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Brute Force 750
Kawasaki Brute Force 750 User Manual
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BRUTE
FORCE
750
4×4i
KVF
750
4×4
All
T
errain
V
ehicle
Service
Manual
Property of www.SmallEngineDiscount.com - Not for Resale
2
Table of Contents
General Information
11
General Information
3
Emission Control Information
7
How to Use this Manual
9
Before Servicing
12
Model Identification
17
General Specifications
18
Unit Conversion Table
21
Periodic Maintenance 2-1 Periodic Maintenance
23
Table of Contents
23
Periodic Maintenance Chart
25
Torque and Locking Agent
27
Periodic Maintenance
28
Specifications
33
Special Tools
35
Periodic Maintenance Procedures
36
Fuel System
36
Throttle Lever Free Play Inspection
36
Throttle Lever Free Play Adjustment
36
Choke Lever Free Play Inspection
36
Choke Lever Free Play Adjustment
37
Idle Speed Inspection
37
Idle Speed Adjustment
38
Fuel System Cleanliness Inspection
38
Air Cleaner Element Cleaning and Inspection
39
Air Cleaner Draining
39
Fuel Hose and Connection Inspection
40
Fuel Hose Replacement
40
Cooling System
41
Radiator Cleaning
41
Radiator Hose and Connection Inspection
42
Coolant Change
42
Engine Top End
45
Valve Clearance Inspection
45
Valve Clearance Adjustment
46
Spark Arrester Cleaning
46
Converter System
47
Drive Belt Inspection
47
Drive Belt Deflection Inspection
47
Drive Belt Deflection Adjustment
48
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
49
Engine Lubrication System
49
Engine Oil Change
49
Oil Filter Replacement
50
Wheels/Tires
50
Tire Inspection
50
Final Drive
51
Variable Differential Control Lever Play Inspection
51
Variable Differential Control Lever Play Adjustment
51
Front Final Gear Case Oil Change
52
Rear Final Gear Case Oil Change
53
Universal Joint Lubrication
54
Brakes
54
Front Brake Pad Wear Inspection
54
Front Brake Hoses and Connections Inspection
54
Front Brake Hose Replacement
55
Brake Fluid Level Inspection
55
Brake Fluid Change
56
Front Brake Master Cylinder Piston Assembly and Dust Seal Replacement
56
Front Brake Caliper Piston Seal and Dust Seal Replacement
56
Rear Brake Plates Replacement
57
Rear Brake Lever Free Play Inspection
57
Brake Pedal Free Play Inspection
57
Rear Brake Lever and Pedal Free Play Adjustment
57
Electrical System
58
Spark Plug Cleaning/Inspection
58
Spark Plug Gap Inspection
58
Brake Light Switch Inspection
59
Brake Light Timing Adjustment
59
Drive Belt Failure Detection System Inspection
59
Steering
58
Steering Inspection
58
Joint Boots Inspection
61
Front Axle/Knuckle Joint Boot Inspection
61
Front Propeller Shaft Boot Inspection
61
Tie-Rod End Boot Inspection
61
Rear Propeller Shaft Joint Boot Inspection
61
Rear Axle/Stabilizer Joint Boot Inspection
61
General Lubrication
62
Fuel System 3-1 Fuel System
65
Exploded View
66
Specifications
70
Special Tools
71
Throttle Lever and Cable
72
Throttle Lever Free Play Inspection
72
Throttle Lever Free Play Adjustment
72
Throttle Case Removal/Disassembly
72
Throttle Case Assembly/Installation
72
Throttle Cable Installation
73
Throttle Case Inspection
73
Throttle Cable Lubrication and Inspection
73
Choke Lever and Cable
74
Choke Lever Free Play Inspection
74
Choke Lever Free Play Adjustment
74
Choke Lever and Cable Removal
74
Choke Lever and Cable Installation
75
Choke Cable Lubrication and Inspection
