of two pulleys With a straightedge the belt deflection gauge and a ruler ePlaceya 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 Belt Deflection Standard HSO5000BS1 C 22 27 mm 0 87 1 06 in at adjusting x If the belt deflection is not within the specified range ad just the deflection again MILITARY USE ONLY 2 30 PERIODIC MAINTENANCE ILTARY USE ONLY Periodic Maintenance Procedures Converter Drive Belt Deflection Adjustment e Disassemble the driven pulley see Driven
296. he cable with a penetrating aerosol cable lubri cant through the pressure cable luber 6004011481 C MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 41 Front Final Gear Case 2WD 4WD Shift Cable Inspection e With the 2WD 4WD 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 Remove Front Final Gear Case Bracket Bolts A Brackets B MILITARY USE ONLY 11 42 FINAL DRIVE MILITARY USE ONLY 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
297. he ignition switch OFF x If the reading is out of the standard replace the sensor xIf 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 Supp are good replace the ECU see ECU Removal Installation Speed Sensor Circuit 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 4i 42 43 44 1Cci15070B8W2 C 1 ECU Electronic Control Unit 3 Power Source 5 Multifunction Meter 2 Speed Sensor 4 Frame Ground 1 MILITARY USE ONLY 3 56 FUEL SYSTEM DFI MILITARY USE ONLY 77 Vehicle down Sensor Service Code 31 Vehicle down Sensor Removal NOTICE 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 riding 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 b
298. heck 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 Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump B and cannot be removed IOC KR MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DEI 3 79 Fuel Pump Fuel Filter Cleaning OThe fuel filter A and fuel strainer B are built into the pump and cannot be cleaned or checked x If the fuel filter is suspected of clogging or being damaged replace the fuel pump Fuel Pump Circuit O 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 i xs m EE ea 1C15077BW3 C 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 OO OO JO Om P GO A MILITARY USE ONLY 3 80 FUEL SYSTEM DFI WU USE ONLY 77 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
299. her damage x Replace the bevel gearas a set if either gear is damaged since they are lapped as a setin 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 MILITARY USE ONLY 41 48 FINAL DRIVE MILITARY USE ONLY 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 Ib Front Final Gear Case Center Cover Bolts M8 24 N m 2 4 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 fro gear case right cover E e Apply a non permanent lockin bearing holder A but do not ap ing agent to one pitch e Install the pinion gear ing side C faces th e Tighten Torque 4 MILITARY USE ONLY 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
300. her tube and the fan motor WN OO OO JO Om A Regulator Rectifier breather tube to the Left Headlight Speed Sensor Ignition Switch 2WD AWD Shift Switch Multifunction Meter Harness Bands Secure the ignition switch 2WD AWD shift switch and mutifunction meter harnesses 10 11 12 13 14 15 16 17 18 Parking Brake Light Switch Lead 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 Frame Ground 2 MILITARY USE ONLY 17 36 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing 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 MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 37 Cable Wire and Hose Routing i 1T N d Are H 3 9 Ze D sch j Top View I 4 Bottom View 1808232884 C 1 Band Right and Left sides 2 Clamp the tail light lead each sides and r
301. hickly 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 MILITARY USE ONLY 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 If 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 of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before checking the toot
302. hold the front fender front see Front Fender Front Removal Quick Rivets A Cover B MILITARY USE ONLY 15 28 FRAME MILITARY USE ONLY 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 Q e When removing the front fender rear from the frame re Right and Left Bars Re moval e Remove the front fend MILITARY USE ONLY MILITARY 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 MILITARY USE ONLY 15 30 FRAME MILITARY USE ONLY 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 Re
303. 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 ar movable sheave Olnsert the shoes so that the rubb ameter faces inward on the small di e Put the drive pulley wrench tighten the bolt C Special Tool Driv e Turn the wrench on the spider B and ise for tightening Torque Spi S 275 N m 28 kgf m 203 Ib e CS ulley wrench YV e Insta spacer u Spring A in the groove of the spider e Align the arrows B on the drive pulley cover and spider 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 MILITARY USE ONLY 6 20 CONVERTER SYSTEM MILITARY USE ONLY 7 Drive Pulley Drive Pulley 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 HS040008S1 e Install the drive pulley stepped waster and two washers on the drive
304. hts Circlips Spring A OHook the spring from the outside with the open side of the hook inwards e Install KACR Unit e Hook the arms B on the pins e Apply a non permanent locking agent to the camshaft 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 Pump 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 MILITARY USE ONLY 5 24 ENGINE TOP END MILITARY USE ONLY 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 Ag 9 e Align the key grooves A on the crankshaft with the em gt bossed line B on the crankcase left side view b
305. iameter 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 A e Remove the retaining ring A e Separate to the axle shaft NS e the steel balls A lide the cage B toward the outboard joint MILITARY USE ONLY 41 72 FINAL DRIVE MILITARY USE ONLY 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 be s e Install d Vu C New Small Band A New Inboard Joint Boot B f Cage C wi c a u IM M pa e Install the inner race A so that the serration side B faces outboard joint N X AM al MILITARY USE ONLY 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 strongly e Install the new retaining ring A so that the aligned with one of the projections C Ve e Tighten the small d e Squeeze the remaining special grease A into the inboard joint boot B MILITARY USE ONL
306. inal Gear Case see Front Final Gear Case Re moval Differential Control 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 5700 e Remove Caps A Yoke B NO hold the 2WD AWD shift shaft lever B coupling C with a wrench D e e upling Nut E MILITARY USE ONLY 11 44 FINAL DRIVE MILITARY USE ONLY 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 4WD Shift Shaft Cover C 2WD AWD Shift Shaft D e Remove Oil Seal A MILITARY USE ONLY 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 Control Shift Shaft Spring e Remove Outer Disc A Needle Bearing ing A and Differential Disc Assembly B er Disc eedle Beari
307. inal Gear Case Coupling Inspechon sse 11 46 Front Final Gear Case Assembly etre orient et deduce dea debe cose ge denn 11 47 Ring Gear DisassSerbly EE 11 54 Ring Gear e EE 11 55 LSD Clutch Torque Inspection ssssssssseRR Ree 11 55 Pinion Gear Unit Disasserbly 4 rear tr ete Ren ien ee en ene Fi ca bete t reb lene 11 56 Pinion Gear Unit Assembly 11 56 enm TARY USE ONLY mmm 11 2 FINAL DRIVE MILITARY USE ONLY Front Final Bevel Gear Adjustment cccccceeeeeseeeeneceeeeeeeetseseeeeeeeeeeeeedessneeneeeeeeeeees 11 57 Front Final Gear Case Backlash Adiustmment eee ceeeeeeeee etre ee eeeaaaeeeeeeeeeeeensneeeeeeeeeees 11 60 Front Final Gear Case Tooth Contact Adjustment ccccceceeeeeeeeeneneeeeeeeeeeeeeteneeeeeeeeeees 11 61 Bevel Gear Inspechon enne nnne nennen nnne sensn nnne nnss 11 64 Differential Gear Inspection ssssssssesse mne rne neis 11 64 Rear Propeller Shaft t trie i e e He b RE RR ARE LE VR ERR RR FE HERR FEE RR E PXER M FRE Rada 11 65 Rear Propeller Shaft Removal ssssssssssssssssssssseeemeeeneene eene 11 65 Rear Propeller Shaft Installation ssssssssssssseee emen 11 65 Rear Propeller Shaft Inspection 11 67 SE le DEMEURE IE 11 68 Rear Axle HRemoval eene enne enn ren nnne nennen rennen nennen nnns 11 68 Rear Axle Installation scire ta rrt t ei LR RES RE ERD RP FC eder e e e a ta anc tg taste 11 68 Rear Ax
308. inder D Cylinder Base Gasket Piston Removal e Remove the cylinder block see Cylinder Removal e Place a piece of clean cloth under the piston and remove the piston pin snap rings A from the outside of each pis ton NOTICE AQ Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall GE16020381 C 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 oilting 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 MILITARY USE ONLY E a ENGINE TOP END 5 39 Cylinder and Piston NOTE OThe 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
309. ing disassembly and assembly AZ excessive force can cause expensive or hard to repair dam E 2 4 age When necessary remove screws that have a non CNTR permanent locking agent applied using an impact driver d Use a plastic faced mallet whenever tapping is necessary V X GB02014B S Gasket O ring Hardening shrinkage or damage of both gaskets D a S and O rings after disassembly cah reduce sealing per it JI formance Remove old gaskets and clean the sealing Noa en surfaces thoroughly so that no gasket material or other SEED WE material remains Jnstalt new oaskeis and replace used BARS O rings when re assembling Go201se S 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 GB02016B S MILITARY USE ONLY MILITARY USE ONLY 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 manuf
310. ions 4Ps essem 13 15 Front Shock Absorber Scrapping Eegen 13 15 Rear Shock Absorber Rebound Damping Force Adjustment eeeeeeneeeeeeeeeeeereeenn 13 16 Rear Shock Absorber Compression Damping Force Adjustment 13 16 Rear Shock Absorber Spring Preload Adiusiment cc cceceeeeeeeeeeeeeeeeeeeeeeteneneeeeeeeeeees Rear Shock Absorber Remo Rear Shock Absorber Installation ccccccccccceccceeeeceeeeeeeceeeeeeeceeeeeeeeeeeeeeeeteeeeeeeeeetenees Rear Shock Absorber Inspection cece ccecccecceecccceeeeeeeeeeeeceeeeeeceeeeeeeeeeeeeeeeeeeeeeeeseeeeeeetetes Rear Shock Absorber Scrapping sss S spension Arm m b ooo re eee Penes Front Suspension Ar Remo Front Suspension Arm Installation ssssssssss em PiI bnt Sspeigft Arm Disassembly ssseseeeeeeeeneeeeeereneeee nnne nnne Ero mousRsgeion Arm Aesembhy Ae R ar SO pension Arm Removal a tinihatet reperto eres xo o Pan ERE Ra PR En E sad cu DE EV Dr d Rear Suspension Arm Installaton m Fer Suspension Arm Disassembly a ceo iore oreet petere east iat ee Cice ovde oO Ene Ene Rear Suspension Arm Assembly a essssseeeeeeee eene nennt tnnt t nnn ne teneri Sabar Eer gereecherte EE ln E UE e Stabilizer Joint Ins pettorina aa a aaa e aa aa eha aeaiiai Rear Knuckle Removal sss eene eene nee eene en nennen nnne Rear Knuckle Installation
311. ir Clamp Bolt 0 in Ib e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter Rear Brake Master C O ring and Boot Replace e Remove Boot MILITARY USE ONLY Rear Brake Maste inder see Rear Brake Master E val rakes chapter Push Rod A MILITARY USE ONLYBERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Remove Circlip A Special Tool Inside Circlip Pliers 57001 143 e Remove Piston A C Cup B la Spring C aly O rings D Wil me mae e Assemble the master cylinder e Clean all the parts including the master cylinder fluid or alcohol and apply brake fluid to the re d and the inner wall of the cylinder NOTICE fluid for cleaning these p e motor oil or any other petroleum di ill cause deterio ration of the rubber parts O be difficult to wash off tely and will eventu ally deteriorate the ber used in the brake e Be careful of the cup A direction B gt S MILITARY USE ONLY 2 40 PERIODIC MAINTENANCE TARY USE ONLY Periodic Maintenance Procedures e Apply silicone grease New Cup A New O 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 G Push Rod New Boot H ODo not apply oil or grease to the seal part I o
312. is is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance 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 theesealing sheet has leaked air into the battery it may require a longer initial charge e Remove the electrolyte container fromthe 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 of otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual Cells 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 kk ELECTRICAL SYSTEM 16 21 GP08020481 C GP08003BS1 C GPO900088S1 C fee GP09000781 C MILITARY USE ONLY 16 22 ELECTRICAL SYSTEM MILITARY USE ONLY 77 Battery e Check
313. is slightly too wide and then return to the seat O D measurement step above MILITARY USE ONLY ENGINE TOP END 5 35 GE15011981 C GE15012181 C A GE15012281 C 5 36 ENGINE TOP END MILITARY USE ONLY Valves xIf the seat width is too wide make the 60 A grind de scribed below x If 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 it is it may have been refaced too much replace it e Be sure to r
314. itable commercially circlip pliers C 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 springdrom 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 xIf any damage exists replace it with a new one e Replace the O rings with new ones MILITARY USE ONLY 11 66 FINAL DRIVE MILITARY USE ONLY 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 H e Install the circlip C into the groove ofthe propeller shaft ODo not contact the boot I and oil seal J 1L06021882 C MILITARY USE ONLY MILI
