2010 – 2011 Kawasaki Teryx 750 Fi 4×4 Le Sport Utv Manual – PDF DOWNLOAD

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2010 – 2011 Kawasaki Teryx 750 Fi 4×4 Le Sport Utv Manual

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2010 – 2011 KAWASAKI TERYX 750 FI 4X4 LE SPORT UTV MANUAL – PDF DOWNLOAD:

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2010 – 2011 Kawasaki Teryx 750 Fi 4×4 Le Sport Utv Manual

FOREWORD:

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, It contains enough detail and basic In- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools. and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes. read the text. thoroughly familiarize yourself with the procedures before starting work. and then do the work care- fully in a clean area.

Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used. and the use of substitute tools may ad-versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed In accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

•  Follow the Periodic Maintenance Chart in the Service Manual.
•  Be alert for problems and non-scheduled maintenance.
•  Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges. and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man- ual. Genuine parts provided as spare parts are listed in the Parts Catalog. 0
• Foilow the procedures in this manual care- fully. Don’t take shortcuts.
• Rememberto keep complete records of main- tenance and repair with dates and any new parts installed.

How to Use This Manual:

In this manual. the product is divided into its major systems and these systems make up the manuals chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, If you want engine oil informa- tion. use the Quick Reference Guide to locate the Engine lubrication System chapter. Then, use the Table of Contents on the first page of the chapter to find the Engine Oil section. Whenever you see symbols, heed their in- structions! Always follow safe operating and mnInIAn-Iunnn nr-cnflrqnl-

TABLE OF CONTENTS:

2010 – 2011 Kawasaki Teryx 750 Fi 4×4 Le Sport Utv Manual

2010-2011 KAWASAKI TERYX 750 FI 4X4 LE SPORT UTV'S.................................  0
	GENERAL INFORMATION............................................................ 13
		Before Servicing........................................................... 14
		Model Identification....................................................... 19
		General Specifications..................................................... 23
		Unit Conversion Table...................................................... 27
	PERIODIC MAINTENANCE........................................................... 29
		Periodic Maintenance Chart................................................. 31
		Torque and Locking Agent................................................... 33
		Specifications............................................................. 41
		Special Tools.............................................................. 43
		Periodic Maintenance Procedures............................................ 44
			Fuel System............................................................ 44
				Throttle Pedal Free Play Inspection................................ 44
				Throttle Pedal Free Play Adjustment................................ 44
				Idle Speed Inspection.............................................. 45
				Idle Speed Adjustment.............................................. 45
				Air Cleaner Element Cleaning and Inspection........................ 45
				Air Cleaner Draining............................................... 46
				Fuel Hose and Connections Inspection .............................. 46
				Fuel Hose Replacement.............................................. 47
			Cooling System......................................................... 48
				Radiator Cleaning.................................................. 48
				Water Hoses and Connections Inspection............................. 48
				Coolant Change..................................................... 48
			Engine Top End......................................................... 51
				Valve Clearance Inspection......................................... 51
				Valve Clearance Adjustment......................................... 53
				Spark Arrester Cleaning............................................ 53
			Converter System....................................................... 54
				Converter Drive Belt Wear Inspection............................... 54
				Drive Belt Deflection Inspection................................... 56
				Converter Drive Belt Deflection Adjustment......................... 58
				Actuator Lever (Engine Brake Control Lever) Assembly Inspection.... 58
			Engine Lubrication System.............................................. 59
				Engine Oil Change.................................................. 59
				Oil Filter Replacement............................................. 60
			Wheels/Tires........................................................... 60
				Tire Inspection.................................................... 60
				Wheels Nuts Tightness Inspection................................... 61
			Final Drive............................................................ 61
				Differential Shift Lever Play Inspection........................... 61
				Differential Shift Lever Play Adjustment........................... 61
				Front Final Gear Case Oil Change................................... 61
				Rear Final Gear Case Oil Change.................................... 62
			Brakes................................................................. 63
				Brake Fluid Level Inspection....................................... 63
				Brake Fluid Change................................................. 63
				Brake Pedal Play Inspection........................................ 65
				Brake Master Cylinder Cup and Dust Seal Replacement................ 65
				Rear Brake Master Cylinder Cup, O-ring and Boot Replace............ 66
				Brake Hose and Pipe Inspection..................................... 68
				Brake Hose Replacement............................................. 69
				Parking Brake Pedal Inspection..................................... 71
				Front Brake Pad Wear Inspection.................................... 71
				Front Brake Caliper Piston Seal and Dust Seal Replacement.......... 72
				Rear Brake Plates Replacement...................................... 73
			Steering............................................................... 73
				Steering Inspection................................................ 73
				Steering Joint Dust Boot Inspection................................ 74
			Frame.................................................................. 74
				Seat Belt Inspection............................................... 74
			Electrical System...................................................... 75
				Spark Plug Cleaning/Inspection..................................... 75
				Spark Plug Gap Inspection.......................................... 75
				Brake Light Switch Inspection...................................... 75
				Brake Light Timing Adjustment...................................... 76
			Joint Boots Inspection................................................. 76
				Front Axle/Steering Knuckle Joint Boots Inspection................. 76
				Front Propeller Shaft Joint Boots Inspection....................... 76
				Tie-rod End Boots Inspection....................................... 76
				Rear Propeller Shaft Joint Boots Inspection........................ 77
				Rear Axle/Stabilizer Joint Boots Inspection........................ 77
			General Lubrication.................................................... 77
				Lubrication........................................................ 77
			Cables................................................................. 78
