2009 KAWASAKI KVF650D9 Service Repair Manual

MODELAPPLICATION

Year Model BeginningFrameNo.

2005 KVF650-D1 JKAVFED1□5B500001

JKAVF650DDB600001

2005 KVF650-E1 JKAVFEE1□5B500001

2006 KVF650D6 JKAVFED1□6B503001

JKAVF650DDB601110

2006 KVF650E6 JKAVFEE1□6B503001

2007 KVF650D7

JKAVFED1□7B515501

JKAVF650DDB602401

2007 KVF650E7 JKAVFEE1□7B505601

2008 KVF650D8 JKAVFED1□8B520300

JKAVF650DDB603400

2008 KVF650E8 JKAVFEE1□8B507500

2009 KVF650D9 JKAVFED1□9B525501

JKAVF650DDB604901

2009 KVF650E9 JKAVFEE1□9B508901

2010 KVF650DA JKAVFED1□AB528001

JKAVF650DDB607001

2011 KVF650DB JKAVFED1□BB529001

JKAVF650DDB607301

2012 KVF650DC JKAVFED1□CB530801

2013 KVF650DD JKAVFED1□DB532001

□:Thisdigitintheframenumberchangesfromonemachinetoanother.

Thisquickreferenceguidewillassist youinlocatingadesiredtopicorprocedure.

•Bendthepagesbacktomatchthe blacktabofthedesiredchapternumberwiththeblacktabontheedgeat eachtableofcontentspage.

•Refertothesectionaltableofcontents fortheexactpagestolocatethespecifictopicrequired.

AllTerrainVehicle ServiceManual

Allrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,or transmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise, withoutthepriorwrittenpermissionofQualityAssuranceDivision/Motorcycle&EngineCompany/Kawasaki HeavyIndustries,Ltd.,Japan.

Noliabilitycanbeacceptedforanyinaccuraciesoromissionsinthispublication,althougheverypossible carehasbeentakentomakeitascompleteandaccurateaspossible.

Therightisreservedtomakechangesatanytimewithout priornoticeandwithoutincurringanobligation tomakesuchchangestoproductsmanufacturedpreviously.Seeyourdealerforthelatestinformationon productimprovementsincorporatedafterthispublication.

Allinformationcontainedinthispublicationisbasedon thelatestproductinformationavailableatthetime ofpublication.Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay notdepictactualmodelcomponentparts.

LISTOFABBREVIATIONS

A ampere(s) lb pounds(s)

ABDC afterbottomdeadcenter m meter(s)

AC alternatingcurrent min minute(s)

ATDC aftertopdeadcenter N newton(s)

BBDC beforebottomdeadcenter Pa pascal(s)

BDC bottomdeadcenter PS horsepower

BTDC beforetopdeadcenter psi pound(s)persquareinch

°C degree(s)Celcius r revolution

DC directcurrent rpm revolution(s)perminute

F farad(s) TDC topdeadcenter

°F degree(s)Fahrenheit TIR totalindicatorreading ft foot,feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

EMISSIONCONTROLINFORMATION

Toprotecttheenvironmentinwhichwealllive,Kawasakihasincorporatedcrankcaseemission (1)andexhaustemission(2)controlsystemsincompliancewithapplicableregulationsofthe UnitedStatesEnvironmentalProtectionAgencyandCaliforniaAirResourcesBoard.

1.CrankcaseEmissionControlSystem

Asealed-typecrankcaseemissioncontrolsystemis usedtoeliminateblow-bygases.Theblow-by gasesareledtothebreatherchamberthroughthecrankcase.Then,itisledtotheaircleaner.Oilis separatedfromthegaseswhilepassingthroughtheinsideofthebreatherchamberfromthecrankcase, andthenreturnedbacktothebottomofcrankcase.

2.ExhaustEmissionControlSystem

Theexhaustemissioncontrolsystemappliedtothisenginefamilyisenginemodificationsthatconsist ofamodifiedcarburetorandanignitionsystemhavingoptimumignitiontimingcharacteristics.

Thecarburetorhasbeencalibratedtoprovideleanair/fuelmixturecharacteristicsandoptimumfuel economywithasuitableaircleanerandexhaustsystem.

