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Kawasaki Prairie 700 - User Manual

Kawasaki Prairie 700
522 pages
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Prairie 700 4×4
KVF 700 4×4
All Terrain Vehicle
Service Manual

Table of Contents

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Summary

ALL TERRAIN VEHICLE SERVICE MANUAL

LIST OF ABBREVIATIONS

List of abbreviations used throughout the manual.

EMISSION CONTROL INFORMATION

Information regarding emission control systems and regulations.

NOISE CONTROL SYSTEM WARNING

Warning against tampering with noise control systems for US models.

FOREWORD

Introduction to the manual, including how to use it.

GENERAL INFORMATION

Before Servicing

Precautions and general procedures before starting vehicle service.

Model Identification

Visual identification of different KVF700 models.

General Specifications

Technical specifications for various vehicle components and systems.

Unit Conversion Table

Table for converting various units of measurement.

PERIODIC MAINTENANCE

Periodic Maintenance Chart

Chart detailing scheduled maintenance intervals and required operations.

Torque and Locking Agent

Lists tightening torques and required locking agents for fasteners.

Specifications

Specific standards and service limits for various maintenance items.

Special Tools

Lists and illustrates special tools required for periodic maintenance.

FUEL SYSTEM

Exploded View

Exploded view illustration of fuel system components.

Specifications

Technical specifications for fuel system components like jets and fuel level.

Special Tools

Lists and illustrates special tools for fuel system maintenance.

Throttle Lever and Cable

Procedures for throttle lever and cable removal, installation, and inspection.

Choke Lever and Cable

Procedures for choke lever and cable removal, installation, and inspection.

Carburetor

Maintenance procedures for the carburetor, including idle speed and pilot screw adjustment.

Air Cleaner

Procedures for removing, cleaning, and inspecting the air cleaner element and housing.

Fuel Tank

Procedures for removing, installing, and cleaning the fuel tank.

Fuel Tap

Procedures for fuel tap removal, installation, and inspection.

Fuel Pump

Procedures for fuel pump removal, cleaning, and installation.

COOLING SYSTEM

Exploded View

Exploded view illustration of cooling system components.

Specifications

Technical specifications for coolant, radiator cap, and thermostat.

Special Tools & Sealant

Lists and illustrates special tools and sealants for cooling system.

Coolant

Procedures for inspecting, draining, and filling coolant, including warnings.

Water Pump

Procedures for removing, installing, inspecting, and replacing water pump components.

Radiator

Procedures for removing, installing, cleaning, and inspecting the radiator and fan.

Thermostat

Procedures for removing, installing, and inspecting the thermostat.

Radiator Fan Switch

Procedures for removing, installing, and inspecting the radiator fan switch.

Water Temperature Switch

Procedures for removing, installing, and inspecting the water temperature switch.

Coolant Filter;Valve

Procedures for cleaning the coolant filter and inspecting the coolant valve.

ENGINE TOP END

Exploded View

Exploded view illustrations of engine top end components.

Specifications

Technical specifications for rocker case, camshaft, cylinder head, and valves.

Special Tools & Sealant

Lists and illustrates special tools for engine top end work.

Camshaft Chain Tensioner

Procedures for removing and installing the camshaft chain tensioner.

Rocker Case

Procedures for removing, installing, and disassembling rocker cases.

Camshaft

Procedures for removing, installing, and inspecting the camshaft.

Cylinder Head

Procedures for removing, installing, cleaning, and inspecting the cylinder head.

Valves

Procedures for removing, installing, inspecting, and repairing valves and valve seats.

Cylinder and Piston

Procedures for removing, installing, and inspecting cylinders and pistons.

Exhaust System

Procedures for removing, installing, and inspecting the exhaust system components.

CONVERTER SYSTEM

Exploded View

Exploded view illustrations of converter system components.

Specifications

Technical specifications for torque converter, drive belt, pulleys, and springs.

Special Tools

Lists and illustrates special tools for converter system maintenance.

