Factory Service Repair Manual For Kawasaki KVF 650A1 KVF 650A2 KVF 650B1 KVF 650B2. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Format: PDF
Language: English
Pages: 523
Bookmarks: Yes
Searchable: No
Wiring Diagrams: Yes
Hydraulic Diagrams: No

Model

Kawasaki ATV PRARIE 650, KVF 650, PRARIE 650 4X4, KVF 650 4X4
KVF650A1
KVF650A2
KVF650B1
KVF650B2

Contents

– General Information
Before Servicing
Model Identification
General Specifications
Periodic Maintenance Chart
Technical Information
Torque And Locking Agent
Special Tools And Sealant
Cable Wire And Hose Routing
– Fuel System
Throttle Lever And Cable
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Throttle Case Removal Disassembly
Throttle Case Assembly/Installation
Throttle Cable Installation
Throttle Case Inspection
Throttle Cable Lubrication
Throttle Cable Inspection
Choke Lever And Cable
Choke Lever Free Play Check
Choke Lever Free Play Adjustment
Choke Lever And Cable Removal Choke Lever And Cable Installation
Choke Cable Lubrication
Choke Cable Inspection
Carburetor
Idling Speed Inspection
Idle Speed Adjustment
Pilot Screw Adjustment
Service Fuel Level Inspection
Service Fuel Level Adjustment
Carburetor Synchronization Inspection
Carburetor Synchronization Adjustment
Fuel System Cleanliness Inspection
– Cooling System
Coolant
Coolant Deterlnratlnn Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Water Pimp
Water Pump Cover Removal
Water Pump Cover Lasts Nation
Impellor Removal
Water Pump Impeller Installation
Water Pump Impeller Inspection
Water Pump Leakage Inspection
Mechanical Seal Replacement
Radiator
Radiator Removal
Radiator Fan Removal
Radiator Fan Installation
Radiator Inspection
Radiator Cleaning
Radiator Cap Inspection
Thermostat
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Radiator Fan Switch
Radiator Fan Switch Removal
Radiator Fan Switch Installation
Radiator Fan Switch Inspection
Coolant Temperature Warning Light Switch
Coolant Temperature Warning Light Switch Removal
Coolant Temperature Warning Light Switch Installation
Coolant Temperature Warning Light Switch Inspection
Coolant Filter/Valve
Coolant Filter Cleaning
Coolant Valve Inspection
– Engine Top End
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Rocker Case
Rocker Case Removal
Rocker Case Installation
Rocker Arn Removal
Rocker Arm Installation
Rocker Arm Inspection
Rocker Shaft Diameter Measurement
Camshaft
Camshaft Removal
Camshaft Installation
Camshaft Assembly
Cam Wear
Camshaft Bearing Wear
Kacr Inspection
Kacr Removal
Kacr Installation
Camshaft Chain Removal
Camshaft Chain Installation
Cylinder Head
Cylinder Compression
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Cleaning
Cylinder Head Warp
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guido Removal
Valve Guide Installation
Valve To Guide Clearance
Measurement
Valve Seat Inspection
Valve Seat Repair (Valve Lapping)
Cylinder And Piston
Cylinder Removal
Piston Removal
Cylinder, Piston Installation
Cylinder Wear
Piston Wear
Piston/Cylinder Clearance
Piston Ring, Piston Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Exhaust System
Spark Arrester Cleaning
Muffler And Exhaust Pipe Removal
Muffler And Exhaust Pipe Installation
Exhaust System Inspection
– Converter System
Torque Converter
Torque Converter Cover Removal
Torque Converter Cover Installation
Torque Converter Cover Disassembly_
Actuator Lever (Engine Brake Control Lover)Assembly Inspection
Torque Converter Cover Assembly
Drive Bet
Drive Belt Removal
Drive Belt Installation
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Drive Belt Inspection
Drive Pulley
Drive Pulley Removal
Drive Pulley Disassembly
Drive Pulley Inspection
Spider Shoe Side Clearance Adjustment
Drive Pulley Assembly
Drive Pulley Installation
Driven Pulley
Driven Pulley Removal
Driven Pulley Disassembly
Driven Pulley Inspection
Driven Pulley Assembly
Driven Pulley Installation
High Altitude Setting Information
Specifications
– Recoil Starter
– Engine Lubrication System
Engine Oil Flow Chart
Engine Oil And Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Change
Oil Screen Removal
Oil Screen Cleaning
Oil Pressure Measurement
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
Oil Pressure Relief Valve Installation
Oil Pressure Relief Valve Inspection