Amaintenancefreeignitionsystemprovidesthemostfavorableignitiontimingandhelpsmaintaina thoroughcombustionprocesswithintheenginewhichcontributestoareductionofexhaustpollutants enteringtheatmosphere.

TheCleanAirAct,whichistheFederallawcoveringmotorvehiclepollution,containswhatiscommonlyreferredtoastheAct’s"tamperingprovisions."

"Sec.203(a)Thefollowingactsandthecausingthereofareprohibited...

3.EvaporativeEmissionControlSystem

Theevaporativeemissioncontrolsystemforthisvehicleconsistsoflowpermeationfuelhosesanda fueltank.

(3)(A)foranypersontoremoveorrenderinoperativeanydeviceorelementofdesigninstalled onorinamotorvehicleormotorvehicleengineincompliancewithregulationsunderthis titlepriortoitssaleanddeliverytotheultimatepurchaser,orforanymanufacturerordealer knowinglytoremoveorrenderinoperativeanysuchdeviceorelementofdesignaftersuch saleanddeliverytotheultimatepurchaser.

(3)(B)foranypersonengagedinthebusinessofrepairing,servicing,selling,leasing,ortrading motorvehiclesormotorvehicleengines,orwhooperatesafleetofmotorvehiclesknowinglytoremoveorrenderinoperativeanydeviceorelementofdesigninstalledonorina motorvehicleormotorvehicleengineincompliancewithregulationsunderthistitlefollowingitssaleanddeliverytotheultimatepurchaser..."

NOTE

Thephrase"removeorrenderinoperativeanydeviceorelementofdesign"hasbeengenerally interpretedasfollows:

1.Tamperingdoesnotincludethetemporaryremovalorrenderinginoperativeofdevicesorelementsofdesigninordertoperformmaintenance.

2.Tamperingcouldinclude:

a.Maladjustmentofvehiclecomponentssuchthattheemissionstandardsareexceeded.

b.Useofreplacementpartsoraccessorieswhichadverselyaffecttheperformance ordurabilityofthevehicle.

c.Additionofcomponentsoraccessoriesthatresultinthevehicleexceedingthestandards.

d.Permanentlyremoving,disconnecting,orrenderinginoperativeanycomponentor elementofdesignoftheemissioncontrolsystems.

PLEASEDONOTTAMPERWITHNOISECONTROLSYSTEM (USMODELonly)

TAMPERINGWITHEMISSIONCONTROLSYSTEMPROHIBITED:

FederalregulationsandCaliforniaStatelawprohibitthefollowingactsorthecausingthereof: (1)theremovalorrenderinginoperativebyanypersonotherthanforpurposesofmaintenance, repair,orreplacement,ofanydeviceorelementofdesignincorporatedintoanynewvehiclefor thepurposesofemissioncontrolpriortoitssaleordeliverytotheultimatepurchaserorwhileit isinuse,or(2)theuseofthevehicleaftersuchdeviceorelementofdesignhasbeenremoved orrenderedinoperativebyanyperson.

Donottamperwiththeoriginalemissionrelatedparts:

• Carburetororinternalparts

• SparkPlug

• Magnetoignitionsystem

• AirCleanerelement

TAMPERINGWITHNOISECONTROLSYSTEMPROHIBITED:

Federallawprohibitsthefollowingactsorthecausingthereof:(1)theremovalorrendering inoperativebyanypersonotherthanforpurposesofmaintenance,repair,orreplacement,ofany deviceorelementofdesignincorporatedintoanynewvehicleforthepurposeofnoisecontrol priortoitssaleordeliverytotheultimatepurchaserorwhileitisinuse,or(2)theuseofthe vehicleaftersuchdeviceorelementofdesignhasbeenremovedorrenderedinoperativeby anyperson.

Amongthoseactspresumedtoconstitutetamperingaretheactslistedbelow:

* Replacementoftheoriginalexhaustsystemormufflerwithacomponentnotincompliance withFederalregulations.

* Removalofthemuffler(s)oranyinternalportionofthemuffler(s).

* Removaloftheairboxorairboxcover.

* Modificationstothemuffler(s)orairintakesystembycutting,drilling,orothermeansifsuch modificationsresultinincreasednoiselevels.

