Factory Service Repair Manual For Kawasaki BRUTE FORCE 650 4×4 KVF 650 4×4 ATV. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.
Format: PDF
Language: English
Pages: 528
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No
Model
Kawasaki BRUTE FORCE 650 4×4, KVF 650 4×4
2005 KVF650-D1
2005 KVF650-E1
2006 KVF650D6F
2006 KVF650E6F
2007 KVF650D7F
2007 KVF650E7F
2008 KVF650D8F
2008 KVF650E8F
2009 KVF650D9F
2009 KVF650E9F
Contents
- – General Information
Before Servicing
Model Identification
General Specifications
Unit Conversion Table - – Periodic Maintenance
Torque And Locking Agent
Specifications
Special Tools
Periodic Maintenance Procedures
Fuel System
Throttle Lever Free Play
Inspection
Throttle Lever Free Play
Adjustment
Choke Lever Free Play
Inspection
Choke Lever Free Play
Adjustment
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness
Air Cleaner Element Cleaning And Air Cleaner Draining
Fuel Hose And Connection
Fuel Hose Replacement
Cooling System
Coolant Change
Radiator Cleaning
Radiator Hose And Connection
Coolant Filter Cleaning
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Spark Arrester Cleaning
Converter System
Actuator Lever (Engine Brake
Control Lever) Assembly
Converter Drive Belt Deflection
Converter Drive Belt Deflection
Converter Drive Belt Wear
Engine Lubrication System
Engine Oil Change
Oil Filter Replacement
Electrical System
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Drive Belt Failure Detection
System Inspection
Wheels/Tires
Tire Inspection
Joint Boots Inspection
Front Axle/Steering Knuckle Joint
Boot Inspection
Front Propeller Shaft Boot
Inspection
Rear Propeller Shaft Joint Boot
Inspection
Tie Rod End Boot Inspection
Final Drive
Variable Differential Control Lever
Play Inspection
Variable Differential Control Lever
Play Adjustment
Front Final Gear Case Oil
Change
Rear Final Gear Case Oil Change
Brakes
Brake Fluid Level Inspection
Brake Fluid Change
Front Brake Master Cylinder
Piston Assembly And Dust Cover Replacement
Front Brake Caliper Fluid Seal
Replacement
Front Brake Caliper Dust Seal Replacement
Front Brake Pad Wear Inspection
Front Brake Hoses And
Connections Inspection
Front Brake Hose Replacement
Rear Brake Lever Free Play Inspection
Rear Brake Pedal Free Play Inspection
Rear Brake Lever And Pedal Free
Play Adjustment
Rear Brake Plates Replacement
Steering
Steering Inspection
General Lubrication
SwitchesLubrication
Brake Light Switch Inspection
Bolts And Nuts Tightening
Brake Light Timing Adjustment
Tightness Inspection - – Fuel System
Throttle Lever And Cable
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Throttle Case Removal/Disassembly
Throttle Case Assembly/Installation
Throttle Cable Installation
Throttle Case Inspection
Throttle Cable Lubrication And Inspection
Choke Lever And Cable
Choke Lever Free Play Inspection
Choke Lever Free Play Adjustment
Choke Lever And Cable Removal
Choke Lever And Cable Installation
Choke Cable Lubrication And Inspection
Carburetor
Idle Speed Inspection
Idle Speed Adjustment
Pilot Screw Adjustment
Service Fuel Level Inspection
Service Fuel Level Adjustment
Carburetor Synchronization Inspection
Carburetor Synchronization Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Separation
Carburetor Joining
Carburetor Cleaning
Carburetor Inspection
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Cleaning And Inspection
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Fuel Tap Removal
Fuel Tap Installation
Fuel Tap Inspection
Fuel Pump
Fuel Pump Removal
Pump Filter Cleaning
Fuel Pump Installation
Fuel Pump Inspection - – Cooling System Engine
Coolant
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Water Pump
Water Pump Cover Removal
Water Pump Cover Installation
Water Pump Impeller Removal
Water Pump Impeller Installation
Water Pump Impeller Inspection
Water Pump Leakage Inspection
Mechanical Seal Replacement
Radiator
Radiator Removal
Radiator Installation
Radiator Fan Removal
Radiator Fan Installation
Radiator Inspection
Radiator Cleaning
Radiator Cap Inspection
Thermostat
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Radiator Fan Switch
