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2013 KAWASAKI BRUTE FORCE KVF750HD Service Repair Manual PDF
2013 KAWASAKI BRUTE FORCE KVF750HD Service Repair Manual PDF
□:This digit in the frame number changes from one machine to another.
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Converter System 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Crankshaft/Transmission 9 j
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
© 2011 Kawasaki Heavy Industries, Ltd. Second Edition (0) : Apr. 24, 2012
LIST OF ABBREVIATIONS
A ampere(s) ISC idle speed control
Kawasaki automatic compression
ABDC after bottom dead center KACR
release
AC alternating current km/h kilometers per hour
Ah ampere hour L liter(s)
ATDC after top dead center lb pound(s)
BBDC before bottom dead center LCD liquid crystal display
BDC bottom dead center LED light emitting diode
BTDC before top dead center LSD limited slip differental
°C degree(s) celsius m meter(s)
cmHg centimeters of mercury min minute(s)
CPU central processing unit mmHg millimeters of mercury
cu in cubic inch(s) mph miles per hour
DC direct current N newton(s)
DFI digital fuel injection oz ounce(s)
DOT department of transportation Pa pascal(s)
ECU electronic control unit PS horsepower
EPS electric power steering psi pound(s) per square inch
F farad(s) qt quart(s)
°F degree(s) fahrenheit r revolution
ft foot, feet rpm revolution(s) per minute
g gram(s) s second(s)
gal gallon(s) TDC top dead center
h hour(s) TIR total indicator reading
HP horsepower(s) V volt(s)
IC integrated circuit W watt(s)
in. inch(s) Ω ohm(s)
To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (1), exhaust emission (2) and evaporative emission (3) control systems in compliance with
applicable regulations of the United States Environmental Protection Agency and California Air
Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by
gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is
separated from the gases while passing through the inside of the breather chamber from the crankcase,
and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this
vehicle. The fuel, ignition and exhaust systems of this vehicle have been carefully designed and con-
structed to ensure an efficient engine with low exhaust pollutant levels.
A maintenance free ignition system provides the most favorable ignition timing and helps maintain a
thorough combustion process within the engine which contributes to a reduction of exhaust pollutants
entering the atmosphere.
3. Evaporative Emission Control System
The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a
fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purchaser..."
NOTE
○The phrase "remove or render inoperative any device or element of design" has been generally
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the vehicle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
(US and CA Models Only)
Among those acts presumed to constitute tampering are the acts listed below:
* Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
* Removal of the muffler or any internal portion of the muffler.
* Removal of the air cleaner housing or air cleaner housing cover.
* Modifications to the muffler or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.
* Modification to the air cleaner element.
Foreword
This manual is designed primarily for use by Guide shows you all of the product’s system
trained mechanics in a properly equipped shop. and assists in locating their chapters. Each
However, it contains enough detail and basic in- chapter in turn has its own comprehensive Ta-
formation to make it useful to the owner who de- ble of Contents.
sires to perform his own basic maintenance and For example, if you want engine oil informa-
repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locate
the proper use of tools, and workshop proce- the Engine lubrication System chapter. Then,
dures must be understood in order to carry out use the Table of Contents on the first page of
maintenance and repair satisfactorily. When- the chapter to find the Engine Oil section.
ever the owner has insufficient experience or Whenever you see symbols, heed their in-
doubts his ability to do the work, all adjust- structions! Always follow safe operating and
ments, maintenance, and repair should be car- maintenance practices.
ried out only by qualified mechanics.
DANGER
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor- DANGER indicates a hazardous situa-
oughly familiarize yourself with the procedures tion which, if not avoided, will result in
before starting work, and then do the work care- death or serious injury.
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift WARNING
tools or equipment. Precision measurements WARNING indicates a hazardous situa-
can only be made if the proper instruments are tion which, if not avoided, could result
used, and the use of substitute tools may ad- in death or serious injury.
versely affect safe operation.
For the duration of the warranty period, NOTICE
we recommend that all repairs and scheduled
maintenance be performed in accordance with NOTICE is used to address practices not
this service manual. Any owner maintenance or related to personal injury.
repair procedure not performed in accordance This manual contains four more symbols
with this manual may void the warranty. which will help you distinguish different types
To get the longest life out of your vehicle: of information.
