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BRUTE FORCE 650 4X4
Kawasaki BRUTE FORCE 650 4X4 User Manual
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2
Table of Contents
Quick Reference Guide
2
List of Abbreviations
4
Foreword
7
General Information
8
Table of Contents
8
Before Servicing
9
Battery Ground
9
Edges of Parts
9
Solvent
9
Arrangement and Cleaning of Removed Parts
10
Storage of Removed Parts
10
Replacement Parts
10
Assembly Order
10
Tightening Sequence/Torque
11
Force
11
Gasket, O-Ring
11
Liquid Gasket, Locking Agent
11
Press
12
Ball Bearing and Needle Bearing
12
Oil Seal, Grease Seal
12
Circlips, Cotter Pins
12
Lubrication
13
Direction of Engine Rotation
13
Electrical Wires
13
Model Identification
14
KVF650-D1 Left Side View
14
KVF650-D1 Right Side View
14
General Specifications
15
Unit Conversion Table
18
Units of Temperature
18
Periodic Maintenance
19
Periodic Maintenance Chart
21
Torque and Locking Agent
23
Basic Torque for General Fasteners of Engine Parts
28
Basic Torque for General Fasteners of Frame Parts
28
Specifications
29
Special Tools
31
Periodic Maintenance Procedures
32
Throttle Lever Free Play Inspection/Adjustment
32
Choke Lever Free Play Inspection
32
Choke Lever Free Play Adjustment
33
Idle Speed Inspection
33
Idle Speed Adjustment
34
Fuel System Cleanliness Inspection
34
Air Cleaner Element Cleaning and Inspection
35
Air Cleaner Draining
35
Fuel Hose and Connection Inspection
36
Fuel Hose Replacement
36
Radiator Cleaning
37
Radiator Hose and Connection Inspection
37
Coolant Change
37
Engine Top End
40
Valve Clearance Inspection
40
Valve Clearance Adjustment
41
Spark Arrester Cleaning
41
Drive Belt Inspection
42
Drive Belt Deflection Inspection
43
Drive Belt Deflection Adjustment
44
Spacers
44
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
44
Engine Oil Change
45
Oil Filter Replacement
45
Tire Inspection
46
Variable Differential Control Lever Play Inspection/Adjustment
46
Front Final Gear Case Oil Change
47
Rear Final Gear Case Oil Change
48
Front Brake Pad Wear Inspection
48
Front Brake Hoses and Connections Inspection
48
Front Brake Hose Replacement
49
Brake Fluid Level Inspection
49
Brake Fluid Change
50
Front Brake Master Cylinder Piston Assembly and Dust Seal Replacement
50
Front Brake Caliper Piston Seal and Dust Seal Replacement
50
Rear Brake Plates Replacement
51
Rear Brake Lever Free Play Inspection
51
Brake Pedal Free Play Inspection
51
Rear Brake Lever and Pedal Free Play Adjustment
51
Steering Inspection
52
Spark Plug Cleaning/Inspection
52
Spark Plug Gap Inspection
52
Brake Light Switch Inspection
53
Brake Light Timing Adjustment
53
Drive Belt Failure Detection System Inspection
53
Joint Boots Inspection
55
Front Axle/Suspension Arm Joint Boot Inspection
55
Rear Propeller Shaft Joint Boot Inspection
55
Tie-Rod End Boot Inspection
55
General Lubrication
56
Bolts and Nuts Tightening
57
Tightness Inspection
57
Fuel System
58
Exploded View
59
Throttle Lever Free Play Inspection
65
Throttle Lever Free Play Adjustment
65
Throttle Case Removal/Disassembly
65
Throttle Case Assembly/Installation
65
Throttle Cable Installation
66
Throttle Case Inspection
66
Throttle Cable Lubrication and Inspection
66
Choke Lever and Cable Removal
67
Choke Cable Lubrication and Inspection
68
Carburetor
69
Idle Speed Inspection/Adjustment
69
Pilot Screw Adjustment
69
Service Fuel Level Inspection
69
Service Fuel Level Adjustment
70
Carburetor Synchronization Inspection
71
Carburetor Synchronization Adjustment
72
Carburetor Removal
72
Carburetor Installation
73
Carburetor Disassembly
73
Carburetor Assembly
75
Carburetor Separation
76
Carburetor Joining
76
Carburetor Cleaning
77
Carburetor Inspection
77
Air Cleaner Element Removal
80
Air Cleaner Housing Removal
80
