2013 Kawasaki Brute Force 650 Kvf650 Service Repair Manual – PDF DOWNLOAD

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2013 Kawasaki Brute Force 650 Kvf650 Service Repair Manual

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2013 KAWASAKI BRUTE FORCE 650 KVF650 SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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2013 Kawasaki Brute Force 650 Kvf650 Service Repair Manual

FOREWORD:

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

• Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried 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 carefully 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 adversely 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 Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
• •Follow the procedures in this manual carefully. Don’t take shortcuts.
• •Remember to keep complete records ofmaintenance 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 manual’s 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 ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices.

TABLE OF CONTENTS:

2013 Kawasaki Brute Force 650 Kvf650 Service Repair Manual

General Information.......................................................................... 11
	Before Servicing......................................................................... 12
	Model Identification..................................................................... 17
	General Specifications................................................................... 18
	Unit Conversion Table.................................................................... 21
Periodic Maintenance......................................................................... 23
	Periodic Maintenance Chart............................................................... 24
	Torque and Locking Agent................................................................. 26
	Specifications........................................................................... 33
	Special Tools............................................................................ 35
	Periodic Maintenance Procedures.......................................................... 36
		Fuel System.......................................................................... 36
			Throttle Lever Free Play Inspection.............................................. 36
			Throttle Lever Free Play Adjustment.............................................. 36
			Choke Lever Free Play Inspection................................................. 36
			Choke Lever Free Play Adjustment................................................. 37
			Idle Speed Inspection............................................................ 37
			Idle Speed Adjustment............................................................ 38
			Fuel System Cleanliness Inspection............................................... 38
			Air Cleaner Element Cleaning and Inspection...................................... 39
			Air Cleaner Draining............................................................. 39
			Fuel Hose and Connection Inspection.............................................. 40
			Fuel Hose Replacement............................................................ 40
		Cooling System....................................................................... 41
			Coolant Change................................................................... 41
			Radiator Cleaning................................................................ 43
			Radiator Hose and Connection Inspection.......................................... 44
			Coolant Filter Cleaning.......................................................... 44
		Engine Top End....................................................................... 44
			Valve Clearance Inspection....................................................... 44
			Valve Clearance Adjustment....................................................... 46
			Spark Arrester Cleaning.......................................................... 46
		Converter System..................................................................... 46
			Actuator Lever (Engine Brake Control Lever) Assembly Inspection.................. 46
			Converter Drive Belt Deflection Inspection....................................... 47
			Converter Drive Belt Deflection Adjustment....................................... 47
			Converter Drive Belt Wear Inspection............................................. 48
		Engine Lubrication System............................................................ 49
			Engine Oil Change................................................................ 49
			Oil Filter Replacement........................................................... 50
		Electrical System.................................................................... 50
			Spark Plug Cleaning/Inspection................................................... 50
			Spark Plug Gap Inspection........................................................ 50
			Drive Belt Failure Detection System Inspection................................... 50
		Wheels/Tires......................................................................... 52
			Tire Inspection.................................................................. 52
		Joint Boots Inspection............................................................... 52
			Front Axle/Steering Knuckle Joint Boot Inspection................................ 52
			Front Propeller Shaft Boot Inspection............................................ 53
			Rear Propeller Shaft Joint Boot Inspection....................................... 53
			Tie-Rod End Boot Inspection...................................................... 53
		Final Drive.......................................................................... 53
			Variable Differential Control Lever Play Inspection.............................. 53
			Variable Differential Control Lever Play Adjustment.............................. 54
			Front Final Gear Case Oil Change................................................. 54
			Rear Final Gear Case Oil Change.................................................. 55
		Brakes............................................................................... 56
			Brake Fluid Level Inspection..................................................... 56
			Brake Fluid Change............................................................... 56
			Front Brake Master Cylinder Piston Assembly and Dust Cover Replacement........... 57
			Front Brake Caliper Fluid Seal Replacement....................................... 57
			Front Brake Caliper Dust Seal Replacement........................................ 58
			Front Brake Pad Wear Inspection.................................................. 58
			Front Brake Hoses and Connections Inspection..................................... 58
			Front Brake Hose Replacement..................................................... 58
			Rear Brake Lever Free Play Inspection............................................ 59
			Rear Brake Pedal Free Play Inspection............................................ 59
			Rear Brake Lever and Pedal Free Play Adjustment.................................. 59
			Rear Brake Plates Replacement.................................................... 59
		Steering............................................................................. 60
			Steering Inspection.............................................................. 60
		Switches............................................................................. 60
			Brake Light Switch Inspection.................................................... 60
			Brake Light Timing Adjustment.................................................... 60
		General Lubrication.................................................................. 61
			Lubrication...................................................................... 61
		Bolts and Nuts Tightening............................................................ 62