Foreword

Thismanualisdesignedprimarilyforuseby trainedmechanicsinaproperlyequippedshop. However,itcontainsenoughdetailandbasicinformationtomakeitusefultotheownerwhodesirestoperformhisownbasicmaintenanceand repairwork.Abasicknowledgeofmechanics, theproperuseoftools,andworkshopproceduresmustbeunderstoodinordertocarryout maintenanceandrepairsatisfactorily.Whenevertheownerhasinsufficientexperienceor doubtshisabilitytodothework,alladjustments,maintenance,andrepairshouldbecarriedoutonlybyqualifiedmechanics.

Inordertoperformtheworkefficientlyand toavoidcostlymistakes,readthetext,thoroughlyfamiliarizeyourselfwiththeprocedures beforestartingwork,andthendotheworkcarefullyinacleanarea.Wheneverspecialtoolsor equipmentarespecified,donotusemakeshift toolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsare used,andtheuseofsubstitutetoolsmayadverselyaffectsafeoperation.

Forthedurationofthewarrantyperiod, werecommendthatallrepairsandscheduled maintenancebeperformedinaccordancewith thisservicemanual.Anyownermaintenanceor repairprocedurenotperformedinaccordance withthismanualmayvoidthewarranty.

Togetthelongestlifeoutofyourvehicle:

• FollowthePeriodicMaintenanceChartinthe ServiceManual.

• Bealertforproblemsandnon-scheduled maintenance.

• UsepropertoolsandgenuineKawasakiVehicleparts.Specialtools,gauges,andtesters thatarenecessarywhenservicingKawasaki vehiclesareintroducedbytheServiceManual.Genuinepartsprovidedasspareparts arelistedinthePartsCatalog.

• Followtheproceduresinthismanualcarefully.Don’ttakeshortcuts.

• Remembertokeepcompleterecordsofmaintenanceandrepairwithdatesandanynew partsinstalled.

HowtoUseThisManual

Inthismanual,theproductisdividedinto itsmajorsystemsandthesesystemsmakeup themanual’schapters.TheQuickReference

Guideshowsyoualloftheproduct’ssystem andassistsinlocatingtheirchapters.Each chapterinturnhasitsowncomprehensiveTableofContents.

Forexample,ifyouwantignitioncoilinformation,usetheQuickReferenceGuidetolocate theElectricalSystemchapter.Then,usethe TableofContentsonthefirstpageofthechaptertofindtheIgnitionCoilsection.

Wheneveryouseesymbols,heedtheirinstructions!Alwaysfollowsafeoperatingand maintenancepractices.

DANGER

DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultin deathorseriousinjury.

WARNING

WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresult indeathorseriousinjury. NOTICE NOTICEisusedtoaddresspracticesnot

Thismanualcontainsfourmoresymbols whichwillhelpyoudistinguishdifferenttypes ofinformation.

NOTE

○Thisnotesymbolindicatespointsofparticularinterestformoreefficientandconvenientoperation.

• Indicatesaproceduralsteporworktobe done.

○Indicatesaproceduralsub-steporhowtodo theworkoftheproceduralstepitfollows.It alsoprecedesthetextofaNOTE.

Indicatesaconditionalsteporwhatactionto takebasedontheresultsofthetestorinspectionintheproceduralsteporsub-stepitfollows.

Inmostchaptersanexplodedviewillustration ofthesystemcomponentsfollowstheTableof Contents.Intheseillustrationsyouwillfindthe instructionsindicatingwhichpartsrequirespecifiedtighteningtorque,oil,greaseoralocking agentduringassembly.

1-2GENERALINFORMATION

BeforeServicing

Beforestartingtoperformaninspectionserviceorcarryoutadisassemblyandreassemblyoperationonavehicle,readtheprecautionsgivenbelow.Tofacilitateactualoperations,notes,illustrations,photographs,cautions,anddetaileddescriptionshavebeenincludedineachchapterwherever necessary.Thissectionexplainstheitemsthatrequireparticularattentionduringtheremovaland reinstallationordisassemblyandreassemblyofgeneralparts.

