Руководство кавасаки 750

Материал из BikesWiki — энциклопедия японских мотоциклов

Перейти к: навигация, поиск

TERYX 750 FI 4×4

TERYX 750 FI 4×4 LE

TERYX 750 FI 4×4 SPORT

Recreation Utility Vehicle

Service Manual

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

Periodic Maintenance

Fuel System (DFI)

Cooling System

Engine Top End

Converter System

Engine Lubrication System

Engine Removal/Installation

Crankshaft/Transmission

Wheels/Tires

Final Drive

Brakes

Suspension

Steering

Frame

Electrical System

Appendix

10 j

11 j

12 j

13 j

14 j

15 j

16 j

17 j

6 j

7 j

8 j

9 j

1 j

2 j

3 j

4 j

5 j

TERYX 750 FI 4×4

TERYX 750 FI 4×4 LE

TERYX 750 FI 4×4 SPORT

Recreation Utility Vehicle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki

Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

© 2009 Kawasaki Heavy Industries, Ltd.

6th Edition (2): Apr. 16, 2012

A

ABDC

AC

ATDC

BBDC

BDC g h

°F ft

L

BTDC

°C

DC

F 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) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)

LIST OF ABBREVIATIONS

rpm

TDC

TIR

V

W

Ω

Pa

PS r psi lb m min

N 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)

Canada

COUNTRY AND AREA CODES

US United States CA

TERYX 750 FI 4×4:

TERYX 750 FI 4×4 LE:

TERYX 750 FI 4×4 SPORT:

KRF750N/T Models

KRF750P/R/V Models

KRF750S Model

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2), and evaporative emission (3) control systems in compliance with applicable regulations of the United States Environmental Protection Agency.

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 catalytic converter in the muffler (US and CA models), a fuel injection and ignition system having optimum ignition timing characteristics.

The fuel injection system 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.

3. Evaporative Emission Control System

The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank.

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

○

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 way which results in an increase in noise level.

TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED:

Federal regulations and California State law prohibit the following acts or the causing thereof:

(1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

•

Do not tamper with the original emission related parts:

Throttle body and internal parts

•

Spark plugs

•

Alternator or electronic battery ignition system

•

•

Fuel filter/Fuel injector/Fuel pump

•

Air cleaner element

ECU (Electronic Control Unit)

Foreword

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 Service 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 engine oil information, use the Quick Reference Guide to locate the Engine lubrication System chapter. Then, use the Table of Contents on the first page of the chapter to find the Engine Oil section.

Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

NOTICE is used to address practices not related to personal injury.

This manual contains four more symbols which will help you distinguish different types of information.

NOTE

○

This note symbol indicates points of particular interest for more efficient and convenient operation.

•

Indicates a procedural step or work to be 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

Table of Contents

Before Servicing ………………………………………………………………………………………………………

Model Identification…………………………………………………………………………………………………..

1-2

1-7

General Specifications………………………………………………………………………………………………

1-12

Unit Conversion Table ………………………………………………………………………………………………

1-16

1

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.

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.

GENERAL INFORMATION 1-3

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, cotter pins or self-locking nuts 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. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. 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

Non-Permanent 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.

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.

GENERAL INFORMATION 1-5

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 right 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.

Instrument

Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

Model Identification

KRF750NA, TA Left Side View

GENERAL INFORMATION 1-7

KRF750NA, TA Right Side View

Frame Number

[A] Frame Number

[B] Right Front Axle

Engine Number

[A] Engine Number

[B] Engine Oil Drain Plug

1-8 GENERAL INFORMATION

Model Identification

KRF750NC Left Side View

KRF750NC Right Side View

Model Identification

KRF750PA Left Side View

GENERAL INFORMATION 1-9

KRF750PA Right Side View

1-10 GENERAL INFORMATION

Model Identification

KRF750RA, VB Left Side View

KRF750RA, VB Right Side View

The KRF750RA, VB are identical to the KRF750PA in every aspect: controls, features, and specifications except for the camouflage surface treatment.

The gun case is an optional part.

Model Identification

KRF750SA Left Side View

GENERAL INFORMATION 1-11

KRF750SA Right Side View

1-12 GENERAL INFORMATION

General Specifications

Items

Dimensions

Overall Length

Overall Width

Overall Height :

(KRF750N/S/T)

(KRF750P/R/V)

Wheelbase

Tread:

Front

Rear

Ground Clearance

Seat Height

Curb Mass:

(KRF750NA

∼

NB)

(KRF750NC)

(KRF750ND)

(KRF750PA/RA

∼

PB/RB/VB)

(KRF750PC/RC/VC)

(KRF750PD/RD)

(KRF750SA

∼

SB)

(KRF750SA

□

A

∼

SB

□

A)

(KRF750SC)

(KRF750SD)

(KRF750T)

Front:

(KRF750NA

∼

NB)

(KRF750NC)

(KRF750ND)

(KRF750PA/RA

∼

PB/RB/VB)

(KRF750PC/RC/VC)

(KRF750PD/RD)

(KRF750SA

∼

SB)

(KRF750SA

□

A

∼

SB

□

A)

(KRF750SC)

(KRF750SD)

(KRF750T)

Rear:

(KRF750NA

∼

NB)

(KRF750NC)

(KRF750ND)

(KRF750PA/RA

∼

PB/RB/VB)

(KRF750PC/RC/VC)

(KRF750PD/RD)

(KRF750SA

∼

SB)

KRF750NA/PA/RA/SA/TA/VB

∼

ND/PD/RD/SD/VC

2 955 mm (116.3 in.)

1 485 mm (58.46 in.)

1 925 mm (75.79 in.)

2 020 mm (79.53 in.)

1 930 mm (75.98 in.)

1 225 mm (48.23 in.)

1 200 mm (47.24 in.)

295 mm (11.6 in.)

780 mm (30.7 in.)

633 kg (1 396 lb), (CA) 630 kg (1 389 lb)

636 kg (1 402 lb), (CA) 633 kg (1 396 lb)

634 kg (1 398 lb), (CA) 631 kg (1 391 lb)

648 kg (1 429 lb), (CA) 645 kg (1 422 lb)

651 kg (1 435 lb), (CA) 648 kg (1 429 lb)

649 kg (1 431 lb), (CA) 646 kg (1 424 lb)

630 kg (1 389 lb), (CA) 627 kg (1 383 lb)

631 kg (1 391 lb), (CA) 628 kg (1 385 lb)

633 kg (1 396 lb), (CA) 630 kg (1 389 lb)

631 kg (1 391 lb), (CA) 628 kg (1 385 lb)

634 kg (1 398 lb)

280 kg (617 lb), (CA) 279 kg (615 lb)

281 kg (620 lb), (CA) 280 kg (617 lb)

278 kg (613 lb), (CA) 277 kg (611 lb)

291 kg (642 lb), (CA) 289 kg (637 lb)

292 kg (644 lb), (CA) 291 kg (642 lb)

289 kg (637 lb), (CA) 288 kg (635 lb)

279 kg (615 lb), (CA) 278 kg (613 lb)

280 kg (617 lb), (CA) 279 kg (615 lb)

280 kg (617 lb), (CA) 279 kg (615 lb)

277 kg (611 lb), (CA) 276 kg (609 lb)

281 kg (620 lb)

353 kg (778 lb), (CA) 351 kg (774 lb)

355 kg (783 lb), (CA) 353 kg (778 lb)

356 kg (785 lb), (CA) 354 kg (780 lb)

357 kg (787 lb), (CA) 356 kg (785 lb)

359 kg (792 lb), (CA) 357 kg (787 lb)

360 kg (794 lb), (CA) 358 kg (789 lb)

351 kg (774 lb), (CA) 349 kg (770 lb)

General Specifications

Items

(KRF750SA

□

A

∼

SB

□

A)

(KRF750SC)

(KRF750SD)

(KRF750T)

Fuel Tank Capacity

Cargo Bed (L × W × H)

Seating Capacity

Performance

Minimum Turning Radius:

Differential Mode (2WD)

Locked-Axle Mode (4WD)

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:

Intake:

Open

Close

Duration

Exhaust:

Open

Close

Duration

Lubrication System

Engine Oil:

Type

Viscosity

Capacity

GENERAL INFORMATION 1-13

KRF750NA/PA/RA/SA/TA/VB

∼

ND/PD/RD/SD/VC

351 kg (774 lb), (CA) 349 kg (770 lb)

353 kg (778 lb), (CA) 351 kg (774 lb)

354 kg (780 lb), (CA) 352 kg (776 lb)

353 kg (778 lb), (CA) 351 kg (774 lb)

28 L (7.4 US gal)

830 × 1 120 × 280 mm (32.68 × 44.09 × 11.10 in.)

2

4.2 m (13.8 ft)

5.0 m (16.4 ft)

4-stroke, SOHC, V2-cylinders

Liquid-cooled

85.0 × 66.0 mm (3.35 × 2.60 in.)

749 cm³ (45.7 cu in.)

8.8 : 1

–

57 N·m (5.8 kgf·m, 42 ft·lb) @5 000 r/min (rpm)

Fuel Injection (Mikuni 34 × 2)

Electric Starter

Battery and Coil (transistorized)

Electronically advanced (digital)

10° BTDC @1 110 r/mi (rpm)

NGK CR7E or DENSO U22ESR-N

Front to rear, 1-2

1-2

20° BTDC

44° ABDC

244°

44° BBDC

20° ATDC

244°

Forced lubrication (wet sump)

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

2.6 L (2.7 US qt)

1-14 GENERAL INFORMATION

General Specifications

Items

Drive Train

Primary Reduction System:

Type

Reduction Ratio

Transmission Gear Ratio:

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

KRF750NA/PA/RA/SA/TA/VB

∼

ND/PD/RD/SD/VC

Belt drive torque converter

3.200

∼

0.721

3.549 (30/26 × 29/18 × 21/11)

5.536 (36/20 × 29/18 × 21/11)

4.614 (16/12 × 18/16 × 29/18 × 21/11)

Shaft 4WD/2WD

4.375 (35/8)

11.195

17.464

14.553

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

0.7 L (0.74 US qt)

MOBIL FLUID 424, CITGO TRANSGARD TRACTOR

HYDRAULIC FLUID or EXXON HYDRAUL 560

1.0 L (1.06 US qt) Capacity

Frame

Type

Caster (Rake Angle)

Camber:

(Front)

(Rear)

King Pin Angle

Trail

Tire:

Front:

Type

Size

Rear:

Type

Size

Rim Size:

Front

Rear

Steering Type

Steel tube, Ladder

2.2°

-0.7°

-0.4°

11.4°

11 mm (0.43 in.)

Tubeless

26 × 8.00 — 12

Tubeless

26 × 10.00 — 12

12 × 6.0AT

12 × 8.0AT

Rack and pinion

GENERAL INFORMATION 1-15

General Specifications

Items

Suspension:

Front:

Type

Wheel Travel

Rear:

Type

Wheel Travel

Brake Type:

Front

Rear

Parking Brake Type

Electrical Equipment

Battery

Headlight:

Type

Bulb

Brake/Tail Light

Alternator:

Type

Max Output

Load Capacity

Maximum Vehicle Load

KRF750NA/PA/RA/SA/TA/VB

∼

ND/PD/RD/SD/VC

Double Wishbone

190 mm (7.48 in.)

Double Wishbone

190 mm (7.48 in.)

Disc × 2

Enclosed wet multi-plate

Enclosed wet multi-plate

(US) 12 V 14 Ah, (CA) 12 V 12 Ah

Semi-sealed beam

12 V 35/35 W × 2

12 V 27/8 W × 2

Three — phase AC

28 A, 14 V @6 000 rpm

(Including Occupants and Cargo) 422 kg (931 lb)

Maximum Cargo Bed Load 227 kg (500 lb)

□

: This blank changes depending on the model.

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

1-16 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units:

Prefix mega kilo centi milli micro

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

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

=

=

=

=

= gal (US) gal (IMP) qt (US) qt (IMP) pint (US) pint (IMP) oz (US) oz (IMP) cu in

Units of Force:

N × 0.1020

N kg

×

×

0.2248

9.807

kg × 2.205

=

=

=

= kg lb

N lb

Units of Length:

km m mm

×

×

×

0.6214

=

3.281

=

0.03937 = mile ft in

Units of Torque:

N·m × 0.1020

=

N·m

N·m kgf·m kgf·m kgf·m

×

×

×

×

×

0.7376

=

8.851

=

9.807

7.233

86.80

=

=

= kgf·m ft·lb in·lb

N·m ft·lb in·lb

Units of Pressure:

kPa kPa kPa

×

×

×

0.01020 =

0.1450

=

0.7501

= kgf/cm² × kgf/cm² × cmHg ×

98.07

14.22

1.333

=

=

= kgf/cm² psi cmHg kPa psi kPa

Units of Speed:

km/h × 0.6214

= mph

Units of Power:

kW kW

PS

PS

×

×

×

×

1.360

1.341

0.7355

=

0.9863

=

=

=

PS

HP kW

HP

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ………………………………………………………………………………………

2-3

Torque and Locking Agent…………………………………………………………………………………………

2-5

Specifications ………………………………………………………………………………………………………….

2-13

Special Tools …………………………………………………………………………………………………………..

2-15

Periodic Maintenance Procedures………………………………………………………………………………

2-16

Fuel System………………………………………………………………………………………………………….

Throttle Pedal Free Play Inspection……………………………………………………………………….

2-16

2-16

Throttle Pedal Free Play Adjustment ……………………………………………………………………..

Idle Speed Inspection ………………………………………………………………………………………….

Idle Speed Adjustment…………………………………………………………………………………………

Air Cleaner Element Cleaning and Inspection …………………………………………………………

Air Cleaner Draining…………………………………………………………………………………………….

Fuel Hose and Connections Inspection …………………………………………………………………

Fuel Hose Replacement ………………………………………………………………………………………

Cooling System……………………………………………………………………………………………………..

2-16

2-17

2-17

2-17

2-18

2-18

2-19

2-21

Radiator Cleaning ……………………………………………………………………………………………….

Water Hoses and Connections Inspection………………………………………………………………

Coolant Change ………………………………………………………………………………………………….

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

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

Valve Clearance Adjustment…………………………………………………………………………………

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

Converter System ………………………………………………………………………………………………….

Converter Drive Belt Wear Inspection…………………………………………………………………….

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

Converter Drive Belt Deflection Adjustment…………………………………………………………….

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

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

Engine Oil Change………………………………………………………………………………………………

Oil Filter Replacement …………………………………………………………………………………………

Wheels/Tires…………………………………………………………………………………………………………

2-27

2-29

2-31

2-31

2-32

2-32

2-33

2-33

2-21

2-21

2-21

2-24

2-24

2-26

2-26

2-27

Tire Inspection ……………………………………………………………………………………………………

Wheels Nuts Tightness Inspection…………………………………………………………………………

Final Drive…………………………………………………………………………………………………………….

Differential Shift Lever Play Inspection …………………………………………………………………..

Differential Shift Lever Play Adjustment………………………………………………………………….

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

Rear Final Gear Case Oil Change …………………………………………………………………………

Brakes………………………………………………………………………………………………………………….

Brake Fluid Level Inspection…………………………………………………………………………………

Brake Fluid Change …………………………………………………………………………………………….

Brake Pedal Play Inspection …………………………………………………………………………………

Brake Master Cylinder Cup and Dust Seal Replacement ………………………………………….

Rear Brake Master Cylinder Cup, O-ring and Boot Replace ……………………………………..

Brake Hose and Pipe Inspection……………………………………………………………………………

Brake Hose Replacement …………………………………………………………………………………….

Parking Brake Pedal Inspection…………………………………………………………………………….

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

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

Rear Brake Plates Replacement……………………………………………………………………………

2-36

2-37

2-38

2-39

2-40

2-42

2-42

2-44

2-33

2-34

2-34

2-34

2-34

2-34

2-35

2-36

2-44

2-45

2-46

2

2-2 PERIODIC MAINTENANCE

Steering ……………………………………………………………………………………………………………….

Steering Inspection ……………………………………………………………………………………………..

Steering Joint Dust Boot Inspection……………………………………………………………………….

Frame ………………………………………………………………………………………………………………….

Seat Belt Inspection …………………………………………………………………………………………….

Electrical System …………………………………………………………………………………………………..

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

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

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

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

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

Front Axle/Steering Knuckle Joint Boots Inspection …………………………………………………

Front Propeller Shaft Joint Boots Inspection……………………………………………………………

Tie-rod End Boots Inspection………………………………………………………………………………..

Rear Propeller Shaft Joint Boots Inspection ……………………………………………………………

Rear Axle/Stabilizer Joint Boots Inspection …………………………………………………………….

General Lubrication ……………………………………………………………………………………………….

Lubrication …………………………………………………………………………………………………………

Cables………………………………………………………………………………………………………………….

Inspection…………………………………………………………………………………………………………..

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

Tightness Inspection ……………………………………………………………………………………………

2-49

2-49

2-49

2-49

2-50

2-50

2-50

2-50

2-46

2-46

2-47

2-47

2-47

2-48

2-48

2-49

2-50

2-50

2-51

2-51

2-52

2-52

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 First Service

After

20 h, or

200 km

(120 mile) of use

After

50 h, or

1 000 km

(600 mile) of use

Every

50 h, or

1 000 km

(600 mile) of use

Regular Service

Every

100 h, or

2 000 km (1

200 mile) of use

Every

200 h, or

4 000 km (2

500 mile) of use

Every year of use

See

Pape

OPERATION

ENGINE

Throttle pedal play-inspect

Fuel hoses and connections-inspect

Fuel hose-replace

Idle speed-inspect

Spark plug-clean and gap inspect

Air cleaner-inspect *

Valve clearance-inspect

Spark arrester-clean

Engine oil-change *

Oil filter-replace *

Front and rear final gear case oil-change

Radiator-clean *

Water hoses and connections-check *

Coolant-change *

Converter drive belt wear-inspect *

Converter drive belt deflection-inspect *

Differential shift lever play-inspect

Engine brake control lever-inspect *

CHASSIS

Rear brake plates-replace *

Front brake pad wear-inspect *

Brake light switch — inspect

Brake fluid — change

Brake master cylinder cup and dust seal

— replace

Rear brake master cylinder cup, O-ring, and boot-replace *

Front brake caliper piston seal and dust seal-replace

Brake hose — replace

Brake fluid level — inspect

Brake pedal play — inspect *

•

•

•

•

•

•

•

•

•

5 years

•

•

•

•

•

•

•

First 2 000 km (1 200 mile); thereafter

•

2-16

2-18

2-19

2-17

2-48

2-17

2-24 every 4 000 km (2 500 mile)

•

6 months

2-26

2-32

•

•

2-33

2-34,

35

•

2-21

2 years

•

2-21

2-21

•

•

•

•

•

2-27

2-29

2-34

2-31 every 10 000 km (6 000 mile)

•

•

2 years

2 years

2 years

2 years

4 years

•

•

•

2-46

2-44

2-48

2-36

2-38

2-39

2-45

2-42

2-36

2-38

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY First Service Regular Service

After

20 h, or

200 km

(120

After

50 h, or

1 000 km

(600

Every

50 h, or

1 000 km

(600

Every

100 h, or

2 000 km (1

200

Every

200 h, or

4 000 km (2

500

Every year of use

See

Pape

OPERATION mile) of use mile) of use mile) of use mile) of use mile) of use

Brake hose and pipe — inspect

Parking brake pedal — inspect

Tire wear-inspect *

Wheel nuts tightness — inspect

•

•

•

•

•

•

•

•

2-41

2-44

2-33

2-34

Joint boots — inspect

Steering-inspect

Steering joint dust boots — inspect

General lubrication — perform *

•

•

•

•

•

•

•

2-49

2-46

2-47

2-50

Bolts, nuts, and fasteners tightness inspect

Seat belt — inspect

Cables — inspect

• •

•

•

2-52

2-47

2-51

*: 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:

L: Apply a non-permanent locking agent.

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

LO: Apply a non-permanent locking agent (Three Bond TB2440B, Orange).

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil (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 (Liquid Gasket, TB1211: 56019-120).

Fastener

N·m

Torque kgf·m ft·lb

Remarks

Fuel System

Element Holder Screw

Element Cover Screw

Air Cleaner Mounting Bolts

ISC Valve Mounting Bolts

Delivery Pipe Mounting Screws

Intake Air Pressure Sensor Mounting Screw

Throttle Cable Locknuts

Throttle Pedal Position Bolt Locknut

Fuel Pump Mounting Bolts

Fuel Tank Band Bolts

ECU Mounting Bolts

Water Temperature Sensor

Vehicle-down Sensor Bolts (KRF750ND/PD/RD/SD)

Cooling System

Radiator Screen Mounting Bolts

Radiator Cover Bracket Mounting Bolts

Radiator Mounting Bolts

Radiator Fan Assembly Bolts

Thermostat Housing Cover Bolts

Water Temperature Sensor

Water Pipe Mounting Bolts, L = 20 mm (0.79 in.)

Water Pipe Mounting Bolt, L = 12 mm (0.47 in.)

Water Pump Impeller

Water Pump Cover Bolts

Coolant Drain Plug (Water Pump)

Coolant Drain Plugs (Cylinder)

Coolant Air Bleed Bolt (Water Pump)

Coolant Air Bleed Bolt (Thermostat)

Radiator Cover Mounting Bolts

(KRF750ND/PD/RD/SD)

4.5

4.5

8.8

8.8

5.0

5.0

4.4

10.8

4.0

11

6.9

12

5.9

8.8

12

8.8

8.8

8.8

8.8

8.8

8.3

7.8

8.8

7.0

7.0

7.0

7.8

8.8

0.46

0.46

0.90

0.90

0.51

0.51

0.45

1.1

0.41

1.1

0.70

1.2

0.60

0.90

0.90

0.90

0.85

0.90

1.2

0.90

0.90

0.80

0.90

0.71

0.71

0.71

0.80

0.90

40 in·lb

40 in·lb

78 in·lb

78 in·lb

44 in·lb

44 in·lb

39 in·lb

96 in·lb

35 in·lb

97 in·lb

61 in·lb

106 in·lb

52 in·lb

78 in·lb

78 in·lb

78 in·lb

73 in·lb

78 in·lb

106 in·lb

78 in·lb

78 in·lb

69 in·lb

78 in·lb

62 in·lb

62 in·lb

62 in·lb

69 in·lb

78 in·lb

L

L

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Engine Top End

Valve Adjusting Cap Bolts

Rocker Case Bolts, L = 55 mm (2.2 in.)

Rocker Case Bolts, L = 130 mm (5.1 in.)

Rocker Case Bolts, L = 30 mm (1.2 in.)

Rocker Case Bolts, L = 25 mm (1.0 in.)

Cylinder Head Bolts (M10), first torque

Cylinder Head Bolts (M10), final torque

Cylinder Head Bolts (M6)

Water Pipe Mounting Bolts

Valve Adjusting Screw Locknuts

Rocker Shaft Bolts

Rear Rocker Case Clamp Bolt

Camshaft Sprocket Bolts

Chain Tensioner Cap Bolts

Chain Tensioner Mounting Bolts

Front Cylinder Camshaft Chain Guide Bolt

Position Plate Bolts

Intermediate Shaft Chain Guide Bolts

Intermediate Shaft Chain Tensioner Bolts

Rear Cylinder Camshaft Chain Guide Bolt

Cylinder Bolts, L = 30 mm (1.2 in.)

Cylinder Bolts, L = 40 mm (1.6 in.)

Coolant Drain Plugs (Cylinder)

Exhaust Pipe Nuts

Exhaust Pipe Cover Bolts

Muffler Clamp Bolts

Muffler Mounting Bolts

Spark Arrester Mounting Bolts

Converter System

Drive Pulley Bolt

Drive Pulley Cover Bolts

Ramp Weight Nuts

Spider

Driven Pulley Nut

Engine Brake Actuator Mounting Bolts

Engine Brake Actuator Cover Bolt

Belt Inspection Opening Cover Bolts

Converter Cover Bolts

Converter Cover Drain Bolt

Joint Duct Bolts

Engine Lubrication System

Oil Filter

Torque kgf·m ft·lb

Remarks

15

78 in·lb

78 in·lb

78 in·lb

15

87 in·lb

87 in·lb

62 in·lb

13

115 in·lb

11

21

115 in·lb

78 in·lb

78 in·lb

87 in·lb

87 in·lb

87 in·lb

18

36

87 in·lb

78 in·lb

106 in·lb

16

78 in·lb

106 in·lb

16

78 in·lb

2.0

0.90

0.90

0.90

2.0

1.0

1.0

0.71

1.7

1.3

1.5

2.9

1.3

1.0

0.90

1.2

2.2

0.90

1.2

2.2

0.90

0.90

0.90

1.0

1.0

1.0

2.5

5.0

S

S

S

S

S, MO

S

L

9.5

1.3

0.71

28

9.5

0.90

0.90

0.90

0.90

2.0

0.90

1.8

69

111 in·lb

62 in·lb

203

69

78 in·lb

78 in·lb

78 in·lb

78 in·lb

15

78 in·lb

13

Lh

R

Lh

R

S

S

S

R

N·m

20

9.8

9.8

7.0

20

8.8

8.8

8.8

17

13

15

28

13

8.8

12

22

8.8

9.8

8.8

12

22

8.8

8.8

9.8

9.8

9.8

25

49

93

8.8

8.8

8.8

93

12.5

7.0

275

8.8

20

8.8

17.5

Torque and Locking Agent

Fastener

Oil Pressure Switch

Oil Pipe Bolts

Engine Oil Drain Plug

Oil Pressure Relief Valve

Oil Pump Cover Bolts

Chain Guide Bolt

Oil Pump Drive Chain Tensioner Bolt

Oil Filter Mounting Bolt

Plate Bolts

Engine Removal/Installation

Engine Bracket Pipe Mounting Nuts

Engine Mounting Bolt

Engine Mounting Nut

Crankshaft/Transmission

Connecting Rod Big End Cap Nuts

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Connecting Rod Big End Cap Nuts

(KRF750ND/PD/RD/SD)

Engine Oil Drain Plug

Crankcase Bolts (M8), L = 75 mm (2.95 in.)

Crankcase Bolts (M8), L = 110 mm (4.33 in.)

Crankcase Bolt (M8), L = 110 mm (4.33 in.)

Crankcase Bolts (M6), L = 40 mm (1.57 in.)

Crankcase Bolts (M6), L = 65 mm (2.56 in.)

Bearing Position Plate Screws

Rear Cylinder Camshaft Chain Guide Bolt

Grip Hold Nut

Tie-rod End Locknut

Shift Lever Assembly Nut

Tie-rod End Bolt

Tie-rod End Front Locknut

Tie-rod End Rear Locknut

Tie-rod End Nut

Shift Shaft Lever Bolt

Shift Shaft Cover Bolts

Shift Shaft Positioning Bolt

Neutral Position Switch

Reverse Position Switch

Shift Shaft Spring Bolt

Stopper Mounting Bolts

Shift Lever Guide Bolt

Shift Lever Pivot Nut

Shift Lever Bracket Bolt , L = 25 mm (0.98 in.)

PERIODIC MAINTENANCE 2-7

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Shift Lever Bracket Bolts , L = 20 mm (0.79 in.)

Front Tie-rod End

Stopper Spring Bolt

Wheel/Tires

Front Axle Nuts

Front Wheel Nuts

Rear Wheel Nuts

Tie-rod End Locknuts

Rear Axle Nuts

Final Drive

(Output Bevel Gears)

Rotor Mounting Bolts

Output Driven Bevel Gear Housing Bolts

Bevel Gear Bearing Holder Nut

Bearing Holder (M64)

Bearing Holder (M75)

Output Shaft Holder Nut

Output Drive Bevel Gear Housing Bolts

Output Drive Bevel Gear Cover Bolt, L = 65 mm

(2.56 in.)

Output Drive Bevel Gear Cover Bolts, L = 20 mm

(0.79 in.)

Forward/Reverse Detecting Sensor Mounting Bolt

(Front Final Gear Case)

Differential Control Shift Shaft Lever Nut

Differential Shift Cable Holder Bolt

Front Final Gear Case Oil Filler Cap

Front Final Gear Case Oil Drain Plug

2WD/4WD Shift Cable Holder Bolts

2WD/4WD Shift Shaft Cover Bolts

2WD/4WD Shift Shaft Lever Nut

Pinion Gear Bearing Holder Nut

Pinion Gear Bearing Holder

Coupling Nut

Front Final Gear Case Center Cover Bolts (M8)

Front Final Gear Case Center Cover Bolts (M10)

Ring Gear Bolts

Front Final Gear Case Left Cover Bolts (M6, 35 mm)

Front Final Gear Case Left Cover Bolts (M6, 40 mm)

Front Final Gear Case Mounting Nuts

Front Final Gear Case Bracket Bolts

Differential Shift Cable Locknuts

2WD/4WD Shift Cable Locknuts

N·m

19.6

9.8

26

266

110

110

44

266

12

26

200

120

250

200

26

8.8

8.8

14.9

250

35

24

49

57

8.8

8.8

90.5

8.8

8.8

20

200

8.8

8.8

29

15

90.5

9.8

4.4

Torque kgf·m

2.0

1.0

2.7

ft·lb

14

87 in·lb

19

Remarks

L

27.1

11.2

11.2

4.5

27.1

196

81

81

32

196

S

S

LB

L

L

LB

R

R

25.5

3.6

2.4

5.0

5.8

0.90

0.90

9.2

0.90

0.90

3.0

1.5

0.90

0.90

2.0

20.4

9.2

1.0

0.45

1.2

2.7

20.4

12.2

25.5

20.4

2.7

0.90

0.90

1.5

106 in·lb

19

148

89

184

148

19

78 in·lb

78 in·lb

11

184

26

18

36

42

78 in·lb

78 in·lb

67

78 in·lb

78 in·lb

21

11

78 in·lb

78 in·lb

15

148

67

87 in·lb

39 in·lb

LO

R

L

L

LB

L

L

R

LB

Torque and Locking Agent

Fastener

4WD Position Switch

Vacuum Actuator Bracket Bolts

Solenoid Valve Bracket Bolts

Vacuum Actuator Mounting Bolts

(Rear Final Gear Case)

Rear Master Cylinder Mounting Bolts

Rear Master Cylinder Bleed Valve

Rear Final Gear Case Front Cover Bolts

Spring Bracket Bolt

Rear Final Gear Case Gasket Screws

Pinion Gear Bearing Holder

Pinion Gear Bearing Holder Nut

Rear Final Gear Case Oil Drain Plug

Rear Final Gear Case Oil Filler Cap

Rear Final Gear Case Right Cover Bolts (M10)

Rear Final Gear Case Right Cover Bolts (M12)

Rear Final Gear Case Mounting Nuts

Rear Final Gear Case Bracket Bolts

Heat Guard Bolts

Brakes

Front Master Cylinder Reservoir Cap

Reservoir Clamp Bolt

Piston Stop Bolt

Brake Pipe Nipples

Brake Pipe Joint

Brake Hose Banjo Bolts

Front Master Cylinder Mounting Bolts

Master Cylinder Bolt

Push Rod Locknut

Parking Brake Pedal Assy Mounting Bolts

Front Brake Pad Mounting Bolts

Caliper Bleed Valves

Brake Hose Clamp Bolts

Caliper Holder Shaft

Brake Caliper Mounting Bolts

Front Brake Disc Mounting Bolts

Parking Brake Position Switch Screws

Rear Master Cylinder Bleed Valve

Rear Master Cylinder Mounting Bolts

Rear Final Gear Case Front Cover Bolts

Spring Bracket Bolt

Rear Final Gear Case Gasket Screws

PERIODIC MAINTENANCE 2-9

29

49

94

90.5

90.5

8.8

1.3

450

200

15

27

7.8

24

8.8

N·m

15

8.8

8.8

8.8

23.5

23.5

17.2

41.5

17.2

7.8

8.8

17.2

3.4

6.2

8.8

17.5

17.5

23.5

27

24

8.8

1.3

33

41.5

0.4

7.8

1.8

0.80

0.90

1.8

2.4

2.4

1.8

4.2

0.35

0.63

0.90

1.8

1.8

2.4

3.4

4.2

0.04

0.80

2.8

2.4

0.90

0.13

3.0

5.0

9.6

9.2

9.2

0.90

2.8

0.80

2.4

0.90

0.13

45.9

20.4

1.5

Torque kgf·m

1.5

0.90

0.90

0.90

ft·lb

11

78 in·lb

78 in·lb

78 in·lb

Remarks

L

30 in·lb

55 in·lb

78 in·lb

13

13

17

17

17

13

31

13

69 in·lb

78 in·lb

13

24

31

4 in·lb

69 in·lb

20

18

78 in·lb

12 in·lb

20

69 in·lb

18

78 in·lb

12 in·lb

332

148

11

21

36

69

67

67

78 in·lb

L

L

LB

L

L

R

L

L

L

L

L

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Suspension

Front Shock Absorber Mounting Nuts

Front Suspension Arm Pivot Nuts

Steering Knuckle Joint Nuts

Rear Shock Absorber Mounting Nuts

Rear Suspension Arm Pivot Nuts

Rear Knuckle Mounting Nuts

Stabilizer Joint Nuts

Stabilizer Holder Bolts

Steering

Steering Wheel Mounting Nut

Steering Knuckle Joint Nuts

Main Shaft Mounting Bolts

Intermediate Shaft Clamp Bolts

Steering Gear Assembly Nuts

Tie-rod End Locknuts

Tie-rod End Nuts

Frame

Right and Left Bar Mounting Bolts

Upper Bar Mounting Bolts

Back Bar Mounting Bolts

Bottom Guard Bolts

Front Guard Bolts

Seat Belt Case Mounting Nuts

Seat Belt Mounting Bolts

Seat Belt Buckle Mounting Bolts

Seat Belt Bracket Mounting Bolts

Seat Plate Bolts

Brake Pedal Bracket Mounting Bolts, L = 20 mm

(0.79 in.)

Brake Pedal Bracket Mounting Bolts, L = 30 mm (1.2

in.)

Center Bracket Mounting Bolts

Right Frame Pipe Mounting Bolts

Bracket Bolts

Heart Guard Bolts

Electrical System

Starter Motor Mounting Bolts

Starter Motor Terminal Locknut

Starter Motor Cable Mounting Nut

Starter Motor Through Bolts

Starter Motor Clutch Bolts

Left Engine Cover Bolts

34.3

22

34.3

47

8.8

98

46.5

46.5

8.8

31.5

46.5

41.5

46.5

46.5

8.8

34.3

8.8

11

6.8

5.0

34

5.9

N·m

57.5

87.5

46.5

95.5

87.5

57.5

57.5

31.5

54

46.5

41.5

21.5

95.5

44

41.5

3.5

2.2

3.5

4.8

0.90

3.2

4.7

4.2

4.7

10

4.7

4.7

0.90

4.7

0.90

3.5

0.90

1.1

0.69

0.51

3.5

0.60

Torque kgf·m

8.9

5.9

5.9

3.2

5.9

8.9

4.7

9.7

5.5

4.7

4.2

2.2

9.7

4.5

4.2

72

34

34

78 in·lb

23

34

31

34

34

78 in·lb

25

25

16

25

35

78 in·lb

78 in·lb

97 in·lb

60 in·lb

44 in·lb

25

52 in·lb

ft·lb

65

42

42

23

42

65

34

70

70

32

31

40

34

31

17

Remarks

R

L

L

L

L

R

R

R

R

L

R

R

R

Torque and Locking Agent

Fastener

Alternator Rotor Bolt

Alternator Cover Plugs

Crankshaft Sensor Mounting Bolts

Alternator Stator Bolts

Alternator Cover Bolts, L = 55 mm (2.17 in.)

Alternator Cover Bolts, L = 30 mm (1.18 in.)

Breather Plate Screws

Ignition Coil Mounting Bolts

Spark Plugs

Vacuum Actuator Bracket Bolts

Solenoid Valve Bracket Bolts

ECU Mounting Bolts

Engine Brake Actuator Mounting Bolts

Engine Brake Actuator Cover Bolt

Forward/Reverse Detecting Sensor Mounting Bolt

Speed Sensor Mounting Bolt

Reverse Position Switch

Neutral Position Switch

4WD Position Switch

Water Temperature Sensor

Radiator Fan Assembly Bolts

Oil Pressure Switch

Battery Holder Mounting Nuts

Regulator/Rectifier Mounting Bolts

PERIODIC MAINTENANCE 2-11

5.9

13

8.8

8.8

6.9

8.8

8.8

14.9

N·m

127

17.5

5.9

13.5

8.8

8.8

2.9

12

8.3

15

16

8.8

8.8

15

15

15

0.90

1.5

0.90

1.5

1.5

1.5

1.2

0.85

1.5

1.6

0.90

0.90

0.30

0.60

1.3

0.90

0.90

0.70

0.90

Torque kgf·m

13.0

1.8

0.60

1.4

0.90

ft·lb

94

13

52 in·lb

10

78 in·lb

78 in·lb

26 in·lb

52 in·lb

115 in·lb

78 in·lb

78 in·lb

61 in·lb

78 in·lb

78 in·lb

11

78 in·lb

11

11

11

106 in·lb

73 in·lb

11

12

78 in·lb

Remarks

L

S

S

SS

2-12 PERIODIC MAINTENANCE

Torque and Locking Agent

The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners of Engine Parts

Threads dia.

mm (in.)

5 (0.20)

6 (0.24)

6 (0.24)

6 (0.24)

8 (0.31)

8 (0.31)

10 (0.39)

10 (0.39)

Mark of bolt head

4T

9T

7T

4T

7T

4T

7T

4T

N·m

2.2

∼

2.6

12

∼

15

7.8

∼

9.8

3.9

∼

4.9

18

∼

22

10

∼

14

39

∼

44

20

∼

24

Torque kgf·m

0.22

∼

0.27

1.2

∼

1.5

0.8

∼

1.0

0.4

∼

0.5

1.8

∼

2.2

1.0

∼

1.4

4.0

∼

4.5

2.0

∼

2.4

ft·lb

19

∼

23 in·lb

104

∼

130 in·lb

69

∼

87 in·lb

35

∼

43 in·lb

13

∼

16

87

∼

122 in·lb

29

∼

33

14

∼

17

Basic Torque for General Fasteners of Frame Parts

Torque

Threads dia. mm (in.)

5 (0.20)

6 (0.24)

8 (0.31)

10 (0.39)

12 (0.47)

14 (0.55)

16 (0.63)

18 (0.71)

20 (0.79)

N·m

3.4

∼

4.9

5.9

∼

7.8

14

∼

19

25

∼

34

44

∼

61

73

∼

98

115

∼

155

165

∼

225

225

∼

325 kgf·m

0.35

∼

0.50

0.60

∼

0.80

1.40

∼

1.90

2.60

∼

3.50

4.50

∼

6.20

7.40

∼

10.0

11.5

∼

16.0

17.0

∼

23.0

23.0

∼

33.0

ft·lb

2.5

∼

3.6

4.3

∼

5.8

10

∼

13

19

∼

25

33

∼

45

54

∼

72

83

∼

115

125

∼

165

165

∼

240

PERIODIC MAINTENANCE 2-13

Specifications

Item

Fuel System

Throttle Pedal Free Play

Standard

Idle Speed

Air Cleaner Element Oil

Cooling System

Coolant:

Type (Recommended)

5

∼

10 mm (0.20

∼

0.39 in.)

1 100 ±50 r/min (rpm)

High-quality foam air filter oil

Color

Mixed Ratio

Freezing Point

Total Amount

Engine Oil:

Type

Viscosity

Permanent type of anitfreze

(soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Green

Soft water 50%, Coolant 50%

−35°C (−31°F)

4.4 L (4.7 US qt)

Engine Top End

Valve Clearance:

Exhaust

Intake

0.20

∼

0.25 mm (0.0079

∼

0.0098 in.)

0.10

∼

0.15 mm (0.0039

∼

0.0059 in.)

Converter System

Belt Width

Belt Deflection

30.0

∼

30.6 mm (1.181

∼

1.205 in.)

22

∼

31 mm (0.87

∼

1.22 in.) (at checking)

22

∼

27 mm (0.87

∼

1.06 in.) (at adjusting)

Actuator Lever Guide Shoe Wear – – –

Engine Lubrication System

API SG, SH, SJ, SL or SM with JASO MA,

MA1 or MA2

SAE 10W-40

Capacity

2.4 L (2.5 US qt)

(When filter is not removed)

2.5 L (2.6 US qt)

(When filter is removed)

2.6 L (2.7 US qt)

(When engine is completely dry)

Wheels/Tires

Tire Tread Depth:

Front

Rear

Standard tire:

Front

– – –

– – –

Rear

26 × 8.00-12

MAXXIS, M989, Tubeless

26 × 10.00-12

MAXXIS, M990, Tubeless

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

28.6 mm (1.126 in.)

– – –

6 mm (0.24 in.)

– – –

– – –

– – –

– – –

– – –

4 mm (0.16 in.)

4 mm (0.16 in.)

– – –

– – –

– – –

– – –

2-14 PERIODIC MAINTENANCE

Specifications

Item

Final Drive

Front Final Gear Case:

Gear Case Oil:

Type

Standard

Viscosity

Oil Level

Capacity

Rear Final Gear Case:

Gear Case Oil:

Type

API SG, SH, SJ, SL or SM with JASO MA,

MA1 or MA2

SAE 10W-40

Filler opening bottom

0.7 L (0.74 US qt)

Oil Level

Capacity

Brakes

Brake Fluid:

MOBIL FLUID 424, CITGO

TRANSGARD TRACTOR HYDRAULIC

FLUID or EXXON HYDRAUL 560

Filler opening bottom

1.0 L (1.06 US qt)

Type

Brake Pads:

DOT 3

Pad Lining Thickness 3.9 mm (0.15 in.)

Brake Pedal:

Brake Pedal Play 2

∼

10 mm (0.08

∼

0.39 in.)

Steering

Steering Wheel Free Play 0

∼

20 mm (0

∼

0.79 in.)

Electrical System

Spark Plug Gap 0.7

∼

0.8 mm (0.028

∼

0.031 in.)

Rear Brake Light Switch Timing ON after 10 mm (0.4 in.) of pedal travel

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

1 mm (0.04 in.)

– – –

– – –

– – –

– – –

Special Tools

Inside Circlip Pliers:

57001-143

Valve Adjusting Screw Holder:

57001-1217

Valve Adjuster:

57001-1232

Oil Filter Wrench:

57001-1249

PERIODIC MAINTENANCE 2-15

Filler Cap Driver:

57001-1454

Pulley Holder Attachment:

57001-1472

Flywheel & Pulley Holder:

57001-1605

Belt Deflection Gauge:

57001-1713

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Throttle Pedal Free Play Inspection

•

Check that the throttle pedal moves smoothly from full open to close.

If the throttle pedal does not return properly, lubricate the throttle cable (see Throttle Cable Lubrication in the Fuel

System chapter).

•

Check the throttle pedal play [A].

Throttle Pedal Play

Standard: 5

∼

10 mm (0.20

∼

0.39 in.)

If the play is incorrect, adjust the throttle cable.

Throttle Pedal Free Play Adjustment

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Throttle Link Case Cover

•

Loosen the locknut [A] and turn the adjusting nut [B] on the throttle cable until the cable has proper amount of play.

•

Tighten the locknut securely after adjustment.

Install:

Throttle Link Case Cover

Engine Upper Cover (see Engine Upper Cover Installation in the Frame chapter)

If the free play cannot be adjusted by using the rear cable adjusting nut, use the cable adjusting nuts [A] at front of the floorboard and make the necessary free play.

○

Move the rubber seat [B].

•

Start the engine.

•

With the transmission in neutral, operate the throttle pedal a few times to make sure that the idle speed does not change.

If the idle speed does change, the throttle cable may be improperly adjusted, incorrectly routed, or it may be damaged.

•

Correct any of these conditions before operation.

WARNING

Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. Follow the service manual to be make sure to correct any of these conditions.

Periodic Maintenance Procedures

•

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

Check the idle speed with a suitable tachometer.

If the idle speed is out of the specified range, check the

ISC valve (see ISC Valve Inspection) and vacuum hoses.

Idle Speed

Standard: 1 100 ±50 r/min (rpm)

PERIODIC MAINTENANCE 2-17

Idle Speed Adjustment

NOTE

○

Idle speed adjustment is best performed by ECU, so idle speed cannot be adjusted.

Air Cleaner Element Cleaning and Inspection

NOTE

○

In dusty areas, the element should be cleaned more frequently than the recommended interval.

○

After riding through rain or muddy terrains, the element should be cleaned immediately.

○

Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low-flash point solvents to clean the element.

•

Remove the air cleaner element (see Air Cleaner Element

Removal in the Fuel System chapter).

•

Clean the element [A] in a bath of high-flash point solvent.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Squeeze it dry in a clean towel [A]. Do not wring the element or blow it dry; the element can be damaged.

•

Check all the parts of the element for visible damage.

If any of the parts of the element are damaged, replace them.

•

After cleaning, saturate the element with a high-quality foam-air-filter oil, squeeze out the excess, then wrap it in a clean towel and squeeze it as dry as possible.

○

Be careful not to tear the sponge filter.

(KRF750ND/PD/RD/SD)

•

Remove the air cleaner element (see Air Cleaner Element

Removal in the Fuel System (DFI) chapter).

•

Clean the paper element [A] by tapping it lightly to loosen dust.

•

Below away the remaining dust by applying compressed air from the inside (clean side) to outside (dirty side).

•

Check all the parts of the element for visible damage.

If the element is damaged, replace it with a new one.

Air Cleaner Draining

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Lift up the cargo bed.

If any water or oil accumulates in the drain boots [A] , drain it by removing the boots. After draining, be sure to install the drain boots and clamps firmly.

Fuel Hose and Connections Inspection

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Check the fuel hose.

Replace the fuel hose if any fraying, leaks [A], cracks [B] or bulges [C] are noticed.

Periodic Maintenance Procedures

Replace the hose if it has been sharply bent or kinked.

[A] Hose Joints

[B] Fuel Hose

PERIODIC MAINTENANCE 2-19

•

Check that the fuel hose joints are securely connected.

○

Push and pull [A] the fuel hose joint [B] back and forth more than two times, and make sure it is locked.

If it does not locked, reinstall the hose joint.

WARNING

Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint.

Fuel Hose Replacement

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

•

Be sure to place a piece of cloth around the fuel hose joint.

•

Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

When removing with standard tip screwdriver

•

Insert the standard tip screwdriver [A] into the slit on the joint lock [B].

•

Turn the driver to disconnect the joint lock.

When removing with fingers

•

Open and push up [C] the joint lock with your fingers.

NOTICE

Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.

•

Pull the fuel hose out of the pipe.

•

Cover the delivery pipe with the vinyl bag to keep it clean.

•

Remove the vinyl bag on the pipe.

•

Check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [A].

•

Replace the fuel hose with a new one.

•

Apply engine oil to the pipe.

•

Insert the fuel hose joint [A] securely onto the pipe [B] and push down the joint lock [C].

•

Push and pull the fuel hose joint back and forth [A] more than two times and make sure it is locked and doesn’t come off.

WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

•

Start the engine and check the fuel hose for leaks.

Periodic Maintenance Procedures

Cooling System

Radiator Cleaning

NOTICE

Clean the radiator screen and the radiator in accordance with the Periodic Maintenance Chart.

In dusty areas, they should be cleaned more frequently than the recommended interval.

After riding through muddy terrains, the radiator screen and the radiator should be cleaned immediately.

PERIODIC MAINTENANCE 2-21

•

Remove the front fender front (see Front Fender Front

Removal in the Frame chapter).

•

Remove:

Radiator Cover (see Radiator Removal in the Cooling chapter)

Radiator Screen Mounting Screws [A] (bothside)

Radiator Screen [B]

•

Clean the radiator screen in a bath of tap water, and then dry it with compressed air or by shaking it.

•

Clean the radiator.

NOTICE

When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage.

Keep the steam gun [A] away more than 0.5 m (20 in.) [B] from the radiator core.

Hold the steam gun perpendicular [C] (not oblique

[D]) to the core surface.

Run the steam gun following the core fin direction.

Water Hoses and Connections Inspection

○

The high pressure inside the water hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.

•

Check that the hoses are securely connected and clamps are tightened correctly.

Coolant Change

WARNING

Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely.

Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Left Cover (see Left Cover Removal in the Frame chapter)

Engine Bottom Guard (see Engine Bottom Guard Removal in the Frame chapter)

•

Place a container and a suitable paper [A] or plate under the drain plug [B] at the bottom of the water pump cover

[C], and then remove the drain plug.

•

Remove the radiator cap [A] in two steps. First, turn the cap counterclockwise to the first step. Then push and turn it further in the same direction and remove the cap.

•

The coolant will drain from the radiator and engine.

•

Remove:

Torque Converter Intake Duct

•

Place a container under the drain plug [A] at the front cylinder, then remove the drain plug.

•

Place a container under the drain plug [A] at the rear cylinder, then remove the drain plug.

Periodic Maintenance Procedures

•

Remove:

Overflow Hose [A] and Clamp

Screw [B]

•

Remove the reserve tank cap [C], and pour the coolant into a container.

PERIODIC MAINTENANCE 2-23

•

Install the water hoses to the water pipes and tighten the clamp screw.

•

Install:

Overflow Hose and Clamp

Reserve Tank [A]

○

Insert the projection [B] into the grommet [C].

•

Tighten the screws.

•

Fill the radiator up to the radiator filler neck [A] with coolant.

NOTE

○

Pour in the coolant slowly so that the air in the engine and radiator can escape.

•

Fill the reserve tank up to the F (Full) level line with coolant.

NOTE

○

Pour in the coolant slowly so that the air in the engine and radiator can escape.

NOTICE

Soft or distilled water must be used with the antifreeze in the cooling system.

If hard water is used in the system, it causes scale accumulation in the water passages, considerably reducing the efficiency of the cooling system.

Water and Coolant Mixture Ratio (when shipping)

Soft Water: 50%

Coolant:

Freezing Point:

50%

−35°C (−31°F)

Total Amount: 4.4 L (4.7 US qt)

NOTE

○

Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Bleed the air from the cooling system as follows.

○

Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant.

○

Tap the radiator hoses to force any air bubbles caught inside.

○

Stop the engine and add coolant up to the radiator filler neck.

•

Install the radiator cap.

•

Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine.

•

Check the coolant level in the reserve tank after the engine cools down.

If the coolant level is lower than the L (Low) level line [A], add coolant to the F (Full) level line [B].

NOTICE

Do not add more coolant above the full level line.

•

Install the reserve tank cap.

Engine Top End

Valve Clearance Inspection

NOTE

○

Check the valve clearance only when the engine is cold

(at room temperature).

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Air Cleaner Housing and Duct (see Air Cleaner Housing and Duct Removal in the Fuel System (DFI) chapter)

Air Outer Duct (see Torque Converter Cover Removal in the Converter System chapter)

Center Bracket (see Center Bracket Removal in the

Frame chapter)

Valve Adjusting Caps [A]

•

Remove

NC/PC/RC/SC/VC):

(KRF750NA/PA/RA/SA/TA

Left Cover (see Left Cover Removal in the Frame chapter)

Bolts [A] and Engine Left Cover [B]

∼

Periodic Maintenance Procedures

•

Remove (KRF750ND/PD/RD/SD):

Alternator Cover Center Cap [A]

Special Tool — Filler Cap Driver: 57001-1454

PERIODIC MAINTENANCE 2-25

•

Remove the timing inspection plug [A].

Special Tool — Filler Cap Driver [B]: 57001-1454

•

Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until “T-R” mark [A] on the alternator rotor aligns with the notch [B] as shown: the end of the compression stroke in the rear cylinder head.

•

Measure the clearance for all four valves, one at a time between the end of the valve stem and the adjusting screw [A] with the thickness gauge [B].

Valve Clearance (when cold)

Exhaust 0.20

∼

0.25 mm (0.0079

∼

0.0098 in.)

Intake 0.10

∼

0.15 mm (0.0039

∼

0.0059 in.)

If the valve clearance is not correct, adjust it (see Valve

Clearance Adjustment).

•

Then, turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until “T-F” mark [A] on the alternator rotor aligns with the notch [B] as shown: the end of the compression stroke in the front cylinder head.

•

Measure the clearance for all four valves, one at a time between the end of the valve stem and the adjusting screw with the thickness gauge.

Valve Clearance (when cold)

Exhaust 0.20

∼

0.25 mm (0.0079

∼

0.0098 in.)

Intake 0.10

∼

0.15 mm (0.0039

∼

0.0059 in.)

If the valve clearance is not correct, adjust it (see Valve

Clearance Adjustment).

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Valve Clearance Adjustment

Remove the valve adjusting caps.

•

Loosen the locknut and turn the adjusting screw until the clearance is correct.

•

For the KRF750NA/PA/RA/SA/TA

∼

NB/PB/RB/SB/VB early models, using the valve adjuster [A], hold the adjusting screw from turning and tighten the locknut.

Special Tool — Valve Adjuster: 57001-1232

Torque — Valve Adjusting Screw Locknuts: 12 N·m (1.2

kgf·m, 106 in·lb)

•

For the KRF750NC/PC/RC/SC/VC

∼ models, holding the adjusting screw with the holder, tighten the locknut.

Special Tool — Valve Adjusting Screw Holder: 57001-1217

Torque — Valve Adjusting Screw Locknuts: 12 N·m (1.2

kgf·m, 106 in·lb)

•

Recheck the clearance.

If the clearance is incorrect, repeat the adjustment procedure.

If the clearance is correct, perform the adjustment procedure on the other valve.

Spark Arrester Cleaning

WARNING

The muffler can become extremely hot during normal operation and cause severe burns. Since the engine must be running during this procedure, wear heat-resistant gloves while cleaning the spark arrester.

•

Remove:

Bolts [A]

Spark Arrester [B]

•

Clean the spark arrester [A] in a bath of high-flash point solvent and if necessary use a fine wire brush to gently remove any particles in the screen.

Periodic Maintenance Procedures

•

In an open area away from combustible materials, start the engine with the transmission in neutral.

•

Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler.

PERIODIC MAINTENANCE 2-27

DANGER

Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas.

Inhaling carbon monoxide can cause serious brain injury or death.

DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area.

•

Stop the engine.

•

Apply grease to the new gasket [A] and install it on the muffler.

•

Install the spark arrester [B] so that the opening [C] of the pipe faces downward.

•

Tighten:

Torque — Spark Arrester Mounting Bolts: 13 N·m (1.3 kgf·m,

115 in·lb)

Converter System

Converter Drive Belt Wear Inspection

Inspection of the drive belt is required at least every 200 hours, 6 months of vehicle use or 4 000 km (2 500 mi.) whichever comes first. An average day of use is calculated as 20 km (13 mi.) per day or 1.1 hours. More frequent inspection is necessary if the vehicle is subjected to hard usage.

WARNING

Neglect, abuse, or failure to maintain the transmission can result in a severely worn or damaged drive belt locking up the transmission and wheels. This can cause the operator to lose control and have an accident resulting in injury or death. Maintain according to periodic maintenance chart.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Bands [A] (cut)

Air Outlet Duct [B]

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Check the belt [A] for breaks.

If necessary, replace the belt.

•

Push the drive belt [A] between the driven sheaves and check the belt position in the driven sheaves.

If the upper surface [B] of the drive belt is lowered 1.5

mm (0.059 in.) [C] or more from the edge [D] of sheaves, check the belt wear as follows.

•

Remove the torque converter cover (see Torque Converter Cover Removal in the Converter System chapter).

•

Measure the width [A] of the belt at several locations with a pair of suitable straightedges [B] as shown.

If any measurements exceed the service limit, replace the belt.

Belt Width

Standard:

Service Limit:

30.0

∼

30.6 mm (1.181

∼

1.205 in.)

28.6 mm (1.126 in.)

•

Check the belt [A] for abnormal wear [B].

○

Measure the width [C] of the belt at abnormal wear point.

If any measurements exceed 0.5 mm (0.02 in.), replace the belt.

•

Check the belt for cracks, breaks, or peeling.

If necessary, replace the belt.

Belt [A]

Crack [B]

Broken [C]

Peeling [D]

Periodic Maintenance Procedures

NOTE

○

Whenever the belt is replaced, inspect the drive and the driven pulleys.

•

Install the air outlet duct (see Torque Converter Cover Installation in the Converter System chapter).

Drive Belt Deflection Inspection

•

Put the transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Bolts [A]

Clamp [B]

Cover [C]

•

Set the cover plate [A] on the torque converter cover [B] with two bolts [C].

Special Tool — Belt Deflection Gauge: 57001-1713

PERIODIC MAINTENANCE 2-29

•

Put the belt deflection gauge [A] along with the semi-circle cutout [B] in the cover plate and let the flat end of the gauge contact at right angle to the belt [C].