			Tightness Inspection............................................................. 62
Fuel System.................................................................................. 63
	Exploded View............................................................................ 64
	Exploded View (KVF650-D1/E1)............................................................. 66
	Exploded View (On and after KVF650D6/E6)................................................. 68
	Specifications........................................................................... 70
	Special Tools............................................................................ 71
	Throttle Lever and Cable................................................................. 72
		Throttle Lever Free Play Inspection.................................................. 72
		Throttle Lever Free Play Adjustment.................................................. 72
		Throttle Case Removal/Disassembly.................................................... 72
		Throttle Case Assembly/Installation.................................................. 72
		Throttle Cable Installation.......................................................... 73
		Throttle Case Inspection............................................................. 73
		Throttle Cable Lubrication and Inspection............................................ 73
	Choke Lever and Cable.................................................................... 74
		Choke Lever Free Play Inspection..................................................... 74
		Choke Lever Free Play Adjustment..................................................... 74
		Choke Lever and Cable Removal........................................................ 74
		Choke Lever and Cable Installation................................................... 75
		Choke Cable Lubrication and Inspection............................................... 75
	Carburetor............................................................................... 76
		Idle Speed Inspection................................................................ 76
		Idle Speed Adjustment................................................................ 76
		Pilot Screw Adjustment (AU Model and ∼ KVF650D6/E6 other than KVF650D6/E6 option).... 76
		Service Fuel Level Inspection........................................................ 76
		Service Fuel Level Adjustment........................................................ 77
		Carburetor Synchronization Inspection................................................ 78
		Carburetor Synchronization Adjustment................................................ 79
		Fuel System Cleanliness Inspection................................................... 79
		Carburetor Removal................................................................... 79
		Carburetor Installation.............................................................. 80
		Carburetor Disassembly............................................................... 80
		Carburetor Assembly.................................................................. 82
		Carburetor Separation................................................................ 83
		Carburetor Joining................................................................... 83
		Carburetor Cleaning.................................................................. 84
		Carburetor Inspection................................................................ 84
	Air Cleaner.............................................................................. 87
		Air Cleaner Element Removal.......................................................... 87
		Air Cleaner Element Cleaning and Inspection.......................................... 87
		Air Cleaner Housing Removal.......................................................... 87
		Air Cleaner Housing Installation..................................................... 88
	Fuel Tank................................................................................ 90
		Fuel Tank Removal (KVF650-D1/E1)..................................................... 90
		Fuel Tank Installation (KVF650-D1/E1)................................................ 90
		Fuel Tank Removal (On and after KVF650D6/E6)......................................... 91
		Fuel Tank Installation (On and after KVF650D6/E6).................................... 91
		Check Valve Installation............................................................. 92
		Fuel Tank Cleaning................................................................... 92
		Fuel Tap Removal (KVF650-D1/E1)...................................................... 93
		Fuel Tap Installation (KVF650-D1/E1)................................................. 93
		Fuel Tap Removal (On and after KVF650D6/E6).......................................... 93
		Fuel Tap Installation (On and after KVF650D6/E6)..................................... 93
		Fuel Tap Inspection (On and after KVF650D6/E6)....................................... 94
		Fuel Tap Inspection (KVF650-D1/E1)................................................... 95
	Fuel Pump (KVF650-D1/E1)................................................................. 96
		Fuel Pump Removal.................................................................... 96
		Pump Filter Cleaning................................................................. 96
		Fuel Pump Installation............................................................... 97
		Fuel Pump Inspection................................................................. 97
	Fuel Pump (On and after KVF650D6/E6)..................................................... 98
		Fuel Pump Removal.................................................................... 98
		Fuel Pump Installation............................................................... 98
		Fuel Pump Inspection................................................................. 98
Cooling System...............................................................................101
	Exploded View............................................................................102
	Coolant Flow Chart.......................................................................104
	Specifications...........................................................................106
	Special Tools & Sealant..................................................................107
	Coolant..................................................................................108
		Coolant Deterioration Inspection.....................................................108
		Coolant Level Inspection.............................................................108
		Coolant Draining.....................................................................108
		Coolant Filling......................................................................108
		Pressure Testing.....................................................................109
	Water Pump...............................................................................110
		Water Pump Cover Removal.............................................................110
		Water Pump Cover Installation........................................................110
		Water Pump Impeller Removal..........................................................110
		Water Pump Impeller Installation.....................................................110
		Water Pump Impeller Inspection.......................................................111
		Water Pump Leakage Inspection........................................................111
		Mechanical Seal Replacement..........................................................111
	Radiator.................................................................................113
		Radiator Removal.....................................................................113
		Radiator Installation................................................................114
		Radiator Fan Removal.................................................................114
		Radiator Fan Installation............................................................115