• Follow the Periodic Maintenance Chart in the
Service Manual. NOTE
• Be alert for problems and non-scheduled ○This note symbol indicates points of par-
maintenance. ticular interest for more efficient and con-
• Use proper tools and genuine Kawasaki Vehi-
cle parts. Special tools, gauges, and testers
venient operation.
General Information
Table of Contents
1
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-9
Unit Conversion Table ............................................................................................................ 1-12
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly oper-
ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any service on the vehicle, disconnect
the battery wires from the battery to prevent the engine from
accidentally turning over. Disconnect the ground wire (–)
first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive
(+) terminal of the battery then the negative (–) wire to the
negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Often, the tightening sequence is followed twice initial
tightening and final tightening with torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per-
formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling.
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
KVF750GC Left Side View
The KVF750H is a camouflage-surface-treated model and the KVF750J is a model with paint
finish, and they are identical to the KVF750G, the base model, in every other aspect: controls,
features, and specifications.
The KVF750L is a model equipped with the conventional steering system and is similar to the
KVF750G other than the electrical power steering equipments in every other aspect: controls,
features and specifications.
1-8 GENERAL INFORMATION
Model Identification
Frame Number Engine Number
Specifications are subject to change without notice, and may not apply to every country.
1-12 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units: Units of Length:
km × 0.6214 = mile
Prefix Symbol Power m × 3.281 = ft
mega M × 1 000 000 mm × 0.03937 = in
kilo k × 1 000
centi c × 0.01
milli m × 0.001 Units of Torque:
micro µ × 0.000001 N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
Units of Mass:
kgf·m × 86.80 = in·lb
kg × 2.205 = lb
g × 0.03527 = oz
Units of Pressure:
kPa × 0.01020 = kgf/cm²
Units of Volume: kPa × 0.1450 = psi
L × 0.2642 = gal (US) kPa × 0.7501 = cmHg
L × 0.2200 = gal (IMP) kgf/cm² × 98.07 = kPa
L × 1.057 = qt (US) kgf/cm² × 14.22 = psi
L × 0.8799 = qt (IMP) cmHg × 1.333 = kPa
L × 2.113 = pint (US)
L × 1.816 = pint (IMP)
mL × 0.03381 = oz (US)
Units of Speed:
km/h × 0.6214 = mph
mL × 0.02816 = oz (IMP)
mL × 0.06102 = cu in
Units of Power:
kW × 1.360 = PS
Units of Force:
kW × 1.341 = HP
N × 0.1020 = kg
PS × 0.7355 = kW
N × 0.2248 = lb
PS × 0.9863 = HP
kg × 9.807 = N
kg × 2.205 = lb
Units of Temperature
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-3
Torque and Locking Agent...................................................................................................... 2-5 2
Specifications ......................................................................................................................... 2-13
Special Tools .......................................................................................................................... 2-15
Periodic Maintenance Procedures.......................................................................................... 2-16
Fuel System......................................................................................................................... 2-16
Throttle Lever Free Play Inspection .................................................................................. 2-16
Throttle Lever Free Play Adjustment ................................................................................ 2-16
Idle Speed Inspection ....................................................................................................... 2-17
Idle Speed Adjustment...................................................................................................... 2-17
Air Cleaner Element Cleaning and Inspection .................................................................. 2-17
Air Cleaner Draining.......................................................................................................... 2-18
Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... 2-18
Fuel Hose Replacement ................................................................................................... 2-19
Cooling System.................................................................................................................... 2-21
Radiator Cleaning ............................................................................................................. 2-21
Water Hoses and Connections Inspection ........................................................................ 2-22
Coolant Change ................................................................................................................ 2-22
Engine Top End ................................................................................................................... 2-24
Valve Clearance Inspection .............................................................................................. 2-24
Valve Clearance Adjustment............................................................................................. 2-26
Spark Arrester Cleaning.................................................................................................... 2-26
Converter System ................................................................................................................ 2-27
Converter Drive Belt Wear Inspection............................................................................... 2-27