Air Cleaner Housing Installation
81
Fuel Tank Removal
83
Fuel Tank Installation
83
Fuel Tank Cleaning
84
Fuel Tap Removal
84
Fuel Tap Installation
84
Fuel Tap Inspection
85
Fuel Pump Removal
86
Pump Filter Cleaning
86
Fuel Pump Installation
87
Cooling System
88
Coolant Flow Chart
91
Special Tools & Sealant
94
Coolant Deterioration Inspection
95
Coolant Level Inspection
95
Coolant Draining/Filling
95
Pressure Testing
96
Water Pump Cover Removal
97
Water Pump Cover Installation
97
Water Pump Impeller Removal
97
Water Pump Impeller Installation
97
Water Pump Impeller Inspection
98
Water Pump Leakage Inspection
98
Mechanical Seal Replacement
98
Water Pump
99
Radiator Removal
100
Radiator Installation
101
Radiator Fan Removal
101
Radiator Fan Installation
102
Radiator Inspection
102
Radiator Cap Inspection
103
Thermostat Removal
104
Thermostat Installation
104
Thermostat Inspection
104
Radiator Fan Switch Removal
106
Radiator Fan Switch Installation
106
Radiator Fan Switch Inspection
106
Coolant Temperature Warning Light Switch Removal
107
Coolant Temperature Warning Light Switch Installation
107
Coolant Temperature Warning Light Switch Inspection
107
Coolant Filter Cleaning
108
Coolant Valve Inspection
108
Engine Top End
109
Camshaft Chain Tensioner Removal
120
Camshaft Chain Tensioner Installation
120
Rocker Case Removal
121
Front/Rear Rocker Case
121
Rocker Case Installation
122
Rocker Arm Removal
123
Rocker Arm Installation
123
Rocker Arm Inspection
124
Rocker Shaft Diameter Measurement
124
Camshaft Removal
125
Camshaft Installation
125
Camshaft Assembly
126
Cam Wear
126
Camshaft Bearing Wear
127
KACR Inspection
128
KACR Removal
128
KACR Installation
129
Camshaft Chain Removal
129
Camshaft Chain Installation
130
Rear Camshaft Chain
130
Front Camshaft Chain
131
Camshaft Chain Guide Wear
133
Cylinder Compression Measurement
134
Cylinder Head Removal
135
Cylinder Head Installation
135
Cylinder Head Cleaning
135
Cylinder Head Warp
136
Valve Removal
137
Valve Installation
137
Valve Guide Removal
137
Valve Guide Installation
138
Valve-To-Guide Clearance Measurement
138
Valve Seat Inspection
139
Valve Seat Repair (Valve Lapping)
140
Seat Cutter Operation Care
140
Marks Stamped on the Cutter
141
Operating Procedures
141
Valve Seat Repair
144
Cylinder Removal
145
Piston Removal
145
Cylinder, Piston Installation
145
Cylinder Wear
147
Piston Wear
147
Piston/Cylinder Clearance
147
Cylinder Boring and Honing
148
Piston Ring, Piston Ring Groove Wear
148
Piston Ring Groove Width
149
Piston Ring Thickness
149
Piston Ring End Gap
149
Exhaust System
150
Muffler and Exhaust Pipe Removal
150
Muffler and Exhaust Pipe Installation
151
Exhaust System Inspection
151
Converter System
152
Torque Converter Cover Removal
160
Torque Converter Cover Installation
161
Torque Converter Cover Disassembly
161
Torque Converter Cover Assembly
162
Actuator Lever Assemblies
163
Drive Belt Removal
164
Drive Belt Installation
164
Drive Pulley Removal
165
Drive Pulley Disassembly
165
Drive Pulley Inspection
167
Spider Shoe Side Clearance Adjustment
168
Drive Pulley Assembly
169
Drive Pulley Installation
170
Measurement Length
172
Drive Pulley Covers
172
Driven Pulley Removal
173
Driven Pulley Disassembly
173
Driven Pulley Inspection
174
Driven Pulley Assembly
175
Driven Pulley Installation
177
High Altitude Setting Information
179
Recoil Starter
180
Engine Lubrication System
183
Engine Oil Flow Chart
188
Engine Oil and Oil Filter
189
Oil Level Inspection
189
Oil Filter Change
189
Oil Screen Removal
189
Oil Screen Cleaning
190
Oil Pressure Measurement
190
Oil Pressure Relief Valve Removal
191
Oil Pressure Relief Valve Installation
191
Oil Pressure Relief Valve Inspection
191
Oil Pump Removal
192
Oil Pump Installation
192
Oil Pipe Removal
194