315. k Absorber Spring Preload Adjustment 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 Adjustin Bamps 9 ing Setting Load Road Speed Length Force 109 5 mm 4 311 in Weak Soft Light Good Low T T T T li T A l l i I l 127 5 mm f 5 020 in 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 MILITARY USE ONLY 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 Apply grease to the grease seal lips A e Install the collars B
316. ke fluid quickly ruinsQpainted 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 timepthe AIR MUST BE BLED FROM THE BRAKE LINE Front Brake Fluid Recommendation Use extra heavy duty brake fluid only from a container marked DOT3 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 MILITARY USE ONLY 12 8 BRAKES MILITARY USE ONLY 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 AWARNING 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
317. kgf m 78 in Ib L 35 mm 1 4 in e Apply grease to the shifter sp and groove e Install Shifter A OFace the dogs C ide x Qu e Press oil seal A in the front final gear case so that e Oil seal surface is flush with the case end cial Tool Oil Seal Driver 57001 1715 pply grease to the oil seal lip B MILITARY USE ONLY 41 52 FINAL DRIVE MILITARY USE ONLY 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 4WD shift shaft cover C as shown in the figure 0 5 1 5 mm 0 020 0 059 in D 1L04053BS1 C e Apply grease to the O ring A e Install 2WD AWD Shift Shaft Cover B S OWhen installing the cover usesthe oil seal guide A for protecting the oil seal 1 Special Tool Oil Seal G 1721 ermanent locking agent to the threads of cover bolts A and tighten them WD 4WD Shift Shaft Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib MILITARY USE ONLY MILITARY USE ONLY 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 Lev
318. king brake pedal inspect 2 43 Tire wear inspect 2 32 Wheel nuts tightness inspect 2 33 Joint boots inspect e 2 48 Steering inspect 2 45 Steering joint dust boots inspect 2 46 General lubrication perform WW Y 2 49 Bolts nuts and fasteners tightness 2 51 inspect Seat belt inspect o 2 46 Cables inspect e 2 50 Service more frequently when operated in mud dust or other harsh riding conditions or when carrying heavy loads or pulling a trailer e Clean adjust lubricate torque or replace parts as necessary MILITARY USE ONLY T MILITARY USE ONLY BERIODIC 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 SS Apply silicone sealant Liquid Gasket TB1211 56019 120 Torque Fast R k astener Nm karm AIB emarks Fuel System Element Holder Screw 4 5 0 46 40 in Ib Element Cover Screw 45 0 46
319. l Temperature 120 C 248 F MILITARY USE ONLY VY MILITARY USEENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart 1608001884 C Oil Pressure Switch Front Camshaft Oil Pipes Gil Filter Crankshaft Oil Pump 1 3 4 5 6 2 Relief Valve Transmission Idle Shaft Oil Screen 7 8 9 10 11 Transmission Driven Shaft Rear Camshaft Breather Hose To Air Cleaner 12 13 MILITARY USE ONLY 7 6 ENGINE LUBRICATION SYSTEWRY USE ONLY 77 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Liquid Gasket TB1211 57001 164 56019 120 7570164ST C T5601208T C Oil Pressure Gauge Adapter PT 1 8 57001 1033 7571033ST C MILITARY USE ONLY MILITARY USFERNIGTN 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 part
320. l Drive chapter e Visually inspect the knuckle joint boots B x If the joint boot is torn worn deteriorated or leaks rease replace the knuckle see Steering Knuckle section in the Steering chapter Front Propeller Shaft Joint Boots Inspection e Remove Center Cover see Center CovemRemoval 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 anspect the tie rod end boots A of the tie rods x If the boot is torm worn deteriorated or leaks grease replace the tie rod end see Tie Rod End Removal in the Steering chapter MILITARY USE ONLY MILITARY USE ONCYBERIODIC 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
321. l Joint Output Bevel Gear Shaft e Apply molybdenum disulfide grease to t lines A of the propeller shaft B and output ar C x 1L06017BS1 C MILITARY USE ONLY 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 NR DN TON SQUE ILO6018BW2 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 ILO6O19BWi C MILITARY USE ONLY 11 26 FINAL DRIVE MILITARY USE ONLY Front Propeller Shaft e Match the boot end A to the groove of the yoke B 1L06020BS1 C Front Propeller Shaft Inspection e Remove Front Propeller Shaft see Front Propeller Shaft Re moval e Check that the universal joint A works smoothly without rattling or sticking xIf it does rattle or stick the universal joint is damaged Replace the universal joint a e Check the splines of the propeller shaft B and universal WW dinis joint Kg 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 xIf the splines are badly worn chipped
322. l seal A e Replace the O rings A with new ones e Insert the armature B so that commutator sid ace hollow side D of the yoke e Align the marks A to asse the yoke and the end cover B as shown A xO SS r Starter Motor Through Bolts A 5 0 N m 0 51 kgf m 44 in Ib wien MILITARY USE ONLY 16 48 ELECTRICAL SYSTEM MILITARY USE ONLY 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 x Replace the starter motor with a new one if there is any damage or wear e Visually inspect the commutator segments for discol enim F oration x Replace the starter motor with a new one if discoloration is noticed Armature Inspection e Using the x 1 O hand tester range measure t tance between any two commutator segments Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading two segments a winding is ope must be replaced e Using the highest hand tester tance between the segments a x If there is any reading at the starter motor must e
323. l 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 following SE Cutter angle B OY oT eN Outer diameter of cutter C GE15011881 C Operating Procedures e Clean the seat area catefully 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 downdightly onthe handle and turn it right or left Grind the Seating surface only until it is smooth 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 MILITARY USE ONLY MILITARY USE ONLY 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 calip
324. l the rivets and remove them MILITARY USE ONLY 15 26 FRAME MILITARY USE ONLY Control Panel Cupholder Installation KRF750P R S Models e Install Cupholder Case A Cupholder B Trim C Rivets D Washers E Guides F Damper G Plate H Tapping Screws I L 8 mm 0 31 in Roller Brackets J Screws K Rollers L Bolts M L 13 mm 0 51 in IP08004BW3 C e Install the cupholder case to the cupholder bracket N e Install Holder O Bolts P L 10 mm 0 39 in e Install the cupholder assembly to the control panel e Tighten the tapping screws Q both sides L 12 mm 0 47 in MILITARY USE ONLY 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 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
325. le Gear Case Oil Seal B e Visually inspect the splines of the axle x If they are badly worn or chipped replace the axle with a new one e Apply molybdenum disulfide grease to the axle splines e Apply grease to the gear case oil sealdips e Push A the end of the re r 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 MILITARY USE ONLY 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 Circlip A Boot B Small Band C Outboard Joint 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 l e Install p New SmallBangd LAT New Boot BLZ OApply the special grease slightly on the inside of the new boot Small diamet
326. le Joint Boot Inspechon EE 11 68 Rear Axle Joint Boot Replacement sse 11 69 Rear Final Gear Case RRE Ns 11 75 Rear Final Gear Case Oil Level Inspechon eese TERR 11 75 Rear Final Gear Case Oil Change eese E ae 11 75 Rear Final Gear Case Remova DES 11 75 Rear Final Gear Case lnstallaton EE 11 77 Rear Final Gear Case Disassembly H 7s 11 77 Rear Final Gear Case Right Cover Assembly EE 11 80 Rear Final Gear Case Front Cover Assembly 49 21 11 80 Rear Final Gear Case Assembly n AR MAT 11 81 Pinion Gear Unit Disassembly 4 2 d B 11 85 Pinion Gear Unit Assembly K E A 9e 11 86 Rear Final Bevel Gear Adjustment AM v 11 86 Rear Final Gear Case Backlash Adjustment 52 5 11 89 Tooth Contact Adjustment 4 09 eeeeeeeeeeeeeeneeeeeeeea 11 90 Bearing and Oil Seal a LA 11 92 Ball or Needle Bearing Inspection 99 59 ueeeesseeeeceeeeeeeeeeeeeeee 11 92 Oil Seal Inspection 8mg hi 11 93 MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 3 Exploded View Dummy Page MILITARY USE ONLY MILITARY USE ONLY 11 4 FINAL DRIVE Exploded View MILITARY
327. le 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 If the measurement is out of the range replace the sensor Water Temperature Sensor Resistance GP18055BS2 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 x If the resistance is within the standard replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit D 1 2573 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 BR BK 0 0 BR BK 2 1 ECU Electronic Control Unit 2 Water Temperature Sensor 1Cc150788W2 C MILITARY USE ONLY V8 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 Referto the Crankshaft Sensor Inspection in the Electrical System e Check the wiring for continuity see Crankshaft Sensor Circuit xIf the crankshaft sen
328. lip Pliers 57001 144 e Apply engine oil Shift Rod A and Shift Fork Ear B d Needle Bearing C e Install Shift Rod with Shift Fork Spacer D Needle Bearing e Install Reverse Drive Gear A Spacer B x MILITARY USE ONLY 9 26 CRANKSHAFT TRANSMISSION USE ONLY 7 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 N m 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 e Install Shift Shaft Cover e Tighten Torque Shift Shaft Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib Shift Fork Bending Inspection e Visually inspect the shift fork xIf the fork is bent replace the shifterod 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 Shift Fork Gear and Shifter Groove Wear Inspection e Meas re the thickness of the shift fork ears A and mea sure the width B of the shifter groove xlf the thickness of a shift fork ear is less than the service limit the shift rod must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm
329. ll the removed parts see appropriate chapter MILITARY USE ONLY 13 22 SUSPENSION MILITARY USE ONLY Suspension Arms Front Suspension Arm Disassembly e Remove Upper Suspension Arm A 8 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 Lei e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove the knuckle jointB 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 MILITARY USE ONLY 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 1N05003BS1 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 Absorbe r Bolt Washer and
330. llow 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 lf it 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 in the Periodic Maintenance chapter Differential Shift Lever Play Adjustment e Referto the Differential Shift Lever Play Adjustmentin 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 MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 35 Front Final Gear Case Differential Shift Lever Installation
331. ludes 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 MILITARY USE ONLY 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 theppump sound in the fuel tank to confirm pump operation e Turn the ignition switch ON and make sure that the fuel pump op
332. m 196 ft Ib e Insert anew 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 1K08001B81 C Brake Caliper see Brake Caliper Installation in the Brakes chapter Front Wheels see Wheel Installation MILITARY USE ONLY 10 14 WHEELS TIRES MILITARY USE ONLY Front Hub Front Hub Disassembly Assembly e Do not remove the hub bolts A x If 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 MILITARY USE ONLY 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 xIf 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 thesremover 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 57
333. 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 in 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 MILITARY USE ONLY MILITARY USE ONLY 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 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 a non permanent lockirg agent is not used OUse the following two spare bolts when installing the rear final gear case right cover A M12 Bolt B L amp E 85 mm 1 38 in P 1 25 mm 0 049 in M10 Bolt C L 35 mm 1 38 in P 1 25 mm 0 049 in FINAL DRIVE 11 89 ILOsO10BW2 C 1LO801i1BS1 C MILITARY USE ONLY 41 90 FINAL DRIVE MILITARY USE ONLY Rear Final Gear Case e Temporarily install the rear axles in the gea
334. move the drain plug MILITARY USE ONLY 2 22 PERIODIC MAINTENANGE TARY USE ONLY 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 Fill the radiator up to the radiator filler neck lt A with coolant NOTE OPour in the coolant slowly so that the air in the engine and radiator can escape e Fill the reserve tank up to the F Full level Jine with coolant NOTE OPour 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 50 Coolant 50 Freezing Point 35 C 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 MILITARY USE ONLY MILITARY USE ONLYBERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Bleed the air from the cooling system as follows