NOTE

○

Take care not to drop the gauge in the converter cover.

•

Press [A] the gauge head until the 59 N (6 kgf, 13 lb) scale line [B] aligns with the top end of the stopper [C].

•

Make a line mark [D] on the gauge at the upper surface of the cover plate [E].

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Remove the gauge and measure the distance [L] between the mark [D] and the gauge bottom end.

•

Calculate the belt deflection [H].

H = L (mm) – 82.4 (mm) or

H = L (in.) – 3.24 (in.) Belt Deflection

Belt Deflection

Standard:

22

∼

31 mm (0.87

∼

1.22 in.) (at checking)

(For reference) The 82.4 mm (3.24 in.) is the distance between the top surface of cover plate and the design base point of the drive belt for measuring.

If the belt deflection is not within the specified range, adjust the deflection by adding or removing spacers on the fixed sheave of the driven pulley.

NOTE

○

This is timesaving preliminary drive belt deflection measuring method. When recheck the belt deflection after deflection adjustment, follow the standard method described below.

○

If the belt deflection is not within the standard, adjust it by adding or removing spacers on the fixed sheave of the driven pulley.

NOTE

○

For easy drive belt deflection judgment, put a 9 mm wide tape [A] at the position on the belt deflection gauge as shown in the figure. With this tool the technician can judge the deflection directly by checking the position of the tape against the cover plate.

Standard Drive Belt Deflection Measurement

•

After deflection adjustment, check the belt deflection before installing the CVT cover following the method described below.

•

Measure the belt deflection [A] at the middle of two pulleys with a straightedge, the belt deflection gauge and a ruler.

•

Place a straightedge [B] on top of the belt between the drive pulley [C] and the driven pulley [D].

•

Push the belt away from the straightedge with the belt deflection gauge. Press the gauge head until the 59 N scale line aligns with the top end of the stopper.

Belt Deflection

Standard:

22

∼

27 mm (0.87

∼

1.06 in.) (at adjusting)

If the belt deflection is not within the specified range, adjust the deflection again.

Periodic Maintenance Procedures

Converter Drive Belt Deflection Adjustment

•

Disassemble the driven pulley (see Driven Pulley Disassembly in the Converter System chapter).

If the belt deflection is more than 31 mm (1.22 in.), remove the spacers to decrease it.

○

The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.3 mm (0.051 in.) change in belt deflection.

If the adjustment cannot be done within the specified range even if the shim is removed, replace the drive belt.

If the belt deflection is less than 22 mm (0.87 in.), add the spacers [A] to increase it.

○

The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.6 mm (0.063 in.) change in belt deflection.

PERIODIC MAINTENANCE 2-31

NOTE

○

When using the plural spacers, install the thick spacer to the movable sheave side and thin spacer to the fixed sheave side.

Spacers

Part No.

92026-0034

92026-1569

92026-1617

92026-1565

Thickness

0.3 mm (0.012 in.)

0.6 mm (0.024 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

92026-1570 1.4 mm (0.055 in.)

•

Assemble the driven pulley (see Driven Pulley Assembly in the Converter System chapter).

•

With the transmission in neutral, rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection.

•

Measure the belt deflection again and repeat the above procedures until it is within the standard range.

•

Using the flywheel & pulley holder and pulley holder attachment, tighten the new driven pulley nut.

Special Tools — Flywheel & Pulley Holder: 57001-1605

Pulley Holder Attachment: 57001-1472

Torque — Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb)

Actuator Lever (Engine Brake Control Lever)

Assembly Inspection

•

Remove the torque converter cover (see Torque Converter Cover Removal in the Converter System chapter).

•

Measure the width [A] of the plastic guide shoe [B] of the actuator lever assembly.

If the guide contact area width is greater than the service limit, replace the actuator lever assembly.

Actuator Lever Guide Shoe

Service Limit: 6 mm (0.24 in.)

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Engine Lubrication System

Engine Oil Change

•

Remove:

Bottom Guard Bolts [A]

Bottom Guard [B]

•

Support the vehicle so that it is level, both side to side and front to rear after warming up the engine.

•

Remove the engine oil drain plug [A] to drain the oil.

○

The oil in the filter can be drained by removing the filter

(see Oil Filter Change).

•

Replace the oil drain plug gasket with a new one.

•

Tighten:

Torque — Engine Oil Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)

•

Pour in the specified type and amount of oil.

Engine Oil

Type: API SG, SH, SJ, SL or SM with JASO MA,

MA1 or MA2

Viscosity: SAE 10W-40

Amount: 2.4 L (2.5 US qt)

(When filter is not removed)

2.5 L (2.6 US qt)

(When filter is removed)

2.6 L (2.7 US qt)

(When engine is completely dry)

NOTE

○

Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.

•

Install:

Bottom Guard (see Engine Bottom Guard Installation in the Frame chapter)

Periodic Maintenance Procedures

Oil Filter Replacement

•

Remove:

Engine Bottom Guard (see Engine Bottom Guard Re-

• moval in the Frame chapter)

Drain the engine oil.

•

Remove the oil filter [A] with the oil filter wrench [B].

Special Tool — Oil Filter Wrench: 57001-1249

PERIODIC MAINTENANCE 2-33

•

Replace the filter with a new one.

•

When installing the oil filter, be careful of the following.

○

Apply oil to the gasket [A] before installation.

○

Tighten the filter with the oil filter wrench.

Special Tool — Oil Filter Wrench: 57001-1249

Torque — Oil Filter: 17.5 N·m (1.8 kgf·m, 13 ft·lb)

○

Pour in the specified type and amount of oil.

•

Install:

Engine Bottom Guard (see Engine Bottom Guard Installation in the Frame chapter)

Wheels/Tires

Tire Inspection

•

Examine the tire for damage and wear.

If the tire is cut or cracked, replace it.

○

Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement.

○

Remove any foreign objects from the tread. After removal, check for leaks with a soap and water solution.

•

Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurements at several places.

If any measurements are less than the service limit, replace the tire.

Tire Tread Depth

Service Limit:

Front 4 mm (0.16 in.)

Rear 4 mm (0.16 in.)

Standard Tire

Front: 26 × 8.00 — 12

MAXXIS, M989, Tubeless

Rear: 26 × 10.00 — 12

MAXXIS, M990, Tubeless

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Wheels Nuts Tightness Inspection

•

Check the tightness of all the wheel nuts.

If there are loose nut, first loosen by 1/2 turn, then retorque them to the specified torque.

Torque — Wheel Nuts: 110 N·m (11.2 kgf·m, 81 ft·lb)

○

Tighten the wheel nuts [1]

∼

[4] in a criss-cross pattern.

Final Drive

•

Differential Shift Lever Play Inspection

Check the differential shift lever travel by feeling clicks.

•

Push the center [A] of the damper [B] with 98 N (10 kgf,

22 lbf) of force.

○

The differential shift lever travel should be about 5 notches (clicks).

Differential Shift Lever Travel

Standard: about 5 notches (clicks) at 98 N (10 kgf, 22 lbf)

If the lever travel is more than 9 notches (clicks) at 98 N

(10 kgf, 22 lbf), adjust the cable.

Differential Shift Lever Play Adjustment

•

Loosen the differential shift cable locknuts [A] at the front final gear case.

•

Turn the nuts to obtain the correct amount of travel.

•

Tighten:

Torque — Differential Shift Cable Locknuts: 9.8 N·m (1.0

kgf·m, 87 in·lb)

Front Final Gear Case Oil Change

•

Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle.

•

Park the vehicle so that it is level, both side-to-side and front-to-rear.

•

Place an oil pan beneath the front final gear case and remove the oil drain plug [A].

WARNING

Oil on tires can cause loss of traction and an accident resulting in serious injury or death. When draining or filling the final gear case, do not spill oil the tire or rim. Clean any oil that may spill with a high-flash point solvent.

•

After the oil has completely drained out, install the oil drain plug with a new O-ring.

○

Apply grease to the O-ring.

•

Tighten:

Torque — Front Final Gear Case Oil Drain Plug: 15 N·m (1.5

kgf·m, 11 ft·lb)

Periodic Maintenance Procedures

•

Fill the gear case up to the bottom of filler opening [A] with the oil specified below.

PERIODIC MAINTENANCE 2-35

Front Final Gear Case Oil

Type: API SG, SH, SJ, SL or SM with JASO MA,

MA1 or MA2

Viscosity: SAE 10W-40

Capacity: 0.7 L (0.74 US qt)

NOTE

○

Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed according to the chart.

•

Be sure the O-ring [A] is in place, and tighten the filler cap

[B].

○

Apply grease to the O-ring.

Torque — Front Final Gear Case Oil Filler Cap: 29 N·m (3.0

kgf·m, 21 ft·lb)

Rear Final Gear Case Oil Change

•

Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle.

•

Park the vehicle so that it is level, both side-to-side and front-to-rear.

•

Place an oil pan beneath the rear final gear case and remove the oil drain plug [A].

WARNING

Oil on tires can cause loss of traction and an accident resulting in serious injury or death. When draining or filling the final gear case, do not spill oil the tire or rim. Clean any oil that may spill with a high-flash point solvent.

•

After the oil has completely drained out, install the oil drain plug with a new O-ring.

○

Apply grease to the O-ring.

•

Tighten:

Torque — Rear Final Gear Case Oil Drain Plug: 15 N·m (1.5

kgf·m, 11 ft·lb)

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Fill the final gear case up to the bottom of filler opening

[A] with the oil specified below.

Rear Final Gear Case Oil

Type: MOBIL FLUID 424, CITGO TRANSGARD

TRACTOR HYDRAULIC FLUID or EXXON

HYDRAUL 560

Capacity: 1.0 L (1.06 US qt)

○

Do not use mixing the above oils.

•

Be sure the O-ring [A] is in place, and tighten the filler cap

[B].

○

Apply grease to the O-ring.

Torque — Rear Final Gear Case Oil Filler Cap: 29 N·m (3.0

kgf·m, 21 ft·lb)

Brakes

Brake Fluid Level Inspection

•

With the vehicle on level ground, check that the fluid level in the reservoir [A] is between the upper and lower level lines.

Upper Level ine (MAX) [B]

Lower Level ine (MIN) [C]

If the fluid level is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line.

WARNING

Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified.

•

Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

WARNING

Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake pedal has a soft or «spongy» feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately.

Periodic Maintenance Procedures

Brake Fluid Change

•

Level the brake fluid reservoir [A].

NOTE

○

The fluid level must be checked several times during the fluid changing and replenished as necessary. If the fluid in the reservoir runs completely out any time during fluid changing, air bleeding must be done since air will have entered the line.

•

Remove the reservoir cap [B].

•

Remove the rubber cap from the bleed valve on the rear master cylinder.

•

Connect a clear plastic hose [A] to the bleed valve, run the other end of the hose into a container.

NOTE

○

Start with the rear master cylinder and finish with the front left or right caliper.

PERIODIC MAINTENANCE 2-37

•

Fill the reservoir with new brake fluid.

•

Change the brake fluid as follows:

1. Open bleed valve.

2. Pump brake pedal and hold it.

3. Close bleed valve.

4. Release brake pedal.

•

Repeat the previous step until fresh brake fluid comes out into the plastic hose or the color of the fluid changes.

•

Remove the clear plastic hose.

•

Tighten:

Torque — Rear Master Cylinder Bleed Valve: 5.4 N·m (0.55

kgf·m, 48 in·lb)

•

Install the rubber cap on the bleed valve.

•

Repeat the previous step for front calipers [A].

•

After changing the fluid, tighten the caliper bleed valves.

Torque — Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

When brake fluid changing is finished, add the fluid to the upper level in the reservoir.

•

Tighten:

Torque — Front Master Cylinder Reservoir Cap: 3.4 N·m

(0.35 kgf·m, 30 in·lb)

•

After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage.

If necessary, bleed the air from the brake lines (see Blake

Line Air Bleeding in the Brakes chapter).

WARNING

Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake pedal has a soft or «spongy» feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately.

Brake Pedal Play Inspection

•

Check the brake pedal play [A].

Brake Pedal Play

Standard: 2

∼

10 mm (0.08

∼

0.39 in.)

If the play is not correct, adjust it.

•

Loosen the locknut [A] and turn the push rod [B] to obtain the correct amount of free play.

•

Tighten:

Torque — Push Rod Locknut: 17.2 N·m (1.8 kgf·m, 13 ft·lb)

•

Check the brake for good braking power and no brake drag.

WARNING

Insufficient free play can cause brake heating and drag, resulting in skidding and loss of control which could cause an accident resulting in serious injury or death. Be sure the brake free play is adjusted to the specification.

Periodic Maintenance Procedures

Brake Master Cylinder Cup and Dust Seal

Replacement

•

Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter).

•

Remove the piston stop bolt [A] and washer [B].

•

Remove the dust seal [C] and then the retainer [D] with the circlip pliers.

Special Tool — Inside Circlip Pliers: 57001-143

○

Remove the piston assembly (two pistons) by lightly tap the master cylinder on a wooden block.

Pistons [E]

Springs [F]

Secondary Cups [G]

Primary Cups [H]

Master Cylinder [I]

○

Be careful of the secondary cup [A] direction [B].

PERIODIC MAINTENANCE 2-39

•

Assemble the master cylinder:

○

Clean all the parts including the master cylinder with brake fluid or alcohol, and apply brake fluid to the removed parts and the inner wall of the cylinder.

NOTICE

Use only brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the brake.

○

Push the piston assembly in all the way with a screwdriver and install the piston stop bolt. Use a new aluminum washer.

○

Tighten:

Torque — Piston Stop Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Reservoir Clamp Bolt: 6.2 N·m (0.63 kgf·m, 55 in·lb)

•

Install the front master cylinder (see Front Master Cylinder

Installation in the Brakes chapter).

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rear Brake Master Cylinder Cup, O-ring and Boot

Replace

•

Remove:

Rear Brake Master Cylinder (see Rear Brake Master

Cylinder Removal in the Brakes chapter)

Push Rod [A]

Boot [B]

•

Remove:

Circlip [A]

Special Tool — Inside Circlip Pliers: 57001-143

•

Remove:

Piston [A]

Cup [B]

Spring [C]

O-rings [D]

•

Assemble the master cylinder.

•

Clean all the parts including the master cylinder with brake fluid or alcohol, and apply brake fluid to the removed parts and the inner wall of the cylinder.

NOTICE

Use only brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the brake.

Periodic Maintenance Procedures

•

Be careful of the cup [A] direction [B].

PERIODIC MAINTENANCE 2-41

•

Apply silicone grease:

New Cup [A]

New O-ring [B]

Push Rod End [C]

•

Install:

Spring [D] (as shown in the figure)

Piston [E]

New Cup and O-ring

New Circlip [F]

Special Tool — Inside Circlip Pliers: 57001-143

•

Install:

New O-ring [G]

Push Rod

New Boot [H]

○

Do not apply oil or grease to the seal part [I] of the boot.

•

Install the rear master cylinder (see Rear Brake Master

Cylinder Installation in the Brakes chapter).

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Hose and Pipe Inspection

•

The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it.

Replace it if any cracks [B] or bulges [C] are noticed.

•

The metal pipe will rust if the plating is damaged.

Replace the pipe if it is rusted, cracked (especially check the fittings), or if the plating is badly scratched.

Brake Hose Replacement

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Lift and hold the front fender rear (see Front Fender Rear

•

Removal in the Frame chapter).

Drain the brake fluid.

•

Remove:

Front Wheels (see Wheel Removal in the Wheels/Tires

• chapter)

Unscrew the nipple [A] and remove the brake pipe [B].

•

Immediately wipe up any brake fluid that spills.

NOTICE

Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.

•

Remove:

Retainer [A]

Banjo Bolt [B], Washers and Brake Hose [C]

•

Remove:

Nipple [A] (unscrew)

Brake Pipe [B]

Bolt [C]

Joint [D]

Periodic Maintenance Procedures

•

Remove:

Banjo Bolt [A], Washers and Brake Hose [B]

PERIODIC MAINTENANCE 2-43

•

Remove:

Clamp Bolts [A] and Clamp [B] (both sides)

Grommets [C] (both sides)

•

Install:

New Brake Hose [A]

Clamp Bolts [B] and Clamp [C] (both sides)

Grommets [D] (both sides)

Banjo Bolts [E] and New Washers

•

Touch the stopper of the brake hose to the stopper on the calliper.

•

Tighten:

Torque — Brake Hose Banjo Bolts: 23.5 N·m (2.4 kgf·m, 17 ft·lb)

•

Install:

Joint [A]

Bolt [B]

Brake Pipe [C]

Nipple [D]

•

Tighten:

Torque — Brake Pipe Nipple: 17.5 N·m (1.8 kgf·m, 13 ft·lb)

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Install:

New Brake Hose [A]

Banjo Bolts [B] and New Washers

○

Touch the brake hose clasp [C] to the stopper [D].

•

Tighten:

Torque — Brake Hose Banjo Bolts: 23.5 N·m (2.4 kgf·m, 17 ft·lb)

•

Install:

Retainer [E]

Brake Pipe [F]

Nipple

•

Tighten:

Torque — Brake Pipe Nipple: 17.5 N·m (1.8 kgf·m, 13 ft·lb)

•

Fill the reservoir with new brake fluid (see Brake Fluid

Change).

•

Check that the brake line has proper fluid pressure and no fluid leakage.

•

Install the removed parts.

Parking Brake Pedal Inspection

•

Push down the parking brake pedal [A] until it is stopped.

○

The vehicle should not roll while parked.

•

Pull the parking release lever [B] above and return the pedal to its rest position.

If the pedal does not work correctly, adjust it (see Parking

Brake Cable Installation in the Brakes chapter).

WARNING

Insufficient free play can cause brake heating and drag, resulting in skidding and loss of control which could cause an accident resulting in serious injury or death. Be sure the brake free play is adjusted to the specification.

Front Brake Pad Wear Inspection

•

Check the lining thickness [A] of the pads in each caliper.

If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.

Pad Lining Thickness

Standard: 3.9 mm (0.15 in.)

Service Limit: 1 mm (0.04 in.)

Periodic Maintenance Procedures

Front Brake Caliper Piston Seal and Dust Seal

Replacement

•

Remove:

Caliper (see Front Brake Caliper Removal in the Brakes chapter)

Pads (see Brake Pad Removal in the Brakes chapter)

Anti-rattle Spring

•

Using compressed air, remove the piston.

○

Cover the caliper opening with a clean, heavy cloth [A].

○

Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper.

WARNING

The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston.

PERIODIC MAINTENANCE 2-45

NOTE

○

If compressed air is not available, do as follows with the brake hose connected to the caliper.

○

Prepare a container for brake fluid.

○

Remove the pads (see Brake Pad Removal) and anti

-rattle spring.

○

Pump the brake pedal to remove the caliper piston.

•

Remove:

Dust Seals [A]

Piston Seals [B]

•

Replace the piston seal [A] with a new one.

○

Apply silicone grease to the piston seal, and install it into the cylinder by hand.

•

Replace the dust seal [B] with a new one.

○

Apply brake fluid to the dust seal, and install it into the cylinder by hand.

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Apply brake fluid to the outside of the pistons [A] and inside of the cylinder

•

Push the seals into the cylinder by hand. Take care that neither the cylinder nor the piston skirt gets scratched.

•

Replace the rubber boots [B] if they are damaged.

•

Apply a thin coat of silicone grease to the caliper holder shafts [C] (Silicone grease is a special high temperature, water-resistant grease).

•

Install:

Caliper Holder [D]

•

Install the anti-rattle spring [A] in the caliper as shown.

•

Install the pads (see Brake Pad Installation in the Brakes chapter).

Rear Brake Plates Replacement

•

Replace the steel plates and friction plates in accordance with the specified interval (see Rear Final Gear Case section in the Final Drive chapter).

Steering

•

Steering Inspection

Check steering wheel free play [A].

○

Set the front wheels straight ahead. Gently turn [B] the steering wheel left and right. The steering wheel free play is the amount of travel in the steering wheel, before the front wheels begin to turn.

Steering Wheel Free Play

Standard: 0

∼

20 mm (0

∼

0.79 in.)

If steering wheel free play is not correct, inspect the following:

Steering Wheel Mounting Nut (see Steering Wheel Centering in the Steering chapter)

Intermediate Shaft Clamp Bolts (see Steering Shaft Installation in the Steering chapter)

Steering Gear Assembly Bracket Bolts (see Steering

Gear Assembly Installation in the Steering chapter)

Steering Gear Assembly Mounting Rubber Dampers

Tie-rod End Nuts (see Steering Gear Assembly Installation in the Steering chapter)

If the inspections above are good but the free play is out of the specified, the steering gear assembly is damaged and should be replaced as a unit.

Periodic Maintenance Procedures

Steering Joint Dust Boot Inspection

•

Visually inspect the dust boots [A] at both the ends of the steering gear assembly.

Front [B]

If there is any signs of deterioration, cracks, or damage, replace the steering gear assembly together with these boots.

PERIODIC MAINTENANCE 2-47

Frame

Seat Belt Inspection

•

Check the belt [A] for damage or tear.

If necessary, replace the belt with a new one.

○

Check the tightness torque of the seat belt mounting bolts.

(both sides)

Torque — Right and Left Bar Mounting Bolts [A]: 98 N·m (10 kgf·m, 72 ft·lb)

Seat Belt Case Mounting Nuts [B]: 46.5 N·m (4.7

kgf·m, 34 ft·lb)

Seat Belt Bracket Mounting Bolt [C]: 41.5 N·m (4.2

kgf·m, 31 ft·lb)

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC [D]

KRF750ND/PD/RD/SD [E]

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Torque — Seat Belt Mounting Bolt [A]: 41.5 N·m (4.2 kgf·m,

31 ft·lb)

Torque — Seat Belt Buckle Mounting Bolts [A]: 46.5 N·m (4.7

kgf·m, 34 ft·lb)

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC [B]

KRF750ND/PD/RD/SD [C]

•

Check the operation of the buckle [A].

○

Set the plate [B] in the buckle, and confirm the plate does not come off when pulling it.

○

Set the plate in the buckle, and confirm the plate comes off when the buckle button [C] is pushed.

If the operation is not correct, visually inspect the plate.

If the plate is damaged, replace the plate assembly with a new one.

If the plate is not damaged, replace the buckle assembly.

Electrical System

Spark Plug Cleaning/Inspection

•

Remove the spark plug (see Spark Plug Removal in the

Electrical System chapter).

•

Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a wire brush or other suitable tool.

If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.

Periodic Maintenance Procedures

Spark Plug Gap Inspection

•

Measure the gap [A] with a wire-type thickness gauge.

If the gap is incorrect, carefully bend the side electrode

[B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

0.7

∼

0.8 mm (0.028

∼

0.031 in.)

PERIODIC MAINTENANCE 2-49

•

Brake Light Switch Inspection

Turn on the ignition switch.

•

Check the operation of the rear brake light switch by depressing the brake pedal.

If it does not as specified, adjust the brake light timing.

Brake Light Timing

Standard: On after about 10 mm (0.4 in.) of pedal travel [A]

Brake Light Timing Adjustment

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Lift and hold the front fender rear (see Front Fender Rear

Removal in the Frame chapter).

•

Adjust the brake light switch [A] up or down. To change the switch position, turn the adjusting nut [B].

Light sooner [C]

Light later [D]

NOTICE

To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.

Joint Boots Inspection

Front Axle/Steering Knuckle Joint Boots

Inspection

•

Visually inspect the front axle joint boots [A].

If the joint boot is torn, worn, deteriorated, or leaks grease, replace the joint boot or front axle assembly (see Front

Axle Joint Boot Replacement in the Final Drive chapter).

•

Visually inspect the knuckle joint boots [B].

If the joint boot is torn, worn, deteriorated, or leaks grease, replace the knuckle (see Steering Knuckle section in the

Steering chapter).

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Front Propeller Shaft Joint Boots Inspection

•

Remove:

Center Cover (see Center Cover Removal in the Frame chapter)

•

Visually inspect the boot [A] of the front propeller shaft.

If damage, tear or deterioration is found, replace the boots

(see Front Propeller Shaft section in the Final Drive chapter).

Tie-rod End Boots Inspection

•

Visually inspect the tie-rod end boots [A] of the tie-rods.

If the boot is torn, worn, deteriorated, or leaks grease, replace the tie-rod end (see Tie-Rod End Removal in the

Steering chapter).

Rear Propeller Shaft Joint Boots Inspection

•

Visually inspect the boots [A] of the rear propeller shaft.

If the joint boot is torn, worn, or deteriorated, replace the joint boot and check the propeller shaft (see Rear Propeller Shaft section in the Final Drive chapter).

Rear Axle/Stabilizer Joint Boots Inspection

•

Visually inspect the rear axle joint boots [A].

If the joint boot is torn, worn, deteriorated, or leaks grease, replace the joint boot or rear axle assembly (see Rear

Axle Joint Boot Replacement in the Final Drive chapter).

•

Visually inspect the stabilizer joint boots [B].

If the joint boot is torn, worn, deteriorated, or leaks grease, replace the stabilizer joint (see Stabilizer Removal in the

Suspension chapter).

General Lubrication

Lubrication

•

Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.

•

Lubricate the points listed below with indicated lubricant.

NOTE

○

Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.

Periodic Maintenance Procedures

Cables: Lubricate with Cable Lubricant

Rear Brake Inner Cable

Throttle Inner Cable

Variable Differential Shift Inner Cable

2WD/4WD Shift Inner Cable

•

Lubricate the cables by seeping the oil between the cable and housing.

○

The cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant.

PERIODIC MAINTENANCE 2-51

Points: Lubricate with Grease.

Throttle Inner Cable Ends [A]

Brake Cable Upper End

Variable Differential Control Cable Ends

2WD/4WD Shift Cable Ends

Slide Points: Lubricate with Grease.

Brake Lever

Brake Pedal Pivot Shaft

Throttle Pedal Pivot Shaft

Cables

Inspection

•

With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Bolts and Nuts Tightening

Tightness Inspection

•

Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition.

If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not listed in the appropriate chapter, see the Basic Torque Table (see Torque and

Locking Agent). For each fastener, first loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Bolts, Nuts, and Fasteners to be checked

Engine:

Engine Mounting Bolts

Engine Bracket Pipe Mounting Bolts

Exhaust Pipe Nuts

Muffler Mounting Bolts

Muffler Clamp Bolt

Spark Arrester Mounting Bolts

Throttle Pedal Pivot Clip

Fuel Tank Band Bolts

Transmission/Final Drive:

Shift Lever Assembly Nut

Shift Shaft Lever Bolt

Tie-rod End Bolt and Nut

Tie-rod End Locknuts

Differential Shift Lever Pivot Clip

Final Gear Case Mounting Bolts

Final Gear Case Bracket Bolts

Wheels:

Axle Nuts and Cotter Pins

Wheel Nuts

Brakes:

Front Master Cylinder Mounting Bolts

Master Cylinder Push Rod Clevis Pin Clip

Rear Master Cylinder Mounting Bolts

Brake Pedal Pivot Shaft Cotter Pin

Brake Caliper Mounting Bolts

Parking Brake Lever Assembly Mounting Bolts

Suspension:

Stabilizer Holder Bolts

Suspension Arm Pivot Nuts

Shock Absorber Mounting Nuts

Steering:

Steering Wheel Mounting Nut

Intermediate Shaft Clamp Bolts

Main Shaft Mounting Bolts and Nuts

Tie-rod End Nuts and Cotter Pins

Tie-rod End Locknuts

Periodic Maintenance Procedures

Frame:

Bars Mounting Bolts and Nuts

Front Guard Mounting Nuts

Cargo Bed Mounting Pin Clips

Seat Belt Mounting Bolts

Battery Holder Nuts

PERIODIC MAINTENANCE 2-53

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

Exploded View…………………………………………………………………………………………………………

DFI System……………………………………………………………………………………………………………..

3-4

3-8

DFI Parts Location……………………………………………………………………………………………………

3-16

Specifications ………………………………………………………………………………………………………….

3-18

Special Tools and Sealant …………………………………………………………………………………………

3-20

DFI Servicing Precautions …………………………………………………………………………………………

3-22

DFI Servicing Precautions ……………………………………………………………………………………

3-22

Troubleshooting the DFI System ………………………………………………………………………………..

3-24

Outline …………………………………………………………………………………………………………………

3-24

Inquiries to Rider……………………………………………………………………………………………………

3-29

DFI System Troubleshooting Guide ……………………………………………………………………………

3-32

Self-Diagnosis …………………………………………………………………………………………………………

3-36

Self-diagnosis Outline (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) …………………….

3-36

Self-diagnosis Outline (KRF750ND/PD/RD/SD) ………………………………………………………

Self-diagnosis Procedures (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ………………

3-36

3-37

Self-diagnosis Procedures (KRF750ND/PD/RD/SD) ………………………………………………..

How to Read Service Codes (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ……………

3-37

3-41

Service Code Reading (KRT750ND/PD/RD/SD) ……………………………………………………..

3-41

Service Code Erasing (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)……………………..

3-41

Service Code Erasing (KRF750ND/PD/RD/SD) ………………………………………………………

3-42

Service Code Table……………………………………………………………………………………………..

3-42

Backups …………………………………………………………………………………………………………….

3-43

Throttle Sensor (Service Code 11) ……………………………………………………………………………..

3-45

Throttle Sensor Removal/Adjustment …………………………………………………………………….

3-45

Throttle Sensor Input Voltage Inspection ………………………………………………………………..

Throttle Sensor Output Voltage Inspection ……………………………………………………………..

Throttle Sensor Resistance Inspection …………………………………………………………………..

Intake Air Pressure Sensor (Service Code 12) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ………………………………………………………………………………………………..

Intake Air Pressure Sensor Removal……………………………………………………………………..

Intake Air Pressure Sensor Installation…………………………………………………………………..

Intake Air Pressure Sensor Input Voltage Inspection………………………………………………..

Intake Air Pressure Sensor Output Voltage Inspection……………………………………………..

3-45

3-46

3-47

3-49

3-49

3-49

3-49

3-50

Intake Air Pressure Sensor (Service Code 12) (KRF750ND/PD/RD/SD)………………………….

3-55

Intake Air Pressure Sensor Removal……………………………………………………………………..

3-55

Intake Air Pressure Sensor Installation…………………………………………………………………..

3-55

Intake Air Pressure Sensor Input Voltage Inspection………………………………………………..

Intake Air Pressure Sensor Output Voltage Inspection……………………………………………..

3-55

3-56

Intake Air Temperature Sensor (Service Code 13)………………………………………………………..

3-61

Intake Air Temperature Sensor Removal/Installation………………………………………………..

Intake Air Temperature Sensor Output Voltage Inspection ………………………………………..

Intake Air Temperature Sensor Resistance Inspection ……………………………………………..

3-61

3-61

3-62

Water Temperature Sensor (Service Code 14) …………………………………………………………….

3-64

Water Temperature Sensor Removal……………………………………………………………………..

3-64

Water Temperature Sensor Installation…………………………………………………………………..

3-64

Water Temperature Sensor Output Voltage Inspection……………………………………………..

Water Temperature Sensor Resistance Inspection…………………………………………………..

3-65

3-66

Crankshaft Sensor (Service Code 21)…………………………………………………………………………

3-68

Crankshaft Sensor Removal/Installation…………………………………………………………………

Crankshaft Sensor Inspection……………………………………………………………………………….

3-68

3-68

3

3-2 FUEL SYSTEM (DFI)

Speed Sensor (Service Code 24)……………………………………………………………………………….

Speed Sensor Removal ……………………………………………………………………………………….

Speed Sensor Installation …………………………………………………………………………………….

Speed Sensor Input Voltage Inspection………………………………………………………………….

Speed Sensor Output Voltage Inspection ……………………………………………………………….

Vehicle-down Sensor (Service Code 31) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ..

Vehicle-down Sensor Removal ……………………………………………………………………………..

Vehicle-down Sensor Installation …………………………………………………………………………..

Vehicle-down Sensor Input Voltage Inspection………………………………………………………..

Vehicle-down Sensor Output Voltage Inspection ……………………………………………………..

Vehicle-down Sensor (Service Code 31) (KRF750ND/PD/RD/SD)………………………………….

Vehicle-down Sensor Removal ……………………………………………………………………………..

Vehicle-down Sensor Installation …………………………………………………………………………..

Vehicle-down Sensor Input Voltage Inspection………………………………………………………..

Vehicle-down Sensor Output Voltage Inspection ……………………………………………………..

Fuel Pump Relay (Service Code 46) …………………………………………………………………………..

Fuel Pump Relay Removal …………………………………………………………………………………..

Fuel Pump Relay Inspection …………………………………………………………………………………

Ignition Coils (#1, #2: Service Code 51, 52)…………………………………………………………………

Ignition Coil Removal/Installation…………………………………………………………………………..

Ignition Coil Winding Resistance …………………………………………………………………………..

Ignition Coil Input Voltage Inspection……………………………………………………………………..

Radiator Fan Relay (Service Code 56) (KRF750ND/PD/RD/SD)…………………………………….

Radiator Fan Relay Removal………………………………………………………………………………..

Radiator Fan Relay Inspection………………………………………………………………………………

Fuel Injectors ………………………………………………………………………………………………………….

Fuel Injector Removal ………………………………………………………………………………………….

Fuel Injector Installation ……………………………………………………………………………………….

Audible Inspection……………………………………………………………………………………………….

Fuel Injector Resistance Inspection ……………………………………………………………………….

Fuel Injector Power Source Voltage Inspection ……………………………………………………….

Fuel Injector Output Voltage Inspection ………………………………………………………………….

Fuel Injector Fuel Line Inspection ………………………………………………………………………….

FI Indicator Symbol (LCD) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ……………………

FI Indicator Symbol (LCD) Inspection …………………………………………………………………….

Yellow Engine Warning Indicator Light (LED) (KRF750ND/PD/RD/SD)……………………………

Yellow Engine Warning Indicator Light (LED) Inspection…………………………………………..

ECU ……………………………………………………………………………………………………………………….

ECU Removal …………………………………………………………………………………………………….

ECU Installation ………………………………………………………………………………………………….

ECU Power Supply Inspection………………………………………………………………………………

3-97

Fuel Line…………………………………………………………………………………………………………………

3-101

Fuel Pressure Inspection ……………………………………………………………………………………..

3-101

Fuel Flow Rate Inspection ……………………………………………………………………………………

3-102

Fuel Pump ………………………………………………………………………………………………………………

3-104

Fuel Pump Removal ……………………………………………………………………………………………

3-104

Fuel Pump Installation …………………………………………………………………………………………

3-104

3-92

3-95

3-95

3-96

3-96

3-97

3-97

3-97

3-86

3-88

3-88

3-88

3-90

3-90

3-90

3-91

3-80

3-80

3-83

3-83

3-83

3-83

3-86

3-86

3-73

3-74

3-76

3-76

3-76

3-76

3-77

3-80

3-70

3-70

3-70

3-70

3-70

3-73

3-73

3-73

Fuel Pump Operation Inspection …………………………………………………………………………..

3-105

Fuel Pump Operating Voltage Inspection ……………………………………………………………….

3-105

Pressure Regulator Removal………………………………………………………………………………..

3-106

Fuel Filter Cleaning……………………………………………………………………………………………..

3-107

Throttle Pedal and Cable…………………………………………………………………………………………..

3-110

Throttle Pedal Free Play Inspection……………………………………………………………………….

3-110

Throttle Pedal Free Play Adjustment ……………………………………………………………………..

3-110

Throttle Pedal Position Adjustment………………………………………………………………………..

3-110

Throttle Pedal Removal ……………………………………………………………………………………….

3-110

Throttle Pedal Installation …………………………………………………………………………………….

3-111

FUEL SYSTEM (DFI) 3-3

Throttle Cable Installation …………………………………………………………………………………….

3-111

Throttle Cable Lubrication and Inspection ………………………………………………………………

3-112

Throttle Body Assy …………………………………………………………………………………………………..

3-113

Idle Speed Inspection ………………………………………………………………………………………….

3-113

Idle Speed Adjustment…………………………………………………………………………………………

3-113

Throttle Body Assy Removal…………………………………………………………………………………

3-113

Throttle Body Assy Installation………………………………………………………………………………

3-114

Throttle Body Assy Disassembly …………………………………………………………………………..

3-115

Throttle Body Assy Assembly ……………………………………………………………………………….

3-116

Engine Vacuum Synchronization Inspection……………………………………………………………

3-116

Engine Vacuum Synchronization Adjustment ………………………………………………………….

3-117

ISC Valve………………………………………………………………………………………………………………..

3-118

ISC Valve Removal ……………………………………………………………………………………………..

3-118

ISC Valve Installation …………………………………………………………………………………………..

3-118

ISC Valve Inspection……………………………………………………………………………………………

3-118

Air Cleaner………………………………………………………………………………………………………………

3-119

Air Cleaner Element Removal (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ………….

3-119

Air Cleaner Element Removal (KRF750ND/PD/RD/SD)……………………………………………

3-120

Air Cleaner Element Installation (KRF750NA/PA/RA/SA/TA ~ NC/PC/RC/SC/VC)……….

3-121

Air Cleaner Element Installation (KRF750ND/PD/RD/SD)…………………………………………

3-122

Air Cleaner Element Cleaning and Inspection …………………………………………………………

3-122

Air Cleaner Housing and Duct Removal …………………………………………………………………

3-122

Air Cleaner Housing and Duct Installaion ……………………………………………………………….

3-123

Fuel Tank and Fuel Hose…………………………………………………………………………………………..

3-125

Fuel Tank Removal ……………………………………………………………………………………………..

3-125

Fuel Tank Installation …………………………………………………………………………………………..

3-125

Fuel Tank Cleaning ……………………………………………………………………………………………..

3-127

Fuel Hose Inspection …………………………………………………………………………………………..

3-127

Fuel Hose Removal …………………………………………………………………………………………….

3-128

Fuel Hose Installation ………………………………………………………………………………………….

3-129

3-4 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-5

Exploded View

No.

Fastener

1 Element Holder Screw

2 Element Cover Screw

3 Air Cleaner Mounting Bolts

4 ISC Valve Mounting Bolts

5 Delivery Pipe Mounting Screws

6 Intake Air Pressure Sensor Mounting Screw

7 Throttle Cable Locknuts

8 Throttle Pedal Position Bolt Locknut

9. Intake Air Temperature Sensor

10. ISC Valve

11. Intake Air Pressure Sensor

12. Fuel Injectors

13. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

CL: Apply cable lubricant.

G: Apply grease.

L: Apply a non-permanent locking agent.

O: Apply high-quality foam air filter oil.

R: Replacement Parts

N·m

4.5

4.5

8.8

8.8

5.0

5.0

4.4

10.8

Torque kgf·m

0.46

0.46

0.90

0.90

0.51

0.51

0.45

1.1

ft·lb

40 in·lb

40 in·lb

78 in·lb

78 in·lb

44 in·lb

44 in·lb

39 in·lb

96 in·lb

Remarks

L

3-6 FUEL SYSTEM (DFI)

Exploded View

Exploded View

No.

Fastener

1 Fuel Pump Mounting Bolts

2 Fuel Tank Band Bolts

3 ECU Mounting Bolts

4 Water Temperature Sensor

5 Vehicle-down Sensor Bolts

6. Fuel Pump

7. ECU (Electronic Control Unit)

8. Fuel Pump Relay

9. Vehicle-down Sensor

10. Ignition Coils

11. Speed Sensor

12. CrankShaft Sensor

13. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

N·m

4.0

11

6.9

12

5.9

FUEL SYSTEM (DFI) 3-7

Torque kgf·m

0.41

1.1

0.70

1.2

0.60

ft·lb

35 in·lb

97 in·lb

61 in·lb

106 in·lb

52 in·lb

Remarks

L

3-8 FUEL SYSTEM (DFI)

DFI System

DFI System

DFI System

1. Battery

2. ECU (Electronic Control Unit)

3. Intake Air Pressure Sensor

4. Throttle Sensor

5. Fuel Injectors

6. Crankshaft Sensor

7. ISC Valve

8. Fuel Pump

9. Speed Sensor

10. Water Temperature Sensor

11. Intake Air Temperature Sensor

12. Vehicle-down Sensor

13. Multifunction Meter

14. Delivery Pipe

15. Air Cleaner Housing

16. Air Cleaner Element

17. Air Flow

18. Fuel Flow

19. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

FUEL SYSTEM (DFI) 3-9

3-10 FUEL SYSTEM (DFI)

DFI System

DFI System Wiring Diagram (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

DFI System

Part Name

1. Throttle Sensor

2. Fuel Injector #1

3. Fuel Injector #2

4. Ignition Switch

5. Speed Sensor

6. Fuse Box

7. Fuel Pump Fuse 10 A

8. Main Fuse 30 A

9. Fuel Pump

10. ECU (Electronic Control Unit)

11. Vehicle-down Sensor

12. Fuel Pump Relay

13. KDS (Kawasaki Diagnostic System) Connector

14. ISC Valve

15. Battery

16. Spark Plugs

17. Ignition Coils

18. Water Temperature Sensor

19. Crankshaft Sensor

20. Multifunction Meter

21. Intake Air Temperature Sensor

22. Intake Air Pressure Sensor

23. Frame Ground 1

FUEL SYSTEM (DFI) 3-11

3-12 FUEL SYSTEM (DFI)

DFI System

DFI System Wiring Diagram (KRF750ND/PD/RD/SD)

DFI System

Part Name

1. ECU (Electronic Control Unit)

2. Fuel Pump Relay

3. KDS (Kawasaki Diagnostic System) Connector

4. ISC Valve

5. Frame Ground 2

6. Battery

7. Spark Plugs

8. Ignition Coils

9. Crankshaft Sensor

10. Waterproof Joint 1

11. Waterproof Joint 2

12. Frame Ground 1

13. Ignition Switch

14. Multifunction Meter

15. Vehicle-down Sensor

16. Water Temperature Sensor

17. Intake Air Pressure Sensor

18. Intake Air Temperature Sensor

19. Throttle Sensor

20. Fuel Injector #1

21. Fuel Injector #2

22. Speed Sensor

23. Fuse Box

24. Ignition Fuse 10 A

25. Fuel Pump Fuse 10 A

26. Main Fuse 30 A

27. Fuel Pump

FUEL SYSTEM (DFI) 3-13

3-14 FUEL SYSTEM (DFI)

DFI System

Terminal Numbers of ECU Connectors (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Terminal Names

1. Intake Air Pressure Sensor: G/Y

2. Intake Air Temperature Sensor: Y

3. Power Supply to Sensors: BR/W

4. Reverse Switch: R/W

5. Brake Light Switch: BL

6. Crankshaft Sensor (–): BL/R

7. Battery Monitor: W/R

8. Power Supply from Battery: W

9. External Communication Line (KDS): LG

10. Ground for Sensors: BR/BK

11. Ground for Control System: BK/Y

12. Ignition Switch: GY

13. Ignition Switch from Battery: BR

14. Water Temperature Sensor: O

15. Throttle Sensor: Y/W

16. Unused

17. Speed Sensor: P

18. Neutral Switch: LG

19. Vehicle-down Sensor: Y/G

20. Parking Brake Switch: G

21. Crankshaft Sensor (+): BK/R

22. Unused

23. Unused

24. Unused

25. Starter Button: BK/W

26. Diagnosis Terminal: LG/BK

27. ISC Valve #4: W/BK

28. 2WD/4WD Shift Switch: G

29. ISC Valve #2: W/BL

30. Fuel Pump Relay: BR/Y

31. Water Temperature Warning Indicator

Symbol (LCD): W/G

32. Radiator Fan Relay: Y

33. Ground: BK/Y

34. Injector #2: V

35. Ignition Coil #2: BL/W

36. ISC Valve #1: V/W

37. 2WD/4WD Solenoid Valve: W/R

38. ISC Valve #3: P/BL

39. FI Indicator Symbol (LCD): R/Y

40. Drive Belt Check Indicator Light (LED): O/R

41. Starter Relay: BL

42. Ground: BK/Y

43. Injector #1: BL/R

44. Ignition Coil #1: G/W

FUEL SYSTEM (DFI) 3-15

DFI System

Terminal Numbers of ECU Connectors (KRF750ND/PD/RD/SD)

Terminal Names

1. Inlet Air Pressure Sensor: G/Y

2. Inlet Air Temperature Sensor: Y

3. Power Supply to Sensors: BR/W

4. Crankshaft Sensor (+): BK/R

5. Battery Monitor: W/R

6. Unused

7. Ground for Sensors: BR/BK

8. Unused

9. Ground for Control System: BK/Y

10. Reverse Switch: R/W

11. Brake Light Switch: BL

12. Ignition Switch from Battery: BR/BL

13. Power Supply from Battery: W/G

14. Water Temperature Sensor: O

15. Throttle Sensor: Y/W

16. Speed Sensor: P

17. Vehicle-down Sensor: Y/G

18. Neutral Switch: LG

19. Parking Brake Switch: G

20. Crankshaft Sensor (–): BL/R

21. 2WD/4WD Shift Switch: BL/BK

22. Unused

23. Unused

24. Unused

25. Unused

26. Starter Button: BK/W

27. ISC Valve #4: W/BK

28. Unused

29. ISC Valve #2: W/Y

30. Fuel Pump Relay: BR/Y

31. Unused

32. Radiator Fan Relay: Y

33. Ground: BK/Y

34. Injector #2: V

35. Ignition Coil #2: W

36. ISC Valve #1: O

37. 2WD/4WD Solenoid Valve: W/R

38. ISC Valve #3: P/BL

39. External Communication Line (KDS): LG

40. Meter Communication Line: BR/R

41. Starter Relay: BL

42. Ground: BK/Y

43. Injector #1: BL/R

44. Ignition Coil #1: G/W

3-16 FUEL SYSTEM (DFI)

DFI Parts Location

FI Indicator Symbol (LCD)

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

[A]

Yellow Engine Warning Indicator Light (LED) [A]

(KRF750ND/PD/RD/SD)

Intake Air Pressure Sensor [A]

Fuel Injectors [B]

Intake Air Temperature Sensor [C]

Spark Plug (Front) [A]

Ignition Coil #1 (Front) [B]

Engine Ground [A]

Crankshaft Sensor [B]

DFI Parts Location

Fuse Box [A]

Vehicle-down Sensor [B]

ECU (Electronic Control Unit) [C]

KDS (Kawasaki Diagnostic System) Connector [D]

Fuel Pump Relay [E]

Battery [F]

Frame Ground [G]

Spark Plug (Rear) [A]

ISC (Idle Speed Control) Valve [B]

Throttle Sensor [C]

Water Temperature Sensor [D]

FUEL SYSTEM (DFI) 3-17

Ignition Coil #2 (Rear) [A]

Fuel Pump [B]

Speed Sensor [A]

3-18 FUEL SYSTEM (DFI)

Specifications

Item

Digital Fuel Injection System

Idle Speed

Throttle Body Assy:

Throttle Valve

Bore

1 100 ±50 r/min (rpm)

Dual throttle valve

34 mm (1.34 in.)

Standard

ECU (Electronic Control Unit):

Make

Type

Mitsubishi Electric

Digital memory type, with built in IC igniter, sealed with resin

294 kPa (3.0 kgf/cm², 43 psi) with engine idling Fuel Pressure (High Pressure Line)

Fuel Pump:

Type

Discharge

Vehicle-down Sensor:

Detection Method

Detection Angle

Input Voltage

Output Voltage

In-tank friction pump

50 mL (1.7 US oz.) or more for 3 seconds

Fuel Injectors:

Type

Resistance

Output Voltage at ECU

Speed Sensor:

Input Voltage

INP-250

Nozzle Type

Resistance

Input Voltage

Output Voltage

One spray type with 4 holes

About 11.7

∼

12.3 Ω at 20°C (68°F)

Throttle Sensor: Non-adjustable and non-removable

Input Voltage DC 4.75

∼

5.25 V between BR/W and BR/BK leads

Output Voltage at Idle Throttle Opening DC 1.00

∼

1.24 V between Y/W and BR/BK leads

Output Voltage at Full Throttle Opening DC 4.0

∼

4.4 V between Y/W and BR/BK leads

Resistance 4

∼

6 kΩ

Intake Air Pressure Sensor:

DC 4.75

∼

5.25 V between BR/W and BR/BK leads

DC 3.80

∼

4.20 V at standard atmospheric pressure

(see this text for details)

Intake Air Temperature Sensor:

Resistance

Output Voltage at ECU

Water Temperature Sensor:

5.4

∼

6.6 kΩ at 0°C (32°F)

0.29

∼

0.39 kΩ at 80°C (176°F)

About 2.25

∼

2.50 V at 20°C (68°F) in the text

About 2.24

∼

2.48 V at 20°C (68°F)

Output Voltage

Battery Voltage at Ignition Switch ON less than DC 0.8 V or over than DC 4.8 V at Ignition

Switch ON and 0 km/h

Magnetic flux detection method more than 55

∼

75° for each bank

DC 4.75

∼

5.25 V with sensor arrow mark pointed up: DC 0.4

∼

1.4 V with sensor tilted 55

∼

75° or more: DC 3.7

∼

4.4 V

ISC Valve:

Resistance 28.8

∼

31.2 Ω at 20°C (68°F)

Specifications

Item

Engine Vacuum

Throttle Pedal and Cable

Throttle Pedal Free Play

Air Cleaner

Air Cleaner Element Oil

FUEL SYSTEM (DFI) 3-19

Standard

29.6 ±1.3 kPa (222 ±9.8 mmHg) at Idle Speed

5

∼

10 mm (0.20

∼

0.39 in.)

High-quality foam air filter oil

3-20 FUEL SYSTEM (DFI)

Special Tools and Sealant

Oil Pressure Gauge, 5 kgf/cm²:

57001-125

Hand Tester:

57001-1394

Jack:

57001-1238

Pilot Screw Adjuster, A:

57001-1239

Needle Adapter Set:

57001-1457

Sensor Harness Adapter:

57001-1561

Fork Oil Level Gauge:

57001-1290

Vacuum Gauge:

57001-1369

Fuel Pressure Gauge Adapter:

57001-1593

Fuel Hose:

57001-1607

Special Tools and Sealant

Measuring Adapter:

57001-1700

FUEL SYSTEM (DFI) 3-21

Liquid Gasket, TB1211:

56019-120

3-22 FUEL SYSTEM (DFI)

DFI Servicing Precautions

DFI Servicing Precautions

There are a number of important precautions that should be followed servicing the DFI system.

○

This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.

○

Do not reverse the battery cable connections. This will damage the ECU.

○

To prevent damage to the DFI parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running.

○

Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis ground.

○

When charging, remove the battery from the vehicle. This is to prevent ECU damage by excessive voltage.

○

Do not turn the ignition switch ON while any of the DFI electrical connectors are disconnected. The ECU memorizes service codes.

○

Do not spray water on the electrical parts, DFI parts, connectors, leads, and wiring.

○

Whenever the DFI electrical connections are to be disconnected, first turn off the ignition switch, and disconnect the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine.

○

Connect these connectors until they click [A].

○

If a transceiver is installed on the vehicle, make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna. Check operation of the system with the engine at idle. Locate the antenna as far as possible away from the ECU.

○

When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage.

○

When any fuel hose is disconnected, do not turn on the ignition switch. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose.

○

Do not operate the fuel pump if the pump is completely dry. This is to prevent pump seizure.

○

Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.

○

To prevent corrosion and deposits in the fuel system, do not add to fuel any fuel antifreeze chemicals.

DFI Servicing Precautions

○

To maintain the correct fuel/air mixture (F/A), there must be no intake air leaks in the DFI system. Be sure to install the oil filler cap [A] after filling the engine oil.

FUEL SYSTEM (DFI) 3-23

3-24 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Outline

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

When an abnormality in the DFI system occurs, the FI indicator symbol [A] (LCD) flashes on the meter panel to alert the driver. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).

With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by the number of times the FI indicator symbol (LCD) blinks.

When due to a malfunction, the FI indicator symbol (LCD) remains flashed, first ask the rider about the conditions [B] of trouble, and then determine the cause [C] of problem.

First, conduct a self-diagnosis inspection and then a non-self-diagnosis inspection.

The non-self-diagnosis items are not indicated by the FI indicator symbol (LCD).

Do not rely solely on the DFI self-diagnosis function, use common sense.

Even when the DFI system is operating normally, the FI indicator symbol (LCD) may appear under strong electrical interference. No repair needed. Turn the ignition switch

OFF to stop the indicator symbol.

When the FI indicator symbol (LCD) flashes and the vehicle is brought in for repair, check the service codes.

When the repair has been done, the symbol disappears.

But the service codes stored in memory of the ECU are not erased to preserve the problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems.

Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. The DFI parts are assembled and adjusted with precision, and it is impossible to disassemble or repair them.

Troubleshooting the DFI System

(KRF750ND/PD/RD/SD)

When a problem occurs with DFI system, the engine warning indicator light (LED) [A] goes on to alert the operator. In addition, the condition of the problem is stored in the memory of the ECU.

FUEL SYSTEM (DFI) 3-25

With the engine stopped and turned in the self-diagnosis mode, the service code [A] is displayed on the LCD (Liquid

Crystal Display) by the number of two digits.

If the problem is with the following parts, the ECU can not recognize these problem. Therefore, the yellow engine warning indicator light (LED) does not go on, and service code is not displayed.

LCD for Meter Unit

Fuel Pump

Fuel Injectors

Ignition Coil Secondary Wiring and Ground Wiring

ECU Power Source Wiring and Ground Wiring

When the service code [A] is displayed, for first ask the operator about the conditions [B] of trouble, and then start to determine the cause [C] of problem.

As a pre-diagnosis inspection, check the ECU for ground and power supply, the fuel line for no fuel leaks, and for correct pressure. The pre-diagnosis items are not indicated by the yellow engine warning indicator light (LED).

Don’t rely solely on the DFI self-diagnosis function, use common sense.

3-26 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

•

When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance.

○

The DFI part connectors [A] have seals [B], including the

ECU.

•

When measuring the input or output voltage with the connector joined, use the needle adapter set [C].

Special Tool — Needle Adapter Set: 57001-1457

•

Insert the needle adapters inside the seals from behind the connector until the adapter reaches the terminal.

NOTICE

Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals.

•

Make sure that measuring points are correct in the connector, noting the position of the lock [D] and the lead color before measurement. Do not reverse connections of the digital meter.

•

Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters.

•

Turn the ignition switch ON and measure the voltage with the connector joined.

NOTICE

Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts.

○

After measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B] for waterproofing.

Sealant — Liquid Gasket, TB1211: 56019-120

•

Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.

•

Trouble may involve one or in some cases all items.

Never replace a defective part without determining what

CAUSED the problem. If the problem was caused by some other item or items, they too must be repaired or replaced, or the new replacement part will soon fail again.

•

Measure coil winding resistance when the DFI part is cold

(at room temperature).

•

Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, short, etc. Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the

DFI system.

If any wiring is deteriorated, replace the wiring.

Troubleshooting the DFI System

•

Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

• is damaged, replace it. Connect the connectors securely.

Check the wiring for continuity.

○

Use the wiring diagram to find the ends of the lead which is suspected of being a problem.

○

Connect the hand tester between the ends of the leads.

Special Tool — Hand Tester: 57001-1394

○

Set the tester to the × 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Replace the lead or the main harness or the sub harness.

○

If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness is open, repair or replace the harness.

FUEL SYSTEM (DFI) 3-27

○

When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end

[C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or replaced.

•

Narrow down suspicious locations by repeating the continuity tests from the ECU connectors.

If no abnormality is found in the wiring or connectors, the

DFI parts are the next likely suspects. Check the part, starting with input and output voltages. However, there is no way to check the ECU itself.

If an abnormality is found, replace the affected DFI part.

If no abnormality is found in the wiring, connectors, and

DFI parts, replace the ECU.

3-28 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

DFI Diagnosis Flow Chart (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Troubleshooting the DFI System

DFI Diagnosis Flow Chart (KRF750ND/PD/RD/SD)

FUEL SYSTEM (DFI) 3-29

Inquiries to Rider

○

Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered.

○

Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.

○

The following sample diagnosis sheet will help prevent you from overlooking any areas, and will help you decide if it is a DFI system problem, or a general engine problem.

3-30 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Sample Diagnosis Sheet

Rider name:

Year of initial registration:

Engine No.:

Registration No. (license plate No.):

Model:

Frame No.:

Date problem occurred:

Weather

Temperature

Problem frequency

Mileage:

Environment when problem occurred.