Engine Left/Right Side Oil Pipe
194
Engine Inside Oil Pipe
194
Oil Pipe Installation
194
Engine Removal/Installation
195
Engine Removal
198
Engine Installation
199
Crankshaft/Transmission
200
Crankcase Disassembly
208
Crankcase Assembly
209
Crankshaft Removal
212
Crankshaft Installation
212
Connecting Rod Removal
212
Connecting Rod Installation
212
Crankshaft/Connecting Rod Cleaning
213
Connecting Rod Bend
213
Connecting Rod Twist
213
Connecting Rod Big End Side Clearance
214
Connecting Rod Big End Bearing/Crankpin Wear
214
Big End Bearing Insert Selection
215
Crankshaft Runout
216
Crankshaft Main Bearing/Journal Wear
216
Transmission
217
Shift Lever Removal
217
Shift Lever Installation
218
Transmission Removal
222
Transmission Installation
222
Shift Fork Bending
225
Shift Fork/Gear and Shifter Groove Wear
225
Transmission and Shift Mechanism Inspection
225
Ball and Needle Bearing Replacement
227
Ball and Needle Bearing Wear
227
Oil Seal Inspection
227
Wheels/Tires
228
Wheel Alignment
233
Steering Centering Inspection
233
Steering Centering Adjustment
233
Toe-In Inspection
234
Toe-In Adjustment
234
Wheel Removal
235
Wheel Installation
235
Wheel (Rim) Inspection
235
Wheel (Rim) Replacement
236
Tire Removal
237
Tire Installation
237
Front Hub Removal
239
Front Hub Installation
239
Front Hub Disassembly/Assembly
240
Rear Hub Removal
241
Rear Hub Installation
241
Rear Hub Disassembly/Assembly
241
Final Drive
242
Output Drive Bevel Gear Removal
254
Output Drive Bevel Gear Installation
254
Output Drive Bevel Gear Disassembly
255
Output Drive Bevel Gear Assembly
257
Output Driven Bevel Gear Removal
257
Output Driven Bevel Gear Installation
258
Output Driven Bevel Gear Disassembly
258
Output Driven Bevel Gear Assembly
259
Output Bevel Gears Adjustment
260
Output Bevel Gear (Backlash-Related Parts)
261
Drive Bevel Gear Shims for Tooth Contact Adjustment
262
Driven Bevel Gear Shims for Backlash Adjustment
262
Bevel Gear Backlash Adjustment
262
Tooth Contact Adjustment
263
Bevel Gears Inspection
265
Front Propeller Shaft Removal
266
Front Propeller Shaft Installation
266
Front Axle Removal
267
Front Axle Installation
267
Front Axle Joint Boot Inspection
267
Front Axle Joint Boot Replacement
268
Inboard Joint Boot Removal
268
Outboard Joint Boot Replacement
269
Inboard Joint Boot Assembly
270
Front Final Gear Case Oil Level Inspection
274
Variable Differential Control Lever Removal
274
Variable Differential Control Lever Installation
274
Variable Differential Control Cable Installation
275
Variable Differential Control Cable Lubrication
275
Variable Differential Control Cable Inspection
275
Front Final Gear Case Removal
275
Front Final Gear Case Installation
276
Front Final Gear Case Disassembly
276
Front Final Gear Case Coupling Inspection
278
Front Final Gear Case Assembly
278
Oil Seal Installation
284
Ring Gear Disassembly
285
Ring Gear Assembly
285
LSD Clutch Torque Inspection
286
Pinion Gear Unit Disassembly
286
Pinion Gear Unit Assembly
287
Front Final Bevel Gear Adjustment
287
Front Final Gear Case (Backlash-Related Parts)
288
Pinion Gear Shims for Backlash Adjustment
289
Ring Gear Right Shims for Tooth Contact Adjustment
289
Ring Gear Left Shims for Tooth Contact Adjustment
289
Backlash Adjustment
289
Bevel Gear Inspection
291
Differential Gear Inspection
291
Correct Tooth Contact Pattern: no Adjustment Is Required
292
Incorrect Tooth Contact Patterns
292
Rear Propeller Shaft Removal
293
Rear Propeller Shaft Installation
293
Rear Propeller Shaft Inspection
293
Rear Axle Removal
294
Rear Axle Installation
294
Ball Bearing Wear
294
Rear Axle Runout Inspection
295
Rear Final Gear Case Oil Level Inspection
296
Rear Final Gear Case Removal
296
Rear Final Gear Case Installation
296
Rear Final Gear Case Disassembly
297