Converter Drive Belt Deflection Inspection ....................................................................... 2-27
Converter Drive Belt Deflection Adjustment...................................................................... 2-28
Actuator Lever (Engine Brake Control Lever) Assembly Inspection ................................. 2-29
Engine Lubrication System .................................................................................................. 2-29
Engine Oil Change............................................................................................................ 2-29
Oil Filter Replacement ...................................................................................................... 2-30
Wheels/Tires ........................................................................................................................ 2-30
Tire Inspection .................................................................................................................. 2-30
Final Drive............................................................................................................................ 2-31
Variable Differential Control Lever Play Inspection ........................................................... 2-31
Variable Differential Control Lever Play Adjustment ......................................................... 2-31
Front Final Gear Case Oil Change ................................................................................... 2-32
Rear Final Gear Case Oil Change .................................................................................... 2-33
Brakes.................................................................................................................................. 2-34
Front Brake Pad Wear Inspection..................................................................................... 2-34
Front Brake Hoses and Connections Inspection............................................................... 2-34
Front Brake Hose Replacement........................................................................................ 2-34
Front Brake Fluid Level Inspection ................................................................................... 2-35
Front Brake Fluid Change................................................................................................. 2-36
Front Brake Master Cylinder Piston Assembly and Dust Cover Replacement ................. 2-37
Front Brake Caliper Fluid Seal Replacement.................................................................... 2-37
Front Brake Caliper Dust Seal and Friction Boot Replacement........................................ 2-37
Rear Brake Plates Replacement....................................................................................... 2-37
Rear Brake Lever Free Play Inspection ............................................................................ 2-38
Rear Brake Pedal Free Play Inspection............................................................................ 2-38
Rear Brake Lever and Pedal Free Play Adjustment ......................................................... 2-38
2-2 PERIODIC MAINTENANCE
FREQUENCY First
Regular Service
Service
Every 90
days, 1
700 km (1
Every Every
100 mi.)
After 10 10 30
of use or
hrs. or days or days or Every
when belt See
100 km 200 km 600 km year of
indicator page
(60 mi.) (120 (360 use
light turns
of use mi.) of mi.) of
on (100
use use
hrs of use)
whichever
OPERATION comes first
Tire wear-inspect* • 2-30
2-32,
Front and rear final gear case oil-change • • 2-33
General lubrication-perform* • 2-44
Front brake fluid level-inspect • • 2-35
Front brake fluid-change • 2-36
Front brake hoses and connections-inspect • 2-34
Front brake master cylinder piston
2 years 2-37
assembly and dust cover-replace
Front brake caliper fluid seal and dust
2 years 2-37
seal-replace
Front brake hose-replace 4 years 2-34
*: Service more frequently when operated in mud, dust, or other harsh riding conditions, or when
carrying heavy loads or pulling a trailer.
•: Clean, adjust, lubricate, torque, or replace parts as necessary.
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners, and the parts requiring use of
a non-permanent locking agent or liquid gasket.
Torque
Fastener Remarks
N·m kgf·m ft·lb
Fuel System
Air Cleaner Housing Bolts 8.8 0.90 78 in·lb
Air Cleaner Element Holder Screw 3.5 0.36 31 in·lb
Air Cleaner Element Holder Tapping Screw 1.5 0.15 13 in·lb
Water Temperature Sensor 12 1.2 106 in·lb
ISC Valve Mounting Bolts 8.8 0.90 78 in·lb
Intake Air Pressure Sensor Mounting Screw 3.5 0.36 31 in·lb
Delivery Pipe Mounting Screws 5.0 0.51 44 in·lb
Valve Adjusting Cap Bolt 8.8 0.90 78 in·lb
Joint Duct Bolts 8.8 0.90 78 in·lb
Heat Guard Bolts 8.8 0.90 78 in·lb
Fuel Pump Bolts 4.0 0.41 35 in·lb
Fuel Tank Mounting Bolts 10 1.0 89 in·lb
Vehicle-down Sensor Mounting Bolts 5.9 0.6 52 in·lb L
Throttle Lever Limiter Screw 3.6 0.37 32 in·lb
Throttle Lever Limiter Nut 3.6 0.37 32 in·lb
Throttle Case Assembly Screws 3.6 0.37 32 in·lb
Cooling System
Radiator Screen Mounting Bolts 4.0 0.41 35 in·lb
Radiator Mounting Bolts 8.8 0.90 78 in·lb
Reserve Tank Mounting Screw 4.0 0.41 35 in·lb L
Coolant Drain Bolts (Cylinder) 7.0 0.71 62 in·lb
Radiator Fan Assembly Bolts 8.4 0.86 74 in·lb
Air Bleed Bolt 7.0 0.71 62 in·lb
Thermostat Housing Cover Bolts 8.8 0.90 78 in·lb
Water Pipe Joint Bolts 8.8 0.90 78 in·lb
Water Pump Impeller 7.8 0.80 69 in·lb
Water Pump Cover Bolts 8.8 0.90 78 in·lb
Coolant Drain Bolt (Water Pump) 7.0 0.71 62 in·lb
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Engine Top End
Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb
Rocker Case Bolts 55 mm (2.2 in.) 8.8 0.90 78 in·lb S
Rocker Case Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb
Rocker Case Bolts 25 mm (1.0 in.) 9.8 1.0 87 in·lb
Rocker Case Bolts 130 mm (5.1 in.) 9.8 1.0 87 in·lb S
Rocker Case Bolts 20 mm (0.8 in.)