75
Carburetor
76
Idle Speed Inspection
76
Idle Speed Adjustment
76
Pilot Screw Adjustment
76
Service Fuel Level Inspection
76
Service Fuel Level Adjustment
78
Carburetor Synchronization Inspection
78
Carburetor Synchronization Adjustment
79
Fuel System Cleanliness Inspection
79
Carburetor Removal
79
Carburetor Installation
81
Carburetor Disassembly
81
Carburetor Assembly
83
Carburetor Separation
84
Carburetor Joining
84
Carburetor Cleaning
85
Carburetor Inspection
86
Air Cleaner
88
Air Cleaner Element Removal
88
Air Cleaner Element Installation
88
Air Cleaner Element Cleaning and Inspection
88
Air Cleaner Housing Removal
88
Air Cleaner Housing Installation
90
Fuel Tank
92
Fuel Tank Removal
92
Fuel Tank Installation
93
Fuel Tank Cleaning
94
Fuel Tap Removal
94
Fuel Tap Installation
94
Fuel Tap Inspection
95
Fuel Tap Cleaning
96
Fuel Pump
97
Fuel Pump Removal
98
Fuel Pump Installation
98
Fuel Pump Inspection
98
Cooling System 4-1 Cooling System
101
Exploded View
102
Coolant Flow Chart
104
Radiator Fan Switch
105
Coolant Temperature Warning Light Switch
105
Specifications
106
Special Tools & Sealant
107
Coolant
108
Coolant Deterioration Inspection
108
Coolant Level Inspection
108
Coolant Draining
108
Coolant Filling
108
Pressure Testing
109
Water Pump
110
Water Pump Cover Removal
110
Water Pump Cover Installation
110
Water Pump Impeller Removal
110
Water Pump Impeller Installation
110
Water Pump Cover Bolts
110
Water Pump Impeller Inspection
111
Water Pump Leakage Inspection
111
Mechanical Seal Replacement
111
Water Pump Impeller
111
Radiator
113
Radiator Removal
113
Radiator Installation
114
Radiator Fan Removal
114
Radiator Fan Installation
114
Radiator Inspection
115
Radiator Cleaning
115
Radiator Cap Inspection
115
Thermostat
116
Thermostat Removal
116
Thermostat Installation
116
Thermostat Inspection
116
Radiator Fan Switch
118
Radiator Fan Switch Removal
118
Radiator Fan Switch Installation
118
Radiator Fan Switch Inspection
118
Coolant Temperature Warning Light Switch
119
Coolant Temperature Warning Light Switch Removal
119
Coolant Temperature Warning Light Switch Installation
119
Coolant Temperature Warning Light Switch Inspection
119
Engine Top End 5-1 Engine Top End
121
Exploded View
122
Water Pipe Mounting Bolts
123
G: Apply Grease
123
Specifications
128
Special Tools and Sealant
131
Camshaft Chain Tensioner
133
Camshaft Chain Tensioner Removal
133
Camshaft Chain Tensioner Installation
133
Rocker Case
135
Rocker Case Removal
135
Rocker Case Installation
136
Rocker Arm Removal
137
Rocker Arm Installation
138
Rocker Arm Inspection
138
Rocker Shaft Diameter Measurement
139
Camshaft
140
Camshaft Removal
140
Camshaft Installation
140
Camshaft Assembly
141
Cam Wear
141
Camshaft Bearing Wear
142
KACR Inspection
143
KACR Removal
143
KACR Installation
144
Camshaft Chain Removal
144
Camshaft Chain Installation
145
Camshaft Chain Guide Wear
148
Cylinder Head
149
Cylinder Compression Measurement
149
Cylinder Head Removal
150
Cylinder Head Installation
150
Cylinder Head Cleaning
151
Cylinder Head Warp
151
Valves
152
Valve Clearance Inspection
152
Valve Clearance Adjustment
152
Valve Removal
152
Valve Installation
152
Valve Guide Removal
152
Valve Guide Installation
153
Valve-To-Guide Clearance Measurement
153
Valve Seat Inspection
154
Valve Seat Repair (Valve Lapping)
154
Cylinder and Piston
159
Cylinder Removal