□ fine,

□ cloudy,

□ rain,

□ snow,

□ always,

□ other:

□ hot,

□ warm,

□ cold,

□ very cold,

□ always

□ chronic,

□ often,

□ once

Road

Altitude

FI indicator symbol (LCD)

(KRF750NA/

PA/RA/SA/TA

∼

NC/PC/RC

/SC/VC)

Yellow engine warning indicator light (LED)

(KRF750NB/

PB/RD/SD)

Starting difficulty

Engine stops

□ street,

□ mountain road (

□ uphill,

□ downhill),

□ bumpy,

□ pebble

□ normal,

□ high (about 1 000 m or more)

Vehicle conditions when problem occurred.

□ symbol appears immediately after ignition switch ON, and disappear after 1

∼

2 seconds (normal).

□ symbol blinks after ignition switch ON (DFI system problem).

□ symbol does not appear. (meter unit, ECU or its wiring fault)

□ sometimes symbol appears. (probably wiring fault)

□ indicator light goes on immediately after ignition switch ON, and goes off after 1

∼

2 seconds (normal).

□ indicator light goes on immediately after ignition switch ON, and it continues

(DFI system problem).

□ indicator light does not go on (meter unit, ECU or its wiring fault).

□ sometimes indicator light goes on (probably wiring fault).

□ starter motor not rotating.

□ starter motor rotating but engine doesn’t turn over.

□ starter motor and engine don’t turn over.

□ no fuel flow (

□ no fuel in tank,

□ no fuel pump sound).

□ engine flooded (do not crank engine with throttle opened, which promotes engine flooding).

□ no spark.

□ other:

□ right after starting.

□ when depressing throttle pedal.

□ when returning throttle pedal.

□ when moving off.

□ when stopping the vehicle.

□ when cruising.

□ other:

FUEL SYSTEM (DFI) 3-31

Troubleshooting the DFI System

Poor running at low speed

Poor running or no power at high speed

□ very low idle speed,

□ very high idle speed,

□ rough idle speed

□ battery voltage is low (charge the battery)

□ spark plug loose (tighten it)

□ spark plug dirty, broken, or gap maladjusted (remedy it).

□ backfiring

□ afterfiring

□ hesitation when acceleration

□ engine oil viscosity too high

□ brake dragging

□ engine overheating

□ other:

□ spark plug loose (tighten it)

□ spark plug dirty, broken, or gap maladjusted (remedy it).

□ spark plug incorrect (replace it)

□ knocking (fuel poor quality or incorrect)

□ brake dragging

□ clutch slipping

□ engine overheating

□ engine oil level too high

□ engine oil viscosity too high

□ other:

3-32 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

NOTE

○

This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in

DFI system.

○

The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and circuits are checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.

Engine Won’t Turn Over

Symptoms or possible Causes

Neutral switch trouble

Crankshaft sensor trouble

Ignition coil shorted or not in good contact

Ignition coil trouble

Spark plug dirty, broken or gap maladjusted

Spark plug incorrect

ECU ground and power supply trouble

ECU trouble

No or little fuel in tank

Fuel injector trouble

Fuel pump not operating

Fuel pump relay trouble

Fuel filter or pump screen clogged

Fuel pressure regulator trouble

Fuel line clogged

Actions (chapter)

Inspect neutral switch (see chapter 16).

Inspect (see chapter 16).

Inspect or Reinstall (see chapter 16).

Inspect (see chapter 16).

Inspect and replace (see chapter 2).

Replace it with the correct plug (see chapter 2).

Inspect (see chapter 3).

Inspect (see chapter 3).

Supply fuel (see Owner’s Manual).

Inspect and replace (see chapter 3).

Inspect (see chapter 3).

Inspect and replace (see chapter 3).

Replace fuel pump (see chapter 3).

Inspect fuel pressure and replace fuel pump (see chapter 3).

Inspect and repair (see chapter 3).

Poor Running at Low Speed

Symptoms or Possible Causes

Spark weak:

Ignition coil shorted or not in good contact

Ignition coil trouble

Spark plug dirty, broken or gap maladjusted

Spark plug incorrect

ECU trouble

Fuel/air mixture incorrect:

Little fuel in tank

Air cleaner clogged, poorly sealed, or missing

Air duct loose

Throttle body assy holder loose

Fuel injector O-ring damage

Fuel filter or pump screen clogged

Fuel pressure regulator trouble

Fuel line clogged

Intake air pressure sensor trouble

Water temperature sensor trouble

Actions (chapter)

Inspect or reinstall (see chapter 16).

Inspect (see chapter 16).

Inspect and replace (see chapter 2).

Replace it with the correct plug (see chapter 2).

Inspect (see chapter 3).

Supply fuel (see Owner’s Manual).

Clean element or inspect sealing (see chapter 2).

Reinstall (see chapter 3).

Reinstall (see chapter 3).

Replace (see chapter 3).

Replace fuel pump (see chapter 3).

Inspect fuel pressure and replace fuel pump (see chapter 3).

Inspect and repair (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

FUEL SYSTEM (DFI) 3-33

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Intake air temperature sensor trouble

Throttle sensor trouble

Unstable (rough) idling:

Fuel pressure too low or too high

Fuel injector trouble

Throttle sensor trouble

Intake air pressure sensor trouble

Water temperature sensor trouble

Intake air temperature sensor trouble

Engine stalls easily:

Spark plug dirty, broken or gap maladjusted

Ignition coil trouble

Throttle sensor trouble

Intake air pressure sensor trouble

Water temperature sensor trouble

Intake air temperature sensor trouble

Fuel pump trouble

Fuel injector trouble

Fuel pressure too low or too high

Fuel pressure regulator trouble

Fuel line clogged

Poor acceleration:

Fuel pressure too low

Water or foreign matter in fuel

Fuel filter or pump screen clogged

Fuel pump trouble

Fuel injector trouble

Throttle sensor trouble

Intake air pressure sensor trouble

Water temperature sensor trouble

Intake air temperature sensor trouble

Spark plug dirty, broken or gap maladjusted

Ignition coil trouble

Stumble:

Fuel pressure too low

Fuel injector trouble

Throttle sensor trouble

Intake air pressure sensor trouble

Water temperature sensor trouble

Intake air temperature sensor trouble

Actions (chapter)

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect and replace (see chapter 2).

Inspect (see chapter 16).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect fuel pressure and replace fuel pump (see chapter 3).

Inspect and repair (see chapter 3).

Inspect (see chapter 3).

Change fuel. Inspect and clean fuel system (see chapter 3).

Replace fuel pump (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect and replace (see chapter 2).

Inspect (see chapter 16).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

3-34 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Surge:

Unstable fuel pressure

Fuel injector trouble

Water temperature sensor trouble

Backfiring when deceleration:

Spark plug dirty, broken or gap maladjusted

Fuel pressure too low

Fuel pump trouble

Throttle sensor trouble

Intake air pressure sensor trouble

Water temperature sensor trouble

Intake air temperature sensor trouble

After fire:

Spark plug burned or gap maladjusted

Fuel injector trouble

Intake air pressure sensor trouble

Water temperature sensor trouble

Intake air temperature sensor trouble

Other:

Intermittent any DFI fault and its recovery

Actions (chapter)

Fuel pressure regulator trouble (Inspect and replace fuel pump) or kinked fuel line (Inspect and repair fuel line ) (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect and replace (see chapter 2).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Replace (see chapter 2).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying

(see chapter 3).

Poor Running or No Power at High Speed:

Symptoms or Possible Causes

Firing incorrect:

Ignition coil shorted or not in good contact

Ignition coil trouble

Spark plug dirty, broken or gap maladjusted

Spark plug incorrect

ECU trouble

Fuel/air mixture incorrect:

Air cleaner clogged, poorly sealed, or missing

Air duct loose

Water or foreign matter in fuel

Fuel injector O-ring damage

Fuel injector clogged

Fuel line clogged

Fuel pump operates intermittently and often DFI fuse blows.

Fuel pump trouble

Intake air pressure sensor trouble

Actions (chapter)

Inspect or Reinstall (see chapter 16).

Inspect (see chapter 16).

Inspect and replace (see chapter 2).

Replace it with the correct plug (see chapter 2).

Inspect (see chapter 3).

Clean element or inspect sealing (see chapter 2).

Reinstall (see chapter 3).

Change fuel. Inspect and clean fuel system (see chapter 3).

Replace (see chapter 3).

Inspect and repair (see chapter 3).

Inspect and repair (see chapter 3).

Fuel pump bearings may wear. Replace the fuel pump (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

FUEL SYSTEM (DFI) 3-35

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Water temperature sensor trouble

Intake air temperature sensor trouble

Throttle sensor trouble

Knocking:

Fuel poor quality or incorrect

Actions (chapter)

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Spark plug incorrect

Ignition coil trouble

ECU trouble

Intake air pressure sensor trouble

Water temperature sensor trouble

Intake air temperature sensor trouble

Miscellaneous:

Speed sensor trouble

Throttle valves will not fully open

Fuel change (Use the gasoline recommended in the Owner’s Manual).

Replace it with the correct plug (see chapter 2).

Inspect (see chapter 16).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Engine overheating — Water temperature sensor, crankshaft sensor or speed sensor trouble

Exhaust Smokes Excessively:

(Black smokes)

Air cleaner element clogged

Fuel pressure too high

Fuel injector trouble

Water temperature sensor trouble

Intake air temperature sensor trouble

(Brown smoke)

Air duct loose

Fuel pressure too low

Water temperature sensor trouble

Intake air temperature sensor trouble

Inspect (see chapter 3).

Inspect throttle cables and lever linkage (see chapter 3).

(see Overheating of Troubleshooting Guide in chapter 17)

Clean element (see chapter 2).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Reinstall (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

3-36 FUEL SYSTEM (DFI)

Self-Diagnosis

Self-diagnosis Outline (KRF750NA/PA/RA/SA/TA

NC/PC/RC/SC/VC)

∼

The self-diagnosis system has two modes and can be switched to another mode by grounding the self-diagnosis terminal (LG/BK) in the KDS connector.

User Mode

The ECU notifies the rider of troubles in DFI system and ignition system by flashing the FI indicator symbol when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, the ECU stops the injection/ignition/starter motor operation.

Dealer Mode

The ECU generate service code(s) to show the problem(s) which the DFI system, and ignition system have at the moment of diagnosis.

Self-diagnosis Outline (KRF750ND/PD/RD/SD)

The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit.

User Mode

The ECU notifies the operator of troubles in DFI system and ignition system by lighting the yellow engine warning indicator light (LED) [A] when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles ECU stops the injection/ignition/starter motor operation.

Dealer Mode

The LCD display the service code(s) [A] to show the problem(s) which the DFI system and ignition system has at the moment of diagnosis.

Self-Diagnosis

Self-diagnosis Procedures

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

○

When a problem occurs with the DFI system and ignition system, the FI indicator symbol [A] (LCD) flashes.

NOTE

○

Use a fully charged battery when conducting self-diagnosis.

○

Keep the self-diagnosis terminal grounded during self

-diagnosis, with an auxiliary lead.

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

•

Remove the cap [A] from the KDS connector [B] (white).

FUEL SYSTEM (DFI) 3-37

•

Connect an auxiliary lead [A] into the self-diagnosis terminal [B] (LG/BK) in the KDS connector [C] for grounding.

•

Turn on the ignition switch.

•

To enter the self-diagnosis dealer mode, ground the self

-diagnosis terminal to the battery (–) terminal [A] for more than 2 seconds, and then keep it grounded continuously.

•

Count the blinks of the FI indicator symbol to read the service code.

•

Keep the auxiliary lead ground until you finish reading the service code.

Self-diagnosis Procedures (KRF750ND/PD/RD/SD)

○

When a problem occurs with the DFI system and ignition system, the yellow engine warning indicator light (LED)

[A] goes on.

NOTE

○

Use a fully charged battery when conducting self-diagnosis. Otherwise, the light (LED) does not go on.

3-38 FUEL SYSTEM (DFI)

Self-Diagnosis

•

Turn the ignition switch to ON.

•

Push the left button [A] to display the odometer.

•

Push the left button [A] for more than two seconds.

•

The service code [B] is displayed on the LCD by the number of two digits.

•

Any of the following procedures ends self-diagnosis.

○

When the service code is displayed on the LCD, push the left button for more than two seconds.

○

When the ignition switch is turned to OFF.

FUEL SYSTEM (DFI) 3-39

Self-Diagnosis

Self-Diagnosis Flow Chart (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

3-40 FUEL SYSTEM (DFI)

Self-Diagnosis

Self-Diagnosis Flow Chart (KRF750ND/PD/RD/SD)

FUEL SYSTEM (DFI) 3-41

Self-Diagnosis

How to Read Service Codes (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

○

The service code(s) is shown by a series of long and short blinks of the FI indicator symbol as shown below.

○

Read 10th digit and unit digit as the FI indicator symbol blinks.

○

When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis terminal is opened.

○

For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the lowest number in the order listed.

(12 → 21) → (12 → 21) → · · · (repeated)

○

If there is no problem or when the repair has been done, no service code is shown.

Service Code Reading (KRT750ND/PD/RD/SD)

○

The service code(s) is displayed on the LCD by two-digit number or a set of a number and an alphabet.

○

When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.

○

Then after completing all codes, the display is repeated until the ignition switch is turned to OFF or

Left button is pushed for more than two seconds.

○

For example, if three problems occurred in the order of 56, 13, 31, the service codes are displayed (each two seconds) from the lowest number in the order listed as shown below.

(13→31→56)→(13→31→56)→· · ·(repeated)

○

If there is no problem or when the repair has been done, yellow engine warning indicator light (LED) goes off and the service code is not displayed.

Service Code Erasing (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

○

When repair has been done, FI indicator symbol will not show service codes any more.

3-42 FUEL SYSTEM (DFI)

Self-Diagnosis

But the service codes stored in memory of the ECU are not erased to preserve the problem history.

In this model, the problem history cannot be erased.

Service Code Erasing (KRF750ND/PD/RD/SD)

○

When repair has been done, yellow engine warning indicator light goes off and the service codes are not displayed.

The service codes stored in memory of the ECU can be erased using the Kawasaki Diagnostic

System (KDS Ver. 3).

Service Code Table

Service

Code

FI Indicator Symbol

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Problems

11

Throttle sensor malfunction, wiring open or short

12

13

14

21

24

31

Intake air pressure sensor malfunction, wiring open or short

Intake air temperature sensor malfunction, wiring open or short

Water temperature sensor malfunction, wiring open or short

Crankshaft sensor malfunction, wiring open or short

Speed sensor malfunction, wiring open or short

Vehicle-down sensor, malfunction, wiring open or short

46

Fuel pump relay malfunction, relay is stuck

51

Ignition coil #1 malfunction, wiring open or short

52

Ignition coil #2 malfunction, wiring open or short

56

–

Radiator fan relay malfunction, wiring open or short (KRF750ND/PD/RD/SD)

Notes:

○

The ECU may be involved in these problems. If all the parts and circuits are checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.

○

When no service code is displayed, the electrical parts of the DFI system has no fault, and the mechanical parts of the DFI system and the engine are suspect.

FUEL SYSTEM (DFI) 3-43

Self-Diagnosis

Backups

○

The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles.

Service

Codes

11

12

13

14

21

24

31

46

51

52

56

Parts

Output Signal Usable

Range or Criteria

Backups by ECU

Throttle

Sensor

Intake Air

Pressure

Sensor

Throttle Sensor Output

Voltage

0.2

∼

4.8 V

Intake Air Pressure

Sensor Output Voltage

0.2

∼

4.8 V

If the throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at opened throttle position and sets the

DFI in the D-J method (1).

Also, the throttle sensor system and intake air pressure sensor fails, the ECU locks ignition timing into the ignition timing at opened throttle position and sets the DFI in the α-N method

(1).

If the intake air pressure sensor system fails

(the signal Pv is out of the usable range, wiring short or open), the ECU sets the DFI in the α

— N method.

If the intake air temperature sensor fails (the signal is out of the usable range, wiring short or open), the ECU sets Ta at 30°C.

If the water temperature sensor system fails

(the signal is out of the usable range, wiring short or open), the ECU sets Tw at 80°C.

Intake Air

Temperature

Sensor

Water

Temperature

Sensor

Crankshaft

Sensor

Speed Sensor

Intake Air Temperature

Sensor Output Voltage

0.2

∼

4.6 V

Water Temperature

Sensor Output Voltage

0.2

∼

4.85 V

Crankshaft sensor must send 22 signals (output signal) to the ECU at the one cranking.

Speed sensor must send

21 signals (output signal) to the ECU at the one rotation of the output driven bevel gear.

If crankshaft sensor does not generate signals, the engine stops by itself.

If the speed sensor system fails (no signal, wiring short or open), the speedometer shows

0.

Vehicle-down

Sensor

Vehicle-down Sensor

Output Voltage

Vd = 0.2

∼

4.6 V

If the vehicle-down sensor system has failures

(the output voltage Vd is more than usable range, wiring open), the ECU shuts off the fuel pump.

Fuel Pump

Relay

Ignition Coil #1

Ignition Coil #2

Radiator Fan

Relay

When the relay ON condition, battery monitor voltage 5 V or more

The ignition coil primary winding must send signals (output voltage) continuously to the ECU.

The ignition coil primary winding must send signals (output voltage) continuously to the ECU.

When the relay is

OFF condition, the fan relay is open.

(KRF750ND/PD/RD/SD)

If the relay fails, battery monitor voltage 12 V.

If the ignition primary winding #1 has failures

(no signal, wiring short or open), the ECU shuts off the injector #1 to stop fuel to the cylinder #1, though the engine keeps running.

If the ignition primary winding #2 has failures

(no signal, wiring short or open), the ECU shuts off the injector #2 to stop fuel to the cylinder #2, though the engine keeps running.

–

3-44 FUEL SYSTEM (DFI)

Self-Diagnosis

Note:

(1) D-J Method and α — N Method: When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (intake air pressure sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called

D-J method (low-speed mode). As the engine speed increases, and the engine load turns middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle sensor output voltage) and the engine speed. This method is called α — N method (high-speed mode).

Throttle Sensor (Service Code 11)

Throttle Sensor Removal/Adjustment

NOTICE

Do not remove or adjust the throttle sensor [A] since it has been adjusted and set with precision at the factory.

Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can damage it.

Throttle Sensor Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

•

Connect a digital meter to the connector [A] with the needle adapter set.

Special Tool — Needle Adapter Set: 57001-1457

Connections:

Meter (+) → BR/W lead

Meter (–) → BR/BK lead

•

Measure the input voltage with the engine stopped and with the connector joined.

•

Turn the ignition switch ON.

Throttle Sensor Input Voltage

Standard: DC 4.75

∼

5.25 V

•

Turn the ignition switch OFF.

If the input voltage is normal, check the output voltage

(see Throttle Sensor Output Voltage Inspection).

If the input voltage is less than the standard, check the wiring for continuity (see Throttle Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-45

3-46 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code 11)

Throttle Sensor Output Voltage Inspection

•

Measure the output voltage in the same way as input voltage inspection. Note the following.

•

Connect a digital meter to the connector [A] with the needle adapter set.

Special Tool — Needle Adapter Set: 57001-1457

Connections to Adapter:

Meter (+) → Y/W lead

•

Meter (–) → BR/BK lead

•

Start the engine and warm it up thoroughly.

Check idle speed to ensure the throttle opening is correct.

Idle Speed

Standard: 1 100 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it

(see Idle Speed Inspection in the Periodic Maintenance

• chapter).

Turn the ignition switch OFF.

•

Measure the output voltage with the engine stopped, and with the connector joined.

•

Turn the ignition switch ON.

Throttle Sensor Output Voltage

Standard: DC 1.00

∼

1.24 V at idle throttle opening

DC 4.0

∼

4.4 V at full throttle opening (for reference)

NOTE

○

Open the throttle, confirm the output voltage will be raise.

○

The standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly.

○

When the input voltage reading shows other than 5 V, derive a voltage range as follows.

Example:

In the case of a input voltage of 4.75 V.

1.00 × 4.75 ÷ 5.00 = 0.95 V

1.24 × 4.75 ÷ 5.00 = 1.18 V

Thus, the valid range is 0.95

∼

1.18 V

•

Turn the ignition switch OFF.

If the output voltage is out of the standard, inspect the throttle sensor resistance (see Throttle Sensor Resistance Inspection).

If the output voltage is normal, check the wiring for continuity (see Throttle Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-47

Throttle Sensor (Service Code 11)

•

Throttle Sensor Resistance Inspection

Turn the ignition switch OFF.

•

Disconnect the harness connector [A].

•

Connect a digital meter to the throttle sensor lead connector.

○

Do not connect the main harness connector.

Connections:

BR/W lead ←→ BR/BK lead

•

Measure the throttle sensor resistance.

Throttle Sensor Resitance

Standard: 4

∼

6 kΩ

If the reading is out of the range, replace the throttle body assy.

If the reading is within the range, but the problem still exists, replace the ECU (see ECU Removal/Installation).

Throttle Sensor Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Throttle Sensor

3-48 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code 11)

Throttle Sensor Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Waterproof Joint 2

3. Throttle Sensor

FUEL SYSTEM (DFI) 3-49

Intake Air Pressure Sensor (Service Code 12) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

NOTICE

Never drop the sensor, especially on a hard surface.

Such a shock to the sensor can damage it.

Intake Air Pressure Sensor Removal

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Screw [A]

•

Disconnect the intake air pressure sensor connector [B] and the vacuum hose [C].

•

Remove the intake air pressure sensor [D].

Intake Air Pressure Sensor Installation

•

Installation is the reverse of removal.

Torque — Intake Air Pressure Sensor Mounting Screw: 5.0

N·m (0.51 kgf·m, 44 in·lb)

Intake Air Pressure Sensor Input Voltage

Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Disconnect the intake air pressure sensor connector [A].

•

Connect the measuring adapter [A] between the main harness connector and intake air pressure sensor.

Special Tool — Sensor Harness Adapter: 57001-1561

•

Connect a digital meter to the harness adapter leads.

Connections to Adapter:

Meter (+) → G/W lead (BR/W lead of Main Harness)

Meter (–) → BK lead (BR/BK lead of Main Harness)

•

Measure the input voltage with the engine stopped, and with the connectors joined.

•

Turn the ignition switch ON.

Intake Air Pressure Sensor Input Voltage

Standard: DC 4.75

∼

5.25 V

If the reading is within the standard range, check the output voltage (see Intake Air Pressure Sensor Output Voltage Inspection).

If the reading is less than the standard check the wiring for continuity (see Intake Air Pressure Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

3-50 FUEL SYSTEM (DFI)

Intake Air Pressure Sensor (Service Code 12) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Intake Air Pressure Sensor Output Voltage

Inspection

NOTE

○

The output voltage changes according to the local atmospheric pressure.

•

Measure the output voltage at the input air pressure in the same way as input voltage inspection. Note the following.

•

Disconnect the intake air pressure sensor connector and connect the harness adapter [A] between these connectors.

Special Tool — Sensor Harness Adapter: 57001-1561

•

Connect a digital meter to the harness adapter leads.

Connections to Adapter:

Meter (+) → G lead (G/Y lead of Main Harness)

Meter (–) → BK lead (BR/BK lead of Main Harness)

•

Measure the output voltage with the engine stopped, and with the connector joined.

•

Turn the ignition switch ON.

Intake Air Pressure Sensor Output Voltage

Usable Range: DC 3.80

∼

4.20 V at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.)

•

Turn the ignition switch OFF.

If the output voltage is within the usable range, check the

ECU for its ground, and power supply (see ECU Power

Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

If the output voltage is out of the usable range, check the wiring for continuity (see Intake Air Pressure Sensor

Circuit).

FUEL SYSTEM (DFI) 3-51

Intake Air Pressure Sensor (Service Code 12) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

If the wiring is good, check the sensor for various vacuum.

•

Remove the intake air pressure sensor [A] and disconnect the vacuum hose from the sensor.

•

Connect an auxiliary hose [B] to the intake air pressure

• sensor.

Temporarily install the intake air pressure sensor.

•

Connect a digital meter [C], vacuum gauge [D], the fork oil level gauge [E] and the harness adapter to the intake air pressure sensor.

Special Tools — Fork Oil Level Gauge: 57001-1290

Vacuum Gauge: 57001-1369

Sensor Harness Adapter: 57001-1561

Intake Air Pressure Sensor Output Voltage

Connections to Adapter

Meter (+) → G/W (sensor G/Y) lead

Meter (–) → BK (sensor BR/BK) lead

•

Turn the ignition switch ON.

•

Measure the output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge.

If the output voltage for various vacuum is normal, check the ECU for its ground, and power supply (see ECU

Power Supply Inspection).

•

Check the output voltage, using the following formula and chart.

3-52 FUEL SYSTEM (DFI)

Intake Air Pressure Sensor (Service Code 12) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Suppose:

Pg: Vacuum Pressure (gauge) to Sensor

Pl: Local Atmospheric Pressure (absolute) measured by a barometer

Pv: Vacuum Pressure (absolute) to Sensor

Vv: Sensor Output Voltage (V) then

Pv = Pl – Pg

For example, suppose the following data is obtained:

Pg = 8 cmHg (Vacuum gauge reading)

Pl = 70 cmHg (Barometer reading)

Vv = 3.2 V (Digital meter reading) then

Pv = 70 – 8 = 62 cmHg (Abs.)

Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you can get the usable range [2] of the sensor output voltage.

Usable range = 3.04

∼

3.49 V

Plot Vv (3.2 V) on the vertical line. → Point [3].

Results: In the chart, Vv is within the usable range and the sensor is normal.

If the reading is out of the usable range, replace the sensor.

If the reading is within the usable range, check the ECU for its ground and power supply (see ECU Power Supply

Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-53

Intake Air Pressure Sensor (Service Code 12) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

ID: Idling

Ps: Standard Atmospheric Pressure (Absolute)

Pv: Throttle Vacuum Pressure (Absolute)

ST: Standard of Sensor Output Voltage (V)

TO: Throttle Full Open

UR: Usable Range of Sensor Output Voltage (V)

Vv: Intake Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)

3-54 FUEL SYSTEM (DFI)

Intake Air Pressure Sensor (Service Code 12) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Intake Air Pressure Sensor Circuit

1. ECU (Electronic Control Unit)

2. Intake Air Pressure Sensor

FUEL SYSTEM (DFI) 3-55

Intake Air Pressure Sensor (Service Code 12) (KRF750ND/PD/RD/SD)

NOTICE

Never drop the sensor, especially on a hard surface.

Such a shock to the sensor can damage it.

Intake Air Pressure Sensor Removal

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Screw [A]

•

Disconnect the intake air pressure sensor connector [B] and the vacuum hose [C].

•

Remove the intake air pressure sensor [D].

Intake Air Pressure Sensor Installation

•

Installation is the reverse of removal.

Torque — Intake Air Pressure Sensor Mounting Screw: 5.0

N·m (0.51 kgf·m, 44 in·lb)

Intake Air Pressure Sensor Input Voltage

Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Disconnect the intake air pressure sensor connector [A].

•

Connect the measuring adapter [A] between the main harness connector and intake air pressure sensor.

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter:

Meter (+) → BR/W lead of Main Harness

Meter (–) → BR/BK lead of Main Harness

•

Measure the input voltage with the engine stopped, and with the connectors joined.

•

Turn the ignition switch ON.

Intake Air Pressure Sensor Input Voltage

Standard: DC 4.75

∼

5.25 V

If the reading is within the standard range, check the output voltage (see Intake Air Pressure Sensor Output Voltage Inspection).

If the reading is less than the standard check the wiring for continuity (see Intake Air Pressure Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

3-56 FUEL SYSTEM (DFI)

Intake Air Pressure Sensor (Service Code 12) (KRF750ND/PD/RD/SD)

Intake Air Pressure Sensor Output Voltage

Inspection

NOTE

○

The output voltage changes according to the local atmospheric pressure.

•

Measure the output voltage at the input air pressure in the same way as input voltage inspection. Note the following.

•

Disconnect the intake air pressure sensor connector and connect the measuring adapter [A] between these connectors.

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter:

Meter (+) → G/Y lead of Main Harness

Meter (–) → BR/BK lead of Main Harness

•

Measure the output voltage with the engine stopped, and with the connector joined.

•

Turn the ignition switch ON.

Intake Air Pressure Sensor Output Voltage

Usable Range: DC 3.80

∼

4.20 V at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.)

•

Turn the ignition switch OFF.

If the output voltage is within the usable range, check the

ECU for its ground, and power supply (see ECU Power

Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

If the output voltage is out of the usable range, check the wiring for continuity (see Intake Air Pressure Sensor

Circuit).

FUEL SYSTEM (DFI) 3-57

Intake Air Pressure Sensor (Service Code 12) (KRF750ND/PD/RD/SD)

If the wiring is good, check the sensor for various vacuum.

•

Remove the intake air pressure sensor [A] and disconnect the vacuum hose from the sensor.

•

Connect an auxiliary hose [B] to the intake air pressure

• sensor.

Temporarily install the intake air pressure sensor.

•

Connect a digital meter [C], vacuum gauge [D], the fork oil level gauge [E] and the measuring adapter to the intake air pressure sensor.

Special Tools — Fork Oil Level Gauge: 57001-1290

Vacuum Gauge: 57001-1369

Measuring Adapter: 57001-1700

Intake Air Pressure Sensor Output Voltage

Connections to Adapter

Meter (+) → G/Y lead of Main Harness

Meter (–) → BR/BK lead of Main Harness

•

Turn the ignition switch ON.

•

Measure the output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge.

If the output voltage for various vacuum is normal, check the ECU for its ground, and power supply (see ECU

Power Supply Inspection).

•

Check the output voltage, using the following formula and chart.

3-58 FUEL SYSTEM (DFI)

Intake Air Pressure Sensor (Service Code 12) (KRF750ND/PD/RD/SD)

Suppose:

Pg: Vacuum Pressure (gauge) to Sensor

Pl: Local Atmospheric Pressure (absolute) measured by a barometer

Pv: Vacuum Pressure (absolute) to Sensor

Vv: Sensor Output Voltage (V) then

Pv = Pl – Pg

For example, suppose the following data is obtained:

Pg = 8 cmHg (Vacuum gauge reading)

Pl = 70 cmHg (Barometer reading)

Vv = 3.2 V (Digital meter reading) then

Pv = 70 – 8 = 62 cmHg (Abs.)

Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you can get the usable range [2] of the sensor output voltage.

Usable range = 3.08

∼

3.48 V

Plot Vv (3.2 V) on the vertical line. → Point [3].

Results: In the chart, Vv is within the usable range and the sensor is normal.

If the reading is out of the usable range, replace the sensor.

If the reading is within the usable range, check the ECU for its ground and power supply (see ECU Power Supply

Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-59

Intake Air Pressure Sensor (Service Code 12) (KRF750ND/PD/RD/SD)

ID: Idling

Ps: Standard Atmospheric Pressure (Absolute)

Pv: Throttle Vacuum Pressure (Absolute)

ST: Standard of Sensor Output Voltage (V)

TO: Throttle Full Open

UR: Usable Range of Sensor Output Voltage (V)

Vv: Intake Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)

3-60 FUEL SYSTEM (DFI)

Intake Air Pressure Sensor (Service Code 12) (KRF750ND/PD/RD/SD)

Intake Air Pressure Sensor Circuit

1. ECU (Electronic Control Unit)

2. Waterproof Joint 2

3. Intake Air Pressure Sensor

Intake Air Temperature Sensor (Service Code 13)

Intake Air Temperature Sensor Removal/Installation

NOTICE

Never drop the sensor, especially on a hard surface.

Such a shock to the sensor can damage it.

•

Remove:

Intake Air Temperature Sensor Connector [A]

Screw [B]

Intake Air Temperature Sensor [C]

•

Install a new O-ring [A].

•

Put the intake air temperature sensor into the air cleaner housing.

•

Tighten the screw securely.

FUEL SYSTEM (DFI) 3-61

Intake Air Temperature Sensor Output Voltage

Inspection

NOTE

○

Be sure the battery is fully charged.

○

The output voltage changes according to the intake air temperature.

•

Turn the ignition switch OFF.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Disconnect the intake air temperature sensor connector and connect the measuring adapter [A] between these connectors.

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to adapter:

Meter (+) → Y lead of Main Harness

Meter (–) → BR/BK lead of Main Harness

•

Measure the output voltage with the engine stopped and the connector joined.

•

Turn the ignition switch ON.

Intake Air Temperature Sensor Output Voltage

Standard: About 2.25

∼

2.50 V at intake air temperature

20°C (68°F)

•

Turn the ignition switch OFF.

If the output voltage is out of the standard, check the wiring for continuity (see Intake Air Temperature Sensor

Circuit).

If the wiring is good, check the sensor resistance (see

Intake Air Temperature Sensor Resistance).

3-62 FUEL SYSTEM (DFI)

Intake Air Temperature Sensor (Service Code 13)

If the output voltage is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply

Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Intake Air Temperature Sensor Resistance

Inspection

•

Remove the intake air temperature sensor (see Intake Air

Temperature Sensor Removal/Installation).

•

Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged.

•

Suspend a thermometer [B] with the heat-sensitive portions [C] located in almost the same depth with the sensor.

NOTE

○

The sensor and thermometer must not touch the container side or bottom.

•

Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature.

•

Using a digital meter, measure the internal resistance of the sensor across the terminals at the temperatures shown in the following.

Intake Air Temperature Sensor Resistance

Standard: 5.4

∼

6.6 kΩ at 0°C (32°F)

0.29

∼

0.39 kΩ at 80°C (176°F)

If the measurement is out of the standard, replace the sensor.

If the measurement is within the specified, replace the

ECU (see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-63

Intake Air Temperature Sensor (Service Code 13)

Intake Air Temperature Sensor Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Intake Air Temperature Sensor

Intake Air Temperature Sensor Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Waterproof Joint 2

3. Intake Air Temperature Sensor

3-64 FUEL SYSTEM (DFI)

Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Removal

NOTICE

Never drop the sensor, especially on a hard surface.

Such a shock to the sensor can damage it.

•

Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal

• in the Frame chapter)

•

Disconnect the switch lead connector [A].

Remove the water temperature sensor [B].

Water Temperature Sensor Installation

•

Apply grease to new O-ring on the water temperature sensor.

•

Tighten:

Torque — Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106 in·lb)

•

Fill the engine with coolant and bleed the air from the cooling system (see Coolant Change in the Periodic Maintenance chapter).

Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Output Voltage

Inspection

NOTE

○

Be sure the battery is fully charged.

○

The output voltage changes according to the coolant temperature in the engine.

•

Turn the ignition switch OFF.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal)

•

Disconnect the water temperature sensor connector and connect the measuring adapter [A] between these connectors.

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter:

Meter (+) → O lead of Main Harness

Meter (–) → BR/BK lead of Main Harness

•

Measure the output voltage with the engine stopped and the connector joined.

•

Turn the ignition switch ON.

Water Temperature Sensor Output Voltage

Standard: About 2.24

∼

2.48 V at 20°C (68°F)

•

Turn the ignition switch OFF.

If the output voltage is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply

Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

If the output voltage is out of the standard, check the wiring for continuity (see Water Temperature Sensor Circuit).

If the wiring is good, check the water temperature sensor resistance (see Water Temperature Sensor Resistance

Inspection).

FUEL SYSTEM (DFI) 3-65

3-66 FUEL SYSTEM (DFI)

Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Resistance Inspection

•

Remove the water temperature sensor (see Water Temperature Sensor Removal/Installation).

•

Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.

•

Suspend an accurate thermometer [B] with heat-sensitive portions [C] located in almost the same depth.

NOTE

○

The sensor and thermometer must not touch the container side or bottom.

•

Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature.

•

Using the hand tester, measure the internal resistance of the sensor across the terminal and the body at the temperatures shown in the table.

If the measurement is out of the range, replace the sensor.

Water Temperature Sensor Resistance

Temperature

−20°C (−4°F)

0°C (32°F)

40°C (104°F)

100°C (212°F)

*: Reference Information

Resistance (kΩ)

*18.80 ±2.37

*(about 6.544)

1.136 ±0.095

0.1553 ±0.0070

If the resistance is within the standard, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-67

Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Water Temperature Sensor

Water Temperature Sensor Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Waterproof Joint 2

3. Water Temperature Sensor

3-68 FUEL SYSTEM (DFI)

Crankshaft Sensor (Service Code 21)

Crankshaft Sensor Removal/Installation

•

Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter.

Crankshaft Sensor Inspection

○

The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no signals.

•

Refer to the Crankshaft Sensor Inspection in the Electrical

System.

•

Check the wiring for continuity (see Crankshaft Sensor

Circuit).

If the crankshaft sensor and the wiring are good, check the ECU for its ground and power supply (see ECU Power

Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Crankshaft Sensor Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Crankshaft Sensor

Crankshaft Sensor (Service Code 21)

Crankshaft Sensor Circuit (KRF750ND/PD/RD/SD)

FUEL SYSTEM (DFI) 3-69

1. ECU (Electronic Control Unit)

2. Crankshaft Sensor

3-70 FUEL SYSTEM (DFI)

Speed Sensor (Service Code 24)

Speed Sensor Removal

•

Refer to the Speed Sensor Removal in the Electrical System chapter.

Speed Sensor Installation

•

Refer to the Speed Sensor Installation in the Electrical

System chapter.

Speed Sensor Input Voltage Inspection

•

Remove:

Right Rear Wheel (see Wheel Removal in the

Wheels/Tires chapter)

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Disconnect the speed sensor connector [A].

•

Connect the measuring adapter [A] between the harness connector [B] and speed sensor [C].

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC):

Meter (+) → BR lead of Main Harness

Meter (−) → BK/Y lead of Main Harness

Connections to Adapter (KRF750ND/PD/RD/SD):

Meter (+) → BR/BL lead of Main Harness

Meter (−) → BK/Y lead of Main Harness

•

Measure the input voltage with the engine stopped, and with the connectors joined.

•

Turn the ignition switch ON.

Speed Sensor Input Voltage

Standard: Battery Voltage

•

Turn the ignition switch OFF.

If the reading is good, check the output voltage (see

Speed Sensor Output Voltage Inspection).

If the reading is out of the range, check the wiring for continuity (see Speed Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Speed Sensor Output Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Using the jack, raise the rear wheel off the ground.

Special Tool — Jack: 57001-1238

Speed Sensor (Service Code 24)

•

Disconnect the speed sensor connector and connect the measuring adapter [A] between the harness connector [B] and speed sensor [C].

Special Tool — Measuring Adapter: 57001-1700

FUEL SYSTEM (DFI) 3-71

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter:

Meter (+) → P lead of Main Harness

•

Meter (–) → BK/Y lead of Main Harness

•

Measure the output voltage with the engine stopped, and with the connectors joined.

•

Turn the ignition switch ON.

Rotate the rear wheel by hand, and confirm whether the output voltage rises or lowers.

Speed Sensor Output Voltage

Standard: less than DC 0.8 V or over than DC 4.8 V

•

Turn the ignition switch OFF.

If the reading is out of the standard, replace the sensor.

If the reading is within the standard, check the wiring for continuity (see Speed Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Speed Sensor Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Speed Sensor

3. Power Source

4. Frame Ground 1

5. Multifunction Meter

3-72 FUEL SYSTEM (DFI)

Speed Sensor (Service Code 24)

Speed Sensor Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Frame Ground 2

3. Power Source

4. Speed Sensor

FUEL SYSTEM (DFI) 3-73

Vehicle-down Sensor (Service Code 31) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Vehicle-down Sensor Removal

NOTICE

Never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it.

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Bolt [A]

Vehicle-down Sensor [B]

Connector [C]

Vehicle-down Sensor Installation

•

The UPPER mark [A] of the sensor should face upward.

WARNING

Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situations like leaning over in a turn with the potential for an accident resulting in injury or death. Ensure that the vehicle-down sensor is held in place by the sensor brackets.

•

Insert the projection [A] of the bracket into the hole of the frame.

•

Tighten the bolt [B] securely.

Vehicle-down Sensor Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Vehicle-down Sensor (see Vehicle-down Sensor Removal)

3-74 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Disconnect the vehicle-down sensor connector [A] and connect the measuring adapter [B] between the main harness connector and vehicle-down sensor [C].

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter:

Meter (+) → BR/W lead of Main Harness

•

Meter (–) → BR/BK lead of Main Harness

Install the vehicle-down sensor temporarily.

•

Measure the input voltage with the engine stopped and with the connectors joined.

•

Turn the ignition switch ON.

Vehicle-down Sensor Input Voltage

Standard: DC 4.75

∼

5.25 V

•

Turn the ignition switch OFF.

If the reading is good, check the output voltage (see Vehicle-down Sensor Output Voltage Inspection).

If the reading is out of the range, check the wiring for continuity (see Vehicle-down Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Vehicle-down Sensor Output Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the vehicle-down sensor (see Vehicle-down

Sensor Removal).

•

Disconnect the vehicle-down sensor connector [A] and connect the measuring adapter [B] between the main harness connector and vehicle-down sensor [C].

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter:

Meter (+) → Y/G lead of Main Harness

•

Meter (–) → BR/BK lead of Main Harness

Hold the sensor vertically.

•

Measure the output voltage with the engine stopped, and with the connectors joined.

FUEL SYSTEM (DFI) 3-75

Vehicle-down Sensor (Service Code 31) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Turn the ignition switch ON.

•

Tilt the sensor 55

∼

75° or more [A] right or left, then hold the sensor almost vertical with the arrow mark [B] pointed up, and measure the output voltage.

Vehicle-down Sensor Output Voltage

Standard: with sensor arrow mark pointed up: DC 0.4

∼

1.4 V with sensor tilted 55

∼

75° or more right or left: DC 3.7

∼

4.4 V

•

Turn the ignition switch OFF.

If the reading is out of the standard, replace the vehicle

-down sensor.

If the reading is within the standard, check the wiring for continuity (see Vehicle-down Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Vehicle-down Sensor Circuit

1. ECU (Electronic Control Unit)

2. Vehicle-down Sensor

3-76 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31) (KRF750ND/PD/RD/SD)

Vehicle-down Sensor Removal

NOTICE

Never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it.

•

Remove:

Left Rear Flap (Rear Flap Removal in the Frame chapter)

Connector [A]

Vehicle-down Sensor Bolts [B]

Vehicle-down Sensor [C]

Vehicle-down Sensor Installation

•

The UPPER mark [A] of the sensor should face upward.

WARNING

Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situations like leaning over in a turn with the potential for an accident resulting in injury or death. Ensure that the vehicle-down sensor is held in place by the sensor brackets.

•

Apply a non-permanent locking agent to the threads of vehicle-down sensor bolts and tighten them.

Torque — Vehicle-down Sensor Bolts: 5.9 N·m (0.60 kgf·m,

52 in·lb)

Vehicle-down Sensor Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Left Rear Flap (Rear Flap Removal in the Frame chapter)

FUEL SYSTEM (DFI) 3-77

Vehicle-down Sensor (Service Code 31) (KRF750ND/PD/RD/SD)

•

Disconnect the vehicle-down sensor connector [A] and connect the measuring adapter [B] between the main harness connector and vehicle-down sensor [C].

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter:

Meter (+) → BR/W lead of Main Harness

Meter (–) → BR/BK lead of Main Harness

•

Measure the input voltage with the engine stopped and with the connectors joined.

•

Turn the ignition switch ON.

Vehicle-down Sensor Input Voltage

Standard: DC 4.75

∼

5.25 V

•

Turn the ignition switch OFF.

If the reading is good, check the output voltage (see Vehicle-down Sensor Output Voltage Inspection).

If the reading is out of the range, check the wiring for continuity (see Vehicle-down Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Vehicle-down Sensor Output Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the vehicle-down sensor (see Vehicle-down

Sensor Removal).

•

Disconnect the vehicle-down sensor connector [A] and connect the measuring adapter [B] between the main harness connector and vehicle-down sensor [C].

Special Tool — Measuring Adapter: 57001-1700

•

Connect a digital meter to the measuring adapter leads.

Connections to Adapter:

Meter (+) → Y/G lead of Main Harness

•

Meter (–) → BR/BK lead of Main Harness

Hold the sensor vertically.

•

Measure the output voltage with the engine stopped, and with the connectors joined.

3-78 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31) (KRF750ND/PD/RD/SD)

•

Turn the ignition switch ON.

•

Tilt the sensor 60

∼

70° or more [A] right or left, then hold the sensor almost vertical with the arrow mark [B] pointed up, and measure the output voltage.

Vehicle-down Sensor Output Voltage

Standard: with sensor arrow mark pointed up: DC

3.55

∼

4.45 V with sensor tilted 60

∼

70° or more right or left: DC 0.65

∼

1.35 V

•

Turn the ignition switch OFF.

If the reading is out of the standard, replace the vehicle

-down sensor.

If the reading is within the standard, check the wiring for continuity (see Vehicle-down Sensor Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-79

Vehicle-down Sensor (Service Code 31) (KRF750ND/PD/RD/SD)

Vehicle-down Sensor Circuit

1. ECU (Electronic Control Unit)

2. Waterproof Joint 2

3. Vehicle-down Sensor

3-80 FUEL SYSTEM (DFI)

Fuel Pump Relay (Service Code 46)

Fuel Pump Relay Removal

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Fuel Pump Relay [A]

Fuel Pump Relay Inspection

•

Refer to the Relay Inspection in the Electrical System chapter.

If the fuel pump relay is normal, check the wiring for continuity (see Fuel Pump Relay Circuit).

Special Tool — Hand Tester: 57001-1394

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-81

Fuel Pump Relay (Service Code 46)

Fuel Pump Relay Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Fuel Pump Relay

3. Engine Ground

4. Battery

5. Frame Ground 1

6. Ignition Switch

7. Fuse Box

8. Fuel Pump Fuse 10 A

9. Main Fuse 30 A

10. Fuel Pump

3-82 FUEL SYSTEM (DFI)

Fuel Pump Relay (Service Code 46)

Fuel Pump Relay Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Fuel Pump Relay

3. Frame Ground 2

4. Engine Ground

5. Battery

6. Waterproof Joint 1

7. Ignition Switch

8. Fuse Box

9. Ignition Fuse 10 A

10. Fuel Pump Fuse 10 A

11. Main Fuse 30 A

12. Fuel Pump

Ignition Coils (#1, #2: Service Code 51, 52)

Ignition Coil #1: Ignition Coil for Front Cylinder (Service

Code 51)

Ignition Coil #2: Ignition Coil for Rear Cylinder (Service

Code 52)

Ignition Coil Removal/Installation

NOTICE

Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can damage it.

•

Refer to the Ignition Coil Removal and Installation in the

Electrical System chapter.

Ignition Coil Winding Resistance

•

Refer to the Ignition Coil Inspection in the Electrical System chapter.

If the resistance is within the standard, check the input voltage (see Ignition Coil Input Voltage Inspection).

Ignition Coil Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

•

Connect a digital voltmeter as shown, using two needle adapters.

Special Tool — Needle Adapter Set: 57001-1457

Connections for Ignition Coil #1 (Front)

Meter (+) → G/W lead (terminal 44)

Meter (–) → Battery (–) Terminal

Connections for Ignition Coil #2 (Rear)

Meter (+) → BL/W lead (terminal 35)

Meter (–) → Battery (–) Terminal

•

Measure the input voltage to each primary winding of the ignition coils with the engine stopped, and with the connectors joined.

•

Turn the ignition switch ON.

Ignition Coil Input Voltage

Standard: 12 V or more

FUEL SYSTEM (DFI) 3-83

3-84 FUEL SYSTEM (DFI)

Ignition Coils (#1, #2: Service Code 51, 52)

•

Turn the ignition switch OFF.

If the input voltage is out of the standard, check the wiring for continuity (see Ignition Coil Circuit).

Special Tool — Hand Tester: 57001-1394

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

If the input voltage is within the standard, check the ECU for its ground and power supply (see ECU Power Supply

Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Ignition Coil Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Engine Ground

3. Battery

4. Ignition Coil #2 (Rear)

5. Ignition Coil #1 (Front)

6. Spark Plug (Rear)

7. Spark Plug (Front)

8. Frame Ground 1

9. Fuse Box

10. Main Fuse 30 A

11. Ignition Switch

Ignition Coils (#1, #2: Service Code 51, 52)

Ignition Coil Circuit (KRF750ND/PD/RD/SD)

FUEL SYSTEM (DFI) 3-85

1. ECU (Electronic Control Unit)

2. Frame Ground 2

3. Engine Ground

4. Battery

5. Ignition Coil #2 (Rear)

6. Spark Plug (Rear)

7. Ignition Coil #1 (Front)

8. Spark Plug (Front)

9. Waterproof Joint 1

10. Ignition Switch

11. Fuse Box

12. Ignition Fuse 10 A

13. Main Fuse 30 A

3-86 FUEL SYSTEM (DFI)

Radiator Fan Relay (Service Code 56) (KRF750ND/PD/RD/SD)

Radiator Fan Relay Removal

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Radiator Fan Relay [A]

Radiator Fan Relay Inspection

•

Refer to the Relay Inspection in the Electrical System chapter.

If the radiator fan relay is normal, check the wiring for continuity (see Radiator Fan Relay Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-87

Radiator Fan Relay (Service Code 56) (KRF750ND/PD/RD/SD)

Radiator Fan Relay

1. ECU (Electronic Control Unit)

2. Radiator Fan Relay

3. Engine Ground

4. Battery

5. Waterproof Joint 2

6. Frame Ground 1

7. Radiator Fan

8. Water Temperature Sensor

9. Radiator Fan Breaker 15 A

10. Fuse Box

11. Main Fuse 30 A

3-88 FUEL SYSTEM (DFI)

Fuel Injectors

Fuel Injector Removal

•

Remove:

Air Cleaner Duct (see Air Cleaner Housing and Duct Removal)

Fuel Hose Joint [A] (see Fuel Hose Removal)

Front Delivery Pipe Mounting Screws [B]

•

Remove the front fuel injector [C] from the throttle body.

•

Disconnect the fuel injector connector [A].

•

Remove the front fuel injector [B] from the delivery pipe

[C].

•

Remove:

Rear Delivery Pipe Mounting Screws [A]

Rear Fuel Injector [B]

•

Disconnect the fuel injector connector [A].

•

Remove the rear fuel injector [B] from the delivery pipe

[C].

Fuel Injector Installation

•

Replace the seals [A] with new ones.

Fuel Injectors

•

Before installation, blow away dirt or dust from the delivery pipe [A] by applying compressed air.

FUEL SYSTEM (DFI) 3-89

•

Replace the O-rings [A] with new ones.

•

Install the rear fuel injector [A] into the delivery pipe [B] securely.

•

Insert the rear fuel injector into the seal and tighten the rear delivery pipe mounting screws [A].

Torque — Delivery Pipe Mounting Screws: 5.0 N·m (0.51

kgf·m, 44 in·lb)

•

Install the front fuel injector [B] into the delivery pipe [C] securely.

•

Insert the front fuel injector into the seal and tighten the front delivery pipe mounting screws [A].

Torque — Delivery Pipe Mounting Screws: 5.0 N·m (0.51

kgf·m, 44 in·lb)

•

Connect the fuel injector connectors [B] as follows.

BL/R and W/R Leads Connector → Front Fuel Injector

V and W/R Leads Connector → Rear Fuel Injector

3-90 FUEL SYSTEM (DFI)

Fuel Injectors

Audible Inspection

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal

• in the Frame chapter)

Start the engine.

•

Apply the tip of a screwdriver [A] to the fuel injector [B].

Put the grip end onto your ear, and listen whether the fuel injector is clicking or not.

○

A sound scope can also be used.

•

Do the same for the other fuel injector.

If all the fuel injectors click at a regular intervals, the fuel injectors are good. The trouble may be related to the fuel line, requiring fuel pressure inspection (see Fuel Pressure

Inspection).

○

The click interval becomes shorter as the engine speed rises.

If any fuel injector(s) does not click, check the fuel injector resistance (see Fuel Injector Resistance Inspection).

Fuel Injector Resistance Inspection

•

Remove:

Fuel Injector (see Fuel Injector Removal)

•

Connect a digital meter [A] to the terminals in the fuel injector.

•

Measure the fuel injector resistance.

Fuel Injector Resistance

Standard: About 11.7

∼

12.3 Ω at 20°C (68°F)

•

If the reading is out of the standard, replace the fuel injector.

•

If the reading within the standard, check the power source voltage (see Fuel Injector Power Source Voltage Inspection).

Fuel Injector Power Source Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Connect the hand tester to the connector [A] with the needle adapter set.

Special Tools — Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

Connections:

Meter (+) → W/R lead

Meter (–) → Battery (–) terminal

•

Measure the power source voltage with the engine stopped.

•

Turn the ignition switch ON.

Fuel Injector Power Source Voltage

Standard: Battery Voltage for 3 seconds, and then 0 V

•

Turn the ignition switch OFF.

Fuel Injectors

If the reading stays on battery voltage and never shows 0

V, check the fuel pump relay (see Relay Inspection in the

Electrical System chapter).

If the fuel pump relay is normal, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

If there is still no battery voltage, check the fuel pump relay

(see Relay Inspection in the Electrical System chapter).

If the fuel pump relay is normal, check the power source wiring (see Fuel Injector Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

If the reading is in specification, check the output voltage

(see Fuel Injector Output Voltage Inspection).

Fuel Injector Output Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Connect the hand tester to the connector [A] with the needle adapter set.

Special Tools — Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

Connections :

Meter (+) → BL/R lead or V lead

•

Meter (–) → Battery (–) terminal

•

Measure the output voltage with the engine stopped.

Turn the ignition switch ON.

Fuel Injector Output Voltage

Standard: Battery Voltage for 3 seconds, and then 0 V

•

Turn the ignition switch OFF.

If the reading is in specification, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

If the reading is out of the specification, check the wiring for continuity (see Fuel Injector Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-91

3-92 FUEL SYSTEM (DFI)

Fuel Injectors

Fuel Injector Fuel Line Inspection

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Fuel Hose (see Fuel Hose Removal)

•

Check the injector fuel line for leakage as follows.

○

Connect a commercially available vacuum/pressure pump [A] to the delivery pipe [B] with the fuel hose [C]

(both ends connected with the clamps [D]) as shown in the figure.

○

Apply soap and water solution to the areas [E] as shown in the figure.

○

Watching the pressure gauge, squeeze the pump lever

[F], and build up the pressure until the pressure reaches the maximum pressure.

Injector Fuel Line Maximum Pressure

Standard: 300 kPa (3.06 kgf/cm², 43 psi)

NOTICE

During pressure testing, do not exceed the maximum pressure for which the system is designed.

○

Watch the gauge for at least 6 seconds.

If the pressure holds steady, the fuel line is good.

If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the delivery pipe assy, injectors and related parts.

•

Repeat the leak test, and check the fuel line for no leakage.

•

Remove the vacuum/pressure pump, and install the fuel hose (see Fuel Hose Installation).

•

Start the engine and check for fuel leakage.

FUEL SYSTEM (DFI) 3-93

Fuel Injectors

Fuel Injector Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. Fuel Injector #1

2. Fuel Injector #2

3. Ignition Switch

4. Fuse Box

5. Fuel Pump Fuse 10 A

6. Main Fuse 30 A

7. ECU (Electronic Control Unit)

8. Fuel Pump Relay

9. Engine Ground

10. Battery

11. Frame Ground 1

3-94 FUEL SYSTEM (DFI)

Fuel Injectors

Fuel Injector Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Fuel Pump Relay

3. Frame Ground 2

4. Engine Ground

5. Battery

6. Waterproof Joint 1

7. Ignition Switch

8. Fuel Injector #1

9. Fuel Injector #2

10. Ignition Fuse 10 A

11. Fuel Pump Fuse 10 A

12. Main Fuse 30 A

13. Fuse Box

FUEL SYSTEM (DFI) 3-95

FI Indicator Symbol (LCD) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

FI Indicator Symbol (LCD) Inspection

•

Refer to the Multifunction Meter Unit Inspection in the

Electrical System chapter for FI indicator symbol [A]

(LCD) Inspection.

If the FI indicator symbol (LCD) is abnormal, replace the meter unit.

If the FI indicator symbol (LCD) is normal, the wiring or

ECU has trouble. Check the wiring (see FI Indicator Symbol (LCD) Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply

Inspection).

FI Indicator Symbol (LCD) Circuit

1. Multifunction Meter

2. Ignition Switch

3. Fuse Box

4. Main Fuse 30 A

5. ECU (Electronic Control Unit)

6. Engine Ground

7. Battery

8. Frame Ground 1

3-96 FUEL SYSTEM (DFI)

Yellow Engine Warning Indicator Light (LED) (KRF750ND/PD/RD/SD)

Yellow Engine Warning Indicator Light (LED)

Inspection

•

Refer to the Multifunction Meter Unit Inspection in the

Electrical System chapter for Yellow Engine Warning Indicator Light (LED) [A] Inspection.

If the yellow engine warning indicator light (LED) is abnormal, replace the meter unit.

