2008 Kawasaki KVF360B6 Prairie Service Repair Manual

MODEL APPLICATION Year

Model

2003

KVF360-A1

2003

KVF360-C1

2004

KVF360-A2

2004

KVF360-C2

2005

KVF360-A3

2005

KVF360-C3

2006

KVF360A6

2006

KVF360C6

2007

KVF360A7

2007

KVF360C7

2008

KVF360A8

2008

KVF360C8

2009

KVF360A9

2009

KVF360C9

2010

KVF360AA

2010

KVF360CA

2011

KVF360AB

2011

KVF360CB

2012

KVF360AC

2013

KVF360AD

Beginning Frame No. JKBVFHA1□3B500001 JKBVF360AAB600001 JKBVFHC1□3B500001 JKBVFHA1□4B529901 JKBVF360AAB602901 JKBVFHC1□4B50361 JKBVFHA1□5B539106 JKBVF360AAB604235 JKBVFHC1□5B506600 JKBVFHA1□6B552400 JKBVF360AAB604801 JKBVFHC1□6B510201 JKBVFHA1□7B561830 JKBVF360AAB606501 JKBVFHC1□7B513201 JKBVFHA1□8B571300 JKBVF360AAB606700 JKBVFHC1□8B515700 JKBVFHA1□9B579001 JKBVF360AAB609201 JKBVFHC1□9B517901 JKBVFHA1□AB582801 JKBVF360AAB609901 JKBVFHC1□AB519201 JKBVFHA1□BB584201 JKBVF360AAB610201 JKBVFHC1□BB519701 JKBVFHA1□CB587200 JKBVF360AAB610801 JKBVFHA1□DB589201 JKBVF360AAB611301

□:This digit in the frame number changes from one machine to another.

Part No.99924-1285-12

Printed in Japan

PRAIRIE 360 4×4 KVF 360 4×4

All Terrain Vehicle Service Manual

Quick Reference Guide

This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.

General Information

1 j

Periodic Maintenance

2 j

Fuel System

3 j

Engine Top End

4 j

Converter System

5 j

Recoil Starter

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

Appendix

17 j

PRAIRIE 360 4×4 KVF 360 4×4

All Terrain Vehicle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

© 2002 Kawasaki Heavy Industries, Ltd.

12th Edition (0) : Mar. 12, 2012

LIST OF ABBREVIATIONS A

ampere(s)

lb

pounds(s)

ABDC

after bottom dead center

m

meter(s)

AC

alternating current

min

minute(s)

ATDC

after top dead center

N

newton(s)

BBDC

before bottom dead center

Pa

pascal(s)

BDC

bottom dead center

PS

horsepower

BTDC

before top dead center

psi

pound(s) per square inch

°C

degree(s) Celcius

r

revolution

DC

direct current

rpm

revolution(s) per minute

F

farad(s)

TDC

top dead center

°F

degree(s) Fahrenheit

TIR

total indicator reading

ft

foot, feet

V

volt(s)

g

gram(s)

W

watt(s)

h

hour(s)

Ω

ohm(s)

L

liter(s)

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (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 The exhaust emission control system applied to this engine family is engine modifications that consist of a catalytic converter in the muffler (US and Canada (KVF360AA/CA âˆź) models), a modified carburetor and ignition system having optimum ignition timing characteristics. The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.

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 knowingly 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 following its sale and delivery to the ultimate purchaser..."

NOTE

â—‹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 devices or elements of design in order to perform maintenance.

2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are exceeded. 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 standards. 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 MODEL only) TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED: Federal regulations and California State law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

• • • •

Do not tamper with the original emission related parts: Carburetor or internal parts Spark Plug Magneto ignition system Air Cleaner element

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

* * * *

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(s) or any internal portion of the muffler(s).

Removal of the air box or air box cover.

Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.

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 of maintenance 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.

DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE NOTICE is used to address practices not related to personal injury.

This manual contains four more symbols which will help you distinguish different types of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information Table of Contents Before Servicing .....................................................................................................................

Model Identification.................................................................................................................

General Specifications............................................................................................................

Unit Conversion Table ............................................................................................................

1 1-2 1-7 1-9 1-15

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustrations, 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 cables from the battery to prevent the engine from accidentally turning over. Disconnect the negative cable (–) first and then the positive cable (+). When completed with the service, first connect the positive cable (+) to the positive cable (+) terminal of the battery then the negative cable (–) 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.

Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, 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 beyond 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 disassembly, 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 sequence 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 quarter 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 damage. 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 performance. 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.

Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Non-Permanent Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Leads A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical leads 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 thoroughly before using the meter. Incorrect values may lead to improper adjustments.

GENERAL INFORMATION 1-7 Model Identification KVF360-A1 Left Side

KVF360-A1 Right Side

1-8 GENERAL INFORMATION Model Identification KVF360-C1 Left Side

KVF360-C1 Right Side

GENERAL INFORMATION 1-9 General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Ground Clearance: Rear Final Gear Case Center of Frame Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration

KVF360-A1 ∼ A3, A6 ∼ A8/C1 ∼ C3, C6 ∼ C8 2 1 1 1

065 205 175 250

mm mm mm mm

(81.30 (47.44 (46.26 (49.21

in.) in.) in.) in.)

195 mm (7.68 in.)

250 mm (9.84 in.)

910 mm (35.83 in.)

274 kg (604 lb) KVF360-A1/C1 ∼ A3/C3 274.5 kg (605 lb) KVF360A6/C6 ∼ 154 kg (340 lb) KVF360-A1/C1 ∼ A3/C3 154.5 kg (341 lb) KVF360A6/C6 ∼ 135 kg (298 lb) 13.5 L (3.6 US gal) 3.1 m (10.17 ft) 4-stroke, SOHC, 1-cylinder Air-cooled 80.0 × 72.0 mm (3.15 × 2.83 in.)

362 cm³ (22.1 cu in.)