159
Piston Removal
159
Cylinder, Piston Installation
159
Cylinder Wear
161
Piston Wear
161
Piston/Cylinder Clearance
161
Piston Ring, Piston Ring Groove Wear
162
Piston Ring Groove Width
162
Piston Ring Thickness
162
Piston Ring End Gap
163
Exhaust System
164
Spark Arrester Cleaning
164
Muffler and Exhaust Pipe Removal
164
Muffler and Exhaust Pipe Installation
165
Exhaust System Inspection
166
Converter System 6-1 Converter System
167
Exploded View
168
Specifications
172
Special Tools
173
Torque Converter
175
Torque Converter Cover Removal
175
Torque Converter Cover Installation
176
Torque Converter Cover Disassembly
176
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
177
Torque Converter Cover Assembly
177
Drive Belt
179
Drive Belt Removal
179
Drive Belt Installation
179
Drive Belt Deflection Inspection
179
Drive Belt Deflection Adjustment
179
Drive Belt Inspection
179
Drive Pulley
180
Drive Pulley Removal
180
Drive Pulley Disassembly
180
Drive Pulley Inspection
181
Spider Shoe Side Clearance Adjustment
183
Drive Pulley Assembly
184
Drive Pulley Installation
185
Driven Pulley
187
Driven Pulley Removal
187
Driven Pulley Disassembly
187
Driven Pulley Inspection
188
Driven Pulley Assembly
189
Driven Pulley Installation
191
High Altitude Setting Information
193
Specifications
193
Engine Lubrication System
199
Exploded View
200
Specifications
202
Special Tools & Sealant
203
Engine Oil Flow Chart
204
Engine Oil and Oil Filter
205
Oil Level Inspection
205
Engine Oil Change
205
Oil Filter Change
205
Oil Screen Removal
205
Oil Screen Cleaning
206
Oil Pressure Measurement
206
Oil Pressure Relief Valve
207
Oil Pressure Relief Valve Removal
207
Oil Pressure Relief Valve Installation
207
Oil Pressure Relief Valve Inspection
207
Oil Pump
208
Oil Pump Removal
208
Oil Pump Installation
208
Oil Pipe
210
Oil Pipe Removal
210
Oil Pipe Installation
210
Engine Removal/Installation
211
Exploded View
212
Engine Removal/Installation
214
Engine Removal
214
Engine Installation
215
Crankshaft/Transmission 10-1 Crankshaft/Transmission
217
Exploded View
218
Specifications
222
Special Tools and Sealant
224
Crankcase
225
Crankcase Disassembly
225
Crankcase Assembly
225
Crankshaft/Connection Rod
229
Crankshaft Removal
229
Crankshaft Installation
229
Connecting Rod Removal
229
Connecting Rod Installation
229
Crankshaft/Connecting Rod Cleaning
230
Connecting Rod Bend
230
Connecting Rod Twist
230
Connecting Rod Big End Side Clearance
231
Connecting Rod Big End Bearing/Crankpin Wear
231
Crankshaft Runout
233
Crankshaft Main Bearing/Journal Wear
233
Transmission
234
Shift Lever Removal
234
Shift Lever Installation
235
Transmission Removal
237
Transmission Installation
238
Shift Fork Bending
240
Shift Fork/Gear and Shifter Groove Wear
240
Transmission and Shift Mechanism Inspection
241
Ball Bearing, Needle Bearing, and Oil Seal
243
Ball and Needle Bearing Replacement
243
Ball and Needle Bearing Wear
243
Oil Seal Inspection
243
Wheels/Tires 11-1 Wheels/Tires
245
Exploded View
246
Specifications
248
Special Tool
249
Wheel Alignment
250
Steering Centering Inspection
250
Steering Centering Adjustment
250
Toe-In Inspection
251
Toe-In Adjustment
251
Wheels (Rims)
253
Wheel Removal
253
Wheel Installation
253
Wheel (Rim) Inspection
253
Wheel (Rim) Replacement
254
Tires
255
Tire Removal
255
Tire Installation
255
Tire Inspection
256
Front Hub
257
