Suzuki Twin Peaks 700 Lt V700f Ltv700f Ltv700 Shop Manual 2004 2005

TOP

LT-V700F K4, K5

K4, K5

LT-V700F

BOTTOM

99500-46051-01E

DIC335

FOREWORD This manual contains an introductory description on the SUZUKI LT-V700F and procedures for its inspection/service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance.

Use this section as well as other sections as a guide for proper inspection and service.

This manual will help you know the vehicle better so that you can assure your customers of fast and reliable service.

A

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual vehicle. * Illustrations in this manual are used to show the basic principles of operation and work procedures.They may not represent the actual vehicle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider.

Š COPYRIGHT SUZUKI MOTOR CORPORATION 2004

This manual was compiled based on the service manual for KVF700 issued by Kawasaki Heavy Industries, Ltd. Therefore, actual motorcycle condition may be different from photos in this manual.

Refer to the list of corresponding materials and tools of two models at the back of the cover of this manual when required in the manual.

The SUZUKI LT-V700F is derived from Kawasaki KVF700 and manufactured by Kawasaki Heavy industries, LTD. All specfications of the LT-V700F equal to the KVF700. Read the KVF700-A1–A2, B1–B2 to the LT-V700FK4 – K5.

SUZUKI LT-V700FK4

List of corresponding materials and tools Select applicable model, lubricant, adhesive, sealing agent, oil or special tools referring to this list when reading this manual.

Lubricant Bond, Sealant and Oil Suzuki Symbol mark or defirecomended lubrcant, nition in this manual bond sealant G: Apply grease 99000-25030 Suzuki Super grease “A” (USA) 99000-25010 Suzuki Super grease “A” (Others) L: Apply a non-perma- 99000-32030 nent locking agent Suzuki Thread Lock Super “1303” (USA) 99000-32110 Suzuki Thread Lock Super “1322” (Others)

56019-120 Kawasaki Bond (Silicone Sealant)

99000-31230 Suzuki Bond “1216B”

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SPECIAL TOOLS Base Manual Tools