		Radiator Inspection..................................................................115
		Radiator Cleaning....................................................................115
		Radiator Cap Inspection..............................................................115
	Thermostat...............................................................................117
		Thermostat Removal...................................................................117
		Thermostat Installation..............................................................117
		Thermostat Inspection................................................................117
	Radiator Fan Switch......................................................................119
		Radiator Fan Switch Removal..........................................................119
		Radiator Fan Switch Installation.....................................................119
		Radiator Fan Switch Inspection.......................................................119
	Coolant Temperature Switch...............................................................120
		Water Temperature Switch Removal.....................................................120
		Water Temperature Switch Installation................................................120
		Water Temperature Switch Inspection..................................................120
	Coolant Filter/Valve.....................................................................121
		Coolant Filter Cleaning..............................................................121
		Coolant Valve Inspection.............................................................121
Engine Top End...............................................................................123
	Exploded View............................................................................124
	Specifications...........................................................................130
	Special Tools & Sealant..................................................................132
	Camshaft Chain Tensioner.................................................................134
		Camshaft Chain Tensioner Removal.....................................................134
		Camshaft Chain Tensioner Installation................................................134
	Rocker Case..............................................................................135
		Rocker Case Removal..................................................................135
		Rocker Case Installation.............................................................136
		Rocker Arm Removal...................................................................137
		Rocker Arm Installation..............................................................137
		Rocker Arm Inspection................................................................138
		Rocker Shaft Diameter Measurement....................................................138
	Camshaft.................................................................................139
		Camshaft Removal.....................................................................139
		Camshaft Installation................................................................139
		Camshaft Assembly....................................................................140
		Cam Wear.............................................................................140
		Camshaft Bearing Wear................................................................141
		KACR Inspection......................................................................142
		KACR Removal.........................................................................142
		KACR Installation....................................................................143
		Camshaft Chain Removal...............................................................143
		Camshaft Chain Installation..........................................................144
		Camshaft Chain Guide Wear............................................................147
	Cylinder Head............................................................................148
		Cylinder Compression Measurement.....................................................148
		Cylinder Head Removal................................................................149
		Cylinder Head Installation...........................................................149
		Cylinder Head Cleaning...............................................................149
		Cylinder Head Warp...................................................................150
	Valves...................................................................................151
		Valve Clearance Inspection...........................................................151
		Valve Clearance Adjustment...........................................................151
		Valve Removal........................................................................151
		Valve Installation...................................................................151
		Valve Guide Removal..................................................................151
		Valve Guide Installation.............................................................152
		Valve-to-Guide Clearance Measurement.................................................152
		Valve Seat Inspection................................................................153
		Valve Seat Repair (Valve Lapping)....................................................154
	Cylinder and Piston......................................................................159
		Cylinder Removal.....................................................................159
		Piston Removal.......................................................................159
		Cylinder, Piston Installation........................................................159
		Cylinder Wear........................................................................161
		Piston Wear..........................................................................161
		Piston/Cylinder Clearance............................................................161
		Cylinder Boring and Honing...........................................................162
		Piston Ring, Piston Ring Groove Wear.................................................162
		Piston Ring Groove Width.............................................................163
		Piston Ring Thickness ...............................................................163
		Piston Ring End Gap..................................................................163
	Exhaust System...........................................................................164
		Spark Arrester Cleaning..............................................................164
		Muffler and Exhaust Pipe Removal.....................................................164
		Muffler and Exhaust Pipe Installation................................................165
		Exhaust System Inspection............................................................165
Converter System.............................................................................167
	Exploded View............................................................................168
	Specifications...........................................................................172
	Special Tools............................................................................173
	Torque Converter.........................................................................175
		Torque Converter Cover Removal.......................................................175
		Torque Converter Cover Installation..................................................176
		Torque Converter Cover Disassembly...................................................176
		Actuator Lever (Engine Brake Control Lever) Assembly Inspection......................177
		Torque Converter Cover Assembly......................................................177
	Drive Belt...............................................................................179