8.3 : 1 15.7 kW (21.4 PS) @7 000 r/min (rpm), (US) (CA) 26.1 N·m (2.66 kgf·m, 19.25 ft·lb) @4 500 r/min (rpm) Carburetor, Keihin CVK34 Electric Starter & Recoil Starter DC-CDI (KVF360-A1/C1 ∼, A6/C6) Digital DC-CDI (KVF360A7/C7 ∼) Electronically advanced From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @5 000 r/min (rpm) NGK DPR8EA-9

38° BTDC 58° ABDC 276° 68° BBDC 28° ATDC 276°

1-10 GENERAL INFORMATION General Specifications Items Lubrication System Engine Oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Transmission: Type Gear Ratios: Forward: High Low Reverse Final Drive System: Type Reduction Ratio Overall Drive Ratio: Forward: High Low Reverse Front Final Gear Case Oil: Type Viscosity Capacity Rear Final Gear Case Oil: Type

Capacity Frame Type Caster (rake angle) Camber King Pin Angle Trail Tread: Front Rear

KVF360-A1 ∼ A3, A6 ∼ A8/C1 ∼ C3, C6 ∼ C8 Forced lubrication (wet sump) API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 2.3 L (2.17 US qt)

Belt converter 3.122 ∼ 0.635 2-speed automatic and reverse

3.548 (30/26 × 29/18 × 21/11) 5.536 (36/20 × 29/18 × 21/11) 4.613 (16/12 × 18/16 × 29/18 × 21/11) Shaft, 2WD/4WD 4.375 (35/8)

48.474 ∼ 9.859 75.619 ∼ 15.380 63.016 ∼ 12.817 API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 430 mL (0.45 US qt) MOBIL Fluid 424 or Kawa Chem Gear & Wet Brake Oil (CITGO TRANSGARD TRACTOR HYDRAULIC FLUID) or Exxon Hydraul 560 900 mL (0.95 US qt) Double cradle, tubular steel 2.5° 0.5° 14.5° 15 mm (0.59 in.)

890 mm (35.04 in.)

895 mm (35.24 in.)

GENERAL INFORMATION 1-11 General Specifications Items Front Tire: Type Size Rear Tire: Type Size Rim Size: Front Rear Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Electrical Equipment Battery Headlight: Type Bulb Brake/Tail Light: Bulb Alternator: Type Rated Output

KVF360-A1 ∼ A3, A6 ∼ A8/C1 ∼ C3, C6 ∼ C8 Tubeless AT25 × 8 - 12 Tubeless AT25 × 10 - 12 12 × 6.0 12 × 7.5

MacPherson strut 170 mm (6.69 in.)

Swingarm 180 mm (7.09 in.)

Disc × 2 Enclosed wet multi-plate 12 V 14 Ah Semi-sealed beam 12 V 30/30 W × 2 12 V 18/5 W Three - phase AC 25 A, 14 V @8 000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country.

1-12 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height

KVF360A9 ∼ AD/C9 ∼ CB 2 065 mm (81.30 in.)

1 205 mm (47.44 in.)

(KVF360A9/C9) 1 155 mm (45.28 in.)

(KVF360AA ∼/CA ∼) 1 145 mm (45.08 in.)

(KVF360A9/C9) 1 253 mm (49.33 in.)

(KVF360AA ∼/CA ∼) 1 255 mm (49.41 in.)

Wheelbase Ground Clearance: Rear Final Gear Case Center of Frame Seat Height

(KVF360A9/C9) 195 mm (7.68 in.)

(KVF360AA ∼/CA ∼) 185 mm (7.28 in.)

(KVF360A9/C9) 238 mm (9.37 in.)

(KVF360AA ∼/CA ∼) 235 mm (9.25 in.)

(KVF360A9/C9) 905 mm (35.63 in.)

(KVF360AA ∼/CA ∼) 895 mm (35.24 in.)

Curb Mass: (US, CA) (AU) (EUR, GB)

(KVF360A9/C9) 290 kg (639 lb) (KVF360AA ∼/CA ∼) 292 kg (644 lb) (KVF360A9 ∼ AB) 290 kg (639 lb) (KVF360A9 ∼) 291 kg (642 lb)

(US, CA) (AU) (EUR, GB)

(KVF360A9 ∼/C9 ∼) 156 kg (344 lb) (KVF360A9 ∼) 156 kg (344 lb) (KVF360A9 ∼) 157 kg (346 lb)

Front

Rear (US, CA)

(KVF360A9/C9) 134 kg (295 lb) (KVF360AA ∼/CA ∼) 136 kg (300 lb) (AU, EUR, GB) (KVF360A9 ∼) 134 kg (295 lb) Fuel Tank Capacity 13.5 L (3.6 US gal) Performance Minimum Turning Radius 3.1 m (10.17 ft) Engine Type 4-stroke, SOHC, 1-cylinder Air-cooled Cooling System Bore and Stroke 80.0 × 72.0 mm (3.15 × 2.83 in.)

Displacement 362 cm³ (22.1 cu in.)

Compression Ratio 8.3 : 1 Maximum Horsepower 15.7 kW (21.4 PS) @7 000 r/min (rpm), (US) (CA) Maximum Torque 26.1 N·m (2.66 kgf·m, 19.25 ft·lb) @4 500 r/min (rpm) Carburetion System Carburetor, Keihin CVK34 Starting System Electric Starter & Recoil Starter Ignition System Digital DC-CDI Timing Advance Electronically advanced Ignition Timing From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @5 000 r/min (rpm)

GENERAL INFORMATION 1-13 General Specifications KVF360A9 ∼ AD/C9 ∼ CB

Items Spark Plug Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System Engine Oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Transmission: Type Gear Ratios: Forward: High Low Reverse Final Drive System: Type Reduction Ratio Overall Drive Ratio: Forward: High Low Reverse Front Final Gear Case Oil: Type Viscosity Capacity Rear Final Gear Case Oil: Type

Capacity

NGK DPR8EA-9

38° BTDC 58° ABDC 276° 68° BBDC 28° ATDC 276° Forced lubrication (wet sump) API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 2.3 L (2.17 US qt)

Belt converter 3.122 ∼ 0.635 2-speed automatic and reverse

3.548 (30/26 × 29/18 × 21/11) 5.536 (36/20 × 29/18 × 21/11) 4.613 (16/12 × 18/16 × 29/18 × 21/11) Shaft, 2WD/4WD 4.375 (35/8)

48.474 ∼ 9.859 75.619 ∼ 15.380 63.016 ∼ 12.817 API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 430 mL (0.45 US qt) MOBIL Fluid 424 or Kawa Chem Gear & Wet Brake Oil (CITGO TRANSGARD TRACTOR HYDRAULIC FLUID) or Exxon Hydraul 560 900 mL (0.95 US qt)

1-14 GENERAL INFORMATION General Specifications KVF360A9 ∼ AD/C9 ∼ CB

Items Frame Type Caster (rake angle) Camber King Pin Angle Trail Tread: Front Rear Front Tire: Type Size Rear Tire: Type Size Rim Size: Front Rear Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Electrical Equipment Battery Headlight: Type Bulb Brake/Tail Light: Bulb Alternator: Type Rated Output AU: Australia CA: Canada GB: United Kingdom EUR: Europe US: United States

Double cradle, tubular steel 3° 0° 14° 17 mm (0.67 in.)