SUZUKI Recommend tools

Base Manual Tools

SUZUKI Recommend tools

57001-135 Bearing puller

KK570-01135 Bearing puller

57001-164 Oil pressure gauge 10 kgf/cm²

09915-77331 Oil pressure gauge

57001-137 Steering stem bearing driver

09941-74910 Steering bearing installer

57001-221 Compression gauge 20 kgf/cm2

09915-64512 Compression gauge

57001-143 Inside circlip pliers

09900-06108 Snap ring pliers

57001-241 Valve spring compressor assembly

09916-14510 Valve spring compressor

57001-144 Outside circlip pliers

09900-06107 Snap ring pliers

57001-910 Piston pin puller assembly

09910-34510 Piston pin puller

Base Manual Tools

SUZUKI Recommend tools

Base Manual Tools

SUZUKI Recommend tools

57001-1017 Fuel level gauge

09913-14511 Fuel level gauge

09923-74511 Bearing remover

57001-1033 Oil pressure gauge adapter, PT 1/8

K5700-11033 Oil pressure gauge adapter, PT 1/8

09930-30104 Slide shaft

57001-1114 Valve seat cutter 45° – 27.5

K5700-11114 Valve seat cutter 45° – 27.5

57001-1058 Oil seal & Bearing remover

09941-64511 Bearing & Oil seal remover

57001-1119 Valve seat cutter 32° – 28

K5700-11119 Valve seat cutter 32° – 28

57001-1123 Valve seat cutter 60° – 30

K5700-11123 Valve seat cutter 60° – 30

Base Manual Tools

SUZUKI Recommend tools

Base Manual Tools

SUZUKI Recommend tools

57001-1128 Valve seat cutter holder bar

K5700-11128 Valve seat cutter holder bar

57001-1202 Valve spring compressor adapter, 22

K5700-11202 Valve spring compressor adapter, 22

57001-1129 Bearing driver set

09913-70210 Bearing installer set

57001-1203 Valve guide arbor, 5

K5700-11203 Valve guide arbor, 5

57001-1187 Valve seat cutter 45° – 30

K5700-11187 Valve seat cutter 45° – 30

57001-1204 K5700-11204 Valve guide reamer, 5 Valve guide reamer, 5

57001-1199 Valve seat cutter 32° – 33

K5700-11199 Valve seat cutter 32° – 33

57001-1208 Valve seat cutter holder, 5

K5700-11208 Valve seat cutter holder, 5

Base Manual Tools

57001-1211 Piston pin puller adapter, 14

SUZUKI Recommend tools

K5700-11211 Piston pin puller adapter

Base Manual Tools

SUZUKI Recommend tools

57001-1241 Timing light

K5700-11241 Timing light

57001-1216 Rotor puller K5700-11216 M16/M18/M20/M22×1.5 Rotor puller

57001-1249 Oil filter wrench

K5700-11249 Oil filter wrench

57001-1238 Jack

57001-1265 Bearing remover shaft 9

K5700-11238 Jack

09913-10130 Carburator adjust 57001-1239 Pilot screw adjuster, A driver

57001-1266 Bearing remover head, 10 × 12

09941-50111 Wheel bearing remover set

Base Manual Tools

SUZUKI Recommend tools

Base Manual Tools

SUZUKI Recommend tools

57001-1269 K5700-11269 Carburetor drain plug Carburetor drain plug wrench, Hex 3 wrench, Hex 3

57001-1394 Hand tester

57001-1313 Flywheel holder

K5700-11313 Flywheel holder

57001-1415 Peak voltage adapter

09900-25008 Multi circuit tester

57001-1343 Flywheel & Pulley holder

K5700-11343 Flywheel & Pulley holder

57001-1405 Flywheel puller assembly M38 × 1.5/M35 × 1.5

K5700-11615 Flywheel puller assembly M38 × 1.5/M35 × 1.5

K5700-11363 Socket wrench

57001-1412 Drive & Driven pulley holder

K5700-11412 Drive & Driven pulley holder

57001-1363 Socket wrench

Base Manual Tools

SUZUKI Recommend tools

Base Manual Tools

SUZUKI Recommend tools

57001-1429 Drive pulley puller bolt

K5700-11429 Drive pulley puller bolt

57001-1473 Drive & Driven pulley holder

K5700-11473 Drive & Driven pulley holder

57001-1454 Filler cap driver

K5700-11454 Filler cap driver

57001-1474 Drive pulley wrench

K5700-11474 Drive pulley wrench

57001-1457 Needle adapter set

09900-25009 Needle pointed probe set

57001-1476 Holder & Guide arbor

K5700-11476 Holder & Guide arbor

57001-1472 Pulley holder attachment

K5700-11472 Pulley holder attachment

57001-1477 Spacer & Holder

K5700-11477 Spacer & Holder

Base Manual Tools

SUZUKI Recommend tools

Base Manual Tools

SUZUKI Recommend tools

57001-1478 K5700-11478 Socket wrench, Hex 50 Socket wrench, Hex 50

57001-1482 Socket wench

K5700-11482 Socket wench

57001-1479 K5700-11479 Output shaft holder & Output shaft holder & spacer, m1.25 spacer

57001-1483 Spring holder set

K5700-11483 Spring holder set

57001-1480 Pinion gear holder m1.667

K5700-11480 Pinion gear holder

57001-1484 K5700-11484 Socket wrench, Hex 41 Socket wrench, Hex 41

57001-1481 Nut holding bolts

K5700-11481 Nut holding bolts

57001-1485 Pinion gear holder m1.0

K5700-11485 Pinion gear holder

Base Manual Tools

SUZUKI Recommend tools

Base Manual Tools

SUZUKI Recommend tools

57001-1486 Compression gauge adapter, M10 × 1.0

09915-63310 Compression pressure gauge adapter

57001-1498 K5700-11498 Drive pulley measure- Drive pulley measurement tool ment tool