		Drive Belt Removal...................................................................179
		Drive Belt Installation..............................................................179
		Converter Drive Belt Deflection Inspection...........................................179
		Converter Drive Belt Deflection Adjustment...........................................179
		Converter Drive Belt Inspection......................................................179
	Drive Pulley.............................................................................180
		Drive Pulley Removal.................................................................180
		Drive Pulley Disassembly.............................................................180
		Drive Pulley Inspection..............................................................182
		Spider Shoe Side Clearance Inspection/Adjustment.....................................183
		Drive Pulley Assembly................................................................184
		Drive Pulley Installation............................................................185
		Drive Pulley Cover Adjustment (KVF650-D1 ∼ DC/-E1 ∼ E9)..............................187
		Drive Pulley Cover Adjustment (KVF650DD).............................................188
	Driven Pulley............................................................................192
		Driven Pulley Removal................................................................192
		Driven Pulley Disassembly............................................................192
		Driven Pulley Inspection.............................................................193
		Driven Pulley Assembly...............................................................194
		Driven Pulley Installation...........................................................196
	High Altitude Setting Information........................................................198
		Specifications.......................................................................198
Recoil Starter...............................................................................199
	Exploded View (KVF650-D1 ∼ D9/E1 ∼ E9)...................................................200
	Recoil Starter (KVF650-D1 ∼ D9/E1 ∼ E9)..................................................202
		Recoil Starter Removal...............................................................202
		Recoil Starter Installation..........................................................202
		Recoil Starter Inspection............................................................202
Engine Lubrication System....................................................................203
	Exploded View............................................................................204
	Specifications...........................................................................206
	Special Tools & Sealant..................................................................207
	Engine Oil Flow Chart....................................................................208
	Engine Oil and Oil Filter................................................................209
		Oil Level Inspection.................................................................209
		Engine Oil Change....................................................................209
		Oil Filter Change....................................................................209
		Oil Screen Removal...................................................................209
		Oil Screen Cleaning..................................................................210
		Oil Pressure Measurement.............................................................210
	Oil Pressure Relief Valve................................................................211
		Oil Pressure Relief Valve Removal....................................................211
		Oil Pressure Relief Valve Installation...............................................211
		Oil Pressure Relief Valve Inspection.................................................211
	Oil Pump.................................................................................212
		Oil Pump Removal.....................................................................212
		Oil Pump Installation................................................................212
	Oil Pipe.................................................................................214
		Oil Pipe Removal.....................................................................214
		Oil Pipe Installation................................................................214
Engine Removal/Installation..................................................................215
	Exploded View............................................................................216
	Engine Removal/Installation..............................................................218
		Engine Removal.......................................................................218
		Engine Installation..................................................................219
Crankshaft/Transmission......................................................................221
	Exploded View............................................................................222
	Specifications...........................................................................226
	Special Tools & Sealant..................................................................228
	Crankcase................................................................................229
		Crankcase Disassembly................................................................229
		Crankcase Assembly...................................................................230
	Crankshaft/Connection Rod................................................................233
		Crankshaft Removal...................................................................233
		Crankshaft Installation..............................................................233
		Connecting Rod Removal...............................................................233
		Connecting Rod Installation..........................................................233
		Crankshaft/Connecting Rod Cleaning...................................................234
		Connecting Rod Bend..................................................................234
		Connecting Rod Twist Inspection......................................................234
		Connecting Rod Big End Side Clearance Inspection.....................................235
		Connecting Rod Big End Bearing/Crankpin Wear Inspection..............................235
		Crankshaft Runout Inspection.........................................................237
		Crankshaft Main Bearing/Journal Wear Inspection......................................237
	Transmission.............................................................................238
		Shift Lever Removal..................................................................238
		Shift Lever Installation.............................................................239
		Transmission Removal.................................................................241
		Transmission Installation............................................................242
		Shift Fork Bending Inspection........................................................244
		Shift Fork/Gear and Shifter Groove Wear Inspection...................................244
		Transmission and Shift Mechanism Inspection..........................................244
	Ball Bearing, Needle Bearing, and Oil Seal...............................................246
		Ball and Needle Bearing Replacement..................................................246
		Ball and Needle Bearing Wear Inspection..............................................246
		Oil Seal Inspection..................................................................246
Wheels/Tires.................................................................................247
	Exploded View............................................................................248