If the yellow engine warning indicator light (LED) is normal, the wiring or ECU has trouble. Check the wiring

(see Yellow Engine Warning Indicator Light (LED) Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

Yellow Engine Warning Indicator Light (LED) Circuit

1. ECU (Electronic Control Unit)

2. Engine Ground

3. Battery

4. Waterproof Joint 1

5. Frame Ground 1

6. Multifunction Meter

7. Ignition Switch

8. Fuse Box

9. Ignition Fuse 10 A

10. Fuel Pump Fuse 10 A

11. Main Fuse 30 A

ECU

NOTICE

Never drop the ECU, especially on a hard surface.

Such a shock to the ECU can damage it.

ECU Removal

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Screws [A]

Quick Rivet [B]

•

Pull out the electrical parts case [C].

•

Remove:

ECU Mounting Bolts [A]

Connectors [B]

ECU [C]

FUEL SYSTEM (DFI) 3-97

•

ECU Installation

Connect the ECU connectors to the ECU.

•

Install the ECU to the electrical parts case.

•

Tighten:

Torque — ECU Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

ECU Power Supply Inspection

•

Visually inspect the ECU connectors.

If the connector is clogged with mud or dust, blow it off with compressed air.

•

Visually inspect the terminals [A] of the ECU connectors.

If the terminals of the main harness connectors are damaged, replace the main harness.

If the terminals of the ECU connectors are damaged, replace the ECU.

3-98 FUEL SYSTEM (DFI)

ECU

•

•

Turn the ignition switch OFF.

Disconnect the ECU connectors [A] (Main Harness).

•

Set the hand tester [B] to the × 1 Ω range and check the following wiring for continuity.

Special Tool — Hand Tester: 57001-1394

Main Harness Grounding Inspection

Connections (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) [C]:

BK/Y leads

(11, 33 or 42 terminal)

←→ Battery (–) Terminal

Engine Ground ←→ Battery (–) Terminal

Connections (KRF750ND/PD/RD/SD) [D]:

BK/Y leads

(9, 33 or 42 terminal)

Engine Ground

Criteria:

All: 0 Ω

←→ Battery (–) Terminal

←→ Battery (–) Terminal

If no continuity, check the connectors, the engine ground lead, or main harness, and repair or replace them.

If the wiring is good, check the power source voltage of the ECU.

NOTE

○

Be sure the battery is fully charged.

•

Connect the ECU connectors.

•

Connect the hand tester [A] to the connector [B] with the needle adapter set.

Special Tool — Needle Adapter Set: 57001-1457

Battery [C]

ECU Power Supply Inspection

Connections (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) [D]:

(I) Tester (+) → Terminal 8 (W)

Tester (–) → Battery (–) Terminal

(II) Tester (+) → Terminal 13 (BR)

Tester (–) → Battery (–) Terminal

Connections (KRF750ND/PD/RD/SD) [E]:

(I) Tester (+) → Terminal 12 (BR/BL)

Tester (–) → Battery (–) Terminal

(II) Tester (+) → Terminal 13 (W/G)

Tester (–) → Battery (–) Terminal

Ignition Switch OFF:

(I) Battery Voltage

(II) 0 V

Ignition Switch ON:

(I) Battery Voltage

(II) Battery Voltage

FUEL SYSTEM (DFI) 3-99

ECU

If the reading is out of the specification, check the following.

Main Fuse 30 A (see Fuse Inspection in the Electrical

System chapter)

Ignition Fuse 10 A (see Fuse Inspection Electrical System chapter) (KRF750ND/PD/RD/SD)

Fuel Pump Fuse 10 A (see Fuse Inspection Electrical

System chapter) (KRF750ND/PD/RD/SD)

Power Source Wiring (see ECU Power Source Circuit)

ECU Power Source Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Frame Ground 1

3. Engine Ground

4. Battery

5. Ignition Switch

6. Fuse Box

7. Main Fuse 30 A

3-100 FUEL SYSTEM (DFI)

ECU

ECU Power Source Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Frame Ground 2

3. Engine Ground

4. Battery

5. Waterproof Joint 1

6. Ignition Switch

7. Fuse Box

8. Ignition Fuse 10 A

9. Fuel Pump Fuse 10 A

10. Main Fuse 30 A

Fuel Line

Fuel Pressure Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the fuel hose (see Fuel Hose Removal).

WARNING

Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.

•

Install the fuel pressure gauge adapter [A] and fuel hoses

[B] (Special Tool) between the fuel pump outlet pipe and the delivery pipe.

•

Connect the pressure gauge [C] to the fuel pressure gauge adapter.

Special Tools — Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Fuel Pressure Gauge Adapter: 57001-1593

Fuel Hose: 57001-1607

WARNING

Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death.

Do not try to start the engine with the fuel hoses disconnected.

•

Turn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop.

NOTE

○

Turn the ignition switch ON and inspect the fuel line leakage after installing the special tools.

NOTICE

Do not drive the fuel pump without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged.

•

Start the engine, and let it idle.

•

Measure the fuel pressure with the engine idling.

Fuel Pressure (Idling)

Standard: 294 kPa (3.0 kgf/cm², 43 psi)

FUEL SYSTEM (DFI) 3-101

3-102 FUEL SYSTEM (DFI)

Fuel Line

NOTE

○

The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.

•

Turn the ignition switch OFF.

If the fuel pressure is much higher than specified, the fuel pressure regulator in the fuel pump has been clogged or stuck. Replace the fuel pump (see Fuel Pump Removal).

If the fuel pressure is much lower than specified, check the following.

Fuel Line Leakage (see Fuel Injector Fuel Line Inspection)

•

Amount of Fuel Flow (see Fuel Flow Rate Inspection)

•

Remove the fuel pressure gauge, hoses and adapter.

Install the removed parts.

Fuel Flow Rate Inspection

NOTE

○

Be sure the battery is fully charged.

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

•

•

Turn the ignition switch OFF.

Wait until the engine cools down.

•

Prepare a fuel hose (Special Tool) and a measuring cylinder.

Special Tool — Fuel Hose: 57001-1607

•

Remove the fuel hose (see Fuel Hose Removal).

WARNING

Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.

Fuel Line

•

Connect the prepared fuel hose [A] to the fuel pump outlet pipe.

•

Secure the fuel hose with a clamp.

•

Insert the fuel hose into the measuring cylinder [B].

WARNING

Wipe off spilled out fuel immediately.

Be sure to hold the measuring cylinder vertical.

•

Turn the ignition switch ON. The fuel pump should operate for 3 seconds, and then should stop.

NOTICE

Do not drive the fuel pump without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged.

•

Measure the discharge for 3 seconds.

Amount of Fuel Flow

Standard: 50 mL (1.7 US oz.) or more for 3 seconds

○

Repeat this operation several times.

•

Turn the ignition switch to OFF.

If the fuel flow is much less than the specified, clean the fuel filter (see Fuel Filter Cleaning).

•

Recheck the amount of fuel flow.

If the fuel flow is much less than the specified, replace the

• fuel pump (see Fuel Pump Removal/Installation).

•

Install the fuel hose (see Fuel Hose Installation).

Start the engine and check for fuel leakage.

FUEL SYSTEM (DFI) 3-103

3-104 FUEL SYSTEM (DFI)

Fuel Pump

Fuel Pump Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Disconnect the battery (–) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

NOTICE

Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it.

•

Remove:

Right Seat (see Seat Removal in the Frame chapter)

Fuel Hose [A] (see Fuel Hose Removal)

Connector [B]

•

Remove:

Fuel Pump Mounting Bolts [A]

Plate [B]

Fuel Pump [C]

O-ring

Fuel Pump Installation

•

Remove dirt or dust from the fuel pump [A] by lightly applying compressed air.

Fuel Pump

•

Replace the O-ring [A] with a new one.

•

Install the plate [A] so that the projections [B] of the fuel tank and fuel pump fit to the hollows of the plate.

•

Tighten the fuel pump bolts to a snug fit, tighten them alternating diagonally.

•

Tighten:

Torque — Fuel Pump Mounting Bolts: 4.0 N·m (0.41 kgf·m,

35 in·lb)

•

Install:

Fuel Hose (see Fuel Hose Installation)

Connector

•

Start the engine and check the fuel hose for leaks.

Fuel Pump Operation Inspection

NOTE

○

Be sure the battery is fully charged.

○

Just listen to the pump sound in the fuel tank to confirm pump operation.

•

Turn the ignition switch ON and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops.

•

Turn the ignition switch OFF.

If the pump does not operate as described above, inspect the operating voltage (see Fuel Pump Operating Voltage

Inspection).

Fuel Pump Operating Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove:

Right Seat (see Seat Removal in the Frame chapter)

FUEL SYSTEM (DFI) 3-105

3-106 FUEL SYSTEM (DFI)

Fuel Pump

•

Disconnect the fuel pump lead connector and connect the measuring adapter [A] between the connectors of the fuel pump and harness.

Special Tool — Measuring Adapter: 57001-1700

•

Connect the hand tester [B] to the measuring adapter leads.

Special Tool — Hand Tester: 57001-1394

Connections to Adapter:

Meter (+) → W/R lead of Main Harness

Meter (–) → BK/Y lead of Main Harness

•

Confirm the color of the lead by opening the cap [A] of the connector.

W/R [B]

BK/Y [C]

•

Measure the operating voltage with engine stopped and with the connector joined.

•

Turn the ignition switch ON.

Fuel Pump Operating Voltage

Standard: Battery Voltage for 3 seconds, and then 0 V

•

Turn the ignition switch OFF.

If the reading is not the standard, check the fuel pump relay (see Relay Inspection in the Electrical System chapter).

If the fuel pump relay is normal, check the wiring for continuity (see Fuel Pump Circuit).

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU

(see ECU Removal/Installation).

Pressure Regulator Removal

○

The pressure regulator [A] is built into the fuel pump [B] and cannot be removed.

Fuel Pump

Fuel Filter Cleaning

WARNING

Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the fuel filter in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Do not use gasoline or low flash-point solvents to clean the fuel filter.

•

Remove:

Cover [A]

Fuel Filter [B]

•

Check the fuel filter of the visible damage.

If the fuel filter is damaged, replace it with a new one.

•

Wash the fuel filter in non-flammable of high flash-point solvent. Use a soft brush to remove any contaminants trapped the fuel filter.

FUEL SYSTEM (DFI) 3-107

3-108 FUEL SYSTEM (DFI)

Fuel Pump

Fuel Pump Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. ECU (Electronic Control Unit)

2. Fuel Pump Relay

3. Engine Ground

4. Battery

5. Frame Ground 1

6. Ignition Switch

7. Fuse Box

8. Fuel Pump Fuse 10 A

9. Main Fuse 30 A

10. Fuel Pump

Fuel Pump

Fuel Pump Circuit (KRF750ND/PD/RD/SD)

FUEL SYSTEM (DFI) 3-109

1. ECU (Electronic Control Unit)

2. Fuel Pump Relay

3. Frame Ground 2

4. Engine Ground

5. Battery

6. Waterproof Joint 1

7. Ignition Switch

8. Fuse Box

9. Ignition Fuse 10 A

10. Fuel Pump Fuse 10 A

11. Main Fuse 30 A

12. Fuel Pump

3-110 FUEL SYSTEM (DFI)

Throttle Pedal and Cable

Throttle Pedal Free Play Inspection

•

Refer to the Throttle Pedal Free Play Inspection in the

Periodic Maintenance chapter.

Throttle Pedal Free Play Adjustment

•

Refer to the Throttle Pedal Free Play Adjustment in the

Periodic Maintenance chapter.

Throttle Pedal Position Adjustment

•

Depress the throttle pedal [A] until the pedal stopper [B] touches to the floorboard [C].

•

Then adjust the gap between the stopper [D] of the link lever and stopper [E] of the throttle body to 1 mm (0.04

in.) [F] by adjusting the adjusting nut [G].

•

Tighten:

Torque — Throttle Cable Locknut [H]: 4.4 N·m (0.45 kgf·m, 39 in·lb)

•

Set the rest position of the throttle pedal by adjusting the throttle pedal position bolt [I] so that the throttle vale is not open.

•

Tighten:

Torque — Throttle Pedal Position Bolt Locknut [J]: 10.8 N·m

(1.1 kgf·m, 96 in·lb)

Throttle Pedal Removal

•

Remove:

Spring [A]

Snap Pin [B] and Washer

•

Remove the throttle pedal from the bracket.

Throttle Pedal and Cable

•

Remove the throttle cable end [A] from the throttle pedal

[B].

FUEL SYSTEM (DFI) 3-111

Throttle Pedal Installation

•

Apply grease:

Throttle Cable End

Pin [A] of Throttle Pedal

•

Install:

Throttle Cable End

Throttle Pedal [B]

Snap Pin [C] and Washer [D]

Spring [E]

•

Do not use a needle nose pliers for the damage prevention of the spring.

•

Install the spring [A] as shown in the figure.

Downward [B]

Throttle Cable Installation

•

Lubricate the throttle cable before installation.

WARNING

Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.

Be sure the cables are routed correctly and properly adjusted.

•

Apply grease to the cable ends [A].

•

Install the front end of the throttle cable [B] as shown in the figure.

•

Install the end [C] of the boot [D] to the groove of the joint.

4

∼

8 mm (0.15

∼

0.31 in.) [E]

Bracket [F]

Front [G]

•

Tighten:

Torque — Throttle Cable Locknuts [H]: 4.4 N·m (0.45 kgf·m,

39 in·lb)

•

Adjust the full throttle pedal position (see Full Throttle

Pedal Position Adjustment).

•

Check the throttle cable (see Throttle Pedal Free Play

Inspection).

3-112 FUEL SYSTEM (DFI)

Throttle Pedal and Cable

Throttle Cable Lubrication and Inspection

•

Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.

•

Lubricate the points listed below with indicated lubricant.

NOTE

○

Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.

•

Lubricate the cables by seeping the oil between the cable and housing.

○

The cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant.

•

With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.

•

Lubricate the inner cable ends [A] with grease.

Throttle Body Assy

Idle Speed Inspection

•

Refer to the Idle Speed Inspection in the Periodic Maintenance chapter.

Idle Speed Adjustment

NOTE

○

Idle speed adjustment is best performed by ECU, so idle speed cannot be adjusted.

Throttle Body Assy Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Disconnect the battery (-) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

•

Remove:

Air Cleaner Duct (see Air Cleaner Housing and Duct Removal)

Fuel Hose (see Fuel Hose Removal)

Fuel Injectors (see Fuel Injector Removal)

ISC Valve Hose [A]

•

Disconnect:

Throttle Sensor Connector [B]

Intake Air Pressure Sensor Connector [C]

•

Remove:

Screws [A] and Washers

Throttle Link Case Cover [B]

FUEL SYSTEM (DFI) 3-113

3-114 FUEL SYSTEM (DFI)

Throttle Body Assy

•

Remove:

Throttle Cable End [A]

•

Loosen the throttle cable locknut [B] and remove the throttle cable [C] from the throttle link case.

•

Loosen the clamp screws [A] fully.

•

Remove the throttle body assy [B] from the throttle body assy holders.

•

Remove:

ISC Valve Hose [A]

Vacuum Hose [B]

•

After removing the throttle body assy, stuff pieces of lint

-free, clean cloth into the throttle body assy holders.

NOTICE

If dirt gets into the engine, excessive engine wear and possible engine damage will occur.

Throttle Body Assy Installation

•

Turn the throttle pulley to check that the throttle valve move smoothly and return by spring force.

If the throttle valve do not move smoothly, replace the throttle body assy.

•

Open the butterfly valves [A], and wipe any carbon off the throttle bores [B] around the valve, using a piece of lint-free cloth penetrated with a high-flash point solvent.

•

Blow away dirt or dust from the throttle body by applying compressed air.

NOTICE

Do not immerse the throttle body in a high-flash point solvent for cleaning. This could damage the throttle sensor on the throttle body.

Throttle Body Assy

•

Be sure to groove [A] of the throttle body assy holder fits on the projection [B] of the cylinder head.

•

Install:

Vacuum Hose

ISC Valve Hoses

Throttle Body Assy

•

Tighten the throttle body assy holder clamp screw securely.

•

Apply a thin coating of grease to the throttle cable rear end [A] .

•

Fit the throttle cable rear end into the throttle pulley [B].

•

Tighten the adjusting nut [C] and locknut [D] (see Throttle

Cable Installation).

FUEL SYSTEM (DFI) 3-115

•

Be sure to install the seal [A] on the throttle link case cover.

•

Install the removed parts.

•

Check the throttle pedal free play (see Throttle Pedal Free

Play Inspection).

WARNING

Operation with an incorrectly routed cable could result in an unsafe riding condition. Be sure the cable is routed correctly.

•

Adjust:

Idle Speed (see Idle Speed Adjustment)

Throttle Body Assy Disassembly

NOTICE

Do not remove, disassemble or adjust the throttle sensor [A] and throttle body assy, because they are adjusted or set at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.

NOTICE

Never drop the throttle body assy , especially on a hard surface. Such a shock to the body assy can damage it.

3-116 FUEL SYSTEM (DFI)

Throttle Body Assy

•

Remove:

Throttle Body Assy (see Throttle Body Assy Removal)

Screw [A]

Intake Air Pressure Sensor [B]

Vacuum Hose [C]

•

Remove the drain tube [D], if necessary.

•

Throttle Body Assy Assembly

Install the drain tube [A], if removed.

•

Install the intake air pressure sensor [B].

•

Tighten:

Torque — Intake Air Pressure Sensor Mounting Screw [C]:

5.0 N·m (0.51 kgf·m, 44 in·lb)

•

Connect the vacuum hose [D].

Engine Vacuum Synchronization Inspection

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

•

Check idle speed (see Idle Speed Inspection).

•

Remove the plug [A] and connect the hose [B] of the vacuum gauge.

Special Tool — Vacuum Gauge: 57001-1369

•

Remove the vacuum hose [A] and connect the hose [B] of the vacuum gauge.

•

Connect the vacuum gauge [C].

•

Start the engine and read the intake vacuum when idling.

If the vacuum is out of the specified range, check the ISC valve (see ISC Valve Inspection).

If the ISC valve is good, adjust the vacuum (see Engine

Vacuum Synchronization Adjustment).

Engine Vacuum

Standard: 29.6 ±1.3 kPa (222 ±9.8 mmHg) at Idle Speed

Throttle Body Assy

Engine Vacuum Synchronization Adjustment

•

Turn in the bypass screws [A] until it seats fully but not tightly.

Special Tool — Pilot Screw Adjuster, A [B]: 57001-1239

NOTICE

Do not over tighten them. They could be damaged, requiring replacement.

•

Turn out the bypass screw until the vacuum enters the standard.

•

Open and close the throttle valves after each measurement and adjust the bypass screw as necessary.

If both vacuums are within the standard, finish the engine vacuum synchronization.

If any vacuum cannot be adjusted within the standard, remove the bypass screws #1, #2 and clean them.

•

Remove:

Bypass Screw [A]

Spring [B]

Washer [C]

O-ring [D]

•

Check the bypass screw and its hole for carbon deposits.

If any carbon accumulates, wipe the carbon off the bypass screw and the hole, using a cotton pad penetrated with a

• high-flash point solvent.

Replace the O-ring with a new one.

•

Check the tapered portion [E] of the bypass screw for wear or damage.

•

If the bypass screw is worn or damaged, replace it.

Turn in the bypass screw until it seats fully but not tightly.

•

Repeat the same procedure for other bypass screw.

•

Repeat the synchronization adjustment.

FUEL SYSTEM (DFI) 3-117

3-118 FUEL SYSTEM (DFI)

ISC Valve

ISC Valve Removal

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Screws [A] and Resonator [B]

Connector [C]

•

Remove:

ISC Valve Hose (Front) [A]

ISC Valve Hose (Rear) [B]

ISC Valve Hose (Primary) [C]

Bolts [D]

ISC Valve [E]

•

ISC Valve Installation

Install the ISC valve.

•

Tighten:

Torque — ISC Valve Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

ISC Valve Inspection

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

ISC Valve Connector [A]

•

Connect the hand tester to the following pair of terminals.

Special Tool — Hand Tester: 57001-1394

•

Set the hand tester to the × 1 Ω range.

Connections:

Terminal A-B,

Terminal B-C

Terminal D-E, Terminal E-F

Standard Resistence:

28.8

∼

31.2 Ω at 20°C(68°F)

If the tester does not read as specified, replace the ISC valve.

Air Cleaner

Air Cleaner Element Removal

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Remove:

Quick Rivets [A] (both sides)

Air Cleaner Top Cover [B]

FUEL SYSTEM (DFI) 3-119

•

Remove:

Clips [A]

Air Cleaner Housing Cap [B]

•

Remove:

Element Holder Screw [A]

Element Assembly [B]

•

After removing the element, stuff pieces of lint-free, clean cloth into the air cleaner ducts to keep dirt out of the carburetor and engine.

WARNING

If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.

Replace the air cleaner element according to the maintenance chart.

NOTICE

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

•

Remove:

Element Cover Screw [A]

Element Cover [B]

3-120 FUEL SYSTEM (DFI)

Air Cleaner

•

Remove:

Element [A]

Element Holder [B]

Air Cleaner Element Removal

(KRF750ND/PD/RD/SD)

•

Remove:

Quick Rivets [A] (both sides)

Air Cleaner Top Cover [B]

•

Remove:

Clips [A]

Air Cleaner Housing Cap [B]

•

Lift the element cover [A] up, and remove the element [B].

•

After removing the element, stuff pieces of lint-free, clean cloth into the air cleaner ducts to keep dirt out of the carburetor and engine.

WARNING

If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.

Replace the air cleaner element according to the maintenance chart.

NOTICE

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Air Cleaner

Air Cleaner Element Installation

(KRF750NA/PA/RA/SA/TA ~ NC/PC/RC/SC/VC)

•

Install:

Element [A]

Element Holder [B]

•

Install the element cover [C] so that the wider side [D] faces projection [E] of the holder and fit the slits [F] onto the projections [G].

FUEL SYSTEM (DFI) 3-121

NOTE

○

Be sure that the edge of the element [A] fits completely in the groove and does not rest on the edge of the element holder [B] or become folded in the groove as shown in the figure.

•

Tighten:

Torque — Element Cover Screw [A]: 4.5 N·m (0.46 kgf·m, 40 in·lb)

•

Push down the element holder [A] until it is bottomed into the housing [B] as shown in the figure.

•

Tighten:

Torque — Element Holder Screw: 4.5 N·m (0.46 kgf·m, 40 in·lb)

•

Install the air cleaner housing cap and fit the clips.

3-122 FUEL SYSTEM (DFI)

Air Cleaner

Air Cleaner Element Installation

(KRF750ND/PD/RD/SD)

•

Install the element [A] at the bottom of the air cleaner housing so that the sponge seal [B] faces to the intake duct.

•

Raise the rear end of the element a little, and install the element cover [C] as shown.

•

Install the element to the air cleaner housing while pushing the element cover to the element.

•

Be sure to insert the tabs [D] of the element cover into the holders of the air cleaner housing.

Air Cleaner Element Cleaning and Inspection

•

Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter.

Air Cleaner Housing and Duct Removal

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal

• in the Frame chapter)

Loosen the clamp screw [A].

•

Remove:

Air Cleaner Mounting Bolts [B] (both sides)

Air Cleaner Housing [C]

•

Remove:

Breather Hose [A] and Clamp

ISC Valve Hose [B]

Air Cleaner

•

Disconnect:

Intake Air Temperature Sensor Connector [A]

•

Loosen:

Clamp Screws [B]

•

Remove:

Hose [C]

Air Cleaner Duct [D]

Air Cleaner Housing and Duct Installaion

•

Install:

Hose [A]

FUEL SYSTEM (DFI) 3-123

•

Install the air cleaner duct assembly [A] to the throttle body assy.

•

Tighten the clamp screws.

•

Connect:

Intake Air Temperature Sensor Connector [B]

•

Tighten:

Clamp Screws [A]

•

When tighten the clamp screws, install the clamp as shown in the figure.

Front [B]

Out Side [C]

30° [D]

View A [E]

3-124 FUEL SYSTEM (DFI)

Air Cleaner

•

Install:

Breather Hose [A] and Clamp [B]

ISC Valve Hose [C]

•

Install the air cleaner housing [A] to the rubber duct [B].

•

Apply a non-permanent locking agent:

Air Cleaner Mounting Bolts [C] (both sides)

•

Tighten:

Torque — Air Cleaner Mounting Bolts: 8.8 N·m (0.90 kgf·m,

78 in·lb)

Fuel Tank and Fuel Hose

Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

•

Remove:

Right Frame Cover (see Frame Cover Removal in the

Frame chapter)

Right Bracket (see Bracket Removal in the Frame chapter)

Fuel Hose [A] (see Fuel Hose Removal)

Breather Hoses [B]

Fuel Pump Connector [C]

•

Remove:

Fuel Tank Band Bolts [A] and Washers

Bands [B]

Fuel Tank [C]

FUEL SYSTEM (DFI) 3-125

Fuel Tank Installation

•

Check the dampers [A] on the frame [B].

If the dampers are damaged or deteriorated, replace them.

•

When installing the dampers, install them as shown in the figure.

44 mm (1.7 in.) [C]

15 mm (0.6 in.) [D]

82 mm (3.2 in.) [E]

Front [F]

3-126 FUEL SYSTEM (DFI)

Fuel Tank and Fuel Hose

•

Check the dampers [A] on the fuel tank.

If the dampers are damaged or deteriorated, replace them.

•

When installing the dampers [A], install them so that the distance to the damper end from the bottom of the fuel tank is 10 mm (0.39 in.) [B].

Right Side View [C]

•

Check the mats [A] on the fuel tank.

If the mat is damaged or deteriorated, replace it.

•

Install:

Fuel Tank

Bands [A]

Fuel Tank Band Bolts [B] and Washers

•

Tighten the bolts until the brackets [C] of the bands touch the frame.

•

Tighten:

Torque — Fuel Tank Band Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

Fuel Tank and Fuel Hose

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

When installing the check valve [A], install it so that the arrow [B] faces fuel tank.

Black Color [C]

Blue Color [D]

•

Fit the hose edge (E-E’) to the line (F-F’) of the check valve.

FUEL SYSTEM (DFI) 3-127

(KRF750ND/PD/RD/SD)

•

When installing the check valve [A], install it so that the orange color side [B] faces fuel tank.

Black Color [C]

•

Install:

Fuel Hose (see Fuel Hose Installation)

Breather Hoses and Clamps

Fuel Tank Cleaning

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Do not use gasoline or low-flash point solvents to clean the tank.

•

Remove the fuel tank and drain it.

•

Remove:

Fuel Pump (see Fuel Pump Removal)

•

Pour some high-flash point solvent into the fuel tank and

• shake the tank to remove dirt and fuel deposits.

Draw the solvent out of the fuel tank.

•

Dry the tank with compressed air.

•

Install:

Fuel Pump (see Fuel Pump Installation)

Fuel Tank (see Fuel Tank Installation)

Fuel Hose Inspection

•

Refer to the Fuel Hose and Connections Inspection in the

Periodic Maintenance chapter.

3-128 FUEL SYSTEM (DFI)

Fuel Tank and Fuel Hose

Fuel Hose Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Be sure to place a piece of cloth around the fuel hose joint.

•

Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush.

When removing with standard tip screwdriver

•

Insert the standard tip screwdriver [A] into the slit on the joint lock [B].

•

Turn the driver to disconnect the joint lock.

When removing with fingers

•

Open and push up the joint [C] lock with your fingers.

NOTICE

Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.

•

Pull the fuel hose out of the pipe.

WARNING

Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.

Fuel Tank and Fuel Hose

•

Clean the pipe [A].

•

Cover the pipe and the hose joint [B] with the vinyl bags

[C] to keep it clean.

FUEL SYSTEM (DFI) 3-129

Fuel Hose Installation

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

•

Remove the vinyl bag on the pipe and fuel hose joint.

•

Check the joint lock for deformation and wear.

If the joint lock is deformed, replace the fuel hose with a new one.

•

Check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [A].

•

Apply engine oil to the pipe.

•

Insert the fuel hose joint [A] securely onto the pipe [B] and push down the joint lock [C].

•

Push and pull the fuel hose joint back and forth [A] more than two times and make sure it is locked and doesn’t come off.

WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

•

Start the engine and check the fuel hose for leaks.

COOLING SYSTEM 4-1

Cooling System

Table of Contents

Exploded View…………………………………………………………………………………………………………

Coolant Flow Chart…………………………………………………………………………………………………..

Specifications ………………………………………………………………………………………………………….

Special Tools …………………………………………………………………………………………………………..

Coolant …………………………………………………………………………………………………………………..

Coolant Deterioration Inspection……………………………………………………………………………

Coolant Level Inspection………………………………………………………………………………………

Coolant Draining …………………………………………………………………………………………………

Coolant Filling …………………………………………………………………………………………………….

4-8

4-8

4-8

Pressure Testing …………………………………………………………………………………………………

4-9

Water Pump…………………………………………………………………………………………………………….

4-10

Water Pump Cover Removal ………………………………………………………………………………..

4-10

4-2

4-4

4-6

4-7

4-8

4-8

Water Pump Cover Installation ……………………………………………………………………………..

Water Pump Impeller Removal ……………………………………………………………………………..

Water Pump Impeller Installation …………………………………………………………………………..

Water Pump Impeller Inspection……………………………………………………………………………

Water Pump Leakage Inspection…………………………………………………………………………..

Mechanical Seal Replacement ……………………………………………………………………………..

Radiator ………………………………………………………………………………………………………………….

4-13

Radiator Removal ……………………………………………………………………………………………….

4-13

Radiator Installation …………………………………………………………………………………………….

4-14

Radiator Fan Removal …………………………………………………………………………………………

Radiator Fan Installation ………………………………………………………………………………………

Radiator Inspection ……………………………………………………………………………………………..

4-14

4-14

4-15

4-10

4-10

4-10

4-11

4-11

4-11

Radiator Cleaning ……………………………………………………………………………………………….

Radiator Cap Inspection ………………………………………………………………………………………

4-15

4-15

Thermostat ……………………………………………………………………………………………………………..

4-16

Thermostat Removal……………………………………………………………………………………………

Thermostat Installation…………………………………………………………………………………………

Thermostat Inspection …………………………………………………………………………………………

4-16

4-16

4-16

Water Temperature Sensor ……………………………………………………………………………………….

4-17

Water Temperature Sensor Removal/Installation …………………………………………………….

4-17

Water Temperature Sensor Inspection …………………………………………………………………..

4-17

4

4-2 COOLING SYSTEM

Exploded View

COOLING SYSTEM 4-3

Exploded View

No.

Fastener

1 Radiator Screen Mounting Bolts

2 Radiator Cover Bracket Mounting Bolts

3 Radiator Mounting Bolts

4 Radiator Fan Assembly Bolts

5 Thermostat Housing Cover Bolts

6 Water Temperature Sensor

7 Water Pipe Mounting Bolts, L = 20 mm (0.79 in.)

8 Water Pipe Mounting Bolts, L = 12 mm (0.47 in.)

9 Water Pump Impeller

10 Water Pump Cover Bolts

11 Coolant Drain Plug (Water Pump)

12 Coolant Drain Plugs (Cylinder)

13 Coolant Air Bleed Bolt (Water Pump)

14 Coolant Air Bleed Bolt (Thermostat)

15

Radiator Cover Mounting Bolts

(KRF750ND/PD/RD/SD)

16. KRF750NB/PB/RB/SB//VB

∼

NC/PC/RC/SC/VC

17. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

G: Apply grease.

R: Replacement Parts

RL: Apply rubber lubricant.

8.8

7.8

8.8

7.0

7.0

7.0

7.8

8.3

8.8

12

8.8

N·m

8.8

8.8

8.8

8.8

1.2

0.90

0.90

0.80

0.90

0.71

0.71

0.71

0.80

Torque kgf·m

0.90

0.90

0.90

0.85

0.90

0.90

ft·lb

78 in·lb

78 in·lb

78 in·lb

73 in·lb

78 in·lb

106 in·lb

78 in·lb

78 in·lb

69 in·lb

78 in·lb

62 in·lb

62 in·lb

62 in·lb

69 in·lb

78 in·lb

Remarks

4-4 COOLING SYSTEM

Coolant Flow Chart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.

When the engine starts, the water pump (coupled with the oil pump) turns and the coolant circulates.

The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. When coolant temperature is below 67°C (153°F), the thermostat closes so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant temperature is more than 69.5

∼

72.5°C (157

∼

163°F), the thermostat opens and the coolant flows. When the coolant temperature goes up beyond 100°C (212°F), the radiator fan relay conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the temperature is below 90°C (194°F), the fan relay opens and the radiator fan stops.

In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies.

The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating. As the engine warms up, the coolant in the radiator and the water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the water jacket contract, and the stored coolant flows back to the radiator from the reserve tank.

The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running. When the pressure exceeds 93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 13

∼

18 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the pressure at 93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 13

∼

18 psi).

When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator.

Coolant Flow Chart

COOLING SYSTEM 4-5

1. Radiator

2. Radiator Cap

3. Radiator Fan

4. Water Temperature Sensor

5. Thermostat

6. Cylinder Head

7. Cylinder

8. Water Pump

9. Reserve Tank

Black Painted Arrow: Hot Coolant

White Painted Arrow: Cold Coolant

4-6 COOLING SYSTEM

Specifications

Item

Coolant Provided when Shipping

Type

Color

Mixed Ratio

Freezing Point

Total Amount

Standard

Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Green

Soft water 50%, coolant 50%

−35°C (−31°F)

4.4 L (4.7 US qt) (reserve tank full level including radiator and engine)

Radiator Cap

Relief Pressure

Thermostat

Valve Opening Temperature

Valve Full Opening Lift

93

∼

69.5

123 kPa (0.95

∼

72.5°C (157

∼

∼

1.25 kgf/cm², 13

163°F)

∼

18 psi)

8 mm (0.31 in.) or more @85°C (185°F)

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

Special Tools

Bearing Driver Set:

57001-1129

Bearing Remover Shaft, 9:

57001-1265

COOLING SYSTEM 4-7

Bearing Remover Head, 10 × 12:

57001-1266

4-8 COOLING SYSTEM

Coolant

Coolant Deterioration Inspection

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Visually inspect the coolant in the reserve tank [A].

If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

If the coolant gives off an abnormal smell, check for cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Coolant Level Inspection

NOTE

○

Check the level when the engine is cold (room or ambient temperature).

•

Check the coolant level in the reserve tank with the vehicle held perpendicularly.

Reserve Tank [A]

F (full) Mark [B]

L (low) Mark [C]

•

If the coolant level is lower than the L mark [A], remove the reserve tank cap [B], then add coolant to the F mark

[A].

NOTICE

For refilling, add the specified mixture of coolant and soft water.

Adding water alone dilutes the coolant and degrades its anticorrosion properties.

The diluted coolant can attach the aluminum engine parts. In an emergency, soft water can be added.

But the diluted coolant must be returned to the correct mixture ratio within a few days.

If coolant must be added often, or the reserve tank has run completely dry; there is probably leakage in the cooling system. Check the system for leaks.

Coolant Draining

•

Refer to the Coolant Change in the Periodic Maintenance chapter.

Coolant Filling

•

Refer to the Coolant Change in the Periodic Maintenance chapter.

Coolant

Pressure Testing

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Remove the radiator cap, and install a cooling system pressure tester [A] on the radiator filler neck.

NOTE

○

Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.

•

Build up pressure in the system carefully until the pressure reaches 123 kPa (1.25 kgf/cm², 18 psi).

NOTICE

During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi).

•

Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is alright.

If the pressure drops soon, check for leaks.

COOLING SYSTEM 4-9

4-10 COOLING SYSTEM

Water Pump

Water Pump Cover Removal

•

Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

•

Remove:

Left Cover (see Left Cover Removal in the Frame chapter)

Water Hose [A]

Water Pump Cover Bolts [B]

Water Pump Cover [C]

Water Pump Cover Installation

•

Install:

Dowel Pins [A]

New Gasket [B]

•

Tighten:

Torque — Water Pump Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Water Pump Impeller Removal

•

Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

•

Remove:

Water Pump Cover (see Water Pump Cover Removal)

•

Loosen the water pump impeller [A] counterclockwise.

Water Pump Impeller Installation

•

Apply a small amount of coolant on the sliding surface [A] of the mechanical seal and the sealing seat.

•

Install the impeller on the water pump shaft and tighten the impeller.

Torque — Water Pump Impeller: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Water Pump

Water Pump Impeller Inspection

•

Visually inspect the impeller [A].

If the surface is corroded or the blades are damaged, replace the impeller.

COOLING SYSTEM 4-11

Water Pump Leakage Inspection

•

Check the drainage tube [A] at the bottom of the water pump body for coolant leakage.

If there is a coolant leak, the mechanical seal in the pump could be damaged. Replace the mechanical seal with a new one (see Mechanical Seal Replacement).

Mechanical Seal Replacement

•

Remove:

Water Pump Impeller (see Water Pump Impeller Removal)

Alternator Cover (see Alternator Cover Removal in the

Electrical System chapter)

•

Take the bearing [A] out of the alternator cover, using the bearing remover.

Special Tools — Bearing Remover Shaft, 9 [B]: 57001-1265

Bearing Remover Head, 10 × 12 [C]:

57001-1266

•

Press out the mechanical seal [A] and oil seal [B] from the inside of the alternator cover with the bearing driver set [C].

Special Tool — Bearing Driver Set: 57001-1129

NOTICE

If either the mechanical seal, oil seal, or the ball bearing is removed, make sure to replace all of them simultaneously with a new one.

Be careful not to block the inspection hole with the oil seal. If the inspection hole is blocked, the coolant may pass through the oil seal and flow into the crankcase.

4-12 COOLING SYSTEM

Water Pump

•

Apply heat-resistance grease on the oil seal lip.

•

From outside the alternator cover, press and insert the oil seal [A] so that its surface is flush with the step portion [B] of the cover as shown.

Special Tool — Bearing Driver Set: 57001-1129

•

From inside the alternator cover, press and insert the ball bearing [A] until it is bottomed.

Special Tool — Bearing Driver Set: 57001-1129

•

Using a suitable socket [A] and the bearing driver [B], press and insert a new mechanical seal [C] until its flange stops at the step [D] of the hole.

Special Tool — Bearing Driver Set: 57001-1129

•

Clean the sliding surface of a new mechanical seal with a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication.

•

Apply coolant to the surfaces of the rubber seal and sealing seat [A], and press the rubber seal [B] and sealing seat into the impeller by hand until the seat bottoms out.

•

Tighten the water pump impeller by turning the bolt clockwise.

Torque — Water Pump Impeller: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Radiator

Radiator Removal

•

Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

•

Remove the front fender front (see Front Fender Front

Removal in the Frame chapter).

•

Remove:

Radiator Cover Mounting Screws

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Radiator Cover Mounting Bolts

(KRF750ND/PD/RD/SD)

Radiator Cover [B]

[A]

[A]

COOLING SYSTEM 4-13

•

Remove:

Radiator Fan Motor Lead Connector [A]

Water Hose [B]

•

Remove:

Reserve Tank Hose [A]

Water Hose [B]

•

Remove:

Radiator Bolts [A]

Radiator [B]

NOTICE

Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.

4-14 COOLING SYSTEM

Radiator

Radiator Installation

•

Install:

Dampers [A]

Collars [B]

•

Tighten:

Torque — Radiator Mounting Bolts [C]: 8.8 N·m (0.90 kgf·m,

78 in·lb)

•

Connect:

Radiator Fan Motor Lead Connector

•

Install the fan motor breather hose.

NOTE

○

Do not apply lubricant at fitting hose region.

•

Install:

Water Hoses

Reserve Tank Hose

•

Run the hoses according to the Cable, Wire, and Hose

Routing section in the Appendix chapter.

•

Install the radiator cover.

•

Tighten:

Torque — Radiator Cover Mounting Bolts

(KRF750ND/PD/RD/SD): 8.8

N·m (0.90

kgf·m, 78 in·lb)

Radiator Fan Removal

•

Remove:

Radiator Cover (see Radiator Removal)

Radiator Screen Mounting Bolts [A] (both side)

Radiator Screen and Radiator Cover Bracket Mounting

Bolts [B] (both side)

Radiator Screen [C]

Radiator Cover Bracket Mounting Bolts [D] (both side)

Radiator Cover Bracket [E] (both side)

•

Remove:

Radiator (see Radiator Removal)

Radiator Fan Assembly Bolts [A]

Fan Assembly [B]

Radiator Fan Installation

•

Install:

Radiator Fan Assembly

•

Tighten:

Torque — Radiator Fan Assembly Bolts: 8.3 N·m (0.85 kgf·m,

73 in·lb)

Radiator

Radiator Inspection

•

Check the radiator core.

If there are obstructions to air flow, remove the radiator and remove obstructions.

If the corrugated fins [A] are deformed, carefully straighten them.

If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.

Radiator Cleaning

•

Refer to the Radiator Cleaning in the Periodic Maintenance chapter.

Radiator Cap Inspection

•

Check the condition of the top and bottom valve seals of the radiator cap.

If any one of them shows visible damage, replace the cap.

Top and Bottom Valve Seals [A]

Valve Spring [B]

COOLING SYSTEM 4-15

•

Install the cap [A] on a cooling system pressure tester [B].

NOTE

○

Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.

•

Watching the pressure gauge, slowly pump the pressure tester to build up the pressure. The relief valve opens, indicated by the gauge hand flicks downward.

○

The relief valve must open within the relief pressure range in the table below and the gauge hand must remain within the specified range at least 6 second.

Radiator Cap Relief Pressure

Standard: 93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 13

∼

18 psi)

If the cap cannot hold the specified pressure, or if it holds too much pressure, replace it with a new one.

4-16 COOLING SYSTEM

Thermostat

Thermostat Removal

•

Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Fuel Hose (see Fuel Hose Removal in the Fuel System

(DFI) chapter)

Thermostat Housing Cover Bolts [A]

Thermostat Housing Cover [B]

Thermostat

•

Thermostat Installation

•

Install:

Thermostat [A]

•

Be sure to install the O-ring [B] on the housing cover.

Tighten:

Torque — Thermostat Housing Cover Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

•

Add coolant (see Coolant Change in the Periodic Maintenance chapter).

Thermostat Inspection

•

Remove the thermostat, and inspect the thermostat valve

[A] at room temperature.

If the valve is open, replace the valve with a new one.

•

To check valve opening temperature, suspend the thermostat [A] and an accurate thermometer [B] in a container of water with the heat-sensitive portions [C] in almost the same depth.

NOTE

○

The thermostat must be completely submerged and the thermostat and thermometer must not touch the container sides or bottom.

•

Gradually raise the temperature of the water while stirring the water gently for even temperature.

If the measurement is out of the specified range, replace the thermostat.

Thermostat Valve Opening Temperature

69.5

∼

72.5°C (157

∼

163°F)

Water Temperature Sensor

Water Temperature Sensor Removal/Installation

NOTICE

The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to water temperature sensor can damage it.

•

Refer to the Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter.

Water Temperature Sensor Inspection

•

Refer to the Water Temperature Sensor Inspection in the

Fuel System (DFI) System chapter.

COOLING SYSTEM 4-17

ENGINE TOP END 5-1

Engine Top End

Table of Contents

Exploded View……………………………..

Exhaust System……………………………

Specifications ………………………………

Special Tools and Sealant ……………..

Camshaft Chain Tensioner …………….

Camshaft Chain Tensioner

Removal ………………………………

Camshaft Chain Tensioner

Installation ……………………………

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 Inspection ………………

Camshaft Bearing Wear

Inspection…………………………….

KACR Inspection……………………..

KACR Removal……………………….

KACR Installation…………………….

Camshaft Chain Removal …………

Camshaft Chain Installation ………

Camshaft Chain Guide Wear

Inspection…………………………….

Cylinder Head………………………………

Cylinder Compression

Measurement ……………………….

Cylinder Head Removal ……………

Cylinder Head Installation …………

5-2

5-8

5-9

5-12

5-15

5-15

5-20

5-21

5-21

5-21

5-22

5-22

5-15

5-17

5-17

5-18

5-19

5-20

5-20

5-23

5-24

5-24

5-25

5-25

5-26

5-29

5-30

5-30

5-31

5-31

Cylinder Head Cleaning ……………

Cylinder Head Warp Inspection …

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 Inspection………….

Piston Wear Inspection …………….

Piston/Cylinder Clearance

Inspection…………………………….

Piston Ring, Piston Ring Groove

Wear Inspection ……………………

Piston Ring Groove Width

Inspection…………………………….

Piston Ring Thickness Inspection

Piston Ring End Gap Inspection ..

Exhaust System……………………………

Spark Arrester Cleaning……………

Muffler and Exhaust Pipe

Removal ………………………………

Exhaust System Inspection……….

Muffler and Exhaust Pipe

Installation …………………………..

5-36

5-41

5-41

5-41

5-41

5-43

5-43

5-43

5-44

5-44

5-45

5-45

5-46

5-46

5-46

5-48

5-48

5-32

5-32

5-33

5-33

5-33

5-33

5-33

5-33

5-34

5-34

5-35

5

5-2 ENGINE TOP END

Exploded View

ENGINE TOP END 5-3

Exploded View

No.

1 Valve Adjusting Cap Bolts

2 Rocker Case Bolts, L = 55 mm (2.2 in.)

3 Rocker Case Bolts, L = 130 mm (5.1 in.)

4 Rocker Case Bolts, L = 30 mm (1.2 in.)

5 Rocker Case Bolts, L = 25 mm (1.0 in.)

6

Rocker Case Bolts, L = 20 mm (0.8 in.)

(KRF750ND/PD/RD/SD)

7

7

8

9

Cylinder Head Bolts (M10), first torque

Cylinder Head Bolts (M10), final torque

Cylinder Head Bolts (M6)

Water Pipe Mounting Bolts

10 Valve Adjusting Screw Locknuts

11 Rocker Shaft Bolts

Fastener

12 Rear Rocker Case Clamp Bolt

N·m

8.8

8.8

9.8

9.8

9.8

9.8

25

49

9.8

8.8

12

22

8.8

Torque kgf·m

0.90

0.90

1.0

1.0

1.0

1.0

2.5

5.0

1.0

0.90

1.2

2.2

0.90

ft·lb

78 in·lb

78 in·lb

87 in·lb

87 in·lb

87 in·lb

87 in·lb

18

36

87 in·lb

78 in·lb

106 in·lb

16

78 in·lb

13. Rocker Case

14. Cylinder Head

15. Front

16. Rear

17. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

EO: Apply engine oil.

G: Apply grease.

LG: Apply liquid gasket (Liquid Gasket, TB1216: 92104-1063).

M: Apply molybdenum disulfide grease.

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.

Remarks

S

S

S, MO

S

5-4 ENGINE TOP END

Exploded View

ENGINE TOP END 5-5

Exploded View

No.

Fastener

1 Camshaft Sprocket Bolts

2 Chain Tensioner Cap Bolts

3 Chain Tensioner Mounting Bolts

4 Front Cylinder Camshaft Chain Guide Bolt

5 Position Plate Bolts

6 Intermediate Shaft Chain Guide Bolts

7 Intermediate Shaft Chain Tensioner Bolts

8 Rear Cylinder Camshaft Chain Guide Bolt

9 Cylinder Bolts, L = 30 mm (1.2 in.)

10 Cylinder Bolts, L = 40 mm (1.6 in.)

11 Coolant Drain Plugs (Cylinder)

12. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

EO: Apply engine oil.

G: Apply grease for oil seal and O-ring.

L: Apply a non-permanent locking agent.

R: Replacement Parts

20

8.8

8.8

8.8

N·m

12

22

8.8

20

9.8

9.8

7.0

Torque kgf·m

1.2

2.2

0.90

2.0

0.90

0.90

0.90

2.0

1.0

1.0

0.71

ft·lb

106 in·lb

16

78 in·lb

15

78 in·lb

78 in·lb

78 in·lb

15

87 in·lb

87 in·lb

62 in·lb

Remarks

L

5-6 ENGINE TOP END

Exploded View

Exploded View

No.

Fastener

1 Exhaust Pipe Nuts

2 Exhaust Pipe Cover Bolts

3 Muffler Clamp Bolts

4 Muffler Mounting Bolts

5 Spark Arrester Mounting Bolts

R: Replacement Parts

ENGINE TOP END 5-7

N·m

17

13

15

28

13

Torque kgf·m

1.7

1.3

1.5

2.9

1.3

ft·lb

13

115 in·lb

11

21

115 in·lb

Remarks

5-8 ENGINE TOP END

Exhaust System

Exhaust System

ENGINE TOP END 5-9

Specifications

Item

Rocker Case

Rocker Arm Inside Diameter

Standard Service Limit

Rocker Shaft Diameter

12.000

∼

12.018 mm

(0.4724

∼

0.4731 in.)

11.983

∼

11.994 mm

(0.4718

∼

0.4722 in.)

12.05 mm (0.474 in.)

11.96 mm (0.471 in.)

Camshafts

Cam Height:

Exhaust

Intake

35.363

∼

35.477 mm

(1.3922

∼

1.3967 in.)

35.622

∼

35.736 mm

(1.4024

∼

1.4069 in.)

35.26 mm (1.388 in.)

35.52 mm (1.398 in.)

Camshaft Bearing Clearance:

18

22

0.016

∼

0.052 mm

(0.0006

∼

0.0020 in.)

0.020

∼

0.059 mm

(0.0008

∼

0.0023 in.)

0.14 mm (0.0055 in.)

0.15 mm (0.0059 in.)

Camshaft Journal Diameter:

18

22

17.966

∼

17.984 mm

(0.7073

∼

0.7080 in.)

21.959

∼

21.980 mm

(0.8645

∼

0.8654 in.)

17.94 mm (0.706 in.)

21.93 mm (0.863 in.)

Camshaft Bearing Inside Diameter:

18

22

18.000

∼

18.018 mm

(0.7087

∼

0.7094 in.)

22.000

∼

22.018 mm

(0.8661

∼

0.8668 in.)

18.08 mm (0.712 in.)

22.08 mm (0.869 in.)

TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.0039 in.) Camshaft runout

KACR (Kawasaki Automatic

Compression Release):

KACR Operating Engine Speed 760 ±30 r/min (rpm)

Cylinder Head

– – –

Cylinder Compression (Usable

Range)

Electric Starter – – – 251

∼

456 kPa (2.56

∼

4.65

kgf/cm², 36

∼

66 psi) @380 r/min

(rpm)

– – – 0.05 mm (0.002 in.) Cylinder head warp

Valve

Valve Clearance:

Exhaust – – –

Intake

0.20

∼

0.25 mm

(0.0079

∼

0.0098 in.)

0.10

∼

0.15 mm

(0.0039

∼

0.0059 in.)

– – –

Valve Head Thickness:

Exhaust

Intake

Valve Stem Bend

0.8 mm (0.031 in.)

0.5 mm (0.020 in.)

0.4 mm (0.016 in.)

0.3 mm (0.012 in.)

TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm (0.002 in.)

5-10 ENGINE TOP END

Specifications

Item

Valve Stem Diameter:

Exhaust

Intake

Valve Guide Inside Diameter:

Exhaust

Intake

Valve/Valve Guide Clearance

(Wobble Method):

Exhaust

Intake

Valve Seat Cutting Angle

Valve Seating Surface:

Outside Diameter:

Exhaust

Intake

Width:

Exhaust

Intake

Valve Spring Free Length:

Exhaust

Intake

Cylinder, Piston

Cylinder Inside Diameter

Piston Diameter

Piston/Cylinder Clearance

Piston Ring/Groove Clearance:

Top

Second

Standard

4.955

∼

4.970 mm

(0.1951

∼

0.1957 in.)

4.975

∼

4.990 mm

(0.1959

∼

0.1965 in.)

5.000

∼

5.012 mm

(0.1969

∼

0.1973 in.)

5.000

∼

5.012 mm

(0.1969

∼

0.1973 in.)

0.09

∼

0.17 mm

(0.0035

∼

0.0067 in.)

0.03

∼

0.11 mm

(0.0012

∼

0.0043 in.)

45°, 32°, 60°

25.2

∼

25.4 mm

(0.992

∼

1.000 in.)

29.4

∼

29.6 mm

(1.157

∼

1.165 in.)

0.5

∼

1.0 mm

(0.02

∼

0.04 in.)

0.5

∼

1.0 mm

(0.02

∼

0.04 in.)

41.3 mm (1.626 in.)

41.3 mm (1.626 in.)

84.994

∼

85.006 mm

(3.3462

∼

3.3467 in.)

84.964

∼

84.979 mm

(3.3450

∼

3.3456 in.)

0.015

∼

0.042 mm

(0.0006

∼

0.0017 in.)

0.04

∼

0.08 mm

(0.0016

∼

0.0031 in.)

0.03

∼

0.07 mm

(0.0012

∼

0.0028 in.)

Service Limit

4.94 mm (0.1945 in.)

4.96 mm (0.1953 in.)

5.08 mm (0.20 in.)

5.08 mm (0.20 in.)

0.37 mm (0.0146 in.)

0.31 mm (0.0122 in.)

– – –

– – –

– – –

– – –

– – –

39.5 mm (1.555 in.)

39.5 mm (1.555 in.)

85.09 mm (3.3500 in.)

84.81 mm (3.3390 in.)

– – –

0.18 mm (0.0071 in.)

0.17 mm (0.0067 in.)

Specifications

Item Standard

Piston Ring Groove Width:

Top:

(KRF750NA/PA/RA/SA/TA

NB/PB/RB/SB/VB)

∼

1.03

∼

1.05 mm

(0.0406

∼

0.0413 in.)

(KRF750NC/PC/RC/SC/VC

∼

) 0.93

∼

0.95 mm

(0.0366

∼

0.0374 in.)

Second 1.02

∼

1.04 mm

(0.0402

∼

0.0409 in.)

Piston Ring Thickness:

Top:

(KRF750NA/PA/RA/SA/TA

NB/PB/RB/SB/VB)

∼

0.97

∼

0.99 mm

(0.0382

∼

0.0390 in.)

(KRF750NC/PC/RC/SC/VC

∼

) 0.87

∼

0.89 mm

(0.0343

∼

0.0350 in.)

Second 0.97

∼

0.99 mm

(0.0382

∼

0.0390 in.)

Piston Ring End Gap:

Top

Second

Oil

0.15

∼

0.25 mm

(0.0059

∼

0.0098 in.)

0.30

∼

0.45 mm

(0.0118

∼

0.0177 in.)

0.20

∼

0.70 mm

(0.0079

∼

0.0276 in.)

ENGINE TOP END 5-11

Service Limit

1.13 mm (0.0445 in.)

1.03 mm (0.0406 in.)

1.12 mm (0.0441 in.)

0.90 mm (0.0354 in.)

0.80 mm (0.0315 in.)

0.90 mm (0.0354 in.)

0.55 mm (0.0217 in.)

0.75 mm (0.0295 in.)

1.00 mm (0.0394 in.)

5-12 ENGINE TOP END

Special Tools and Sealant

Inside Circlip Pliers:

57001-143

Valve Seat Cutter, 45° — 27.5:

57001-1114

Outside Circlip Pliers:

57001-144

Valve Seat Cutter, 32° — 28:

57001-1119

Compression Gauge, 20 kgf/cm²:

57001-221

Valve Seat Cutter, 60° — 30:

57001-1123

Valve Spring Compressor Assembly:

57001-241

Valve Seat Cutter Holder Bar:

57001-1128

Piston Pin Puller Assembly:

57001-910

Valve Seat Cutter, 45° — 30:

57001-1187

Special Tools and Sealant

Valve Seat Cutter, 32° — 33:

57001-1199

ENGINE TOP END 5-13

Piston Pin Puller Adapter, 14:

57001-1211

Valve Spring Compressor Adapter, 22:

57001-1202

Compression Gauge Adapter, M10 × 1.0:

57001-1317

Valve Guide Arbor, 5:

57001-1203

Filler Cap Driver:

57001-1454

Valve Guide Reamer, 5:

57001-1204

Valve Seat Cutter Holder, 5:

57001-1208

Valve Guide Driver:

57001-1564

Valve Guide Driver Attachment, E:

57001-1677

5-14 ENGINE TOP END

Special Tools and Sealant

Spacer:

57001-1785

Liquid Gasket, TB1216:

92104-1063

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

NOTICE

This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Observe all the rules listed below:

When removing the tensioner, do not take out the mounting bolts only partway.

Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in “Camshaft Chain Tensioner Installation”.

Do not turn over the crankshaft while the tensioner is removed. This could upset the cam chain timing, and damage the valves.

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Cap Bolt [A] and Washer

Pin and Spring

ENGINE TOP END 5-15

•

Remove:

Tensioner Mounting Bolts [A]

Camshaft Chain Tensioner [B]

Camshaft Chain Tensioner Installation

•

Push the stopper [A] to release the ratchet and push the push rod [B] into the tensioner body.

