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Table of Contents
- 2. Quick Reference Guide
- 4. List of abbreviations
- 7. Foreword
- 8. General Information
- 9. Before Servicing
- 10. Arrangement and Cleaning of Removed Part...
- 11. Tightening Sequence/Torque
- 12. Press
- 13. Lubrication
- 14. Model Identification
- 15. General Specifications
- 18. Unit Conversion Table
- 19. Periodic Maintenance
- 21. Periodic Maintenance Chart
- 23. Torque and Locking Agent
- 28. Basic Torque for General Fasteners of En...
- 29. Specifications
- 31. Special Tools
- 32. Periodic Maintenance Procedures
- 33. Choke Lever Free Play Adjustment
- 34. Idle Speed Adjustment
- 35. Air Cleaner Element Cleaning and Inspect...
- 36. Fuel Hose and Connection Inspection
- 37. Radiator Cleaning
- 40. Engine top end
- 41. Valve Clearance Adjustment
- 42. Drive Belt Inspection
- 43. Drive Belt Deflection Inspection
- 44. Drive Belt Deflection Adjustment
- 45. Engine Oil Change
- 46. Tire Inspection
- 47. Front Final Gear Case Oil Change
- 48. Rear Final Gear Case Oil Change
- 49. Front Brake Hose Replacement
- 50. Brake Fluid Change
- 51. Rear Brake Plates Replacement
- 52. Steering Inspection
- 53. Brake Light Switch Inspection
- 55. Joint Boots Inspection
- 56. General Lubrication
- 57. Bolts and Nuts Tightening
- 58. Fuel System
- 59. Exploded View
- 65. Throttle Lever Free Play Inspection
- 66. Throttle Cable Installation
- 67. Choke Lever and Cable Removal
- 68. Choke Cable Lubrication and Inspection
- 69. Carburetor
- 70. Service Fuel Level Adjustment
- 71. Carburetor Synchronization Inspection
- 72. Carburetor Synchronization Adjustment
- 73. Carburetor Installation
- 75. Carburetor Assembly
- 76. Carburetor Separation
- 77. Carburetor Cleaning
- 80. Air Cleaner Element Removal
- 81. Air Cleaner Housing Installation
- 83. Fuel Tank Removal
- 84. Fuel Tank Cleaning
- 85. Fuel Tap Inspection
- 86. Fuel Pump Removal
- 87. Fuel Pump Installation
- 88. Cooling System
- 91. Coolant Flow Chart
- 94. Special Tools & Sealant
- 95. Coolant Deterioration Inspection
- 96. Pressure Testing
- 97. Water Pump Cover Removal
- 98. Water Pump Impeller Inspection
- 99. Water Pump
- 100. Radiator Removal
- 101. Radiator Installation
- 102. Radiator Fan Installation
- 103. Radiator Cap Inspection
- 104. Thermostat Removal
- 106. Radiator Fan Switch Removal
- 107. Coolant Temperature Warning Light Switch...