Radiator Fan Switch Removal
Radiator Fan Switch Installation
Radiator Fan Switch Inspection
Coolant Temperature Switch
Water Temperature Switch Removal
Water Temperature Switch Installation
Water Temperature Switch Inspection
Coolant Filter/Valve
Coolant Filter Cleaning
Coolant Valve Inspection - – Engine Top End
Special Tools & Sealant
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Rocker Case
Rocker Case Removal
Rocker Case Installation
Rocker Arm Removal
Rocker Arm Installation
Rocker Arm Inspection
Rocker Shaft Diameter Measurement
Camshaft
Camshaft Removal
Camshaft Installation
Camshaft Assembly
Cam Wear
Camshaft Bearing Wear
Kacr Inspection
Kacr Removal
Kacr Installation
Camshaft Chain Removal
Camshaft Chain Installation
Camshaft Chain Guide Wear
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Cleaning
Cylinder Head Warp
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
ValveToGuide Clearance Measurement
Valve Seat Inspection
Valve Seat Repair (Valve Lapping)
Cylinder And Piston
Cylinder Removal
Piston Removal
Cylinder, Piston Installation
Cylinder Wear
Piston Wear
Piston/Cylinder Clearance
Cylinder Boring And Honing
Piston Ring, Piston Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Exhaust System
Spark Arrester Cleaning
Muffler And Exhaust Pipe Removal
Muffler And Exhaust Pipe Installation
Exhaust System Inspection - – Converter System
Torque Converter
Torque Converter Cover Removal
Torque Converter Cover Installation
Torque Converter Cover Disassembly
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
Torque Converter Cover Assembly
Drive Belt
Drive Belt Removal
Drive Belt Installation
Converter Drive Belt Deflection Inspection
Converter Drive Belt Deflection Adjustment
Converter Drive Belt Inspection
Drive Pulley
Drive Pulley Removal
Drive Pulley Disassembly
Drive Pulley Inspection
Spider Shoe Side Clearance Inspection/Adjustment
Drive Pulley Assembly
Drive Pulley Installation
Driven Pulley
Driven Pulley Removal
Driven Pulley Disassembly
Driven Pulley Inspection
Driven Pulley Assembly
Driven Pulley Installation
High Altitude Setting Information - – Recoil Starter
Recoil Starter
Recoil Starter Removal
Recoil Starter Installation
Recoil Starter Inspection - – Engine Removal/Installation
Engine Removal
Engine Installation - – Crankshaft/Transmission
Crankcase
Crankcase Disassembly
Crankcase Assembly
Crankshaft/Connection Rod
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend
Connecting Rod Twist Inspection
Connecting Rod Big End Side Clearance Inspection
Connecting Rod Big End Bearing/Crankpin Wear Inspection
Crankshaft Runout Inspection
Crankshaft Main Bearing/Journal Wear Inspection
Transmission
Shift Lever Removal
Shift Lever Installation
Transmission Removal
Transmission Installation
Shift Fork Bending Inspection
Shift Fork/Gear And Shifter Groove Wear Inspection
Transmission And Shift Mechanism Inspection
Ball Bearing, Needle Bearing, And Oil Seal
Ball And Needle Bearing Replacement
Ball And Needle Bearing Wear Inspection
Oil Seal Inspection - – Wheels/Tires
Wheel Alignment
Steering Centering Inspection
Steering Centering Adjustment
Toe In Inspection
Toe In Adjustment
Wheels (Rims)
Wheel Removal
Wheel Installation
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tires
Tire Removal
Tire Installation
Tire Inspection
Front Hub
Front Hub Removal
Front Hub Installation
Front Hub Disassembly/Assembly
Rear Hub
Rear Hub Removal
Rear Hub Installation
Rear Hub Disassembly/Assembly - – Final Drive
Output Bevel Gears
Output Drive Bevel Gear Removal
Output Drive Bevel Gear Installation
Output Drive Bevel Gear Disassembly
Output Drive Bevel Gear Assembly
Output Driven Bevel Gear Removal
Output Driven Bevel Gear Installation
Output Driven Bevel Gear Disassembly
Output Driven Bevel Gear Assembly
Output Bevel Gears Adjustment
Bevel Gears Inspection
Front Propeller Shaft
Front Propeller Shaft Removal
Front Propeller Shaft Installation
Front Axle
Front Axle Removal
Front Axle Installation
Front Axle Joint Boot Inspection
Front Axle Joint Boot Replacement
Front Final Gear Case
Front Final Gear Case Oil Level Inspection
