2013 Kawasaki Brute Force 650 Kvf650 Service Repair Manual
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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]