- 108. Coolant Filter Cleaning
- 109. Engine Top End
- 120. Camshaft Chain Tensioner Removal
- 121. Rocker Case Removal
- 122. Rocker Case Installation
- 123. Rocker Arm Removal
- 124. Rocker Arm Inspection
- 125. Camshaft Removal
- 126. Camshaft Assembly
- 127. Camshaft Bearing Wear
- 128. KACR Inspection
- 129. KACR Installation
- 130. Camshaft Chain Installation
- 131. Front Camshaft Chain
- 133. Camshaft Chain Guide Wear
- 134. Cylinder Compression Measurement
- 135. Cylinder Head Removal
- 136. Cylinder Head Warp
- 137. Valve Removal
- 138. Valve Guide Installation
- 139. Valve Seat Inspection
- 140. Valve Seat Repair (Valve Lapping)
- 141. Marks Stamped on the Cutter
- 144. Valve Seat Repair
- 145. Cylinder Removal
- 147. Cylinder Wear
- 148. Cylinder Boring and Honing
- 149. Piston Ring Groove Width
- 150. Exhaust System
- 151. Muffler and Exhaust Pipe Installation
- 152. Converter System
- 160. Torque Converter Cover Removal
- 161. Torque Converter Cover Installation
- 162. Torque Converter Cover Assembly
- 163. Actuator Lever Assemblies
- 164. Drive Belt Removal
- 165. Drive Pulley Removal
- 167. Drive Pulley Inspection
- 168. Spider Shoe Side Clearance Adjustment
- 169. Drive Pulley Assembly
- 170. Drive Pulley Installation
- 172. Measurement Length
- 173. Driven Pulley Removal
- 174. Driven Pulley Inspection
- 175. Driven Pulley Assembly
- 177. Driven Pulley Installation
- 179. High Altitude Setting Information
- 180. Recoil Starter
- 183. Engine Lubrication System
- 188. Engine Oil Flow Chart
- 189. Engine Oil and Oil Filter
- 190. Oil Screen Cleaning
- 191. Oil Pressure Relief Valve Removal
- 192. Oil Pump Removal
- 194. Oil Pipe Removal
- 195. Engine Removal/Installation
- 198. Engine Removal
- 199. Engine Installation
- 200. Crankshaft/Transmission
- 208. Crankcase Disassembly
- 209. Crankcase Assembly
- 212. Crankshaft Removal
- 213. Crankshaft/Connecting Rod Cleaning
- 214. Connecting Rod Big End Side Clearance
- 215. Big End Bearing Insert Selection
- 216. Crankshaft Runout
- 217. Transmission
- 218. Shift Lever Installation
- 222. Transmission Removal
- 225. Shift Fork Bending
- 227. Ball and Needle Bearing Replacement
- 228. Wheels/Tires
- 233. Wheel Alignment
- 234. Toe-in Inspection
- 235. Wheel Removal
- 236. Wheel (Rim) Replacement
- 237. Tire Removal
- 239. Front Hub Removal
- 240. Front Hub Disassembly/Assembly
- 241. Rear Hub Removal
- 242. Final Drive
- 254. Output Drive Bevel Gear Removal
- 255. Output Drive Bevel Gear Disassembly
- 257. Output Drive Bevel Gear Assembly
- 258. Output Driven Bevel Gear Installation
- 259. Output Driven Bevel Gear Assembly
- 260. Output Bevel Gears Adjustment
- 261. Output Bevel Gear (Backlash-related Part...
- 262. Drive Bevel Gear Shims for Tooth Contact...
- 263. Tooth Contact Adjustment
- 265. Bevel Gears Inspection
- 266. Front Propeller Shaft Removal
- 267. Front Axle Removal
- 268. Front Axle Joint Boot Replacement
- 269. Outboard Joint Boot Replacement
- 270. Inboard Joint Boot Assembly
- 274. Front Final Gear Case Oil Level Inspecti...
- 275. Variable Differential Control Cable Inst...
- 276. Front Final Gear Case Installation
- 278. Front Final Gear Case Coupling Inspectio...
- 284. Oil Seal Installation
- 285. Ring Gear Disassembly
- 286. LSD Clutch Torque Inspection
- 287. Pinion Gear Unit Assembly
- 288. Front Final Gear Case (Backlash-related ...
- 289. Pinion Gear Shims for Backlash Adjustmen...
- 291. Bevel Gear Inspection
- 292. Correct Tooth Contact Pattern: No adjust...
- 293. Rear Propeller Shaft Removal
- 294. Rear Axle Removal
- 295. Rear Axle Runout Inspection
- 296. Rear Final Gear Case Oil Level Inspectio...
- 297. Rear Final Gear Case Disassembly
- 298. Rear Final Gear Case Assembly
- 299. Rear Final Bevel Gear Adjustment
- 300. Rear Final Gear Case (Backlash-related P...
- 301. Pinion Gear Shims for Tooth Contact Adju...
- 304. Bearing and Oil Seal
- 306. Brakes
- 313. Brake Fluid Recommendation
- 314. Brake Line Air Bleeding
- 315. Master Cylinder Removal
- 316. Master Cylinder Assembly
- 317. Caliper Removal
- 318. Caliper Disassembly
- 319. Dust Seal and Friction Boot Damage
- 320. Brake Pad Removal
- 321. Brake Discs
- 322. Brake Hose Inspection
- 323. Brake Pedal Position Inspection/Adjustme...