(KVF360A9/C9) 894 mm (35.20 in.)

(KVF360AA ∼/CA ∼) 895 mm (35.24 in.)

(KVF360A9/C9) 895 mm (35.24 in.)

(KVF360AA ∼/CA ∼) 900 mm (35.43 in.)

Tubeless AT25 × 8 - 12 Tubeless AT25 × 10 - 12 12 × 6 12 × 7.5

MacPherson strut 170 mm (6.69 in.)

Swingarm 180 mm (7.09 in.)

Disc × 2 Enclosed wet multi-plate 12 V 14 Ah Semi-sealed beam 12 V 30/30 W × 2 12 V 18/5 W Three - phase AC 25 A, 14 V @8 000 r/min (rpm)

GENERAL INFORMATION 1-15 Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Symbol M k c m µ

Units of Length:

× × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass: kg g

× ×

2.205 0.03527

= =

lb oz

Units of Volume: L L L L L L mL mL mL

× × × × × × × × ×

0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102

= = = = = = = = =

gal (US) gal (IMP) qt (US) qt (IMP) pint (US) pint (IMP) oz (US) oz (IMP) cu in

km m mm

× × ×

0.6214 3.281 0.03937

= = =

mile ft in

= = = = = =

kg·m ft·lb in·lb N·m ft·lb in·lb

= = = = = =

kg/cm² psi cmHg kPa psi kPa

=

mph

= = = =

PS HP kW HP

Units of Torque: N·m N·m N·m kg·m kg·m kg·m

× × × × × ×

0.1020 0.7376 8.851 9.807 7.233 86.80

Units of Pressure: kPa kPa kPa kg/cm² kg/cm² cmHg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed: km/h

×

0.6214

Units of Power: Units of Force: N N kg kg

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature:

= = = =

kg lb N lb

kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance Table of Contents Periodic Maintenance Chart ..............

Torque and Locking Agent.................

Specifications ....................................

Special Tools .....................................

Periodic Maintenance Procedures.....

Fuel System....................................

Throttle Lever Free Play Inspection..................................

Throttle Lever Free Play Adjustment ................................

Idle Speed Inspection ..................

Idle Speed Adjustment.................

Fuel System Cleanliness Inspection..................................

Air Cleaner Element Cleaning and Inspection..................................

Air Cleaner Draining.....................

Fuel Hose and Connection Check ........................................

Fuel Hose Replacement ..............

Engine Top End ..............................

Valve Clearance Inspection .........

Valve Clearance Adjustment........

Spark Arrester Cleaning...............

Converter System ...........................

Actuator Lever (Engine Brake Control Lever) Assembly Inspection..................................

Drive Belt Inspection ....................

Drive Belt Deflection Inspection ...

Drive Belt Deflection Adjustment .

Engine Lubrication System .............

Engine Oil Change.......................

Oil Filter Change ..........................

Oil Cooler Cleaning and Inspection..................................

Oil Hose and Connection Check..

Wheels/Tires ...................................

Tire Inspection .............................

Final Drive.......................................

Variable Differential Control Lever Position Inspection ....................

2-2 2-4 2-10 2-12 2-13 2-13 2-13 2-13 2-14 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-17 2-17 2-18 2-18

2-18 2-19 2-20 2-21 2-22 2-22 2-22 2-23 2-23 2-24 2-24 2-24 2-24

Variable Differential Control Lever Position Adjustment ..................

Front Final Gear Case Oil Change......................................

Rear Final Gear Case Oil Change Joint Boots Inspection..................

Rear Propeller Shaft Joint Boot Inspection..................................

Brakes.............................................

Front Brake Pad Wear Inspection Brake Hose and Connection Inspection..................................

Brake Hose Replacement ............

Brake Fluid Level Inspection........

Brake Fluid Change .....................

Front Brake Master Cylinder Piston Assembly and Dust Cover Replacement ..................

Front Brake Caliper Fluid Seal Replacement .............................

Front Brake Caliper Dust Seal and Rubber Boot, Dust Cover Replacement .............................

Rear Brake Plates Replacement..

Rear Brake Lever and Pedal Free Play Inspection..........................

Rear Brake Lever and Pedal Free Play Adjustment ........................

Steering ..........................................

Steering Inspection ......................

Electrical System ............................

Battery Inspection ........................

Spark Plug Cleaning/Inspection...

Spark Plug Gap Inspection ..........

Drive Belt Failure Detection System Inspection.....................

Brake Light Switch Inspection......

General Lubrication ........................

Lubrication ...................................

Bolts and Nuts Tightening...............

Tightness Inspection ....................

