Factory Service Repair Manual For BRUTE FORCE 750 4x4i KVF750 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: 531
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No
Model
Kawasaki ATV BRUTE FORCE 750 4x4i, KVF 750 4×4
KVF750A1
KVF750B1
Years: 2005, 2006, 2007
Contents
– General Information
Before Servicing
Model Identification
General Specifications
Unit Conversion Table
– Periodic Maintenance
Periodic Maintenance Chart
Torque And Locking Agent
Specifications
Special Tools
Periodic Maintenance Procedures
Fuel System
Throttle Lever Free Play
Choke Lever Free Play
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
Radiator Cleaning
Radiator Hose And Connection
Coolant Change
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Spark Arrester Cleaning
Converter System
Drive Belt Inspection
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Actuator Lever (Engine Brake
Control Lever) Assembly
Engine Lubrication System
Engine Oil Change
Oil Filter Replacement
Wheels/Tires
Tire 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
Universal Joint Lubrication
Brakes
Front Brake Pad Wear Inspection
Front Brake Hoses And Connections Inspection
Front Brake Hose Replacement
Brake Fluid Level Inspection
Brake Fluid Change
Front Brake Master Cylinder
Piston Assembly And Dust Seal Replacement
Front Brake Caliper Piston Seal
And Dust Seal Replacement
Rear Brake Plates Replacement
Rear Brake Lever Free Play Inspection
Brake Pedal Free Play Inspection
Rear Brake Lever And Pedal Free Play Adjustment
Steering
Steering Inspection
Electrical System
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Brake Light Switch Inspection
Brake Light Timing Adjustment
Drive Belt Failure Detection
System Inspection
Joint Boots Inspection
Front Axle/Knuckle Joint Boot Inspection
Front Propeller Shaft Boot Inspection
Tie Rod End Boot Inspection
Rear Propeller Shaft Joint Boot Inspection
Rear Axle/Stabilizer Joint Boot Inspection
General Lubrication
Periodic Maintenance Lubrication
Bolts And Nuts Tightening
Tightness Inspection
– Fuel System
Exploded View
Specifications
Special Tools
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 Installation
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 Tap Cleaning
Fuel Pump
Fuel Pump Removal
Fuel Pump Removal
Fuel Pump Installation
Fuel Pump Inspection
– Cooling System
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 Warning Light Switch
Coolant Temperature Warning Light Switch Removal
Coolant Temperature Warning Light Switch Installation
Coolant Temperature Warning Light Switch Inspection
– Engine Top End
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
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
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Drive Belt Inspection
Drive Pulley
Drive Pulley Removal
Drive Pulley Disassembly
Drive Pulley Inspection
Spider Shoe Side Clearance 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
Specifications
– Recoil Starter
Recoil Starter
Recoil Starter Removal
Recoil Starter Installation
Recoil Starter Inspection
– Engine Lubrication System
Engine Oil Flow Chart
Engine Oil And Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Change
Oil Screen Removal
Oil Screen Cleaning
Oil Pressure Measurement
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
Oil Pressure Relief Valve Installation
Oil Pressure Relief Valve Inspection
Oil Pump
Oil Pump Removal
Oil Pump Installation
Oil Pipe
Oil Pipe Removal
Oil Pipe Installation
– Engine Removal/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
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing/Crankpin Wear
Crankshaft Runout
Crankshaft Main Bearing/Journal Wear
Transmission
Shift Lever Removal
Shift Lever Installation
Transmission Removal
Transmission Installation
Shift Fork Bending
Shift Fork/Gear And Shifter Groove Wear
Transmission And Shift Mechanism Inspection
Ball Bearing, Needle Bearing, And Oil Seal
Ball And Needle Bearing Replacement
Ball And Needle Bearing Wear
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
Rear Axle Joint Boot Inspection
Rear Axle Joint Boot
Replacement
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
Rear Final Gear Case Right Cover Assembly
Rear Final Gear Case Front Cover Assembly
Final Drive
Rear Final Gear Case Assembly