Front Final Gear Case Oil Change
Variable Differential Control Lever Play Inspection
Variable Differential Control Lever Play Adjustment
Variable Differential Control Lever Removal
Variable Differential Control Lever Installation
Variable Differential Control Cable Installation
Variable Differential Control Cable Lubrication
Variable Differential Control Cable Inspection
Front Final Gear Case Removal
Front Final Gear Case Installation
Front Final Gear Case Disassembly
Front Final Gear Case Coupling Inspection
Front Final Gear Case Assembly
Oil Seal Installation
Ring Gear Disassembly
Ring Gear Assembly
Lsd Clutch Torque Inspection
Pinion Gear Unit Disassembly
Pinion Gear Unit Assembly
Front Final Bevel Gear Adjustment
Bevel Gear Inspection
Differential Gear Inspection
Rear Propeller Shaft
Rear Propeller Shaft Removal
Rear Propeller Shaft Installation
Rear Propeller Shaft Joint Boot Inspection
Rear Propeller Shaft Inspection
Rear Axle
Rear Axle Removal
Rear Axle Installation
Ball Bearing Wear
Rear Axle Runout Inspection
Rear Final Gear Case
Rear Final Gear Case Oil Level Inspection
Rear Final Gear Case Oil Change
Rear Final Gear Case Removal
Rear Final Gear Case Installation
Rear Final Gear Case Disassembly
Rear Final Gear Case Assembly
Oil Seal Installation
Rear Final Bevel Gear Adjustment
Pinion Gear Unit Disassembly
Pinion Gear Unit Assembly
Final Drive
Bevel Gear Inspection
Ball Or Needle Bearing Inspection
Bearing And Oil Seal
Oil Seal Inspection - – Brakes
Brake Fluid
Front Brake Fluid Recommendation
Front Brake Fluid Level Inspection
Front Brake Fluid Change
Front Brake Line Air Bleeding
Master Cylinder
Front Brake Master Cylinder Removal
Front Brake Master Cylinder Installation
Front Brake Master Cylinder Disassembly
Front Brake Master Cylinder Assembly
Master Cylinder Inspection (Visual Inspection)
Calipers
Front Brake Caliper Removal
Front Brake Caliper Installation
Front Brake Caliper Disassembly
Front Brake Caliper Assembly
Front Brake Caliper Piston And
Cylinder Damage Inspection
Front Brake Caliper Holder Shaft Wear Inspection
Brake Pads
Front Brake Pad Removal
Front Brake Pad Installation
Front Brake Pad Wear Inspection
Brake Discs
Front Brake Disc Cleaning
Front Brake Disc Removal
Front Brake Disc Installation
Front Brake Disc Wear Inspection
Front Brake Disc Runout Inspection
Brake Hoses
Front Brake Hose Inspection
Front Brake Hose Replacement
Rear Brake Lever, Pedal And Cables
Rear Brake Pedal Position Inspection
Rear Brake Pedal Position Adjustment
Rear Brake Lever Free Play
Inspection
Rear Brake Pedal Free Play Inspection
Rear Brake Lever And Pedal Free
Play Adjustment
Rear Brake Pedal Removal
Rear Brake Pedal Installation
Rear Brake Cable Removal
Rear Brake Cable Installation
Rear Brake Cable Lubrication
Internal Wet Brake
Internal Wet Brake Disassembly
Internal Wet Brake Assembly - – Suspension
Shock Absorbers
Front Shock Absorber Removal
Front Shock Absorber Installation
Front Shock Absorber Inspection
Front Shock Absorber Spring Replacement
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Preload Adjustment
Rear Shock Absorber Spring Replacement
Rear Shock Absorber Inspection
Rear Shock Absorber Scrapping
Suspension Arms
Suspension Arm Removal
Suspension Arm Installation
Suspension Arm Disassembly
Suspension Arm Assembly
Swingarm
Swingarm Removal
Swingarm Installation
Swingarm Disassembly
Swingarm Assembly
Swingarm Bearing Inspection
Swingarm Bearing Lubrication - – Steering
Steering
Steering Stem Removal
Steering Stem Installation
Steering Knuckle Removal
Steering Knuckle Installation (KvfD/E)
Steering Knuckle Installation (On And After KvfDF/EF)
Steering Knuckle Bearing Removal
Steering Knuckle Bearing Installation
Tie Rod Removal
Tie Rod Installation
Tie Rod End Removal
Tie Rod End Installation
Steering Maintenance
Steering Inspection
Steering Stopper Inspection
Steering Stem Straightness
Steering Bearing Sleeve Lubrication
Steering Stem Clamp Inspection
Steering Stem Bearing Inspection
Steering Knuckle Bearing Inspection
TieRod End And Steering Knuckle Joint Inspection
Handlebar
Handlebar Removal?