				Inspection......................................................... 78
			Bolts and Nuts Tightening.............................................. 79
				Tightness Inspection............................................... 79
	FUEL SYSTEM (DFI).............................................................. 81
		Exploded View.............................................................. 84
		DFI System................................................................. 88
		DFI Parts Location......................................................... 93
		Specifications............................................................. 95
		Special Tools and Sealant.................................................. 97
		DFI Servicing Precautions.................................................. 99
			DFI Servicing Precautions.............................................. 99
		Troubleshooting the DFI System.............................................101
			Outline................................................................101
			Inquiries to Rider.....................................................104
		DFI System Troubleshooting Guide...........................................107
		Self-Diagnosis.............................................................111
			Self-diagnosis Outline.................................................111
			Self-diagnosis Procedures..............................................111
			How to Read Service Codes..............................................114
			Service Code Erasing...................................................114
			Service Code Table.....................................................114
			Backups................................................................116
		Throttle Sensor (Service Code 11)..........................................118
			Throttle Sensor Removal/Adjustment.....................................118
			Throttle Sensor Input Voltage Inspection...............................118
			Throttle Sensor Output Voltage Inspection..............................119
			Throttle Sensor Resistance Inspection..................................120
		Inlet Air Pressure Sensor (Service Code 12)................................121
			Inlet Air Pressure Sensor Removal......................................121
			Inlet Air Pressure Sensor Installation.................................121
			Inlet Air Pressure Sensor Input Voltage Inspection.....................121
			Inlet Air Pressure Sensor Output Voltage Inspection....................122
		Inlet Air Temperature Sensor (Service Code 13).............................127
			Inlet Air Temperature Sensor Removal/Installation......................127
			Inlet Air Temperature Sensor Output Voltage Inspection.................127
			Inlet Air Temperature Sensor Resistance Inspection.....................128
		Water Temperature Sensor (Service Code 14).................................130
			Water Temperature Sensor Removal.......................................130
			Water Temperature Sensor Installation..................................130
			Water Temperature Sensor Output Voltage Inspection.....................131
			Water Temperature Sensor Resistance Inspection.........................132
		Crankshaft Sensor (Service Code 21)........................................133
			Crankshaft Sensor Removal/Installation.................................133
			Crankshaft Sensor Inspection...........................................133
		Speed Sensor (Service Code 24).............................................134
			Speed Sensor Removal...................................................134
			Speed Sensor Installation..............................................134
			Speed Sensor Input Voltage Inspection..................................134
			Speed Sensor Output Voltage Inspection.................................134
		Vehicle-down Sensor (Service Code 31)......................................136
			Vehicle-down Sensor Removal............................................136
			Vehicle-down Sensor Installation.......................................136
			Vehicle-down Sensor Input Voltage Inspection...........................136
			Vehicle-down Sensor Output Voltage Inspection..........................137
		Fuel Pump Relay (Service Code 46)..........................................139
			Fuel Pump Relay Removal................................................139
			Fuel Pump Relay Inspection.............................................139
		Ignition Coils (#1, #2: Service Code 51, 52)...............................141
			Ignition Coil Removal/Installation.....................................141
			Ignition Coil Winding Resistance.......................................141
			Ignition Coil Input Voltage Inspection.................................141
		Fuel Injectors ............................................................143
			Fuel Injector Removal..................................................143
			Fuel Injector Installation.............................................143
			Audible Inspection.....................................................145
			Fuel Injector Resistance Inspection....................................145
			Fuel Injector Power Source Voltage Inspection..........................145
			Fuel Injector Output Voltage Inspection................................146
			Fuel Injector Fuel Line Inspection.....................................147
		FI Indicator Symbol (LCD)..................................................149
			FI Indicator Symbol (LCD) Inspection...................................149
		ECU........................................................................150
			ECU Removal............................................................150
			ECU Installation.......................................................150
			ECU Power Supply Inspection............................................150
		Fuel Line..................................................................153
			Fuel Pressure Inspection...............................................153
			Fuel Flow Rate Inspection..............................................154
		Fuel Pump..................................................................156
			Fuel Pump Removal......................................................156
			Fuel Pump Installation.................................................156
			Fuel Pump Operation Inspection.........................................157
			Fuel Pump Operating Voltage Inspection.................................157
			Pressure Regulator Removal.............................................158
			Fuel Filter Cleaning...................................................159
		Throttle Pedal and Cable...................................................160
			Throttle Pedal Free Play Inspection....................................160
			Throttle Pedal Free Play Adjustment....................................160
			Throttle Pedal Position Adjustment.....................................160
			Throttle Pedal Removal.................................................160
			Throttle Pedal Installation............................................161
			Throttle Cable Installation............................................161
			Throttle Cable Lubrication and Inspection..............................162
		Throttle Body Assy.........................................................163
			Idle Speed Inspection..................................................163
			Idle Speed Adjustment..................................................163
			Throttle Body Assy Removal.............................................163
			Throttle Body Assy Installation........................................164
			Throttle Body Assy Disassembly.........................................165
			Throttle Body Assy Assembly............................................166