	Specifications...........................................................................250
	Special Tool.............................................................................251
	Wheel Alignment..........................................................................252
		Steering Centering Inspection........................................................252
		Steering Centering Adjustment........................................................252
		Toe-in Inspection....................................................................253
		Toe-in Adjustment....................................................................253
	Wheels (Rims)............................................................................254
		Wheel Removal........................................................................254
		Wheel Installation...................................................................254
		Wheel (Rim) Inspection...............................................................254
		Wheel (Rim) Replacement..............................................................255
	Tires....................................................................................256
		Tire Removal.........................................................................256
		Tire Installation....................................................................256
		Tire Inspection......................................................................257
	Front Hub................................................................................258
		Front Hub Removal....................................................................258
		Front Hub Installation...............................................................258
		Front Hub Disassembly/Assembly.......................................................259
	Rear Hub.................................................................................260
		Rear Hub Removal.....................................................................260
		Rear Hub Installation................................................................260
		Rear Hub Disassembly/Assembly........................................................260
Final Drive..................................................................................261
	Exploded View............................................................................262
	Specifications...........................................................................268
	Special Tools............................................................................269
	Output Bevel Gears.......................................................................272
		Output Drive Bevel Gear Removal......................................................272
		Output Drive Bevel Gear Installation.................................................272
		Output Drive Bevel Gear Disassembly..................................................273
		Output Drive Bevel Gear Assembly.....................................................275
		Output Driven Bevel Gear Removal.....................................................275
		Output Driven Bevel Gear Installation................................................276
		Output Driven Bevel Gear Disassembly.................................................276
		Output Driven Bevel Gear Assembly....................................................277
		Output Bevel Gears Adjustment........................................................278
		Bevel Gears Inspection...............................................................283
	Front Propeller Shaft....................................................................284
		Front Propeller Shaft Removal........................................................284
		Front Propeller Shaft Installation...................................................284
	Front Axle...............................................................................285
		Front Axle Removal...................................................................285
		Front Axle Installation..............................................................285
		Front Axle Joint Boot Inspection.....................................................285
		Front Axle Joint Boot Replacement....................................................286
	Front Final Gear Case....................................................................292
		Front Final Gear Case Oil Level Inspection...........................................292
		Front Final Gear Case Oil Change.....................................................292
		Variable Differential Control Lever Play Inspection..................................292
		Variable Differential Control Lever Play Adjustment..................................292
		Variable Differential Control Lever Removal..........................................292
		Variable Differential Control Lever Installation.....................................292
		Variable Differential Control Cable Installation.....................................293
		Variable Differential Control Cable Lubrication......................................293
		Variable Differential Control Cable Inspection.......................................293
		Front Final Gear Case Removal........................................................293
		Front Final Gear Case Installation...................................................294
		Front Final Gear Case Disassembly....................................................294
		Front Final Gear Case Coupling Inspection............................................296
		Front Final Gear Case Assembly.......................................................296
		Oil Seal Installation................................................................300
		Ring Gear Disassembly................................................................301
		Ring Gear Assembly...................................................................301
		LSD Clutch Torque Inspection.........................................................302
		Pinion Gear Unit Disassembly.........................................................302
		Pinion Gear Unit Assembly............................................................303
		Front Final Bevel Gear Adjustment....................................................303
		Bevel Gear Inspection................................................................307
		Differential Gear Inspection.........................................................307
	Rear Propeller Shaft.....................................................................309
		Rear Propeller Shaft Removal.........................................................309
		Rear Propeller Shaft Installation....................................................309
		Rear Propeller Shaft Joint Boot Inspection...........................................309
		Rear Propeller Shaft Inspection......................................................309
	Rear Axle................................................................................310
		Rear Axle Removal....................................................................310
		Rear Axle Installation...............................................................310
		Ball Bearing Wear....................................................................310
		Rear Axle Runout Inspection..........................................................311
	Rear Final Gear Case.....................................................................312
		Rear Final Gear Case Oil Level Inspection............................................312
		Rear Final Gear Case Oil Change......................................................312
		Rear Final Gear Case Removal ........................................................312
		Rear Final Gear Case Installation....................................................312
		Rear Final Gear Case Disassembly ....................................................313
		Rear Final Gear Case Assembly........................................................314
		Oil Seal Installation................................................................315