335. move the gas spring dampers A following procedure as follows OLift up the cargo bed Olnsert the standard tip screwdriver B between the clamp 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 JD and Washers C both sides Cargo Bed D Cargo Bed Installation 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 MILITARY USE ONLY 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 IPO4005BS1 C MILITARY USE ONLY 15 32 FRAME MILITARY USE ONLY 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 upp
336. mpeller A counterclockwise Water Pump Impeller Installation e Apply a smalhamount 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 MILITARY USE ONLY 108 MILITARY USE ONLY COOLING SYSTEM 4 11 Water Pump Water Pump Impeller Inspection e Visually inspect the impeller A x If 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 lf there is a coolant 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 Jmpeller Re moval Alternator Cover see Alternator Cover Removal in the Electrical System chapter e Take the bearing A out of the alternatormeover using the bearing remover Special Tools Bearing Remover Shatt 9 B 57001 1265 Bearing Remover Head 010 x 12 C 57001 1266 HD06000781 C 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
337. n 18 000 18 018 mm 0 7087 0 7094 in 22 000 22 018 mm 0 866 1 0 8668 in TIR 0 02 mm 0 00068 in or less 760 30 r min rpm Service Limit 12 05 mm 0 474 in 11 96 mm 0 471 in 35 26 mm 1 388 in 35 52 mmr 1 398 in 0 44 mm 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 1 mm 0 0039 in Cylinder Head Cylinder Compression Usable Range Electric Starter Cylinder head warp Valve Valve Clearance Exhaust Inlet Valve Head Thickness Exhaust Inlet Valve Stem Bend 251 456 kPa 2 56 4 65 kgf cm 36 66 psi 380 r min rpm 0 20 0 25 mm 0 0079 0 0098 in 0 10 0 15 mm 0 0039 0 0059 in 0 8 mm 0 031 in 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less MILITARY USE ONLY 0 05 mm 0 002 in 0 4 mm 0 016 in 0 3 mm 0 012 in TIR 0 05 mm 0 002 in MILITARY USE ONLY Specifications ENGINE TOP END 5 9 Item Standard Service Limit Valve Stem Diameter Exhaust 4 955 4 970 mm 4 94 mm 0 1945 in 0 1951 0 1957 in Inlet 4 975 4 990 mm 4 96 mm 0 1953 in 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
338. n 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 MILITARY USE ONLY 8 6 ENGINE REMOVAL INSTALMATIONUSE ONLY 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 dampers 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 Nm 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 kgfm 44 ft Ib e Install the removed parts e Adjust Throttle Cable see Throttle Pedal Free Pla
339. n Torque Rear Master Cylinder Bleed Valve 7 8 N m 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 ispfinished add fluid up to the upper level inthe reservoir e Tighten Torque Front Master Cylinder Reservoir Cap 3 4 N m 0 35 kgf m 30 in Ib e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings MILITARY USE ONLY 12 10 BRAKES MILITARY USE ONLY 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 installed bend the spring ends B to
340. n der Cylinder Head Installation 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 N m 2 0 kgf m 15 ft Ib MILITARY USE ONLY 5 30 ENGINE TOP END 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 HE12006BS1 e Tighten the cylinder head bolt M6 B Torque Cylinder Head Bolt M6 9 8 N m 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 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 hea
341. n 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 MILITARY USE ONLY MILITARY USE ONLY STEERING 14 1 Steering Table of Contents Exploded EE 14 2 eene de 14 4 Special TOONS EE 14 5 Steering Wheel and Main Shaft Assembly EN 14 6 Steering Wheel Position Adjustment eeeeeee A 14 6 Steering Wheel Free Play Inspechon kennen ua oa nna 14 6 Steering Wheel Centering irent tear tton dau E o A 14 6 Steering Wheel Removal eeeeeeeeeeeenemenmerenr rennen ad 14 6 Steering Wheel Installatigri uu ure uie ko qa ed cet de creano mede 14 7 Steering Shafts Removal eeeeeeeseeeneeenee idm 14 7 Steering Shafts Installation Me D A 14 8 Steering Gear Assembly oe ioetsjeneed Ned TE 14 9 Steering Gear Assembly Remowval e E eee 14 9 Steering Gear Assembly Installation a NN cree 14 9 Tie rod Length Adjustment P 09e sss 14 11 Steering Joint Dust Boot Inspection dm 9 M e ee 14 11 Steering Gale rdi aui ooo 14 12 Steering Knuckle Remowval 8 amp eeeeeeeeeseeessesessessssss 14 12 Steering Knuckle Installation
342. n System chapter e Tighten Torque Output Drive Bevel Gear Cover Bolts D 8 8 N m 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 ft Ib 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 Special Tool Nut Holding Bolts 57001 1481 D OutputDrive Bevel Gear Housing E Outer Ball Bearing F laner Ball Bearing G Bearing Holder H Output Drive Bevel Gear HK16001682 C MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 15 Output Bevel Gears 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
343. n in the figure Correct e Tighten Torque Element Cover Sc A 4 5 N m 0 46 kgf m 40 in Ib A NN SN element holder A until it is bottomed into t SI B as shown in the figure MILITARY USE ONLY Not Correct 1C08003BS1 C MILITARY USE ONLY FUEL SYSTEM DEI 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 and 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 A Inlet Air Temperature Sensor Connector A e Loosen Clamp Screws B e Remove 4 Hose C Air Cleaner Duct D A r Cleaner Housing and Duct Installaion Install Hose A MILITARY USE ONLY 3 92 FUEL SYSTEM DFI MILITARY USE ONLY 7 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 Install Breather Hose A and Clamp B ISC Valve Hose C e Install the ai
344. n lb 8 Water Pipe Mounting Bolts i 78 in lb 9 Valve Adjusting Screw Locknuts 106 in Ib 10 Rocker Shaft Bolts 16 L11 RearRocerCaseClampBot 88 CO TOM 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 MILITARY USE ONLY 5 4 ENGINE TOP END MILITARY USE ONLY Exploded View lel J E EA F a S Nes MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 5 Exploded View No Fastener E Remarks N m kgf m ft Ib 1 Camshaft Sprocket Bolts 12 1 2 106 in Ib L 2 Chain Tensioner Cap Bolts 22 2 2 16 3 Chain Tensioner Mounting Bolts 8 8 0 90 78 mb 4 Front Cylinder Camshaft Chain Guide Bolt 20 2 0 15 5 Position Plate Bolts 8 8 0 90 78 mb 6 Intermediate Shaft Chain Guide Bolts 8 8 0 90 78 in lb 7 Intermediate Shaft Chain Tensioner Bolts 8 8 0 90 78 in Ib 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 OCylinder Bolts L 40 mm 1 6 in 9 8 1 0 87 in lb 11 Coolant Drain Plugs Cylind
345. nal 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 MILITARY USE ONLY 7 MILITARY USE RANKSHAFT 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 MILITARY USE ONLY 9 8 CRANKSHAFT TRANSMISSIONNY USE ONLY 77 Special Tools and Sealant Outside Circlip Pliers 57001 144 AE 7570144ST C Bearing Driver Set 57001 1129 7571129ST C Crankshaft Jig 57001 1174 ST5711448T C Liquid Gasket TB1216 92104 1063 Cup 7921063ST MILITARY USE ONLY 71 MILITARY USE RANKSHAFT 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
346. nal cap on the positive terminal For CA Model e Check that the d mpers A on the plate B and bracket C are properly in place 1008023BS1 C MILITARY USE ONLY 16 20 ELECTRICAL SYSTEM MILITARY USE ONLY 77 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 1008020BS1 C e Check that the damper A on the battery bracket B is properly in place 1008024BS1 C e Install Battery Brackets A Battery Bracket Mounting Bolts B Battery C Collars D Battery Holder E e Tighten Torque lt Battery Holder Mounting Bolts F 16 N m 1 6 kgf m 12 ft Ib e Connect the positive cable first and then negative cable Positive Terminal G e Put a light coat of grease on the terminals to prevent cor rosion e Install the terminal cap on the positive terminal 1008025BS1 C MILITARY USE ONLY 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 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 Th
347. nator 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 failuresa 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 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 itat 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 V AC One black lead od SC 52 78V 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 MILITARY USE ONLY 7 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 Sta
348. nds 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 MILITARY USE ONLY Year 2010 2010 2010 2010 2010 2010 O This digit in the frame numbernchanges from one machine to another MILITARY USE ONLY MODEL APPLICATION Model Beginning Frame No KRF750NAF JKARFDN1C3AB500004 KRF750PAF JKARFDP1E1AB500001 KRF750RAF JKARFDR1T1AB500001 KRF750SAF JKARFDS10AB500001 KRF750SAFA JKARFDS10AB500001 KRF750TAF JKARFDT10AB500001 i 4 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 98p24r14 84 08 Printed in Japan
349. nect the wires in the same manner as Check 3 e Pushing the MODE button A cycle the trip meter A or B Bl AE e Raise the input requency of the oscillator to see the result ZE a of this inspection x lf the value indicated by the trip meter A or B does not increase replacesthe meter unit NOTE OThe ntegrated value of the odometer cannot be reset 1019038BS1 C 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 MILITARY USE ONLY 16 62 ELECTRICAL SYSTEM MILITARY USE ONLY Meter OThe belt check indicator light LED A should go on xIf 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 If the symbol does not flash replace the meter unit IST ZWD s Cn WM O 1019040BS1 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 Symbot ECD A should appear 1S Co Fi BE 1019041BS1 C e Connect terminal 4 to the battery terminal 1019026BS1 C MILITARY USE ONLY MILITARY USE ONLY
350. ng ILOON E MILITARY USE ONLY 41 46 FINAL DRIVE MILITARY USE ONLY 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 Front Final Gear Case Center Cover Bolts M1 Front Final Gear Case Center Cover C OUsing the pry points D remove the cover e Remove Ring Gear Assembly A Shim s B Final Gear Case Coupling Bushing Inside Diameter Standard 20 000 20 021 mm 0 7874 0 7882 in Service Limit 20 051 mm 0 7894 in 1L04027BS1 C MILITARY USE ONLY 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 1L04029BS1 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 1L04031BS1 C e Visually check the pinion gear and ring gear for scoring chipping or ot
351. ng 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 related 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 MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 87 Rear Final Gear Case Rear Final Gear Case Backlash related Parts gt bs _ ILO08009BW3 C Ring Gear Shim s Ring Gear Shim s Pinion Gear Shim s Pinion Gear Bearing Holder Ball Be rings GeamCase Right Cover Pinion Gear Ring Gear Co OO Om P Gabi A MILITARY USE ONLY 11 88 FINAL DRIVE MILITARY USE ONLY 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
352. nt 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 x If any measurements are less than the service limit re place the tire Tire Tread Depth Service Limit Front 4 mm 0 16 in Rear 4mm 0 16 in Standard Tire Front 26x 8 00 12 MAXXIS M989 Tubeless Rear 26 x 10 00 12 MAXXIS M990 Tubeless MILITARY USE ONLY MILITARY USE ONLYBERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Wheels Nuts Tightness Inspection e Check the tightness of all the wheel nuts x lf there are loose nut first loosen by 1 2 turn then re torque them to the specified torque Torque Wheel Nuts 137 N m 14 kgf m 101 ft Ib 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 A of the damper B with 98 N 10 kgf 22 Ibf 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 1813000881 C x If the lever travel is more than 9 notches clicks sat 98 N 10 kgf 22 Ibf adjust the cable Differential Shift Lever Play Adjus
353. nt Fender Rear Installation in the Frame chapter MILITARY USE ONLY WU USE ONLY ELECTRICAL SYSTEM 16 59 Meter Multifunction Meter Unit Inspection e Remove Multifunction Meter Unit see Multifunction Meter Unit Removal 1 E2 JE E4 NOTICE s Le 7 8 Do not drop the meter unit A Meter Unit Lead Connectors 1 Speed Sensor Pulse 2 Belt Indicator Light LED 3 Water Temperature Warning Symbol 4 2WD AWD 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 Oil 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
354. nt or rear final gear case overheating Insufficient oil Bevel gears maladjusted LSD clutches in front final 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 spring 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 sealed or misgimgiTARY USE ONLY 17 4 APPENDIX MILITARY USE ONLY 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 sm