			Engine Vacuum Synchronization Inspection...............................166
			Engine Vacuum Synchronization Adjustment...............................167
		ISC Valve..................................................................168
			ISC Valve Removal......................................................168
			ISC Valve Installation.................................................168
			ISC Valve Inspection...................................................168
		Air Cleaner................................................................169
			Air Cleaner Element Removal............................................169
			Air Cleaner Element Installation.......................................170
			Air Cleaner Element Cleaning and Inspection............................171
			Air Cleaner Housing and Duct Removal...................................171
			Air Cleaner Housing and Duct Installaion...............................171
		Fuel Tank and Fuel Hose....................................................173
			Fuel Tank Removal......................................................173
			Fuel Tank Installation.................................................173
			Fuel Tank Cleaning.....................................................175
			Fuel Hose Inspection...................................................175
			Fuel Hose Replacement..................................................175
	COOLING SYSTEM.................................................................177
		Exploded View..............................................................178
		Coolant Flow Chart.........................................................180
		Specifications.............................................................182
		Special Tools..............................................................183
		Coolant....................................................................184
			Coolant Deterioration Inspection.......................................184
			Coolant Level Inspection...............................................184
			Coolant Draining.......................................................184
			Coolant Filling........................................................184
			Pressure Testing.......................................................185
		Water Pump.................................................................186
			Water Pump Cover Removal...............................................186
			Water Pump Cover Installation..........................................186
			Water Pump Impeller Removal............................................186
			Water Pump Impeller Installation.......................................186
			Water Pump Impeller Inspection.........................................187
			Water Pump Leakage Inspection..........................................187
			Mechanical Seal Replacement............................................187
		Radiator...................................................................189
			Radiator Removal.......................................................189
			Radiator Installation..................................................190
			Radiator Fan Removal...................................................190
			Radiator Fan Installation..............................................190
			Radiator Inspection....................................................191
			Radiator Cleaning......................................................191
			Radiator Cap Inspection................................................191
		Thermostat.................................................................192
			Thermostat Removal.....................................................192
			Thermostat Installation................................................192
			Thermostat Inspection..................................................192
		Water Temperature Sensor...................................................193
			Water Temperature Sensor Removal/Installation..........................193
			 Water Temperature Sensor Inspection...................................193
	ENGINE TOP END.................................................................195
		Exploded View..............................................................196
		Exhaust System.............................................................202
		Specifications.............................................................203
		Special Tools and Sealant..................................................206
		Camshaft Chain Tensioner...................................................208
			Camshaft Chain Tensioner Removal.......................................208
			Camshaft Chain Tensioner Installation..................................208
		Rocker Case................................................................210
			Rocker Case Removal....................................................210
			Rocker Case Installation...............................................211
			Rocker Arm Removal.....................................................212
			Rocker Arm Installation................................................213
			Rocker Arm Inspection..................................................213
			Rocker Shaft Diameter Measurement......................................213
		Camshaft...................................................................214
			Camshaft Removal.......................................................214
			Camshaft Installation..................................................214
			Camshaft Assembly......................................................215
			Cam Wear Inspection....................................................215
			Camshaft Bearing Wear Inspection.......................................216
			KACR Inspection........................................................217
			KACR Removal...........................................................217
			KACR Installation......................................................218
			Camshaft Chain Removal.................................................218
			Camshaft Chain Installation............................................219
			Camshaft Chain Guide Wear Inspection...................................222
		Cylinder Head..............................................................223
			Cylinder Compression Measurement.......................................223
			Cylinder Head Removal..................................................224
			Cylinder Head Installation.............................................224
			Cylinder Head Cleaning.................................................225
			Cylinder Head Warp Inspection..........................................225
		Valves.....................................................................226
			Valve Clearance Inspection.............................................226
			Valve Clearance Adjustment.............................................226
			Valve Removal..........................................................226
			Valve Installation.....................................................226
			Valve Guide Removal....................................................226
			Valve Guide Installation...............................................227
			Valve-to-Guide Clearance Measurement...................................227
			Valve Seat Inspection..................................................228
			Valve Seat Repair (Valve Lapping)......................................228
		Cylinder and Piston........................................................233
			Cylinder Removal.......................................................233
			Piston Removal.........................................................233
			Cylinder, Piston Installation..........................................233
			Cylinder Wear Inspection...............................................235