5-16 ENGINE TOP END

Camshaft Chain Tensioner

•

Tighten:

Torque — Chain Tensioner Mounting Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

•

Install:

Pin [A] and Spring [B]

Washer [C] and Chain Tensioner Cap Bolt [D]

•

Tighten:

Torque — Chain Tensioner Cap Bolt: 22 N·m (2.2 kgf·m, 16 ft·lb)

Rocker Case

Rocker Case Removal

Front Rocker Case

•

Remove:

Center Bracket (see Center Bracket Removal in the

Frame chapter)

Right Water Pipe Bolts [A]

ENGINE TOP END 5-17

•

Remove

NC/PC/RC/SC/VC):

(KRF750NA/PA/RA/SA/TA

Left Cover (see Left Cover Removal in the Frame chapter)

Bolts [A] and Engine Left Cover [B]

∼

•

Remove (KRF750ND/PD/RD/SD):

Alternator Cover Center Cap [A]

Special Tool — Filler Cap Driver: 57001-1454

•

Remove:

Timing Inspection Plug [A]

Special Tool — Filler Cap Driver [B]: 57001-1454

•

Remove:

Front Camshaft Chain Tensioner (see Camshaft Chain

Tensioner Removal)

Valve Adjusting Caps

•

Using a wrench on the alternator bolt, turn the crankshaft counterclockwise until “T-F” mark [A] is aligned with the notch [B] in the inspection window, and the cam lobes are pointing away from the rocker arms: the end of the compression stroke.

NOTICE

Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case. The rocker arms could bend the valves.

5-18 ENGINE TOP END

Rocker Case

•

Remove:

Rocker Case Bolts [A]

Rocker Case Bolts [B] (KRF750ND/PD/RD/SD)

•

Lift the rocker case to clear of the dowel pins in the cylinder head and remove the front rocker case [B].

Rear Rocker Case

•

Remove:

Front Rocker Case

Air Cleaner Housing and Duct (see Air Cleaner Housing and Duct Removal in the Fuel System (DFI) chapter)

Clamp Bolts [A]

•

Using a wrench on the alternator bolt, turn the crankshaft

counterclockwise (270°) until “T-R” mark [A] is aligned with the notch [B] in the inspection window, and the cam lobes are pointing away from the rocker arms: the end of the compression stroke.

NOTICE

Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case. The rocker arms could bend the valves.

•

Remove:

Rear Camshaft Chain Tensioner (see Camshaft Chain

Tensioner Removal)

Rocker Case Bolts [A]

Rocker Case Bolts [B] (KRF750ND/PD/RD/SD)

•

Lift the rocker case to clear of the dowel pins in the cylinder head and remove the rear rocker case [C].

Rocker Case Installation

•

Check that the crankshaft is positioned at TDC and at the end of the compression stroke.

NOTICE

Be sure to position the crankshaft is at TDC of the end of the compression stroke. The rocker arms could bend the valves.

Rocker Case

•

Apply liquid gasket to the outer surface of the cap [A] and the cylinder head upper surface [B] as shown in the figure.

Sealant — Liquid Gasket, TB1216: 92104-1063

ENGINE TOP END 5-19

•

Tighten the rocker case bolts following the tightening sequence as shown in the figure.

Torque — Rocker Case Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

[1, 2, 3, 4] L = 55 mm (2.2 in.) with washers

Rocker Case Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

[5, 6] L = 130 mm (5.1 in.)

[A] L = 30 mm (1.2 in.)

[B] L = 25 mm (1.0 in.)

[C] L = 20 mm (0.8 in.) (KRF750ND/PD/RD/SD)

•

Check the valve clearance and adjust it if necessary.

•

Apply grease to the O-rings [A].

•

Install:

Bracket [B]

•

Tighten:

Torque — Valve Adjusting Cap Bolts [C]: 8.8 N·m (0.90 kgf·m,

78 in·lb)

Rocker Arm Removal

•

Remove:

Rocker Case (see Rocker Case Removal)

Rocker Shaft Bolts [A]

•

Using a M8 bolt [A], remove the rocker shaft [B].

•

Remove:

Rocker Arm [C]

Washers [D]

○

Mark and record the rocker arm location so it can be installed in the original position.

○

The rocker arms come off with the rocker shafts.

5-20 ENGINE TOP END

Rocker Case

Rocker Arm Installation

•

Apply engine oil:

Rocker Shafts [A]

•

Hole in Rocker Arms [B]

Replace the copper washers [C] with new ones.

•

Install:

Wave Washers [D] (as shown)

Rocker Arms (as shown)

Rocker Shafts and Copper Washers

•

Tighten:

Torque — Rocker Shaft Bolts [E]: 22 N·m (2.2 kgf·m, 16 ft·lb)

Rocker Arm Inspection

•

Inspect the area [A] on the rocker arm where the cam rubs.

If the rocker arm is scored, discolored or otherwise damaged, replace it. Also inspect the camshaft lobes.

•

Inspect the end of the valve clearance adjusting screws

[B] where it contacts the valve stem.

If the end of the adjusting screw is mushroomed or damaged in any way, or if the screw will not turn smoothly, replace it. Also inspect the end of the valve stem.

•

Measure the inside diameter [C] of the rocker arm with a dial bore gauge.

If the rocker arm inside diameter is larger than the service limit, replace it. Also check the rocker shaft diameter (see

Rocker Shaft Diameter Measurement).

Rocker Arm Inside Diameter

Standard: 12.000

∼

12.018 mm (0.4724

∼

0.4731 in.)

Service Limit: 12.05 mm (0.474 in.)

Rocker Shaft Diameter Measurement

•

Measure the diameter [A] of the rocker shaft where the rocker arm pivots on it with a micrometer.

If the rocker shaft diameter is smaller than the service limit, replace it. Also check the rocker arm inside diameter

(see Rocker Arm Inspection).

Rocker Shaft Diameter

Standard: 11.983

∼

11.994 mm (0.4718

∼

0.4722 in.)

Service Limit: 11.96 mm (0.471 in.)

Camshaft

Camshaft Removal

•

Remove:

Camshaft Chain Tensioners (see Camshaft Chain Tensioner Removal)

Rocker Cases (see Rocker Case Removal)

Camshafts [A]

•

Support the chain using a suitable tool.

Camshaft Installation

•

Using a wrench on the alternator bolt, turn the crankshaft

clockwise until “T-R” mark [A] is aligned with the notch

[B] in the inspection window.

ENGINE TOP END 5-21

•

The rear camshaft [A] has a groove [B].

•

First, install the rear camshaft.

•

Face the arrow [A] of the rear camshaft sprocket upward

(left side view).

•

Engage the rear camshaft chain with the rear camshaft sprocket.

•

Align the marks [B] on the weights with the rear cylinder head upper surface.

•

Using a wrench on the alternator bolt, turn the crankshaft

clockwise 270°.

○

Align the “T-F” mark [A] with the notch [B] in the inspection window.

5-22 ENGINE TOP END

Camshaft

•

Face the arrow [A] of the front camshaft sprocket upward

(right side view).

•

Engage the front camshaft chain with the front camshaft sprocket.

•

Align the marks [B] on the weights with the front cylinder head upper surface.

•

Install:

Rocker Cases (see Rocker Case Installation)

Camshaft Chain Tensioners (see Camshaft Chain Tensioner Installation)

•

Check the valve clearance (see Valve Clearance Inspection).

Camshaft Assembly

•

Install the KACR unit [A] (sprocket) on the camshaft so that the unit fits onto the camshaft pins [B].

•

Apply a non-permanent locking agent to the camshaft sprocket bolts [C].

•

Tighten:

Torque — Camshaft Sprocket Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

•

Cam Wear Inspection

Remove the camshaft.

•

Measure the height [A] of the cam with a micrometer.

If the cams are worn past the service limit, replace the camshaft.

Cam Height

Standard:

Exhaust

Intake

Service Limit:

Exhaust

Intake

35.363

∼

35.477 mm (1.3922

∼

1.3967 in.)

35.622

∼

35.736 mm (1.4024

∼

1.4069 in.)

35.26 mm (1.388 in.)

35.52 mm (1.398 in.)

Camshaft

Camshaft Bearing Wear Inspection

○

The journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be measured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled.

•

Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft with the camshaft installed in the correct position so that the plastigage will be compressed between the journal and rocker case.

•

Install the rocker case, tightening the bolts in the correct sequence to the specified torque (see Rocker Case Installation).

NOTE

○

Do not turn the camshaft when the plastigage is between the journal and rocker case.

•

Remove the rocker case and measure the plastigage width [A] to determine the clearance between the journal and the rocker case. Measure the widest portion of the plastigage.

Camshaft Bearing Clearance ( 18)

Standard: 0.016

∼

0.052 mm (0.0006

∼

0.0020 in.)

Service Limit: 0.14 mm (0.0055 in.)

Camshaft Bearing Clearance ( 22)

Standard: 0.020

∼

0.059 mm (0.0008

∼

0.0023 in.)

Service Limit: 0.15 mm (0.0059 in.)

If any clearance exceeds the service limit, measure the diameter of the camshaft journal.

Camshaft Journal Diameter ( 18)

Standard: 17.966

∼

17.984 mm (0.7073

∼

0.7080 in.)

Service Limit: 17.94 mm (0.706 in.)

Camshaft Journal Diameter ( 22)

Standard: 21.959

∼

21.980 mm (0.8645

∼

0.8654 in.)

Service Limit: 21.93 mm (0.863 in.)

If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

If the clearance still remains out of the limit, replace the cylinder head and the rocker case.

NOTICE

The cylinder head and rocker case are machined as a set, and must be replaced as a set.

ENGINE TOP END 5-23

5-24 ENGINE TOP END

Camshaft

KACR Inspection

The Kawasaki Automatic Compression Release (KACR) momentarily opens the exhaust valves on the compression stroke at very low speeds. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting.

Due to the simplicity of the mechanism, no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism [A]: compression is not released during starting, and compression is released during running.

(1) If compression is not released during starting, the

• weights are not returning to their rest position.

Remove the camshaft (see Camshaft Removal).

•

Remove the KACR unit.

•

Visually inspect the spring.

If damaged, deformed, or missing, replace the spring.

•

Remove the spring and move the weights back and forth.

If the weights do not move smoothly, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary.

[A] Rest Position (compression is released)

[B] Weights

[C] Spring

(2) If compression is released while the engine is running, the weights are not swinging out.

•

Remove the spring and move the weights back and forth.

If the weights do not move easily from the retracted position, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary.

[A] Running Position (compression is not released)

[B] Weights

[C] Spring

KACR Removal

•

Remove:

Camshaft (see Camshaft Removal)

Camshaft Sprocket Bolts [A]

KACR Unit [B]

Camshaft

•

Remove:

Circlips [A]

Weights [B]

Spring [C]

NOTE

○

Do not remove the shaft [A] and pin [B].

○

If the parts are removed, they cannot be reinstalled.

ENGINE TOP END 5-25

KACR Installation

•

Install:

Weights

Circlips

Spring [A]

○

Hook the spring from the outside with the open side of the hook inwards.

•

Install:

KACR Unit

•

Hook the arms [B] on the pins.

•

Apply a non-permanent locking agent to the camshaft sprocket bolts [C] and tighten them.

Torque — Camshaft Sprocket Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

Camshaft Chain Removal

•

Remove (left side view):

Rear and Front Camshafts (see Camshaft Removal)

Alternator Rotor (see Alternator Rotor Removal in the

Electrical System chapter)

Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter)

Intermediate Shaft Chain Tensioner [A]

Circlip [B] and Washer

Special Tool — Outside Circlip Pliers: 57001-144

•

Remove:

Intermediate Shaft Chain Guides [C]

Position Plate Bolts [D] and Position Plate

5-26 ENGINE TOP END

Camshaft

•

Remove (right side view):

Torque Converter Cover (see Torque Converter Cover

Removal in the Converter System chapter)

•

Using a M6 bolt [A], pull out the cover [B].

•

Remove (left side view):

Circlip [A]

Special Tool — Outside Circlip Pliers: 57001-144

•

Remove:

Intermediate Shaft Sprocket [B]

Intermediate Shaft Drive Chain [C]

Rear Camshaft Chain [D]

Front Camshaft Chain (right side)

Camshaft Chain Installation

Rear Camshaft Chain

•

Align the key grooves [A] on the crankshaft with the embossed line [B] on the crankcase (left side view).

•

Face the arrow [A] of the rear camshaft sprocket upward.

•

Align the marks [B] on the weights with the rear cylinder head upper surface [C].

•

Place the rear camshaft chain [D] onto the rear camshaft sprocket.

•

Engage the camshaft and intermediate shaft chains on the intermediate shaft sprocket [A] and insert the intermediate shaft (left side view).

○

Fit the splines of the intermediate shaft [B] and grooves

[C] of the sprocket as shown.

•

Align the punch mark [D] on the sprocket with the embossed mark [E] on the crankcase.

Camshaft

•

Front Camshaft Chain

•

Install the circlip [A].

Special Tool — Outside Circlip Pliers: 57001-144

•

Rotate the crankshaft clockwise 270°.

Align the key grooves [B] on the crankshaft with the embossed line [C] on the crankcase.

•

Move the intermediate shaft [A] to the left side of the engine.

•

Engage the front camshaft chain [B] with the sprocket on the intermediate shaft.

ENGINE TOP END 5-27

•

Install (left side view):

Position Plate [A]

•

Tighten:

Torque — Position Plate Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install:

Intermediate Shaft Chain Guide [A] (front)

•

Tighten:

Torque — Intermediate Shaft Chain Guide Bolts [B]: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

•

Install:

Intermediate Shaft Chain Guide [A] (Rear)

Washer [B]

Circlip [C]

Special Tool — Outside Circlip Pliers: 57001-144

5-28 ENGINE TOP END

Camshaft

•

Install the intermediate shaft chain tensioner [A] as follows:

•

Release the stopper [B] and push the push rod [C] into the tensioner body.

•

Insert a wire [D] into the rod hole to hold the rod in place.

•

Install:

Intermediate Shaft Chain Tensioner [A]

•

Tighten:

Torque — Intermediate Shaft Chain Tensioner Bolts [B]: 8.8

N·m (0.90 kgf·m, 78 in·lb)

•

Remove the wire [C] to free the push rod.

•

Confirm that the punch mark [A] on the intermediate shaft sprocket (Right Side) is aligned with the embossed mark

[B] on the crankcase.

•

Face the arrow mark [A] upward.

•

Align the marks [B] on the weights with the front cylinder head upper surface [C].

•

Place the front camshaft chain on the front camshaft sprocket.

•

Apply grease to the O-ring [A] and install the cover [B] into the right side of the crankcase so that the tapped hole [C] faces outward.

Camshaft

•

Install:

Rocker Cases (see Rocker Case Installation)

Camshaft Chain Tensioners (see Camshaft Chain Tensioner Installation)

•

Check the valve clearances (see Valve Clearance Inspection).

Camshaft Chain Guide Wear Inspection

•

Visually inspect the rubber on the guides.

If the rubber is damaged, cut, or is missing pieces, replace the guide.

ENGINE TOP END 5-29

5-30 ENGINE TOP END

Cylinder Head

Cylinder Compression Measurement

NOTE

○

Use the battery which is fully charged.

•

Warm up the engine thoroughly, and stop the engine.

•

Remove the spark plug (see Spark Plug Removal in the

Electrical System chapter).

•

Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole.

Special Tools — Compression Gauge, 20 kgf/cm²: 57001-221

Compression Gauge Adapter, M10 × 1.0:

57001-1317

•

Hold the throttle wide open and crank the engine with the electric starter or the recoil starter several times.

○

When the gauge stops rising, stop cranking and read the gauge.

Cylinder Compression (Usable Range)

Electric Starter: 251

∼

456 kPa (2.56

∼

4.65 kgf/cm², 36

∼

66 psi) @380 r/min (rpm)

The following table should be consulted if the obtainable compression reading is not within the usable range.

Problem

Cylinder compression is higher than usable range.

Cylinder compression is lower than usable range.

Diagnosis

Carbon accumulation on piston, cylinder head, and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke).

Remedy (Action)

Remove the carbon deposits and replace damaged parts if necessary.

Incorrect cylinder head gasket thickness

Damaged or missing compression release cam spring

Replace the gasket with a standard part.

Replace the spring.

Compression release weights do not move smoothly.

Replace the compression release unit.

Gas leakage around cylinder head Replace damaged gasket and check cylinder head warp.

Bad condition of valve seating

Incorrect valve clearance

Repair if necessary.

Adjust the valve clearance.

Incorrect piston/cylinder clearance Replace the piston and/or cylinder.

Piston seizure Inspect the cylinder and liner and replace/repair the cylinder and/or piston as necessary.

Replace the piston and/or the piston rings.

Bad condition of piston ring and/or piston ring grooves

Compression release weights do not move smoothly.

Replace the compression release unit.

Cylinder Head

Cylinder Head Removal

•

Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

•

Remove:

Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System chapter)

Exhaust Pipe (see Muffler and Exhaust Pipe Removal)

Spark Plug Cap

Water Pipe Bolt [A]

Front Water Pipe [B]

•

Remove:

Water Pipe Bolt [A] (for Rear Water Pipe)

ENGINE TOP END 5-31

•

Remove:

Bolt [A]

Rear Water Pipe [B]

Vacuum Hoses [C]

Spark Plug Cap [D]

Rocker Case (see Rocker Case Removal)

Camshaft (see Camshaft Removal)

•

Remove:

Cylinder Head Bolt (M6) [A]

Cylinder Head Bolts (M10) [B] and Washers

Cylinder Head [C] and Gasket

○

Lift the cylinder head to clear the dowel pins in the cylinder.

Cylinder Head Installation

•

Apply grease to the O-rings on the oil pipe [A], and insert the pipe.

•

Install:

Camshaft Chain Guides [B]

Dowel Pins [C]

New Cylinder Head Gasket [D]

•

Tighten:

Torque — Front Cylinder Camshaft Chain Guide Bolt: 20

N·m (2.0 kgf·m, 15 ft·lb)

5-32 ENGINE TOP END

Cylinder Head

•

Apply molybdenum disulfide oil to the threads and seating surface of the cylinder head bolts (M10) and both sides of the washers.

•

Tighten the cylinder head bolts [A] following the tightening sequence as shown.

First Torque — Cylinder Head Bolts (M10): 25 N·m (2.5

kgf·m, 18 ft·lb)

Final Torque — Cylinder Head Bolts (M10): 49 N·m (5.0

kgf·m, 36 ft·lb)

•

Tighten the cylinder head bolt (M6) [B].

Torque — Cylinder Head Bolt (M6): 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Cylinder Head Cleaning

Remove the cylinder head (see Cylinder Head Removal).

•

Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool.

•

Wash the head with a high-flash point solvent.

•

Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air.

•

Cylinder Head Warp Inspection

Clean the cylinder head (see Cylinder Head Cleaning).

•

Lay a straightedge across the lower surface of the cylinder head.

•

Use a thickness gauge [A] to measure the space between the straightedge [B] and the head at several locations.

Cylinder Head Warp

Service Limit: 0.05 mm (0.002 in.)

If the cylinder head is warped more than the service limit, replace it.

If the cylinder head is warped less than the service limit, repair the head by lapping the lower surface with emery paper secured to a surface plate (first No. 200, then No.

400).

Valves

Valve Clearance Inspection

•

Refer to the Valve Clearance Inspection in the Periodic

Maintenance chapter.

Valve Clearance Adjustment

•

Refer to the Valve Clearance Adjustment in the Periodic

Maintenance chapter.

•

Valve Removal

Remove the cylinder head (see Cylinder Head Removal).

○

Mark and record the valve location so it can be installed in the original position.

•

Using the valve spring compressor assembly, remove the valve.

Special Tools — Valve Spring Compressor Assembly [A]:

57001-241

Valve Spring Compressor Adapter, 22 [B]:

57001-1202

•

Valve Installation

Install the spring seat.

•

Replace the valve stem oil seal.

If a new valve is to be used, check the valve-to-guide clearance (see Valve-to-Guide Clearance Measurement).

If there is too little clearance, ream the valve guide (see

Valve Guide Installation).

If there is too much clearance, install a new valve guide

•

(see Valve Guide Removal and Valve Guide Installation).

Check the valve seat (see Valve Seat Inspection).

•

Apply a thin coat of molybdenum disulfide grease to the valve stem.

•

Install each spring so that the closed coil end faces downwards.

○

The white paint on the spring faces upwards.

Valve Stem [A]

Oil Seal [B]

Spring Seat [C]

Spring [D]

Retainer [E]

Split Keepers [F]

Closed Coil End [G]

Valve Guide Removal

•

Remove:

Valve (see Valve Removal)

Valve Stem Oil Seal

•

Hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.

Special Tool — Valve Guide Arbor, 5: 57001-1203

ENGINE TOP END 5-33

5-34 ENGINE TOP END

Valves

Valve Guide Installation

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Lightly oil the valve guide outer surface.

•

Using the valve guide arbor [A], drive the valve guide [B] until its flange touches the cylinder head.

Special Tool — Valve Guide Arbor, 5: 57001-1203

•

(KRF750ND/PD/RD/SD)

Lightly oil the valve guide outer surface.

•

Using the valve guide driver [A], valve guide driver attachment [B] and spacer [C], press and insert the valve guide until the valve guide driver attachment touches the spacer.

16.0

∼

16.4 mm (0.63

∼

0.65 in.) [D]

Special Tools — Valve Guide Driver: 57001-1564

Valve Guide Driver Attachment, E: 57001

-1677

Spacer: 57001-1785

•

Ream the valve guide with the valve guide reamer [A] , it may be necessary to ream the guide even if the old guide is reused.

Special Tool — Valve Guide Reamer, 5: 57001-1204

Valve-to-Guide Clearance Measurement

If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below.

•

Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.

•

Move [C] the stem back and forth to measure valve/valve guide clearance.

•

Repeat the measurement in a direction at a right angle to the first.

If the reading exceeds the service limit, replace the guide.

Valves

NOTE

○

The reading is not actual valve/valve guide clearance because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)

Standard:

Exhaust 0.09

∼

0.17 mm (0.0035

∼

0.0067 in.)

Intake 0.03

∼

0.11 mm (0.0012

∼

0.0043 in.)

Service Limit:

Exhaust

Intake

0.37 mm (0.0146 in.)

0.31 mm (0.0122 in.)

•

Valve Seat Inspection

Remove the valve (see Valve Removal).

•

Check the valve seating surface [A] between the valve [B] and valve seat [C].

○

Coat the valve seat with machinist’s dye.

○

Push the valve into the guide.

○

Rotate the valve against the seat with a lapping tool.

○

Pull the valve out, and check the seating pattern on the valve head. It must be the correct width and even all the way around.

•

Measure the outside diameter [D] of the seating pattern on the valve seat.

If the outside diameter of the valve seating pattern is too large or too small, repair the seat (see Valve Seat Repair).

Valve Seating Surface Outside Diameter

Exhaust: 25.2

∼

25.4 mm (0.992

∼

1.000 in.)

Intake: 29.4

∼

29.6 mm (1.157

∼

1.165 in.)

NOTE

○

The valve stem and guide must be in good condition, or this check will not be valid.

If the valve seating pattern is not correct, repair the seat

(see Valve Seat Repair).

•

Measure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with vernier calipers.

If the width is too wide, too narrow or uneven, repair the seat (see Valve Seat Repair).

[F] Good

[G] Too Wide

[H] Too Narrow

[J] Uneven

Valve Seating Surface Width

Exhaust: 0.5

∼

1.0 mm (0.02

∼

0.04 in.)

Intake: 0.5

∼

1.0 mm (0.02

∼

0.04 in.)

ENGINE TOP END 5-35

5-36 ENGINE TOP END

Valves

Valve Seat Repair (Valve Lapping)

•

Using the valve seat cutters [A], repair the valve seat.

Special Tools — Valve Seat Cutters:

Exhaust Valves:

Valve Seat Cutter, 45° — 27.5: 57001-1114

Valve Seat Cutter, 32° — 28: 57001-1119

Valve Seat Cutter, 60° — 30: 57001-1123

Intake Valves:

Valve Seat Cutter, 45° — 30: 57001-1187

Valve Seat Cutter, 32° — 33: 57001-1199

Valve Seat Cutter, 60° — 30: 57001-1123

Holder and Bar:

Valve Seat Cutter Holder, 5: 57001-1208 [B]

Valve Seat Cutter Holder Bar: 57001-1128 [C]

If the manufacturer’s instructions are not available, use the following procedure.

Seat Cutter Operation Care

1. This valve seat cutter is developed to grind the valve seat for repair. Therefore the cutter must not be used for other purposes than seat repair.

2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.

3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.

NOTE

○

Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.

NOTE

○

Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil.

5. After use, wash it with washing oil and apply thin layer of engine oil before storing.

Marks Stamped on the Cutter

The marks stamped on the back of the cutter [A] represent the following.

60° ……………………… Cutter angle [B]

37.5

………………….. Outer diameter of cutter [C]

Valves

•

Operating Procedures

Clean the seat area carefully.

•

Coat the seat with machinist’s dye.

•

Fit a 45° cutter into the holder and slide it into the valve guide.

•

Press down lightly on the handle and turn it right or left.

Grind the seating surface only until it is smooth.

NOTICE

Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced.

Widened Width [A] of engagement by machining with

45° cutter

Ground Volume [B] by 32° cutter

32° [C]

Correct Width [D]

Ground Volume [E] by 60° cutter

60° [F]

•

Measure the outside diameter of the seating surface with vernier calipers.

If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.

Original Seating Surface [B]

NOTE

○

Remove all pittings of flaws from 45° ground surface.

○

After grinding with 45° cutter, apply thin coat of machinist’s dye to seating surface. This makes seating surface distinct and 32° and 60° grinding operation easier.

○

When the valve guide is replaced, be sure to grind with

45° cutter for centering and good contact.

ENGINE TOP END 5-37

5-38 ENGINE TOP END

Valves

If the outside diameter (O.D.) [A] of the seating surface is too large, make the 32° grind described below.

If the outside diameter of the seating surface is within the specified range, measure the seat width as described below.

•

Grind the seat at a 32° angle [B] until the seat O.D. is within the specified range.

○

To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide.

○

Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.

NOTICE

The 32° cutter removes material very quickly.

Check the seat outside diameter frequently to prevent overgrinding.

After making the 32° grind, return to the seat O.D. measurement step above.

•

To measure the seat width, use vernier calipers to measure the width of the 45° angle portion of the seat at several places around the seat.

If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat

O.D. measurement step above.

If the seat width is too wide, make the 60° [A] grind described below.

If the seat width is within the specified range, lap the valve to the seat as described below.

•

Grind the seat at a 60° angle until the seat width is within the specified range.

○

To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide.

○

Turn the holder, while pressing down lightly.

○

After making the 60° grind, return to the seat width measurement step above.

Correct Width [B]

Valves

•

Lap the valve to the seat, once the seat width and O.D.

are within the ranges specified above.

○

Put a little coarse grinding compound on the face of the valve in a number of places around the valve head.

○

Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve.

○

Repeat the process with a fine grinding compound.

[A] Lapper

[B] Valve Seat

[C] Valve

•

The seating area should be marked about in the middle of the valve face.

If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it.

•

Be sure to remove all grinding compound before assembly.

•

When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment in the Periodic Maintenance chapter).

ENGINE TOP END 5-39

5-40 ENGINE TOP END

Valves

Cylinder and Piston

Cylinder Removal

•

Remove:

Cylinder Head (see Cylinder Head Removal)

Oil Pipe [A]

Chain Guide [B]

Cylinder Bolts [C]

Cylinder [D]

Cylinder Base Gasket

•

Piston Removal

Remove the cylinder block (see Cylinder Removal).

•

Place a piece of clean cloth under the piston and remove the piston pin snap rings [A] from the outside of each piston.

NOTICE

Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

•

Using the piston pin puller assembly (special tool), remove the piston pins.

Special Tools — Piston Pin Puller Assembly [A]: 57001-910

Piston Pin Puller Adapter, 14 [B]: 57001

-1211

•

Remove the piston.

•

Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it.

•

Remove the 3-piece oil ring with your thumbs in the same manner.

ENGINE TOP END 5-41

Cylinder, Piston Installation

NOTE

○

If a new piston or cylinder is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston rings.

5-42 ENGINE TOP END

Cylinder and Piston

NOTE

○

The oil ring rails have no “top” or “bottom”.

•

Install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together.

•

Install the oil ring steel rails, one above the expander and one below it.

○

Spread the rail with your thumbs, but only enough to fit the rail over the piston.

○

Release the rail into the bottom piston ring groove.

•

Do not mix up the top ring and second ring.

•

For the KRF750NA/PA/RA/SA/TA

∼

NB/PB/RB/SB/VB models, install the top ring [A] so that the “R” mark [B] faces up.

•

For the KRF750NC/PC/RC/SC/VC

∼ models, install the top ring [A] so that the “1R” mark [B] faces up.

•

Install the second ring [C] so that the “RN” mark [D] faces up.

•

The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails do not align.

Top Ring [A]

Second Ring [B]

Oil Ring Steel Rails [C]

Oil Ring Expander [D]

F mark [E] must be faced toward Front Side for front and rear pistons

Opening Positions [F]

•

Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit

[B] of the piston pin hole.

○

When installing the piston pin snap ring, compress it only enough to install it and no more.

•

Apply engine oil to the cylinder bore and, piston skirt.

•

Install:

Dowel Pins [A]

New Cylinder Base Gasket [B]

Cylinder and Piston

•

Install:

Cylinder

•

Tighten:

Torque — Cylinder Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install:

Chain Guide [B]

•

Apply grease to the O-rings on the oil pipe [C], and insert the pipe.

Cylinder Wear Inspection

•

Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the three locations (total of six measurements) shown in the figure.

If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder.

10 mm (0.4 in.) [A]

60 mm (2.4 in.) [B]

20 mm (0.8 in.) [C]

Cylinder Inside Diameter

Standard: 84.994

∼

85.006 mm (3.3462

∼

3.3467

in.), and less than 0.01 mm (0.0004

in.) difference between any two measurements.

Service Limit: 85.09 mm (3.3500 in.), or more than 0.05

mm (0.0020 in.) difference between any two measurements.

Piston Wear Inspection

•

Measure the outside diameter [A] of each piston 5 mm

(0.20 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin.

If the measurement is under service limit, replace the piston.

Piston Diameter

Standard: 84.964

∼

84.979 mm (3.3450

∼

3.3456 in.)

Service Limit: 84.81 mm (3.3390 in.)

Piston/Cylinder Clearance Inspection

•

Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance.

Piston/Cylinder Clearance

Standard: 0.015

∼

0.042 mm (0.0006

∼

0.0017 in.)

ENGINE TOP END 5-43

5-44 ENGINE TOP END

Cylinder and Piston

Piston Ring, Piston Ring Groove Wear Inspection

•

Check for uneven groove wear by inspecting the ring seating.

The rings should fit perfectly parallel to groove surfaces.

If not, replace the piston and all the piston rings.

•

With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance.

Piston Ring/Groove Clearance

Standard:

Top

Second

0.04

∼

0.08 mm (0.0016

∼

0.0031 in.)

0.03

∼

0.07 mm (0.0012

∼

0.0028 in.)

Service Limit:

Top

Second

0.18 mm (0.0071 in.)

0.17 mm (0.0067 in.)

If the piston ring/groove clearance is greater than the service limit, measure the ring thickness and groove width as follows to decide whether to replace the rings, the piston or both.

•

Piston Ring Groove Width Inspection

Measure the piston ring groove width.

○

Use a vernier caliper at several points around the piston.

Piston Ring Groove Width

Standard:

Top (KRF750NA/PA/RA/SA/TA

∼

NB/PB/RB/SB/VB)

1.03

∼

1.05 mm (0.0406

∼

0.0413 in.)

(KRF750NC/PC/RC/SC/VC

∼

)

0.93

∼

0.95 mm (0.0366

∼

0.0374 in.)

Second 1.02

∼

1.04 mm (0.0402

∼

0.0409 in.)

Service Limit:

Top (KRF750NA/PA/RA/SA/TA

∼

NB/PB/RB/SB/VB)

1.13 mm (0.0445 in.)

(KRF750NC/PC/RC/SC/VC

∼

)

1.03 mm (0.0406 in.)

Second 1.12 mm (0.0441 in.)

If the width of any of the two grooves is wider than the service limit at any point, replace the piston.

Cylinder and Piston

•

Piston Ring Thickness Inspection

Measure the piston ring thickness.

○

Use a micrometer to measure at several points around the ring.

Piston Ring Thickness

Standard:

Top (KRF750NA/PA/RA/SA/TA

∼

NB/PB/RB/SB/VB)

0.97

∼

0.99 mm (0.0382

∼

0.0390 in.)

(KRF750NC/PC/RC/SC/VC

∼

)

0.87

∼

0.89 mm (0.0343

∼

0.0350 in.)

Second 0.97

∼

0.99 mm (0.0382

∼

0.0390 in.)

Service Limit:

Top (KRF750NA/PA/RA/SA/TA

∼

NB/PB/RB/SB/VB)

0.90 mm (0.0354 in.)

(KRF750NC/PC/RC/SC/VC

∼

)

0.80 mm (0.0315 in.)

Second 0.90 mm (0.0354 in.)

If any of the measurements is less than the service limit on either of the rings, replace all the rings.

NOTE

○

When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston.

Piston Ring End Gap Inspection

•

Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low.

•

Measure the gap [B] between the ends of the ring with a thickness gauge.

Piston Ring End Gap

Standard:

Top

Second

Oil

0.15

∼

0.25 mm (0.0059

∼

0.0098 in.)

0.30

∼

0.45 mm (0.0118

∼

0.0177 in.)

0.20

∼

0.70 mm (0.0079

∼

0.0276 in.)

Service Limit:

Top

Second

Oil

0.55 mm (0.0217 in.)

0.75 mm (0.0295 in.)

1.00 mm (0.0394 in.)

If the end gap of either ring is greater than the service limit, replace all the rings.

ENGINE TOP END 5-45

5-46 ENGINE TOP END

Exhaust System

This vehicle is equipped with a spark arrester approved for off-road use by the United States Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester.

Spark Arrester Cleaning

•

Refer to the Spark Arrester Cleaning in the Periodic Maintenance chapter.

Muffler and Exhaust Pipe Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Engine Bottom Guard (see Engine Bottom Guard Removal in the Frame chapter)

•

Loosen:

Muffler Clamp Bolts [A] (both sides)

•

Remove:

Muffler Mounting Bolts [A] and Washers

Bracket [B]

Muffler [C]

•

Remove:

Rear Exhaust Pipe Nuts [A]

Rear Exhaust Pipe [B]

Exhaust System

•

Remove:

Front Exhaust Pipe Nuts [A]

Front Exhaust Pipe [B]

•

Remove:

Circlips [A] and Washers [B] (both sides)

Special Tool — Inside Circlip Pliers: 57001-143

•

Remove:

Damper [C]

ENGINE TOP END 5-47

5-48 ENGINE TOP END

Exhaust System

Exhaust System Inspection

•

Before removing the exhaust system, check for signs of leakage at the exhaust pipe gasket in the cylinder head and at the muffler clamp.

If there are signs of leakage around the exhaust pipe gasket, it should be replaced. If the muffler-to-exhaust pipe joint leaks, tighten the clamp.

•

Remove the exhaust pipe and muffler (see Muffler and

Exhaust Pipe Removal).

•

Inspect the gasket for damage and signs of leakage.

If the gasket is damaged or has been leaking, replace it.

•

Check the exhaust pipe and muffler for dents, cracks, rust and holes.

If the exhaust pipe or muffler is damaged or has holes, it should be replaced for best performance and least noise.

Muffler and Exhaust Pipe Installation

•

When installing the muffler bracket dampers [A], do as follows.

•

Install the following parts in the muffler bracket [B].

Muffler Bracket Damper

Washers [C]

New Circlips [D]

Special Tool — Inside Circlip Pliers: 57001-143

•

Install the muffler brackets to the muffler.

Exhaust System

•

When installing the exhaust pipe covers [A], do as follows.

○

Install:

Exhaust Pipe Covers

Collars [B]

Dampers [C]

Washers [D]

Exhaust Pipe Cover Bolts [E]

○

Tighten:

Torque — Exhaust Pipe Cover Bolts: 13 N·m (1.3 kgf·m, 115 in·lb)

○

Install the cover clamp screws [F] as shown in the figure.

•

Replace the exhaust pipe gaskets [G] with new ones.

•

Install:

New Exhaust Pipe Gaskets

Front Exhaust Pipe [H] and Exhaust Pipe Nuts (lightly)

•

Rear Exhaust Pipe [I] and Exhaust Pipe Nuts (lightly)

Replace and muffler gasket with new ones.

•

Install the new muffler gasket [J], collar [K] and clamp [L] to the front side intake pipe of the muffler as follows.

○

Install the new muffler gasket more deeply than the first wide ditch [M] of the intake pipe and contact the clamp claws [N] to the bottom [O] of the ditch.

•

Install the new muffler gasket [P], collar [K] and clamp [Q] to the rear side intake pipe of the muffler as follows.

○

Install the new muffler gasket to the bottom of the intake pipe.

○

The distance [R] between the intake pipe end and gasket end is 8 ±0.5 mm (0.31 ±0.02 in.).

○

Install the collar more deeply than the first wide ditch [S] of the rear side intake pipe and contact the clamp claws

•

[T] to the bottoms [U] of the ditch.

Install the muffler to the exhaust pipes.

•

Install the muffler bracket [V] to the bracket [W] of the frame side.

•

Install:

Washer and Muffler Mounting Bolts [X] (lightly)

•

Tighten:

Torque — Exhaust Pipe Nuts [Y]: 17 N·m (1.7 kgf·m, 13 ft·lb)

•

Push the muffler to front, and then confirm that the gasket entered into the muffler.

•

Tighten the muffler clamp bolts [Z] in the direction of the figure.

Torque — Muffler Clamp Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb)

•

Tighten:

Torque — Muffler Mounting Bolts: 28 N·m (2.9 kgf·m, 21 ft·lb)

•

After installation, thoroughly warm up the engine, wait until the engine cools down, and then retighten the exhaust pipe nuts, muffler clamp bolts and muffler mounting bolts.

ENGINE TOP END 5-49

5-50 ENGINE TOP END

Exhaust System

CONVERTER SYSTEM 6-1

Converter System

Table of Contents

Exploded View…………………………………………………………………………………………………………

Specifications ………………………………………………………………………………………………………….

Special Tools …………………………………………………………………………………………………………..

Torque Converter Cover ……………………………………………………………………………………………

Torque Converter Cover Removal …………………………………………………………………………

Torque Converter Cover Installation ………………………………………………………………………

Torque Converter Cover Disassembly ……………………………………………………………………

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

Torque Converter Cover Assembly ………………………………………………………………………..

6-10

6-11

6-11

Drive Belt ………………………………………………………………………………………………………………..

6-13

Drive Belt Removal ……………………………………………………………………………………………..

6-13

Drive Belt Installation …………………………………………………………………………………………..

6-13

6-2

6-6

6-7

6-9

6-9

6-9

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

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

Drive Belt Inspection ……………………………………………………………………………………………

6-13

6-13

6-13

Drive Pulley …………………………………………………………………………………………………………….

6-14

Drive Pulley Removal…………………………………………………………………………………………..

6-14

Drive Pulley Disassembly …………………………………………………………………………………….

6-14

Drive Pulley Inspection ………………………………………………………………………………………..

Spider Shoe Side Clearance Inspection/Adjustment ………………………………………………..

6-15

6-17

6-18 Drive Pulley Assembly …………………………………………………………………………………………

Drive Pulley Installation………………………………………………………………………………………..

Drive Pulley Cover Adjustment (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)…………

Drive Pulley Cover Adjustment (KRF750ND/PD/RD/SD) ………………………………………….

6-20

6-21

6-22

Driven Pulley …………………………………………………………………………………………………………..

6-26

Driven Pulley Removal…………………………………………………………………………………………

6-26

Driven Pulley Disassembly …………………………………………………………………………………..

6-26

Driven Pulley Inspection ………………………………………………………………………………………

Driven Pulley Assembly ……………………………………………………………………………………….

Driven Pulley Installation………………………………………………………………………………………

6-27

6-28

6-30

6

6-2 CONVERTER SYSTEM

Exploded View

CONVERTER SYSTEM 6-3

Exploded View

No.

1 Drive Pulley Bolt

2

3 Ramp Weight Nuts

Fastener

Drive Pulley Cover Bolts

N·m

93

12.5

7.0

Torque kgf·m

9.5

1.3

0.71

ft·lb

69

111 in·lb

62 in·lb

Remarks

Lh

R

4 Spider

5 Driven Pulley Nut

275

93

28

9.5

203

69

Lh

R

6. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

G: Apply grease.

Lh: Left-hand Threads

R: Replacement Parts

WR: Apply grease (WR500-No2. KYODO YUSHI, POWER LITE WR #2 KYODO YUSHI, or SERAN

-HV TOTAL FINA).

6-4 CONVERTER SYSTEM

Exploded View

Exploded View

No.

Fastener

1 Engine Brake Actuator Mounting Bolts

2 Engine Brake Actuator Cover Bolt

3 Belt Inspection Opening Cover Bolts

4 Converter Cover Bolts

5 Converter Cover Drain Bolt

6 Joint Duct Bolts

G: Apply grease.

M: Apply molybdenum disulfide grease.

R: Replacement Parts

S: Follow the specific tightening sequence.

CONVERTER SYSTEM 6-5

N·m

8.8

8.8

8.8

8.8

20

8.8

Torque kgf·m

0.90

0.90

0.90

0.90

2.0

0.90

ft·lb

78 in·lb

78 in·lb

78 in·lb

78 in·lb

15

78 in·lb

Remarks

S

S

S

6-6 CONVERTER SYSTEM

Specifications

Item

Torque Converter

Actuator Lever Guide Shoe

Standard Service Limit

– – – 6 mm (0.24 in.)

Actuator Lever Assembly

Installation Length

Drive Belt

164.63

∼

165.77 mm (6.481

∼

6.526 in.) – – –

Belt Width

Belt Deflection

30.0

∼

30.6 mm (1.181

∼

1.205 in.)

22

∼

31 mm (0.87

∼

1.22 in.) (at checking)

22

∼

27 mm (0.87

∼

1.06 in.) (at adjusting)

28.6 mm (1.126 in.)

– – –

Drive Pulley

Shoe Side Clearance Up to 0.20 mm (0.008 in.) (in the text) – – –

Cover Bushing Inside Diameter 27.985

∼

28.085 mm (1.1018

∼

1.1057 in.) 28.12 mm (1.107 in.)

Sheave Bushing Inside

Diameter

37.985

∼

38.085 mm (1.4955

∼

1.4994 in.) 38.12 mm (1.501 in.)

Spring Free Length 60.0 mm (2.36 in.)

Drive Pulley Installation Length 164.85

∼

165.95 mm (6.490

∼

6.533 in.)

Driven Pulley

Sheave Bushing Inside

Diameter

Spring Free Length

40.000

∼

40.085 mm (1.5748

99 mm (3.9 in.)

∼

– – –

– – –

1.5781 in.) 40.30 mm (1.587 in.)

– – –

Special Tools

Outside Circlip Pliers:

57001-144

Fork Oil Seal Driver, 30:

57001-1337

Drive & Driven Pulley Holder:

57001-1412

Pulley Holder Attachment:

57001-1472

Drive & Driven Pulley Holder:

57001-1473

CONVERTER SYSTEM 6-7

Drive Pulley Wrench:

57001-1474

Spring Holder Set:

57001-1483

Drive Pulley Measurement Tool:

57001-1498

Actuator Lever Measurement Tool:

57001-1499

Fork Oil Seal Driver, 43:

57001-1530

6-8 CONVERTER SYSTEM

Special Tools

Flywheel & Pulley Holder:

57001-1605

Puller Bolt:

57001-1711

Leg:

57001-1712

Drive Pulley Holder:

57001-1620

Rod:

57001-1710

Torque Converter Cover

WARNING

Excessive imbalance or operating rpm could cause torque converter pulley failure resulting in severe injury or death. The pulleys of the belt drive torque converter are precision balanced components designed to operate within certain rpm limits. Disassembly/assembly and servicing procedures of the pulley assemblies must be followed closely. Modifications to the engine or pulleys that increase rpm may cause failure.

Torque Converter Cover Removal

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)

Right Frame Pipe (see Right Frame Pipe Removal in the

Frame chapter)

Band [A] (cut)

Air Outlet Duct [B]

•

Remove:

Actuator Lead Connector [A]

Torque Converter Cover Bolts [B]

Clamp [C]

Torque Converter Cover [D]

CONVERTER SYSTEM 6-9

Torque Converter Cover Installation

•

Check the actuator lever assembly installation length (see

Torque Converter Cover Assembly).

•

Fit the trim seal [A] into the converter cover.

6-10 CONVERTER SYSTEM

Torque Converter Cover

•

Tighten the two cover bolts following the tightening sequence [1, 2] and tighten the other bolts [A] in arbitrary order.

[B] Clamp

Torque — Converter Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install the clamp [C] in this area [D] (about 30 mm (1.2

in.)).

•

Install the rubber duct [A] to the converter cover [B].

○

Fit the projection [C] of the converter cover into the slit of the rubber duct.

○

Do not run up [D] the rubber duct onto the converter cover.

•

Install the duct [E] to the rubber duct.

○

Fit the projection [F] of the duct into the slit of the rubber duct.

○

Push the duct until the rib [G] of the duct touches the rubber duct.

Right [H]

Wrong [I]

•

Tighten the bands on the rubber duct.

Torque Converter Cover Disassembly

•

Remove:

Torque Converter Cover (see Torque Converter Cover

Removal)

Engine Brake Actuator (see Engine Brake Actuator Removal in the Electrical System chapter)

Circlip [A]

Spring [B]

Torque Converter Cover

•

Remove:

Bushing [A]

Washer [B]

Actuator Lever Assembly [C]

Actuator Lever (Engine Brake Control Lever)

Assembly Inspection

•

Refer to the Actuator Lever (Engine Brake Control Lever)

Assembly Inspection in the Periodic Maintenance chapter.

Torque Converter Cover Assembly

•

When installing the bushing [A] into the cover [B], press it until it is stopped as shown in the figure.

CONVERTER SYSTEM 6-11

•

Install:

Actuator Lever Assembly

Washer

Bushing

Spring

New Circlip

Engine Brake Actuator (see Engine Brake Actuator Installation in the Electrical System chapter)

Torque — Engine Brake Actuator Mounting Bolts: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

•

Measure the installation length [A] of the actuator lever assembly between the cover end [B] and resin tips [C] on the actuator lever assembly as follows:

Actuator Lever Assembly Installation Length

Standard: 164.63

∼

165.77 mm (6.481

∼

6.526 in.)

6-12 CONVERTER SYSTEM

Torque Converter Cover

○

Remove the trim seal.

○

Install the actuator lever measurement tool (plate [A] and rods (57001-1710) [B]) on the torque converter cover [C] and tighten the two cover bolts.

Special Tools — Actuator Lever Measurement Tool: 57001

-1499

Rod: 57001-1710

○

Set the rod ends on the resin tips [D].

○

Measure the recess length [E] between the plate and rods with Vernier calipers [F] or depth gauge.

Measurement Length [E]

Standard: 1.33

∼

2.47 mm (0.052

∼

0.097 in.)

If the measurement is less than 1.33 mm (0.052 in.), use the actuator lever assembly (13236-0123) of yellow paint.

If the measurement is more than 2.47 mm (0.097 in.), use the actuator lever assembly (13236-0124) of green paint.

If the length is not within the specified length after the actuator lever assembly is replaced, replace the torque converter cover, and install the actuator lever assembly

(13236-0125).

Actuator Lever Assemblies

Part Number Paint Color [A]

13236-0123 Yellow

13236-0125

13236-0124

None

Green

Length [B]

0.4 ±0.1 mm (0.016 ±0.004 in.)

1.0 ±0.1 mm (0.039 ±0.004 in.)

1.6 ±0.1 mm (0.063 ±0.004 in.)

Drive Belt

Drive Belt Removal

•

Remove the drive pulley [A] (see Drive Pulley Removal).

NOTE

○

Before removing, observe the direction the belt’s printed information [B] (such as manufacturer’s name) is facing so that it may be reinstalled on the pulleys to rotate in the same direction as originally installed.

•

Lift the drive belt [C] off the driven pulley [D].

Drive Belt Installation

NOTE

○

Be sure the printed information faces the same direction so the belt rotates in the same direction as originally installed. When installing a new belt, install it so the printed information [A] can be read from beside the vehicle.

•

Installation is basically the reverse of removal.

•

Loop the belt [B] over the drive and driven pulleys.

•

Install the drive pulley (see Drive Pulley Installation).

•

Put the transmission in neutral, and rotate the driven pulley to allow the belt to return to the top [A] of the sheaves, before measuring belt deflection.

CONVERTER SYSTEM 6-13

Drive Belt Deflection Inspection

•

Refer to the Drive Belt Deflection Inspection in the Periodic Maintenance chapter.

Drive Belt Deflection Adjustment

•

Refer to the Drive Belt Deflection Adjustment in the Periodic Maintenance chapter.

Drive Belt Inspection

•

Refer to the Drive Belt Inspection in the Periodic Maintenance chapter.

6-14 CONVERTER SYSTEM

Drive Pulley

Drive Pulley Removal

•

Remove the torque converter cover (see Torque Converter Cover Removal).

•

Remove the three cover bolts [A] and install the drive pulley holder [B].

Special Tool — Drive Pulley Holder: 57001-1620

•

Tighten the three cover bolts:

Torque — Drive Pulley Cover Bolts: 12.5 N·m (1.3 kgf·m, 111 in·lb)

•

Loosen the drive pulley bolt [C] (left-hand threads), holding the drive pulley with the drive pulley holder.

NOTE

○

The drive pulley bolt has left-hand threads. Turn the wrench clockwise for loosening.

•

Remove the drive pulley bolt, two washers, and the stepped washer, but do not remove the drive pulley holder yet.

•

Remove the drive pulley [A] from the crankshaft by screwing the drive pulley puller bolt [B] clockwise, while holding the drive pulley with the drive pulley holder [C].

Special Tools — Puller Bolt: 57001-1711

Drive Pulley Holder: 57001-1620

Drive Pulley Disassembly

•

Hold the drive & driven pulley holder (57001-1473) [A] and the tapered guide of the holder (57001-1412) [B] in a vise so that the upper surface on the holder is 7 mm (0.28 in.)

[C] above the vise.

Special Tools — Drive & Driven Pulley Holder: 57001-1473

Drive & Driven Pulley Holder: 57001-1412

•

Set the pulley onto the pulley holder.

•

Remove:

Drive Pulley Cover Bolts [A]

Drive Pulley Cover [B]

Drive Pulley

•

Remove:

Spring [A]

Spacer

•

Put the drive pulley wrench [A] on the spider [B] and tighten the bolt [C].

Special Tool — Drive Pulley Wrench: 57001-1474

•

Turn the wrench clockwise and remove the spider with the movable sheave.

NOTE

○

The spider has left-hand threads. Turn the wrench clockwise for loosening.

•

Remove:

Spider [A]

Shoes [B]

Nuts [C]

Ramp Weight Pin [D]

Ramp Weight [E]

Movable Sheave [F]

Fixed Sheave [G]

CONVERTER SYSTEM 6-15

Drive Pulley Inspection

If the sheave surfaces [A] appear damaged, replace the sheaves.

6-16 CONVERTER SYSTEM

Drive Pulley

If the cover bushing is damaged or worn, replace the drive pulley cover.

Cover Bushing Inside Diameter [A]

Standard: 27.985

∼

28.085 mm (1.1018

∼

1.1057 in.)

Service Limit: 28.12 mm (1.107 in.)

If the sheave bushing is damaged or worn, replace it.

Sheave Bushing Inside Diameter [A]

Standard: 37.985

∼

38.085 mm (1.4955

∼

1.4994 in.)

Service Limit: 38.12 mm (1.501 in.)

If the spider shoes [A] are damaged, replace them.

•

Check the spider shoe side clearance (see Spider Shoe

Side Clearance Inspection).

If the ramp weights [A] in the movable sheave are damaged or worn, replace them.

If the pins [B] are damaged or worn, replace them.

If the rollers [A] are damaged or worn, replace the spider

[B].

If the washers [C] are damaged or worn, replace the spider.

Drive Pulley

If the spring is worn or damaged, replace the spring.

Spring Free Length [A]

Standard: 60.0 mm (2.36 in.)

CONVERTER SYSTEM 6-17

Spider Shoe Side Clearance Inspection/Adjustment

•

Remove:

Drive Pulley (see Drive Pulley Removal)

Drive Pulley Cover and Spring (see Drive Pulley Disassembly)

•

Set the drive pulley [A] without the spring onto the pulley holders (see Drive Pulley Disassembly).

Special Tools — Drive & Driven Pulley Holder: 57001-1473

Drive & Driven Pulley Holder: 57001-1412

•

Temporarily install the following parts on the movable sheave.

Dowel Pins (2)

Drive Pulley Cover [B]

Two Bolts [C] (at dowel pins)

○

Do not install the spring.

6-18 CONVERTER SYSTEM

Drive Pulley

•

Turn the spider clockwise.

•

Measure the resulting clearance [A] between the shoe [B] and the post [C] on the movable sheave at two positions as shown.

[D] Arrow Mark

Shoe Side Clearance

Standard: up to 0.20 mm (0.008 in.), and there must be kept a clearance which the movable sheave [E] moves smoothly until it touches the fixed sheave [F] with its own weight.

If the clearance is not the specified range, adjust it using the following shoes.

Standard Shoe

Adjustment Shoes

Part Number

49048-1090

49048-1087

49048-1088

49048-1089

49048-1091

49048-1092

49048-1093

49048-1094

49048-1095

Thickness

7.5 mm (0.295 in.)

7.2 mm (0.283 in.)

7.3 mm (0.287 in.)

7.4 mm (0.291 in.)

7.6 mm (0.299 in.)

7.7 mm (0.303 in.)

7.8 mm (0.307 in.)

7.9 mm (0.311 in.)

8.0 mm (0.315 in.)

If the clearance is not the specified range after the above shoes are replaced, use the spacer [A] (92026-0038) of the option part.

[B] Shoe

[C] Spider

[D] Post

[E] Clearance

Drive Pulley Assembly

•

When installing the bushing [A], press [B] the bushing into the movable sheave [C] so that the bushing end is flush with the boss [D] of the sheave.

Drive Pulley

•

•

Install the ramp weight [A] as shown.

Replace the ramp weight nuts with new ones.

•

Tighten:

Torque — Ramp Weight Nuts [B]: 7.0 N·m (0.71 kgf·m, 62 in·lb)

•

Check that the ramp weights swing smoothly.

CONVERTER SYSTEM 6-19

•

Hold the fixed sheave [A] with the drive pulley holder [B] in a vise.

Special Tool — Drive & Driven Pulley Holder: 57001-1473

•

Clean the threads of the fixed sheave and spider.

•

Install:

Movable Sheave

Spider [A] and Shoes [B]

○

Align the arrow [C] on the spider with the arrow [D] on the movable sheave.

○

Insert the shoes so that the rubber side (black, small diameter) faces inward.

•

Put the drive pulley wrench [A] on the spider [B] and tighten the bolt [C].

Special Tool — Drive Pulley Wrench: 57001-1474

•

Turn the wrench counterclockwise for tightening.

Torque — Spider (left-hand threads): 275 N·m (28 kgf·m, 203 ft·lb)

•

Remove the drive pulley wrench.

•

Install the spacer.

•

Put the spring [A] in the groove of the spider.

•

Align the arrows [B] on the drive pulley cover and spider.

•

Install:

Dowel Pins [C]

Drive Pulley Cover

•

Tighten:

Torque — Drive Pulley Cover Bolts: 12.5 N·m (1.3 kgf·m, 111 in·lb)

•

Clean the surface of the sheaves with an oil-less cleaning fluid.

6-20 CONVERTER SYSTEM

Drive Pulley

Drive Pulley Installation

•

Using a cleaning fluid, clean off any oil or dirt on the following portions and dry them with a clean cloth.

Fixed Sheave Tapered Portion [A]

Crankshaft Tapered Portion [B]

WARNING

These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings.

•

Install the drive pulley, stepped waster and two washers on the drive pulley bolt as shown.

Crankcase Side [A]

Stepped Washer [B]

Two Washers [C]

Bolt Head Side [D]

•

Remove the three cover bolts [A] and install the drive pulley holder [B].