Front Hub Removal
257
Front Hub Installation
257
Front Hub Disassembly/Assembly
258
Rear Hub
259
Rear Hub Removal
259
Rear Hub Installation
259
Rear Hub Disassembly/Assembly
260
Final Drive 12-1 Final Drive
261
Exploded View
263
Specifications
270
Special Tools
271
Output Bevel Gears
274
Output Drive Bevel Gear Removal
274
Output Drive Bevel Gear Installation
274
Output Drive Bevel Gear Disassembly
275
Output Drive Bevel Gear Assembly
277
Output Driven Bevel Gear Removal
277
Output Driven Bevel Gear Installation
278
Output Driven Bevel Gear Disassembly
278
Output Driven Bevel Gear Assembly
279
Output Bevel Gears Adjustment
280
Bevel Gears Inspection
284
Front Propeller Shaft
285
Front Propeller Shaft Removal
285
Front Propeller Shaft Installation
285
Front Axle
286
Front Axle Removal
286
Front Axle Installation
286
Front Axle Joint Boot Inspection
286
Front Axle Joint Boot Replacement
286
Front Final Gear Case
294
Front Final Gear Case Oil Level Inspection
294
Front Final Gear Case Oil Change
294
Variable Differential Control Lever Play Inspection
294
Variable Differential Control Lever Play Adjustment
294
Variable Differential Control Lever Removal
294
Variable Differential Control Lever
294
Installation
294
Variable Differential Control Cable Installation
295
Variable Differential Control Cable Lubrication
295
Variable Differential Control Cable Inspection
295
Front Final Gear Case Removal
295
Front Final Gear Case Installation
296
Front Final Gear Case Disassembly
297
Front Final Gear Case Coupling Inspection
299
Front Final Gear Case Assembly
299
Oil Seal Installation
303
Ring Gear Disassembly
304
Ring Gear Assembly
304
LSD Clutch Torque Inspection
305
Pinion Gear Unit Disassembly
305
Pinion Gear Unit Assembly
306
Front Final Bevel Gear Adjustment
306
Bevel Gear Inspection
310
Differential Gear Inspection
310
Rear Propeller Shaft
312
Rear Propeller Shaft Removal
312
Rear Propeller Shaft Installation
312
Rear Propeller Shaft Joint Boot Inspection
313
Rear Propeller Shaft Inspection
313
Rear Axle
314
Rear Axle Removal
314
Rear Axle Installation
314
Rear Axle Joint Boot Inspection
314
Rear Axle Joint Boot Replacement
315
Rear Final Gear Case
321
Rear Final Gear Case Oil Level Inspection
321
Rear Final Gear Case Oil Change
321
Rear Final Gear Case Removal
321
Rear Final Gear Case Installation
322
Rear Final Gear Case Disassembly
322
Rear Final Gear Case Assembly
324
Rear Final Gear Case Right Cover Assembly
325
Rear Final Gear Case Front Cover Assembly
325
Rear Final Gear Case Assembly
325
Pinion Gear Unit Disassembly
332
Brakes 13-1 Brakes
335
Exploded View
336
Specifications
340
Special Tool
341
Brake Fluid
342
Brake Fluid Recommendation
342
Brake Fluid Level Inspection
342
Brake Fluid Change
342
Brake Line Air Bleeding
343
Master Cylinder
344
Master Cylinder Removal
344
Master Cylinder Installation
344
Master Cylinder Disassembly
345
Master Cylinder Assembly
345
Master Cylinder Inspection (Visual Inspection)
346
Calipers
347
Caliper Removal
347
Caliper Installation
347
Caliper Disassembly
348
Caliper Assembly
348
Fluid Seal Damage
349
Dust Seal and Friction Boot Damage
349
Piston and Cylinder Damage
350
Caliper Holder Shaft Wear Inspection
350
Brake Pads
351
Brake Pad Removal
351
Brake Pad Installation
351
Brake Pad Wear Inspection
351
Brake Discs
352
Disc Cleaning
352
Disc Removal
352
Disc Installation