Torque Converter

Procedures for removing, installing, disassembling, and assembling the torque converter cover.

Drive Belt

Procedures for removing, installing, inspecting, and adjusting the drive belt.

Drive Pulley

Procedures for removing, disassembling, inspecting, and assembling the drive pulley.

Driven Pulley

Procedures for removing, disassembling, inspecting, and assembling the driven pulley.

High Altitude Setting Information

Specifications for adjusting settings at high altitudes.

RECOIL STARTER

Exploded View

Exploded view illustration of the recoil starter assembly.

Recoil Starter

Procedures for removing, installing, and inspecting the recoil starter.

ENGINE LUBRICATION SYSTEM

Exploded View

Exploded view illustrations of engine lubrication system components.

Specifications

Technical specifications for engine oil and oil pressure.

Special Tools & Sealant

Lists and illustrates special tools and sealants for lubrication system.

Engine Oil and Oil Filter

Procedures for checking oil level, changing oil, and replacing the oil filter.

Oil Pressure Relief Valve

Procedures for removing, installing, and inspecting the oil pressure relief valve.

Oil Pump

Procedures for removing, installing, and inspecting the oil pump.

Oil Pipe

Procedures for removing and installing oil pipes.

ENGINE REMOVAL;INSTALLATION

Exploded View

Exploded view illustration of engine mounting components.

Engine Removal;Installation

Detailed procedures for removing and installing the engine.

CRANKSHAFT;TRANSMISSION

Exploded View

Exploded view illustrations of crankshaft and transmission components.

Specifications

Technical specifications for connecting rods, crankshaft, and transmission parts.

Special Tools & Sealant

Lists and illustrates special tools for crankshaft and transmission work.

Crankcase

Procedures for disassembling and assembling the crankcase.

Crankshaft;Connection Rod

Procedures for removing, installing, cleaning, and inspecting crankshaft and connecting rods.

Transmission

Procedures for removing, installing, inspecting, and adjusting transmission components like shift levers and forks.

WHEELS;TIRES

Exploded View

Exploded view illustrations of wheels and tires components.

Specifications

Technical specifications for wheel alignment, rims, tires, and tread depth.

Special Tool

Illustrates the special tool (jack) used for wheel service.

Wheel Alignment

Procedures for steering centering and toe-in inspection and adjustment.

Wheels (Rims)

Procedures for wheel removal, installation, inspection, and replacement.

Tires

Procedures for tire removal, installation, and inspection, including air pressure.

Front Hub

Procedures for removing, installing, and disassembling/assembling the front hub.

Rear Hub

Procedures for removing, installing, and disassembling/assembling the rear hub.

FINAL DRIVE

Exploded View

Exploded view illustrations of final drive components.

Specifications

Technical specifications for gear backlash, oil levels, and shaft runout.

Special Tools

Lists and illustrates special tools for final drive maintenance.

Output Bevel Gears

Procedures for removing, installing, disassembling, and assembling output bevel gears.

Front Propeller Shaft

Procedures for removing, installing, and inspecting the front propeller shaft.

Front Axle

Procedures for removing, installing, and inspecting front axle components, including joint boots.

Rear Axle

Procedures for removing, installing, and inspecting the rear axle and its bearings.

Rear Final Gear Case

Procedures for oil level inspection, oil change, removal, installation, and disassembly of the rear final gear case.

Pinion Gear Unit Disassembly;Assembly

Procedures for disassembling and assembling the pinion gear unit.

BRAKES

Exploded View

Exploded view illustrations of front and rear brake systems.

Specifications

Technical specifications for brake fluid, pads, discs, and cables.

Special Tool

Illustrates the special tool (circlip pliers) for brake maintenance.

Brake Fluid

Recommendations, level inspection, and changing procedures for brake fluid.

Master Cylinder

Procedures for removing, installing, disassembling, assembling, and inspecting the master cylinder.