355. nt solvent into the fuel tank and shake the tank to 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 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 FuekHose Replacement in the Periodic Main tenance chapter MILITARY USE ONLY MILITARY USE ONLY COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded TEE 4 2 Coolant Flow Chart cerne a e EC RE HEX UR T E CHR YR A ET ER NOME Yr cA 4 4 Specifications 2 ots ete EE 4 6 Special Tools TEE mg 4 7 rep c UM 4 8 Coolant Deterioration Inspechon Aen 4 8 AR Coolant Level Inspechon e eee Re 4 8 Coolant D PAG WEEN s 4 8 COOlant FING EE 4 8 Pressure Testing WER e 4 9 Water Pumpen pff A 4 10 Water Pump Cover Removal A ug deeg 4 10 Water Pump Cover Installation AEN 4 10 Water Pump Impeller Removal AE EN 4 10 Water Pump Impeller Installation EE EN 4 10 Water Pump Impeller Inspection 9 4 11 Water Pump Leakage Inspection 45 7 ERR eene nnne 4 11 Mechanical Seal Replacement suse 4 11 Ee TEE E 4 13 Radiator Removal enn A Ie e a e e eaea eeina 4 13 Radiator Installation Augen E 4 14 Radiator Fan Removal
356. ntact Inspect or reinstall see chapter 16 Ignition coil trouble Inspect see chapter 16 Spark plugpdirtys 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 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 V ARY U ON 3 28 FUEL SYSTEM DFI MILITARY USE ONLY DEI 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 In
357. ntil 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 If 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 necessaryifree play OMove the rubber seat B e Start the engine e With the transmission in neutral operate the throttle pedal a few times to make sure that the idle speed does not change x If theddle 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 AA 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 MILITARY USE ONLY MILITARY USE ONCYBERIODIC 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 xIf 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 adju
358. odels getestet 15 54 Front Fender Front Installation 15 27 Windshield Installation Front Fender Rear Removal 15 27 KRF750P R Models 15 54 Front Fender Rear Installation 15 28 Sun Top Cover Removal Rear Fender Remowval 15 28 KRF750P R Models 15 55 Rear Fender Installation S a 15 29 Sun Top Cover Installation Rear Flap Remowval 4 15 29 KRF750P R Models 15 55 Rear Flap Installation 4 a 15 29 EI TEE 15 57 Cargo Bed A WA 15 30 Front Guard Removal aaaeeeee 15 57 Cargo Bed Removalz 15 30 Front Guard Installation 15 57 Cargo Bed Installation 15 30 Front Bottom Guard Removal 15 57 Cargo Bed Disassembhy 13 15 32 Front Bottom Guard Installation 15 58 Cargo BecdAssembhy 15 35 Middle Bottom Guard Removal 15 58 Bars A B fe 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 o D 2 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 Fl orb ard TE 15 60 Center Cover Removal 15 44 Floorboard Removal 15 60 Center Cover Installation
359. 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 MILITARY USE ONLY 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
360. 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 A 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 inoperative 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 Ommotor 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 OThe 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 ino
361. 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 Mounting Bolt B Bracket Boltse C Left Bracket D e Remove the leads A from the clamp MILITARY USE ONLY 45 50 FRAME MILITARY USE ONLY Covers Right and Left Brackets Installation e Install Right and Left Brackets Bracket Bolts e Tighten Torque Bracket Bolts 47 N m 4 8 kgf m 35 ft lb Center Bracket Mounting Bolts 22 N m 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 ch
362. ofter 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 57001 135 Output Shaft Holder amp Spacer m1 2 1479 Output Driven Bevel Gear e Press the new ball bearing unti Special Tool Bearing Dri housing assembly A with the holder B in a ol Holder amp Guide Arbor 57001 1476 MILITARY USE ONLY 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 N m 25 5 kgf m 184 ft Ib Hold the output shaft holder A in 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 bearing driver B until it is bottomed Special Tool Steering Stem Bearing Drive WO P e Apply a non permanent agent Three Bond TB2471 Blue to the threads of the output shaft holder nut A and tighten i at the projection side B faces outward Output Bevel Gear Adjustmen
363. oltage 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 GPO8011381 C MILITARY USE ONLY 16 26 ELECTRICAL SYSTEM MILITARY USE ONLY 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 MILITARY USE ONLY MILITARY USE ONLY 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
364. olts 12 N m 1 2 kgfm 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 O Cam Height Standard Exhaust 35 363 35 477 mm 1 3922 1 3967 in Inlet 35 622 35 736 mm 1 4024 1 4069 in PERDE Service Limit Exhaust 35 26 mm 1 388 in Inlet 35152 mm 1 398 in MILITARY USE ONLY MILITARY USE ONLY 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 18 Standard 0 016 0
365. on 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 0 02 in C 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 MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 37 Front 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 6004011481 C 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 C 2WD AWD Shift Cable Removal e Remove Seat Lower Cover see Seat Lower Cover Removal in the Frame chapter Right Bracket see Right Bracket Removakin the Frame chapter e Remove Snap Pin A Pin B and Washer e Loosen the nu
366. on Coils 1 2 Service Code 51 52 Ignition Coil Removal Iristallation ionic oir eee tre rettet qe eaa euet eae ose beue Ignition Coil Winding Resistance enti i ie tS f ia det ete keen a stb uet vind Ignition Coil Input Voltage Inspection eeeeeeeeeeeeeeeeeecee enne nenne Ne T ie tnrnetecetadadsueees secahnd E e Tee EE Re Een WEE Audible EE EE Fuel Injector Resistance Inspection eese nennen Fuel Injector Power Source Voltage Inspection EE Fuel Injector Output Voltage Inspection seseeeeeeeeeeeeeee vn Fuel Injector Fuel Line Inspection eeieeeeeeennnnmeene Ne El Indicator Symbol LOD J e TT FI Indicator Symbol LCD Inspection kk EEN E ae ze EE a e ECU e RE C E ECU Installatipfi eerte deren tee N eme ECU Power Supply Inspection temen nene nemen nnns Fuel Line EE Cu Tn QD I aas Fuel Pressure Inspection Fuel Flow Rate Inspection ENEE Fuel PUMP WEE ee Soo eene Fuel Pump Remo E Fuel Pump Installation nn AA ND oem Fuel Pump Operation Inspection EE Fuel Pump Operating Voltage Inspections sues Pressure Regulator Remowval 99 amp 8 59 eeeeseeeceeeeeeenenennee Fuel Filter Cleaning AO a Boe reden timen reta eee iere Throttle Pedal and Cable VV ifl eese Throttle Pedal Free Play Inspectigff esee Throttle Pedal Free Play Adju
367. on 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 ue 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 1Q10011B F MILITARY USE ONLY 7 MILITARY USE ONLY ELECTRICAL SYSTEM 16 43 Ignition System Ignition System Circuit gt H 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 Inl
368. oothly 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 Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorreet 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 Dri
369. or Control System Actuator Control System Circuit OS o 1020009BW3 C 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 MILITARY USE ONLY MILITARY USE ONLY EL ECTRICAL SYSTEM 16 73 2WD 4WD Solenoid Valve 2WD 4WD Solenoid Valve Inspection e Remove Right Bracket see Right Bracket Removal in the Frame chapter 2WD 4WD 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 Q at 20 C 68 F xlf the reading is out of the standard replace the 2WD AWD solenoid valve x lf the reading is standard resistance check the operation of the 2WD 4WD solenoid valve as follows 1022001BS1 C e Connect the 12 V battery A to the termin ls in the 2WD AWD solenoid valve connector as shown in the figure e When the battery is connected check that the 2WD AWD solenoid valve makes a clicking sound operating sound x If the 2WD 4WD solenoid valve doesmot click replace it e When the
370. 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 OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for anydamage holes broken wires or gasket pulling off x If 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 MILITARY USE ONLY MILITARY USFERNIGTN 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 Oil Pressure Standard 515 kPa 5 3 kgf cm 74 7 psi 4 000 r min rpm Oil Temperature 120 C 248 F x If the oil pressure is much lower than the standard inspect the relief valve oil pump and or cranksh
371. or loose replace the damaged parts MILITARY USE ONLY 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 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 If they are badly worn or chipped replace the axle with a 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 Peri odic Maintenance chapter Front Axle Joint Boot Replacement Outboard Joint Boot Removal e Remove Front Axle See Front Axle 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 MILITARY USE ONLY 41 28 FINAL DRIVE MILITARY USE ONLY Front Axle e Tap the be
372. ot free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable a ss eon 6004020132 C MILITARY USE ONLY MILITARY USE ONLYBERIODIC 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 x lf 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 If 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 Glip Final Gear Case Mounting Bolts Final Gear Case Bracket Bolts Wheels Axle Nuts and Cotter Pins Wheel Nuts Brakes
373. oting 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 DFI 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 x lf any wiring is deteriorated replace the wiring 6017572081 6170
374. ounting 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 MILITARY USE ONLY MILITARY USE ONLY Radiator Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove the radiator and remove obstructions xIf the corrugated fins A are deformed carefully straighten them xIf the air passages of the radiator core are blocked more than 20 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 t ster B NOTE OWet 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
375. ower 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 eonnect 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 WIR lead Meter 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 Turn the ignition switch OFF MILITARY USE ONLY 3 66 FUEL SYSTEM DFI MILITARY USE ONLY 77 Fuel Injectors x If 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 If the ground and power supply are good replace the ECU see ECU Removal Installation x lf 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 r
376. park 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 in 3 75 6 25 kQ 7 mm 0 28 in or more 1 84 2 7650 10 4 15 6 kO 160 V or more 110 140 Q 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 4WD Solenoid Valve Solenoid Valve Resistance Switches Brake Light Switch Timing Water Temperature Sensor Resistance 12 mm 0 47 in 10 Q 120 O 3 15 Q between R and BK leads 3 5 6 5 KQ between O and BL leads 630 5 330 O between Y and BL leads 1 2 1 6 KQ 37 43 Q at 20 C 68 F ON after 10 mm 0 4 in of pedal travel 18 80 2 37 KQ at 20 C 4 F about 6 544 kO at 0 C 32 F 1 136 0 095 kQ at 40 C 104 F 0 1553 0 0070 KQ at 100 C 212 F Reference Information 6 5 mm 0 26 in 7 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 em 7571129ST C ST571405ST C Timing Light Peak Voltage Adapter 57001 1241 57001 1415 f T5712418T
377. pection 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 Connect the hand tester to the regulator rectifier xIf 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 oo oo oo oo BEN es vm e EE F D 2 26 eo eo eo E 2 50 2 26 2 26 2 206 M Tester Lead Connection MILITARY USE ONLY 7T MILITARY USE ONLY ELECTRICAL SYSTEM 16 35 Charging System Circuit 1909019882 C Ignition Switch Fuse Box Main Fuse 30 A Regulator rectifier Engine Ground Battery Alternator Loads Frame Ground 2 O00 9o90PROM MILITARY USE ONLY 16 36 ELECTRICAL SYSTEM MILITARY USE ONLY 77 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 electrical shock
378. perative 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 dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems MILITARY USE ONLY MILITARY USE ONLY WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION MILITARY USE ONLY 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
379. pper are damaged replace them heck the needle bearing and grease seals in the lower ot x If they are damaged replace them MILITARY USE ONLY 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 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 MILITARY USE ONLY 13 20 SUSPENSION MILITARY USE ONLY 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 Nut
380. pulley bolt as shown Crankcase Side A Stepped Washer B Two Washers C Bolt Head Side D HS06024BS1 C 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 N m 1 3 kgf m 111 in Ib Drive Pulley Bolt C new left hand threads 93 N m 9 5 kgf m 69 ft Ib 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 MILITARY USE ONLY 008 MILITARY USE ONLY CONVERTER SYSTEM 6 21 Drive Pulley Olnstall the drive pulley measurement tool 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 If 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
381. quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method high speed mode MILITARY USE ONLY 3 38 FUEL SYSTEM DFI MILITARY USE ONLY 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 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 elt the input voltag is less than the standard check the wiring for continuity See Throttle Sensor Circuit x If