Especiallynotethefollowing:

BatteryGround

Beforecompletinganyserviceonthevehicle,disconnect thebatterywiresfromthebatterytopreventtheenginefrom accidentallyturningover.Disconnectthegroundcable(–) firstandthenthepositive(+).Whencompletedwiththe service,firstconnectthepositive(+)cabletothepositive (+)terminalofthebatterythenthenegative(–)cabletothe negativeterminal.

EdgesofParts

Liftlargeorheavypartswearingglovestopreventinjury frompossiblesharpedgesontheparts.

Solvent

Useahighflash-pointsolventwhencleaningparts.High flash-pointsolventshouldbeusedaccordingtodirections ofthesolventmanufacturer.

Cleaningvehiclebeforedisassembly

Cleanthevehiclethoroughlybeforedisassembly.Dirtor otherforeignmaterialsenteringintosealedareasduringvehicledisassemblycancauseexcessivewearanddecrease performanceofthevehicle.

BeforeServicing

ArrangementandCleaningofRemovedParts

Disassembledpartsareeasytoconfuse.Arrangethe partsaccordingtotheorderthepartsweredisassembled andcleanthepartsinorderpriortoassembly.

StorageofRemovedParts

Afterallthepartsincludingsubassemblypartshavebeen cleaned,storethepartsinacleanarea.Putacleancloth orplasticsheetoverthepartstoprotectfromanyforeign materialsthatmaycollectbeforere-assembly.

Inspection

Reuseofwornordamagedpartsmayleadtoseriousaccident.Visuallyinspectremovedpartsforcorrosion,discoloration,orotherdamage.Refertotheappropriatesections ofthismanualforservicelimitsonindividualparts.Replace thepartsifanydamagehasbeenfoundorifthepartisbeyonditsservicelimit.

ReplacementParts

ReplacementPartsmustbeKAWASAKIgenuineor recommendedbyKAWASAKI.Gaskets,O-rings,Oilseals, Greaseseals,circlipsorcotterpinsmustbereplacedwith newoneswheneverdisassembled.

AssemblyOrder

Inmostcasesassemblyorderisthereverseofdisassembly,however,ifassemblyorderisprovidedinthisService Manual,followtheproceduresgiven.

1-4GENERALINFORMATION

BeforeServicing

TighteningSequence

Generally,wheninstallingapartwithseveralbolts,nuts, orscrews,startthemallintheirholesandtightenthemto asnugfit.Thentightenthemaccordingtothespecifiedsequencetopreventcasewarpageordeformationwhichcan leadtomalfunction.Converselywhenlooseningthebolts, nuts,orscrews,firstloosenallofthembyaboutaquarterturnandthenremovethem.Ifthespecifiedtightening sequenceisnotindicated,tightenthefastenersalternating diagonally.

TighteningTorque

Incorrecttorqueappliedtoabolt,nut,orscrewmay leadtoseriousdamage.Tightenfastenerstothespecified torqueusingagoodqualitytorquewrench.

Often,thetighteningsequenceisfollowedtwiceinitial tighteningandfinaltighteningwithtorquewrench.

Force

Usecommonsenseduringdisassemblyandassembly, excessiveforcecancauseexpensiveorhardtorepairdamage.Whennecessary,removescrewsthathaveanon -permanentlockingagentappliedusinganimpactdriver. Useaplastic-facedmalletwhenevertappingisnecessary.

Gasket,O-ring

Hardening,shrinkage,ordamageofbothgaskets andO-ringsafterdisassemblycanreducesealingperformance.Removeoldgasketsandcleanthesealing surfacesthoroughlysothatnogasketmaterialorother materialremains.Installnewgasketsandreplaceused O-ringswhenre-assembling.

LiquidGasket,LockingAgent

ForapplicationsthatrequireLiquidGasketora Non-PermanentLockingAgent,cleanthesurfacesso thatnooilresidueremainsbeforeapplyingliquidgasketor non-permanentlockingagent.Donotapplythemexcessively.Excessiveapplicationcanclogoilpassagesand causeseriousdamage.

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BeforeServicing

Press

Foritemssuchasbearingsoroilsealsthatmustbe pressedintoplace,applysmallamountofoiltothecontactarea.Besuretomaintainproperalignmentanduse smoothmovementswheninstalling.

BallBearingandNeedleBearing

Donotremovepressedballorneedleunlessremovalis absolutelynecessary.Replacewithnewoneswhenever removed.Pressbearingswiththemanufacturerandsize marksfacingout.Pressthebearingintoplacebyputting pressureonthecorrectbearingraceasshown.

