Factory Service Repair Manual For Kawasaki Prairie 700 4×4 KVF 700 4×4 ATV. 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: 509
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No

Model

Kawasaki ATV Prairie 700 4×4, KVF 700 4×4
KVF700A1
KVF700B1

Years 2004, 2005, 2006

Contents

– Foreword
– General Information
Before Servicing
Model Identification
General Specifications
Unit Conversion Table
– Periodic Maintenance
Periodic Maintenance Chart
Torque And Locking Agent
Specifications
Special Tools
Periodic Maintenance Procedures
Fuel System
Throttle Lever Free Play
Throttle Lever Free Play
Choke Lever Free Play Inspection
Choke Lever Free Play
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness
Air Cleaner Element Cleaning
Air Cleaner Draining
Fuel Hose And Connection
Fuel Hose Replacement
Cooling System
Radiator Cleaning
Radiator Hose And Connection
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
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
Brake Fluid Change
Front Brake Master Cylinder
Piston Assembly And Dust Seal
Front Brake Caliper Piston Seal And Dust Seal Replacement
Rear Brake Plates Replacement
Rear Brake Lever Free Play
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
Rear Propeller Shaft Joint Boot
Tie Rod End Boot Inspection
General Lubrication
Lubrication
Bolts And Nuts Tightening
Tightness Inspection
– Fuel System
Throttle Lever And Cable
Throttle Lever Free Play
Throttle Case
Throttle Cable Installation
Throttle Case Inspection
Throttle Cable Lubrication And
Choke Lever And Cable
Choke Lever Free Play Inspection
Choke Lever Free Play
Adjustment
Choke Lever And Cable Removal
Choke Lever And Cable
Choke Cable Lubrication And
Carburetor
Idle Speed Inspection
Idle Speed Adjustment
Pilot Screw Adjustment
Service Fuel Level Inspection
Service Fuel Level Adjustment
Carburetor Synchronization
Fuel System Cleanliness
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Separation
Carburetor Joining
Carburetor Cleaning
Carburetor Inspection
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Cleaning And
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Fuel Tap Removal
Fuel Tap Installation
Fuel Tap Inspection
Fuel Pump
Fuel Pump Removal
Pump Filter Cleaning
Fuel Pump Installation
Fuel Pump Inspection
– Cooling System
Coolant
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Water Pump
Water Pump Cover Removal
Water Pump Cover Installation
Impeller 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
Special Tools & Sealant
Camshaft Chain Tensioner
Camshaft Chain Tensioner
Camshaft Chain Tensioner
Rocker Case
Rocker Case Removal
Rocker Case Installation
Rocker Arm 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
Camshaft Chain Guide Wear
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 Guide 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
Cylinder Boring And Honing
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
Exhaust System Inspection
– Converter System
Torque Converter
Torque Converter Cover Removal
Torque Converter Cover Installation
Torque Converter Cover Disassembly
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
Torque Converter Cover Assembly
Drive Belt
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
– Recoil Starter
Recoil Starter
Recoil Starter Removal
Recoil Starter Installation
Recoil Starter Inspection
– 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
– Engine Removal/Installation
– Crankshaft/Transmission
Crankcase
Crankcase Disassembly
Crankcase Assembly
Crankshaft/Connection Rod
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend
Connecting Rod Twist
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
ToeIn Inspection
ToeIn 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 Gears
Output Drive Bevel Gear Removal
Output Drive Bevel Gear
Output Drive Bevel Gear
Output Drive Bevel Gear
Output Driven Bevel Gear
Output Driven Bevel Gear
Output Driven Bevel Gear
Output Driven Bevel Gear
Output Bevel Gears Adjustment
Bevel Gears Inspection
Front Propeller Shaft
Front Propeller Shaft Removal
Front Propeller Shaft Installation
Front Axle
Front Axle Removal
Front Axle Installation
Front Axle Joint Boot Inspection
Front Axle Joint Boot
Front Final Gear Case
Front Final Gear Case Oil Level
Front Final Gear Case Oil Change
Variable Differential Control Lever
Play Inspection
Variable Differential Control Lever
Play Adjustment
Variable Differential Control Lever
Variable Differential Control Cable
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
Pinion Gear Unit Assembly
Front Final Bevel Gear
Bevel Gear 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 Final Gear Case
Rear Final Gear Case Oil Level
Rear Final Gear Case Oil Change
Rear Final Gear Case Removal
Rear Final Gear Case Installation
Rear Final Gear Case
Rear Final Gear Case Assembly
Final Drive
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
Calipers
Caliper Removal
Caliper Installation
Caliper Disassembly
Caliper Assembly
Fluid Seal Damage
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
Rear Brake Lever, Pedal And Cables
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Rear Brake Lever Free Play
Brake Pedal Free Play Inspection
Rear Brake Lever And Pedal Free
Play Adjustment
Brake Pedal Removal
Brake Pedal Installation
Brake Cable Removal
Brake Cable Installation
Brake Cable Lubrication
Internal Wet Brake
Internal Wet Brake Disassembly
Internal Wet Brake Assembly
– 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 R Preload Adjustment
Rear Shock Absorber Spring Replacement
Rear Shock Absorber Inspection
Rear Shock Absorber Scrapping
Suspension Arms
Suspension Arm Removal
Suspension Arm 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
Covers
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
Engine Brake Actuator Installation
Actuator Control System Outline
Actuator Control System
Troubleshooting
Drive Belt Failure Detection System
Drive Belt Failure Detection
System Inspection
Switches
Brake Light Switch Adjustment
Radiator Fan Switch Inspection
Coolant Temperature Warning
Light Switch Inspection
Switch Inspection
Drive Belt Failure Detection
Fuses
Main Fuse Removal
Fuse Removal
Fuse Inspection
Wiring Diagram
– Wiring Diagram
– Appendix
Troubleshooting Guide
Cable, Wire, and Hose Routing