382. que 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 in E es WP SO Ve ote a Ji Ta 1F04029BS2 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 the 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 IF04028BS2 C 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 MILITARY USE ONLY 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 Con
383. r Lever Engine Brake Control Lever Assembly Inspection 2 30 Engine Lubrication Siem NE M5 oir rte hte sene tuc e enne cedet certe ug ce bod anaes 2 31 Engine Oil Changer MMe io eee rre ek vou ente rer eant con tuner epa 2 31 Oil Filter Replacement A 2 32 Wheels Tire gg E E ENEE 2 32 Tire BIS DOU ei dn oes ous oele fected ore a ai eee na rt ret oa eda eed 2 32 Wheels Nuts Tightness Inspection eeeeercreeeeeeeeennHss 2 33 REK elt We EE 2 33 Differential Shift Lever Play Inspection AAA 2 33 Differential Shift Lever Play Adlustmment nen 2 33 NiontWinal Gear Case Oil Change eeeeeeeeenenneeeen eren nnne ette nuin nn tenens 2 33 Rear Final Gear Case Oil Change eeeeeeeneeeeeee nennen nnne nnne 2 34 n AE 2 35 Brake Fluid Level Inspechon emm 2 35 Brake Flua Cage EE 2 35 Brake Pedal Play Inspection s emot tre acras eese icon ence inn Ee rae e asset npo dRd 2 37 Brake Master Cylinder Cup and Dust Seal Renlacement enee rnen enerne nenen 2 37 Rear Brake Master Cylinder Cup O ring and Boot Hepnlace 2 38 Brake Hose and Pipe Inspechon Hee 2 40 Brake Hose Replacement ne eene nen nnne nnne n nennen en nnne 2 41 Parking Brake Pedal InSpectiOr 2 eiue ed ER Re E Ret vara utres ae DeL DR ere sadi tut ERES 2 43 Front Brake Pad Wear Inspection 2 43 Front Brake Caliper Piston Seal and Dust Seal Renlacement 2 44 Rear Brake Plates Replacement 2 45
384. r 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 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 KACR cam sticks open Engine stalls when moving off Poor R
385. r 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 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 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 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 Tooth Contact Adjustment e 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 even coat with a fairly stiff paint brush If painted too t
386. r 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 k i 78 in Ib MILITARY USE ONLY T77 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 onthe frame B xIf the dampers are damaged or deteriorated replace them e When installing the dampers install them as shown in the figure 44mm 1 7 in C 15 mm 0 6 in D 82mm 3 2 in E Front F 161101288 MILITARY USE ONLY 3 94 FUEL SYSTEM DFI WU USE ONLY 77 Fuel Tank and Fuel Hose e Check the dampers
387. r 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 MILITARY USE ONLY ENGINE TOP END 5 43 5 44 ENGINE TOP END oe TAR USE ONLY S 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 d IER P MILITARY USE ONLY MILITARY USE ONLY Exhaust System 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 If 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 xIf 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 exh
388. rain Plug 15 1 5 11 5 2WD AWD Shift Cable Holder Bolts 8 8 0 90 78 inb L 6 2WD AWD Shift Shaft Cover Bolts 8 8 0 90 78 inb L 7 2WD AWD Shift Shaft Lever Nut 20 2 0 15 R 8 Enion Gear EE Holder Nut 20 4 LB EECH 1 Front Final Gear Case Center Cover Bolts M8 24 12 Front Final Gear Case Center Cover Bolts wid 49 Bref ee E 14 Front Final Gear Case Left Cover Bolts M6 35 mm 15 Front Final Gear Case Left Cover Bolts M6 40 mm Front Final Gear Case Mounting Nuts 90 5 i Front Final Gear Case Bracket Bolts 90 5 9 2 20 4WD Position Switch 15 1 5 21 Vacuum Actuator Bracket Bolts 8 8 0 90 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 a non permanent locking agent Three Bond TB2440B Orange M Apply molybdenum disulfide grease RaReplacement Parts MILITARY USE ONLY MILITARY USE ONLY 11 8 FINAL DRIVE Exploded View MILITARY USE ONLY MILITARY USE ONLY FINAL DRIVE 11 9 Exploded View Torque No Fastener Nem kgf m ftlb Remarks 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 RearFinal Gear Case Front Cover Bolts 24 2 4 18 4 Spring Bracket Bolt 8 8 0 90 78 in Ib
389. rake 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 installing 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 O Torque Parking Brake Indicator Light Switch Screws 0 4 N m 0 04 kgf m 4 in Ib MILITARY USE ONLY 12 20 BRAKES MILITARY USE ONLY Parking Brake Pedal and Cables Parking Brake Cable Removal e Remove Control Panel see Cont
390. rallel to the line B 1004006BS1 C 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 PaneliRemoval 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 MILITARY USE ONLY 14 8 STEERING MILITARY USE ONLY 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 ft Ib 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 Q LV K GER TTT eu MILITARY USE ONLY MILITARY USE ONLY STEERING 14 9 Steering Gear Assembly Steering Gear Assembly Removal e Remove Front Wheel see Wheel Removal in the Wheel Tires chapter Intermediate Shaft Cl
391. ricant G Apply grease L Apply a non permanent locking agent O Apply high quality foam air filter oil R Replacement Parts MILITARY USE ONLY MILITARY USE ONLY 3 6 FUEL SYSTEM DFI Exploded View MILITARY USE ONLY 7 MILITARY USE ONLY FUEL SYSTEM DFI 3 7 Exploded View No Fastener TOITE Remarks j N m kgf m ft Ib 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 in Ib 4 Water Temperature Sensor 12 1 2 106 in Ib 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 G Apply grease R Replacement Parts MILITARY USE ONLY 3 8 FUEL SYSTEM DFI MILITARY USE ONLY DFI System DFI System Weg SON E amp Y ER p v i Ge A acm el RK M3 MA AN QU Lee J L i MILITARY USE ONLY MILITARY USE ONLY DFI System OONOABRWN Battery ECU Electronic Control Unit Inlet Air Pressure Sensor Throttle Sensor Fuel Injectors Crankshaft Sensor ISC Valve Fuel Pump Speed Sensor Water Temperature Sensor Vehicle down Sensor Inlet Air Temperature Sensor Multifunction Meter Delivery Pipe Air Cleaner Housing Air Cleaner El
392. river 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 in xIf the valve clearance is not correct adjust it see Valve Clearance Adjustment e Then turn the crankshaft counterclockwise with a 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 A screw with the thickness gauge Valve Clearance when cold A HE10001881 Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in x lf the valve clearance is not correct adjust it see Valve Clearance Adjustment MILITARY USE ONLY MILITARY USE ONCYBERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Valve Clearance Adjustment e Remove the valve adjusting caps e Loosen the locknut and turn th
393. rmining what CAUSED the failure If the failure was caused Dy 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 affectelectrical 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 Light green W White CH Chocolates O Orange Y Yellow DG Darkgreen P Pink G Green PU Purple MILITARY USE ONLY 1T MILITARY USE ONLY ELECTRICAL SYSTEM 16 17 Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is defective replace the damaged wiring e Pull each connector A apart and inspect for corrosion dirt and damage x If 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 MILITARY USE ONLY
394. rn 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 SUSPENSION 13 13 Adjuster Dampin Gen GE Setting Load Road Speed Counterclockwise Clockwise Softer Harder 25 Turns Weak Soft Light Good Low RID Out 1 1 1 1 1 1 D d l l 1 A 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 Adjustment EE EEN En pk Setting h Load Road Speed GE Harder Light Good Low d d a R R re Heavy Bad High INO40088 1 C MILITARY USE ONLY 13 14 SUSPENSION MILITARY USE ONLY Shock Absorbers KRF750S Model Front Shock Absorber Spring Preload Adjustment e Tilt up and hold the front fender front see Front Fend
395. rol 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 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 ret rn spring Setting Position G e Then tighten the adjuster until the4pin 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 ye CE ot M O wy Phe ae 1M09002BS2 C Parking Brake Cable Lubrication Whenever the brake cable is removed lubricate the cable as follows e Lubricate the cable with a penetrating aerosol cable lubri cant through the pressure cable luber 6004011481 C MILITARY USE ONLY MILITARY USE ONLY BRAKES 12 21 Internal We
396. ront 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 1L04039BS1 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 Support 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 rightfront 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 cl t
397. 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 thecrankshaft so that woodruff key C fits into the groove D in the hub of the rotor MILITARY USE ONLY C MILITARY USE ONLY ELECTRICAL SYSTEM 16 31 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 N m ft lb e Install Crankshaft Sensor see Crankshaft Senso tion e Fit the lead grommets into the alternator cover Grommets A for Alternator Leads Grommets B for Crankshaft Sen Sor beads ORun the alternator stator leads under the crankshaft sen sor leads OFit the
398. rrectly 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 groove 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 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 MILITARY USE ONLY 1015087BS1 C 3 82 FUEL SYSTEM DFI MILITARY USE ONLY 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 6004011481 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 i
399. rt replacement is required x lf 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 crankpingclearance with plastigage The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x lf theeclearance exceeds the service limit measure the diameter of the crankpin Crankpin Diameter Standard 39 984 40 000 mm 1 5742 1 5748 in Service Limit 39 97 mm 1 5736 in Klf the crankpin has worn past the service limit replace the crankshaft with a new one MILITARY USE ONLY 105056BS1 C 6105041781 C 9 16 CRANKSHAFT TRANSMISSION USE ONLY 7 Crankshaft Connection Rod x If 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 mm 1 5742 1 57449 in O 39 993 40 000 mm 1 57452 1 5748 in Crankpin Diameter Mark B O mark or no mark HI05021BS1 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 ft lb NO
400. s A Front Upper Suspension Arm Pivot Bolt Caps and Nut B Knuckle C and Front Suspension Arms Assembly e Remove the kn ckle joints A from the knuckle using a Suitable joint remover B MILITARY USE ONLY MILITARY USE ONLY SUSPENSION 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 Nm 4 7 kgf m 34 ft Ib Front Shock Absorber Mounting Nut 57 5 N m 5 9 kgf m 42 ft Ib e Install New Cotter Pins A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the c tter 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 e Bend the cotter pin A over the nut B HNO4001BS1 C e Insta
401. s ignition timing into the ignition timing at opened throttle position and sets the Throttle Throttle Sensor Output Top in the D J method 1 11 Voltage Sensor Also the throttle sensor system and inlet air 0 2 48V Ki pressure sensor fails the ECU locks ignition timing into the ignition timing at Opened throttle position and sets the DEI in the a N method 1 inlet AT inlet Air Press re Sensor If the inlet air pressuresensor system fails the 12 EE Output Voltage signal Pv is out of the usable range wiring Sansor 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 omopen the ECW sets Ta at 30 C Water Water Temperature If the water temperature sensor system fails 14 Temperature Sensor Output Voltage the signal is out of the usable range wiring Sensor 0 2 4 85 V short or 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 sensormustisend 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 Vilicle dffin
402. s kinked C replace the cable 6004020132 C e Lubricate the inner cable ends A with grease 6004040381 C MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DEI 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 Conn ctor C e Remove Screws A and Washers Throttle Link Case Cover B UN EC ET dicem p HAV MILITARY USE ONLY 3 84 FUEL SYSTEM DFI MILITARY USE ONLY Throttle Body Assy e Remo
403. s 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 syringe or other suitable device x lf the level is toolow add oil through the filler hole Use the same typeand 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 MILITARY USE ONLY 7 8 ENGINE LUBRICATION SYSTEWPY USE ONLY 77 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 a high flash point solvent and remove any particles stuck to it A WARNING Gasoline and low flash point solvents can be flammable and
404. s 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 MILITARY USE ONLY MILITARY USEENIGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents s tollore or 1 2 Specifications ecce es ot n e EO E EC RR ee REX REN RR XT XX CHEER ORARE Te ERO Y Ede RA 7 4 Engine Qil ee Ec Pp TR 7 5 Special Tools and Gealant eenen ernen r aen rnerreerreenreenreennnennnennnenneennee nne tenna 7 6 Engine Oll and Oil EE ots 7 7 Oil Level INSPECTION ET D 7 7 Engine OIL el Le GE GE A 7 7 OILFINGR CMAN EE WEE M 7 7 Oil ScreeniReroVal nie trece eege deed Ee degree age 7 8 Oil Screen Cleaning 5 uae tenerte tete actos t ceo dm ee 7 8 Oil Pressure Measurement e AM eee 7 8 Oil Pressure Relief Valve A RS 7 10 Oil Pressure Relief Valve Hemoval ENEE 7 10 Oil Pressure Relief Valve Installation eeuses esses senes eene 7 10 Oil Pressure Relief Valve Inspection sees bees 7 10 Oil PUMP ien nme mne o NEC ooo eee 7 11 Oil Pump REMOVAL a LIUM esee