57001-1487 Oil seal driver, 47.5

K5700-11487 Oil seal driver

57001-1499 Actuator lever measurement tool

K5700-11499 Actuator lever measurement tool

57001-1489 Gear holder & Socket wrench, Hex 24

K5700-11489 Gear holder & Socket wrench, Hex 24

57001-1505 Oil seal driver, 18.5

K5700-11505 Oil seal driver, 18

57001-1491 Hexagon wench Hex 41

K5700-11491 Hexagon wench Hex 41

57001-1506 Oil seal driver, 70

K5700-11506 Oil seal driver, 48

Base Manual Tools

SUZUKI Recommend tools

57001-1520 Drive pulley holder

K5700-11520 Drive pulley holder

57001-1570 Output shaft holder

K5700-11570 Output shaft holder

Base Manual Tools

57001-1605 Flywheel & Pulley holder

SUZUKI Recommend tools

K5700-11605 Flywheel & Pulley holder

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

Cooling System

4 j

Engine Top End

5 j

Converter System

6 j

Recoil Starter

7 j

Engine Lubrication System

8 j

Engine Removal/Installation

9 j

Crankshaft/Transmission

10 j

Wheels/Tires

11 j

Final Drive

12 j

Brakes

13 j

Suspension

14 j

Steering

15 j

Frame

16 j

Electrical System

17 j

Appendix

18 j

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L

ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celcius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)

lb m min N Pa PS psi r rpm TDC TIR V W Ω

pounds(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the 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 modified carburetor and an 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.

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.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only) To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level.

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 Special Tool Catalog or 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 these WARNING and CAUTION symbols, heed their instructions!

Always follow safe operating and maintenance practices.

WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) 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

1

Table of Contents Before Servicing .....................................................................................................................

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

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

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

1-2 1-7 1-10 1-13

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 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.

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 or cotter pins 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. 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 Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or 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 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.

GENERAL INFORMATION 1-7 Model Identification LT-V700FK4 Side View

1-8 GENERAL INFORMATION Model Identification LT-V700FK5 Side View

GENERAL INFORMATION 1-9 Model Identification

1-10 GENERAL INFORMATION General Specifications LT-V700FK4

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 Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System

2 1 1 1

190 180 175 290

192 240 870 273

mm mm mm mm

(86.22 (46.46 (46.26 (50.79

LT-V700FK5 ~

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

mm (7.56 in.) mm (9.45 in.) mm (34.25 in.) kg (602 lb)

154 kg (340 lb) 140 kg (309 lb) 17 L (4.5 US gal)

139 kg (306 lb)

3.1 m (10.17 ft) 4-stroke, SOHC, V2-cylinders Liquid-cooled 82.0 × 66.0 mm (3.23 × 2.60 in.)

697 mL (42.5 cu in.)

9.9 : 1 34.3 kW (46.6 PS) @6 500 r/min (rpm), (US) 60.1 N·m (6.13 kgf·m, 44.33 ft·lb) @5 000 r/min (rpm) Carburetor, Keihin CVKR-32 Electric Starter & Recoil Starter Digital DC-CDI Electronically advanced From 5° BTDC @1 100 r/min (rpm) to 28° BTDC @5 000 r/min (rpm) NGK CR7E, DENSO U22ESR-N Front to rear, 1-2 1-2

30° BTDC 34° ABDC 244° 54° BBDC 10° ATDC 244° Forced lubrication (wet sump)

GENERAL INFORMATION 1-11 General Specifications Items 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 Front Tire: Type Size

LT-V700FK4

LT-V700FK5 ~

API SF or SG API SH or SJ with JASO MA class SAE 10W-40 2.05 L (2.17 US qt)

Belt converter 3.122 ∼ 0.635 2-speed and reverse

3.098 (30/26 × 29/18 × 20/12) 4.833 (36/20 × 29/18 × 20/12) 4.028 (16/12 × 18/16 × 29/18 × 20/12) Shaft 2WD/4WD 4.375 (35/8)

42.32 ∼ 8.61 66.02 ∼ 13.43 55.01 ∼ 11.19 API SF or SG API SH or SJ with JASO MA class SAE10W-40 0.43 L (0.45 US qt) MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or Exxon Hydraul 560 0.9 L (0.95 US qt) Double tubular 3.5° 0° 15° 15 mm (0.59 in.)

906 mm (35.67 in.)

910 mm (35.83 in.)

Tubeless AT25 × 8 - 12

1-12 GENERAL INFORMATION General Specifications Items Rear Tire: Type Size Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Electrical Equipment Battery Headlight: Type Bulb Tail/Brake Light: Bulb Reverse Light: Bulb Alternator: Type Rated Output

LT-V700FK4

LT-V700FK5 ~

Tubeless AT25 × 10 - 12

MacPherson strut 170 mm (6.69 in.)