Oil Pump
Oil Pump Removal
Oil Pump Installation
Oil Pipe
Oil Pipe Removal
Oil Pipe Installation
– Crankshaft/Transmission
Crankcase Assembly
Crankshaft/Connection Rod
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Crankpin Wear
Crankshaft Runout
Crankshaft Main Bearing/Journal Wear
Transmission
Shift Lever Removal
Shift Lever Installation
Transmission Removal
Transmission Installation
Shift Fork Bending
Shift Fork/Gear And Shifter Groove Wear
Transmission And Shift Mechanism Inspection
Ball Bearing Needle Bearing, And Oil Seal
Ball And Needle Bearing Replacement
Ball And Needle Bearing Wear
Oil Seal Inspection
– Wheels & Tires
Wheel Alignment
Steering Centering Inspection
Steering Centering Adjustment
Toe In Inspection
Toe In Adjustment
Wheels (Rims)
Wheel Removal
Wheel Installation
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tires
Tire Removal
Tire Installation
Tire Inspection
Front Hub
Front Hub Removal
Front Hub Installation
Front Hub Disassembly/Assembly
Rear Hub
Rear Hub Removal
Rear Hub Installation
Rear Hub Disassembly/Assembly
– Final Drive
Output Bevel Goals
Output Drive Bevel Gear Removal
Output Drive Bevel Gear Installation
Output Drive Bevel Gear Disassembly
Output Drive Bevel Gear Assembly
Output Drive Bevel Gear Removal
Output Drive Bevel Gear Installation
Output Driven Bevel Gear Assembly
Drive Gears Inspection
Cam Damper Inspection
Front Propeller Shaft
Front Propeller Shaft Removal
Front Propeller Shaft Installation
Front Axle
Front Axle Removal
Front Axle Installation
Front Axle Joint Oot Inspection Front Axle Joint Boot Replacement
Front Final Gear Case
Front Final Gear Case Oil Level Inspection
Front Final Gear Case Oil Charge
Variable Differential Control Lever Position Inspection
Variable Differential Control Lever Position Adjustment
Variable Differential Control Lever
Variable Differential Control Lever
Variable Differential Control Cable
Variable Differential Control Cable Lubrication
Variable Differential Control Cable Inspection
Front Final Gear Case Removal
Front Final Gear Case Installation
Front Final Gear Case
Front Final Gear Case Coupling
Front Final Gear Case Assembly
Oil Seal Installation
Ring Gear Disassembly
Ring Gear Assembly
Lsd Clutch Torque Inspection
Pinion Gear Unit Disassembly
Front Final Bevel Gear
Bevel Cedi Inspection
Differential Gear Inspection
Rear Propeller Shaft
Rear Propeller Shaft Removal
Rear Propeller Shaft Installation
Rear Propeller Shaft Joint Boot
Rear Propeller Shaft Inspection
Rear Axle
Rear Axle Removal
Rear Axle Installation
Ball Bearing Wear
Rear Axle Runout Inspection
Rear Axle
Rear Axte Installation
Ball Bearing Wear
Rear Axle Runout Inspection
Rear Final Gear Case
Rear Final Gear Case Oil Level
Inspection
Rear Final Gear Case Oil Change Rear Final Gear Case Removal
Rear Final Goar Case Installation
Rear Final Gear Case Assembly
Oil Seal Installation
Rear Final Bevel Gear Adjustment
Pinion Gear Unit Disassembly
Pinion Gear Unit Assembly
Bevel Gear Inspection
Bearing And Oil Seal
Ball Or Needle Bearing Inspection Oil Seal Inspection
– Brakes
Brake Fluid
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Air Bleeding
Master Cylinder
Master Cylinder Removal
Master Cylinder Installation
Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection (Visual Inspection)
Calipers
Caliper Removal
Caliper Installation
Caliper Disassembly
Caliper Assembly
Fluid Seal Ddtnayt
Dust Seal And Friction Boot Damage
Piston And Cylinder Damage
Caliper Holder Shaft Wear Inspection
Brake Pads
Brake Pad Removal
Brake Pad Installation
Brake Pad Wear Inspection
Brake Discs
Disc Cleaning
Disc Removal
Disc Installation
Disc Wear
Disc Runout
Brake Hoses
Brake Hose Inspection
Brake Hose Replacement
Brake Pedal Removal
Brake Pedal Installation
Brake Cable Removal
Brake Cable Installation
Brake Cable Lubrication
Internal Wet Brake
Internal Wet Brake Disassembly
– Suspension
Shock Absorbers
Front Shock Absorber Removal
Front Shock Absorber Installation
Front Shock Absorber Inspection
Front Shock Absorber Spring Replacement
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Preload Adjustment
Rear Shock Absorber Inspection
Rear Shock Absorber Scrapping
Suspension Arms
Suspension Arm Removal
Suspension Ami Installation
Suspension Arm Disassembly