405. saki 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 Second Edition 1 Sep 16 2009 M MILITARY USE ONLY MILITARY USE ONLY LIST OF ABBREVIATIONS 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 C 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 Canad
406. se SS e Tighten the rocker case bolts following the tightening se quence as shown in the figure Torque Rocker Case Bolts 8 8 N m 0 90 kgf m 78 in Ib 1 2 3 4 L 55 mm 22 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 M8 bolt A remove the rocker shaft B e Remove 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 E10 P MILITARY USE ONLY 5 18 ENGINE TOP END 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 N m 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
407. se Breather Hose 2 Bands 3 Clamp 4 Reserve Tank Overflow Hose 5 Fan Motor Breather Hose 6 Frame Clamp MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 13 Cable Wire and Hose Routing ze 4 EET C Le Y VW Wak Lat SE Cx VAN Ne Ka M d l nee eX S SET 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 MILITARY USE ONLY 17 14 APPENDIX MILITARY USE ONLY Cable Wire and Hose Routing 1808223884 C Clamp Insert the breather hose to outside lower fitting Band Install the band so that the position is about middle in 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 to Frame View A View B Go NA Odo OO JO A P MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 15 Cable Wire and Hose Routing KIN G ae CAE A REX U A deg A Ce CET ly PES Ka EE 1808224884 C 1 Filter 9 Clamp 2 Bre
408. se Routing Qi P P E ae A M Wee SANK X Ap 7 p 7 Z Detail L Em Ned NUS N bai m o e 18082388W5 C MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 33 Cable Wire and Hose Routing OONDABRWDN a Ces Ce e DX 2X OO P oh O ISC Valve Harness Water Temperature Sensor 2WD 4WD 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 MILITARY USE ONLY Right Side View MILITARY USE ONLY Cable Wire and Hose Routing 17 34 APPENDIX im l Nr WV Top View Za m fei j e E is n 9 Front MILITARY USE ONLY MILITARY USE ONLY APPENDIX 17 35 Cable Wire and Hose Routing 1 Cover the regulator rectifier connector with cover Band Secure the regulator rectifier lead with the front gear case breat
409. se illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly MILITARY USE ONLY ve MILITARY USE ONLY GENERAL INFORMATION 1 1 General Information Table of Contents Before SEM ICING WEE Model e E due en WEE General Specifications Unit Conversion Table MILITARY USE ONLY 1 2 GENERAL INFORMATION MILITARY USE ONLY 77 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 negative wire to the negative terminal ASSEMBLY GB02024B S Edges of Parts Lift large or heavy parts wearing gloves to prevent injury
410. 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 HD06000881 C MILITARY USE ONLY 4 12 COOLING SYSTEM MILITARY USE ONLY 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 shown Special Tool Bearing Driver Set 57001 1129 HD060009S1 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 flanige stops at the step D of the hole Special Tool Bearing Driver Set 57001 1129 HD06001181 C e Clean the sliding surface of a 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
411. 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 tainer sides or bottom e Gradually raise the temperature of the water while stirring the water gently for even temperature xIf the measurement is out of the specified range replace the thermostat Thermostat Valve Opening Temperature 69 5 72 5 C 157 163 F GD09020282 C MILITARY USE ONLY 08 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 MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded View sess 5 2 Cylinder Head Cleaning 5 30 Specifications sssssss 5 8 Cylinder Head Warp Inspection 5 30 Special Tools and Sealant 5 11 Wal m aa aeiia 5 31 Camshaft Chain Tensioner 5 13 Valve Clearance Inspection
412. shaft tapered end the shorter end into the right crankcase using a press and two crankshaft jigs Special Tools Crankshaft Jig 57001 1174 x 2 WiO40014 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 HIO40015 P 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 MILITARY USE ONLY 9 14 CRANKSHAETITRANSMISSIONTT USE ONLY 7 Crankshaft Connection 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 ft lb
413. short Water temperature sensor malfunction wiring M open or short Crankshaft sensor malfunction wiring open 21 or short short Vehicle down sensor malfunction wiring S open or short 46 JUL DS EH J LJUUL JI UWL CON IL 24 TULAI Speed sensor malfunction wiring open or SA JUUU LIUUUUUL Fuel pump relay malfunction relay is stuck MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DFI 3 35 Self Diagnosis Service Code FI Indicator Light Problems Ignition coil 1 malfunction wiring open or 51 short Ignition coil 2 malfunction wiring open or 52 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 faultwand the mechanical parts of the DFI system and the engine are suspect MILITARY USE ONLY 3 36 FUEL SYSTEM DFI MILITARY USE ONLY 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 Pars Range or Criteria EE If the throttle sensor system fails the signal is out of the usable range wiring short or open the ECU lock
414. sing a wrench on the alternator bolt turn the crankshaft clockwise until T R mark A is aligned with the notch B in the inspection window f tg A 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 a wrench on the alternator bolt turn the crankshaft clockwise 270 OAlign the T F mark A with the notch B in the inspection window HE10001BS1 C MILITARY USE ONLY 5 20 ENGINE TOP END MILITARY USE ONLY Camshaft e Face the arrow A of the front camshaft sprocket upward right side view e Engage the front camshaft chain with the front camshaft sprocket e Align the marks B on the weights with the front cylinder head upper surface HE09010BS1 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 B
415. sis Sheet Year of initial registration Models ngieNo Frame Ofine Ocloudy Orain Osnow Dalways Dother Temperature Ohot Owarm Ocold Overy cold Dalways Problem Ochronic Doften Donce frequency Ostreet Omountain road Ouphill Odownhill Cbumpy Opebble Altitude Onormal Ohigh about 1 000 m or more Vehicle conditions when problem occurred Fl indicator symbol appears immediately after ignition switch ON and disappear after 1 2 symbol LCD seconds normal Hengine flooded do not erank engine with throttle opened which promotes engine flooding Engine stops L1 L1 sometimes symbol appears probablyswiring fault when returning throttle pedal DIwhen Stopping the vehicle Ewen cruising Mother Poor running Overy low idle speed Overy high idle speed Orough idle speed atlow Speed ribattery voltage is low charge the battery Ospark plug loose tighten it Ospark plug dirty broken or gap maladjusted remedy it Obackfiring Dafterfiring Ohesitation when acceleration Hengine oil viscosity too high Obrake dragging Oengine overheating Dother MILITARY USE ONLY 3 26 FUEL SYSTEM DFI MILITARY USE ONLY Troubleshooting the DEI System Poor running Ospark plug loose tighten it or no power at spark plug dirty broken or gap maladjusted remedy it high speed Ospark plug incorrect replace it
416. sor and the wiring are 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 Crankshaft Sensor Circuit Ze 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 BL R B BK R BK W 2 BL R BL 1C15081BW2 C 1 ECU Electronic Control Unit 2 Crankshaft Sensor MILITARY USE ONLY 3 54 FUEL SYSTEM DFI WU USE ONLY 77 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 O
417. sory Connector 12 V 120 W Power Outlet Actuator Controller Air Temperature Sensor Brake Light Switch Apply grease Follow the specific tightening sequence MILITARY USE ONLY 16 10 ELECTRICAL SYSTEM MILITARY USE ONLY Exploded View 1902050B8W5 C MILITARY USE ONLY 7T MILITARY USE ONLY ELECTRICAL SYSTEM 16 11 Exploded View No Fastener Torang Remarks i N m kgf m ft Ib 1 Water Temperature Sensor 12 1 2 106 in Ib 2 Radiator Fan Assembly Bolts 8 3 0 85 73 in lb 3 Oil Pressure Switch 15 1 5 11 SS 4 Battery Holder Mounting Bolts 16 1 6 12 5 Regulator Rectifier Mounting Bolts 8 8 0 90 78 in Ib 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 MILITARY USE ONLY 16 12 ELECTRICAL SYSTEM MILITARY USE ONLY 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 15V 52 78 V at 4 000 r min rpm 0 24 0 36 O Service Limit Ignition System Spark Plug Spark Plug Gap S
418. spect Inspect Inspect see chapter 3 see chapter 3 see chapter 3 see chapter 3 see chapter 3 Inlet air temperature sensor trouble LL jaja s 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 e Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Fuel pressure too low or too high 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 chap
419. ssion is released during oe running 1 If compression is not released during starting the A 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 and move the weights back and forth xIf 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 HE09001BS1 C 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 xIf 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 KAGR Unit B HE09002BS1 C HME090078 P MILITARY USE ONLY MILITARY USE ONLY ENGINE TOP END 5 23 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 Weig
420. stance 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 temperature 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 KQ at 0 C 32 F 0 29 0 39 kO at 80 C 176 F x If 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 MILITARY USE ONLY G0176080S2 C 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 MILITARY USE ONLY
421. sted 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 element 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 MILITARY USE ONLY 2 18 PERIODIC MAINTENANGE TARY USE ONLY 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 lf 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 fu
422. stment ccccceeesceeeeeeeeeeeeeeeeseeseeseeeeeeeeeseeeeseneeeeeeeeeenees Throttle Pedal Position Zerf EEEEEREEERRNEEEEEEEEREEEEREEEERREEEEEEEEEEEEERRNEEEEN Throttle Pedal Remover R WEE Throttle Pedal Installation 9 er ner e Rh t hte t Mader tct nn rene Throttle Gable cn OM N N EE Throttle Cable Lubrication and Inspection eee Throttle Bady Mv eege EE Idles amp amp peed InSpection ssssssssssseenemeeennnemenemenemenemene mener nnn nennen nnns IL ER Go allt ET otro Eo EODD e boc Rete bebes uv ln Siet TI ue CIE Wrote BOW Assy E te EE Er maiteWwody Assy Disassembly EEN Marone Body Assy Assembly EE Engine Vacuum Synchronization Inspection Engine Vacuum Synchronization Adjustment 2 eee eeeeeeeeee eee eeeeeeaaeeeeeeeeeeeeeeeneeeeeeeeeees ES Ee EE EE ISC Valve EE ISG Valve Installatio eter ISC Valve Inspection PIC E Air Cleaner Element Removeal ccccccecsseecencnsceeneenseneeseneneeeeeesenedeeeeeeeeeeetessssceeneenensenes Air Cleaner Element Installation ccccccccccsecceeeeeeeeeeesdeneceeeeeeeeeenseeeeeeeeeeeesnedsneceneeeenenes Air Cleaner Element Cleaning and Inspection sssssseee D ct Removal ee eh geen Air Cleaner Housing and Duct Remo AN ICARY USE ONLY 3 59 3 59 3 59 3 61 3 61 3 61 3 61 3 63 3 63 3 63 3 65 3 65 3 65 3 66 3 67 3 69 3 69 3 70 3 70 3 70 3 70 3 73 3 73 3 74 3 76 3 76 3 76 3 7
423. t C and remove th 2WD AWD shift cable from the bracket D e Remove 2WD AWD Shift Cable Locknuts A 2WD 4WD Shift Cable End B e Remove the 2WD AWD shift cable from the frame MILITARY USE ONLY 41 38 FINAL DRIVE MILITARY USE ONLY Front Final Gear Case 2WD 4WD Shift Cable Installation e Apply grease to the front end of the cable e Run the 2WD 4WD shift cable according to the Cable Wire and Hose Routing section in the Appendix chapter e Install 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 AWD Shift Cable Locknut A 4 4 N m 0 45 kgf m 39 in Ib e Install the cable tension adj sting tool A on the cable and between the brackets as shown in the figure Special Tool Cable Tension Adjusting Tool 57001 1716 1L04049BS1 C MILITARY USE ONLY 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 N m 0 45 kgf m 39 in Ib
424. t D e Tighten Torque Spring Bracket Bolt 8 8 N m 0 90 kgf m 78 in Ib 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 Di Y SS e Remove Pinion Gear Uni see r Final Gear Case Disas sembly e Hold the pi earing holder nut B with the socket ocket Wrench 57001 1363 Pinion Gear Holder m1 0 57001 1281 KS he ball bearing E as necessary ecial Tool Bearing Puller 57001 135 MILITARY USE ONLY 41 86 FINAL DRIVE MILITARY USE ONLY 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 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 Beari
425. t 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 both sides Torque Right and Left Bar Mounting Bolts A 9 kgf m 72 ft lb Seat Belt Case Mounting Nuts B kgf m 34 ft lb Torque Seat Belt Mounti 31 ft lb 5 N m 4 2 kgf m MILITARY USE ONLY MILITARY USE ONCYBERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Torque Seat Belt 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 x lf the plate is damaged replace the plate assembly with a new one x lf 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 ot 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
