Factory Service Repair Manual For Kawasaki PRAIRIE 360 KVF360 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: 408
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No
Model
Kawasaki KVF 360, PRAIRIE 360
KVF360A1
Contents
- – General Info
Before Servicing
Model Identification
General Specifications
Special Tools And Sealant
Unit Conversion Table - – Periodic Maintenance
Periodic Maintenance Chart
Torque And Locking Agent
Specifications
Periodic Maintenance Procedures
Fuel System
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Fuel System Cleanliness Inspection
Air Cleaner Element Cleaning And Inspection
Air Cleaner Draining
Fuel Hose And Connection Check
Fuel Hose Replacement
Engine Top End
Valve Clearance Inspection
Spark Arrester Cleaning
Converter System
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
Drive Belt Inspection
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Engine Lubrication System
Engine Oil Change
Oil Filter Change
Oil Cooler Cleaning And Inspection
Oil Hose And Connection Check
Wheels/Tires
Tire Inspection
Final Drive
Variable Differential Control Lever Position Inspection
Variable Differential Control Lever Position Adjustment
Front Final Gear Case Oil Change
Rear Final Gear Case Oil Change
Joint Boots Inspection
Rear Propeller Shaft Joint Boot Inspection
Brakes
Front Brake Pad Wear Inspection
Brake Hose And Connection Check
Brake Hose Replacement
Brake Fluid Level Inspection
Brake Fluid Change
Brake Master Cylinder Piston Assembly And Dust
Seal Replacement
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
Battery Inspection
Spark Plug Cleaning / Inspection
Spark Plug Gap Inspection
Drive Belt Failure Detection System Inspection
Brake Light Switch Adjustment
General Lubrication
Lubrication
Bolts And Nuts Tightening
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
Throttle Cable Inspection
Choke Lever And Cable
Choke Lever And Cable Removal
Choke Lever And Cable Installation
Choke Cable Lubrication
Choke Cable Inspection
Carburetor
Idle Speed Inspection
Idle Speed Adjustment
Pilot Screw Adjustment
Service Fuel Level Inspection
Fuel Level Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning
Carburetor Inspection
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Installation
Air Cleaner Element Cleaning And Inspection
Air Cleaner Draining
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Snorkel Duct Removal
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tap Removal
Fuel Tap Installation
Fuel Tank And Fuel Tap Cleaning
Fuel Tap Inspection
Fuel Level Gauge Removal
Fuel Level Gauge Installation
Fuel Level Gauge Check - – Engine Top End
Specifications
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Camshaft Sprocket
Camshaft Sprocket Removal
Camshaft Sprocket Installation
Rocker Arms And Shafts
Rocker Arm And Shaft Removal
Rocker Arm And Shaft Installation
Rocker Arm And Shaft Inspection
Camshaft
Camshaft Removal
Camshaft Installation
Cam Wear Inspection
Camshaft Bearing Inspection
Kacr Inspection
Camshaft Chain And Guides
Camshaft Chain Removal
Camshaft Chain Installation
Camshaft Chain Guide Removal
Camshaft Chain Guide Installation
Camshaft Chain Guide Wear
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Assembly
Cylinder Head Cleaning
Cylinder Head Warp
Valves, Guides, Seats, Springs, Oil Seals
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Visual Inspection
Valve Guide Removal
Valve Guide Installation
ValveToGuide Clearance Measurement
Valve Seat Inspection
Valve Seat Repair (Valve Lapping)
Cylinder And Piston
Cylinder Removal
Cylinder Installation
Cylinder Assembly
Piston Removal
Piston Installation
Cylinder/Piston Wear
Piston/Cylinder Clearance
Piston Ring And Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap Measurement
Exhaust System
Spark Arrester Cleaning
Muffler Removal
Exhaust Pipe Removal
Exhaust Pipe And Muffler 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 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 Hose
Oil Pipe Removal
Oil Pipe Installation
Oil Hose Removal
Oil Hose Installation
Oil Cooler
Oil Cooler Removal
Oil Cooler Installation
Oil Cooler Disassembly
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch Removal
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch Installation
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch Inspection
Oil Cooler Inspection - – Engine Removal/Installation
- – Crankshaft/Transmission
Crankcase
Crankcase Disassembly
Crankcase Assembly
Crankshaft/Balancer Shaft And Connection Rod
Crankshaft/Balancer Shaft Removal
Crankshaft/Balancer Shaft Installation
Crankshaft Disassembly
Crankshaft Assembly
Connecting Rod Big End Seizure
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Alignment
Connecting Rod Bend/Twist
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
ToeIn Inspection
ToeIn 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
Cam Damper 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 Position Inspection
Variable Differential Control Lever Position 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 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
Bevel Gear Inspection
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 Removal
Front Shock Absorber Installation
Front Shock Absorber Inspection
Front Shock Absorber Spring Removal
Front Shock Absorber Spring Installation
Rear Shock Absorber Preload Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Inspection
Rear Shock Absorber Spring Removal
Rear Shock Absorber Spring Installation
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
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 Stem Straightness
Steering Lubrication
Steering Stem Clamp Inspection
Steering Stem Bearing Inspection
Steering Knuckle Bearing Inspection
Tie Rod 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
Headlight Cover Removal
Headlight Cover Installation
Front Inner Cover Removal
Front Inner Cover Installation
Fuel Tank Cover Removal
Fuel Tank Cover Installation
Left Side Cover Removal
Exhaust Pipe Cover Removal
Guards
Front Guard Removal
Front Lower 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
Precautions
Exploded View
Specifications
Parts Location
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Electrolyte Level Inspection
Electrolyte Specific Gravity Inspection
Initial Charging
Ordinary Charging
Battery Test Charging
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
Pickup Coil Removal
Pickup Coil Installation
Pickup Coil Inspection
Pickup Coil Peak Voltage Inspection
Alternator Rotor Inspection
Ignition Timing Test
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
Headlight Body Removal
Headlight Body Installation
Taillight Bulb Replacement
Oil Cooler Fan System
Oil Cooler Fan Circuit Inspection
Oil Cooler Fan Motor Inspection
Speedometer (Optional Part For US Model)
Speedometer Removal
Speedometer Inspection
Led Indicator
Drive Belt Failure Mode Memory Clearing Procedure
Led Indicator Removal
Led Indicator Installation
Led Indicator Inspection
Actuator Control 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
Carburetor Heater System
Air Temperature Sensor Inspection
Carburetor Heater Inspection
Switches
Brake Light Switch Adjustment
Oil Cooler Fan Switch Inspection
Oil Temperature Warning Light Switch Inspection
Switch Inspection
Drive Belt Failure Detection Switch
Fuses
Fuses Removal
Fuse Inspection
Wiring Diagram - – Appendix
Troubleshooting Guide
Cable, Wire, And Hose Routing
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