- 324. Brake Cable Removal
- 325. Brake Cable Installation
- 326. Internal Wet Brake Disassembly
- 327. Internal Wet Brake Assembly
- 329. Suspension
- 334. Front Shock Absorber Removal
- 335. Front Shock Absorber Inspection
- 337. Rear Shock Absorber Removal
- 338. Spring Action
- 340. Rear Shock Absorber Inspection
- 341. Suspension Arm Removal
- 343. Swingarm Removal
- 344. Swingarm Disassembly
- 345. Swingarm Assembly
- 346. Swingarm Bearing Lubrication
- 347. Steering
- 353. Steering Knuckle Removal
- 354. Steering Knuckle Installation
- 355. Tie-Rod End Removal
- 356. Steering Maintenance
- 357. Steering Stem Bearing Inspection
- 358. Handlebar Removal
- 360. Frame
- 367. Seat Removal
- 368. Front Carrier Removal
- 369. Rear Carrier Installation
- 370. Front Fender Removal
- 371. Front Fender Installation
- 373. Inner Cover Front and Front Lower Shroud...
- 374. Air Cleaner Upper Cover Installation
- 375. Left Side Cover Removal
- 376. Front Guard Removal
- 377. Engine Bottom Guard Removal
- 378. Front Flap Removal
- 379. Rear Flap Installation
- 380. Footboard Installation
- 381. Trailer Hitch Bracket Removal
- 382. Electrical System
- 384. Parts Location
- 396. Precautions
- 399. Battery Installation
- 401. Initial Charge
- 402. Interchange
- 403. Refreshing Charge
- 404. Charging System
- 405. Alternator Cover Installation
- 406. Alternator Rotor Removal
- 407. Alternator Stator Removal
- 408. Alternator Inspection
- 409. Regulator/Rectifier Inspection
- 411. Charging System Circuit
- 412. Ignition System
- 413. Ignition Coil Removal
- 414. Ignition Coil Inspection
- 415. Ignition Coil Primary Peak Voltage Inspe...
- 416. Crankshaft Sensor Installation
- 417. Alternator Rotor Inspection
- 418. Vehicle-down Sensor Removal
- 419. Vehicle-down Sensor Inspection
- 421. Ignition System Troubleshooting
- 422. Ignition System Circuit
- 423. Electric Starter System
- 424. Starter Motor Disassembly
- 425. Starter Motor Assembly
- 426. Commutator Cleaning/Inspection
- 427. Starter Motor Brush Length
- 428. Starter Circuit Relay Inspection
- 429. Electric Starter Circuit
- 430. Starter Motor Clutch Installation
- 431. Lighting System
- 433. Taillight Bulb Replacement
- 435. Lighting System Circuit
- 436. Radiator Fan Circuit Inspection
- 437. Radiator Fan System
- 438. Fuel Pump Inspection
- 439. Fuel Level Sensor Inspection
- 440. Fuel Pump/Fuel/Level Sensor Circuit
- 441. Multifunction Meter Unit Removal
- 442. Multifunction Meter Unit Inspection
- 443. Speedometer Check
- 444. Trip Meter A/B Check
- 445. Coolant Temperature Warning Symbol Check
- 446. Neutral Indicator Light Check
- 447. Belt Check Indicator Light check
- 450. Meter Circuit
- 451. Actuator Control System
- 452. Engine Brake Actuator Installation
- 453. Actuator Control System Outline
- 454. Failure Indication Pattern and Failure P...
- 455. 2WD/4WD Actuator Inspection
- 456. Controller Power Supply Inspection
- 457. 2WD/4WD Shift Switch Inspection
- 460. Forward/Reverse Detecting Sensor Inspect...
- 461. Actuator Control System Circuit
- 462. Drive Belt Failure Detection System Circ...
- 463. Brake Light Switch Adjustment
- 464. Switch Inspection
- 465. Neutral Switch Connection
- 466. 30 A Main Fuse Removal
- 467. Wiring Diagram
- 469. Appendix
- 470. Troubleshooting Guide
- 475. Cable, Wire, and Hose Routing
- 493. Model application
Page 1 of 493
Table of Contents
- 2. Quick Reference Guide
- 4. List of abbreviations
- 7. Foreword
- 8. General Information
- 9. Before Servicing
- 10. Arrangement and Cleaning of Removed Part...