426. t 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 MILITARY USE ONLY MILITARY USE ONLY SUSPENSION 13 1 Suspension Table of Contents Exploded E 13 2 Specifications attt ento ete ERO ed bae etas 13 6 ele ierMeelc e rbrcc EEUU 13 7 Shock Absorbers Other than KRF750S Model 13 8 Front Shock Absorber Spring Preload Adjustment EE 13 8 Front Shock Absorber Remova sse ke 13 8 Front Shock Absorber Installation EE 13 8 Front Shock Absorber Inspechon EE 13 9 Front Shock Absorber Scrapping RE 13 9 Rear Shock Absorber Spring Preload Adjustment 4 ee Ress 13 10 Rear Shock Absorber Removal A ue Tess 13 10 Rear Shock Absorber Installation EEN 13 11 Rear Shock Absorber Inspection EE 13 11 Rear Shock Absorber Scrapping AN 13 12 Shock Absorbers KRF750S Model 9 E EEN 13 13 Front Shock Absorber Rebound Damping Forcee Adjustment essssssessss 13 13 Front Shock Absorber Compression Damping Force Adjustment 13 13 Front Shock Absorber Spring Preload Adjustment 0 cece ceeeeeneeeeeeeeeeeeteneeeeeeeeeeees 13 14 Front Shock Absorber Remowval essen nennen 13 14 Front Shock Absorber Installation eegen 13 14 Front Shock Absorber Inspect
427. t 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 chapter Brake Cable Rear End B Breather Hose C MILITARY USE ONLY 41 76 FINAL DRIVE MILITARY USE ONLY 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 MILITARY USE ONLY 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 N m 9 2 kgf m 67 ft lb Re
428. t Procedure acklash and tooth contact pattern of the bevel must be correct to prevent the gears from making ise and being damaged hen 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 Adjust gear backlash Adjust tooth contact pattern Assemble the output bevel gear completely HK16005BS1 C MILITARY USE ONLY 11 20 FINAL DRIVE MILITARY USE ONLY Output Bevel Gears Output Bevel Gear Backlash related Parts HK08008BW3 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 Thickn ss 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 0 039 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 SEIN
429. t cracked worn swollen or other wise damaged x If 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 mustslide smoothly on the caliper holder shafts A H 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 xIf the rubber boot is damaged replace the rubber boot xIf caliper holder shaft is damaged replace the caliper holder shaft and rubber boot as a unit HLOG014BS1 C MILITARY USE ONLY 12 16 BRAKES MILITARY USE ONLY 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 iip 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 1
430. t ret eMe eek aM ie be e nta iauahcaddaedbealuewcete 2 3 Torque and le e Agenter iann an eaaa eaa nae a aE A AE AE E Ai Ka ET SETENE DEA 2 5 eene de 2 13 Special TOONS EE 2 15 Periodic Maintenance Procedures eeeeeeeenenee meme ih 2 16 Fuel Syste GEET E 2 16 Throttle Pedal Free Play Inspection Matt 2 16 Throttle Pedal Free Play Adjustment eec MA A 2 16 Idle Speed Inspection E 2 17 Idle Speed Adjustment esce a E ban 2 17 Air Cleaner Element Cleaning and Inspection ERAN 2 17 Air Cleaner Draining onere ert et t rl cna em 2 18 Fuel Hose and Connections Inspection AER 2 18 Fuel Hose Replacement EE 2 19 COGIING SV STOTTE EEN Coe 2 20 Radiator Cleaning EE df eem 2 20 Water Hoses and Connections Inspection 45 E 2 20 Coolant Charges ctetu E E Soc 2 20 Engine Top End ec o tette hosce Nifi t Ere 2 23 Valve Clearance Inspection eese mener 2 23 Valve Clearance Adjustr ent o NEC 09B eene ee etre docerent 2 25 Spark Arrester Cleaning Mid A B 2 25 Converter System noce ON eerie ce eO d mue Une er Ux ee 2 26 Converter Drive Belt Wear Jngpechon dadhy cccccccccecccecccecccececeeeeeeeececeeeeeeeeeeeeeeeseeeeteeess 2 26 Drive Belt Deflection Inspection a suus Ree 2 28 Converter Drive Belt DeflecthgMAdjuStment ccc ccceeeeeeseeeeneeeeeeeeeeeeeseeeaeeeeeeeeeenenneaeeees 2 30 Actuato
431. ter 3 Inlet ir 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 LN IL Inspect see chapter 3 Surge MILITARY USE ONLY 77 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 Bacifiring when deceleration A Fuel pump trouble spect see chapter 3 Throttle sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble nspect 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 temper
432. terminal 44 Meter Battery Terminal HC11083BS1 C Connections for Ignition Coil 2 Rear Meter BL W lead terminal 35 Meter Battery Terminal e Measurerthe input voltage to each primary winding of the ignition coils with the engine stopped and with the con nectors joined e Turn the ignition switch ON Ignition Coil Input Voltage Standard 12 V or more MILITARY USE ONLY 3 62 FUEL SYSTEM DFI MILITARY USE ONLY Ignition Coils 1 2 Service Code 51 52 e Turn the ignition switch OFF x If the input voltage is out of the standard check the wiring for continuity see Ignition Coil Circuit Special Tool Hand Tester 57001 1394 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 input voltage is within the standard 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 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 NS bc x ea ta e G W 1C15081BW3 C 1 ECU Electronic Control Unit 7 Spark Plug Front 2 Engine Ground 8
433. ternator Stator Removal 16 31 Alternator Stator Installation 16 31 Regulator Rectifier Output Voltage Inspection eier 16 31 Alternator Inspection 5 16 32 Regulator Rectifier Removal 16 33 Regulator Rectifier Installation 16 33 Regulator Rectifier Inspection 16 34 Ignition System sem M A 16 36 Spark Plug Hemoval 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 Peak Voltage Inspechon n on 16 39 Crankshaft Sensor Removal 16 39 Crankshaft Sensor Installation 16 40 Crankshaft Sensor Inspection 16 40 Crankshaft Sensor Peak Voltage Inspechon nnee 16 40 Alternator Rotor Inspection 16 41 Ignition Timing Test 16 41 Electric Starter System 16 44 Starter Motor Removal 16 44 Starter Motor Installation 16 44 Starter Motor Assembly Brush Inspection Commutator Cleaning and Inspection Armature Inspection 1 Brush Lead Inspection 4 Right hand End Cover Inspection Starter Relay Inspectionyy 4 Starter Relay Installation
434. tery Monitor W R Power Supply from Battery W External Communication Line KDS LG 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 Y W Unused Speed Sensor P gt Neutral Switch LG Vehicle down Sensor Y G Parking Brake Switch G Crankshaft Sensor BK R Unused Unused Unused Starter Button BK W Diagnosis Terminal LG BK ISC Valve 4 W BK 2WD 4WD 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 Ignition Coil 2 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 Check Indicator Light LED O R Starter Relay BL Ground BK Y Injector 1 BL R Ignition Coil 1 G W MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DEI 3 13 DFI Parts Location Fl Indicator Symbol LCD A f EE SECH 1019047851 C 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
435. the breaker push the reset button after ten seconds or more pass 12vpc 1 a HP13002BS1 C 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 Battery 1 2 3 4 5 6 7 8 9 MILITARY USE ONLY 16 58 ELECTRICAL SYSTEM MILITARY USE ONLY 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 1Q19001BS1 C e Install Meter Assembly and Upper Damper Meter Bracket Screws e Connect Meter Lead Connector e Install Cover see Fro
436. the steel balls and cage e Squeeze about half a tube of the special grease A into the bearing cup B itosi P e Install the bearing cup A onto the balls and cage assem Q e Install the new retaining ring ei the opening B is aligned with one of the projections NS eezet maining special grease A into the bearing inboard joint boot C HK10004BS1 C MILITARY USE ONLY MILITARY USE ONLY 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 eqalize the pressures Q e Pinch the boot band A with a able tool B to install it Recommend Tool OETIKER 192 NS e he outside diameter of the band A is less than e maximum diameter aximum Outside Diameter of Band 73 4 mm 2 89 in MILITARY USE ONLY FINAL DRIVE 11 33 1L07018BS1 C 41 34 FINAL DRIVE MILITARY USE ONLY 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 a
437. the tester does not read as specified replace the ISC valve HC11086BS1 C MILITARY USE ONLY MILITARY USEONLY FUEL SYSTEM DEI 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 AE 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 through into the engine excessive en gine wear and_ possibly engine damage will occur e Remove h Element Cover Screw A Element Cover B MILITARY USE ONLY 3 90 FUEL SYSTEM DFI MILITARY USE ONLY 77 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 G NOTE OBe sure that the edge of the element A fits comp Y in the groove and does not rest on the edge c ement holder B or become folded in the groc show
438. 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 Vehicle down Sensor Circuit Me 1C15059BS2 C 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 Kc BR W r BR BK 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 BR BK Y G BR W q Je HC110578W2 C 1 ECU Electronic Control Unit 2 Vehicle down Sensor MILITARY USE ONLY TTT 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 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 MILITARY USE ONLY 3 60 FUEL SYSTEM DFI MILITARY USE ONLY Fuel Pump Relay Service Code 46 Fuel Pump Relay Circuit O 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 3
439. 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 H 4 4 N m 0 45 kgf m 39 in Ib 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 N m 1 1 kgf m 96 in Ib Throttle Pedal Removal e Remove Spring A Snap Pin B and Washer e Remove the throttle pedal from the bracket MILITARY USE ONLY 77 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 tion of the spring 1C04004BS1 C e Install the spring A as shown in the figure Downward B 1C04001BS1 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 co
440. tin 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 MILITARY USE ONLY 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 OBrakes overheat OThere is a large difference in inner and outer pad wear OThe seal is stuck to the pistons x lf the piston seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed HL06011BS1 C 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 no
441. tment 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 Bocknuts 9 8 N m 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 vehicle so that it is level both side to side and front to rear 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 Afterthe 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 kgf m 11 ft Ib MILITARY USE ONLY 2 34 PERIODIC MAINTENANCE TARY USE ONLY 7 Periodic Maintenance Procedures e Fill the gear case up to the bottom of filler opening with SAE 208 50 gt the oil specified below SAE 20W 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
442. tom Guard Removal e Remove Bottom Guard Bolts A and Collars Rear Bottom Guard B Rear Bottom Guard Installation e Install Rear Bottom Guard A Bottom Guard Bolts B and Collars C IP14004BS1 C MILITARY USE ONLY 45 60 FRAME MILITARY USE ONLY 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 Bracket Mounting Bolts A al Bracket B MILITARY USE ONLY 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 Collars Q e Remove Screws A and ZA AO Tapping Screws A and Collars rews B and Collars uick Rivets C Left Floorboard D MILITARY USE ONLY 15 62 FRAME MILITARY USE ONLY 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
443. 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 mm 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 in 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 45 627 5 57001 1114 Valve Seat Cutter 32 628 57001 1119 Valve Seat Cutter 60 530 57001 1123 Inlet Valves Valve Seat Cutter 45 630 57001 1187 Valve Seat Cutter 32 533 57001 1199 Valve Seat Cutter 60 530 57001 1123 Holder and Bar Valve Seat Cutter Holder 5 57001 1208 B Valve Seat Cutter Holder Bar 57001 1128 C xIf the manufacturer s instructions are not available use the following procedure MILITARY USE ONLY 5 34 ENGINE TOP END MILITARY USE ONLY 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 wil
444. tor Coil Resistance at 20 C 68 F Connections Tester Range Reading Tester to Tester to x10 One black lead iud eae 0 24 0 36 Q x If there is more resistance than shown in the table or no reading infinity for any two leads the stator has an open and must be replaced 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 x Any reading less than infinity lt indicates a short neces sitating stator replacement x If 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 1009020BS1 C Regulator Rectifier Installation e Connect the regulator rectifier lead connector e Install Regulator Rectifier e Tighten Torque Regulator Rectifier Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib MILITARY USE ONLY 16 34 ELECTRICAL SYSTEM MILITARY USE ONLY Charging System Regulator Rectifier Ins
445. tors B as follows BL R and W R Leads Connector Front Fuel Injector V and WIR Leads Connector Rear Fuel Injector MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DEI 3 65 Fuel Injectors Audible Inspection e Remove Engine Upper Cover see Engine Upper Cover 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 O at 20 C 68 F e f the reading is out of the standard replace the fuel in jector SS e f the reading within the standard check the power source voltage see Fuel Injector Power Source Voltage Inspec tion Fuel Injector P