9.8 1.0 87 in·lb
(KVF750GD/HD/JD/LD Late Models)
Cylinder Head Bolt (M6) 9.8 1.0 87 in·lb
Cylinder Head Bolts (M10), First Torque 25 2.5 18
MO, S
Cylinder Head Bolts (M10), Final Torque 55 5.6 41
Water Pipe Bolts 8.8 0.90 78 in·lb
Valve Adjusting Screw Locknuts 12 1.2 106 in·lb
Rocker Shaft Bolts 22 2.2 16
Camshaft Sprocket Bolts 12 1.2 106 in·lb L
Camshaft Chain Tensioner Cap Bolts 22 2.2 16
Camshaft Chain Tensioner Mounting Bolts 8.8 0.90 78 in·lb
Front Cylinder Camshaft Chain Guide Bolt 20 2.0 15
Rear Cylinder Camshaft Chain Guide Bolt 20 2.0 15
Position Plate Bolts 8.8 0.90 78 in·lb
Intermediate Shaft Chain Guide Bolts 8.8 0.90 78 in·lb EO
Intermediate Shaft Chain Tensioner Bolts 8.8 0.90 78 in·lb
Cylinder Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb
Cylinder Bolts 40 mm (1.6 in.) 9.8 1.0 87 in·lb
Coolant Drain Bolts (Cylinder) 7.0 0.71 62 in·lb
Exhaust Pipe Holder Nuts 17 1.7 13
Exhaust Pipe Cover Clamp Screws 2.1 0.21 19 in·lb
Muffler Clamp Bolts 15 1.5 11
Muffler Mounting Bolts 34 3.5 25
Converter System
Drive Pulley Bolt 93 9.5 69 R, Lh
Drive Pulley Cover Bolts 13 1.3 115 in·lb
Spider 275 28.0 203 Lh
Ramp Weight Nuts 7.0 0.71 62 in·lb R
Driven Pulley Nut 93 9.5 69 R
Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb S
Torque Converter Cover Bolts 8.8 0.90 78 in·lb S
Joint Duct Bolts 8.8 0.90 78 in·lb
Engine Lubrication System
Oil Pipe Bolts 8.8 0.90 78 in·lb
Oil Filter 17.5 1.78 12.9 R
Oil Filter Mounting Bolt 25 2.5 18 L (15 mm)
Oil Pressure Relief Valve 15 1.5 11 L
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Oil Pressure Switch 15 1.5 11 SS
Oil Pump Chain Guide Bolt 8.8 0.90 78 in·lb
Oil Pump Cover Bolts 8.8 0.90 78 in·lb
Engine Oil Drain Bolt 20 2.0 15
Oil Pump Drive Chain Tensioner Bolt 25 2.5 18
Drive Pulley Back Plate Bolts 8.8 0.90 78 in·lb
Engine Removal/Installation
Engine Mounting Bracket Bolts 71.5 7.3 53 L
Engine Mounting Bolt 101.5 10.4 75 LB
Engine Mounting Nut 101.5 10.4 75 R
Crankshaft/Transmission
Connecting Rod Big End Cap Nuts 34.3 3.50 25.3 MO
Rear Cylinder Camshaft Chain Guide Bolt 20 2.0 15
Bearing Position Plate Screws 4.9 0.50 43 in·lb L
Engine Oil Drain Bolt 20 2.0 15
Crankcase Bolt (M8, L = 110 mm) 20 2.0 15 S, L
Crankcase Bolts (M8, L = 75 mm) 20 2.0 15 S
Crankcase Bolts (M6, L = 40 mm) 9.8 1.0 87 in·lb
Crankcase Bolts (M8, L = 110 mm) 20 2.0 15 S
Crankcase Bolts (M6, L = 65 mm) 9.8 1.0 87 in·lb
Shift Lever Guide Mounting Bolts 19.6 2.00 14.5
Grip Holder Nut 9.8 1.0 87 in·lb
Tie-rod End Front Locknut 9.8 1.0 87 in·lb Lh
Tie-rod End Rear Locknut 9.8 1.0 87 in·lb
Tie-rod End Nut 19.6 2.00 14.5 R
Shift Lever Clamp Bolt 13.5 1.38 119 in·lb
Shift Shaft Cover Bolts 8.8 0.90 78 in·lb