Special Tool — Drive Pulley Holder: 57001-1620

•

Tighten:

Torque — Drive Pulley Cover Bolts: 12.5 N·m (1.3 kgf·m, 111 in·lb)

Drive Pulley Bolt [C] (new, left-hand threads): 93

N·m (9.5 kgf·m, 69 ft·lb)

•

Remove the drive pulley holder and install three drive pulley cover bolts to the specified torque.

•

Adjust the installation length [A] of the drive pulley between the surface of the crankcase [B] and the collar [C] on the drive pulley as followings.

Drive Pulley Installation Length [A]

Standard: 164.85

∼

165.95 mm (6.490

∼

6.533 in.)

Drive Pulley

○

Install the legs (57001-1712) [A] and plate [B] in the drive pulley measurement tool on the crankcase [C].

Special Tools — Drive Pulley Measurement Tool: 57001-1498

Leg: 57001-1712

○

Measure the length [D] between the plate and collar [E] with vernier calipers [F] or a depth gauge.

Special Tool Measurement Length [D]

Standard: 14.55

∼

15.65 mm (0.5728

∼

0.6161 in.)

If the measurement is not within the specified range, adjust it (see Drive Pulley Cover Adjustment).

CONVERTER SYSTEM 6-21

Drive Pulley Cover Adjustment

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Select the drive pulley cover according to the following table.

Status Quo

Measurement

Length

Paint Color of Cover less than

14.55 mm

(0.573 in.) more than

15.65 mm

(0.616 in.)

Blue

No Paint

Red

Blue

No Paint

Red

Replacement Part

Replace Part

(Part Number)

Paint Color of Cover

Pulley Cover

(14041-0037)

Pulley Cover

(14041-0035)

No Paint

Red

Drive Pulley Assembly

(49093-0029)

Drive Pulley Assembly

(49093-0029)

Pulley Cover

(14041-0036)

Blue

Pulley Cover

(14041-0037)

No Paint

6-22 CONVERTER SYSTEM

Drive Pulley

Drive Pulley Covers

Part Number

14041-0035

14041-0036

Paint Color [A]

Red

Blue

Length [B]

24.0 mm

25.4 mm

14041-0037 No Paint 24.7 mm

•

Remove the drive pulley bolt (see Drive Pulley Removal).

•

Replace the drive pulley cover (see Drive Pulley Disassembly/Assembly).

○

Remove the drive pulley cover only.

•

Install the drive pulley bolt, and measure the special tool measurement length again (see Drive Pulley Installation).

If the length is not within the specified length, replace the drive pulley assembly.

Drive Pulley Cover Adjustment

(KRF750ND/PD/RD/SD)

NOTE

○

In this adjustment, the following new parts and work are necessary.

Drive Pulley Cover (P/No. 14091-1804)

Bushing (P/No. 92028-1980)

Bearing (P/No. 92045-1453)

Snap Ring (P/No. 92033-0063)

Collar and Shim (by calculation in below text)

Cutting a Groove in Drive Pulley Measurement Tool

(57001-1498)

•

Remove the drive pulley bolt (see Drive Pulley Removal).

•

Remove the drive pulley cover (see Drive Pulley Disassembly).

○

Remove the drive pulley cover only and discard it.

•

Press the new bushing [A] in the new drive pulley cover

[B] so that the bushing end [C] is flush with the end of hole.

Special Tool — Bearing Driver Set [D]: 57001-1129

•

Install the drive pulley cover without the shim, collar and bearing (see Drive Pulley Assembly).

•

Install the drive pulley bolt (see Drive Pulley Installation).

Drive Pulley

•

Cut a groove in the drive pulley measurement tool [A] for a vernier calipers.

About 5 mm (0.2 in.) [B]

About 7 mm (0.3 in.) [C]

Special Tool — Drive Pulley Measurement Tool: 57001-1498

CONVERTER SYSTEM 6-23

•

Install the legs (57001-1712) [A] and plate [B] in the drive pulley measurement tool on the crankcase [C].

Special Tool — Drive Pulley Measurement Tool: 57001-1498

Leg: 57001-1712

•

Measure the length [D] between the plate and bearing installing surface [E] on the drive pulley cover with a vernier calipers [F] or depth gauge.

Special Tool Measurement Length [D]

Standard: 26.70

∼

29.70 mm (1.051

∼

1.169 in.)

If the measurement is within the specified range, select the sizes of the collar and shim(s) from the table below based on the adjustment length.

If the measurement is not within the specified range, replace the drive pulley Assembly.

6-24 CONVERTER SYSTEM

Drive Pulley

Adjustment Length Calculation formula

Adjustment Length = Measurement Length – 25.10 mm

25.10 mm: Fixed Length

Calculation Example:

Measurement Length = 28.40 mm

Adjustment Length = 28.40 mm – 25.10 mm = 3.30 mm

Select the collar and shim(s) from the table.

Collar Size: 3.0 mm

Shim Size: 0.3 mm

Collar Size

(mm)

1.6

2.3

3.0

3.7

Shim Size (mm)

None

0.1

0.2

0.3

0.4 (= 0.1 + 0.3)

0.5 (= 0.2 + 0.3)

0.6 (= 0.3 + 0.3)

None

0.1

0.2

0.3

0.4 (= 0.1 + 0.3)

0.5 (= 0.2 + 0.3)

0.6 (= 0.3 + 0.3)

None

0.1

0.2

0.3

0.4 (= 0.1 + 0.3)

0.5 (= 0.2 + 0.3)

0.6 (= 0.3 + 0.3)

None

0.1

0.2

0.3

0.4 (= 0.1 + 0.3)

0.5 (= 0.2 + 0.3)

0.6 (= 0.3 + 0.3)

0.7 (= 0.1 + 0.3 + 0.3)

0.8 (= 0.2 + 0.3 + 0.3)

0.9 (= 0.3 + 0.3 + 0.3)

3.40

3.50

3.60

3.70

3.80

3.90

4.00

4.10

4.20

2.80

2.90

3.00

3.10

3.20

3.30

Adjustment

Length (mm)

1.60

1.70

1.80

1.90

2.00

2.10

2.20

2.30

2.40

2.50

2.60

2.70

4.30

4.40

4.50

4.60

NOTE

○

Do not use more than three shims.

○

Combinations of the shims on the table are for reference.

Drive Pulley

Collars

Thickness

1.6 mm

2.3 mm

3.0 mm

3.7 mm

Part Number

92152-1436

92152-1438

92152-1437

92152-1440

Shims

Thickness

0.1 mm

0.2 mm

0.3 mm

Part Number

92180-1378

92180-1379

92180-1380

•

Remove the drive pulley bolt (see Drive Pulley Removal).

•

Remove the drive pulley cover (see Drive Pulley Disassembly).

•

Put the shim(s) [A] on the collar [B].

•

Press the inner race of the new bearing [C] on the collar until it is bottomed.

Special Tool — Fork Oil Seal Driver, 30 [D]: 57001-1337

CONVERTER SYSTEM 6-25

•

With the stepped side [A] of the collar facing upward, press the outer race of the bearing assy [B] in the drive pulley cover [C] until it is bottomed.

Special Tool — Fork Oil Seal Driver, 43 [D]: 57001-1530

•

Install the snap ring [A].

•

Install the drive pulley cover (see Drive Pulley Assembly).

•

Install the drive pulley bolt, and measure the special tool measurement length again (see Drive Pulley Installation).

6-26 CONVERTER SYSTEM

Driven Pulley

Driven Pulley Removal

•

Remove:

Torque Converter Cover (see Torque Converter Cover

Removal)

Drive Pulley (see Drive Pulley Removal)

Drive Belt (see Drive Belt Removal)

•

Using the flywheel & pulley holder [A] and attachments

[B], remove the driven pulley nut [C] and washers. (Nut has R/H threads.)

Special Tools — Flywheel & Pulley Holder: 57001-1605

•

Remove:

Driven Pulley

Pulley Holder Attachment: 57001-1472

Driven Pulley Disassembly

•

Hold the drive & driven pulley holder [A] in a vise.

Special Tool — Drive & Driven Pulley Holder: 57001-1473

•

Screw the guide bar [B] into the holder.

•

Special Tool — Spring Holder Set: 57001-1483

Put the driven pulley [C] on the guide bar.

•

Install the two bolts [D] so that the bolts protrude from the spring holder [E] about 7 mm (0.28 in.) [F].

•

Tighten the nut [G], and compress the spring with the spring holder.

Special Tool — Spring Holder Set: 57001-1483

•

Remove the circlip [A] with circlip pliers [B].

Special Tool — Outside Circlip Pliers: 57001-144

•

Remove the nut and spring holder [C].

The spring seat [A] may not lift even if the nut [B] loosens.

○

Then tap the spring seat with a plastic mallet [C] lightly to release the stuck spring.

Driven Pulley

•

Remove:

Spring Seats [A]

Spring [B]

Thrust Plate [C]

•

Confirm the paint mark “0” [A] on the movable sheave [B] in alignment with the point [C] on the fixed sheave [D] for phase fit of the sheaves.

CONVERTER SYSTEM 6-27

•

Wipe off the molybdenum disulfide grease.

•

Remove the four pins [A] with a thin standard tip screwdriver [B].

•

Remove the movable sheave from the fixed sheave.

•

Remove:

Spacer(s) [A] (for Drive Belt Deflection Adjustment)

Driven Pulley Inspection

If the sheave surfaces [A] appear damaged, replace the sheaves.

6-28 CONVERTER SYSTEM

Driven Pulley

•

Replace the sheave with uneven wear on the belt contacting surfaces.

[A] Sheave Surface

[B] Straight Edge

If the sheave bushings [A] are damaged or worn, replace the movable sheave.

Sheave Bushing Inside Diameter

Standard: 40.000

∼

40.085 mm (1.5748

∼

1.5781 in.)

Service Limit: 40.30 mm (1.587 in.)

•

Inspect seals for damage.

If seals are damaged, replace the movable sheave.

If the splines [A] are damaged or worn, replace the fixed sheave.

If the spring is damaged or worn, replace the spring.

Spring Free Length [A]

Standard: 99 mm (3.9 in.)

If the spring coils are distorted, replace the spring.

Driven Pulley Assembly

•

Clean off any grease or dirt on the movable and fixed sheaves, and dry them with a clean cloth.

•

Install:

Spacers [A] (see Converter Drive Belt Deflection Adjustment in the Periodic Maintenance chapter)

Driven Pulley

•

Apply grease to the oil seal lips [A].

•

Press the oil seals [B] in the movable sheave assembly so that the oil seal surface is flush [C] with the sleeve end.

•

Apply [D] grease (WR500-No.2 (KYODO YUSHI),

POWER LITE WR #2 (KYODO YUSHI), or SERAN-HV

(TOTAL FINA)) to the inner surfaces of the busings.

CONVERTER SYSTEM 6-29

•

Align the paint mark “0” [A] on the movable sheave [B] with the point [C] on the fixed sheave [D] for phase fit of the sheaves.

○

In that case the opening [A] and hole [B] will be matched easily.

•

Apply grease (WR500-No.2 (KYODO YUSHI), POWER

LITE WR #2 (KYODO YUSHI), or SERAN-HV (TOTAL

FINA)) to the seating surface [A] of the pins, and insert them into the holes in the movable sheave.

•

Draw the movable sheave onto the fixed sheave, and apply grease of 1 g (0.035 oz) to all openings [A].

Grease — WR500-No.2 (KYODO YUSHI) or

POWER LITE WR #2 (KYODO YUSHI) or

SERAN-HV (TOTAL FINA)

NOTE

○

Do not heap up the grease out of the openings.

6-30 CONVERTER SYSTEM

Driven Pulley

•

Check that the O-rings [A] are in good condition.

If any of the O-rings are damaged, replace them.

•

Apply grease to the O-rings.

•

Hold the drive & driven pulley holder in a vise.

Special Tool — Drive & Driven Pulley Holder: 57001-1473

•

Screw the guide bar into the holder.

Special Tool — Spring Holder Set: 57001-1483

•

Put the driven pulley [A] onto the guide bar.

•

Put the thrust plate [B] so that the alloy side (gray) faces the movable sheave.

•

Install:

Spring Seat [C]: 18.5 mm (0.728 in.)

Spring [D]

Spring Seat [E]: 23.3 mm (0.917 in.)

Circlip [F]

•

Tighten the nut [A], and compress the spring with the spring holder [B].

•

Special Tool — Spring Holder Set: 57001-1483

•

Install a new circlip [C] with circlip pliers [D].

Special Tool — Outside Circlip Pliers: 57001-144

•

Remove the driven pulley from the spring holder set.

Clean the surface of the sheaves with an oil-less cleaning fluid.

•

Driven Pulley Installation

Clean the transmission driven shaft [A].

•

Install:

Driven Pulley

NOTE

○

When engaging the spline on the driven pulley with the spline [B] on the shaft, do not damage the pulley’s spline. If any damage occurs, remove it with a file.

Driven Pulley

•

Clean the threads of the driven shaft and driven pulley ends to open the air vent passage. Wipe off any extra grease.

○

Wipe off any protruding grease [A].

CONVERTER SYSTEM 6-31

•

Install two washers [A] on the shaft as shown.

Crankcase Side [B]

Bolt Head Side [C]

•

Using the flywheel & pulley holder [A] and attachments

[B], tighten the new driven pulley nut [C].

Special Tools — Flywheel & Pulley Holder: 57001-1605

Pulley Holder Attachment: 57001-1472

Torque — Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb)

ENGINE LUBRICATION SYSTEM 7-1

Engine Lubrication System

Table of Contents

Exploded View…………………………………………………………………………………………………………

Specifications ………………………………………………………………………………………………………….

Engine Oil Flow Chart……………………………………………………………………………………………….

Special Tools and Sealant …………………………………………………………………………………………

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 …………………………………………………………………………………………………………………..

7-13

Oil Pipe Removal ………………………………………………………………………………………………..

7-13

Oil Pipe Installation ……………………………………………………………………………………………..

7-14

7-10

7-10

7-10

7-11

7-11

7-11

7-7

7-7

7-8

7-8

7-8

7-10

7-2

7-4

7-5

7-6

7-7

7-7

7

7-2 ENGINE LUBRICATION SYSTEM

Exploded View

ENGINE LUBRICATION SYSTEM 7-3

Exploded View

No.

Fastener

1 Oil Filter

2 Oil Pressure Switch

3 Oil Pipe Bolts

4 Engine Oil Drain Plug

5 Oil Pressure Relief Valve

6 Oil Pump Cover Bolts

7 Chain Guide Bolt

8 Oil Pump Drive Chain Tensioner Bolt

9 Oil Filter Mounting Bolt

25

25

10 Plate Bolts 8.8

11. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).

20

15

8.8

8.8

N·m

17.5

15

8.8

Torque kgf·m

1.8

1.5

0.90

2.0

1.5

0.90

0.90

2.5

2.5

0.90

ft·lb

13

11

78 in·lb

15

11

78 in·lb

78 in·lb

18

18

78 in·lb

Remarks

R

SS

L

L (15 mm)

7-4 ENGINE LUBRICATION SYSTEM

Specifications

Engine Oil

Type

Viscosity

Capacity

Item Standard

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

2.4 L (2.5 US qt) (when filter is not removed)

2.5 L (2.6 US qt) (when filter is removed)

2.6 L (2.7 US qt) (when engine is completely dry)

Oil Pressure Measurement

Oil Pressure 515 kPa (5.3 kgf/cm², 74.7 psi) at 4 000 r/min (rpm), Oil

Temperature 120°C (248°F)

Engine Oil Flow Chart

ENGINE LUBRICATION SYSTEM 7-5

1. Front Camshaft

2. Oil Filter

3. Crankshaft

4. Oil Pressure Switch

5. Oil Pipes

6. Oil Pump

7. Relief Valve

8. Transmission Idle Shaft

9. Oil Screen

10. Transmission Driven Shaft

11. Rear Camshaft

12. Breather Hose

13. To Air Cleaner

7-6 ENGINE LUBRICATION SYSTEM

Special Tools and Sealant

Oil Pressure Gauge, 10 kgf/cm²:

57001-164

Liquid Gasket, TB1211:

56019-120

Oil Pressure Gauge Adapter, PT 1/8:

57001-1033

ENGINE LUBRICATION SYSTEM 7-7

Engine Oil and Oil Filter

WARNING

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.

Oil Level Inspection

•

Park the vehicle so that it is level, both side-to-side and front-to-rear.

If the oil has just been changed, start the engine, and run it for several minutes to fill the oil filter.

NOTICE

Allow the engine to idle for several minutes so that oil may reach all parts of the engine. Racing a «dry» engine may cause severe damage.

•

Stop the engine and wait several minutes for all the oil to drain back to the sump.

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Quick Rivets [A]

Heat Guard Plate [B]

•

Unscrew the oil filler cap [A], wipe its dipstick [B] dry, and tighten it into the filler opening.

•

Unscrew the oil filler cap and check the oil level. The oil level should be between the upper (H) and lower (L) level lines [C].

If the level is too high, suck the excess oil out the filler hole with a syringe or other suitable device.

If the level is too low, add oil through the filler hole. Use the same type and make of oil that is already in the engine.

Engine Oil Change

•

Refer to the Engine Oil Change in the Periodic Maintenance chapter.

Oil Filter Change

•

Refer to the Oil Filter Change in the Periodic Maintenance chapter.

7-8 ENGINE LUBRICATION SYSTEM

Engine Oil and Oil Filter

Oil Screen Removal

•

Split the crankcase (see Crankcase Disassembly in the

Crankshaft/Transmission chapter).

•

Pull the oil screen [A] out of the crankcase.

Oil Screen Cleaning

•

Clean the oil screen [A] thoroughly whenever it is removed for any reason.

•

Clean the oil screen with a high-flash point solvent and remove any particles stuck to it.

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the screen in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the screen.

NOTE

○

While cleaning the screen, check for any metal particles that might indicate internal engine damage.

•

Check the screen carefully for any damage, holes, broken wires, or gasket pulling off.

If the screen is damaged, replace it.

Oil Pressure Measurement

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Engine Bottom Guard (see Engine Bottom Guard Removal in the Frame chapter)

Water Pipe Bolts [A]

•

Remove:

Oil Pressure Switch Lead [A] (disconnect)

Oil Pressure Switch [B]

ENGINE LUBRICATION SYSTEM 7-9

Engine Oil and Oil Filter

•

Attach the oil pressure gauge adapter [A] and gauge hose

[B] to the engine.

Special Tools — Oil Pressure Gauge, 10 kgf/cm²: 57001-164

Oil Pressure Gauge Adapter, PT 1/8: 57001

-1033

•

Start the engine and warm up the engine.

•

Run the engine at the specified speed, and read the oil pressure gauge [A].

Oil Pressure

Standard: 515 kPa (5.3 kgf/cm², 74.7 psi) @4 000 r/min (rpm), Oil Temperature 120°C

(248°F)

If the oil pressure is much lower than the standard, inspect the relief valve, oil pump, and/or crankshaft bearing insert wear.

If the oil pressure is much higher than the standard, inspect the oil filter, oil screen, and other areas of the lubri-

• cation system for clogging.

Stop the engine.

•

Remove the oil pressure gauge and adapter.

WARNING

Hot oil can cause severe burns. Beware of hot engine oil that will drain through the oil passage when the gauge adapter is removed.

•

Apply silicone sealant to the oil pressure switch, and tighten it.

Sealant — Liquid Gasket, TB1211: 56019-120

Torque — Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

7-10 ENGINE LUBRICATION SYSTEM

Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal

•

Split the crankcase (see Crankcase Disassembly in the

Crankshaft/Transmission chapter).

•

Remove the oil pressure relief valve [A].

Oil Pressure Relief Valve Installation

•

See crankcase assembly (see Crankcase Assembly in the Crankshaft/Transmission chapter).

•

Apply a non-permanent locking agent to the threads of oil pressure relief valve, and tighten it.

Torque — Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb)

•

Oil Pressure Relief Valve Inspection

Remove the relief valve.

•

Using a wooden stick, push the inner valve to make sure that the valve [A] moves smoothly and that it returns to its original position by the force of the spring [B].

NOTE

○

The relief valve cannot be disassembled and it must be inspected in the assembled state.

If the valve movement is not smooth, wash the relief valve with high-flash point solvent, and use compressed air to remove any foreign particles from it.

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns.

Clean the oil pressure relief valve in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the oil pressure relief valve.

If the valve does not move smoothly even after washing it, replace the relief valve. The oil pressure relief valve is precision made with no allowance for replacement of individual parts.

ENGINE LUBRICATION SYSTEM 7-11

Oil Pump

Oil Pump Removal

•

Remove:

Alternator Rotor and Starter Clutch Gear (see Alternator

Rotor Removal in the Electrical System chapter)

Oil Pump Drive Chain Tensioner Bolt [A]

Chain Guide Bolt [B] and Collar

Chain Guide [C]

•

Remove:

Oil Pump Bolts [A]

Oil Pump Drive Chain [B] and Oil Pump Assembly [C]

•

Remove:

Circlip [A]

Inner Rotor [B]

Outer Rotor [C]

Oil Pump Drive Shaft [D]

Oil Pump Cover [E]

Oil Pump Installation

•

Apply engine oil:

Oil Pump Drive Shaft

Inner and Outer Rotors

•

Install:

Oil Pump Drive Shaft

Oil Pump Cover

Inner Rotor

Outer Rotor

New Circlip

•

Check to see that the dowel pins [A] are in place.

•

Apply engine oil in the oil pump housing.

7-12 ENGINE LUBRICATION SYSTEM

Oil Pump

•

Install the oil pump drive chain [A] with the oil pump assembly [B].

•

Tighten:

Torque — Oil Pump Cover Bolts [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install:

Chain Guide [A] and Collar [B]

•

Tighten:

Torque — Chain Guide Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Apply grease to the O-ring [A].

•

Install:

Pin [B]

Spring [C]

O-ring

Oil Pump Drive Chain Tensioner Bolt [D]

•

Tighten:

Torque — Oil Pump Drive Chain Tensioner Bolt: 25 N·m (2.5

kgf·m, 18 ft·lb)

ENGINE LUBRICATION SYSTEM 7-13

Oil Pipe

Oil Pipe Removal

Engine Left Side Oil Pipe (Engine Outside)

•

Drain:

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)

•

Remove:

Left Cover (see Left Cover Removal in the Frame chapter)

Engine Bottom Guard (see Engine Bottom Guard Removal in the Frame chapter)

Oil Pipe Bolts [A]

Oil Pipe [B]

Engine Left Side Oil Pipe (Engine Inside)

•

Remove:

Alternator Cover (see Alternator Cover Removal in the

Electrical System chapter)

Oil Pump (see Oil Pump Removal)

Oil Pipe Bolts [A]

Oil Pipe [B]

Engine Right Side Oil Pipe

•

Remove:

Drive Pulley (see Drive Pulley Removal in the Converter

System chapter)

Plate Bolts [A]

Plate [B]

•

Remove:

Oil Pipe Bolt [A]

Oil Pipe [B]

7-14 ENGINE LUBRICATION SYSTEM

Oil Pipe

Engine Inside Oil Pipe

•

Remove:

Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter)

Oil Pipe [A]

•

Oil Pipe Installation

•

Replace the O-rings [A] with new ones if they are damaged.

•

Apply engine oil to the O-rings before installation.

Tighten:

Torque — Oil Pipe Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

ENGINE REMOVAL/INSTALLATION 8-1

Engine Removal/Installation

Table of Contents

Exploded View…………………………………………………………………………………………………………

Engine Removal/Installation ………………………………………………………………………………………

Engine Removal………………………………………………………………………………………………….

Engine Installation……………………………………………………………………………………………….

8-2

8-4

8-4

8-6

8

8-2 ENGINE REMOVAL/INSTALLATION

Exploded View

Exploded View

No.

Fastener

1 Engine Bracket Pipe Mounting Nuts

2 Engine Mounting Bolt

3 Engine Mounting Nut

R: Replacement Parts

ENGINE REMOVAL/INSTALLATION 8-3

N·m

41.5

60.1

60.1

Torque kgf·m

4.2

6.1

6.1

ft·lb

31

44

44

Remarks

R

R

8-4 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

Engine Removal

•

Drain:

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)

Coolant (see Coolant Change in the Periodic Maintenance chapter)

•

Remove:

Bars (If required) (see Bars Removal in the Frame chapter)

Air Cleaner Housing and Duct (see Air Cleaner Housing and Duct Removal in the Fuel System chapter)

Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)

Right Frame Pipe (see Right Frame Pipe Removal in the

Frame chapter)

Shift Lever (see Shift Lever Removal in the Crankshaft/Transmission chapter)

Center Bracket (see Center Bracket Removal in the

Frame chapter)

Muffler and Exhaust Pipe (see Muffler and Exhaust Pipe

Removal in the Engine Top End chapter)

Front Propeller Shaft (see Front Propeller Shaft Removal in the Final Drive chapter)

Rear Propeller Shaft (see Rear Propeller Shaft Removal in the Final Drive chapter)

Torque Converter Outlet Duct (see Torque Converter

Cover Removal in the Converter System chapter)

•

Remove:

Neutral Switch Lead Connector [A]

Reverse Switch Lead Connector [B]

Forward/Reverse Detecting Sensor Lead Connector [C]

•

Remove:

Alternator Lead Connectors [A]

Crankshaft Sensor Lead Connector [B]

Engine Removal/Installation

•

Remove:

Engine Ground Lead Terminal [A]

Oil Pressure Switch Lead Connector [B]

Starter Motor Cable [C]

Water Hose [D]

ENGINE REMOVAL/INSTALLATION 8-5

•

Remove:

Water Pipes [A] and Thermostat Housing

Torque Converter Intake Duct [B]

Engine Brake Actuator Lead Connector [C]

•

Remove:

Speed Sensor Connector [A]

•

Remove:

Bolts [A]

Plate [B]

•

Hold the engine with a lifter [A].

•

Remove:

Engine Mounting Bolt and Nut [B]

Engine Mounting Bolt [C]

8-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

•

Remove:

Engine [A]

Engine Installation

•

When installing the engine bracket pipes [A], note the following.

•

Install the red painted dampers [B] (part number stamped:

92161-0571) and cover [C] at the front left position.

○

Touch the projection of the cover to the bracket of front side.

•

Install:

No Painted Dampers [D]

•

Replace the engine bracket pipe mounting nuts [A] with new ones.

•

Tighten:

Torque — Engine Bracket Pipe Mounting Nuts [A]: 41.5 N·m

(4.2 kgf·m, 31 ft·lb)

Front Engine Bracket Pipe [B]

Rear Engine Bracket Pipe [C]

•

Install:

Engine

Rear Engine Mounting Bolt [A]

Front Engine Mounting Bolt and Nut [B]

○

Insert the front engine mounting bolt from right side.

•

Tighten:

Torque — Engine Mounting Bolt and Nut : 60.1 N·m (6.1

•

kgf·m, 44 ft·lb)

Install the removed parts.

•

Adjust:

Throttle Cable (see Throttle Pedal Free Play Adjustment in the Periodic Maintenance chapter)

Differential Control Cable (see Differential Control Lever

Free Play Adjustment in the Periodic Maintenance chapter)

CRANKSHAFT/TRANSMISSION 9-1

Crankshaft/Transmission

Table of Contents

Exploded View…………………………………………………………………………………………………………

Specifications ………………………………………………………………………………………………………….

Special Tools and Sealant …………………………………………………………………………………………

Crankcase ………………………………………………………………………………………………………………

Crankcase Disassembly ………………………………………………………………………………………

Crankcase Assembly …………………………………………………………………………………………..

9-9

Crankshaft/Connection Rod ………………………………………………………………………………………

9-13

Crankshaft Removal ……………………………………………………………………………………………

9-13

Crankshaft Installation …………………………………………………………………………………………

Connecting Rod Removal …………………………………………………………………………………….

Connecting Rod Installation ………………………………………………………………………………….

9-13

9-13

9-13

9-2

9-6

9-8

9-9

9-9

Crankshaft/Connecting Rod Cleaning…………………………………………………………………….

Connecting Rod Bend Inspection ………………………………………………………………………….

Connecting Rod Twist Inspection…………………………………………………………………………..

Connecting Rod Big End Side Clearance Inspection………………………………………………..

Connecting Rod Big End Bearing/Crankpin Wear Inspection…………………………………….

Crankshaft Runout Inspection……………………………………………………………………………….

Crankshaft Main Bearing/Journal Wear Inspection…………………………………………………..

9-17

Transmission …………………………………………………………………………………………………………..

9-18

Shift Lever Removal (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ……………………….

9-18

Shift Lever Installation (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) …………………….

Shift Lever Removal (KRF750ND/PD/RD/SD)…………………………………………………………

9-19

9-23

Shift Lever Installation (KRF750ND/PD/RD/SD)………………………………………………………

9-25

9-14

9-14

9-14

9-15

9-15

9-17

Transmission Removal ………………………………………………………………………………………..

Transmission Installation ……………………………………………………………………………………..

Shift Fork Bending Inspection ……………………………………………………………………………….

9-27

9-28

9-30

Shift Fork/Gear and Shifter Groove Wear Inspection ……………………………………………….

Transmission and Shift Mechanism Inspection………………………………………………………..

9-31

9-31

Ball Bearing, Needle Bearing, and Oil Seal………………………………………………………………….

9-33

Ball and Needle Bearing Replacement …………………………………………………………………..

Ball and Needle Bearing Wear Inspection ………………………………………………………………

Oil Seal Inspection ………………………………………………………………………………………………

9-33

9-33

9-33

9

9-2 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 9-3

Exploded View

No.

Fastener

N·m

Torque kgf·m ft·lb

Remarks

1

2

3

4

5

6

7

8

9

Connecting Rod Big End Cap

Nuts (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Connecting Rod Big End Cap Nuts

(KRF750ND/PD/RD/SD)

Engine Oil Drain Plug

Crankcase Bolts (M8), L = 75 mm (2.95 in.)

Crankcase Bolts (M8), L = 110 mm (4.33 in.)

Crankcase Bolt (M8), L = 110 mm (4.33 in.)

Crankcase Bolts (M6), L = 40 mm (1.57 in.)

Crankcase Bolts (M6), L = 65 mm (2.56 in.)

Bearing Position Plate Screws

10 Rear Cylinder Camshaft Chain Guide Bolt

34.3

36

9.8

9.8

4.9

20

20

20

20

20

3.5

3.7

2.0

2.0

2.0

2.0

1.0

1.0

0.50

2.0

25

27

15

15

15

15

87 in·lb

87 in·lb

43 in·lb

15

MO

MO

S

S

S, L (1)

L

11. About 12 mm (0.47 in.)

12. Do not apply a non-permanent locking agent to this area (2

∼

3 mm, 0.08

∼

0.12 in.)

13. Face the seal of the bearing to the left side (outward).

14. White Mark: Align the white mark with the crankcase mark.

15. Left Crankcase

16. Right Crankcase

17. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

LG: Apply liquid gasket (Liquid Gasket, TB1216: 92104-1063).

M: Apply molybdenum disulfide grease.

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.

9-4 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 9-5

Exploded View

No.

1 Grip Hold Nut

2

3

Fastener

Tie-rod End Locknut

Shift Lever Assembly Nut

4 Tie-rod End Bolt

5 Tie-rod End Front Locknut

6

7

Tie-rod End Rear Locknut

Tie-rod End Nut

8 Shift Shaft Lever Bolt

9 Shift Shaft Cover Bolts

10

11

Shift Shaft Positioning Bolt

Neutral Position Switch

12 Reverse Position Switch

13 Shift Shaft Spring Bolt

14

15

Stopper Mounting Bolts

Shift Lever Guide Bolt

16 Shift Lever Pivot Nut

17 Shift Lever Bracket Bolt , L = 25 mm (0.98 in.)

18 Shift Lever Bracket Bolts , L = 20 mm (0.79 in.)

19 Front Tie-rod End

N·m

9.8

19.6

19.6

9.8

9.8

9.8

19.6

13.5

8.8

25

15

15

31

9.8

8.8

8.8

19.6

19.6

9.8

Torque kgf·m

1.0

2.0

2.0

1.0

1.0

1.0

2.0

1.4

0.90

2.5

1.5

1.5

3.2

1.0

0.90

0.90

2.0

ft·lb

87 in·lb

14

14

87 in·lb

87 in·lb

87 in·lb

14

10

78 in·lb

18

11

11

23

87 in·lb

78 in·lb

78 in·lb

14

14

87 in·lb

Remarks

R

Lh

R

LB

L

L

R

L

L 2.0

1.0

20 Stopper Spring Bolt 26 2.7

19

21. Do not apply a non-permanent locking agent to this end.

22. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

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

Lh: Left-hand Threads

M: Apply molybdenum disulfide grease.

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

R: Replacement Parts

9-6 CRANKSHAFT/TRANSMISSION

Specifications

Item

Crankshaft, Connecting Rods

Connecting Rod Bend – – –

Standard

Connecting Rod Twist – – –

Connecting Rod Big End Side Clearance

Connecting Rod Big End Bearing Insert/Crankpin

Clearance

Crankpin Diameter:

0.16

∼

0.46 mm

(0.0063

∼

0.0181 in.)

0.028

∼

0.052 mm

(0.0011

∼

0.0020 in.)

39.984

∼

40.000 mm

(1.5742

∼

1.5748 in.)

Marking:

None

○

Connecting Rod Big End Inside Diameter:

39.984

∼

39.992 mm

(1.5742

∼

1.57449 in.)

39.993

∼

40.000 mm

(1.57452

∼

1.5748 in.)

43.000

∼

43.016 mm

(1.6929

∼

1.6935 in.)

Marking:

None

○

43.000

∼

43.008 mm

(1.6929

∼

1.69322 in.)

43.009

∼

43.016 mm

(1.69326

∼

1.6935 in.)

Connecting Rod Big End Bearing Insert Thickness:

Brown

Yellow

Green

1.482

∼

1.486 mm

(0.05835

∼

0.05850 in.)

1.486

∼

1.490 mm

(0.05850

∼

0.05866 in.)

1.490

∼

1.494 mm

(0.05866

∼

0.05882 in.)

Connecting Rod Big End Bearing Insert Selection:

– – –

– – –

– – –

– – –

– – –

Con-rod Big End Bore

Diameter Marking

None

None

○

○

Crankpin Diameter

Marking

○

None

○

None

Crankshaft Runout

Crankshaft Main Journal Diameter

Crankshaft Main Bearing Bore Diameter

Bearing Insert

Size Color Part Number

Brown 92028-1963

Yellow

Green

92028-1962

92028-1961

TIR 0.04 mm (0.0016 in.) or less

41.984

∼

42.000 mm

(1.6529

∼

1.6535 in.)

42.025

∼

42.041 mm

(1.6545

∼

1.6552 in.)

TIR 0.10 mm

(0.0039 in.)

41.96 mm

(1.6520 in.)

42.07 mm

(1.6563 in.)

Service Limit

TIR 0.2/100 mm

(0.008/3.94 in.)

TIR 0.2/100 mm

(0.008/3.94 in.)

0.7 mm

(0.028 in.)

0.09 mm

(0.0035 in.)

39.97 mm

(1.5736 in.)

– – –

– – –

– – –

Specifications

Item

Transmission

Shift Fork Ear Thickness

Shifter Groove Width

CRANKSHAFT/TRANSMISSION 9-7

Standard

5.9

∼

6.0 mm

(0.2323

∼

0.2362 in.)

6.05

∼

6.15 mm

(0.2382

∼

0.2421 in.)

Service Limit

5.8 mm

(0.2283 in.)

6.25 mm

(0.2461 in.)

9-8 CRANKSHAFT/TRANSMISSION

Special Tools and Sealant

Outside Circlip Pliers:

57001-144

Crankshaft Jig:

57001-1174

Bearing Driver Set:

57001-1129

Liquid Gasket, TB1216:

92104-1063

CRANKSHAFT/TRANSMISSION 9-9

Crankcase

Crankcase Disassembly

•

Remove:

Engine (see Engine Removal in the Engine Removal/Installation chapter)

Starter Motor (see Starter Motor Removal in the Electrical System chapter)

Oil Filter (see Oil Filter Replacement in the Periodic

Maintenance chapter)

Cylinder Blocks and Pistons (see Cylinder and Piston

Removal in the Engine Top End chapter)

Intermediate Shaft and Chains (see Camshaft Chain Removal in the Engine Top End chapter)

Right Crankcase Bolt (M6) [A]

Right Crankcase Bolts (M8) [B]

•

Remove:

Shift Shaft Positioning Bolt [A], Washer, Spring, and

Steel Ball

Left Crankcase Bolts (M6) [B]

Left Crankcase Bolts (M8) [C]

•

Wrap the teeth on the sprockets [A] by taping for protecting the bushing in the crankcase.

•

Using the pry points [B], split the crankcase halves.

•

Lift off the left crankcase half.

Crankcase Assembly

NOTICE

The right and left crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.

NOTE

○

Be certain that all parts are cleaned thoroughly before assembly.

○

Blow through all oil passages with compressed air to clear any blockage in the crankcase halves and crankshaft.

WARNING

Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or low-flash point solvents to clean parts. A fire or explosion could result.

9-10 CRANKSHAFT/TRANSMISSION

Crankcase

•

Press and insert the new ball bearings until they are bottomed.

Special Tool — Bearing Driver Set: 57001-1129

[A] Ball Bearing

[B] Ball Bearing (sealed side towards crankcase)

•

Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole.

[C] Needle Bearing

•

[D] Needle Bearing (Insert it from outside.)

Apply engine oil to the bearings.

•

Install:

Oil Pressure Relief Valve [E] (see Oil Pressure Relief

Valve Installation in the Engine Lubrication System chapter)

•

Install:

Rear Cylinder Camshaft Chain Guide [A]

•

Tighten:

Torque — Rear Cylinder Camshaft Chain Guide Bolt [B]: 20

N·m (2.0 kgf·m, 15 ft·lb)

•

Press and insert the new ball bearings [A] until they are bottomed.

○

When install the crankshaft bearing, the stepped side faces engine inside.

Special Tool — Bearing Driver Set: 57001-1129

•

Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole.

[B] Needle Bearing

[C] Needle Bearing (Insert it from outside.)

•

Apply engine oil to the bearings.

•

Install:

Plates [A]

Bearing Position Plate Screws [B]

•

Tighten:

Torque — Bearing Position Plate Screws: 4.9 N·m (0.50

kgf·m, 43 in·lb)

CRANKSHAFT/TRANSMISSION 9-11

Crankcase

•

Be sure the following parts are in place in the right crankcase half.

Crankshaft

Transmission Shafts and Shift Rod [A]

Spacers [B]

Oil Tube [C]

Oil Screen [D]

O-ring [E] (Apply Grease)

Dowel Pins [F]

•

Apply liquid gasket [A] to mating surface of the left crankcase half.

Sealant — Liquid Gasket, TB1216: 92104-1063

•

Apply a non-permanent locking agent to the area [C] (12 mm, 0.47 in.) except for the tip [D] (2

∼

3 mm, 0.08

∼

0.12

in.).

Left Crankcase Bolt (M8) [3]

•

Tighten the right and left crankcase bolts (M8) following the tightening sequence [1

∼

8].

Torque — Crankcase Bolts (M8): 20 N·m (2.0 kgf·m, 15 ft·lb)

[1, 2, 5, 6] L = 75 mm (2.95 in.)

[3, 4, 7, 8] L = 110 mm (4.33 in.)

•

Tighten:

Torque — Crankcase Bolts (M6): 9.8 N·m (1.0 kgf·m, 87 in·lb)

[A] L = 40 mm (1.57 in.)

[B] L = 65 mm (2.56 in.)

•

Grease the lip [A] of the oil seal [B] and press the seal 3 mm (0.12 in.) [C] inwards from the end of the boss.

9-12 CRANKSHAFT/TRANSMISSION

Crankcase

•

Install the breather tube [A] on the crankcase fitting.

○

Align the white line on the tube with the mark [B] on the crankcase.

○

Face the open end of the clamp [C] towards the left side

[D] as shown.

•

Apply grease to the steel ball [A] and spring [B].

•

Install:

Steel Ball

Spring

Washer [C]

Shift Shaft Positioning Bolt [D]

•

Tighten:

Torque — Shift Shaft Positioning Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Check:

Crankshaft and driven shaft turn freely.

If any of the shafts do not turn freely, split the crankcase to locate the problem.

CRANKSHAFT/TRANSMISSION 9-13

Crankshaft/Connection Rod

•

Crankshaft Removal

Split the crankcase (see Crankcase Disassembly).

•

Remove the crankshaft [A] from the crankcase using a press.

•

Crankshaft Installation

•

The left shaft [A] of the crankshaft is longer than the right shaft [B].

•

Apply engine oil to the both main journals.

Insert the right crankshaft tapered end (the shorter end) into the right crankcase using a press and two crankshaft jigs.

Special Tools — Crankshaft Jig: 57001-1174 × 2

•

Connecting Rod Removal

Remove the crankshaft (see Crankshaft Removal).

•

Remove the connecting rods [A] from the crankshaft.

NOTE

○

Mark and record the locations of the connecting rods and their big end caps [B] so that they can be installed in their original positions.

○

Remove the connecting rod big end nuts, and take off the rod and cap with the bearing inserts.

Connecting Rod Installation

NOTICE

If the connecting rods, bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage before assembling the engine to be sure the correct bearing inserts are installed.

•

Apply molybdenum disulfide oil:

Inner Surface [A] of Bearing Inserts

•

Face the “OUT” marks [B] of both connecting rods towards the outsides of the crankshaft.

•

Fit the connecting rod cap so that the grooves [C] of the cap and connecting rod are on the same side.

9-14 CRANKSHAFT/TRANSMISSION

Crankshaft/Connection Rod

•

Apply molybdenum disulfide oil:

Threads [A] of Connecting Rod Big End Cap Bolts

Seating Surface [B] of Connecting Rod Big End Cap

Nuts [C]

•

Tighten:

Torque — Connecting Rod Big End Cap Nuts

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC):

34.3 N·m (3.5 kgf·m, 25 ft·lb)

Connecting Rod Big End Cap Nuts

(KRF750ND/PD/RD/SD): 36 N·m (3.7 kgf·m, 27 ft·lb)

Crankshaft/Connecting Rod Cleaning

•

After removing the connecting rods from the crankshaft, clean them with a high flash-point solvent.

•

Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.

Connecting Rod Bend Inspection

•

Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap.

•

Select an arbor [A] of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end.

•

Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor

•

[B] through the connecting rod small end.

On a surface plate, set the big-end arbor on a V block [C].

•

With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend.

If connecting rod bend exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Bend

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Twist Inspection

•

With the big-end arbor [A] still on the V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel with the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist.

If connecting rod twist exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Twist

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

CRANKSHAFT/TRANSMISSION 9-15

Crankshaft/Connection Rod

Connecting Rod Big End Side Clearance

Inspection

•

Measure the side clearance of the connecting rod big end

[A].

○

Insert a thickness gauge [B] between the big end and either crank web to determine clearance.

Connecting Rod Big End Side Clearance

Standard: 0.16

∼

0.46 mm (0.0063

∼

0.0181 in.)

Service Limit: 0.7 mm (0.028 in.)

If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again.

If clearance is too large after connecting rod replacement, the crankshaft also must be replaced.

Connecting Rod Big End Bearing/Crankpin Wear

Inspection

•

Measure the bearing insert/crankpin [A] clearance with plastigage [B].

○

Tighten the big end cap nuts to the specified torque.

Torque — Connecting Rod Big End Cap Nuts: 34.3 N·m (3.5

kgf·m, 25 ft·lb)

NOTE

○

Do not move the connecting rod and crankshaft during clearance measurement.

Connecting Rod Big End Bearing Insert/Crankpin

Clearance

Standard: 0.028

∼

0.052 mm (0.0011

∼

0.0020 in.)

Service Limit: 0.09 mm (0.0035 in.)

If the clearance is within the standard, no bearing insert replacement is required.

If the clearance is between 0.052 mm (0.0020 in.) and the service limit 0.09 mm (0.0035 in.), replace the bearing inserts [A] with inserts painted green [B]. Check insert/crankpin clearance with plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.

If the clearance exceeds the service limit, measure the diameter of the crankpin.

Crankpin Diameter

Standard: 39.984

∼

40.000 mm (1.5742

∼

1.5748 in.)

Service Limit: 39.97 mm (1.5736 in.)

If the crankpin has worn past the service limit, replace the crankshaft with a new one.

9-16 CRANKSHAFT/TRANSMISSION

Crankshaft/Connection Rod

If the measured crankpin diameter [A] is not less than the service limit, but does not coincide with the original diameter marking on the crankshaft, make a new mark on it.

Crankpin Diameter Marks

None: 39.984

∼

39.992 mm (1.5742

∼

1.57449 in.)

○

:

39.993

∼

40.000 mm (1.57452

∼

1.5748 in.)

Crankpin Diameter Mark [B]: “

○

” mark or no mark

•

Measure the connection rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter.

•

Tighten the big end nuts to the specified torque.

Torque — Connecting Rod Big End Cap Nuts: 34.3 N·m (3.5

kgf·m, 25 ft·lb)

NOTE

○

The mark already on the big end should almost coincide with the measurement because of little wear.

Connecting Rod Big End Inside Diameter Marks

None: 43.000

∼

43.008 mm (1.6929

∼

1.69322 in.)

○

:

43.009

∼

43.016 mm (1.69326

∼

1.6935 in.)

Diameter Mark [A]: “

○

” or no mark

•

Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding.

Size Color [B]

Big End Bearing Insert Selection

Con-rod Big

End Bore

Diameter Mark

Crankpin

Bearing Insert

Diameter Mark

Size Color Part Number

None

○

Brown 92028-1963

None

○

○

None

○

None

Yellow

Green

92028-1962

92028-1961

•

Install the new inserts in the connecting rod and check insert/crankpin clearance with the plastigage.

CRANKSHAFT/TRANSMISSION 9-17

Crankshaft/Connection Rod

Crankshaft Runout Inspection

•

Measure the crankshaft runout.

If the measurement exceeds the service limit, replace the crankshaft.

Crankshaft Runout

Standard: TIR 0.04 mm (0.0016 in.) or less

Service Limit: TIR 0.10 mm (0.0039 in.)

Crankshaft Main Bearing/Journal Wear Inspection

•

Measure the diameter [A] of the crankshaft main journal.

Crankshaft Main Journal Diameter

Standard: 41.984

∼

42.000 mm (1.6529

∼

1.6535 in.)

Service Limit: 41.96 mm (1.6520 in.)

If any journal has worn past the service limit, replace the crankshaft with a new one.

•

Measure the main bearing bore diameter [A] in the crankcase halves.

Crankcase Main Bearing Bore Diameter

Standard: 42.025

∼

42.041 mm (1.6545

∼

1.6552 in.)

Service Limit: 42.07 mm (1.6563 in.)

If there is any signs of seizure, damage, or excessive wear, replace the crankcase halves as a set.

9-18 CRANKSHAFT/TRANSMISSION

Transmission

Shift Lever Removal (KRF750NA/PA/RA/SA/TA

NC/PC/RC/SC/VC)

•

Set the shift lever in the neutral position.

•

Remove:

∼

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Shift Shaft Lever Bolt [A]

•

Remove the shift shaft lever [B] from the shift shaft.

•

Remove:

Grip [A]

Grip Hold Nut [B]

•

Remove:

Spring [A]

Ratchet Assembly Bolts [B]

•

Remove:

Allen Bolts [A]

•

Move the ratchet [B] and bracket [C] forward.

•

Remove:

Shift Lever Assembly Nut [D]

•

Remove:

Tie-rod End Bolt [A]

Tie-rod [B]

Spring [C]

CRANKSHAFT/TRANSMISSION 9-19

Transmission

•

Remove:

Oil Seals [A]

Collar [B]

Shift Lever Installation (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Twist the tie-rod end [A] and tie-rod end locknut [B] to bottom of the screw and then turn back the tie-rod end to dimension with 94° ±10° [C] as shown in the figure.

•

Tighten the locknut against the tie-rod end:

Torque — Tie-rod End Locknut: 19.6 N·m (2.0 kgf·m, 14 ft·lb)

9-20 CRANKSHAFT/TRANSMISSION

Transmission

•

Align the mark [A] on the shaft end with the slit [B] of the shift shaft lever.

•

Position the shift shaft lever end [C] on the boss-center

[D] of the crankcase as shown in the figure.

•

Tighten:

Torque — Shift Shaft Lever Bolt [E]: 13.5 N·m (1.4 kgf·m, 10 ft·lb)

•

Install:

Shift Lever Assembly [F]

Spring [G] (to Shift Lever Assembly)

Washer [H]

Shift Lever Assembly Nut [I]

•

Tighten:

Torque — Shift Lever Assembly Nut: 19.6 N·m (2.0 kgf·m, 14

•

Install:

Tie-rod [J]

ft·lb)

•

Tighten:

Torque — Tie-rod End Nut [K]: 19.6 N·m (2.0 kgf·m, 14 ft·lb)

•

Turn the tie-rod until the upper tie-rod end [L] will be adjusted to hole [M] of the shift lever assembly as shown in the figure.

○

The connection length of the upper and lower tie-rod end

[N] should be equal.

CRANKSHAFT/TRANSMISSION 9-21

Transmission

•

Apply molybdenum disulfide grease to the collar [A].

•

Install the following parts to the shift lever assembly [B].

Oil Seals [C]

Tie-rod End Bolt [D]

•

Tighten:

Torque — Tie-rod End Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Turn the tie-rod [E] and align the lever [F] with neutral position of the guide [G] as shown in the figure.

9-22 CRANKSHAFT/TRANSMISSION

Transmission

•

Tighten the tie-rod end rear locknut [A] so that the thread length is 6 mm (0.24 in.) [B].

Torque — Tie-rod End Rear Locknut: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Holding the rear tie-rod end [C], and tighten the front locknut [D] so that the thread length is 6 mm (0.24 in.) [B].

Torque — Tie-rod End Front Locknut: 9.8 N·m (1.0 kgf·m, 87 in·lb)

NOTE

○

The front locknut has left-hand threads.

○

The thread length [B] of the front and rear are almost same.

○

Do not lean the tie-rod rear end after tightening the front locknut.

Right [E]

•

Wrong [F]

Install the lower end of the spring [G] to the bracket.

•

Confirm the lever [H] does not scrub the ditch of guide excessively, when the lever leaned to right side [I].

Clearance [J] 0 mm (0 in.)

8 mm (0.31 in.) [K]

18 mm (0.71 in.) [L]

Lighting Range [M] of Neutral Indicator Light

•

If the excessive friction [N] occurs to the lever and the ditch of guide, readjust the thread length of the tie-rod.

Good [O]

Readjustment [P]

•

Tighten the grip hold nut [Q] lightly by finger until it is stopped.

•

Twist the grip [R] to bottom of the screw and then turn back in accordance with the direction of figure.

○

In view of [S], the mark [T] becomes the position of figure.

•

Hold the grip and tighten the grip hold nut.

Torque — Grip Hold Nut: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Transmission

CRANKSHAFT/TRANSMISSION 9-23

•

Shift Lever Removal (KRF750ND/PD/RD/SD)

Set the shift lever in the neutral position.

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Air Outlet Duct (see Torque Converter Cover Removal in the Converter System chapter)

Shift Shaft Lever Bolt [A]

•

Remove the shift shaft lever [B] from the shift shaft.

•

Remove:

Screw [A] and Collar

Grip [B]

•

Cut the bands [A], and remove the cover [B].

9-24 CRANKSHAFT/TRANSMISSION

Transmission

•

Remove:

Screw [A] and Collar

•

Clear the tab [B], and remove the shift shaft cover [C].

•

Remove:

Shift Lever Bracket Bolts [A]

•

Remove the shift lever assembly [B] forward [C].

•

Remove:

Stopper Spring Bolt [A]

Shift Lever Guide Bolt [B] and Collar [C]

•

Shift Lever Pivot Bolt [D] and Nut [E]

Separate the shift lever [F] and bracket [G].

•

Remove:

Stopper Mounting Bolts [H]

Stopper [I]

Spring [J]

Spring Seat [K]

Roller [L]

Bushings [M]

Collar [N]

•

Remove the tie-rod assy from the shift lever.

NOTE

○

The tie-rod end front locknut and front tie-lod end have left-hand threads.

•

Loosen:

Tie-rod End Front Locknut [A]

Tie-rod End Rear Locknut [B]

•

Remove:

Front Tie-rod End [C]

Rear Tie-rod End [D]

Tie-rod [E]

Tie-rod End Nut [F]

Shift Shaft Lever [G]

CRANKSHAFT/TRANSMISSION 9-25

Transmission

Shift Lever Installation (KRF750ND/PD/RD/SD)

•

Apply a non-permanent locking agent to the stopper mounting bolts and shift lever guide bolt.

•

Replace shift lever pivot nut with a new one.

•

Assemble the shift lever and shift lever bracket in the reverse order of removal.

•

Tighten:

Torque — Stopper Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Shift Lever Guide Bolt: 8.8N·m (0.90 kgf·m, 78 in·lb)

Shift Lever Pivot Nut: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Stopper Spring Bolt: 26 N·m (2.7 kgf·m, 19 ft·lb)

•

Install the tie-rod [A] into the bottom of the front tie-rod end [B] (left-hand threads) and rear tie-rod end [C].

•

Install the front tie-rod end to the shift lever assy [D].

•

Tighten:

Torque — Front Tie-rod End: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Replace the tie-rod end nut [E] with a new one.

•

Install the rear tie-rod end to shift shaft lever [F].

•

Tighten:

Torque — Tie-rod End Nut: 19.6 N·m (2.0 kgf·m, 14 ft·lb)

•

Apply a non-permanent locking agent to the shift lever bracket bolts.

•

Install the shift lever assy to the frame.

•

Tighten:

Torque — Shift Lever Bracket Bolt, L = 25 mm (0.98 in.) [G]:

19.6 N·m (2.0 kgf·m, 14 ft·lb)

Shift Lever Bracket Bolts, L = 20 mm (0.79 in.) [H]:

19.6 N·m (2.0 kgf·m, 14 ft·lb)

9-26 CRANKSHAFT/TRANSMISSION

Transmission

•

Place the shift lever in neutral position [A].

•

Hold the rear tie-rod end [B] and the shift shaft lever [C], and turn the tie-rod [D] so that both thread lengths of the tie-rod ends are almost same.

•

Hold the rear tie-rod end and the shift shaft lever, and turn the tie-rod so that the slit [E] of the shift shaft lever align

• with the mark [F] on the shaft end.

Install the shift shaft lever to the shaft end.

•

Tighten:

Torque — Shift Shaft Lever Bolt [G]: 13.5 N·m (1.4 kgf·m, 10

•

ft·lb)

Turn the ignition switch on.

•

Confirm that the neutral and reverse indication on multifunction meter matches the neutral and reverse location of shift lever.

If the indication is incorrect, adjust the tie-rod.

•

Tighten the tie-rod end locknuts.

Torque — Tie-rod End Front Locknut [H]: 9.8 N·m (1.0 kgf·m,

87 in·lb)

Tie-rod End Rear Locknut [I]: 9.8 N·m (1.0 kgf·m,

87 in·lb)

NOTE

○

The tie-rod end front locknut has left-hand threads.

○

Do not lean the rear tie-rod end after tightening the locknuts.

Right [J]

Wrong [K]

•

Install the grip [L] and collar [M], and tighten the screw [N].

Transmission

CRANKSHAFT/TRANSMISSION 9-27

•

Install the shift shaft cover [A] so that the gap [B] between the cover and the shift shaft is cleared, and insert the tab

[C] into the slit.

•

Insert the collar into two holes of the cover, and tighten the screw [D].

•

Install the removed parts (see appropriate chapters).

•

Transmission Removal

Split the crankcase (see Crankcase Disassembly).

•

Remove:

Shift Shaft Cover Bolts [A]

Shift Shaft Cover [B]

9-28 CRANKSHAFT/TRANSMISSION

Transmission

•

Remove:

Shift Shaft Spring Bolt [A]

Shift Shaft [B]

•

Remove:

Reverse Idle Shaft [A]

Spacer [B]

Reverse Drive Gear [C], Needle Bearing, and Spacer

Shifter [D]

Shift Rod [E]

•

Remove:

Circlip [A]

Special Tool — Outside Circlip Pliers: 57001-144

•

Remove:

Spacer [A]

Idle Gear Assembly [B]

Washers and Spacer [C]

Low and High Gears [D]

•

Remove:

Needle Bearings [A]

•

Remove the driven shaft [B] from the crankcase using a press.

Transmission Installation

•

Insert the driven shaft in the crankcase until it is bottomed using a press.

•

Apply engine oil to the needle bearings and install them.

CRANKSHAFT/TRANSMISSION 9-29

Transmission

•

Install the following parts on the low gear [A].