Rear Final Gear Case Assembly
298
Rear Final Bevel Gear Adjustment
299
Rear Final Gear Case (Backlash-Related Parts)
300
Pinion Gear Shims for Tooth Contact Adjustment
301
Ring Gear Shims for Backlash Adjustment
301
Bearing and Oil Seal
304
Ball or Needle Bearing Inspection
304
Brakes
306
Brake Fluid Recommendation
313
Brake Line Air Bleeding
314
Master Cylinder Removal
315
Master Cylinder Installation
315
Master Cylinder Disassembly
315
Master Cylinder Assembly
316
Master Cylinder Inspection (Visual Inspection)
316
Caliper Removal
317
Caliper Installation
317
Caliper Disassembly
318
Caliper Assembly
318
Dust Seal and Friction Boot Damage
319
Piston and Cylinder Damage
319
Caliper Holder Shaft Wear Inspection
319
Brake Pad Removal
320
Brake Pad Installation
320
Brake Pad Wear Inspection
320
Brake Discs
321
Disc Cleaning
321
Disc Removal/Installation
321
Disc Wear/Runout
321
Brake Hose Inspection
322
Brake Hose Replacement
322
Brake Pedal Position Inspection/Adjustment
323
Brake Pedal Removal
323
Brake Cable Removal
324
Brake Cable Installation
325
Brake Cable Lubrication
325
Internal Wet Brake Disassembly
326
Internal Wet Brake Assembly
327
Suspension
329
Front Shock Absorber Removal
334
Front Shock Absorber Installation
334
Front Shock Absorber Inspection
335
Front Shock Absorber Spring Replacement
335
Rear Shock Absorber Removal
337
Rear Shock Absorber Installation
337
Rear Shock Absorber Preload Adjustment
337
Spring Action
338
Rear Shock Absorber Spring Replacement
338
Rear Shock Absorber Inspection
340
Rear Shock Absorber Scrapping
340
Suspension Arm Removal
341
Suspension Arm Installation
341
Suspension Arm Disassembly
341
Suspension Arm Assembly
341
Swingarm Removal
343
Swingarm Installation
343
Swingarm Disassembly
344
Swingarm Assembly
345
Swingarm Bearing Inspection
345
Swingarm Bearing Lubrication
346
Steering
347
Steering Stem Removal
352
Steering Stem Installation
352
Steering Knuckle Removal
353
Steering Knuckle Installation
354
Steering Knuckle Bearing Removal
354
Steering Knuckle Bearing Installation
354
Tie-Rod Removal/Installation
354
Tie-Rod End Removal
355
Tie-Rod End Installation
355
Steering Maintenance
356
Steering Stopper/Stem Clamp Inspection
356
Steering Stem Straightness
356
Steering Bearing Sleeve Lubrication
356
Steering Stem Bearing Inspection
357
Steering Knuckle Bearing Inspection
357
Handlebar Removal
358
Handlebar Installation
358
Frame
360
Seat Removal
367
Seat Installation
367
Front Carrier Removal
368
Front Carrier Installation
368
Rear Carrier Removal
368
Rear Carrier Installation
369
Front Fender Removal
370
Front Fender Installation
371
Rear Fender Removal
371
Inner Cover Front and Front Lower Shroud Removal/Installation
373
Inner Cover Rear Removal
373
Inner Cover Rear Installation
373
Air Cleaner Upper Cover Removal
373
Air Cleaner Upper Cover Installation
374
Air Cleaner Cover Removal
374
Air Cleaner Cover Installation
374
Left Side Cover Removal
375
Left Side Cover Installation
375
Front Guard Removal
376
Front Guards Installation
376
Engine Bottom Guard Removal
377
Engine Bottom Guard Installation
377
Rear Bottom Guard Removal
377
Rear Bottom Guard Installation
377
Front Flap Removal
378
Front Flap Installation
378
Rear Flap Removal
378
Rear Flap Installation
379
Footboard Removal
379
Footboard Installation
380
Trailer Hitch Bracket Removal
381
Trailer Hitch Bracket Installation
381
Electrical System
382
Parts Location
384
Precautions
396
Electrical Wiring
398
Wiring Inspection
398
Battery Installation
399
Battery Activation
399
Electrolyte Filling
399
Initial Charge
401
Interchange
402
Charging Condition Inspection
402
Refreshing Charge
403
Charging System
404
Alternator Cover Removal
404
Alternator Cover Installation
405
Alternator Rotor Removal
406
Alternator Rotor Installation