			Piston Wear Inspection.................................................235
			Piston/Cylinder Clearance Inspection...................................235
			Piston Ring, Piston Ring Groove Wear Inspection........................236
			Piston Ring Groove Width Inspection....................................236
			Piston Ring Thickness Inspection.......................................236
			Piston Ring End Gap Inspection.........................................237
		Exhaust System.............................................................238
			Spark Arrester Cleaning................................................238
			Muffler and Exhaust Pipe Removal.......................................238
			Exhaust System Inspection..............................................240
			Muffler and Exhaust Pipe Installation .................................240
	CONVERTER SYSTEM...............................................................243
		Exploded View..............................................................244
		Specifications.............................................................248
		Special Tools..............................................................249
		Torque Converter Cover.....................................................251
			Torque Converter Cover Removal.........................................251
			Torque Converter Cover Installation....................................251
			Torque Converter Cover Disassembly.....................................252
			Actuator Lever (Engine Brake Control Lever) Assembly Inspection........253
			Torque Converter Cover Assembly........................................253
		Drive Belt.................................................................255
			Drive Belt Removal.....................................................255
			Drive Belt Installation................................................255
			Drive Belt Deflection Inspection.......................................255
			Drive Belt Deflection Adjustment.......................................255
			Drive Belt Inspection..................................................255
		Drive Pulley...............................................................256
			Drive Pulley Removal...................................................256
			Drive Pulley Disassembly...............................................256
			Drive Pulley Inspection................................................257
			Spider Shoe Side Clearance Inspection/Adjustment.......................259
			Drive Pulley Assembly..................................................260
			Drive Pulley Installation..............................................262
		Driven Pulley..............................................................264
			Driven Pulley Removal..................................................264
			Driven Pulley Disassembly..............................................264
			Driven Pulley Inspection...............................................265
			Driven Pulley Assembly.................................................266
			Driven Pulley Installation.............................................268
	ENGINE LUBRICATION SYSTEM......................................................271
		Exploded View..............................................................272
		Specifications.............................................................274
		Engine Oil Flow Chart......................................................275
		Special Tools and Sealant..................................................276
		Engine Oil and Oil Filter..................................................277
			Oil Level Inspection...................................................277
			Engine Oil Change......................................................277
			Oil Filter Change......................................................277
			Oil Screen Removal.....................................................278
			Oil Screen Cleaning....................................................278
			Oil Pressure Measurement...............................................278
		Oil Pressure Relief Valve..................................................280
			Oil Pressure Relief Valve Removal......................................280
			Oil Pressure Relief Valve Installation.................................280
			Oil Pressure Relief Valve Inspection...................................280
		Oil Pump...................................................................281
			Oil Pump Removal.......................................................281
			Oil Pump Installation..................................................281
		Oil Pipe...................................................................283
			Oil Pipe Removal.......................................................283
			Oil Pipe Installation..................................................284
	ENGINE REMOVAL/INSTALLATION....................................................285
		Exploded View..............................................................286
		Engine Removal/Installation................................................288
			Engine Removal.........................................................288
			Engine Installation....................................................290
	CRANKSHAFT/TRANSMISSION........................................................291
		Exploded View..............................................................292
		Specifications.............................................................296
		Special Tools and Sealant..................................................298
		Crankcase..................................................................299
			Crankcase Disassembly..................................................299
			Crankcase Assembly.....................................................299
		Crankshaft/Connection Rod..................................................303
			Crankshaft Removal.....................................................303
			Crankshaft Installation................................................303
			Connecting Rod Removal.................................................303
			Connecting Rod Installation............................................303
			Crankshaft/Connecting Rod Cleaning.....................................304
			Connecting Rod Bend Inspection.........................................304
			Connecting Rod Twist Inspection........................................304
			Connecting Rod Big End Side Clearance Inspection.......................305
			Connecting Rod Big End Bearing/Crankpin Wear Inspection................305
			Crankshaft Runout Inspection...........................................307
			Crankshaft Main Bearing/Journal Wear Inspection........................307
		Transmission...............................................................308
			Shift Lever Removal....................................................308
			Shift Lever Installation...............................................309
			Transmission Removal...................................................313
			Transmission Installation..............................................314
			Shift Fork Bending Inspection..........................................316
			Shift Fork/Gear and Shifter Groove Wear Inspection.....................316
			Transmission and Shift Mechanism Inspection............................317
		Ball Bearing, Needle Bearing, and Oil Seal.................................319
			Ball and Needle Bearing Replacement....................................319
			Ball and Needle Bearing Wear Inspection................................319
			Oil Seal Inspection....................................................319
	WHEELS/TIRES...................................................................321
		Exploded View..............................................................322