2-24 2-25 2-26 2-27 2-27 2-27 2-27 2-28 2-28 2-28 2-29

2-30 2-30

2-30 2-30 2-30 2-31 2-32 2-32 2-32 2-32 2-32 2-32 2-32 2-33 2-33 2-33 2-35 2-35

2

2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY

First Service After 10 hrs. or 100 km (60 mi.) of use

OPERATION ENGINE

Regular Service Every 10 days or 200 km (120 mi.) of use

Every 30 days or 600 km (360 mi.) of use

Every 90 days or 1 700 km (1 100 mi.) of use, Every or when BELT year of indicator light comes on (100 use hrs.) whichever comes first

• •

Converter drive belt wear - inspect * Converter drive belt deflection - inspect * Drive belt failure detection system function - inspect*

•

•

Engine brake control lever - inspect* Air cleaner - inspect* Throttle lever play - inspect

• •

• •

Idle speed - inspect Valve clearance - inspect Fuel system cleanliness - inspect* Engine oil - change * Oil filter - replace* Spark plug - clean and gap

• • • • •

(NOTE)

•

• • • • •

Spark arrester - clean Oil cooler- clean*

•

•

Oil hoses and connections - inspect*

•

Fuel hoses and connections - inspect Fuel hose - replace CHASSIS Joint boots - inspect* Rear brake pedal and lever adjustment inspect* Rear brake plates - change* Cables adjustment* Bolts and nuts - tighten Front brake pad wear - inspect* Brake light switch - inspect* Battery - inspect Steering - inspect Differential control lever play- inspect Tire wear - inspect*

5 years

• •

• • every 10 000 km (6 000 mi.)

• • • • • • •

• •

•

• • • •

•

• •

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY

First Service After 10 hrs. or 100 km (60 mi.) of use

OPERATION Front and rear finial gear case oil - change

•

General lubrication* Front brake fluid level - inspect

•

Regular Service Every 10 days or 200 km (120 mi.) of use

Every 30 days or 600 km (360 mi.) of use

Every 90 days or 1 700 km (1 100 mi.) of use, Every or when BELT year of indicator light comes on (100 use hrs.) whichever comes first

•

• •

•

Front brake fluid - change Front brake master cylinder piston assembly and dust seal - replace

2 years

Front caliper fluid seal and dust seal replace Front brake hoses and connectionsinspect Front brake hose - replace

2 years

• 4 years

*: 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.

•

NOTE

○When the drive belt failure detection system is activated, inspect the drive belt.

2-4 PERIODIC MAINTENANCE 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.

Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent.

LB: Apply a non-permanet locking agent (ThreeBond TB2471, Blue).

MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1).

EO: Apply engine oil.

M: Apply molybdenum disulfide grease.

SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).

Lh: Left-hand Threads R: Replacement Parts S: Follow the specific tightening sequence.

St: Stake the fasteners to prevent loosening.

Fastener Fuel System Throttle Cable Locknut Air Cleaner Duct Front Clamp Screw Air Cleaner Duct Rear Clamp Screw Air Cleaner Housing Mounting Bolts Air Cleaner Intake Duct Clamp Screws Engine Top End Valve Adjusting Cap Bolts Cylinder Head Bolts (M11), first torque Cylinder Head Bolts (M11), final torque Cylinder Head Bolts (M6) Camshaft Cover Bolts Engine Breather Plate Screws Camshaft Sprocket Bolts Bearing Retainer Bolts Rear Camshaft Chain Guide Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Guard Bolts Valve Adjusting Screw Locknuts (KVF360-A1, C1 ∼ A6, C6) (KVF360A7/C7 ∼) Rocker Shaft Holder Bolts Muffler Mounting Bolts Converter System Drive Pulley Bolt Driven Pulley Nut Drive Pulley Cover Bolts Ramp Weight Nuts Spider Converter Cover Bolts

N·m

Torque kgf·m

ft·lb

1.3 1.4 4 6.9 1.4

0.13 0.14 0.41 0.70 0.14

11 in·lb 12 in·lb 36 in·lb 61 in·lb 12 in·lb

8.8 25 44 12 8.8 4.4 14 12 9.8 8.8 8.8

0.90 2.5 4.5 1.2 0.90 0.45 1.4 1.2 1.0 0.90 0.90

78 in·lb 18 33 104 in·lb 78 in·lb 39 in·lb 10 104 in·lb 87 in·lb 78 in·lb 78 in·lb

12 8.8 8.8 26

1.2 0.90 0.90 2.7

104 in·lb 78 in·lb 78 in·lb 20

(M6) (M5)

93 93 13 6.9 275 8.8

9.5 9.5 1.3 0.70 28 0.90

69 69 113 in·lb 61 in·lb 203 78 in·lb

R, Lh R

Remarks

MO, S S S

L

R Lh S

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Engine Brake Actuator Mounting Bolts Converter Air Duct Bolts Recoil Starter Recoil Starter Mounting Bolts Engine Lubrication System Oil Cooler Mounting Bolts Oil Pipe Joint Nuts Oil Cooler Fan Switch Oil Temperature Warning Light Switch Oil Hose Banjo Bolts Oil Pipe Bolts Oil Filter Oil Filter Mounting Bolt Oil Pressure Relief Valve Oil Pressure Switch Oil Pump Cover Screws Oil Pump Cover Bolt Oil Line Plug Engine Oil Drain Plug Oil Pressure Switch Terminal Bolt Engine Removal/Installation Upper Engine Mounting Bracket Nut Lower Engine Mounting Bracket Bolts Lower Engine Mounting Nuts Upper Engine Mounting Nut Crankshaft/Transmission Crankshaft Chain Guard Bolts Oil Line Plugs Engine Oil Drain Plug Crankcase Bolts (M8) Crankcase Bolts (M6) (∼ KVF360A8/C8) Crankcase Bolts (M6) (KVF360A9/C9 ∼) Bearing Position Plate Screws (KVF360-A3/C3 ∼) Grip Hold Nut Shift Lever Assembly Bracket Bolts Tie-Rod End Bolt Tie-Rod End Locknut Shift Lever Assembly Nut Tie-Rod End Front Locknut Tie-Rod End Rear Locknut Tie-Rod End Nut Shift Shaft Cover Bolts Neutral Position Switch

N·m 8.8 8.8

Torque kgf·m 0.90 0.90

ft·lb 78 in·lb 78 in·lb

5.9

0.60

52 in·lb

8.8 29 16 16 29 8.8 17.5 25 15 15 5.4 20 23 20 1.5

0.90 3.0 1.6 1.6 3.0 0.90 1.8 2.5 1.5 1.5 0.55 2.0 2.3 2.0 0.15

78 in·lb 22 12 12 22 78 in·lb 13 18 11 11 48 in·lb 14 17 14 13 in·lb

42 25 42 25

4.3 2.5 4.3 2.5

31 18 31 18

8.8 23 20 20 8.8 9.8 4.9 9.8 20 9.8 20 20 9.8 9.8 20 8.8 15

0.90 2.3 2.0 2.0 0.90 1.0 0.50 1.0 2.0 1.0 2.0 2.0 1.0 1.0 2.0 0.90 1.5

78 in·lb 17 14 14 78 in·lb 87 in·lb 43 in·lb 87 in·lb 14 87 in·lb 14 14 87 in·lb 87 in·lb 14 78 in·lb 11