406
Alternator Stator Removal
407
Alternator Stator Installation
407
Regulator/Rectifier Output Voltage Inspection
407
Alternator Inspection
408
Alternator Output Voltage
408
Stator Coil Resistance
408
Regulator/Rectifier Inspection
409
Rectifier Circuit Inspection
409
Regulator Circuit Check
409
Regulator Circuit Test
409
Charging System Circuit
411
Ignition System
412
Spark Plug Removal
412
Spark Plug Installation
412
Ignition Coil Removal
413
Ignition Coil Installation
413
Ignition Coil Inspection
414
Ignition Coil Primary Peak Voltage Inspection
415
Crankshaft Sensor Removal
415
Crankshaft Sensor Installation
416
Crankshaft Sensor Inspection
416
Crankshaft Sensor Peak Voltage Inspection
416
Alternator Rotor Inspection
417
Ignition Timing Test
417
Vehicle-Down Sensor Outline
417
Vehicle-Down Sensor Removal
418
Vehicle-Down Sensor Installation
418
Vehicle-Down Sensor Inspection
419
Ignition System Troubleshooting
421
Ignition System Circuit
422
Electric Starter System
423
Starter Motor Removal
423
Starter Motor Installation
423
Starter Motor Disassembly
424
Starter Motor Assembly
425
Commutator Cleaning/Inspection
426
Armature Inspection
426
Starter Motor Brush Length
427
Brush Assembly Inspection
427
Brush Plate and Terminal Bolt Inspection
427
Starter Relay Inspection
427
Starter Circuit Relay Inspection
428
Electric Starter Circuit
429
Starter Motor Clutch Installation
430
Starter Motor Clutch Inspection
430
Torque Limiter Inspection
430
Lighting System
431
Headlight Beam Vertical Adjustment
431
Headlight Bulb Replacement
431
Taillight Bulb Replacement
433
Lighting System Circuit
435
Radiator Fan Circuit Inspection
436
Radiator Fan Motor Inspection
436
Radiator Fan Breaker Inspection
436
Radiator Fan System
437
Radiator Fan Breaker Installation
437
Radiator Fan Circuit
437
Fuel Pump Inspection
438
Fuel Level Sensor Inspection
439
Fuel Pump/Fuel/Level Sensor Circuit
440
Multifunction Meter Unit Removal
441
Multifunction Meter Unit Inspection
442
LCD Segments Check
442
Mode and Time Set Buttons Operation Check
442
Speedometer Check
443
Odometer Check
443
Trip Meter A/B Check
444
Fuel Meter Check
444
2WD/4WD Indicator Lights Check
444
Coolant Temperature Warning Symbol Check
445
Oil Pressure Warning Light Check
445
Neutral Indicator Light Check
446
Reverse Indicator Light Check
446
Meter Illumination Check
446
Belt Check Indicator Light Check
447
Drive Belt Failure Mode Memory Clearing Procedure
447
Meter Circuit
450
Actuator Control System
451
2WD/4WD Actuator Removal
451
2WD/4WD Actuator Installation
451
Engine Brake Actuator Removal
451
Engine Brake Actuator Installation
452
Actuator Control System Outline
453
Actuator Control System Troubleshooting
453
Failure Indication Pattern and Failure Part
454
Malfunction Mode
454
2WD/4WD Actuator Inspection
455
Engine Brake Actuator Inspection
455
Controller Power Supply Inspection
456
Speed Sensor Inspection
456
2WD/4WD Shift Switch Inspection
457
Controller Unit Inspection
457
Forward/Reverse Detecting Sensor Inspection
460
Indicator Light (LCD) Inspection
460
Actuator Control System Circuit
461
Drive Belt Failure Detection System Circuit
462
Brake Light Switch Adjustment
463
Switch Inspection
464
Neutral Switch Connection
465
Reverse Switch Connections
465
Oil Pressure Switch Connections
465
Drive Belt Failure Detection Switch
465
30 A Main Fuse Removal
466
Fuse Removal
466
Fuse Inspection
466
Wiring Diagram
467
Appendix
469
Troubleshooting Guide
470
Cable, Wire, and Hose Routing
475
Model Application
493
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Kawasaki BRUTE FORCE 650 4X4 Specifications
General
Brand
Kawasaki
Model
BRUTE FORCE 650 4X4
Category
Offroad Vehicle
Language
English
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