		Specifications.............................................................324
		Special Tools..............................................................325
		Wheel Alignment............................................................326
			Toe-in Inspection......................................................326
			Toe-in Adjustment......................................................326
		Wheels (Rims)..............................................................328
			Wheel Removal..........................................................328
			Wheel Installation.....................................................328
			Wheel (Rim) Inspection.................................................328
			Wheel (Rim) Replacement................................................329
		Tires......................................................................330
			Tire Removal...........................................................330
			Tire Installation......................................................330
			Tire Inspection........................................................331
		Front Hub .................................................................332
			Front Hub Removal......................................................332
			Front Hub Installation.................................................333
			Front Hub Disassembly/Assembly.........................................334
		Rear Hub ..................................................................335
			Rear Hub Removal.......................................................335
			Rear Hub Installation..................................................335
			Rear Hub Disassembly/Assembly..........................................336
	FINAL DRIVE....................................................................337
		Exploded View..............................................................339
		Specifications.............................................................346
		Special Tools..............................................................347
		Output Bevel Gears.........................................................349
			Output Drive Bevel Gear Removal........................................349
			Output Drive Bevel Gear Installation...................................349
			Output Drive Bevel Gear Disassembly....................................350
			Output Drive Bevel Gear Assembly.......................................352
			Output Driven Bevel Gear Removal.......................................352
			Output Driven Bevel Gear Installation..................................353
			Output Driven Bevel Gear Disassembly...................................353
			Output Driven Bevel Gear Assembly......................................354
			Output Bevel Gears Adjustment..........................................355
			Bevel Gears Inspection.................................................359
		Front Propeller Shaft......................................................360
			Front Propeller Shaft Removal..........................................360
			Front Propeller Shaft Installation.....................................360
			Front Propeller Shaft Inspection.......................................362
		Front Axle.................................................................363
			Front Axle Removal.....................................................363
			Front Axle Installation................................................363
			Front Axle Joint Boot Inspection.......................................363
			Front Axle Joint Boot Replacement......................................363
		Front Final Gear Case......................................................370
			Front Final Gear Case Oil Level Inspection.............................370
			Front Final Gear Case Oil Change.......................................370
			Differential Shift Lever Play Inspection...............................370
			Differential Shift Lever Play Adjustment...............................370
			Differential Shift Lever Removal.......................................370
			Differential Shift Lever Installation..................................371
			Differential Shift Cable Removal.......................................371
			Differential Shift Cable Installation..................................372
			Differential Shift Cable Lubrication...................................373
			Differential Shift Cable Inspection....................................373
			2WD/4WD Shift Cable Removal............................................373
			2WD/4WD Shift Cable Installation.......................................374
			2WD/4WD Vacuum Actuator Removal........................................375
			2WD/4WD Vacuum Actuator Installation...................................376
			2WD/4WD Shift Cable Lubrication........................................376
			2WD/4WD Shift Cable Inspection.........................................377
			Front Final Gear Case Removal..........................................377
			Front Final Gear Case Installation.....................................378
			Front Final Gear Case Disassembly......................................379
			Front Final Gear Case Coupling Inspection..............................382
			Front Final Gear Case Assembly.........................................383
			Ring Gear Disassembly..................................................390
			Ring Gear Assembly.....................................................391
			LSD Clutch Torque Inspection...........................................391
			Pinion Gear Unit Disassembly...........................................392
			Pinion Gear Unit Assembly..............................................392
			Front Final Bevel Gear Adjustment......................................393
			Front Final Gear Case Backlash Adjustment..............................396
			Front Final Gear Case Tooth Contact Adjustment.........................397
			Bevel Gear Inspection..................................................400
			Differential Gear Inspection...........................................400
		Rear Propeller Shaft.......................................................401
			Rear Propeller Shaft Removal...........................................401
			Rear Propeller Shaft Installation......................................401
			Rear Propeller Shaft Inspection........................................403
		Rear Axle..................................................................404
			Rear Axle Removal......................................................404
			Rear Axle Installation.................................................404
			Rear Axle Joint Boot Inspection........................................404
			Rear Axle Joint Boot Replacement.......................................405
		Rear Final Gear Case.......................................................411
			Rear Final Gear Case Oil Level Inspection..............................411
			Rear Final Gear Case Oil Change........................................411
			Rear Final Gear Case Removal...........................................411
			Rear Final Gear Case Installation......................................413
			Rear Final Gear Case Disassembly.......................................413
			Rear Final Gear Case Right Cover Assembly..............................416
			Rear Final Gear Case Front Cover Assembly..............................416
			Rear Final Gear Case Assembly..........................................417
			Pinion Gear Unit Disassembly...........................................421
			Pinion Gear Unit Assembly..............................................422
			Rear Final Bevel Gear Adjustment.......................................422
			Rear Final Gear Case Backlash Adjustment...............................425