352
Disc Wear
352
Disc Runout
352
Brake Hoses
353
Brake Hose Inspection
353
Brake Hose Replacement
353
Rear Brake Lever, Pedal and Cables Brake Pedal Position Inspection
354
Brake Pedal Position Adjustment
354
Rear Brake Lever Free Play Inspection
354
Brake Pedal Free Play Inspection
354
Rear Brake Lever and Pedal Free Play Adjustment
354
Brake Pedal Removal
354
Brake Pedal Installation
355
Brake Cable Removal
355
Brake Cable Installation
356
Brake Cable Lubrication
356
Internal Wet Brake
357
Internal Wet Brake Disassembly
357
Internal Wet Brake Assembly
357
Suspension 14-1 Suspension
359
Exploded View
360
Specifications
364
Special Tools
365
Shock Absorbers
366
Front Shock Absorber Preload Adjustment
366
Front Shock Absorber Removal
366
Front Shock Absorber Installation
366
Front Shock Absorber Inspection
367
Front Shock Absorber Scrapping
367
Rear Shock Absorber Preload Adjustment
367
Rear Shock Absorber Removal
367
Rear Shock Absorber Installation
368
Rear Shock Absorber Inspection
368
Shock Absorber Spring Replacement
368
Rear Shock Absorber Scrapping
369
Suspension Arms
370
Front Suspension Arm Removal
370
Front Suspension Arm Installation
371
Front Suspension Arm Disassembly
371
Front Suspension Arm Assembly
372
Rear Suspension Arm Removal
373
Rear Suspension Arm Installation
373
Rear Suspension Arm Disassembly
374
Rear Suspension Arm Assembly
374
Stabilizer Removal
375
Stabilizer Installation
376
Steering 15-1 Steering
377
Exploded View
378
Specifications
380
Special Tools
381
Steering
381
Steering Stem Removal
382
Steering Stem Installation
382
Front Knuckle Removal
383
Front Knuckle Installation
384
Front Knuckle Bearing Removal
385
Front Knuckle Bearing Installation
386
Tie-Rod Removal
386
Tie-Rod Installation
386
Tie-Rod End Removal
386
Tie-Rod End Installation
386
Steering Maintenance
388
Steering Inspection
388
Steering Stem Straightness
388
Steering Bearing Sleeve Lubrication
388
Steering Stem Clamp Inspection
388
Steering Stem Bearing Inspection
388
Steering Knuckle Bearing Inspection
389
Tie-Rod End Inspection
389
Steering Knuckle Joint Inspection
389
Handlebar
390
Handlebar Removal
390
Handlebar Installation
390
Frame 16-1 Frame
393
Exploded View
394
Seat
400
Seat Removal
400
Seat Installation
400
Carriers
401
Front Carrier Removal
401
Front Carrier Installation
401
Front Carrier Bracket Installation
401
Rear Carrier Removal
401
Rear Carrier Installation
401
Rear Carrier Bracket Installation
402
Fenders
403
Front Fender Removal
403
Front Fender Installation
403
Rear Fender Removal
403
Rear Fender Installation
404
Covers
405
Middle Cover Removal
405
Middle Cover Installation
405
Left Side Cover Removal
406
Left Side Cover Installation
406
Right Side Cover Removal
406
Right Side Cover Installation
407
Electrical Parts Case Removal
407
Electrical Parts Case Installation
408
Radiator Cover Removal
408
Radiator Cover Installation
408
Guards
409
Front Guard Removal
409
Front Guard Installation
409
Front Bottom Guard Removal
409
Front Bottom Guard Installation
410
Engine Bottom Guard Removal
410
Engine Bottom Guard Installation
410
Rear Bottom Guard Removal
410
Rear Bottom Guard Installation
410
Flaps and Footboards
411
Left Footboard Removal
411
Left Footboard Installation
411
Right Footboard Removal
411
Right Footboard Installation
412
Footboard Bracket Installation
412
Trailer Hitch Bracket
413