Needle Bearings [B]

Spacer [C] (P/No. 92026-1599, 48.2 × 54.3 × 1.0)

High Gear [D]

•

Apply engine oil to the journal of the idle shaft [A].

•

Install:

Idle Shaft with Gear Assembly [B]

Spacer [C]

•

Spacer [D] (P/No. 92026-1599, 48.2 × 54.3 × 1.0)

Apply engine oil to the inner surface of the spacer [E].

•

Install the spacer [E] so that the rounded side [F] faces outward [G].

•

Install:

Spacer [A]

Toothed Washer [B]

Circlip

Special Tool — Outside Circlip Pliers: 57001-144

•

Apply engine oil:

Shift Rod [A] and Shift Fork Ear [B]

Needle Bearing [C]

•

Install:

Shift Rod with Shift Fork

Spacer [D]

Needle Bearing

•

Install:

Reverse Drive Gear [A]

Spacer [B]

9-30 CRANKSHAFT/TRANSMISSION

Transmission

•

Install:

Reverse Idle Shaft [A]

•

Apply molybdenum disulfide oil to the shift shaft [A].

•

Install:

Shift Shaft Spring Bolt [B]

Spring [C]

Guide [D]

•

Apply a non-permanent locking agent (Three Bond:

TB2471 Blue) to the shift shaft spring bolt.

•

Tighten:

Torque — Shift Shaft Spring Bolt: 31 N·m (3.2 kgf·m, 23 ft·lb)

•

When an oil seal [A] is installed in the shift shaft cover [B], press and insert the oil seal so that its surface is flush with the end of the hole.

•

Install:

Shift Shaft Cover

•

Tighten:

Torque — Shift Shaft Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Shift Fork Bending Inspection

•

Visually inspect the shift fork.

If the fork is bent, replace the shift rod with a new one.

A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power.

[A] 90°

CRANKSHAFT/TRANSMISSION 9-31

Transmission

Shift Fork/Gear and Shifter Groove Wear

Inspection

•

Measure the thickness of the shift fork ears [A], and measure the width [B] of the shifter groove.

If the thickness of a shift fork ear is less than the service limit, the shift rod must be replaced.

Shift Fork Ear Thickness

Standard: 5.9

∼

6.0 mm (0.2323

∼

0.2362 in.)

Service Limit: 5.8 mm (0.2283 in.)

If the groove is worn over the service limit, the shifter must be replaced.

Shifter Groove Width

Standard: 6.05

∼

6.15 mm (0.2382

∼

0.2421 in.)

Service Limit: 6.25 mm (0.2461 in.)

Transmission and Shift Mechanism Inspection

•

Visually inspect:

Gears

Dogs of Gear and Shifter

If they are damaged or worn excessively, replace them.

9-32 CRANKSHAFT/TRANSMISSION

Transmission

1. Driven Shaft

2. Spacer (17.3 × 30 × 2.0)

3. Reverse Gear (12T)

4. Spacer (21.2 × 29 × 1.6)

5. Shifter

6. Circlip

7. Toothed Washer T = 1.5

8. Spacer (28.2 × 34.5 × 1.6)

9. Spacer (Hi and Low)

10. Spacer (48.2 × 54.3 × 1.0)

11. Drive Hi Gear (26T)

12. Drive Low Gear (20T)

13. Reverse Idle Shaft

14. Reverse Driven Gear (16T)

15. Reverse Driven Output Gear (16T)

16. Idle Shaft

17. Spacer (20.3 × 33 × 2.0)

18. Driven Output Gear (18T)

19. Driven Hi Gear (30T)

20. Driven Low Gear (36T)

21. Needle Bearing

CRANKSHAFT/TRANSMISSION 9-33

Ball Bearing, Needle Bearing, and Oil Seal

Ball and Needle Bearing Replacement

NOTICE

Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.

•

Using a press or puller, remove the ball bearing and/or three needle bearings.

NOTE

○

In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out.

NOTICE

Do not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil.

•

Using a press and the bearing driver set [A], install the new ball bearing until it stops at the bottom of its housing.

○

Three new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole.

Special Tool — Bearing Driver Set: 57001-1129

Ball and Needle Bearing Wear Inspection

NOTICE

Do not remove the bearings for inspection. Removal may damage them.

•

Check the ball bearings.

○

Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.

○

Spin [A] the bearing by hand to check its condition.

If the bearing is noisy, does not spin smoothly, or has any

• rough spots, replace it.

Check the needle bearings.

○

The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a needle bearing, replace it.

Oil Seal Inspection

•

Inspect the oil seals.

Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.

WHEELS/TIRES 10-1

Wheels/Tires

Table of Contents

Exploded View…………………………………………………………………………………………………………

10-2

Specifications ………………………………………………………………………………………………………….

10-4

Special Tools …………………………………………………………………………………………………………..

10-5

Wheel Alignment ……………………………………………………………………………………………………..

10-6

Toe-in Inspection…………………………………………………………………………………………………

10-6

Toe-in Adjustment ……………………………………………………………………………………………….

10-6

Wheels (Rims) …………………………………………………………………………………………………………

10-8

Wheel Removal…………………………………………………………………………………………………..

10-8

Wheel Installation………………………………………………………………………………………………..

Wheel (Rim) Inspection………………………………………………………………………………………..

Wheel (Rim) Replacement……………………………………………………………………………………

10-8

10-8

10-9

Tires……………………………………………………………………………………………………………………….

10-10

Tire Removal………………………………………………………………………………………………………

10-10

Tire Installation……………………………………………………………………………………………………

10-10

Tire Inspection ……………………………………………………………………………………………………

10-11

Front Hub ……………………………………………………………………………………………………………….

10-12

Front Hub Removal……………………………………………………………………………………………..

10-12

Front Hub Installation…………………………………………………………………………………………..

10-13

Front Hub Disassembly/Assembly …………………………………………………………………………

10-14

Rear Hub ……………………………………………………………………………………………………………….

10-15

Rear Hub Removal ……………………………………………………………………………………………..

10-15

Rear Hub Installation …………………………………………………………………………………………..

10-15

Rear Hub Disassembly/Assembly………………………………………………………………………….

10-16

10

10-2 WHEELS/TIRES

Exploded View

Exploded View

No.

Fastener

1 Front Axle Nuts

2

Front Wheel Nuts

Rear Wheel Nuts

3 Tie-rod End Locknuts

4 Rear Axle Nuts

5. KRF750S

R: Replacement Parts

S: Follow the specified tightening sequence.

W: Apply water or soap and water solution.

WHEELS/TIRES 10-3

N·m

266

110

110

44

266

Torque kgf·m

27.1

11.2

11.2

4.5

27.1

ft·lb

196

81

81

32

196

Remarks

S

S

10-4 WHEELS/TIRES

Specifications

Item

Wheel Alignment

Caster

Camber:

Front

Rear

Toe-in

Wheels (Rims)

Rims Size:

Front

Rear

Tires

Standard Tire:

Front

Rear

Tire Air Pressure (when cold):

Front

Rear

Maximum Tire Air Pressure (to seat beads, when cold)

Tire Tread Depth:

Front

Rear

Standard

2.2° (non-adjustable)

–0.7° (non-adjustable)

–0.4° (non-adjustable)

20

∼

40 mm (0.79

∼

1.57 in.) at 1G

12 × 6.0AT

12 × 8.0AT

26 × 8.00-12

MAXXIS, M989, Tubeless

26 × 10.00-12

MAXXIS, M990, Tubeless

60 kPa (0.6 kgf/cm², 8.7 psi)

90 kPa (0.9 kgf/cm², 13.1 psi)

250 kPa (2.5 kgf/cm², 36 psi)

– – –

– – –

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

4 mm (0.16 in.)

4 mm (0.16 in.)

Special Tools

Rotor Puller, M16/M18/M20/M22 × 1.5:

57001-1216

WHEELS/TIRES 10-5

Brake Drum Remover Nuts:

57001-1326

Jack:

57001-1238

Brake Drum Remover:

57001-1260

Brake Drum Pusher & Washer:

57001-1709

Brake Drum Pusher:

57001-1714

Brake Drum Holder:

57001-1325

10-6 WHEELS/TIRES

Wheel Alignment

Toe-in is the difference between the distance of front and the one of rear at the axle height position in the front wheels.

When there is toe-in, the distance A (Rear) is the greater than B (Front) as shown.

The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. If toe-in is incorrect, the front wheels will be dragged along the ground, scuffing and wearing the tread knobs.

Caster and camber are build-in and require no adjustment.

A (Rear ) – B (Front) = Amount of Toe-in

(Distance A and B are measured at axle height with the vehicle sitting on the ground, or at 1G.)

•

Toe-in Inspection

Lift the front wheels off the ground.

•

Apply a heavy coat of chalk near the center of the front tires.

•

Using a needle nose scriber, make a thin mark near the center of the chalk coating while turning the wheel.

•

Set the wheels so that the marks on the tires are at the front side and at the level of the axle height.

•

Ground the front wheels.

•

Set the steering wheel straight ahead.

•

At the level of the axle height, measure the distance between the scribed lines with a measure.

•

Move the vehicle rearward until the marks on the front

• tires are at the rear side and at the same level as the axle.

Measure the distance between the scribed lines.

•

Subtract the measurement of the front from the measurement of the rear to get the toe-in.

Toe-in of Front Wheels

Standard: 20

∼

40 mm (0.79

∼

1.57 in.) at 1G

If the toe-in is not the specified range,go on to the Toe-in

Adjustment procedure.

Toe-in Adjustment

•

Loosen the locknuts [A] on each tie-rod and turn the adjusting rods [B] the same number of turns and the same direction on both sides to achieve the specified toe-in.

Wheel Alignment

NOTE

○

The toe-in will be near the specified range, if the length of the tie-rod distance between the dust boot end [A] of steering gear assembly and the locknut [B] is 80 mm

(3.15 in.) [C] on both the left and right tie-rods.

•

Tighten:

Torque — Tie-rod End Locknuts: 44 N·m (4.5 kgf·m, 32 ft·lb)

•

Check the toe-in again.

•

Test drive the vehicle.

WHEELS/TIRES 10-7

10-8 WHEELS/TIRES

Wheels (Rims)

•

Wheel Removal

Loosen the wheel nuts [A].

•

Lift the wheels off the ground.

Special Tool — Jack: 57001-1238

•

Remove:

Wheel Nuts

Wheel

(Figure is the aluminium wheel (KRF750S Model).)

Wheel Installation

•

Check the tire rotation mark [A] on the tire, and install the tire on the rim accordingly.

NOTE

○

The direction of the tire rotation [B] is shown by an arrow on the tire sidewall.

•

Using a cleaning fluid, clean off any oil or dirt on the following portions and dry them with a clean cloth.

Bolt Threads Portion [A]

Wheel Nut Threads Portion [B]

•

Position the wheel so that the air valve [A] is toward the outside of the vehicle.

•

Tighten the wheel nuts in a criss-cross pattern.

Torque — Wheel Nuts: 110 N·m (11.2 kgf·m, 81 ft·lb)

(Figure is the aluminium wheel (KRF750S Model).)

Wheel (Rim) Inspection

•

Examine both sides of the rim for dents [A]. If the rim is dented, replace it.

Wheels (Rims)

If the tire is removed, inspect the air sealing surfaces [A] of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary.

WHEELS/TIRES 10-9

•

Wheel (Rim) Replacement

Remove the wheel (see Wheel Removal).

•

Disassemble the tire from the rim (see Tire Removal).

○

Remove the air valve and discard it.

NOTICE

Replace the air valve whenever the tire is replaced.

Do not reuse the air valve.

Plastic Cap [A]

Valve Core [B]

Stem Seal [C]

Valve Stem [D]

Valve Seat [E]

Valve Opened [F]

•

Install a new air valve in the new rim.

○

Remove the valve cap, lubricate the stem with a soap and water solution, and pull [A] the stem through the rim from the inside out until it snaps into place.

NOTICE

Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber.

•

•

Mount the tire on the new rim (see Tire Installation).

•

Install the wheel (see Wheel Installation).

Install the air valve cap.

10-10 WHEELS/TIRES

Tires

•

Tire Removal

Remove the wheel.

•

Unscrew the valve core to deflate the tire.

○

Use a proper valve core tool [A].

•

Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water [A].

This helps the tire beads slip off the rim flanges.

NOTICE

Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire.

•

Remove the tire from the rim using a suitable commercially available tire changer.

NOTE

○

The tires cannot be removed with hand tools because they fit the rims tightly.

•

Tire Installation

Inspect the rim (see Wheel (Rim) Inspection).

•

Replace the air valve with a new one.

NOTICE

Replace the air valve with whenever the tire is replaced. Do not reuse the air valve.

•

Check the tire for wear and damage (see Tire Inspection in the Periodic Maintenance chapter).

•

Lubricate the tire beads and rim flanges with a soap and water solution, or water.

WARNING

Lubricants other than water or a water and soap solution can cause the bead to separate from the rim and cause an accident resulting in serious injury or death. Use only water or a water and soap solution to lubricate the bead when installing the tire.

Tires

•

Check the tire rotation mark [A] on the tire, and install the tire on the rim accordingly.

○

The tires should be installed on the rims so that each air valve is toward the outside of the vehicle.

NOTE

○

The direction of the tire rotation [B] is shown by an arrow on the tire sidewall.

•

Install the tire on the rim using a suitable commercially available tire changer.

•

Lubricate the tire beads again and center the tire on the rim.

•

Support the wheel rim [A] on a suitable stand [B] to prevent the tire from slipping off.

•

Inflate the tire until the tire beads seat on the rim.

Maximum Tire Air Pressure (to seat beads when cold)

Front and Rear 250 kPa (2.5 kgf/cm², 36 psi)

WARNING

Overinflating a tire can cause it to explode, causing serious injury or death. Be sure to install the valve core whenever inflating the tire, and do not inflate the tire to more than maximum pressure.

•

Check to see that rim lines [A] on both sides of the tire are parallel with the rim flanges [B].

If the rim lines and the rim flanges are not parallel, deflate the tire, lubricate the sealing surfaces again, and reinflate

• the tire.

After the beads are properly seated, check for air leaks.

○

Apply a soap and water solution around the tire bead and check for bubbles.

•

Deflate the tire to the specified pressure.

•

Check the tire pressure using an air pressure gauge.

Tire Air Pressure (when cold)

Front

60 kPa (0.6 kgf/cm², 8.7 psi)

Rear 90 kPa (0.9 kgf/cm², 13.1 psi)

•

Install the air valve cap.

•

Install the wheel (see Wheel Installation).

•

Wipe off the soap and water solution on the tire and dry the tire before operation.

WARNING

Water or soap solution on the tire bead can cause tire separation and an accident resulting in serious injury or death. Do not operate the vehicle until any water or soap solution applied to the bead has completely dried.

Tire Inspection

•

Refer to the Tire Inspection in the Periodic Maintenance chapter.

WHEELS/TIRES 10-11

10-12 WHEELS/TIRES

Front Hub

Front Hub Removal

•

Remove:

Cap [A]

Cotter Pin [B]

•

Loosen the axle nut [C], while applying the brake.

•

Remove the front wheel (see Wheel Removal).

•

Remove the caliper by taking off the mounting bolts [A], and let the caliper [B] hang free.

•

Remove:

Axle Nut [A] and Washer [B]

Front Hub [C] with Brake Disc

If the front hub seems too difficult to remove, use the following special tools.

○

Mount the brake drum remover [A] on the hub bolt with the remover nuts [B] and washers [C] (parts in the remover set).

Special Tools — Brake Drum Remover: 57001-1260

Brake Drum Remover Nut: 57001-1326

○

Tighten the rotor puller [D], and remove the front hub.

Special Tool — Rotor Puller, M16/M18/M20/M22 × 1.5 :

57001-1216

•

Separate the brake disc from the front hub (see Disc Removal in the Brakes chapter).

Front Hub

•

Front Hub Installation

•

Install:

Brake Disc (see Disc Installation in the Brakes chapter)

•

Apply grease to the spline [A] of the front axle.

Install:

Front Hub [B]

If the front hub seems too difficult to install, use the following special tool.

○

Using the brake drum pusher [A], and tighten it until the pusher stops.

Special Tool — Brake Drum Pusher: 57001-1714

WHEELS/TIRES 10-13

○

Remove the brake drum pusher, and install one spacer [A] in the brake drum pusher set (57001-1709) to the pusher.

○

Tighten the hub pusher [B] until the pusher stops.

○

Remove the brake drum pusher and spacer.

Special Tool — Brake Drum Pusher & Washer: 57001-1709

•

Install:

Washer [A]

Axle Nut [B]

•

Using the brake drum holder [C], hold the front hub [D].

Special Tool — Brake Drum Holder: 57001-1325

•

Tighten:

Torque — Front Axle Nut: 266 N·m (27.1 kgf·m, 196 ft·lb)

•

Insert a new cotter pin [A].

•

Bend the cotter pin over the axle shaft end [B] and install the cap.

WARNING

A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin.

•

Install:

Brake Caliper (see Brake Caliper Installation in the

Brakes chapter)

Front Wheels (see Wheel Installation)

10-14 WHEELS/TIRES

Front Hub

Front Hub Disassembly/Assembly

•

Do not remove the hub bolts [A].

If any hub bolt is damaged, replace the hub [B] and bolts as a unit.

•

When installing the hub bolt, press in it using a press.

Rear Hub

Rear Hub Removal

•

Remove:

Cap [A]

Cotter Pin [B]

•

Loosen the axle nut [C], while applying the brake.

•

Remove the rear wheel (see Wheel Removal).

•

Remove:

Axle Nut [A] and Washer [B]

Rear Hub [C]

If the rear hub seems too difficult to remove, use the following special tools.

○

Mount the brake drum remover [A] on the hub bolt with the remover nuts [B] and washers [C] (parts in the remover set).

Special Tools — Brake Drum Remover: 57001-1260

Brake Drum Remover Nut: 57001-1326

○

Tighten the rotor puller [D], and remove the rear hub.

Special Tool — Rotor Puller, M16/M18/M20/M22 × 1.5 :

57001-1216

•

Rear Hub Installation

Apply grease to the spline [A] of the rear axle.

•

Install the collar [B] so that the small diameter side [C] faces to knuckle.

•

Install:

Rear Hub

If the rear hub seems too difficult to install, use the following special tool.

○

Using the brake drum pusher [A], and tighten it until the pusher stops.

Special Tool — Brake Drum Pusher & Washer: 57001-1709

WHEELS/TIRES 10-15

10-16 WHEELS/TIRES

Rear Hub

○

Remove the brake drum pusher, and install one spacer

[A] in the brake drum pusher set to the pusher.

○

Tighten the brake drum pusher [B] until the pusher stops.

○

Remove the brake drum pusher, and install two spacers

[A] in the brake drum pusher set to the pusher.

○

Tighten the brake drum pusher [B] until the pusher stops.

○

Remove the brake drum pusher and spacers.

•

Install:

Washer [A]

Axle Nut [B]

•

Using the brake drum holder [C], hold the rear hub [D].

Special Tool — Brake Drum Holder: 57001-1325

•

Tighten:

Torque — Rear Axle Nut: 266 N·m (27.1 kgf·m, 196 ft·lb)

•

Insert a new cotter pin [A].

•

Bend the cotter pin over the axle shaft end [B] and install the cap.

WARNING

A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin.

•

Install the rear wheel (see Wheel Installation).

Rear Hub Disassembly/Assembly

•

Do not remove the hub bolts [A].

If any hub bolt is damaged, replace the hub [B] and bolts as a unit.

•

When installing the hub bolt, press in it using a press.

FINAL DRIVE 11-1

Final Drive

Table of Contents

Exploded View…………………………………………………………………………………………………………

11-3

Specifications ………………………………………………………………………………………………………….

11-10

Special Tools …………………………………………………………………………………………………………..

11-11

Output Bevel Gears ………………………………………………………………………………………………….

11-13

Output Drive Bevel Gear Removal…………………………………………………………………………

11-13

Output Drive Bevel Gear Installation………………………………………………………………………

11-13

Output Drive Bevel Gear Disassembly …………………………………………………………………..

11-14

Output Drive Bevel Gear Assembly ……………………………………………………………………….

11-16

Output Driven Bevel Gear Removal……………………………………………………………………….

11-16

Output Driven Bevel Gear Installation…………………………………………………………………….

11-17

Output Driven Bevel Gear Disassembly …………………………………………………………………

11-17

Output Driven Bevel Gear Assembly ……………………………………………………………………..

11-18

Output Bevel Gears Adjustment ……………………………………………………………………………

11-19

Bevel Gears Inspection………………………………………………………………………………………..

11-23

Front Propeller Shaft ………………………………………………………………………………………………..

11-24

Front Propeller Shaft Removal………………………………………………………………………………

11-24

Front Propeller Shaft Installation……………………………………………………………………………

11-24

Front Propeller Shaft Inspection ……………………………………………………………………………

11-26

Front Axle ……………………………………………………………………………………………………………….

11-27

Front Axle Removal …………………………………………………………………………………………….

11-27

Front Axle Installation ………………………………………………………………………………………….

11-27

Front Axle Joint Boot Inspection ……………………………………………………………………………

11-27

Front Axle Joint Boot Replacement ……………………………………………………………………….

11-27

Front Final Gear Case ………………………………………………………………………………………………

11-34

Front Final Gear Case Oil Level Inspection …………………………………………………………….

11-34

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

11-34

Differential Shift Lever Play Inspection …………………………………………………………………..

11-34

Differential Shift Lever Play Adjustment………………………………………………………………….

11-34

Differential Shift Lever Removal ……………………………………………………………………………

11-34

Differential Shift Lever Installation …………………………………………………………………………

11-35

Differential Shift Cable Removal ……………………………………………………………………………

11-35

Differential Shift Cable Installation …………………………………………………………………………

11-36

Differential Shift Cable Lubrication…………………………………………………………………………

11-37

Differential Shift Cable Inspection………………………………………………………………………….

11-37

2WD/4WD Shift Cable Removal ……………………………………………………………………………

11-37

2WD/4WD Shift Cable Installation …………………………………………………………………………

11-38

2WD/4WD Vacuum Actuator Removal …………………………………………………………………..

11-39

2WD/4WD Vacuum Actuator Installation ………………………………………………………………..

11-40

2WD/4WD Shift Cable Lubrication…………………………………………………………………………

11-40

2WD/4WD Shift Cable Inspection ………………………………………………………………………….

11-41

Front Final Gear Case Removal ……………………………………………………………………………

11-41

Front Final Gear Case Installation …………………………………………………………………………

11-42

Front Final Gear Case Disassembly ………………………………………………………………………

11-43

Front Final Gear Case Coupling Inspection…………………………………………………………….

11-46

Front Final Gear Case Assembly…………………………………………………………………………..

11-47

Ring Gear Disassembly ……………………………………………………………………………………….

11-54

Ring Gear Assembly ……………………………………………………………………………………………

11-55

LSD Clutch Torque Inspection ………………………………………………………………………………

11-55

Pinion Gear Unit Disassembly (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)………….

11-56

Pinion Gear Unit Assembly (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ……………..

11-56

11

11-2 FINAL DRIVE

Front Final Bevel Gear Adjustment………………………………………………………………………..

11-57

Front Final Gear Case Backlash Adjustment…………………………………………………………..

11-60

Front Final Gear Case Tooth Contact Adjustment ……………………………………………………

11-61

Bevel Gear Inspection………………………………………………………………………………………….

11-64

Differential Gear Inspection ………………………………………………………………………………….

11-64

Rear Propeller Shaft …………………………………………………………………………………………………

11-65

Rear Propeller Shaft Removal ………………………………………………………………………………

11-65

Rear Propeller Shaft Installation ……………………………………………………………………………

11-65

Rear Propeller Shaft Inspection …………………………………………………………………………….

11-68

Rear Axle………………………………………………………………………………………………………………..

11-69

Rear Axle Removal ……………………………………………………………………………………………..

11-69

Rear Axle Installation …………………………………………………………………………………………..

11-69

Rear Axle Joint Boot Inspection…………………………………………………………………………….

11-69

Rear Axle Joint Boot Replacement ………………………………………………………………………..

11-70

Rear Final Gear Case……………………………………………………………………………………………….

11-76

Rear Final Gear Case Oil Level Inspection……………………………………………………………..

11-76

Rear Final Gear Case Oil Change …………………………………………………………………………

11-76

Rear Final Gear Case Removal…………………………………………………………………………….

11-76

Rear Final Gear Case Installation………………………………………………………………………….

11-78

Rear Final Gear Case Disassembly……………………………………………………………………….

11-78

Rear Final Gear Case Right Cover Assembly …………………………………………………………

11-81

Rear Final Gear Case Front Cover Assembly …………………………………………………………

11-81

Rear Final Gear Case Assembly …………………………………………………………………………..

11-82

Pinion Gear Unit Disassembly (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)………….

11-86

Pinion Gear Unit Assembly (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ……………..

11-87

Rear Final Bevel Gear Adjustment ………………………………………………………………………..

11-87

Rear Final Gear Case Backlash Adjustment …………………………………………………………..

11-90

Tooth Contact Adjustment…………………………………………………………………………………….

11-91

Bearing and Oil Seal…………………………………………………………………………………………………

11-93

Ball or Needle Bearing Inspection………………………………………………………………………….

11-93

Oil Seal Inspection ………………………………………………………………………………………………

11-94

Exploded View

This page intentionally left blank.

FINAL DRIVE 11-3

11-4 FINAL DRIVE

Exploded View

FINAL DRIVE 11-5

Exploded View

No.

Fastener

Torque

N·m kgf·m ft·lb

12 1.2

106 in·lb 1 Rotor Mounting Bolts

2

3

Output Driven Bevel Gear Housing Bolts

Bevel Gear Bearing Holder Nut

4 Bearing Holder (M64)

5 Bearing Holder (M75)

6

7

Output Shaft Holder Nut

Output Drive Bevel Gear Housing Bolts

26 2.7

19

200 20.4

148

120

250

12.2

25.5

89

184

200 20.4

148

26 2.7

19

8 Output Drive Bevel Gear Cover Bolt, L = 65 mm (2.56 in.) 8.8

0.90 78 in·lb

9 Output Drive Bevel Gear Cover Bolts, L = 20 mm (0.79 in.) 8.8

0.90 78 in·lb

10 Forward/Reverse Detecting Sensor Mounting Bolt 14.9

1.5

11

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

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

M: Apply molybdenum disulfide grease.

R: Replacement Parts

W: Apply soap and water solution.

Remarks

LB

L

L

LB

11-6 FINAL DRIVE

Exploded View

FINAL DRIVE 11-7

Exploded View

No.

2

3

4 Front Final Gear Case Oil Drain Plug

5 2WD/4WD Shift Cable Holder Bolts

6

7

10 Coupling Nut

Fastener

1 Differential Control Shift Shaft Lever Nut

Differential Shift Cable Holder Bolt

Front Final Gear Case Oil Filler Cap

2WD/4WD Shift Shaft Cover Bolts

2WD/4WD Shift Shaft Lever Nut

8 Pinion Gear Bearing Holder Nut

9 Pinion Gear Bearing Holder

11 Front Final Gear Case Center Cover Bolts (M8)

12 Front Final Gear Case Center Cover Bolts (M10)

13 Ring Gear Bolts

14 Front Final Gear Case Left Cover Bolts (M6, 35 mm)

15 Front Final Gear Case Left Cover Bolts (M6, 40 mm)

16 Front Final Gear Case Mounting Nuts

17 Front Final Gear Case Bracket Bolts

18 Differential Shift Cable Locknuts

19 2WD/4WD Shift Cable Locknuts

20 4WD Position Switch

21 Vacuum Actuator Bracket Bolts

N·m

8.8

8.8

29

15

8.8

8.8

20

200

250

35

24

49

57

8.8

8.8

90.5

90.5

9.8

4.4

15

8.8

Torque kgf·m ft·lb

0.90

78 in·lb

0.90

78 in·lb

3.0

21

1.5

0.90

20.4

25.5

3.6

2.4

5.0

5.8

11

78 in·lb

0.90

78 in·lb

2.0

15

148

184

26

18

36

42

0.90

78 in·lb

0.90

78 in·lb

9.2

9.2

67

67

1.0

87 in·lb

0.45

39 in·lb

1.5

0.90

11

78 in·lb

22 Solenoid Valve Bracket Bolts

23 Vacuum Actuator Mounting Bolts

8.8

8.8

0.90

0.90

24. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

AG: Apply lithium grease (NLGI Grade No.2).

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

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

LO: Apply a non-permanent locking agent (Three Bond TB2440B (Orange)).

M: Apply molybdenum disulfide grease.

R: Replacement Parts

78 in·lb

78 in·lb

Remarks

R

R

LB

LO

R

L

L

L

R

L

LB

11-8 FINAL DRIVE

Exploded View

FINAL DRIVE 11-9

Exploded View

No.

Fastener

N·m

27

7.8

24

8.8

1.3

450

200

15

29

49

94

Torque kgf·m

2.8

1 Rear Master Cylinder Mounting Bolts

2

3

Rear Master Cylinder Bleed Valve

Rear Final Gear Case Front Cover Bolts

4 Spring Bracket Bolt

5 Rear Final Gear Case Gasket Screws

6

7

10

11

Pinion Gear Bearing Holder

Pinion Gear Bearing Holder Nut

8 Rear Final Gear Case Oil Drain Plug

9 Rear Final Gear Case Oil Filler Cap

Rear Final Gear Case Right Cover Bolts (M10)

Rear Final Gear Case Right Cover Bolts (M12)

12 Rear Final Gear Case Mounting Nuts

13 Rear Final Gear Case Bracket Bolts

90.5

90.5

0.80

2.4

0.90

0.13

45.9

20.4

1.5

3.0

5.0

9.6

9.2

9.2

14 Heat Guard Bolts 8.8

0.90

15. KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD

16. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

G: Apply grease.

L: Apply a non-permanent locking agent.

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

M: Apply molybdenum disulfide grease.

MF: Apply gear oil (MOBIL FLUID 424 or equivalent oil).

R: Replacement Parts

Si: Apply silicone grease.

ft·lb

20

69 in·lb

18

78 in·lb

12 in·lb

332

148

11

21

36

69

67

67

78 in·lb

Remarks

L

L

L

LB

L

L

R

11-10 FINAL DRIVE

Specifications

Item

Output Bevel Gear Case

Output Bevel Gear Backlash

Standard Service Limit

0.05

∼

0.11 mm (0.002

∼

0.004 in.)

(at output drive shaft spline)

– – –

Front Final Gear Case

Gear Case Oil (same engine oil):

Type

Viscosity

0.08

∼

0.16 mm (0.003

(at pinion gear spline)

∼

0.006 in.)

– – –

– – –

Oil Level Filler opening bottom – – –

Capacity 0.7 L (0.74 US qt) – – –

Coupling Bushing Inside Diameter 20.000

∼

20.021 mm (0.7874

∼

0.7882 in.) 20.051 mm

(0.7894 in.)

LSD Clutch Torque:

When differential shift lever is locked position (5 notches).

Bevel Gear Backlash

API SG, SH, SJ, SL or SM with JASO MA,

MA1 or MA2

SAE 10W-40

300 N·m (31 kgf·m, 221 ft·lb) or more – – –

– – –

Rear Final Gear Case

Gear Case Oil:

Type – – –

Oil Level

Capacity

Rear Final Bevel Gear Backlash

MOBIL FLUID 424, CITGO TRANSGARD

TRACTOR HYDRAULIC FLUID or

EXXON HYDRAUL 560

Filler opening bottom

1.0 L (1.06 US qt)

0.05

∼

0.11 mm (0.002

∼

0.004 in.)

(at pinion gear spline)

– – –

– – –

– – –

Special Tools

Bearing Puller:

57001-135

Steering Stem Bearing Driver:

57001-137

Inside Circlip Pliers:

57001-143

Outside Circlip Pliers:

57001-144

Oil Seal & Bearing Remover:

57001-1058

Bearing Driver Set:

57001-1129

FINAL DRIVE 11-11

Pinion Gear Holder, m1.0:

57001-1281

Socket Wrench:

57001-1363

Holder & Guide Arbor:

57001-1476

Socket Wrench, Hex 50:

57001-1478

11-12 FINAL DRIVE

Special Tools

Output Shaft Holder & Spacer, m1.25:

57001-1479

Output Shaft Holder:

57001-1570

Nut Holding Bolts:

57001-1481

Socket Wrench:

57001-1482

Pinion Gear Holder:

57001-1708

Oil Seal Driver:

57001-1715

Bearing Driver, 54.3:

57001-1488

Hexagon Wench, Hex 41:

57001-1491

Cable Tension Adjusting Tool:

57001-1716

Oil Seal Guide:

57001-1721

Output Bevel Gears

Output Drive Bevel Gear Removal

•

Remove:

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)

•

Remove:

Left Cover (see Left Cover Removal in the Frame chapter)

Engine Left Side Oil Pipe (Engine Outside) (see Oil Pipe

Removal in the Engine Lubrication System chapter)

Output Drive Bevel Gear Cover Bolts [A]

Output Drive Bevel Gear Cover [B]

•

Remove:

Circlip [A]

Special Tool — Outside Circlip Pliers: 57001-144

•

Remove:

Output Drive Idle Gear [B]

•

Remove:

Output Drive Bevel Gear Housing Bolts [A]

Output Drive Bevel Gear Housing [B]

FINAL DRIVE 11-13

•

Output Drive Bevel Gear Installation

Install the output drive bevel gear housing.

•

Tighten:

Torque — Output Drive Bevel Gear Housing Bolts: 26 N·m

(2.7 kgf·m, 19 ft·lb)

•

Install the rotor [A] so that the projections [B] face outward.

•

Tighten:

Torque — Rotor Mounting Bolts [C]: 12 N·m (1.2 kgf·m, 106 in·lb)

•

Install:

Output Drive Idle Gear

New Circlip

Special Tool — Outside Circlip Pliers: 57001-144

11-14 FINAL DRIVE

Output Bevel Gears

•

Apply grease:

O-rings [A]

O-ring [B] (If it is removed.)

•

Install:

Output Drive Bevel Gear Cover [C]

Engine Left Side Oil Pipe (see Oil Pipe Installation in the

Engine Lubrication System chapter)

•

Tighten:

Torque — Output Drive Bevel Gear Cover Bolts [D]: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

○

Tighten the cover bolt [E] with the oil pipe.

•

When installing the forward/reverse detecting sensor [A], install it after the output drive bevel gear cover is installed.

•

Tighten:

Torque — Forward/Reverse Detecting Sensor Mounting

Bolt: 14.9 N·m (1.5 kgf·m, 11 ft·lb)

Output Drive Bevel Gear Disassembly

•

Remove:

Output Drive Bevel Gear Housing [A] (see Output Drive

•

Bevel Gear Removal)

Look through the hole [B] in the housing.

•

Turn the bevel gear [C] until the groove of the output drive bevel gear holder nut is seen.

•

Tighten the nut holding bolts [A] (4) securely into the grooves [B] of the bevel gear bearing holder nut [C] in the output drive bevel gear housing.

Special Tool — Nut Holding Bolts: 57001-1481

[D] Output Drive Bevel Gear Housing

[E] Outer Ball Bearing

[F] Inner Ball Bearing

[G] Bearing Holder

[H] Output Drive Bevel Gear

Output Bevel Gears

•

Hold the output drive bevel gear housing [A] in a vise.

•

Loosen the bevel gear [B] using an Allen wrench about four rotations.

•

Remove one nut holding bolt, and look at through the hole.

If the groove of the bevel gear holder nut is not seen, loosen the other three bolts.

•

Drive the gear shaft end using a copper mallet until the grooves of the bearing holder nut can be seen again.

•

Retighten the nut holding bolts (4) securely into the groove of the bevel gear holder nut in the output drive bevel gear housing.

Special Tool — Nut Holding Bolts: 57001-1481

•

Repeat the above procedure, and remove the bevel gear from the housing.

•

Remove the bearing holder [A] using the hexagon wrench

[B].

Special Tool — Hexagon Wrench, Hex 41: 57001-1491

○

If it is difficult to break free the holder, apply the heat to it to softer the locking agent.

•

Remove:

Outer Ball Bearing [A]

Special Tool — Oil Seal & Bearing Remover [B]: 57001-1058

FINAL DRIVE 11-15

•

Remove:

Output Drive Bevel Gear Holder Nut

Inner Ball Bearing [A]

Special Tool — Oil Seal & Bearing Remover [B]: 57001-1058

11-16 FINAL DRIVE

Output Bevel Gears

Output Drive Bevel Gear Assembly

•

Press the new inner ball bearing until it is bottomed.

Special Tool — Bearing Driver Set [A]: 57001-1129

•

Apply a non-permanent locking agent to the threads of the bearing holder [A] and tighten it so that the deep side

[B] faces outward.

Torque — Bearing Holder (M64): 120 N·m (12.2 kgf·m, 89 ft·lb)

•

Press the output drive bevel gear until it is bottomed.

•

Apply a non-permanent locking agent (Three Bond:

TB2471 Blue) to the threads of the bevel gear bearing holder nut [A] and tighten it so that the projection side [B] faces outward.

Special Tool — Socket Wrench [C]: 57001-1482

Torque — Bevel Gear Bearing Holder Nut: 200 N·m (20.4

kgf·m, 148 ft·lb)

•

Press the new outer ball bearing until it is bottomed.

Output Driven Bevel Gear Removal

•

Remove:

Engine (Engine Removal in the Engine Removal/Installation chapter)

Output Driven Bevel Gear Housing Bolts [A]

Output Driven Bevel Gear Housing [B]

Output Bevel Gears

○

Tap lightly the front end [A] of the output driven bevel gear shaft using a plastic mallet.

○

The output driven bevel gear shaft assembly comes off with the housing.

FINAL DRIVE 11-17

Output Driven Bevel Gear Installation

•

Apply grease:

O-ring [A]

•

Install the output driven bevel gear shaft assembly.

•

Tighten:

Torque — Output Driven Bevel Gear Housing Bolts: 26 N·m

(2.7 kgf·m, 19 ft·lb)

Output Driven Bevel Gear Disassembly

•

Remove:

Output Driven Bevel Gear Housing Assembly (see Output Driven Bevel Gear Removal)

Oil Seal

•

Hold the output shaft holder [A] in a vise, and set the housing assembly [B] on the holder.

Special Tool — Output Shaft Holder: 57001-1570

•

Remove:

Output Shaft Holder Nut [A]

Special Tool — Socket Wrench [B]: 57001-1482

•

Remove the output shaft [A] from the housing [B] using a press.

11-18 FINAL DRIVE

Output Bevel Gears

•

Hold the housing assembly [A] with the holder [B] in a vise.

Special Tool — Holder & Guide Arbor: 57001-1476

•

Remove:

Bearing Holder [C]

Special Tool — Socket Wrench, Hex 50 [D]: 57001-1478

○

If the holder seems too difficult to break free, apply heat to softer the locking agent.

•

Remove:

Ball Bearing

Special Tool — Oil Seal & Bearing Remover: 57001-1058

•

Remove the output driven bevel gear [A] from the output shaft [B] using the bearing puller [C] and spacer [D].

Special Tools — Bearing Puller: 57001-135

Output Shaft Holder & Spacer, m1.25: 57001

-1479

Output Driven Bevel Gear Assembly

•

Press the new ball bearing until it is bottomed.

Special Tool — Bearing Driver Set [A]: 57001-1129

•

Hold the housing assembly [A] with the holder [B] in a vise.

Special Tool — Holder & Guide Arbor: 57001-1476

Output Bevel Gears

•

Apply a non-permanent locking agent to the threads of the bearing holder [A] and tighten it.

Special Tool — Socket Wrench, Hex 50 [B]: 57001-1478

Torque — Bearing Holder (M75): 250 N·m (25.5 kgf·m, 184 ft·lb)

•

Hold the output shaft holder [A] in a vise, and set the output shaft [B] on the holder.

Special Tool — Output Shaft Holder: 57001-1570

•

Press the output driven bevel gear [C] using the steering stem bearing driver [D] until it is bottomed.

Special Tool — Steering Stem Bearing Driver: 57001-137

•

Press the housing assembly [A] using the steering stem bearing driver [B] until it is bottomed.

Special Tool — Steering Stem Bearing Driver: 57001-137

FINAL DRIVE 11-19

•

Apply a non-permanent locking agent (Three Bond :

TB2471 Blue) to the threads of the output shaft holder nut [A] and tighten it so that the projection side [B] faces outward.

Special Tool — Socket Wrench: 57001-1482

Torque — Output Shaft Holder Nut: 200 N·m (20.4 kgf·m, 148 ft·lb)

•

Apply grease to the oil seal and press it so that it is flush with the end surface of the housing.

Output Bevel Gears Adjustment

The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.

When replacing any one of the backlash-related parts, be sure to check and adjust the backlash and tooth contact.

First adjust the backlash, and then tooth contact by replacing shims.

These two adjustments are of critical importance and must be carried out in the correct sequence, using the procedures shown.

11-20 FINAL DRIVE

Output Bevel Gears

Output Bevel Gear (Backlash-related Parts)

1. Ball Bearings

2. Drive Bevel Gear Shims

3. Output Drive Bevel Gear

4. Bearing Housings

5. Output Driven Bevel Gear

Drive Bevel Gear Shims for Tooth Contact Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1311

92180-1312

92180-1313

92180-1314

92180-1351

92180-1352

Driven Bevel Gear Shims for Backlash Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1307

92180-1308

92180-1309

92180-1310

92180-1349

92180-1350

6. Output Driven Shaft

7. Driven Bevel Gear Shims

Output Bevel Gears

Bevel Gear Backlash Adjustment

○

The amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position.

•

Remove the output drive idle gear (see Output Drive

Bevel Gear Removal).

•

Set up a dial gauge [A] against the output drive shaft spline groove to check gear backlash.

○

To measure the backlash, turn the shaft clockwise and counterclockwise slightly so as not to move the mate gear.

The difference between the highest and lowest gauge reading is the amount of backlash.

If the backlash is not within the limit, replace the shim(s) at the driven bevel gear.

Change the thickness a little at a time.

•

Recheck the backlash, and readjust as necessary.

Output Bevel Gear Backlash

Standard: 0.05

∼

0.11 mm (0.002

∼

0.004 in.)

(at output drive shaft spline)

Tooth Contact Adjustment

○

Tooth contact location is influenced by drive gear position more than by driven gear position.

•

Clean any dirt and oil off the bevel gear teeth.

•

Apply checking compound to 4 or 5 teeth on the output driven bevel gear.

NOTE

○

Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear.

○

The checking compound must be smooth and firm with the consistency of tooth paste.

○

Special compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use this for checking the bevel gears.

•

Turn the output driven shaft for 3 or 4 turns in the drive and reverse (coast) directions, while creating a drag on the drive bevel gear shaft.

•

Check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth, and a little closer to the toe of the tooth.

If the tooth contact pattern is incorrect, replace the shim(s) at the drive bevel gear and shim(s) at the driven bevel gear, following the examples shown. Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shims are replaced. Repeat the shim change procedure as necessary.

NOTE

○

If the backlash is out of the standard range after changing shims, correct the backlash before checking the tooth contact pattern.

FINAL DRIVE 11-21

11-22 FINAL DRIVE

Output Bevel Gears

Example 1: Decrease the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or increase the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below. Repeat in 0.1 mm (0.004

in.) steps if necessary.

Example 2: Increase the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or decrease the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004

in.) to correct the pattern shown below. Repeat in 0.1 mm

(0.004 in.) steps if necessary.

Output Bevel Gears

Bevel Gears Inspection

•

Visually check the bevel gears [A] for scoring, chipping, or other damage.

Replace the bevel gears as a set if either gear is damaged.

FINAL DRIVE 11-23

11-24 FINAL DRIVE

Front Propeller Shaft

Front Propeller Shaft Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in

• the Frame chapter)

Move the rubber boot [A] rearward.

•

Push the front propeller shaft [B] forward, and remove the rear end from the universal joint.

•

Remove the front propeller shaft and spring from the vehicle.

•

Remove:

Universal Joint [A]

Front Propeller Shaft Installation

•

Wipe off any old grease on the splines of the following parts.

Universal Joint of Front Final Gear Case

Propeller Shaft

Universal Joint

Output Bevel Gear Shaft

•

Apply molybdenum disulfide grease to the splines [A] of the propeller shaft [B] and output bevel gear shaft [C].

Front Propeller Shaft

•

Install:

Universal Joint [A]

Boot [B]

○

Align each yoke [C] with the other yoke as shown in the figure.

FINAL DRIVE 11-25

•

Apply soap and water solution on the yoke [A].

•

Install:

Spring [B]

Boot [C]

Propeller Shaft [D]

○

Install the front end of the propeller shaft, and then install the rear end as shown in the figure.

11-26 FINAL DRIVE

Front Propeller Shaft

•

Match the boot end [A] to the groove of the yoke [B].

Front Propeller Shaft Inspection

•

Remove:

Front Propeller Shaft (see Front Propeller Shaft Removal)

•

Check that the universal joint [A] works smoothly without rattling or sticking.

If it does rattle or stick, the universal joint is damaged.

Replace the universal joint.

•

Check the splines of the propeller shaft [B] and universal joint.

If the splines are twisted or damaged in any way, replace the damaged parts.

•

Also, inspect the splines in the universal joint of the front final gear case and the output bevel gear shaft.

If the splines are badly worn, chipped, or loose, replace the damaged parts.

Front Axle

Front Axle Removal

•

Drain the front final gear case oil (see Front Final Gear

Case Oil Change in the Periodic Maintenance chapter).

•

Remove:

Front Wheel (see Wheel Removal in the Wheels/Tires chapter)

Steering Knuckle (see Steering Knuckle Removal in the

Steering chapter)

•

Pull the front axle [A] in a straight line out of the front final gear case.

Front Axle Installation

•

Wipe the old grease off the splines of the axle and the gear case oil seal.

•

Visually inspect the splines of the axle.

If they are badly worn or chipped, replace the axle with a

• new one.

Apply molybdenum disulfide grease to the axle splines.

•

Apply grease to the gear case oil seal.

•

Push [A] the end of the front axle straght and install it in the gear case.

NOTE

○

The axle shaft must not come off easily.

Front Axle Joint Boot Inspection

•

Refer to the Front Axle Joint Boot Inspection in the Periodic Maintenance chapter.

Front Axle Joint Boot Replacement

Outboard Joint Boot Removal

•

Remove:

Front Axle (see Front Axle Removal)

•

Tap the joint portion of the boot bands [A] with a suitable

• tool.

•

Scrap the removed boot bands.

Slide the joint boot [B] toward the inboard joint.

FINAL DRIVE 11-27

11-28 FINAL DRIVE

Front Axle

•

Tap the bearing housing [A] straight [B] with a plastic hammer to separate it from the shaft.

NOTICE

Do not tap on the cage. Be careful not get hurt when the housing comes out. If the splined portion of shaft cracked or damaged during disassembling of outboard joint, do not reuse the shaft.

•

Remove:

Circlip [A]

Boot [B]

•

Outboard Joint Boot Installation

Clean the axle shaft by wiping off the used grease on it.

•

Wind the tape on the splines of the axle shaft in order to protect the joint boot.

•

Install:

New Small Band [A]

New Boot [B]

○

Apply the special grease slightly on the inside of the new boot small diameter, and install the boot on the axle shaft.

NOTICE

Only the special grease that is included with the boot kit can be applied to the boots.

•

Install:

New Circlip [C]

•

Place the special grease tube nozzle in the bore of the housing and squeeze the tube [A] until the grease comes out from the joint bearing.

Front Axle

•

Tap the shaft end [A] straight with a plastic hammer until it is locked by the circlip.

FINAL DRIVE 11-29

•

Pinch the small boot band [A] with a suitable tool [B] to install it.

Recommend Tool: OETIKER 192

•

Squeeze all of the special grease [A] into the new boot

[B], and slide the boot onto the outboard joint [C].

•

Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot.

•

Hold the axle at this setting.

Standard Length of Assembling:

Front Axle:

206 mm (8.11 in.) [A]

•

Open the edge [A] of the boot in order to equalize the air pressures.

11-30 FINAL DRIVE

Front Axle

•

Pinch the boot bands [A] with a suitable tool [B] to install it.

Recommend Tool: OETIKER 192

•

Be sure outside diameter of the band [A] is less than the maximum diameter.

Maximum Outside Diameter of Band: 82.9 mm (3.26 in.)

Inboard Joint Boot Removal

•

Remove:

Front Axle (see Front Axle Removal)

•

Tap the joint portion of the boot bands [A] with a suitable

• tool.

•

Scrap the removed boot bands.

Slide the joint boot [B] toward the outboard joint.

•

Remove the retaining ring [A].

•

Separate the bearing cup [B] from the axle shaft.

•

Remove the steel balls [A].

•

Slide the cage [B] toward the outboard joint.

Front Axle

•

Remove:

Circlip [A]

Special Tool — Outside Circlip Pliers [B]: 57001-144

•

Remove:

Inner Race [A]

Cage [B]

Inboard Joint Boot [C]

Inboard Joint Boot Installation

•

Install:

New Small Band [A]

New Inboard Joint Boot [B]

Cage [C]

•

Install the inner race [A] so that the flat serration side [B] faces outboard joint.

FINAL DRIVE 11-31

•

Install:

New Circlip [A]

Special Tool — Outside Circlip Pliers: 57001-144

•

Slide the cage [B] on the inner race and install the steel balls [C].

11-32 FINAL DRIVE

Front Axle

•

Apply the special grease [A] to the steel balls and cage.

•

Squeeze about half a tube of the special grease [A] into the bearing cup [B].

•

Install the bearing cup [A] onto the balls and cage assembly.

•

Install the new retaining ring [A] so that the opening [B] is aligned with one of the projections [C].

•

Squeeze the remaining special grease [A] into the bearing cup [B] and inboard joint boot [C].

Front Axle

•

Pinch the small boot band [A] with a suitable tool [B] to install it.

Recommend Tool: OETIKER 192

FINAL DRIVE 11-33

•

Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot.

•

Hold the axle at this setting.

Standard Length of Assembling

Front Axle: 162.2 mm (6.39 in.) [A]

•

Open the edge [A] of the boot in order to eqalize the air pressures.

•

Pinch the boot band [A] with a suitable tool [B] to install it.

Recommend Tool: OETIKER 192

•

Be sure the outside diameter of the band [A] is less than the maximum diameter.

Maximum Outside Diameter of Band: 73.4 mm (2.89 in.)

11-34 FINAL DRIVE

Front Final Gear Case

Front Final Gear Case Oil Level Inspection

•

Park the vehicle so that it is level, both side-to-side and front-to-rear.

•

Remove the filler cap.

NOTICE

Be careful not to allow any dirt or foreign materials to enter the gear case.

•

Check the oil level. The oil level should come to the bottom of the filler opening [A].

If it is insufficient, first check the front final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that

• is already in the final gear case.

Be sure the O-ring is in place.

•

Apply grease to the O-ring and tighten the filler cap.

Torque — Front Final Gear Case Oil Filler Cap: 29 N·m (3.0

kgf·m, 21 ft·lb)

Front Final Gear Case Oil Change

•

Refer to the Front Final Gear Case Oil Change in the Periodic Maintenance chapter.

Differential Shift Lever Play Inspection

•

Refer to the Differential Shift Lever Play Inspection in the

Periodic Maintenance chapter.

Differential Shift Lever Play Adjustment

•

Refer to the Differential Shift Lever Play Adjustment in the

Periodic Maintenance chapter.

Differential Shift Lever Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Differential Shift Cable Rear End (see Differential Shift

Cable Removal)

Cap [A]

Damper [B]

Bolts [C]

•

Remove the double stick tape for damper.

•

Remove:

Bolts [A]

Bracket [B]

Ratchet [C]

Snap Pin [D]

Pin [E]

Differential Shift Lever Assembly [F]

Front Final Gear Case

Differential Shift Lever Installation

•

Install:

Lever Assembly [A]

Spring [B]: Coil Length = 16 mm (0.63 in.)

Spring [C]: Coil Length = 20 mm (0.79 in.)

Rod [D]

Lever [E]

Washers [F]

New Circlip [G]

•

Apply lithium grease (NLGI Grade No.2):

Teeth [A] of Ratchet

Pin [B]

•

Install:

Lever Assembly [C]

Bushings [D]

Bracket [E]

Ratchet [F]

Bolts [G]

Pin [B]

Snap Pin [H]

Bolts [I]

Damper [J]

Cap [K]

•

Tighten the bolts [I] with bracket [E] pushed to the arrow

[L] direction.

○

The line [M] shall be parallel to line [N].

•

Install the damper [A] to the rod [B] of lever assembly as shown in the figure.

Double Stick Tape [C]

1

∼

2 mm (0.04

∼

0.08 in.) [D]

40 mm (1.57 in.) [E]

Cap [F]

Differential Shift Cable Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

•

Loosen the locknut [A].

FINAL DRIVE 11-35

11-36 FINAL DRIVE

Front Final Gear Case

•

•

Loosen the locknuts [A].

•

Remove the cable [B] from the bracket [C].

Remove both cable ends.

•

Differential Shift Cable Installation

Lubricate the differential shift cable before installation.

•

Apply grease to the end of the cable.

•

Route the cable correctly the according to the Cable,

Wire, and Hose Routing in the Appendix chapter.

WARNING

Operation with an improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding Condition. Follow the service manual to make sure to correct any of these conditions.

•

When installing the new cable, set the cable as shown in the figure.

Differential Shift Cable [A]

Differential Shift Cable Locknuts [B]

6 ±0.5 mm (0.24 ±0.02 in.) [C]

•

Tighten:

Torque — Differential Shift Cable Locknut [A]: 9.8 N·m (1.0

kgf·m, 87 in·lb)

•

Check the differential shift lever play (see Differential Shift

Lever Play Inspection in the Periodic Maintenance chapter).

Front Final Gear Case

Differential Shift Cable Lubrication

Whenever the differential shift cable is removed, lubricate the cable as follows:

•

Apply a small amount of multi-purpose grease to the cable

(both ends).

•

Lubricate the cable with a penetrating aerosol cable lubricant through the pressure cable luber.

Differential Shift Cable Inspection

•

With the differential shift cable disconnected at both ends, the cable should move freely within the cable housing.

If the cable does not move freely [A] after lubricating, if the cable is frayed [B], or if the housing is kinked [C], replace the cable.

2WD/4WD Shift Cable Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Right Bracket (see Right Bracket Removal in the Frame chapter)

•

Remove:

Snap Pin [A]

Pin [B] and Washer

•

Loosen the nut [C] and remove the 2WD/4WD shift cable from the bracket [D].

•

Remove:

2WD/4WD Shift Cable Locknuts [A]

2WD/4WD Shift Cable End [B]

•

Remove the 2WD/4WD shift cable from the frame.

FINAL DRIVE 11-37

11-38 FINAL DRIVE

Front Final Gear Case

•

2WD/4WD Shift Cable Installation

Apply grease to the front end of the cable.

•

Run the 2WD/4WD shift cable according to the Cable,

Wire and Hose Routing section in the Appendix chapter.

•

Install:

2WD/4WD Shift Cable Rear End

2WD/4WD Shift Cable Front End

Pin and Washer

Snap Pin

•

Support the vehicle on a stand or a jack so that the all wheels are off the ground.

•

Shift the transmission in neutral position.

•

Remove:

Vacuum Hose [A]

•

Tighten:

Torque — 2WD/4WD Shift Cable Locknut [A]: 4.4 N·m (0.45

kgf·m, 39 in·lb)

•

Install the cable tension adjusting tool [A] on the cable and between the brackets as shown in the figure.

Special Tool — Cable Tension Adjusting Tool: 57001-1716

Front Final Gear Case

•

Push the 2WD/4WD shift shaft lever [A] rearward (4WD position) and make the engagement of the shifter maximum while turning the propeller shaft by hand.

•

Turn the nut [B] with fingers and pull slightly the inner cable.

•

Tighten:

Torque — 2WD/4WD Shift Cable Locknut [C]: 4.4 N·m (0.45

kgf·m, 39 in·lb)

•

Remove the cable tension adjusting tool.

•

Confirm the 2WD/4WD shift shaft lever [A] return to 2WD position [B].

•

4WD Position [C]

•

Install the vacuum hose to the actuator.

Install the removed parts.

2WD/4WD Vacuum Actuator Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Right Bracket (see Right Bracket Removal in the Frame chapter)

Vacuum Hose [A]

•

Loosen the clamp screw [A] and duct [B].

FINAL DRIVE 11-39

•

Remove:

Snap Pin [A]

Pin [B] and Washer

•

Loosen the nut [C] and remove the 2WD/4WD shift cable from the bracket.