- 11. Tightening Sequence/Torque
- 12. Press
- 13. Lubrication
- 14. Model Identification
- 15. General Specifications
- 18. Unit Conversion Table
- 19. Periodic Maintenance
- 21. Periodic Maintenance Chart
- 23. Torque and Locking Agent
- 28. Basic Torque for General Fasteners of En...
- 29. Specifications
- 31. Special Tools
- 32. Periodic Maintenance Procedures
- 33. Choke Lever Free Play Adjustment
- 34. Idle Speed Adjustment
- 35. Air Cleaner Element Cleaning and Inspect...
- 36. Fuel Hose and Connection Inspection
- 37. Radiator Cleaning
- 40. Engine top end
- 41. Valve Clearance Adjustment
- 42. Drive Belt Inspection
- 43. Drive Belt Deflection Inspection
- 44. Drive Belt Deflection Adjustment
- 45. Engine Oil Change
- 46. Tire Inspection
- 47. Front Final Gear Case Oil Change
- 48. Rear Final Gear Case Oil Change
- 49. Front Brake Hose Replacement
- 50. Brake Fluid Change
- 51. Rear Brake Plates Replacement
- 52. Steering Inspection
- 53. Brake Light Switch Inspection
- 55. Joint Boots Inspection
- 56. General Lubrication
- 57. Bolts and Nuts Tightening
- 58. Fuel System
- 59. Exploded View
- 65. Throttle Lever Free Play Inspection
- 66. Throttle Cable Installation
- 67. Choke Lever and Cable Removal
- 68. Choke Cable Lubrication and Inspection
- 69. Carburetor
- 70. Service Fuel Level Adjustment
- 71. Carburetor Synchronization Inspection
- 72. Carburetor Synchronization Adjustment
- 73. Carburetor Installation
- 75. Carburetor Assembly
- 76. Carburetor Separation
- 77. Carburetor Cleaning
- 80. Air Cleaner Element Removal
- 81. Air Cleaner Housing Installation
- 83. Fuel Tank Removal
- 84. Fuel Tank Cleaning
- 85. Fuel Tap Inspection
- 86. Fuel Pump Removal
- 87. Fuel Pump Installation
- 88. Cooling System
- 91. Coolant Flow Chart
- 94. Special Tools & Sealant
- 95. Coolant Deterioration Inspection
- 96. Pressure Testing
- 97. Water Pump Cover Removal
- 98. Water Pump Impeller Inspection
- 99. Water Pump
- 100. Radiator Removal
- 101. Radiator Installation
- 102. Radiator Fan Installation
- 103. Radiator Cap Inspection
- 104. Thermostat Removal
- 106. Radiator Fan Switch Removal
- 107. Coolant Temperature Warning Light Switch...
- 108. Coolant Filter Cleaning
- 109. Engine Top End
- 120. Camshaft Chain Tensioner Removal
- 121. Rocker Case Removal
- 122. Rocker Case Installation
- 123. Rocker Arm Removal
- 124. Rocker Arm Inspection
- 125. Camshaft Removal
- 126. Camshaft Assembly
- 127. Camshaft Bearing Wear
- 128. KACR Inspection
- 129. KACR Installation
- 130. Camshaft Chain Installation
- 131. Front Camshaft Chain
- 133. Camshaft Chain Guide Wear
- 134. Cylinder Compression Measurement
- 135. Cylinder Head Removal
- 136. Cylinder Head Warp
- 137. Valve Removal
- 138. Valve Guide Installation
- 139. Valve Seat Inspection
- 140. Valve Seat Repair (Valve Lapping)
- 141. Marks Stamped on the Cutter
- 144. Valve Seat Repair
- 145. Cylinder Removal
- 147. Cylinder Wear
- 148. Cylinder Boring and Honing
- 149. Piston Ring Groove Width
- 150. Exhaust System
- 151. Muffler and Exhaust Pipe Installation
- 152. Converter System
- 160. Torque Converter Cover Removal
- 161. Torque Converter Cover Installation
- 162. Torque Converter Cover Assembly