Rear Final Bevel Gear Adjustment
Pinion Gear Unit Disassembly
Pinion Gear Unit Assembly
Bearing And Oil Seal
Ball Or Needle Bearing Inspection
Oil Seal Inspection
– Brakes
Brake Fluid
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Air Bleeding
Master Cylinder
Master Cylinder Removal
Master Cylinder Installation
Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection (Visual Inspection)
Calipers
Caliper Removal
Caliper Installation
Caliper Disassembly
Caliper Assembly
Fluid Seal Damage
Dust Seal And Friction Boot Damage
Piston And Cylinder Damage
Caliper Holder Shaft Wear Inspection
Brake Pads
Brake Pad Removal
Brake Pad Installation
Brake Pad Wear Inspection
Brake Discs
Disc Cleaning
Disc Removal
Disc Installation
Disc Wear
Disc Runout
Brake Hoses
Brake Hose Inspection
Brake Hose Replacement
Rear Brake Lever, Pedal And Cables
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Rear Brake Lever Free Play Inspection
Brake Pedal Free Play Inspection
Rear Brake Lever And Pedal Free
Play Adjustment
Brake Pedal Removal
Brake Pedal Installation
Brake Cable Removal
Brake Cable Installation
Brake Cable Lubrication
Internal Wet Brake
Internal Wet Brake Disassembly
Internal Wet Brake Assembly
– Suspension
Shock Absorbers
Front Shock Absorber Preload Adjustment
Front Shock Absorber Removal
Front Shock Absorber Installation
Front Shock Absorber Inspection
Front Shock Absorber Scrapping
Rear Shock Absorber Preload Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Inspection
Shock Absorber Spring Replacement
Rear Shock Absorber Scrapping
Suspension Arms
Front Suspension Arm Removal
Front Suspension Arm Installation
Front Suspension Arm Disassembly
Front Suspension Arm Assembly
Rear Suspension Arm Removal
Rear Suspension Arm Installation
Rear Suspension Arm Disassembly
Rear Suspension Arm Assembly
Stabilizer Removal
Stabilizer Installation
– Steering
Steering Stem Removal
Steering Stem Installation
Front Knuckle Removal
Front Knuckle Installation
Front Knuckle Bearing Removal
Front Knuckle Bearing Installation
Tie Rod Removal
Tie Rod Installation
Tie Rod End Removal
Tie Rod End Installation
Steering Maintenance
Steering Inspection
Steering Stem Straightness
Steering Bearing Sleeve Lubrication
Steering Stem Clamp Inspection
Steering Stem Bearing Inspection
Steering Knuckle Bearing Inspection
Tie Rod End Inspection
Steering Knuckle Joint Inspection
Handlebar
Handlebar Removal
Handlebar Installation
– Frame
Seat
Seat Removal
Seat Installation
Carriers
Front Carrier Removal
Front Carrier Installation
Front Carrier Bracket Installation
Rear Carrier Removal
Rear Carrier Installation
Rear Carrier Bracket Installation
Fenders
Front Fender Removal
Front Fender Installation
Rear Fender Removal
Rear Fender Installation
Covers
Middle Cover Removal
Middle Cover Installation
Left Side Cover Removal
Left Side Cover Installation
Right Side Cover Removal
Right Side Cover Installation
Electrical Parts Case Removal
Electrical Parts Case Installation
Radiator Cover Removal
Radiator Cover Installation
Guards
Front Guard Removal
Front Guard Installation
Front Bottom Guard Removal
Front Bottom Guard Installation
Engine Bottom Guard Removal
Engine Bottom Guard Installation
Rear Bottom Guard Removal
Rear Bottom Guard Installation
Flaps And Footboards
Left Footboard Removal
Left Footboard Installation
Right Footboard Removal
Right Footboard Installation
Footboard Bracket Installation
Trailer Hitch Bracket
Trailer Hitch Bracket Removal
Trailer Hitch Bracket Installation
– Electrical System
Parts Location
Exploded View
Wiring Diagram
Precautions
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
Starter Motor Brush Length
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 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
Actuator Control System
Wd/Wd Actuator Removal
Wd/Wd 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
Carburetor Heater System
Air Temperature Sensor Inspection
Carburetor Heater Inspection
Switches
Brake Light Switch Adjustment
Radiator Fan Switch Inspection
Coolant Temperature Warning
Light Switch Inspection
Switch Inspection
Drive Belt Failure Detection Switch
Fuses
Fuse Removal
Fuse Installation
Fuse Inspection
– Appendix
Troubleshooting Guide
Cable, Wire, And Hose Routing
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