			Tooth Contact Adjustment...............................................426
		Bearing and Oil Seal.......................................................428
			Ball or Needle Bearing Inspection......................................428
			Oil Seal Inspection....................................................429
	BRAKES.........................................................................431
		Exploded View..............................................................432
		Specifications.............................................................436
		Brake Fluid................................................................437
			Front Brake Fluid Recommendation.......................................437
			Front Brake Fluid Level Inspection.....................................437
			Front Brake Fluid Change...............................................437
			Brake Line Air Bleeding................................................438
		Brake Pedal and Master Cylinder............................................440
			Brake Pedal Play Inspection............................................440
			Brake Pedal Removal....................................................440
			Brake Pedal Installation...............................................440
			Front Master Cylinder Removal..........................................441
			Front Master Cylinder Installation.....................................441
			Front Master Cylinder Disassembly/Assembly.............................441
			Front Master Cylinder Inspection.......................................442
			Rear Master Cylinder Removal...........................................442
			Rear Master Cylinder Installation......................................442
			Rear Master Cylinder Disassembly/Assembly..............................442
			Rear Master Cylinder Inspection........................................443
		Calipers...................................................................444
			Front Brake Caliper Removal............................................444
			Front Brake Caliper Installation.......................................444
			Front Brake Caliper Disassembly........................................444
			Front Brake Caliper Assembly...........................................444
			Caliper Piston Seal Damage Inspection..................................445
			Dust Seal and Friction Boot Damage Inspection..........................445
			Front Brake Caliper Piston and Cylinder Damage Inspection..............445
			Front Brake Caliper Holder Shaft Wear Inspection.......................445
		Brake Pads.................................................................446
			Front Brake Pad Removal................................................446
			Front Brake Pad Installation...........................................446
			Front Brake Pad Wear Inspection........................................446
		Brake Discs................................................................447
			Front Brake Disc Cleaning..............................................447
			Front Brake Disc Removal...............................................447
			Front Brake Disc Installation..........................................447
			Front Brake Disc Wear Inspection.......................................447
			Front Brake Disc Runout Inspection.....................................447
		Brake Hoses and Pipes......................................................448
			Brake Hose and Pipe Inspection.........................................448
			Brake Hose Replacement.................................................448
		Parking Brake Pedal and Cables.............................................449
			Parking Brake Pedal Inspection.........................................449
			Parking Brake Pedal Removal............................................449
			Parking Brake Pedal Installation.......................................449
			Parking Brake Cable Removal............................................450
			Parking Brake Cable Installation.......................................450
			Parking Brake Cable Lubrication........................................450
		Internal Wet Brake.........................................................451
			Internal Wet Brake Disassembly.........................................451
			Internal Wet Brake Assembly............................................451
	SUSPENSION.....................................................................453
		Exploded View..............................................................454
		Specifications.............................................................458
		Special Tools..............................................................459
		Shock Absorbers (Other than KRF750S Model).................................460
			Front Shock Absorber Spring Preload Adjustment.........................460
			Front Shock Absorber Removal...........................................460
			Front Shock Absorber Installation......................................460
			Front Shock Absorber Inspection........................................461
			Front Shock Absorber Scrapping.........................................461
			Rear Shock Absorber Spring Preload Adjustment..........................462
			Rear Shock Absorber Removal............................................462
			Rear Shock Absorber Installation.......................................463
			Rear Shock Absorber Inspection.........................................463
			Rear Shock Absorber Scrapping..........................................464
		Shock Absorbers (KRF750S Model)............................................465
			Front Shock Absorber Rebound Damping Force Adjustment..................465
			Front Shock Absorber Compression Damping Force Adjustment..............465
			Front Shock Absorber Spring Preload Adjustment.........................466
			Front Shock Absorber Removal...........................................466
			Front Shock Absorber Installation......................................466
			Front Shock Absorber Inspection........................................467
			Front Shock Absorber Scrapping.........................................467
			Rear Shock Absorber Rebound Damping Force Adjustment...................468
			Rear Shock Absorber Compression Damping Force Adjustment...............468
			Rear Shock Absorber Spring Preload Adjustment..........................469
			Rear Shock Absorber Removal............................................469
			Rear Shock Absorber Installation.......................................470
			Rear Shock Absorber Inspection.........................................470
			Rear Shock Absorber Scrapping..........................................471
		Suspension Arms............................................................472
			Front Suspension Arm Removal...........................................472
			Front Suspension Arm Installation......................................473
			Front Suspension Arm Disassembly.......................................474
			Front Suspension Arm Assembly..........................................474
			Rear Suspension Arm Removal............................................475
			Rear Suspension Arm Installation.......................................476
			Rear Suspension Arm Disassembly........................................476
			Rear Suspension Arm Assembly...........................................477
			Stabilizer Removal.....................................................477
			Stabilizer Installation................................................478
			Stabilizer Joint Inspection............................................478
			Rear Knuckle Removal...................................................478
			Rear Knuckle Installation..............................................479