		Rear Final Bevel Gear Adjustment.....................................................315
		Pinion Gear Unit Disassembly.........................................................318
		Pinion Gear Unit Assembly............................................................319
		Bevel Gear Inspection................................................................319
	Bearing and Oil Seal.....................................................................320
		Ball or Needle Bearing Inspection....................................................320
		Oil Seal Inspection..................................................................321
Brakes.......................................................................................323
	Exploded View............................................................................324
	Specifications...........................................................................328
	Special Tool.............................................................................329
	Brake Fluid..............................................................................330
		Front Brake Fluid Recommendation.....................................................330
		Front Brake Fluid Level Inspection...................................................330
		Front Brake Fluid Change.............................................................330
		Front Brake Line Air Bleeding........................................................331
	Master Cylinder..........................................................................332
		Front Brake Master Cylinder Removal..................................................332
		Front Brake Master Cylinder Installation.............................................332
		Front Brake Master Cylinder Disassembly..............................................332
		Front Brake Master Cylinder Assembly.................................................333
		Master Cylinder Inspection (Visual Inspection).......................................333
	Calipers.................................................................................334
		Front Brake Caliper Removal..........................................................334
		Front Brake Caliper Installation.....................................................334
		Front Brake Caliper Disassembly......................................................335
		Front Brake Caliper Assembly.........................................................335
		Front Brake Caliper Piston and Cylinder Damage Inspection............................336
		Front Brake Caliper Holder Shaft Wear Inspection.....................................336
	Brake Pads...............................................................................337
		Front Brake Pad Removal..............................................................337
		Front Brake Pad Installation.........................................................337
		Front Brake Pad Wear Inspection......................................................337
	Brake Discs..............................................................................338
		Front Brake Disc Cleaning............................................................338
		Front Brake Disc Removal.............................................................338
		Front Brake Disc Installation........................................................338
		Front Brake Disc Wear Inspection.....................................................338
		Front Brake Disc Runout Inspection...................................................338
	Brake Hoses..............................................................................339
		Front Brake Hose Inspection..........................................................339
		Front Brake Hose Replacement.........................................................339
	Rear Brake Lever, Pedal and Cables.......................................................340
		Rear Brake Pedal Position Inspection.................................................340
		Rear Brake Pedal Position Adjustment.................................................340
		Rear Brake Lever Free Play Inspection................................................340
		Rear Brake Pedal Free Play Inspection................................................340
		Rear Brake Lever and Pedal Free Play Adjustment......................................340
		Rear Brake Pedal Removal.............................................................340
		Rear Brake Pedal Installation........................................................341
		Rear Brake Cable Removal.............................................................341
		Rear Brake Cable Installation........................................................342
		Rear Brake Cable Lubrication.........................................................342
	Internal Wet Brake.......................................................................343
		Internal Wet Brake Disassembly.......................................................343
		Internal Wet Brake Assembly..........................................................344
Suspension...................................................................................347
	Exploded View............................................................................348
	Specifications...........................................................................350
	Special Tools............................................................................351
	Shock Absorbers..........................................................................352
		Front Shock Absorber Removal.........................................................352
		Front Shock Absorber Installation....................................................352
		Front Shock Absorber Inspection......................................................353
		Front Shock Absorber Spring Replacement..............................................353
		Rear Shock Absorber Removal..........................................................355
		Rear Shock Absorber Installation.....................................................355
		Rear Shock Absorber Preload Adjustment...............................................355
		Rear Shock Absorber Spring Replacement...............................................356
		Rear Shock Absorber Inspection.......................................................358
		Rear Shock Absorber Scrapping........................................................358
	Suspension Arms..........................................................................359
		Suspension Arm Removal (KVF650-D1/E1)................................................359
		Suspension Arm Removal (On and after KVF650D6/E6)....................................359
		Suspension Arm Installation..........................................................359
		Suspension Arm Disassembly...........................................................360
		Suspension Arm Assembly..............................................................360
	Swingarm.................................................................................362
		Swingarm Removal.....................................................................362
		Swingarm Installation................................................................362
		Swingarm Disassembly.................................................................363
		Swingarm Assembly....................................................................364
		Swingarm Bearing Inspection..........................................................364
		Swingarm Bearing Lubrication.........................................................365
Steering.....................................................................................367
	Exploded View............................................................................368
	Specifications...........................................................................370
	Special Tools............................................................................371