Pressingtheincorrectracecancausepressurebetween theinnerandouterraceandresultinbearingdamage.

OilSeal,GreaseSeal

Donotremovepressedoilorgreasesealsunlessremoval isnecessary.Replacewithnewoneswheneverremoved. Pressnewoilsealswithmanufactureandsizemarksfacing out.Makesurethesealisalignedproperlywheninstalling.

Applyspecifiedgreasetothelipofsealbeforeinstalling theseal.

Circlips,CotterPins

Replacecirclipsorcotterpinsthatwereremovedwithnew ones.Takecarenottoopentheclipexcessivelywheninstallingtopreventdeformation.

1-6GENERALINFORMATION

BeforeServicing

Lubrication

Itisimportanttolubricaterotatingorslidingpartsduring assemblytominimizewearduringinitialoperation.Lubricationpointsarecalledoutthroughoutthismanual,apply thespecificoilorgreaseasspecified.

DirectionofEngineRotation

Whenrotatingthecrankshaftbyhand,thefreeplay amountofrotatingdirectionwillaffecttheadjustment.Rotatethecrankshafttopositivedirection(clockwiseviewed fromoutputside).

ElectricalWires

Atwo-colorwireisidentifiedfirstbytheprimarycolorand thenthestripecolor.Unlessinstructedotherwise,electrical wiresmustbeconnectedtothoseofthesamecolor.

Instrument

Useameterthathasenoughaccuracyforanaccurate measurement.Readthemanufacture’sinstructionsthoroughlybeforeusingthemeter.Incorrectvaluesmaylead toimproperadjustments.

ModelIdentification

KVF650-D1LeftSideView

KVF650-D1RightSideView

TheKVF650-E1isacamouflage-surface-treatedmodelandidenticaltotheKVF650-D1,thebase model,ineveryotheraspect:controls,features,andspecifications.

1-8GENERALINFORMATION

GeneralSpecifications

Items KVF650-D1,E1 KVF650D6 DD,E6 E9

Dimensions

OverallLength 2185mm(86.02in.)

OverallWidth 1209mm(47.60in.) (KVF650D6 ∼ DB/E6 ∼E9) 1212mm(47.72in.)

(KVF650DC ∼) 1210mm(47.63in.)

OverallHeight 1166mm(45.91in.) (KVF650D6 DB/E6 E9) 1164mm(45.83in.)

(KVF650DC ) 1165mm(45.87in.)

Wheelbase (KVF650D6 ∼ DB/E6 ∼E9)1294mm(50.94in.)

(KVF650DC )1295mm(50.98in.)

GroundClearance: 192mm(7.56in.) 185mm(7.28in.)

SeatHeight 864mm(34.02in.) 862mm(33.94in.)

DryMass (KVF650-D1/D6 D8(US,CA,AU)/E1 E8)273kg(602lb)

(KVF650D6 ∼ D8(EUR))273.5kg(603lb)

CurbMass: (KVF650D9 DD(US,CA,AU)/E9)293kg(646lb)

(KVF650D9 DB(EUR))294kg(648lb)

Front 152kg(335lb) 154kg(339.6lb) (KVF650D6 D8(EUR))154.2kg(340lb) (KVF650D9 DB(EUR))155kg(342lb)

Rear 141kg(311lb) 139kg(306lb)

(KVF650D6 D8(EUR))139.3kg(307lb)

MaximumHorsepower

MaximumTorque

30.9kW(42.0PS)@6500r/min(rpm),(US,CA)–

52.1N·m(5.3kgf·m,38.0ft·lb)@4000r/min(rpm),(US,CA)–

CarburetionSystem Carburetor,KeihinCVKR-D32

StartingSystem

ElectricStarter&RecoilStarter(KVF650-D1 D9/E1 E9)

ElectricStarter(KVF650DA ∼ DD)

IgnitionSystem DigitalDC-CDI

TimingAdvance Electronicallyadvanced

IgnitionTiming

From5°BTDC@1100r/min(rpm)to28°BTDC@5000r/min(rpm)

SparkPlug NGKCR7E

GeneralSpecifications