446. ttle pedal play inspect Fuel hoses and connections inspect Fuel hose replace Idle speed inspect Spark plug clean and gap inspect Air cleaner inspect Valve clearance inspect Spark arrester clean First 2 000 km 1 200 mile thereafter every 4 000 km 2 500 mile Engine oil change Oil filter replace Front and rear final gear case oil change Radiator clean Water hoses and connections check Coolant change Converter drive belt weatsinspect Converter drive beltdeflection inspect Differential shiftlever play 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 replace Rear brake master cylinder cup O ring and boot replace 2 years Front brake caliper piston seal and dust seal replace Brake hose replace Brake fluid level inspect Brake pedal play inspect MILITARY USE ONLY 2 38 2 4 PERIODIC MAINTENANCE MILITARY USE ONLY 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 Brake hose and pipe inspect 2 40 Par
447. tween any r motor easure the resis Al nan IB Le circuit components check good but motor still does not turn over or only turns replace the starter motor with a new one MILITARY USE ONLY 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 anda 12 V battery B to the starter relay as shown x If the relay does notwork as specified the relay is defec tive Replace theelay Testing Relay Hand Tester Range x 10 range Criteria When battery is connected gt 0 Q When battery is disconnected gt oO
448. unning at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or sparksplug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect ECH trouble Grankshaft 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 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 MILITARY USE ORigh 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
449. uring inspect the bearing for abrasion color change or other damage xIf there is any doubt as to the condition of a needle bear ing replace it 6114010181 C Oil Seal Inspection e Inspect the oil seals x Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged MILITARY USE ONLY MILITARY USE ONLY WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded TEE eigene e ele a Le Wheel Alignment ET RN Toe in lnspechon nn sees Toe in Adjustment ET ese Wheels RIMS NET TE Wheel Hemoval NR BR oo Wheel Installations ote cete t HP A dte bdo be RR PB ee Wheel Rim InspectOon ecce i rte ot all m aee Wheel Rim Replacement esee ur a Tire Inspection EE H nscnesenssaeenansaaees FON TUD DEE AA e Front Hub Remowval ad P E aaraa Front Hub Installation 4E 99 OOo raer Front Hub Disassembly Assembly BXstz nM Uh Kc Rear Hub Removal RN We ei teen tiri belek cen Fe eh ined Rear Hub Installation h SW A Rear Hub Disassembly Assemblyf S T ek MILITARY USE ONLY 10 2 WHEELS TIRES MILITARY USE ONLY Exploded View 1K020078W85 C MILITARY USE ONLY MILITARY USE ONLY WHEELS TIRES 10 3 Exploded View
450. uspension Arms Stabilizer Installation e Install the stabilizer A so that the recess side B faces to lower side 1N05011BS1 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 N m 3 2 kgf m 23 ft Ib 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 If 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 MILITARY USE ONLY 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 Tight
451. val 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 st ering wheel before the front wheels begin to turn Steering Wheel FreesPlay Standard 0 20 mm 0 079 in x lf steering wheel free play isnot correct inspect the fol E lowing Steering Wheel Mounting Nut see Steering Wheel Cen tering in the Steering chapter lntermediateyShaft Clamp Bolts see Steering Shaft In stallation in the Steering chapter Steering Gear Assembly Bracket Bolts see Steering Gear Assembly 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 xIf 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 MILITARY USE ONLY 2 46 PERIODIC MAINTENANCE ILITARY USE ONLY 77 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 1816001BS Frame Sea
452. ve Screws A e Remove Headlight Connector A Vertical Adjustment Screw B Spring and Nut Bolts C both sides 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 MILITARY USE ONLY 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 19138112 P e Install the removed parts A Screw M5 L 10 mm 0 39 in B Screw M6 L 25 mm 0 98 in e Connect the headlight lead connector A and install the champs B e After installation adjuiStythe 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 MILITARY USE ONLY 16 54 ELECTRICAL SYSTEM MILITARY USE ONLY Lighting System e Remove Tail Brake Light Lens Mounting Scre
453. ve 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 piecesyof 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 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 MILITARY USE ONLY MILITARY USE ONLY FUEL SYSTEM DEI 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 Install Vacuum Hose ISC Valve Hoses Throttle Body Assy e Tighten the throttle body assy holder clamp screw se cur
454. ve Shaft Oil Pump Cover Inner Rotor 4 4Out r Rotor New Circlip Se e Check to see that the dowel pins A are in place Apply engine oil in the oil pump housing MILITARY USE ONLY 7 12 ENGINE LUBRICATION SYSTEM USE ONLY 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 e Tighten Torque Chain Guide Bolt 8 8 N m 0 90 kgf m 78 in Ib e Apply grease to the O ring A e Install Pin B Spring C O ring Oil Pump Drive Chain Tensioner Bolt D 25 e Tighten Torque Oil Pump Drive Chain Tensioner kgf m 18 ft lb V MILITARY USE ONLY HG06002BS1 C HG06001BS1 C 7 MILITARY USENGHNE LUBRICATION SYSTEM 7 13 Oil 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 Oil Pump Removal Oil Pipe Bolts A Oil Pipe B Engine Right Side Oil Pipe NK e Remove Drive Pulle
455. ve Stem A Oil Seal B Spring Seat C ON Spring D Retainer eS ii ES emoval HE13000BS2 C e see Valve Removal Stem Oil Seal mer lightly on the valve guide arbor A to remove the uide from the top of the head Special Tool Valve Guide Arbor 5 57001 1203 MILITARY USE ONLY 5 32 ENGINE TOP END MILITARY USE ONLY 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 necessary 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 HETSODIBS P the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance
456. ve or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mountloose 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 gear 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 MILITARY USE BNaMe oil level too high 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 damag
457. ver 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 Put the belt deflection gauge A along with theisemi circle cutout B in the cover plate and let the flat end of the gauge contact at right angle to th belt C NOTE OTake 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 MILITARY USE ONLY MILITARY USE ONLYBERIODIC MAINTENANCE 2 29 Periodic 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 SIRF253181 C 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 t
458. verter Cover Assembly e When installing the bushing A into the cover B press it until it is 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 Measuresthe installation length A of the actuator lever assembly between the cover end B and resin 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 CZ e Va 1IF04022BS1 C MILITARY USE ONLY 6 12 CONVERTER SYSTEM MILITARY USE ONLY 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 If the measurement is less than 1 33 mm 0 052 in use the actuator lever assembly 13236 0123 of yellow paint x If the measurement is more than 2 47 mm 0 097 in
459. vice Limit Torque Converter Actuator Lever Guide Shoe 6 mm 0 24 in EE Mp 164 63 165 77 mm 6 481 6 526 in Drive Belt Belt Width 30 0 30 6 mm 1 181 1 205 in 28 6 mm 1 126 ing Belt Deflection 22 31 mm 0 87 1 22 in at checking Ie 22 27 mm 0 87 1 06 in at adjusting Drive Pulley Shoe Side Clearance Up to 0 20 mm 0 008 in in the text e Cover Bushing Inside Diameter 27 985 28 085 mm 1 1018 1 1057 in 28 12 mm 1 107 in Sheave Bushing Inside 37 985 38 085 mm 1 4955 1 4994 in 38 12 mm 1 501 in Diameter Spring Free Length 60 0 mm 2 36 in Drive Pulley Installation Length 164 85 165 95 mm 6 490 6 533 in Driven Pulley Sheave Bushing Inside 40 000 40 039 mm 1 5748 4 5763 in 40 07 mm 1 578 in Diameter Spring Free Length 99 mm 3 9 in MILITARY USE ONLY 7 MILITARY USE ONLY CONVERTER SYSTEM 6 7 Special Tools Outside Circlip Pliers Spring Holder Set 57001 144 57001 1483 7570144ST C ST571483ST C Drive amp Driven Pulley Holder Drive Pulley Measurement Tool 57001 1412 57001 1498 O BY Vd 75714128T C 7571498ST C Pulley Holder Attachment Actuator Lever Measurement Tool 57001 1472 57001 1499 Drive amp Driven Pulley Holder Flywheel amp Pulley Holder 57001 1473 57001 1605 7571473ST C T571605ST C Drive Pulley Wrench Drive Pulley Holder 57001 1474
460. wer supply are good replace the 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 4 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 MILITARY USE ONLY 3 58 FUEL SYSTEM DFI MILITARY USE O NLY 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 Voltage 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 4V e Turn the ignition switch OFF xIf the reading is out of the standard replace the vehicle down sensor xIf the reading is within the standard check the wiring for continuity see Vehicle down Sensor Circuit xIf
461. witch 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 lame 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 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 pr
462. wn 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 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 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 und r 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 Piston Cylinder Clearance Inspection e Subtract the piston diameter from the cylinder inside di ameter to getthe piston cylinder clearance Piston Cylinder Clearance Standard 0 015 0 042 mm 0 0006 0 0017 in BAN SSSS SSS NS SSSSSS C S NSNSNSSSN NG SSS SSS HE14003BS1 C MILITARY USE ONLY HE14004BS1 C E ge ENGINE TOP END 5 41 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
463. ws 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 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 311AA0400 F e Install the removed parts 1013014BS1 C MILITARY USE ONLY 77 MILITARY USE ONLY ELECTRICAL SYSTEM 16 55 Lighting System Lighting 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 beft 12 V 35 35 W Brake TailgLights 12 V 27 8 W Battery Engine Ground Frame Ground 1 MILITARY USE ONLY 16 56 ELECTRICAL SYSTEM MILITARY USE ONLY 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 N
464. y see Drive Pulley Removal in the Converter System chapter Y Plate Bolts A Plate B e Remove Oil Pipe Bolt A Oil Pipe B MILITARY USE ONLY 7 14 ENGINE LUBRICATION S YSTENI USE ONLY 7 Oil 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 N m 0 90 kgf m 78 in Ib MILITARY USE ONLY tT MILITARY NGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded EE 8 2 Engine Removal InstallatiQn autern tra rien tiet eno n nan tme DE PR ieee ERR MER ce 8 4 Engine ee EE EE 8 4 Engine InstalldatlOri itio eee eb eet exer tlbi bete possession 8 6 MILITARY USE ONLY 8 2 ENGINE REMOVAL INSTALMATIONUSE ONLY Exploded View NND iS di KO Y e Ay A Jv es j M a V o a ef BREN dS e be k VA NS xj SS CON yY CR Miz NE 7 MILITARY USE ONLY v MILITARY NGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener em kgf m ftlb Remarks 1 Engine Bracket Pipe Mounting Nuts 41 5 4 2 31 R 2 Engine Mounting Bolt 60 1 6 1 44 60 1 6 1 44 R 3 Engine Mounting Nut R R
465. y Adjustment in the Periodic Maintenance chapter Differential Control Cable see Differential Control Lever Free Play Adjustment in the Periodic Maintenance chap ter MILITARY USE ONLY 77 MILITARY USE CIPANIKCSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded TE EE 9 2 eigene e 9 6 Special Tools and Gealant eem mener 9 8 CIraANkGCAS6 vines ul 9 9 Crankcase Disassembly EE GE 9 9 Crankcase Assembly TEST a 9 9 Crankshaft Connection Rod sse atm 9 13 Crankshaft Removal EE 9 13 Crankshaft Installation A EE 9 13 Connecting Rod Rerroval ier t ete EE E Ek hatte 9 13 Connecting Rod Installation c eo aif 9 13 Crankshaft Connecting Rod Cleaning BK M 9 14 Connecting Rod Bend Inspection PA sees 9 14 Connecting Rod Twist Inspection H 9 14 Connecting Rod Big End Side Clearance Inspection AP Ba eis 9 15 Connecting Rod Big End Bearing Crankpin Wear Inspechon 9 15 Crankshaft Runout Inspection 4 sse 9 17 Crankshaft Main Bearing Journal Wear Inepechon J i 9 17 TRANSMISSIONS 5 cde terere Ned e ce eO IP Hte Pre eR eh es 9 18 Shift Lever Remowval Nc cc cecccecceecceeecceccceecceseceeeceseceeeeeseseeeeeeeseess 9 18 Shift Lever Installation
466. y 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 MILITARY USE ONLY Um USE ONLY FUEL SYSTEM DFI 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 CH 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 Output Voltage Inspection xIf the reading is out of the range 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 If the ground and po

2008-09 KRF750RAF Teryx -Service Manual

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