Remarks S

L

R L L SS

L

R

L S, L (1)

L

R Lh

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Reverse Position Switch Shift Shaft Positioning Bolt Shift Shaft Spring Bolt Wheels/Tires Tie-Rod Adjusting Sleeve Locknuts Wheel Nuts Front Axle Nuts Rear Axle Nuts Final Drive (Output Bevel Gears) Output Driven Bevel Gear Housing Bolts Output Drive Bevel Gear Housing Bolts Output Driven Bevel Gear Bearing Holder Bevel Gear Holder Nut Output Drive Bevel Gear Bearing Holder Output Shaft Holder Nut Rotor Mounting Bolts Output Drive Bevel Gear Cover Bolts Forward/Reverse Detecting Sensor Mounting Bolts (Front Final Gear Case) Variable Front Differential Control Shift Shaft Lever Bolt Front Final Gear Case Left Cover Bolts (M6) Ring Gear Bolts Front Final Gear Case Center Cover Bolts (M8) Front Final Gear Case Center Cover Bolts (M6) Oil Filler Cap Pinion Gear Bearing Holder Nut Pinion Gear Bearing Holder Front Final Gear Case Coupling Nut Oil Drain Plug (KVF360-A1/C1 ∼ A2/C2) Oil Drain Plug (KVF360-A3/C3 ∼) 2WD/4WD Actuator Mounting Bolts Variable Differential Control Cable Locknut Variable Differential Control Lever Bolt Parking Brake Lever Screw Front Final Gear Case Bolts and Nuts (Rear Final Gear Case) Oil Filler Cap Oil Drain Plug Pinion Gear Bearing Holder Pinion Gear Bearing Holder Nut Trailer Hitch Bracket Bolt (M10)

N·m 15 25 25

Torque kgf·m 1.5 2.5 2.5

ft·lb 11 18 18

37 52 196 265

3.8 5.3 20 27

27 38 145 195

26 26 250 200 118 200 12 8.8 15

2.7 2.7 26 20 12 20 1.2 0.90 1.5

20 20 184 148 87 148 104 in·lb 78 in·lb 11

8.8

0.90

78 in·lb

9.8 57 24 9.8 29 127 137 20 24 15 9.8 17 3.5 2.2 42

1.0 5.8 2.4 1.0 3.0 13 14 2.0 2.4 1.5 1.0 1.7 0.36 0.22 4.3

87 in·lb 42 17 87 in·lb 22 94 101 14 17 11 87 in·lb 12 31 in·lb 19 in·lb 31

29 20 137 157 49

3.0 2.0 14 16 5.0

22 14 101 116 36

Remarks

L

S

L L L L

S, L (4) LB L, S L, S St L

L, S

L R

L L L

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Rear Final Gear Case Bolts Rear Final Gear Case Right Cover Bolts (M8) Rear Final Gear Case Right Cover Bolts (M10) Rear Final Gear Case Left Cover Bolts (M12) Brakes Reservoir Cap Screws Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Master Cylinder Clamp Bolts Brake Switch Mounting Bolt Brake Hose Banjo Bolts Pad Mounting Bolts Bleed Valves Caliper Mounting Bolts Caliper Holder Shaft Caliper Holder Shaft (Allen Bolt) Disc Mounting Bolts Suspension Front Shock Absorber Clamp Bolts and Nuts Front Shock Absorber Mounting Nuts Rear Shock Absorber Mounting Nuts Steering Knuckle Joint Nuts Knuckle Joint Mounting Nuts (KVF360A6/C6 ∼) Piston Rod Nut Suspension Arm Pivot Bolts Swingarm Pivot Right Shaft Swingarm Pivot Left Shaft Swingarm Pivot Left Nut Steering Steering Stem Bottom End Nut Steering Stem Clamp Bolts Tie-Rod End Nuts Steering Knuckle Joint Nuts Knuckle Joint Mounting Nuts (KVF360A6/C6 ∼) Front Shock Absorber Clamp Bolts and Nuts Tie-Rod Adjusting Sleeve Locknuts Handlebar Lower Holder Nuts Handlebar Holder Bolts Frame Rear Carrier Bolts and Nuts Front Carrier Bolts Front Guard Bolts Footboard Mounting Nuts

N·m 42 24 49 93

Torque kgf·m 4.3 2.4 5.0 9.5

ft·lb 31 17 36 69

1.5 5.9 5.9 8.8 12 25 18 7.8 25 18 23 37

0.15 0.60 0.60 0.90 0.12 2.5 1.8 0.80 2.5 1.8 2.3 3.8

13 in·lb 52 in·lb 52 in·lb 78 in·lb 10 in·lb 18 13 69 in·lb 18 13 17 27

47 74 62 42 29 49 88 152 20 152

4.8 7.5 6.3 4.3 30 5.0 9.0 15.5 2.0 15.5

35 54 46 31 22 36 65 112 14 112

62 25 42 42 29 47 37 37 27

6.3 2.5 4.3 4.3 30 4.8 3.8 3.8 2.8

46 18 31 31 22 35 27 27 20

25 – 20 –

2.5 – 2.0 –

18 – 14 –

Remarks S L L L

L L

L L

R

L, R S R L L

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Electrical System Alternator Cover Bolts Alternator Rotor Bolts Alternator Stator Bolts Spark Plug Ignition Coil Mounting Bolt Crankshaft Sensor Mounting Bolts Starter Motor Mounting Bolts Starter Motor Terminal Nut (∼ KVF360A8/C8) Starter Motor Terminal Nut (KVF360A9/C9 ∼) Starter Motor Terminal Locknut (∼ KVF360A8/C8) Starter Motor Terminal Locknut (KVF360A9/C9 ∼) Starter Motor Bolts (∼ KVF360A8/C8) Starter Motor Bolt (KVF360A9/C9 ∼) Starter Motor Clutch Bolts 2WD/4WD Actuator Mounting Bolts Engine Brake Actuator Mounting Bolts Reverse Position Switch Forward/Reverse Detecting Sensor Mounting Bolt Neutral Position Switch Starter Relay Terminal Nuts Igniter Mounting Bolts Ignition Switch Nut Oil Pressure Switch Terminal Bolt Regulator/Rectifier Mounting Bolts Speed Sensor Mounting Bolt

