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