	Steering.................................................................................372
		Steering Stem Removal................................................................372
		Steering Stem Installation...........................................................372
		Steering Knuckle Removal.............................................................374
		Steering Knuckle Installation (KVF650-D1/E1).........................................374
		Steering Knuckle Installation (On and after KVF650D6/E6).............................374
		Steering Knuckle Bearing Removal.....................................................376
		Steering Knuckle Bearing Installation................................................376
		Tie-Rod Removal......................................................................376
		Tie-Rod Installation.................................................................376
		Tie-Rod End Removal..................................................................376
		Tie-Rod End Installation.............................................................377
	Steering Maintenance.....................................................................378
		Steering Inspection..................................................................378
		Steering Stopper Inspection..........................................................378
		Steering Stem Straightness...........................................................378
		Steering Bearing Sleeve Lubrication..................................................378
		Steering Stem Clamp Inspection.......................................................378
		Steering Stem Bearing Inspection.....................................................379
		Steering Knuckle Bearing Inspection..................................................379
		Tie-Rod End and Steering Knuckle Joint Inspection....................................379
	Handlebar................................................................................380
		Handlebar Removal....................................................................380
		Handlebar Installation...............................................................380
Frame........................................................................................383
	Exploded View............................................................................384
	Seat.....................................................................................390
		Seat Removal.........................................................................390
		Seat Installation....................................................................390
	Carriers.................................................................................391
		Front Carrier Removal................................................................391
		Front Carrier Installation...........................................................391
		Rear Carrier Removal.................................................................391
		Rear Carrier Installation............................................................392
	Fenders..................................................................................393
		Front Fender Removal.................................................................393
		Front Fender Installation............................................................394
		Rear Fender Removal..................................................................394
		Rear Fender Installation.............................................................395
	Covers...................................................................................396
		Inner Cover Front and Front Lower Shroud Removal.....................................396
		Inner Cover Front and Front Lower Shroud Installation................................396
		Inner Cover Rear Removal.............................................................396
		Inner Cover Rear Installation........................................................396
		Air Cleaner Upper Cover Removal......................................................396
		Air Cleaner Upper Cover Installation.................................................397
		Air Cleaner Cover Removal............................................................397
		Air Cleaner Cover Installation.......................................................397
		Left Side Cover Removal..............................................................398
		Left Side Cover Installation (KVF650-D1 ∼ D8/E1 ∼ E8)................................398
		Left Side Cover Installation (KVF650D9 ∼/E9).........................................398
	Guards...................................................................................399
		Front Guard Removal..................................................................399
		Front Guards Installation............................................................399
		Engine Bottom Guard Removal..........................................................400
		Engine Bottom Guard Installation.....................................................401
		Rear Bottom Guard Removal............................................................401
		Rear Bottom Guard Installation.......................................................401
	Flaps and Footboards.....................................................................402
		Front Flap Removal...................................................................402
		Front Flap Installation..............................................................402
		Rear Flap Removal....................................................................402
		Rear Flap Installation...............................................................403
		Footboard Removal....................................................................403
		Footboard Installation...............................................................404
	Trailer Hitch Bracket....................................................................405
		Trailer Hitch Bracket Removal........................................................405
		Trailer Hitch Bracket Installation...................................................405
Electrical System............................................................................407
	Parts Location...........................................................................409
	Exploded View............................................................................412
	Specifications...........................................................................418
	Special Tools............................................................................420
	Precautions..............................................................................421
	Electrical Wiring........................................................................422
		Wiring Inspection....................................................................422
	Battery..................................................................................423
		Battery Removal......................................................................423
		Battery Installation.................................................................423
		Battery Activation...................................................................423
		Precautions..........................................................................426
		Interchange..........................................................................427
		Charging Condition Inspection........................................................427
		Refreshing Charge ...................................................................427
	Charging System..........................................................................429
		Alternator Cover Removal.............................................................429
		Alternator Cover Installation........................................................430
		Alternator Rotor Removal ............................................................431