N·m

Torque kgf·m

ft·lb

8.8 127 14 14 8.8 5.9 8.8 4.9 6.8 6.9 11 3.4 5.0 34 9.8 8.8 15 15 15 4.9 2.3 2.7 1.5 8.8 8.8

0.90 13 1.4 1.4 0.90 0.60 0.90 0.50 0.69 0.70 1.1 0.30 0.51 3.5 1.0 0.90 1.5 1.5 1.5 0.50 0.23 0.28 0.15 0.90 0.90

78 in·lb 94 10 10 78 in·lb 52 in·lb 78 in·lb 43 in·lb 60 in·lb 61 in·lb 97 in·lb 30 in·lb 44 in·lb 25 87 in·lb 78 in·lb 11 11 11 43 in·lb 20 in·lb 24 in·lb 13 in·lb 78 in·lb 78 in·lb

Remarks

L L, S S

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent 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. mm (in.)

5 (0.20) 6 (0.24) 6 (0.24) 6 (0.24) 8 (0.31) 8 (0.31) 10 (0.39) 10 (0.39)

Mark of bolt head 4T 9T 7T 4T 7T 4T 7T 4T

N·m 2.2 ∼ 2.6 12 ∼ 15 7.8 ∼ 9.8 3.9 ∼ 4.9 18 ∼ 22 10 ∼ 14 39 ∼ 44 20 ∼ 24

Torque kgf·m 0.22 ∼ 0.27 1.2 ∼ 1.5 0.8 ∼ 1.0 0.4 ∼ 0.5 1.8 ∼ 2.2 1.0 ∼ 1.4 4.0 ∼ 4.5 2.0 ∼ 2.4

ft·lb 19 ∼ 23 in·lb 104 ∼ 130 in·lb 69 ∼ 87 in·lb 35 ∼ 43 in·lb 13 ∼ 16 87 ∼ 122 in·lb 29 ∼ 33 14 ∼ 17

Basic Torque for General Fasteners of Frame Parts Threads dia. mm (in.)

5 (0.20) 6 (0.24) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 18 (0.71) 20 (0.79)

N·m 3.4 ∼ 4.9 5.9 ∼ 7.8 14 ∼ 19 25 ∼ 34 44 ∼ 61 73 ∼ 98 115 ∼ 155 165 ∼ 225 225 ∼ 325

Torque kgf·m 0.35 ∼ 0.5 0.6 ∼ 0.8 1.4 ∼ 1.9 2.6 ∼ 3.5 4.5 ∼ 6.2 7.4 ∼ 10.0 11.5 ∼ 16.0 17.0 ∼ 23.0 23 ∼ 33

ft·lb 30 ∼ 43 in·lb 52 ∼ 69 in·lb 10.0 ∼ 13.5 19.0 ∼ 25 33 ∼ 45 54 ∼ 72 83 ∼ 115 125 ∼ 165 165 ∼ 240

2-10 PERIODIC MAINTENANCE Specifications Item Fuel System Throttle Lever Free Play Air Cleaner Element Oil Engine Top End Valve Clearance: Exhaust Inlet Converter System Actuator Lever Guide Shoe Wear Belt Width (KVF360-A1/C1 ∼ A2/C2) (KVF360-A3/C3 ∼) Belt Deflection Engine Lubrication System Engine Oil: Type Viscosity Capacity

Wheels/Tires Tire Tread Depth: Front Rear Standard Tire: Front

Rear

Final Drive Front Final Gear Case: Gear Case Oil: Type Viscosity

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

High-quality foam air filter oil

– – – – – –

0.15 ∼ 0.20 mm (0.0059 ∼ 0.0079 in.)

0.08 ∼ 0.13 mm (0.0032 ∼ 0.0051 in.)

– – – – – –

––– 29.9 ∼ 31.1 mm (1.18 ∼ 1.22 in.)

29.7 ∼ 30.3 mm (1.17 ∼ 1.19 in.)

22 ∼ 27 mm (0.87 ∼ 1.06 in.)

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 1.50 L (1.59 US qt) (When filter is not removed) 1.74 L (1.84 US qt) (When filter is removed) 2.3 L (2.43 US qt) (When engine is completely dry)

––– –––

6 mm (0.24 in.)

29.4 mm (1.16 in.)

28.0 mm (1.10 in.)

– – –

– – – – – – – – – – – – – – –

3 mm (0.12 in.)

4 mm (0.16 in.)

AT 25 × 8-12 Dunlop, KT121, Tubeless (KVF360-A1/C1 ∼ A9/C9) MAXXIS, M911Y, Tubeless (KVF360AA ∼/CA ∼) AT 25 × 10-12 Dunlop, KT405C/KT127A, Tubeless (KVF360-A1/C1 ∼ A9/C9) MAXXIS, M912Y, Tubeless (KVF360AA ∼/CA ∼)

– – –

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40

– – – – – – – – –

– – –

– – – – – –

PERIODIC MAINTENANCE 2-11 Specifications Item Oil level Capacity Rear Final Gear Case: Gear Case Oil: Type

Oil level Capacity Brakes Front Brake Fluid: Grade Front Disc Brake: Pad lining thickness Rear Brake Lever, Pedal and Cables: Rear brake lever free play Brake pedal free play Electrical System Spark plug gap Rear brake light switch timing

Standard Filler opening bottom 430 mL (0.45 US qt)

Service Limit – – – – – –

MOBIL Fluid 424 or Kawa Chem Gear & Wet Brake Oil (CITGO TRANSGARD TRACTOR HYDRAULIC FLUID) or Exxon Hydraul 560 Filler opening bottom 900 mL (0.95 US qt)

– – –

DOT 3 or DOT 4

– – –

4.5 mm (0.18 in.)

1 mm (0.04 in.)