			Rear Knuckle Disassembly...............................................479
			Rear Knuckle Assembly..................................................480
		Bearing and Oil Seal.......................................................481
			Ball Bearing Inspection................................................481
			Oil Seal Inspection....................................................481
	STEERING.......................................................................483
		Exploded View..............................................................484
		Specifications.............................................................486
		Special Tools..............................................................487
		Steering Wheel and Main Shaft Assembly.....................................488
			Steering Wheel Position Adjustment.....................................488
			Steering Wheel Free Play Inspection....................................488
			Steering Wheel Centering...............................................488
			Steering Wheel Removal.................................................488
			Steering Wheel Installation............................................489
			Steering Shafts Removal................................................489
			Steering Shafts Installation...........................................490
		Steering Gear Assembly.....................................................491
			Steering Gear Assembly Removal.........................................491
			Steering Gear Assembly Installation....................................491
			Tie-rod Length Adjustment..............................................493
			Steering Joint Dust Boot Inspection....................................493
		Steering Knuckles..........................................................494
			Steering Knuckle Removal...............................................494
			Steering Knuckle Installation..........................................494
			Knuckle Bearing Removal................................................495
			Knuckle Bearing Installation...........................................495
	FRAME..........................................................................497
		Exploded View..............................................................498
		Seat and Seat Belts........................................................512
			Seat Removal...........................................................512
			Seat Installation......................................................512
			Seat Disassembly.......................................................512
			Seat Assembly..........................................................513
			Seat Belt Removal......................................................514
			Seat Belt Installation.................................................515
		Control Panel..............................................................516
			Control Panel Removal..................................................516
			Control Panel Installation.............................................518
			Glove Compartment Removal..............................................518
			Glove Compartment Installation.........................................519
			Cupholder Removal (KRF750P/R/S/V Models)...............................519
			Cupholder Installation (KRF750P/R/S/V Models)..........................522
		Fenders....................................................................523
			Front Fender Front Removal.............................................523
			Front Fender Front Installation........................................523
			Front Fender Rear Removal..............................................523
			Front Fender Rear Installation.........................................524
			Rear Fender Removal....................................................524
			Rear Fender Installation...............................................525
			Rear Flap Removal......................................................525
			Rear Flap Installation.................................................525
		Cargo Bed..................................................................526
			Cargo Bed Removal......................................................526
			Cargo Bed Installation.................................................526
			Cargo Bed Disassembly..................................................528
			Cargo Bed Assembly.....................................................531
		Bars.......................................................................536
			Right and Left Bars Removal............................................536
			Right and Left Bars Installation.......................................536
		Covers.....................................................................539
			Engine Upper Cover Removal.............................................539
			Engine Upper Cover Installation........................................539
			Center Cover Removal...................................................540
			Center Cover Installation..............................................540
			Side Cover Removal.....................................................540
			Side Cover Installation................................................542
			Seat Lower Cover Removal...............................................542
			Seat Lower Cover Installation..........................................543
			Seat Lower Right Plate Removal.........................................544
			Seat Lower Right Plate Installation....................................544
			Seat Lower Left Plate Removal..........................................544
			Seat Lower Left Plate Installation.....................................545
			Right and Left Brackets Removal........................................545
			Right and Left Brackets Installation...................................546
			Center Bracket Removal.................................................546
			Center Bracket Installation............................................547
			Right Frame Pipe Removal...............................................547
			Right Frame Pipe Installation..........................................548
			Left Cover Removal.....................................................548
			Left Cover Installation................................................549
			Windshield Removal (KRF750P/R/V Models)................................550
			Windshield Installation (KRF750P/R/V Models)...........................550
			Sun Top Cover Removal (KRF750P/R/V Models).............................551
			Sun Top Cover Installation (KRF750P/R/V Models)........................551
		Guards.....................................................................553
			Front Guard Removal....................................................553
			Front Guard Installation...............................................553
			Front Bottom Guard Removal.............................................553
			Front Bottom Guard Installation........................................554
			Middle Bottom Guard Removal............................................554
			Middle Bottom Guard Installation.......................................554
			Engine Bottom Guard Removal............................................554
			Engine Bottom Guard Installation.......................................555
			Rear Bottom Guard Removal..............................................555
			Rear Bottom Guard Installation.........................................555
		Floorboard.................................................................556
			Floorboard Removal.....................................................556
			Floorboard Installation................................................559
	ELECTRICAL SYSTEM..............................................................561