Swingarm 184 mm (7.24 in.)

Disc × 2 Enclosed wet multi-plate 12 V 12 Ah Semi-sealed beam 12 V 45/45 W × 2 12 V 5/21 W (EUR) (GB) 12 V/10 W Three - phase AC 25 A, 14 V @6 000 r/min (rpm)

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

EUR: Europe Model GB: United Kingdom Model US: United States Model

GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Units of Length:

Symbol M k c m µ

× × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass: kg g

× ×

2.205 0.03527

= =

lb oz

= = = = = = = = =

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

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

km m mm

× × ×

0.6214 3.281 0.03937

= = =

mile ft in

= = = = = =

kgf·m ft·lb in·lb N·m ft·lb in·lb

= = = = = =

kgf/cm² psi cmHg kPa psi kPa

=

mph

= = = =

PS HP kW HP

Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m

× × × × × ×

0.1020 0.7376 8.851 9.807 7.233 86.80

Units of Pressure: kPa kPa kPa kgf/cm² kgf/cm² cm Hg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed: km/h

×

0.6214

Units of Force: N N kg kg

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature:

= = = =

kg lb N lb

Units of Power: kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance 2

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 ................................................................................

Choke Lever Free Play Inspection....................................................................................

Choke 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 Inspection ..............................................................................

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

Cooling System....................................................................................................................

Radiator Cleaning .............................................................................................................

Radiator Hose and Connection Inspection .......................................................................

Coolant Change ................................................................................................................

Coolant Filter Cleaning .....................................................................................................

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

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

Valve Clearance Adjustment.............................................................................................

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

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

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

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

Drive Belt Deflection Adjustment ......................................................................................

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

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

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

Oil Filter Replacement ......................................................................................................

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

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

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

Variable Differential Control Lever Play Inspection ...........................................................

Variable Differential Control Lever Play Adjustment .........................................................

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

Rear Final Gear Case Oil Change ....................................................................................

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

Front Brake Pad Wear Inspection.....................................................................................

Front Brake Hoses and Connections Inspection...............................................................

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

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

2-3 2-5 2-11 2-13 2-14 2-14 2-14 2-14 2-14 2-15 2-15 2-15 2-16 2-16 2-17 2-17 2-18 2-18 2-18 2-19 2-19 2-21 2-22 2-22 2-23 2-23 2-23 2-23 2-24 2-25 2-25 2-26 2-26 2-26 2-27 2-27 2-27 2-27 2-27 2-28 2-29 2-29 2-29 2-29 2-30 2-30

2-2 PERIODIC MAINTENANCE Brake Fluid Change ..........................................................................................................

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

Front Brake Caliper Piston Seal and Dust Seal Replacement..........................................

Rear Brake Plates Replacement.......................................................................................

Rear Brake Lever Free Play Inspection ............................................................................

Brake Pedal Free Play Inspection.....................................................................................

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

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

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

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

Spark Plug Cleaning/Inspection........................................................................................

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

Brake Light Switch Inspection...........................................................................................

Brake Light Timing Adjustment .........................................................................................

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

Joint Boots Inspection..........................................................................................................

Front Axle/Suspension Arm Joint Boot Inspection............................................................

Front Propeller Shaft Boot Inspection ...............................................................................

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

Tie-rod End Boot Inspection .............................................................................................

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

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

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

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

2-31 2-31 2-31 2-32 2-32 2-32 2-32 2-33 2-33 2-33 2-33 2-33 2-34 2-34 2-34 2-36 2-36 2-36 2-36 2-36 2-37 2-37 2-38 2-38

PERIODIC MAINTENANCE 2-3 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

OPERATION ENGINE

First Service

Regular Service

Every 90 days, 1 700 km (1 Every Every 100 mi.) or After 10 10 days 30 days when belt Every hrs. or or 200 or 600 indicator See year of km km 100 km light turns page use (60 mi.) (120 (360 on (100 of use mi.) of mi.) of hrs. of use use use) 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 Choke lever play - inspect Idle speed - inspect