– – – – – –

1 ∼ 2 mm (0.04 ∼ 0.08 in.)

15 ∼ 25 mm (0.6 ∼ 1.0 in.)

– – – – – –

0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)

On after 10 mm (0.4 in.) of pedal travel

– – – – – –

2-12 PERIODIC MAINTENANCE Special Tools Valve Adjusting Screw Holder: 57001-1217

Belt Measuring Gauge: 57001-1519

Oil Filter Wrench: 57001-1249

Flywheel & Pulley Holder: 57001-1605

Carburetor Drain Plug Wrench, Hex 3: 57001-1269

Belt Measuring Gauge: 57001-1646

Pulley Holder Attachment: 57001-1472

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection

that the throttle lever moves smoothly from full • Check open to close, and the throttle closes quickly and com-

• •

pletely in all steering positions by the return spring.

If the throttle lever does not return properly, check the throttle cable routing, lever free play, and for possible cable damage. Then lubricate the throttle cable.

Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increases, check the throttle lever free play and the cable routing.

Stop the engine and check the throttle lever free play [A].

Throttle Lever Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

If the free play is not within the specified range, adjust the cable.

Throttle Lever Free Play Adjustment

the rubber cover off the adjuster at the throttle case.

• Slide Loosen locknut [A] and turn the throttle cable upper • adjuster the [B] until the cable has proper amount of play.

Tighten the locknut and reinstall the rubber cover.

• Torque - Throttle Cable Locknut: 1.3 N·m (0.13 kgf·m, 11 in·lb)

If the free play cannot be adjusted by using the upper cable adjuster, remove the throttle cable pulley cover and then use the cable adjusting nuts [A] at the lower end of the throttle cable and make the necessary free play.

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection

the engine and warm it up thoroughly.

• Start the engine idling, turn the handlebar to both sides to • With check for any changes in the idle speed.

If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted incorrectly routed, or damaged. Be sure to correct any of these conditions before riding.

WARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. Follow the service manual to be make sure to correct any of these conditions.

• Check idle speed with a suitable tachometer.

Idle Speed Standard:

1 300 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it.

Idle Speed Adjustment

the engine and warm it up thoroughly.

• Start Turn • correct.the idle adjusting screw [A] until the idle speed is

○Open and close the throttle a few times to make sure that the idle speed is within the specified range.

Fuel System Cleanliness Inspection

WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the fuel tap to the OFF position.

• Turn Remove check valve [A] at the end of the carburetor • overflow the hose.

Run the lower end of the carburetor overflow hose to a • suitable container. out the carburetor drain plug a few turns and drain • Turn the fuel system.

Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001-1269 [A]

to see if water or dirt comes out.

• Check Tighten the drain plug.

• If any water or dirt appears during the above inspection, clean the fuel system (carburetor, tank, fuel hose).

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Air Cleaner Element Cleaning and Inspection NOTE

○In dusty areas, the element should be cleaned more frequently than the recommended interval. ○After riding through rain or muddy terrains, the element should be cleaned immediately. ○Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.

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 anywhere near the working areas. Do not use gasoline or low-flash point solvents to clean the element. the air cleaner element.

• Remove Clean the in a bath of high-flash point solvent • using a softelement bristle brush. it dry in a clean towel [A]. Do not wring the ele• Squeeze ment or blow it dry; the element can be damaged. the element for damage.

• Inspect If it is torn, punctured, or hardened, replace it.

NOTE

○Replace the element after cleaning it five times or if it is damaged. cleaning, saturate the element with a high-quality • After foam-air-filter oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element.

Air Cleaner Draining A drain tube [A] is connected to the bottom of the air cleaner housing to drain water or oil accumulated in the housing.

Visually check the drain tube if the water or oil accumulates in the tube.

If any water or oil accumulates in the tube, drain it by taking off the tube. After draining, be sure to install the tube and clamp firmly.

•

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose and Connection Check

the fuel tap to the OFF position.

• Turn • Remove: Fuel Tank Cover (see Frame chapter)

• •

• •

Exhaust Cover (see Frame chapter) Check the fuel hose [A].

If the fuel hose is frayed, cranked, or bulged, replace the fuel hose.

Check that the hose is securely connected and clamps [B] are tightened.

If the fuel hose has been sharply bent or kinked, replace the fuel hose.

If the clamps are loosened or damaged, replace the clamps.

When installing the fuel hose, route the hose according to Cable, Wire, and Hose Routing section in Appendix chapter.

When installing the fuel hose, avoid sharp bending, kinking, flattening or twisting, and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed.

Fuel Hose Replacement

WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the fuel tap to the OFF position.

• Turn • Remove: Fuel Tank Cover (see Frame chapter) Exhaust Cover (see Frame chapter) Clamps [A] Fuel Hose [B] the fuel hose [A] onto the pipe fully and install the • Fit clamps [B] beyond the raised rib [C].

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE

○Check the valve clearance only when the engine is cold (at room temperature).

• Remove: Left Front Wheel (see Wheels/Tires chapter) Left Front Inner Cover (see Frame chapter) Fuel Tank (see Fuel System chapter) Rubber Cover Bolts [A] and Valve Adjusting Caps [B]

• Remove: Recoil Starter (see Recoil Starter chapter) •

Timing Inspection Plug Position the crankshaft at TDC of the end of the compression stroke (see Camshaft Sprocket Installation in Engine Top End chapter).

the clearance of each valve between the end of • Measure the valve stem and the adjusting screw on the rocker arm with a thickness gauge [A].

Valve Clearance (when cold) Exhaust: 0.15 ∼ 0.20 mm (0.0059 ∼ 0.0079 in.)

Inlet:

0.08 ∼ 0.13 mm (0.0032 ∼ 0.0051 in.)

If the valve clearance is not correct, adjust it.

Valve Clearance Adjustment

the valve adjusting cap.

• Remove Loosen the locknut [A] and turn the adjusting screw [B] • until the clearance is correct.

Hold the adjusting screw from turning and tighten the lock• nut to the specified torque.

Torque - Valve Adjusting Screw Locknuts: 12 N·m (1.2 kgf·m, 104 in·lb) (KVF360-A1/C1 ∼ A6/C6) 8.8 N·m (0.90 kgf·m, 78 in·lb) (KVF360A7/C7) Special Tool - Valve Adjusting Screw Holder: 57001-1217 (AVF360A7/C7 ∼)

the clearance.