Shift Lever Guide Mounting Nut 19.6 2.00 14.5 R
Tie-rod End Bolt 9.8 1.0 87 in·lb
Tie-rod End Locknut 19.6 2.00 14.5
Shift Lever Assembly Nut 19.6 2.00 14.5 R
Neutral Switch 15 1.5 11
Heat Guard Bolt 8.8 0.90 78 in·lb
Reverse Switch 15 1.5 11
Shift Shaft Positioning Bolt 25 2.5 18
Shift Shaft Spring Bolt 31 3.2 23 LB
Wheel/Tires
Wheel Nuts (First Torque) 15 1.5 11 S
Wheel Nuts (Final Torque) 76.5 7.8 56 S
Front Axle Nuts 195.5 19.9 144
Tie-rod Locknuts 36.5 3.7 27 Lh (2)
Tie-rod End Nuts 41.5 4.2 31 R
Rear Axle Nuts 264.5 27.0 195
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Final Drive
(Output Bevel Gears)
Bearing Holder 120 12.2 88.5 L
Bevel Gear Holder Nut 200 20.4 148 LB
Bearing Holder 250 25.5 184 L
Output Shaft Holder Nut 200 20.4 148 LB
Output Driven Bevel Gear Housing Bolts 26 2.7 19
Output Drive Bevel Gear Housing Bolts 26 2.7 19
Rotor Mounting Bolts 12 1.2 106 in·lb
Output Drive Bevel Gear Cover Bolts 8.8 0.90 78 in·lb
Forward/Reverse Detecting Sensor Mounting Bolt 14.9 1.52 11.0
(Front Final Gear Case)
Variable Differential Control Lever Bolt 3.4 0.35 30 in·lb L
Variable Differential Control Cable Locknut 17 1.7 13
Front Final Gear Case Oil Filler Cap 29 3.0 21 EO
2WD/4WD Actuator Cover Mounting Bolts 9.8 1.0 87 in·lb
Variable Differential Control Shift Shaft Lever Nut 8.8 0.90 78 in·lb R
Front Final Gear Case Oil Drain Bolt 15 1.5 11 EO
Ring Gear Bolts 57 5.8 42 LB, S
2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·lb L, S
Pinion Gear Bearing Holder Nut 127 13.0 93.7 St
Pinion Gear Bearing Holder 137 14.0 101 L
Front Final Gear Case Coupling Nut 25 2.5 18
Front Final Gear Case Mount Nuts 59 6.0 44 R
Front Final Gear Case Left Cover Bolts (M6) 9.8 1.0 87 in·lb L (4), S
Front Final Gear Case Center Cover Bolts (M6) 9.8 1.0 87 in·lb L
Front Final Gear Case Center Cover Bolts (M8) 24 2.4 18 L
(Rear Final Gear Case)
Rear Final Gear Case Front Cover Bolts 24 2.4 18 L
Pinion Gear Bearing Holder Nut 157 16.0 116 LB, R
Pinion Gear Bearing Holder 450 45.9 332 L, St
Rear Final Gear Case Gasket Screws 1.25 0.127 11.1 in·lb
Rear Final Gear Case Oil Filler Cap 29 3.0 21
Rear Final Gear Case Oil Drain Bolt 15 1.5 11
Rear Final Gear Case Bracket Bolts 59 6.0 44 L
Rear Final Gear Case Mount Nuts 90.5 9.23 66.8 R, L
Rear Final Gear Case Right Cover Bolts (M10) 49 5.0 36 L
Rear Final Gear Case Right Cover Bolts (M12) 95 9.7 70 L
Rear Final Gear Case Right Cover Bolts (M8) 24 2.4 18 L
Brakes
Reservoir Cap Screws 1.5 0.15 13 in·lb
Front Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si
Front Brake Light Switch Mounting Screw 1.2 0.12 11 in·lb
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Front Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