		Alternator Rotor Installation........................................................431
		Alternator Stator Removal............................................................432
		Alternator Stator Installation.......................................................432
		Regulator/Rectifier Output Voltage Inspection........................................432
		Alternator Inspection................................................................433
		Regulator/Rectifier Inspection.......................................................434
	Ignition System..........................................................................437
		Spark Plug Removal...................................................................437
		Spark Plug Installation..............................................................437
		Spark Plug Cleaning/Inspection.......................................................438
		Spark Plug Gap Inspection............................................................438
		Ignition Coil Removal................................................................438
		Ignition Coil Installation...........................................................438
		Ignition Coil Inspection.............................................................439
		Ignition Coil Primary Peak Voltage Inspection........................................440
		Crankshaft Sensor Removal............................................................440
		Crankshaft Sensor Installation.......................................................441
		Crankshaft Sensor Inspection.........................................................441
		Crankshaft Sensor Peak Voltage Inspection............................................441
		Alternator Rotor Inspection..........................................................442
		Ignition Timing Test.................................................................442
		Vehicle-down Sensor Outline..........................................................442
		Vehicle-down Sensor Removal..........................................................443
		Vehicle-down Sensor Installation.....................................................443
		Vehicle-down Sensor Inspection.......................................................444
	Electric Starter System..................................................................448
		Starter Motor Removal................................................................448
		Starter Motor Installation...........................................................448
		Starter Motor Disassembly............................................................450
		Starter Motor Assembly...............................................................451
		Commutator Cleaning/Inspection.......................................................454
		Armature Inspection..................................................................455
		Brush Length Inspection..............................................................455
		Brush Assembly Inspection............................................................456
		Brush Plate and Terminal Bolt Inspection.............................................456
		Starter Relay Inspection.............................................................457
		Starter Circuit Relay Inspection.....................................................457
		Starter Motor Clutch Removal.........................................................458
		Starter Motor Clutch Installation....................................................459
		Starter Motor Clutch Inspection......................................................459
		Torque Limiter Inspection............................................................459
	Lighting System..........................................................................460
		Headlight Beam Vertical Adjustment...................................................460
		Headlight Bulb Replacement...........................................................460
		Taillight Bulb Replacement...........................................................462
	Radiator Fan System......................................................................465
		Radiator Fan Circuit Inspection......................................................465
		Radiator Fan Motor Inspection........................................................465
		Radiator Fan Breaker Inspection......................................................465
		Radiator Fan Breaker Installation....................................................466
	Fuel Pump/Fuel Level Sensor (KVF650-D1/E1)...............................................467
		Fuel Pump Inspection.................................................................467
		Fuel Level Sensor Inspection.........................................................468
	Fuel Level Sensor (On and after KVF650D6/E6).............................................470
		Fuel Level Sensor Removal............................................................470
		Fuel Level Sensor Installation.......................................................470
		Fuel Level Sensor Inspection.........................................................470
	Meter....................................................................................472
		Multifunction Meter Unit Removal.....................................................472
		Multifunction Meter Unit Inspection..................................................473
		Drive Belt Failure Mode Memory Clearing Procedure....................................478
		Drive Belt Failure Mode Memory Clearing Procedure....................................480
	Actuator Control System..................................................................483
		2WD/4WD Actuator Removal.............................................................483
		2WD/4WD Actuator Installation........................................................483
		Engine Brake Actuator Removal........................................................483
		Engine Brake Actuator Installation...................................................484
		Actuator Control System Outline......................................................485
		Actuator Control System Troubleshooting..............................................485
	Drive Belt Failure Detection System......................................................495
		Drive Belt Failure Detection System Inspection.......................................495
	Switches and Sensor......................................................................496
		Brake Light Switch Adjustment........................................................496
		Radiator Fan Switch Inspection.......................................................496
		Water Temperature Switch Inspection..................................................497
		Switch Inspection....................................................................497
		Drive Belt Failure Detection Switch..................................................498
		Speed Sensor Removal/Installation....................................................499
		Speed Sensor Inspection..............................................................499
	Fuses....................................................................................500
		30 A Main Fuse Removal...............................................................500
		Fuse Removal.........................................................................500
		Fuse Inspection......................................................................500
	Wiring Diagram (KVF650-D1/E1)............................................................502
	Wiring Diagram (KVF650D6 ∼/E6 ∼).........................................................504
Appendix.....................................................................................507
	Troubleshooting Guide....................................................................508
	Cable, Wire, and Hose Routing............................................................513

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]