- 163. Actuator Lever Assemblies
- 164. Drive Belt Removal
- 165. Drive Pulley Removal
- 167. Drive Pulley Inspection
- 168. Spider Shoe Side Clearance Adjustment
- 169. Drive Pulley Assembly
- 170. Drive Pulley Installation
- 172. Measurement Length
- 173. Driven Pulley Removal
- 174. Driven Pulley Inspection
- 175. Driven Pulley Assembly
- 177. Driven Pulley Installation
- 179. High Altitude Setting Information
- 180. Recoil Starter
- 183. Engine Lubrication System
- 188. Engine Oil Flow Chart
- 189. Engine Oil and Oil Filter
- 190. Oil Screen Cleaning
- 191. Oil Pressure Relief Valve Removal
- 192. Oil Pump Removal
- 194. Oil Pipe Removal
- 195. Engine Removal/Installation
- 198. Engine Removal
- 199. Engine Installation
- 200. Crankshaft/Transmission
- 208. Crankcase Disassembly
- 209. Crankcase Assembly
- 212. Crankshaft Removal
- 213. Crankshaft/Connecting Rod Cleaning
- 214. Connecting Rod Big End Side Clearance
- 215. Big End Bearing Insert Selection
- 216. Crankshaft Runout
- 217. Transmission
- 218. Shift Lever Installation
- 222. Transmission Removal
- 225. Shift Fork Bending
- 227. Ball and Needle Bearing Replacement
- 228. Wheels/Tires
- 233. Wheel Alignment
- 234. Toe-in Inspection
- 235. Wheel Removal
- 236. Wheel (Rim) Replacement
- 237. Tire Removal
- 239. Front Hub Removal
- 240. Front Hub Disassembly/Assembly
- 241. Rear Hub Removal
- 242. Final Drive
- 254. Output Drive Bevel Gear Removal
- 255. Output Drive Bevel Gear Disassembly
- 257. Output Drive Bevel Gear Assembly
- 258. Output Driven Bevel Gear Installation
- 259. Output Driven Bevel Gear Assembly
- 260. Output Bevel Gears Adjustment
- 261. Output Bevel Gear (Backlash-related Part...
- 262. Drive Bevel Gear Shims for Tooth Contact...
- 263. Tooth Contact Adjustment
- 265. Bevel Gears Inspection
- 266. Front Propeller Shaft Removal
- 267. Front Axle Removal
- 268. Front Axle Joint Boot Replacement
- 269. Outboard Joint Boot Replacement
- 270. Inboard Joint Boot Assembly
- 274. Front Final Gear Case Oil Level Inspecti...
- 275. Variable Differential Control Cable Inst...
- 276. Front Final Gear Case Installation
- 278. Front Final Gear Case Coupling Inspectio...
- 284. Oil Seal Installation
- 285. Ring Gear Disassembly
- 286. LSD Clutch Torque Inspection
- 287. Pinion Gear Unit Assembly
- 288. Front Final Gear Case (Backlash-related ...
- 289. Pinion Gear Shims for Backlash Adjustmen...
- 291. Bevel Gear Inspection
- 292. Correct Tooth Contact Pattern: No adjust...
- 293. Rear Propeller Shaft Removal
- 294. Rear Axle Removal
- 295. Rear Axle Runout Inspection
- 296. Rear Final Gear Case Oil Level Inspectio...
- 297. Rear Final Gear Case Disassembly
- 298. Rear Final Gear Case Assembly
- 299. Rear Final Bevel Gear Adjustment
- 300. Rear Final Gear Case (Backlash-related P...
- 301. Pinion Gear Shims for Tooth Contact Adju...
- 304. Bearing and Oil Seal
- 306. Brakes
- 313. Brake Fluid Recommendation
- 314. Brake Line Air Bleeding
- 315. Master Cylinder Removal
- 316. Master Cylinder Assembly
- 317. Caliper Removal
- 318. Caliper Disassembly
- 319. Dust Seal and Friction Boot Damage
- 320. Brake Pad Removal
- 321. Brake Discs
- 322. Brake Hose Inspection
- 323. Brake Pedal Position Inspection/Adjustme...