Handlebar Installation - – Frame
Seat
Seat Removal
Seat Installation
Carriers
Front Carrier Removal
Front Carrier Installation
Rear Carrier Removal
Rear Carrier Installation
Fenders
Front Fender Removal
Front Fender Installation
Rear Fender Removal
Rear Fender Installation
Covers
Inner Cover Front And Front Lower Shroud Removal
Inner Cover Front And Front Lower Shroud Installation
Inner Cover Rear Removal
Inner Cover Rear Installation
Air Cleaner Upper Cover Removal
Air Cleaner Upper Cover Installation
Air Cleaner Cover Removal
Air Cleaner Cover Installation
Left Side Cover Removal
Left Side Cover Installation
Guards
Front Guard Removal
Front Guards Installation
Engine Bottom Guard Removal
Engine Bottom Guard Installation
Rear Bottom Guard Removal
Rear Bottom Guard Installation
Flaps And Footboards
Front Flap Removal
Front Flap Installation
Rear Flap Removal
Rear Flap Installation
Footboard Removal
Footboard Installation
Trailer Hitch Bracket
Trailer Hitch Bracket Removal
Trailer Hitch Bracket Installation - – Electrical System
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Battery Activation
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Charging System
Alternator Cover Removal
Alternator Cover Installation
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Stator Removal
Alternator Stator Installation
Regulator/Rectifier Output
Voltage Inspection
Alternator Inspection
Regulator/Rectifier Inspection
Ignition System
Spark Plug Removal
Spark Plug Installation
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Ignition Coil Primary Peak Voltage Inspection
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Crankshaft Sensor Inspection
Crankshaft Sensor Peak Voltage Inspection
Alternator Rotor Inspection
Ignition Timing Test
VehicleDown Sensor Outline
VehicleDown Sensor Removal
VehicleDown Sensor Installation
VehicleDown Sensor Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Commutator Cleaning/Inspection
Armature Inspection
Brush Length Inspection
Brush Assembly Inspection
Brush Plate And Terminal Bolt Inspection
Starter Relay Inspection
Starter Circuit Relay Inspection
Starter Motor Clutch Removal
Starter Motor Clutch Installation
Starter Motor Clutch Inspection
Torque Limiter Inspection
Lighting System
Headlight Beam Vertical Adjustment
Headlight Bulb Replacement
Taillight Bulb Replacement
Radiator Fan System
Radiator Fan Circuit Inspection
Radiator Fan Motor Inspection
Radiator Fan Breaker Inspection
Radiator Fan Breaker Installation
Fuel Pump/Fuel Level Sensor
Fuel Pump Inspection
Fuel Level Sensor Inspection
Fuel Level Sensor
Fuel Level Sensor Removal
Fuel Level Sensor Installation
Fuel Level Sensor Inspection
Meter
Multifunction Meter Unit Removal
Multifunction Meter Unit Inspection
Drive Belt Failure Mode Memory Clearing Procedure
Drive Belt Failure Mode Memory Clearing Procedure
Actuator Control System
Electrical System
Actuator Removal
Actuator Installation
Engine Brake Actuator Removal
Engine Brake Actuator Installation
Actuator Control System Outline
Actuator Control System Troubleshooting
Drive Belt Failure Detection System
Drive Belt Failure Detection
System Inspection
Switches And Sensor
Brake Light Switch Adjustment
Radiator Fan Switch Inspection
Water Temperature Switch Inspection
Switch Inspection
Drive Belt Failure Detection Switch
Speed Sensor Removal/Installation
Speed Sensor Inspection
Fuses
Main Fuse Removal
Fuse Removal
Fuse Inspection
Wiring Diagram - – Appendix
Troubleshooting Guide
Cable, Wire, And Hose Routing
What you get
You will receive PDF file with high-quality manual on your email immediately after the payment.
Anonymous (verified owner) –
Definitely worth the price
Anonymous (verified owner) –
The best service I have found yet and affordable.