• • •

• • •

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

•

Radiator hoses and connections - check*

•

•

Coolant filter of carburetor - clean CHASSIS Joint boots - inspect * Rear brake pedal and lever play - inspect * Rear brake plates - replace * Bolts and nuts - tighten Front brake pad wear - inspect * Brake light switch - inspect *

• • • • •

2-16 2-17

•

2-22 2-16 2-26 2-26 2-33

•

2-23 2-17 2-18 2-18

2 years

Coolant - change*

2-25

2-15

• • • • 4 years

•

2-34

2-14

Fuel hoses and connections - inspect Radiator - clean*

2-24

2-14

• • • •

Fuel hose - replace

2-23

•

2-19

•

2-21

2-19

• •

2-36

•

2-38

2-32

every 10 000 km (6 000 mile)

• •

2-32 2-29 2-34

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY

OPERATION Steering - inspect Differential control lever play - inspect Tire wear - inspect * Front and rear final gear case oil - change

First Service

Every 90 days, 1 700 km (1 Every Every 100 mi.) or After 10 10 days 30 days when belt hrs. or or 200 or 600 Every indicator See 100 km km km year of page light turns (360 use (60 mi.) (120 on (100 of use mi.) of mi.) of hrs. of use use use) whichever comes first

• •

Front brake fluid - change

•

•

•

2-27 2-27

• • •

2-28 2-29 2-37 2-30

•

Front brake hoses and connections- inspect Front brake master cylinder piston assembly and dust seal - replace Front brake caliper piston seal and dust seal - replace Front brake hose - replace

2-33

•

•

General lubrication * Front brake fluid level - inspect

Regular Service

•

2-31 2-29

2 years

2-31

2 years

2-31

4 years

2-30

*: 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.

Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

L: Apply a non-permanent locking agent.

LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue).

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

R: Replacement Parts S: Follow the specific tightening sequence.

SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

St: Stake the fasteners to prevent loosening.

Fastener Fuel System Heat Guard Plate Mounting Bolts Air Cleaner Housing Bolts (M5) Air Cleaner Housing Bolts (M6) 28.7 mm (1.13 in.)

Air Cleaner Housing Bolts (M6) 33 mm (1.30 in.)

Fuel Tap Plate Screws Air Cleaner Element Bracket Screws Cooling System Radiator Fan Switch Water Pump Cover Bolts Coolant Drain Plug Water Pump Fitting Bolt Water Pump Impeller Thermostat Housing Cover Bolts Coolant Temperature Warning Light Switch Radiator Fan Mounting Nut Radiator Fan Assembly Bolts Radiator Mounting Bolts Engine Top End Water Pipe Bolts Rocker Case Bolts 55 mm (2.2 in.)

Rocker Case Bolts 130 mm (5.1 in.)

Rocker Case Bolts 30 mm (1.2 in.)

Rocker Case Bolts 25 mm (1.0 in.)

Cylinder Head Bolts (M10), First Torque Cylinder Head Bolt (M10), Final Torque Cylinder Head Bolts (M6) Cylinder Head Jacket Plugs Valve Adjusting Cap Bolts Valve Adjusting Screw Locknuts Rocker Shaft Bolts

N·m

Torque kgf·m

ft·lb

8.8 5.9 8.8 8.8 0.8 4.9

0.90 0.60 0.90 0.90 0.08 0.50

78 in·lb 52 in·lb 78 in·lb 78 in·lb 7 in·lb 43 in·lb

18 8.8 8.8 9.8 7.8 8.8 7.8 2.7 8.8 8.8

1.8 0.90 0.90 1.0 0.80 0.90 0.80 0.28 0.90 0.90

13 78 in·lb 78 in·lb 87 in·lb 69 in·lb 78 in·lb 69 in·lb 24 in·lb 78 in·lb 78 in·lb

9.8 8.8 9.8 9.8 9.8 25 49 9.8 20 8.8 12 8.8

1.0 0.90 1.0 1.0 1.0 2.5 5.0 1.0 2.0 0.90 1.2 0.90

87 in·lb 78 in·lb 87 in·lb 87 in·lb 87 in·lb 18 36 87 in·lb 14 78 in·lb 104 in·lb 78 in·lb

Remarks

L

SS L

S S S S S, MO S L

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