Suspension Arm Assembly
Swingarm
Swingarm Removal
Swingarm Installation
Swingarm Disassembly
Swingarm Assembly
Swingarm Bearing Inspection
Swingarm Bearing Lubrication
– Steering
Steering
Steering Stem Removal
Steering Stem Installation
Steering Knuckle Removal
Steering Knuckle Installation
Steering Knuckle Bearing Removal
Steering Knuckle Bearing Installation
Tie Rod Removal
Tie Rod Installation
Tie Rod End Removal
Tie Rod End Installation
Steering Maintenance
Steering Inspection
Steering Stopper Inspection
Steering Stem Straightness
Steering Bearing Sleeve Lubrication
Steering Stem Clamp Inspection
Steering Stem Bearing Inspection
Steering Knuckle Bearing Inspection
Tie Rod End And Steering Knuckle Joint Inspection
Handlebar
Handlebar Removal
Handlebar Installation
– Frame
Seat
Seat Removal
Seat Installation
Carriers
Front Carrier Removal
Front Carrier Installation
Rear Carrier Removal
Rear Carrier Installation
Fenders
Front Fender Removal
Front Fender Installation
Rear Fender Removal
Rear Fender Installation
Inner Cover Front And Front Lower Shroud Removal
Inner Cover Front And Front Lower Shroud Installation
Inner Cover Rear Removal
Inner Cover Rear Installation
Air Cleaner Upper Cover Removal
Air Cleaner Upper Cover Installation
Air Cleaner Cover Removal
Air Cleaner Cover Installation
Left Side Cover Removal
Left Side Cover Installation
Guards
Front Guard Removal
Front Guards Installation
Engine Bottom Guard Removal
Engine Bottom Guard Installation
Rear Bottom Guard Removal
Rear Bottom Guard Installation
Flaps And Footboards
Front Flap Removal
Front Flap Installation
Rear Flap Removal
Rear Flap Installation
Footboard Removal
Footboard Installation
Trailer Hitch Bracket
Trailer Hitch Bracket Removal
Trailer Hitch Bracket Installation
– Electrical System
Electrical Wiring Ie
Wiring Inspection
Battery
Battery Removal
Battery Installation
Electrolyte Filling
Initial Charge
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Charging System
Alternator Cover Removal
Alternator Cover Installation
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Stator Removal
Alternator Stator Installation
Regulator/Rectifier Output
Voltage Inspection
Alternator Inspection
Regulator/Rectifier Inspection
Ignition System
Spark Plug Removal
Spark Plug Installation
Spark Plug Cleaning/Inspection
Spark Mug Gap Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Ignition Coil Primary Peak Voltage Inspection
Pickup Coil Removal
Pickup Coil Installation
Pickup Coil Inspection
Pickup Coil Peak Voltage Inspection
Alternator Rotor Inspection
Ignition Timing Test
Vehicle Down Sensor Outline
Vehicle Down Sensor Removal
Vehicle Down Sensor Installation
Vehicle Down Sensor Inspection,
Electric Staler System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Commirator Cleaning’lnspjction
Armature Inspector!
Starter Motor Brush Length
Brush Assembly Inspection
Brush Plate And Terminal Bolt
Inspection
Starter Relay Inspection
Starter Circuit Relay Inspection
Starter Motor Clutch Removal
Starter Motor Clutch Installation
Starter Motor Clutch Inspection
Torque Limiter Inspection
Lighting System
Headlight Beam Vertical
Adjustment
Headlight Bulb Replacement
Taillight Bulb Replacement
Radiator Fan System
Radiator Fan Circuit Inspection
Radiator Fan Motor Inspection
Fuel Pump/Fuel Level Sensor
Fuel Pump Inspection
Fuel Level Sensor Inspection
Meter
Multifunction Meter Unit Hemoval Multifunction Meter Unit
Inspection
Drive Belt Failure Mode
Memory Clearing Procedure
Actuator Central System
Actuator Removal
Actuator Installation
Engine Brake Actuator Removal
Actuator Control System Outline
Actuator Control System Troubleshooting
Drive Belt Failure Detection System
Flashing Relay Inspection
System Circuit Relay Inspection
Diodes Inspection
Drive Belt Failure Defection
System Inspection
Drive Belt Failure Detection System
System Inspection
Switches
Brake Light Switch Adjustment
Radiator Fan Switch Inspection
Light Switch Inspection
Switch Inspection
Drive Belt Failure Detection
Switch
Fuses
Fuse Removal
Fuse Inspection
Wiring Diagram
– Appendix
Considerations For Various Riding Conditions
Carburetor
Spark Plug:
Troubleshooting Guide
General Lubrication
Lubrication
Boll And Nut Tightening
Tightness Inspection
Unit Conversion Table