Front Brake Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
Brake Hose Banjo Bolts 25 2.5 18
Front Brake Pad Mounting Bolts 17 1.7 13
Bleed Valves 7.8 0.80 69 in·lb
Front Brake Disc Mounting Bolts 36.5 3.72 26.9 L
Front Brake Caliper Mounting Bolts 24.5 2.50 18.1
Front Brake Caliper Holder Shaft 17 1.7 13 Si
Front Brake Caliper Holder Shaft Nut 22 2.2 16 L
Rear Brake Lock Lever Pivot Screw 2.2 0.22 19 in·lb L
Rear (Parking) Brake Lever Pivot Bolt 2.2 0.22 19 in·lb
Rear (Parking) Brake Lever Pivot Nut 3.4 0.35 30 in·lb
Variable Differential Control Lever Bolt 3.4 0.35 30 in·lb L
Rear Final Gear Case Gasket Screws 1.25 0.127 11.1 in·lb
Suspension
Front Shock Absorber Mounting Nuts 34 3.5 25 R
Front Suspension Arm Pivot Upper Nuts 59 6.0 44 R
Steering Knuckle Joint Nuts 50 5.1 37
Front Suspension Arm Pivot Lower Nuts 46.5 4.7 34 R
Rear Shock Absorber Mounting Nuts 34 3.5 25 R
Stabilizer Holder Bolts 21.5 2.2 16
Stabilizer Joint Nuts 57.5 5.9 42 R
Rear Suspension Arm Pivot Nuts 46.5 4.7 34 R
Rear Knuckle Mounting Nuts 46.5 4.7 34 R
Steering
Rear Brake Lock Lever Pivot Screw 2.2 0.22 19 in·lb L
Rear (Parking) Brake Lever Pivot Bolt 2.2 0.22 19 in·lb
Rear (Parking) Brake Lever Pivot Nut 3.4 0.35 30 in·lb
Variable Differential Control Lever Bolt 3.4 0.35 30 in·lb L
Left Handlebar Switch Housing Screws 3.5 0.36 31 in·lb
Throttle Case Assembly Screws 3.6 0.37 32 in·lb
Throttle Lever Limiter Screw 3.6 0.37 32 in·lb
Throttle Lever Limiter Nut 3.6 0.37 32 in·lb
Front Brake Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
Handlebar Holder Bolts 29 3.0 21 S
Tie-rod End Nuts 41.5 4.23 30.6 R
Tie-rod Locknuts 36.5 3.72 29.9 Lh (2)
Steering Knuckle Joint Nuts 50 5.1 37
(KVF750G/H/J)
Steering Shaft Upper Bracket Bolts 20 2.0 15 S
EPS Unit Mounting Bolts 20 2.0 15
EPS Unit Mounting Bracket Bolts 35 3.6 26
Steering Shaft Lower Clamp Nut 24.5 2.50 18.1 R
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Steering Shaft Holder Nuts (First) 10 1.0 89 in·lb R, S
Steering Shaft Holder Nuts (Final) 18 1.8 13 R, S
Pitman Arm Mounting Nut 110 11.2 81.1
Steering Shaft Lower End Stopper Mounting Bolts 22.5 2.29 16.6 L
EPS ECU Mounting Nut 6.9 0.70 61 in·lb
(KVF750L)
Steering Shaft Upper Bracket Bolts 20 2.0 15
Steering Shaft Lower End Holder Mounting Bolts 35 3.6 26
Steering Shaft Holder Nuts 18 1.8 13 R
Pitman Arm Mounting Nut 90 9.2 66
Frame
Front Carrier Bolts, L = 70 mm (2.8 in.) 31.5 3.21 23.2 L
Front Carrier Bolts, L = 50 mm (2.0 in.) 31.5 3.21 23.2 L
Front Carrier Bracket Bolts 31.5 3.21 23.2 L
Front Guard Bolts 36.5 3.72 26.9
Rear Carrier Bolts, L = 14 mm (0.55 in.)
(KVF750GC/HC/JC/LC Early Models)
54 5.5 40 L
Rear Carrier Bolts, L = 16 mm (0.63 in.)