Trailer Hitch Bracket Removal
413
Trailer Hitch Bracket Installation
413
Electrical System 17-1 Electrical System
415
Parts Location
417
Exploded View
420
Specifications
426
Wiring Diagram
428
Special Tools
430
Precautions
431
Electrical Wiring
433
Wiring Inspection
433
Battery
434
Battery Removal
434
Battery Installation
434
Battery Activation
434
Precautions
436
Interchange
437
Charging Condition Inspection
438
Refreshing Charge
438
Charging System
440
Alternator Cover Removal
440
Alternator Cover Installation
441
Alternator Rotor Removal
442
Alternator Rotor Installation
442
Alternator Stator Removal
443
Alternator Stator Installation
443
Regulator/Rectifier Output Voltage Inspection
443
Alternator Inspection
444
Regulator/Rectifier Inspection
445
Ignition System
448
Spark Plug Removal
448
Spark Plug Installation
448
Spark Plug Cleaning/Inspection
449
Spark Plug Gap Inspection
449
Ignition Coil Removal
449
Ignition Coil Installation
449
Ignition Coil Inspection
450
Ignition Coil Primary Peak Voltage Inspection
451
Crankshaft Sensor Removal
451
Crankshaft Sensor Installation
452
Crankshaft Sensor Inspection
452
Crankshaft Sensor Peak Voltage Inspection
453
Alternator Rotor Inspection
453
Ignition Timing Test
453
Vehicle-Down Sensor Outline
454
Vehicle-Down Sensor Removal
455
Vehicle-Down Sensor Installation
455
Vehicle-Down Sensor Inspection
455
Electric Starter System
459
Starter Motor Removal
459
Starter Motor Installation
459
Starter Motor Disassembly
460
Starter Motor Assembly
461
Commutator Cleaning/Inspection
462
Armature Inspection
462
Starter Motor Brush Length
463
Brush Assembly Inspection
463
Brush Plate and Terminal Bolt Inspection
463
Starter Relay Inspection
463
Starter Circuit Relay Inspection
464
Starter Motor Clutch Removal
466
Starter Motor Clutch Installation
466
Starter Motor Clutch Inspection
466
Torque Limiter Inspection
467
Lighting System
468
Headlight Beam Vertical Adjustment
468
Headlight Bulb Replacement
468
Taillight Bulb Replacement
470
Radiator Fan System
472
Radiator Fan Circuit Inspection
472
Radiator Fan Motor Inspection
472
Radiator Fan Breaker Inspection
472
Radiator Fan Breaker Installation
473
Fuel Level Sensor
474
Fuel Level Sensor Removal
474
Fuel Level Sensor Installation
474
Fuel Level Sensor Inspection
474
Meter
476
Multifunction Meter Unit Removal
477
Multifunction Meter Unit Inspection
477
Drive Belt Failure Mode Memory Clearing Procedure
482
Actuator Control System
486
2WD/4WD Actuator Removal
486
2WD/4WD Actuator Installation
486
Engine Brake Actuator Removal
486
Engine Brake Actuator Installation
487
Actuator Control System Outline
487
Actuator Control System Troubleshooting
488
Drive Belt Failure Detection System
497
Drive Belt Failure Detection System Inspection
497
Carburetor Heater System
498
Air Temperature Sensor Inspection
498
Carburetor Heater Inspection
499
Radiator Fan Switch Inspection
500
Switches
500
Brake Light Switch Adjustment
500
Coolant Temperature Warning Light Switch Inspection
501
Switch Inspection
501
Drive Belt Failure Detection Switch
502
Fuse Inspection
503
Fuse Installation
503
Fuse Removal
503
Fuses
503
4
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Kawasaki Brute Force 750 Specifications
General
Brand
Kawasaki
Model
Brute Force 750
Category
Offroad Vehicle
Language
English
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