- 324. Brake Cable Removal
- 325. Brake Cable Installation
- 326. Internal Wet Brake Disassembly
- 327. Internal Wet Brake Assembly
- 329. Suspension
- 334. Front Shock Absorber Removal
- 335. Front Shock Absorber Inspection
- 337. Rear Shock Absorber Removal
- 338. Spring Action
- 340. Rear Shock Absorber Inspection
- 341. Suspension Arm Removal
- 343. Swingarm Removal
- 344. Swingarm Disassembly
- 345. Swingarm Assembly
- 346. Swingarm Bearing Lubrication
- 347. Steering
- 353. Steering Knuckle Removal
- 354. Steering Knuckle Installation
- 355. Tie-Rod End Removal
- 356. Steering Maintenance
- 357. Steering Stem Bearing Inspection
- 358. Handlebar Removal
- 360. Frame
- 367. Seat Removal
- 368. Front Carrier Removal
- 369. Rear Carrier Installation
- 370. Front Fender Removal
- 371. Front Fender Installation
- 373. Inner Cover Front and Front Lower Shroud...
- 374. Air Cleaner Upper Cover Installation
- 375. Left Side Cover Removal
- 376. Front Guard Removal
- 377. Engine Bottom Guard Removal
- 378. Front Flap Removal
- 379. Rear Flap Installation
- 380. Footboard Installation
- 381. Trailer Hitch Bracket Removal
- 382. Electrical System
- 384. Parts Location
- 396. Precautions
- 399. Battery Installation
- 401. Initial Charge
- 402. Interchange
- 403. Refreshing Charge
- 404. Charging System
- 405. Alternator Cover Installation
- 406. Alternator Rotor Removal
- 407. Alternator Stator Removal
- 408. Alternator Inspection
- 409. Regulator/Rectifier Inspection
- 411. Charging System Circuit
- 412. Ignition System
- 413. Ignition Coil Removal
- 414. Ignition Coil Inspection
- 415. Ignition Coil Primary Peak Voltage Inspe...
- 416. Crankshaft Sensor Installation
- 417. Alternator Rotor Inspection
- 418. Vehicle-down Sensor Removal
- 419. Vehicle-down Sensor Inspection
- 421. Ignition System Troubleshooting
- 422. Ignition System Circuit
- 423. Electric Starter System
- 424. Starter Motor Disassembly
- 425. Starter Motor Assembly
- 426. Commutator Cleaning/Inspection
- 427. Starter Motor Brush Length
- 428. Starter Circuit Relay Inspection
- 429. Electric Starter Circuit
- 430. Starter Motor Clutch Installation
- 431. Lighting System
- 433. Taillight Bulb Replacement
- 435. Lighting System Circuit
- 436. Radiator Fan Circuit Inspection
- 437. Radiator Fan System
- 438. Fuel Pump Inspection
- 439. Fuel Level Sensor Inspection
- 440. Fuel Pump/Fuel/Level Sensor Circuit
- 441. Multifunction Meter Unit Removal
- 442. Multifunction Meter Unit Inspection
- 443. Speedometer Check
- 444. Trip Meter A/B Check
- 445. Coolant Temperature Warning Symbol Check
- 446. Neutral Indicator Light Check
- 447. Belt Check Indicator Light check
- 450. Meter Circuit
- 451. Actuator Control System
- 452. Engine Brake Actuator Installation
- 453. Actuator Control System Outline
- 454. Failure Indication Pattern and Failure P...
- 455. 2WD/4WD Actuator Inspection
- 456. Controller Power Supply Inspection
- 457. 2WD/4WD Shift Switch Inspection
- 460. Forward/Reverse Detecting Sensor Inspect...
- 461. Actuator Control System Circuit
- 462. Drive Belt Failure Detection System Circ...
- 463. Brake Light Switch Adjustment
- 464. Switch Inspection
- 465. Neutral Switch Connection
- 466. 30 A Main Fuse Removal
- 467. Wiring Diagram
- 469. Appendix
- 470. Troubleshooting Guide
- 475. Cable, Wire, and Hose Routing
- 493. Model application
Also for: KVF 650 4x4
File size: 63.55 MB
Created: March 07, 2023
Last updated: March 25, 2023
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