Calipers

Procedures for removing, installing, disassembling, assembling, and inspecting brake calipers.

Brake Pads

Procedures for removing, installing, and inspecting front brake pads.

Brake Discs

Procedures for cleaning, removing, installing, inspecting wear, and runout of brake discs.

Brake Hoses

Inspection and replacement procedures for front brake hoses.

Rear Brake Lever, Pedal and Cables

Procedures for rear brake pedal position and lever/pedal free play inspection and adjustment.

Internal Wet Brake

Procedures for disassembling and assembling the internal wet brake system.

SUSPENSION

Exploded View

Exploded view illustrations of suspension components.

Specifications

Technical specifications for front and rear shock absorbers.

Special Tools

Lists and illustrates special tools for suspension maintenance.

Shock Absorbers

Procedures for removing, installing, inspecting, and replacing front and rear shock absorbers.

Suspension Arms

Procedures for removing, installing, disassembling, and assembling suspension arms.

Swingarm

Procedures for removing, installing, disassembling, and assembling the swingarm and its bearings.

STEERING

Exploded View

Exploded view illustrations of steering system components.

Specifications

Tie-rod length specifications.

Special Tools

Lists and illustrates special tools for steering maintenance.

Steering

Procedures for removing, installing, and inspecting steering stem and knuckle components.

Steering Maintenance

Procedures for inspecting steering components like stoppers, bearings, and clamps.

Handlebar

Procedures for removing, installing, and inspecting the handlebar.

FRAME

Exploded View

Exploded view illustrations of frame components.

Seat

Procedures for removing and installing the seat.

Carriers

Procedures for removing and installing front and rear carriers.

Fenders

Procedures for removing and installing front and rear fenders.

Covers

Procedures for removing and installing various covers, including air cleaner covers.

Guards

Procedures for removing and installing front, engine, and rear bottom guards.

Flaps and Footboards

Procedures for removing and installing front and rear flaps, and footboards.

Trailer Hitch Bracket

Procedures for removing and installing the trailer hitch bracket.

ELECTRICAL SYSTEM

Parts Location

Identifies the location of various electrical components on the vehicle.

Exploded View

Exploded view illustrations of electrical system components.

Specifications

Technical specifications for battery, charging system, ignition, and starter systems.

Special Tools

Lists and illustrates special tools for electrical system maintenance.

Precautions

Important safety precautions and color codes for electrical servicing.

Electrical Wiring

Procedures for inspecting wiring for signs of damage and checking continuity.

Battery

Procedures for removing, installing, activation, and charging the battery.

Charging System

Procedures for alternator cover removal/installation, rotor/stator inspection, and regulator/rectifier checks.

Ignition System

Procedures for spark plug removal/installation, ignition coil inspection, and timing tests.

Electric Starter System

Procedures for starter motor removal/installation, disassembly/assembly, and clutch inspection.

Lighting System

Procedures for adjusting headlights and replacing bulbs for headlights and taillights.

Radiator Fan System

Procedures for inspecting radiator fan circuits, motors, and breakers.

Fuel Pump;Fuel Level Sensor

Procedures for inspecting fuel pump operation, pressure, and fuel level sensor.

Meter

Procedures for removing, inspecting, and testing the multifunction meter unit.

Actuator Control System

Procedures for removing, installing, and inspecting 2WD/4WD and engine brake actuators.

Drive Belt Failure Detection System

Information and procedures for the drive belt failure detection system.

Switches

Procedures for inspecting and adjusting various switches like brake light and radiator fan.

Fuses

Procedures for removing and inspecting fuses.

APPENDIX

Troubleshooting Guide

Comprehensive guide to diagnosing and resolving common vehicle problems.

Cable, Wire, and Hose Routing

Diagrams illustrating the correct routing of cables, wires, and hoses.

Kawasaki Prairie 700 Specifications

General IconGeneral
BrandKawasaki
ModelPrairie 700
CategoryOffroad Vehicle
LanguageEnglish

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