(KVF750GC/HC/JC/LC Late Models ∼)
Rear Carrier Bolts, L = 44 mm (1.7 in.) 54 5.5 40 L
Rear Carrier Bracket Bolts 46.5 4.74 34.3
Rear Final Gear Case Mounting Bracket Bolts 59 6.0 44 L
Trailer Hitch Bracket Bolts 81.5 8.31 60.1 L
Footboard Bracket Bolts 46.5 4.74 34.2
Electrical System
Harness Clamp Bolt 8.8 0.90 78 in·lb
Starter Motor Mounting Bolts 8.8 0.90 78 in·lb
Starter Motor Cable Mounting Nut 6.8 0.69 60 in·lb
Starter Motor Terminal Locknut 11 1.1 97 in·lb
Starter Motor Through Bolts 5.0 0.51 44 in·lb
Starter Motor Clutch Bolts 34 3.5 25 L
Crankshaft Sensor Mounting Bolts 5.9 0.60 52 in·lb
Alternator Rotor Bolt 127 13.0 93.7
Alternator Stator Bolts 13.5 1.38 119 in·lb LB
Breather Plate Screws 2.9 0.30 26 in·lb L
Alternator Cover Plugs 17.5 1.78 12.9
Alternator Rotor Bolt Cap 2.5 0.25 22 in·lb
Timing Inspection Cap 5.0 0.51 44 in·lb
Alternator Cover Bolts 8.8 0.90 78 in·lb
2WD/4WD Actuator Cover Mounting Bolts 9.8 1.0 87 in·lb
2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·lb L, S
Ignition Coil Bracket Mounting Bolts 8.8 0.90 78 in·lb
Ignition Coil Mounting Bolts 5.9 0.60 52 in·lb
PERIODIC MAINTENANCE 2-11
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Spark Plugs 13 1.3 115 in·lb
Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb S
Speed Sensor Mounting Bolt 8.8 0.90 78 in·lb
Neutral Switch 15 1.5 11
Heat Guard Bolt 8.8 0.90 78 in·lb
Reverse Switch 15 1.5 11
Forward/Reverse Detecting Sensor Mounting Bolt 14.9 1.52 11.0
Left Switch Housing Screws 3.5 0.36 31 in·lb
Throttle Lever Limiter Screw 3.6 0.37 32 in·lb
Throttle lever Limiter Nut 3.6 0.37 32 in·lb
Throttle Case Assembly Screws 3.6 0.37 32 in·lb
Radiator Fan Assembly Bolts 8.4 0.86 74 in·lb
Tail/Brake Light Lens Screws 1.47 0.150 13.0 in·lb
Regulator/Rectifier Mounting Bolts 8.8 0.90 78 in·lb
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb
Joint Duct Bolts 8.8 0.90 78 in·lb
The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts
and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of
the values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners of Engine Parts
Threads dia. Torque
Mark of bolt head
mm (in.) N·m kgf·m ft·lb
5 (0.20) 4T 2.2 ∼ 2.6 0.22 ∼ 0.27 19 ∼ 23 in·lb
6 (0.24) 9T 12 ∼ 15 1.2 ∼ 1.5 104 ∼ 130 in·lb
6 (0.24) 7T 7.8 ∼ 9.8 0.8 ∼ 1.0 69 ∼ 87 in·lb
6 (0.24) 4T 3.9 ∼ 4.9 0.4 ∼ 0.5 35 ∼ 43 in·lb
8 (0.31) 7T 18 ∼ 22 1.8 ∼ 2.2 13 ∼ 16
8 (0.31) 4T 10 ∼ 14 1.0 ∼ 1.4 87 ∼ 122 in·lb
10 (0.39) 7T 39 ∼ 44 4.0 ∼ 4.5 29 ∼ 33
10 (0.39) 4T 20 ∼ 24 2.0 ∼ 2.4 14 ∼ 17
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the element in a well-ventilated area,
and take care that there is no spark or flame any-
where near the working areas. Do not use gasoline
or low flash-point solvents to clean the element.
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTICE
When removing and installing the fuel hose joint,
do not apply strong force to the outlet pipe on the
fuel pump and delivery pipe on the throttle body
assy. The fuel pump pipe made from resin could
be damaged.
• Disconnect the fuel hose from the fuel pump (see Fuel
Pump Removal in the Fuel System (DFI) chapter).
• Be sure to place a piece of cloth [A] around the fuel hose
joint.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
• Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.
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