		Parts Location.............................................................563
		Exploded View..............................................................566
		Specifications.............................................................572
		Special Tools..............................................................573
		Wiring Diagram.............................................................574
		Precautions................................................................576
		Electrical Wiring..........................................................577
			Wiring Inspection......................................................577
		Battery....................................................................578
			Battery Removal........................................................578
			Battery Installation...................................................578
			Battery Activation (CA Model)..........................................581
			Precautions............................................................583
			Interchange............................................................584
			Charging Condition Inspection..........................................584
			Refreshing Charge .....................................................585
		Charging System............................................................587
			Alternator Cover Removal...............................................587
			Alternator Cover Installation..........................................588
			Alternator Rotor Removal ..............................................590
			Alternator Rotor Installation..........................................590
			Alternator Stator Removal..............................................591
			Alternator Stator Installation.........................................591
			Regulator/Rectifier Output Voltage Inspection..........................591
			Alternator Inspection..................................................592
			Regulator/Rectifier Removal............................................593
			Regulator/Rectifier Installation.......................................593
			Regulator/Rectifier Inspection.........................................594
		Ignition System............................................................596
			Spark Plug Removal.....................................................596
			Spark Plug Installation................................................596
			Spark Plug Cleaning/Inspection.........................................596
			Spark Plug Gap Inspection..............................................596
			Ignition Coil Removal..................................................596
			Ignition Coil Installation.............................................597
			Ignition Coil Inspection...............................................598
			Ignition Coil Primary Peak Voltage Inspection..........................599
			Crankshaft Sensor Removal..............................................599
			Crankshaft Sensor Installation.........................................600
			Crankshaft Sensor Inspection...........................................600
			Crankshaft Sensor Peak Voltage Inspection..............................600
			Alternator Rotor Inspection............................................601
			Ignition Timing Test...................................................601
		Electric Starter System....................................................604
			Starter Motor Removal..................................................604
			Starter Motor Installation.............................................604
			Starter Motor Disassembly..............................................605
			Starter Motor Assembly.................................................606
			Brush Inspection.......................................................608
			Commutator Cleaning and Inspection.....................................608
			Armature Inspection....................................................608
			Brush Lead Inspection..................................................609
			Right-hand End Cover Inspection........................................609
			Starter Relay Inspection...............................................609
			Starter Relay Installation.............................................609
			Starter Control Relay Inspection.......................................609
			Starter Motor Clutch Removal...........................................610
			Starter Motor Clutch Installation......................................611
			Starter Motor Clutch Inspection........................................611
			Torque Limiter Inspection..............................................611
		Lighting System............................................................612
			Headlight Beam Vertical Adjustment.....................................612
			Headlight Bulb Replacement.............................................612
			Tail/Brake Light Bulb Replacement......................................613
		Radiator Fan System........................................................616
			Radiator Fan Circuit Inspection........................................616
			Radiator Fan Motor Inspection..........................................616
			Radiator Fan Breaker Inspection........................................616
			Radiator Fan Breaker Installation......................................617
			Radiator Fan Relay Inspection..........................................617
		Meter......................................................................618
			Multifunction Meter Unit Removal.......................................618
			Multifunction Meter Unit Installation..................................618
			Multifunction Meter Unit Inspection....................................619
		Actuator Control System....................................................627
			Engine Brake Actuator Removal..........................................627
			Engine Brake Actuator Installation.....................................627
			Actuator Control System Outline........................................628
			Engine Brake Actuator Inspection.......................................628
			Speed Sensor Circuit Inspection........................................629
			Controller Unit Inspection.............................................630
			Forward/Reverse Detecting Sensor Inspection............................631
		2WD/4WD Solenoid Valve.....................................................633
			2WD/4WD Solenoid Valve Inspection......................................633
		Relay......................................................................635
			Relay Inspection.......................................................635
		Switches and Sensor........................................................636
			Brake Light Switch Adjustment..........................................636
			Water Temperature Switch Inspection....................................636
			Fuel Level Sensor Inspection...........................................636
			Speed Sensor Removal/Installation......................................636
			Speed Sensor Inspection................................................637
			Switch Inspection......................................................637
		Fuses .....................................................................639
			Fuse Removal...........................................................639
			Fuse Installation......................................................639
			Fuse Inspection........................................................640
	APPENDIX.......................................................................641
		Troubleshooting Guide......................................................642
		Cable, Wire, and Hose Routing..............................................646

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