• Recheck If the clearance is incorrect, repeat the adjustment procedure.

If the clearance is correct, perform the adjustment procedure on the other valve.

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures grease to the O-ring [A].

• Apply Install • upward.the valve adjusting cap so that the “UP” mark facing • Tighten: Torque - Valve Adjusting Cap Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Spark Arrester Cleaning

WARNING The muffler can become extremely hot during normal operation and cause severe burns. Since the engine must be running during this procedure, wear heat-resistant gloves while cleaning the spark arrester. the drain plug [A] on the muffler.

• Remove In an open area away from combustible materials, start • the engine with the transmission in neutral.

Raise and lower speed while tapping on the muf• fler with a rubberengine mallet until carbon particles are purged from the muffler.

DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death.

DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area. the engine.

• Stop molybdenum disulfide grease to the drain plug.

• Apply Install the drain plug.

•

Converter System Actuator Lever (Engine Brake Control Lever) Assembly Inspection

• Measure the width [A] of the guide [B].

Actuator Lever Guide Shoe Wear Service Limit: 6 mm (0.24 in.)

If the guide contact area width is greater than the service limit, replace the actuator lever assembly.

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Drive Belt Inspection Inspection of the drive belt is required at least every 90 days of vehicle use (average 12 mile/day) not to exceed 1 100 mile. More frequent inspection is necessary if the vehicle is subjected to hard usage.

WARNING Neglect, abuse, or failure to maintain the transmission can result in a severely worn or damaged drive belt locking up the transmission and wheels. This can cause the operator to lose control and have an accident resulting in injury or death. Maintain according to periodic maintenance chart.

KVF360-A1/C1 ∼ A2/C2 Measure the width [A] of the belt at several locations with a suitable straightedge [B] as shown.

•

Belt Width Standard: Service Limit:

29.9 ∼ 31.1 mm (1.18 ∼ 1.22 in.)

29.4 mm (1.16 in.)

If any measurements exceed the service limit, replace the belt.

NOTE

○Use the belt measuring gauge [A] in order to make easy to inspect the drive belt width.

Special Tool - Belt Measuring Gauge: 57001-1519

the belt measuring gauge [A] to the drive belt [B].

• Fit If the upper surface [C] of the belt sinks below the upper surface [D] of the gauge, replace the belt.

KVF360-A3/C3 ∼ Remove the torque converter cover (see Converter System chapter).

Measure the width [A] of the belt at several locations with a pair of suitable straightedges [B] as shown.

If any measurements exceed the service limit, replace the belt.

• •

Belt Width Standard: Service Limit:

29.7 ∼ 30.3 mm (1.17 ∼ 1.19 in.)

28.0 mm (1.10 in.)

NOTE

○Use the belt measuring gauge [A] in order to make easy to inspect the drive belt width.

Special Tool - Belt Measuring Gauge: 57001-1646

the belt measuring gauge [A] to the drive belt [B].

• Fit If the upper surface [C] of the belt sinks below the upper surface [D] of the gauge, replace the belt.

[E] 28 mm (1.10 in.)

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures the belt [A] for abnormal wear [B].

•○Check Measure the width [C] of the belt at abnormal wear point.

If any measurements exceed 0.5 mm (0.02 in.), replace the belt. ○When using the belt of large abnormal wear, the drive belt failure detection switch could be activated.

the belt for cracks, breaks, or peeling.

• Check If necessary, replace the belt with a new one.

Belt [A] Crack [B] Broken [C] Peeling [D]

NOTE

○Whenever the belt is replaced, inspect the drive and the driven pulleys.

Drive Belt Deflection Inspection NOTE

○If the drive belt failure detection system is activated by abnormal belt, the drive belt failure detection switch is damaged. Make sure to replace the torque converter cover. the torque converter cover (see Torque Con• Remove verter Cover Removal in Converter System chapter). the transmission in neutral and rotate the driven pulley • Put by hand to make sure the belt is shifted all the way to the top of the driven pulley. the belt deflection [A] as shown: •○Measure Place a straightedge [B] on top of the belt between the drive pulley [C] and the driven pulley [D]. ○Use a ruler to push the belt away from the straightedge.

Push hard, but with no more force than 59 N (6 kgf, 13 lb).

Belt Deflection Standard:

•

22 ∼ 27 mm (0.87 ∼ 1.06 in.)

If the belt deflection is not within the specified range, first measure the drive belt width (see Drive Belt Inspection).

Adjust the deflection by adding or removing spacers on the fixed sheave.

When adjusting the deflection, less is better than more.

Less deflection will maintain better performance for more time as the belt width decreases by normal wear, which causes the deflection to increase with usage.

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Drive Belt Deflection Adjustment

the driven pulley (see Driven Pulley Disas• Disassemble sembly in Converter System chapter).

If the belt deflection is more than 27 mm (1.06 in.), remove the spacers to decrease it. ○The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.3 mm (0.051 in.) change in belt deflection.

If the belt deflection is less than 22 mm (0.87 in.), add the spacers [A] to increase it. ○The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.6 mm (0.063 in.) change in belt deflection.

Spacers Part No.

Thickness

92026-0034

0.3 mm (0.012 in.)

92026-1569

0.6 mm (0.024 in.)

92026-1617

0.8 mm (0.032 in.)

92026-1565

1.0 mm (0.039 in.)

92026-1570

1.4 mm (0.055 in.)

the driven pulley (see Driven Pulley Assembly • Assemble in Converter System chapter). the transmission in neutral, rotate the driven pulley • With to allow the belt to return to the top of the sheaves before

• • •

measuring the belt deflection.

Measure the belt deflection again and repeat the above procedures until it is within the standard range.

Replace the driven pulley nut with a new one.

Using the flywheel & pulley holder and adapter, tighten the driven pulley nut.

Special Tools - Flywheel & Pulley Holder: 57001-1605 Pulley Holder Attachment: 57001-1472 Torque - Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb)

NOTE

○When some spacers are used to adjust the belt deflection, install the thinner one first to the fixed sheave.

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