•

Remove:

2WD/4WD Vacuum Actuator Mounting Bolts [D]

2WD/4WD Vacuum Actuator [E]

11-40 FINAL DRIVE

Front Final Gear Case

•

Remove:

Lower Hose [A]

2WD/4WD Vacuum Actuator Installation

•

Install:

Lower Hose

•

Install the 2WD/4WD vacuum actuator to the bracket and tighten the 2WD/4WD vacuum actuator mounting bolts.

Torque — Vacuum Actuator Mounting Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

•

Install:

2WD/4WD Shift Cable (see 2WD/4WD Shift Cable Installation)

•

Install the duct [A] so that the projection [B] of the duct inserts the groove of the rubber duct [C].

•

Install the removed parts.

2WD/4WD Shift Cable Lubrication

Whenever the 2WD/4WD shift cable is removed, lubricate the cable as follows:

•

Apply a small amount of multi-purpose grease to the cable

(both ends).

•

Lubricate the cable with a penetrating aerosol cable lubricant through the pressure cable luber.

Front Final Gear Case

2WD/4WD Shift Cable Inspection

•

With the 2WD/4WD shift cable disconnected at both ends, the cable should move freely within the cable housing.

If the cable does not move freely [A] after lubricating, if the cable is frayed [B], or if the housing is kinked [C], replace the cable.

Front Final Gear Case Removal

•

Drain the gear case oil (see Front Final Gear Case Oil

Change in the Periodic Maintenance chapter).

•

Remove:

Front Bottom Guard (Front Bottom Guard Removal in the Frame chapter)

Front Axles (see Front Axle Removal)

Front Propeller Shaft (Front Propeller Shaft Removal)

Differential Shift Cable Holder Bolts [A] and Cable Holder

[B]

Differential Shift Cable End [C]

•

Remove:

Cable Holder Bolts [A] and Cable Holder [B]

2WD/4WD Shift Cable End [C]

2WD/4WD Shift Position Switch Lead Connector [D]

FINAL DRIVE 11-41

•

Remove:

Front Final Gear Case Mounting Bolts [A] and Nuts

Breather Hose [B]

•

Remove:

Front Final Gear Case Bracket Bolts [A]

Brackets [B]

11-42 FINAL DRIVE

Front Final Gear Case

•

Remove front final gear case [A] from under the vehicle.

Front Final Gear Case Installation

•

Install:

Front Final Gear Case

Front Side Bolts (2) and Nuts

Front Final Gear Case Bracket and Bolts

Rear Side Bolt and Nut

•

Tighten:

Torque — Front Final Gear Case Bracket Bolts: 90.5 N·m (9.2

kgf·m, 67 ft·lb)

Front Final Gear Case Mounting Nuts: 90.5 N·m

(9.2 kgf·m, 67 ft·lb)

•

Install:

Breather Hose

2WD/4WD Shift Cable End (see 2WD/4WD Shift Cable

Installation)

2WD/4WD Shift Cable Holder and Bolts

•

2WD/4WD Shift Position Switch Lead Connector

Apply a non-permanent locking agent to the holder bolts.

•

Tighten:

Torque — 2WD/4WD Shift Cable Holder Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

•

Install:

Differential Shift Cable End (see Variable Shift Cable Installation)

Differential Shift Cable Holder and Bolts

•

Tighten:

Torque — Front Final Gear Case Left Cover Bolts (M6): 8.8

N·m (0.90 kgf·m, 78 in·lb)

Differential Shift Cable Holder Bolt: 8.8 N·m (0.90

kgf·m, 78 in·lb)

•

Install the differential shift cable so that the distance [A] between the nut and casing cap is 6 mm (0.24 in.).

Front Final Gear Case

•

Install the drain plug and a new O-ring.

○

Apply grease to the O-ring.

•

Tighten:

Torque — Front Final Gear Case Oil Drain Plug: 15 N·m (1.5

•

kgf·m, 11 ft·lb)

Install the removed parts.

•

Fill the front final gear case with the specified oil (see

Front Final Gear Case Oil Change in the Periodic Maintenance chapter)

Front Final Gear Case Disassembly

•

Remove:

Front Final Gear Case (see Front Final Gear Case Removal)

Differential Control Shift Shaft Lever Bolt [A] and Nut [B]

Differential Control Shift Shaft Lever [C]

•

Remove:

Snap Rings [A] (both sides)

Special Tool — Outside Circlip Pliers [B]: 57001-144

FINAL DRIVE 11-43

•

Remove:

Caps [A]

Yoke [B]

•

•

Push [A] and hold the 2WD/4WD shift shaft lever [B].

Hold the coupling [C] with a wrench [D].

•

Remove:

Coupling Nut [E]

11-44 FINAL DRIVE

Front Final Gear Case

•

Remove:

Washer [A]

Coupling [B]

•

Remove:

2WD/4WD Shift Shaft Lever Nut [A]

2WD/4WD Shift Shaft Lever [B]

Spring [C]

•

Remove:

Washer [A]

2WD/4WD Shift Shaft Cover Bolts [B]

2WD/4WD Shift Shaft Cover [C]

2WD/4WD Shift Shaft [D]

•

Remove:

Oil Seal [A]

•

Remove:

Shifter [A]

Front Final Gear Case

•

Hold the front final gear case in a vise, and remove the bearing holder using the socket wrench [A].

Special Tool — Socket Wrench, Hex 50: 57001-1478

If the holder seems too difficult to break free, apply heat to softer the locking agent.

•

Remove:

Pinion Gear Bearing Holder

•

Remove:

Pinion Gear Unit [A]

Shim(s) [B]

FINAL DRIVE 11-45

•

Remove:

Front Final Gear Case Left Cover Bolts [A]

Front Final Gear Case Left Cover [B]

Differential Control Shift Shaft

Spring

•

Remove:

Outer Disc [A]

Needle Bearing

•

Remove:

Housing [A] and Differential Disc Assembly [B]

Inner Disc

Needle Bearing

11-46 FINAL DRIVE

Front Final Gear Case

•

Remove:

Cam Plate [A]

•

Remove:

Steel Balls [A]

Dowel Pins [B]

•

Remove:

Front Final Gear Case Center Cover Bolts (M8) [A]

Front Final Gear Case Center Cover Bolts (M10) [B]

Front Final Gear Case Center Cover [C]

○

Using the pry points [D], remove the cover.

•

Remove:

Ring Gear Assembly [A]

Shim(s) [B]

Front Final Gear Case Coupling Inspection

If the coupling bushing [A] is damaged or worn, replace the front final gear case coupling.

Front Final Gear Case Coupling Bushing Inside Diameter

[B]

Standard: 20.000

∼

20.021 mm (0.7874

∼

0.7882 in.)

Service Limit: 20.051 mm (0.7894 in.)

Front Final Gear Case

Front Final Gear Case Assembly

•

Press the following parts in the right cover [A] until they are bottomed.

Ball Bearing [B]

Needle Bearing [C]

•

Oil Seal [D]

Apply grease to the oil seal lips [E].

•

Install:

Circlip [F]

Special Tool — Inside Circlip Pliers: 57001-143

•

Press the following parts in the left cover [A] until they are bottomed.

Ball Bearing [B]

Oil Seal [C]

•

Press the oil seal [D] so that the surface is flush with the end of the hole.

•

Apply grease to the oil seal lips [E].

•

Press the fitting pipe [A] in the left cover [B] as shown in the figure.

14 mm (0.55 in.) [C]

FINAL DRIVE 11-47

•

Visually check the pinion gear and ring gear for scoring, chipping, or other damage.

Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact.

•

Refer to the gear backlash and tooth contact pattern (see

Front Final Bevel Gear Adjustment).

•

Apply engine oil to the teeth of the ring gear.

•

Install:

Shim(s) [A] (both sides)

Ring Gear Assembly [B]

11-48 FINAL DRIVE

Front Final Gear Case

•

Apply grease to the O-ring [A] on the front final gear case center cover.

•

Install:

Front Final Gear Case Center Cover [A]

•

Apply a non-permanent locking agent:

Front Final Gear Case Center Cover Bolts (M10) [B]

Front Final Gear Case Center Cover Bolts (M8) [C]

•

Tighten:

Torque — Front Final Gear Case Center Cover Bolts (M10):

49 N·m (5.0 kgf·m, 36 ft·lb)

Front Final Gear Case Center Cover Bolts (M8): 24

N·m (2.4 kgf·m, 18 ft·lb)

•

Apply engine oil to the journal [A] and teeth [B].

•

Insert the shim [C] and pinion gear unit [D] in the front final gear case right cover [E].

•

Apply a non-permanent locking agent to the pinion gear bearing holder [A], but do not apply a non-permanent locking agent to one pitch [B] from the tip.

•

Install the pinion gear bearing holder so that the no coating side [C] faces the bearing.

•

Tighten:

Torque — Pinion Gear Bearing Holder: 250 N·m (25.5 kgf·m,

184 ft·lb)

•

Install:

Dowel Pins [A]

Steel Balls [B]

Front Final Gear Case

•

Install:

Cam Lever [A]

Needle Bearing [B]

•

Apply engine oil to the needle bearing.

•

Check the wear of the disc assembly as follows.

○

Measure the width [A] of the disc assembly [B] at three locations, and calculate average for three points.

NOTE

○

Be careful not to damage the facing surface [C] on the outer plates.

•

Select the inner disc in accordance with the width of the disc assembly, refer to the below table.

Width of Disc Assembly

Thickness of Inner

Disc [A]

Part Number

16.7

∼

17.3 mm

(0.6675

∼

0.6811 in.)

17.31

∼

17.9 mm

(0.6815

∼

0.7047 in.)

17.91

∼

18.5 mm

(0.7051

∼

0.7283 in.)

2.4 mm (0.0945 in.) 41080-1501

1.8 mm (0.0709 in.) 41080-1500

1.2 mm (0.0472 in.) 41080-1499

If the width is within the specified range, install the inner disc and disc assembly.

If the width is not within the specified range, replace the disc assembly.

•

Install:

Inner Disc [A]

FINAL DRIVE 11-49

11-50 FINAL DRIVE

Front Final Gear Case

•

Install:

Disc Assembly [A]

•

Install:

Housing [A]

•

Apply engine oil to the needle bearing [A].

•

Install:

Needle Bearing

•

Install:

Outer Disc [A]

New Gasket [B]

•

Apply engine oil to the differential control shift shaft [A].

•

Install the spring [B] as shown in the figure.

Front Final Gear Case

•

Install the shaft [A] and spring in the front final gear case as shown in the figure.

○

Insert the spring end into the slit [B] and insert the tab of the shift shaft into the groove [C] of the cam plate.

FINAL DRIVE 11-51

•

Install:

Front Final Gear Case Left Cover [A]

○

To fix the cover turn the shaft [B] counterclockwise.

•

Tighten:

Torque — Front Final Gear Case Left Cover Bolts (M6) [A]:

8.8 N·m (0.90 kgf·m, 78 in·lb)

L = 35 mm (1.4 in.)

•

Apply grease to the shifter splines and groove.

•

Install:

Shifter [A]

○

Face the dogs side [B] to outside.

•

Press the oil seal [A] in the front final gear case so that the oil seal surface is flush with the case end.

Special Tool — Oil Seal Driver: 57001-1715

•

Apply grease to the oil seal lip [B].

11-52 FINAL DRIVE

Front Final Gear Case

•

Apply grease to the shaft [A] and pin [B] of the 2WD/4WD shift shaft lever.

•

Insert the 2WD/4WD shift shaft lever so that the pin [B] is opposite side of the 2WD/4WD shift switch [C].

•

Insert the pin into the groove [D] of the shifter.

•

Apply grease to the oil seal lip [A].

•

Press the oil seal [B] in the 2WD/4WD shift shaft cover

[C] as shown in the figure.

0.5

∼

1.5 mm (0.020

∼

0.059 in.) [D]

•

Apply grease to the O-ring [A].

•

Install:

2WD/4WD Shift Shaft Cover [B]

○

When installing the cover, use the oil seal guide [A] for protecting the oil seal.

Special Tool — Oil Seal Guide: 57001-1721

•

Apply a non-permanent locking agent to the threads of the shift shaft cover bolts [A] and tighten them.

Torque — 2WD/4WD Shift Shaft Cover Bolts: 8.8 N·m (0.90

•

Install:

Washer [B]

kgf·m, 78 in·lb)

Front Final Gear Case

•

Install:

Spring [A]

2WD/4WD Shift Shaft Lever [B]

•

Align the lines [C] of the shaft and lever.

•

Install:

2WD/4WD Shift Shaft Lever Nut [A]

•

Tighten:

Torque — 2WD/4WD Shift Shaft Lever Nut: 20 N·m (2.0

kgf·m, 15 ft·lb)

•

Apply grease to the oil seal lip [A].

•

Press the oil seal [B] in the coupling [C] as shown in the figure.

1

∼

1.5 mm (0.039

∼

0.059 in.) [D]

•

Install:

Coupling [A]

Washer [B]

FINAL DRIVE 11-53

•

Install:

Coupling Nut [A]

•

Push [B] and hold the 2WD/4WD shift shaft lever [C].

•

Hold the coupling [D] with a wrench [E].

•

Tighten:

Torque — Coupling Nut: 35 N·m (3.6 kgf·m, 26 ft·lb)

11-54 FINAL DRIVE

Front Final Gear Case

•

Press the plug [A] into the yoke [B] as shown in the figure.

10.5 ±1 mm (0.413 ±0.039 in.) [C]

•

Install:

Yoke [A]

Caps [B]

New Snap Rings [C]

•

Install:

Differential Control Shift Shaft Lever [A]

•

Align the punch marks [B] of the shaft and lever.

•

Install:

Differential Control Shift Shaft Lever Bolt [C] and Nut [D]

•

Tighten:

Torque — Differential Control Shift Shaft Lever Nut: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

Ring Gear Disassembly

•

Remove:

Ring Gear Assembly (see Front Final Gear Case Disassembly)

Ring Gear Bolts [A]

Ring Gear [B]

•

Remove:

Differential Gear Case Cover [A]

Right Side Gear (16T) [B]

Spider Gear Shaft [C]

Spider Gears (10T) [D]

Left Side Gear (16T) [E]

Left Differential Gear Case [F]

Front Final Gear Case

Ring Gear Assembly

•

Press the bearing [A] on the left differential gear case [B] until it is bottomed.

•

Apply engine oil to the teeth [C] of the gears.

•

Apply molybdenum disulfide grease to the diagonal line parts [D].

•

Install:

Left Side Gear (16T)[E]

Spider Gears (10T) [F]

Spider Gear Shaft [G]

•

Apply engine oil to the teeth [A] of the gear.

•

Apply molybdenum disulfide grease to the diagonal line parts [B].

•

Install:

Right Side Gear (16T) [C]

Pin [D]

Differential Gear Case Cover [E]

Ring Gear [F]

•

Apply a non-permanent locking agent (Three Bond:

TB2471 Blue) to the ring gear bolts [G], and tighten them.

Torque — Ring Gear Bolts: 57 N·m (5.8 kgf·m, 42 ft·lb)

LSD Clutch Torque Inspection

If the vehicle has the following symptoms, check the LSD

(Limited Slip Differential) clutch torque.

-The steering wheel is hard to turn.

-The front final gear case overheats.

-Abnormal noises come from the front final gear case

• when rounding a curve.

Ensure 2WD mode.

•

Support the vehicle so that the front wheels are off the ground.

•

Remove:

Left Front Wheel (see Wheel Removal in the

Wheels/Tires chapter)

Front Axle Nut Cotter Pin

•

Secure the right front wheel from rotating.

•

Pull the differential shift lever (5 notches), and shift to the differential lock position.

•

Measure the clutch torque using a torque wrench [A]. Turn the wrench evenly.

○

The clutch torque is the mean torque reading during about a quarter turn of the wrench.

LSD Clutch Torque

Standard: 300 N·m (31 kgf·m, 221 ft·lb) or more

If the clutch torque is out of the specified range, check the width of the disc assembly (see Front Final Gear Case

Assembly).

NOTE

○

The correct type of oil must be installed.

FINAL DRIVE 11-55

11-56 FINAL DRIVE

Front Final Gear Case

Pinion Gear Unit Disassembly

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Remove:

Pinion Gear Unit (see Front Final Gear Case Disassembly)

•

Hold the pinion gear unit [A] with the socket wrench [B] in a vise and put the rubber mat [C] (1 mm or more) at the bottom of the unit.

Special Tool — Socket Wrench: 57001-1363

•

Loosen the pinion gear bearing holder nut a little with the pinion gear holder [A].

Special Tool — Pinion Gear Holder: 57001-1708

○

Turn the wrench [B] clockwise a little.

•

Set the pinion gear unit [A] upside down in a vise as shown in the figure.

•

Hold the pinion gear unit and remove the pinion gear bearing holder nut.

•

Remove the ball bearing if required.

Special Tool — Bearing Puller: 57001-135

Pinion Gear Unit Assembly

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Visually inspect the bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a bearing, replace the bearing.

•

Be sure to check and adjust the bevel gear backlash and tooth contact, when any of the backlash-related parts are replaced (see Front Final Bevel Gear Adjustment).

•

Press the ball bearing [A] on the pinion gear until it is bottomed.

•

Apply a non-permanent locking agent (Three Bond:

TB2471 Blue) to the pinion gear bearing holder nut [B].

•

Install the pinion gear bearing holder nut so that the projection [C] faces outward.

Front Final Gear Case

•

Hold the pinion gear unit [A] with the socket wrench [B] in a vise (see Pinion Gear Unit Disassembly).

Special Tools — Socket Wrench: 57001-1363

Pinion Gear Holder [C]: 57001-1708

•

Turn the wrench [D] counterclockwise and tighten the nut.

Torque — Pinion Gear Bearing Holder Nut: 200 N·m (20.4

kgf·m, 148 ft·lb)

Front Final Bevel Gear Adjustment

The backlash (distance one gear will move back and forth without moving the mate gear) and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.

Above two adjustments are of critical importance and must be carried out following the correct sequence and method.

•

When any one of the backlash-related parts are replaced, check and adjust the bevel gear backlash, and tooth contact by replacing shims.

○

The amount of backlash is influenced by the ring gear position more than by the pinion gear position.

○

Tooth contact location is influenced by the pinion gear position more than by the ring gear position.

FINAL DRIVE 11-57

11-58 FINAL DRIVE

Front Final Gear Case

Front Final Gear Case (Backlash-related Parts)

1. Ring Gear Right Shim(s)

2. Ring Gear Left Shim(s)

3. Pinion Gear Shim(s)

4. Front Final Gear Case Center Cover

5. Front Final Gear Case Right Cover

6. Ball Bearings

7. Ring Gear

8. Ring Gear Assembly

9. Pinion Gear

Front Final Gear Case

1. Ring Gear Right Shims for Backlash Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Parts Number

92180-0260

92180-0261

92180-1207

92180-0259

92180-1205

92180-0262

2. Ring Gear Left Shims for Backlasht Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.7 mm (0.028 in.)

0.8 mm (0.031 in.)

0.9 mm (0.035 in.)

1.0 mm (0.039 in.)

1.1 mm (0.043 in.)

1.2 mm (0.047 in.)

Parts Number

92180-1390

92180-1391

92180-1392

92180-1393

92180-1394

92180-1395

92180-1396

92180-1397

92180-1398

3. Pinion Gear Shims for Tooth Contact Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1423

92180-1424

92180-1425

92180-1426

92180-1427

92180-1428

FINAL DRIVE 11-59

11-60 FINAL DRIVE

Front Final Gear Case

•

Front Final Gear Case Backlash Adjustment

Clean dirt and oil off bevel gear teeth.

•

Measure length [A], [B] and [C], and calculate the clearance [D] between the ring gear assembly and gear case covers.

[D] = [A] + [B] – [C]

[E] Front Final Gear Case Center Cover

[F] Ring Gear Assembly

[G] Front Final Gear Case Right Cover

•

Assemble the front final gear case (see Front Final Gear

Case Assembly).

○

It is not necessary to install the variable front differential control unit.

○

When installing the pinion gear bearing holder, a non-permanent locking agent is not used.

○

Use the following two spare bolts when installing the front final gear case center cover [A].

M10 Bolt [B] L = 35 mm (1.38 in.), P = 1.25 mm (0.049

in.)

M8 Bolt [C] L = 40 mm (1.57 in.), P = 1.25 mm (0.049 in.)

Front Final Gear Case

•

Temporarily install the right front axle in the gear case and hold it in a vise.

•

Mount a dial gauge [A] so that the tip of the gauge is against the splined portion [B] of the pinion gear shaft.

•

To measure backlash, turn the pinion gear shaft right and left [C] while holding the front axle steady. The difference between the highest and lowest gauge reading is the amount of backlash.

○

Measure backlash at three locations (equally spaced on the splines).

Front Final Bevel Gear Backlash

Standard: 0.08

∼

0.16 mm (0.003

∼

0.006 in.)

(at pinion gear spline)

If the backlash is not within the standard, replace the ring gear shims according to the below NOTE. To increase backlash, increase the thickness of the shim(s) [1] and decrease the thickness of the shim(s) [2]. To decrease backlash, decrease the thickness of the shim(s) [1] and increase the thickness of the shim(s) [2].

NOTE

○

The total of the ring gear shims, [1] and [2], should be less than [D] (the clearance between the ring gear assembly and gear case covers).

○

Example:

D = 2.34 mm →[1] + [2] = 2.30 mm

D = 2.26 mm →[1] + [2] = 2.25 mm

○

The second decimal of the total of [1] and [2] should be

.x0 or .x5 nearest of D.

•

Recheck the backlash, and readjust if necessary.

•

Front Final Gear Case Tooth Contact Adjustment

Clean any dirt and oil off the bevel gear teeth.

•

Apply checking compound to 4 or 5 teeth on the pinion gear.

NOTE

○

Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear.

○

The checking compound must be smooth and firm, with the consistency of tooth paste.

○

Special compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use one of these for checking the bevel gears.

FINAL DRIVE 11-61

11-62 FINAL DRIVE

Front Final Gear Case

•

Assemble the front final gear case (see Front Final Gear

Case Backlash Adjustment).

•

Turn the pinion gear shaft [A] for one revolution in the drive and reverse (coast) direction, while creating a drag on the ring gear.

•

Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth.

○

The tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe.

If the tooth contact pattern is incorrect, replace the pinion gear shim(s), following the examples shown.

•

Then erase the tooth contact patterns and check them again. Also check the backlash every time the shim(s) are replaced. Repeat the shim change procedure as necessary.

NOTE

○

If the backlash is out of the standard range after changing the pinion gear shim(s), change the ring gear shim(s) to correct the backlash before checking the tooth contact pattern.

Front Final Gear Case

FINAL DRIVE 11-63

11-64 FINAL DRIVE

Front Final Gear Case

Bevel Gear Inspection

•

Visually check the bevel gears [A] for scoring, chipping, or other damage.

Replace the bevel gears as a set if either gear is damaged.

Differential Gear Inspection

•

Visually check the differential gears [A] for scoring, chipping, or other damage.

Replace the differential gears as a set if either gear is damaged.

•

Also, inspect the differential gear shaft [B], gear case [C], and cover [D] where the differential gears rub.

If they are scored, discolored, or otherwise damaged, replace them as a set.

Rear Propeller Shaft

Rear Propeller Shaft Removal

•

Remove:

Right Rear Wheel (see Wheel Removal in the

Wheels/Tires chapter)

•

Slip the O-rings [A] off the grooves on the rubber boot [B]

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC).

•

Slide the boot [A] forward, and remove the circlip [B] with a suitable commercially circlip pliers [C].

FINAL DRIVE 11-65

•

Push the rear propeller shaft [A] rearward, and remove the front end [B] from the output bevel gear shaft [C].

•

Remove the rear propeller shaft and spring from the vehicle.

•

Remove:

Universal Joint [A]

Boot [B] and O-rings (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Rear Propeller Shaft Installation

•

Wipe off any old grease on the splines of the following parts.

Output Bevel Gear Shaft

Propeller Shaft

Universal Joint

Pinion Gear Shaft of Rear Final Gear Case

•

Check the boots for damage.

If any damage exists, replace it with a new one.

•

Replace the O-rings with new ones

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC).

11-66 FINAL DRIVE

Rear Propeller Shaft

•

Apply molybdenum disulfide grease to the splines [A] of the pinion gear shaft [B] of rear final gear case.

•

Install:

Boot [A]

NC/PC/RC/SC/VC)

O-rings [B]

NC/PC/RC/SC/VC)

Universal Joint [C]

(KRF750NA/PA/RA/SA/TA

(KRF750NA/PA/RA/SA/TA

∼

∼

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Apply molybdenum disulfide grease to the splines [A] and inside [B] of the rear propeller shaft.

•

Install:

New Circlip [C] (on the Rear Propeller Shaft)

Boot [D] and New O-rings

Rear Propeller Shaft [E]

Spring [F]

•

Align each yoke with the other yoke (see Front Propeller

Shaft Installation).

•

Push the rear propeller shaft rearward [G], and install the

• front end to the output bevel gear shaft [H].

Install the circlip [C] into the groove of the propeller shaft.

○

Do not contact the boot [I] and oil seal [J].

Rear Propeller Shaft

•

Fit the boots into the grooves of the yoke and shaft.

•

Fit the O-rings into the grooves of the boot.

(KRF750ND/PD/RD/SD)

•

Apply molybdenum disulfide grease to the splines [A] and inside [B] of the rear propeller shaft.

•

Install:

New Circlip [C] (on the Rear Propeller Shaft)

Boot [D]

Rear Propeller Shaft [E]

Spring [F]

•

Align each yoke with the other yoke (see Front Propeller

Shaft Installation).

•

Push the rear propeller shaft rearward [G], and install the

• front end to the output bevel gear shaft [H].

Install the circlip [C] into the groove of the propeller shaft.

•

Apply grease to the oil seal lips [I].

•

Set the projection [J] of the boot to the groove of the universal joint.

○

It is unnecessary to set the projection [K] of the boot to the groove of the rear propeller shaft.

FINAL DRIVE 11-67

11-68 FINAL DRIVE

Rear Propeller Shaft

Rear Propeller Shaft Inspection

•

Remove:

Rear Propeller Shaft (see Rear Propeller Shaft Removal)

•

Check that the universal joint [A] works smoothly without rattling or sticking.

If it does rattle or stick, the universal joint is damaged.

Replace the universal joint.

•

Check the splines of the propeller shaft [B] and universal joint.

If the splines are twisted or damaged in any way, replace the damaged parts.

•

Also, inspect the splines of output bevel gear shaft and pinion gear shaft of the rear final gear case.

If the splines are badly worn, chipped, or loose, replace the damaged parts.

Rear Axle

Rear Axle Removal

•

Drain the rear final gear case oil (see Rear Final Gear

Case Oil Change in the Periodic Maintenance chapter).

•

Remove:

Rear Wheels (see Wheel Removal in the Wheels/Tires chapter)

Stabilizer Joint (see Stabilizer Removal in the Suspension chapter)

Rear Knuckle [A] (see Rear Knuckle Removal in the Suspension chapter)

Upper Suspension Arm [B] (see Rear Suspension Arm

Removal in the Suspension chapter)

•

Pull the rear axle [A] in a straight line out of the rear final gear case.

FINAL DRIVE 11-69

Rear Axle Installation

•

Wipe off any old grease:

Splines [A] of Axle

Gear Case Oil Seal [B]

•

Visually inspect the splines of the axle.

If they are badly worn or chipped, replace the axle with a

• new one.

•

Apply molybdenum disulfide grease to the axle splines.

Apply grease to the gear case oil seal lips.

•

Push [A] the end of the rear axle straight and install the rear axle.

NOTE

○

The axle shaft must not come off easily.

Rear Axle Joint Boot Inspection

•

Refer to the Axle Joint Boot Inspection in the Periodic

Maintenance chapter.

11-70 FINAL DRIVE

Rear Axle

Rear Axle Joint Boot Replacement

Outboard Joint Boot Removal

•

Remove:

Rear Axle (see Rear Axle Removal)

•

Boot Bands [A]

•

Scrap the removed boot bands.

Slide the joint boot [B] toward the inboard joint.

•

Tap the bearing housing [A] straight [B] with a plastic hammer to separate it from the shaft.

NOTICE

Do not tap on the cage. Be careful not get hurt when the housing comes out. If the splined portion of shaft cracked or damaged during disassembling of outboard joint, do not reuse the shaft.

•

Remove:

Circlip [A]

Boot [B]

Small Band [C]

•

Outboard Joint Boot Installation

Clean the axle shaft by wiping off the used grease on it.

•

Wind the tape on the splines of the axle shaft in order to protect the joint boot.

•

Install:

New Small Band [A]

New Boot [B]

○

Apply the special grease slightly on the inside of the new boot small diameter, and install the boot on the axle shaft.

NOTICE

Only the special grease that is included with the boot kit can be applied to the boots.

•

Install:

New Circlip [C]

Rear Axle

•

Apply the special grease slightly on the part [A] of the band installation in order to make easy to install the boot band.

•

Tighten the small boot band [B].

○

Tighten the boot band [A] and bend the tangs [B] securely to hold down the end of the band.

FINAL DRIVE 11-71

•

Place the special grease tube nozzle in the bore of the housing and squeeze the tube [A] until the grease comes out from the joint bearing.

•

Tap the shaft end [A] straight with a plastic hammer until it is locked by the circlip.

•

Squeeze all of the special grease [A] into the new boot

[B], and slide the boot onto the outboard joint [C].

11-72 FINAL DRIVE

Rear Axle

•

Compress the axle assembly to the specified length while relieving the air pressure inside the outboard boot.

•

Hold the axle at this setting.

Standard Length of Assembling:

Outboard: 228.9 mm (9.01 in.) [A]

•

Open the edge of the boot in order to equalize the air pressures.

•

Tighten the large band [A] and tap down the tangs securely to hold down the end of the band.

•

Be sure outside diameter of the band is less than the maximum diameter.

Maximum Outside Diameter of Band: 85.3 mm (3.36 in.)

Inboard Joint Boot Removal

•

Remove:

Rear Axle (see Rear Axle Removal)

•

Boot Bands [A]

•

Scrap the removed boot bands.

Slide the joint boot toward the outboard joint.

•

Remove the retaining ring [A].

•

Separate to the axle shaft.

•

Remove the steel balls [A].

•

Slide the cage [B] toward the outboard joint.

Rear Axle

•

Remove:

Circlip [A]

Special Tool — Outside Circlip Pliers [B]: 57001-144

•

Remove:

Inner Race [A]

Cage [B]

Inboard Joint Boot [C]

Boot Band [D]

Inboard Joint Boot Installation

•

Install:

New Small Band [A]

New Inboard Joint Boot [B]

Cage [C]

•

Install the inner race [A] so that the flat serration side [B] faces outboard joint.

FINAL DRIVE 11-73

•

Install:

Circlip [A]

Special Tool — Outside Circlip Pliers: 57001-144

•

Slide the cage [B] on the inner race and install the steel balls [C].

11-74 FINAL DRIVE

Rear Axle

•

Apply the special grease [A] to the steel balls and cage.

•

Squeeze about half a tube of the special grease [A] into the bearing cup [B].

•

Insert the balls and cage assembly in the bearing cup strongly.

•

Install the new retaining ring [A] so that the opening [B] is aligned with one of the projections [C].

•

Tighten the small band.

•

Squeeze the remaining special grease [A] into the inboard joint boot [B].

Rear Axle

•

Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot.

•

Hold the axle at this setting.

Standard Length of Assembling:

Left Rear Axle: 244.3 mm (9.62 in.) [A]

Right Rear Axle: 193.8 mm (7.63 in) [A]

FINAL DRIVE 11-75

•

Open the edge of the boot in order to eqalize the air pressures.

•

Tighten the large band [A] and tap down the tangs securely to hold down the end of the band.

•

Be sure outside diameter of the band [A] is less than the maximum diameter.

Maximum Outside Diameter of Band: 94.6 mm (3.72 in.)

11-76 FINAL DRIVE

Rear Final Gear Case

Rear Final Gear Case Oil Level Inspection

•

Park the vehicle so that it is level, both side-to-side and front-to-rear.

•

Remove the filler cap.

NOTICE

Be careful not to allow any dirt or foreign materials to enter the gear case.

•

Check the oil level. The oil level should come to the bottom of the filler opening [A].

If it is insufficient, first check the rear final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is

• already in the final gear case.

Apply grease to the O-ring.

•

Be sure the O-ring is in place.

Torque — Rear Final Gear Case Oil Filler Cap: 29 N·m (3.0

kgf·m, 21 ft·lb)

Rear Final Gear Case Oil Change

•

Refer to the Rear Final Gear Case Oil Change in the Periodic Maintenance chapter.

Rear Final Gear Case Removal

•

Remove:

Rear Bottom Guard (see Rear Bottom Guard Removal in the Frame chapter)

Rear Suspension Arm (see Rear Suspension Arm in the

Suspension chapter)

Rear Axles (see Rear Axle Removal)

Rear Propeller Shaft (see Rear Propeller Shaft Removal)

•

Remove:

Rear Brake Master Cylinder [A] (see Rear Brake Master

Cylinder Removal in the Brakes chapter)

Brake Cable Rear End [B]

Breather Hose [C]

Rear Final Gear Case

•

Remove:

Rear Final Gear Case Bolt [A] and Nut

•

Remove:

Rear Final Gear Case Bracket Bolts [A]

Rear Final Gear Case Brackets [B]

•

Support the rear final gear case with a suitable jack and/or stand [A].

•

Remove:

Rear Final Gear Case Bolts [B] and Nuts

•

Remove:

Rear Final Gear Case [A]

FINAL DRIVE 11-77

11-78 FINAL DRIVE

Rear Final Gear Case

Rear Final Gear Case Installation

•

Install:

Rear Final Gear Case

Bracket [A]

Bracket Bolts [B]

•

Apply a non-permanent locking agent to the rear final gear case bolts.

•

Install:

Rear Final Gear Case Bolts [C], L=120 mm (4.72 in.)

Rear Final Gear Case Bolts [D], L=70 mm (2.76 in.)

•

Tighten:

Torque — Rear Final Gear Case Bracket Bolts: 90.5 N·m (9.2

kgf·m, 67 ft·lb)

Rear Final Gear Case Mounting Nuts [E]: 90.5 N·m

(9.2 kgf·m, 67 ft·lb)

[F] Front

•

Install:

Removed Parts (see applicable chapters)

Rear Final Gear Case Disassembly

•

Remove:

Rear Final Gear Case (see Rear Final Gear Case Removal)

Spring [A]

•

Remove:

Master Cylinder Mounting Bolts [A]

Master Cylinder [B]

•

Remove:

Bolt [A] and Nut

Brake Cam Lever [B]

Rear Final Gear Case

•

Remove:

Rear Final Gear Case Front Cover Bolts [A]

Rear Final Gear Case Front Cover [B]

•

Remove:

Gasket Screws [A]

Gasket [B]

•

Remove:

Set Pins [A], Steel Plates [B] and Friction Plates [C]

FINAL DRIVE 11-79

•

Remove:

Brake Cam Plate [A]

Brake Camshaft [B]

•

Remove:

Steel Balls [A]

11-80 FINAL DRIVE

Rear Final Gear Case

•

Remove:

Rear Final Gear Case Right Cover Bolts (M10) [A]

Rear Final Gear Case Right Cover Bolts (M12) [B]

Rear Final Gear Case Right Cover [C]

•

Using the pry points [A], remove the rear final gear case right cover [B].

•

Remove:

Shims [A] (both sides)

Ring Gear [B]

•

Remove:

Pinion Gear Bearing Holder [A]

○

Hold the rear final gear case [A] in a vise, and remove the bearing holder using the socket wrench [B].

Special Tool — Socket Wrench, Hex 50: 57001-1478

○

If it is difficult to break free the holder, apply the heat to it to softer the locking agent.

Rear Final Gear Case

•

Remove:

Pinion Gear Unit [A]

Shim(s) [B]

•

Drill out the spring pin [A] with a drill bit of the 3 mm (0.12

in) diameter and remove it.

•

Remove the needle bearing [B].

Rear Final Gear Case Right Cover Assembly

[A] Rear Final Gear Case Right Cover

•

Press:

Ball Bearing (until bottomed)

Special Tool — Bearing Driver, 54.3 [B]: 57001-1488

[A] Rear Final Gear Case Right Cover

[B] Ball Bearing

•

Press the oil seal [C] so that the projecting distance is 3.5

mm (0.14 in.) [D] as shown in the figure.

Special Tool — Bearing Driver Set: 57001-1129

•

Apply Grease:

Oil Seal Lips [E]

Rear Final Gear Case Front Cover Assembly

[A] Rear Final Gear Case Front Cover

•

Press:

Ball Bearing [B] (until bottomed)

Special Tool — Bearing Driver Set: 57001-1129

•

Press the faces of the oil seals [C] are flush with the ends of the housing.

•

Apply Grease:

Oil Seal Lips

FINAL DRIVE 11-81

11-82 FINAL DRIVE

Rear Final Gear Case

•

Rear Final Gear Case Assembly

Apply specified oil to the bearings.

•

Press:

Ball Bearing [A] (until bottomed)

Special Tool — Bearing Driver Set: 57001-1129

○

When pressing the bearing, support the face [B] of the rear final gear case [C] with a suitable block or press the bearing with less than 5 ton.

•

Install:

New Circlip [D]

Special Tool — Inside Circlip Pliers: 57001-143

•

Press:

Ball Bearing (until bottomed)

Special Tool — Baring Driver, 54.3 [A]: 57001-1488

[B] Rear Final Gear Case

•

Press the needle bearing [A] in the rear final gear case

[B] so that the surface is flush with the case end [C].

•

Press the pin [D] in the rear final gear case so that the surface is flush with the case end [E].

•

Press the oil seal [F] so that the projecting distance is 3.5

mm (0.14 in.) [G] as shown in the figure.

•

Apply grease:

Oil Seal Lip

Rear Final Gear Case

•

Press the fitting [A] so that the projecting distance is 14 mm (0.55 in.) [B] as shown in the figure.

[C] Rear Final Gear Case

FINAL DRIVE 11-83

•

Visually check the pinion gear [A] and ring gear [B] for scoring, chipping, or other damage.

Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact.

•

Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash-related parts are replaced (see Rear Final Bevel Gear Adjustment).

•

Apply specified oil to the journal [A] and teeth [B].

•

Insert the shim [C] and pinion gear unit [D] in the rear final gear case [E].

•

Apply a non-permanent locking agent to the pinion gear bearing holder [A], but do not apply a non-permanent locking agent to one pitch [B] from the tip.

•

Install the pinion gear bearing holder so that the no coating side [C] faces the bearing.

•

Tighten:

Torque — Pinion Gear Bearing Holder: 450 N·m (45.9 kgf·m,

332 ft·lb)

•

Apply molybdenum disulfide grease to the spline [A] in the ring gear [B].

•

Apply specified oil to the journal and teeth [C].

•

Install:

Shim [D]

Ring Gear

11-84 FINAL DRIVE

Rear Final Gear Case

•

Install:

Shim [A]

•

Apply specified oil to the journal [B].

•

Apply grease to the O-ring [A] and install the rear final gear case right cover [B].

•

Apply a non-permanent locking agent to the rear final gear case right cover bolts.

•

Tighten:

Torque — Rear Final Gear Case Right Cover Bolts (M12) [A]:

94 N·m (9.6 kgf·m, 69 ft·lb)

Rear Final Gear Case Right Cover Bolts (M10) [B]:

49 N·m (5.0 kgf·m, 36 ft·lb)

•

Apply specified oil to the journal [A] of the brake camshaft.

•

Install:

Brake Camshaft [A]

Steel Balls [B]

Rear Final Gear Case

•

Install the brake cam plate [A] so that the recess side faces to steel balls.

FINAL DRIVE 11-85

•

Install:

Steel Plate [A] (P/No. 41080-1483, two holes) (as shown in the gigure)

Set Pins [B] and Springs [C]

•

Install (alternately):

Friction Plates [A]

Steel Plates (P/No. 41080-1484, without hole)

•

Install:

Steel Plate [A] (P/No. 41080-1483, two holes)

○

Insert the pins [B] into the holes of the steel plate.

•

Install:

Dowel Pins [A]

New Gasket [B]

•

Tighten:

Torque — Rear Final Gear Case Gasket Screws [C]: 1.3 N·m

(0.13 kgf·m, 12 in·lb)

11-86 FINAL DRIVE

Rear Final Gear Case

•

Install:

Rear Final Gear Case Front Cover [A]

•

Tighten:

Torque — Rear Final Gear Case Front Cover Bolts [B]: 24

N·m (2.4 kgf·m, 18 ft·lb)

•

Install:

Spring Bracket [C]

•

Apply a non-permanent locking agent to the spring bracket bolt [D].

•

Tighten:

Torque — Spring Bracket Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install:

Brake Cam Lever [A]

○

Align the punch mark [B] of the brake cam lever with the punch mark [C] of the brake camshaft.

•

Install:

Bolt [D] and Nut

•

Install:

Spring [A]

Pinion Gear Unit Disassembly

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Remove:

Pinion Gear Unit [A] (see Rear Final Gear Case Disassembly)

•

Hold the pinion gear bearing holder nut [B] with the socket wrench [C] in a vise, and loosen the pinion gear shaft using the pinion gear holder [D].

Special Tools — Socket Wrench: 57001-1363

Pinion Gear Holder, m1.0: 57001-1281

•

Remove the ball bearing [E] as necessary.

Special Tool — Bearing Puller: 57001-135

Rear Final Gear Case

Pinion Gear Unit Assembly

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Visually inspect the bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a bearing, replace the bearing.

•

Be sure to check and adjust the bevel gear backlash and tooth contact, when any of the backlash-related parts are replaced (see Rear Final Bevel Gear Adjustment).

•

Press the bearing [A] on the pinion gear until it is bottomed.

•

Install the pinion gear bearing holder nut [B] so that the projection [C] faces outward.

•

Apply a non-permanent locking agent (Three Bond:

TB2471 Blue) to the pinion gear bearing holder nut [A], and tighten it.

Special Tools — Socket Wrench [B]: 57001-1363

Pinion Gear Holder, m1.0 [C]: 57001-1281

Torque — Pinion Gear Bearing Holder Nut: 200 N·m (20.4

kgf·m, 148 ft·lb)

Rear Final Bevel Gear Adjustment

○

The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.

•

After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears. First, adjust backlash, and then tooth contact by replacing shims.

○

The amount of backlash is influenced by the ring gear position more than by the pinion gear position.

○

Tooth contact locations is influenced by the pinion gear position more than by the ring gear position.

FINAL DRIVE 11-87

11-88 FINAL DRIVE

Rear Final Gear Case

Rear Final Gear Case (Backlash-related Parts)

1. Ring Gear Shim(s)

2. Ring Gear Shim(s)

3. Pinion Gear Shim(s)

4. Pinion Gear Bearing Holder

5. Ball Bearings

6. Gear Case Right Cover

7. Pinion Gear

8. Ring Gear

Rear Final Gear Case

1. Ring Gear Shims for Backlash Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-0248

92180-0247

92180-0246

92180-0245

92180-0244

92180-0243

2. Ring Gear Shims for Backlash Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1417

92180-1418

92180-1419

92180-1420

92180-1421

92180-1422

3. Pinion Gear Shims for Tooth Contact Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1423

92180-1424

92180-1425

92180-1426

92180-1427

92180-1428

FINAL DRIVE 11-89

11-90 FINAL DRIVE

Rear Final Gear Case

•

Rear Final Gear Case Backlash Adjustment

Clean dirt and oil off bevel gear teeth.

•

Measure length [A], [B] and [C], and calculate the clearance [D] between the ring gear assembly and gear case covers.

[D] = [A] + [B] – [C]

[E] Rear Final Gear Case

[F] Ring Gear Assembly

[G] Rear Final Gear Case Right Cover

•

Assemble the rear final gear case (see Rear Final Gear

Case Assembly).

○

When installing the pinion gear bearing holder, a non-permanent locking agent is not used.

○

Use the following two spare bolts when installing the rear final gear case right cover [A].

M12 Bolt [B] L = 35 mm (1.38 in.), P = 1.25 mm (0.049

in.)

M10 Bolt [C] L = 35 mm (1.38 in.), P = 1.25 mm (0.049

in.)

Rear Final Gear Case

•

Temporarily install the rear axles in the gear case and hold them.

•

Mount a dial gauge [A] so that the tip of the gauge is against the splined portion [B] of the pinion gear shaft.

•

To measure backlash, turn the pinion gear shaft right and left [C] while holding the rear axles steady. The difference between the highest and lowest gauge reading is the amount of backlash.

○

Measure backlash at three locations (equally spaced on the splines).

Rear Final Bevel Gear Backlash

Standard: 0.05

∼

0.11 mm (0.002

∼

0.004 in.)

(at pinion gear spline)

If the backlash is not within the standard, replace the ring gear shims according to the below NOTE. To increase backlash, decrease the thickness of the shim(s) [1] and increase the thickness of the shim(s) [2]. To decrease backlash, increase the thickness of the shim(s) [1] and decrease the thickness of the shim(s) [2].

NOTE

○

The total of the ring gear shims, [1] and [2], should be less than [D] (the clearance between the ring gear assembly and gear case covers).

○

Example:

D = 2.34 mm →[1] + [2] = 2.30 mm

D = 2.26 mm →[1] + [2] = 2.25 mm

○

The second decimal of the total of [1] and [2] should be

.×0 or .×5 nearest of D.

•

Recheck the backlash, and readjust if necessary.

•

Tooth Contact Adjustment

Clean any dirt and oil off the bevel gear teeth.

•

Apply checking compound to 4 or 5 teeth of the pinion gear.

NOTE

○

Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear.

○

The checking compound must be smooth and firm, with the consistency of tooth paste.

○

Special compounds are available at automotive supply stores for the purpose of checking gear tooth patterns and contact. Use one of these for checking the bevel gears.

FINAL DRIVE 11-91

11-92 FINAL DRIVE

Rear Final Gear Case

•

Assemble the rear final gear case (see Rear Final Gear

Case Assembly).

•

Turn the pinion gear for one revolution in the drive and reverse (coast) direction, while creating drag on the ring gear.

•

Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth.

○

The tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe.

If the tooth contact pattern is incorrect, replace the pinion gear shim(s), following the examples shown (see Front

Final Gear Case Tooth Contact Adjustment).

•

Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shim(s) are replaced. Repeat the shim change procedure as necessary.

NOTE

○

If the backlash is out of the standard range after changing the pinion gear shim(s), change the ring gear shim(s) to correct the backlash before checking the tooth contact pattern.

Bearing and Oil Seal

Ball or Needle Bearing Inspection

Since the bearings are made to extremely close tolerances, the clearance cannot normally be measured.

NOTICE

Do not remove any bearings for inspection except the right rear axle bearing.

•

Turn each bearing in the case or hub back and forth [A] while checking for plays, roughness, or binding.

If bearing play, roughness, or binding is found, replace the bearing.

FINAL DRIVE 11-93

•

Check the needle bearings [A].

○

The rollers in the needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.

If the bearing is damaged, replace the bearing.

11-94 FINAL DRIVE

Bearing and Oil Seal

Oil Seal Inspection

•

Inspect the oil seals [A].

Replace any if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.

BRAKES 12-1

Brakes

Table of Contents

Exploded View……………………………..

Specifications ………………………………

Brake Fluid ………………………………….

12-2

12-6

12-7

Front Brake Fluid

Recommendation ………………….

Front Brake Fluid Level

Inspection…………………………….

12-7

Front Brake Fluid Change…………

Brake Line Air Bleeding ……………

12-7

12-7

12-8

Brake Pedal and Master Cylinder……

12-10

Brake Pedal Play Inspection ……..

12-10

Brake Pedal Removal ………………

12-10

Brake Pedal Installation ……………

12-10

Front Master Cylinder Removal …

12-11

Front Master Cylinder Installation 12-11

Front Master Cylinder

Disassembly/Assembly ………….

12-11

Front Master Cylinder Inspection .

12-12

Rear Master Cylinder Removal….

12-12

Rear Master Cylinder Installation.

12-12

Rear Master Cylinder

Disassembly/Assembly ………….

12-12

Rear Master Cylinder Inspection..

12-13

Calipers ………………………………………

12-14

Front Brake Caliper Removal…….

12-14

Front Brake Caliper Installation….

12-14

Front Brake Caliper Disassembly 12-14

Front Brake Caliper Assembly …..

12-14

Caliper Piston Seal Damage

Inspection…………………………….

12-15

Dust Seal and Friction Boot

Damage Inspection ……………….

12-15

Front Brake Caliper Piston and

Cylinder Damage Inspection …..

12-15

Front Brake Caliper Holder Shaft

Wear Inspection ……………………

12-15

Brake Pads ………………………………….

12-16

Front Brake Pad Removal…………

12-16

Front Brake Pad Installation………

12-16

Front Brake Pad Wear Inspection 12-16

Brake Discs …………………………………

12-17

Front Brake Disc Cleaning ………..

12-17

Front Brake Disc Removal ………..

12-17

Front Brake Disc Installation ……..

12-17

Front Brake Disc Wear Inspection 12-17

Front Brake Disc Runout

Inspection…………………………….

12-17

Brake Hoses and Pipes …………………

12-18

Brake Hose and Pipe Inspection..

12-18

Brake Hose Replacement …………

12-18

Parking Brake Pedal and Cables…….

12-19

Parking Brake Pedal Inspection…

12-19

Parking Brake Pedal Removal …..

12-19

Parking Brake Pedal Installation ..

12-19

Parking Brake Cable Removal…..

12-20

Parking Brake Cable Installation..

12-20

Parking Brake Cable Lubrication .

12-20

Internal Wet Brake………………………..

12-21

Internal Wet Brake Disassembly..

12-21

Internal Wet Brake Assembly…….

12-21

12

12-2 BRAKES

Exploded View

Exploded View

No.

Fastener

1 Front Master Cylinder Reservoir Cap

2 Reservoir Clamp Bolt

3 Piston Stop Bolt

4 Brake Pipe Nipples

5 Brake Hose Banjo Bolts

6 Front Master Cylinder Mounting Bolts

7 Master Cylinder Bolt

8 Push Rod Locknut

9 Parking Brake Pedal Assy Mounting Bolts

10 Front Brake Pad Mounting Bolts

11 Caliper Bleed Valves

12 Brake Hose Clamp Bolts

13 Caliper Holder Shaft

14 Brake Caliper Mounting Bolts

15 Front Brake Disc Mounting Bolts

16 Parking Brake Indicator Light Switch Screws

17. Apply sealing material to the hatched area.

B. Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Apply silicone grease.

BRAKES 12-3

17.2

41.5

17.2

7.8

8.8

17.2

33

41.5

0.4

N·m

3.4

6.2

8.8

17.5

23.5

23.5

23.5

1.8

0.80

0.90

1.8

2.4

2.4

1.8

4.2

Torque kgf·m

0.35

0.63

0.90

1.8

2.4

3.4

4.2

0.04

13

31

13

69 in·lb

78 in·lb

13

24

31

4 in·lb

ft·lb

30 in·lb

55 in·lb

78 in·lb

13

17

17

17

Remarks

L

L

L

12-4 BRAKES

Exploded View

BRAKES 12-5

Exploded View

No.

Fastener

1 Brake Hose Banjo Bolts

2 Brake Pipe Nipples

3 Rear Master Cylinder Bleed Valve

4 Rear Master Cylinder Mounting Bolts

5 Rear Final Gear Case Front Cover Bolts

6 Spring Bracket Bolt

7 Rear Final Gear Case Gasket Screws

8 Brake Pipe Joint

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

MF: Apply gear oil (MOBIL FLUID 424 or equivalent oil).

R: Replacement Parts

Si: Apply silicone grease.

N·m

23.5

17.5

7.8

27

24

8.8

1.3

17.5

Torque kgf·m

2.4

1.8

0.80

2.8

2.4

0.90

0.13

1.8

ft·lb

17

13

69 in·lb

20

18

78 in·lb

12 in·lb

13

Remarks

L

L

12-6 BRAKES

Specifications

Item

Brake Fluid

Type

Fluid Level

Brake Pedal

Brake Pedal Play

Front Disc Brake

Pad Lining Thickness

Disc Thickness

Disc Runout

Standard Service Limit

DOT3

Between upper and lower level lines

2

∼

10 mm (0.08

∼

0.39 in.)

3.9 mm (0.15 in.)

4.6

∼

5.0 mm (0.18

∼

0.20 in.)

TIR 0.25 mm (0.010 in.) or less

– – –

– – –

– – –

1 mm (0.04 in.)

4.3 mm (0.17 in.)

TIR 0.3 mm (0.012 in.)

Brake Fluid

WARNING

When working with the disc brake, observe the precautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid.

5. Don’t add or change the fluid in the rain or when a strong wind is blowing.

6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.

7. When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them.

Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.

8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately.

9. If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED

FROM THE BRAKE LINE.

Front Brake Fluid Recommendation

Use extra heavy-duty brake fluid only from a container marked DOT3.

Recommended Disc Brake Fluid

Type DOT 3

Front Brake Fluid Level Inspection

•

Refer to the Brake Fluid Level Inspection in the Periodic

Maintenance chapter.

Front Brake Fluid Change

•

Refer to the Brake Fluid Change in the Periodic Maintenance chapter.

BRAKES 12-7

12-8 BRAKES

Brake Fluid

Brake Line Air Bleeding

The brake fluid has a very low compression coefficient so that almost all the movement of the brake pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power.

WARNING

Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake lever has a soft or «spongy» feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately.

NOTE

○

The procedure to bleed the brake line is as follows.

•

Remove the reservoir cap [A] and fill the reservoir with new brake fluid.

•

Slowly pump the brake pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir.

○

Bleed the air completely from the front master cylinder by this operation.

NOTE

○

Start with the rear master cylinder and finish with the front left or right caliper.

•

Remove the rubber cap from the bleed valve on the rear master cylinder.

•

Connect a clear plastic hose [A] to the bleed valve on the rear master cylinder, and run the other end of the hose into a container.

Brake Fluid

•

Bleed the brake line and the rear master cylinder as follows:

○

Repeat this operation until no more air can be seen coming out into the plastic hose.

1. Pump the brake pedal until it becomes hard, and apply the brake pedal and hold it [A].

2. Quickly open and close [B] the bleed valve while holding the brake pedal applied.

3. Release the brake pedal [C].

NOTE

○

The fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line.

•

Remove the clear plastic hose.

•

Tighten:

Torque — Rear Master Cylinder Bleed Valve: 7.8 N·m (0.80

kgf·m, 69 in·lb)

•

Install the rubber cap.

•

Repeat the previous step for front calipers [A].

•

After the air bleeding, tighten the caliper bleed valves.

Torque — Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•

When air bleeding is finished, add fluid up to the upper level in the reservoir.

•

Tighten:

Torque — Front Master Cylinder Reservoir Cap: 3.4 N·m

(0.35 kgf·m, 30 in·lb)

•

Apply the brake forcefully for a few seconds, and check for fluid leakage around the fittings.

BRAKES 12-9

12-10 BRAKES

Brake Pedal and Master Cylinder

Brake Pedal Play Inspection

•

Refer to the Brake Pedal Play Inspection in the Periodic

Maintenance chapter.

Brake Pedal Removal

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Lift and hold the front fender rear (see Front Fender Rear

Removal in the Frame chapter).

•

Remove:

Brake Light Switch Spring [A]

•

Remove:

Cotter Pin and Pin [A]

Cotter Pin and Brake Shaft [B]

Spring [C]

Brake Pedal [D]

•

Brake Pedal Installation

Apply grease to the brake shaft [A].

•

Install:

Brake Pedal [B]

Spring [C]

Bushings [D]

Brake Shaft

Push Rod [E] and Pin [F]

New Cotter Pins [G]

•

Bend the cotter pins over the shaft and pin ends.

•

Install:

Brake Light Switch Spring [A]

•

After the spring is installed, bend the spring ends [B] to prevent it from coming off.

•

Install:

Front Fender Rear (see Front Fender Rear Installation in the Frame chapter)

Brake Pedal and Master Cylinder

Front Master Cylinder Removal

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Remove:

Brake Hose Banjo Bolts [A]

Brake Pipe Nipple [B] (unscrew)

•

Immediately wipe up any brake fluid that spills.

NOTICE

Brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately.

•

Remove:

Front Master Cylinder Mounting Bolts [C]

Front Master Cylinder [D]

Front Master Cylinder Installation

•

Install:

Front Master Cylinder

Front Master Cylinder Mounting Bolts

•

Tighten:

Torque — Front Master Cylinder Mounting Bolts: 23.5 N·m

(2.4 kgf·m, 17 ft·lb)

•

Replace the washers on each side of the hose fitting with new ones.

○

Touch the brake hose clasp [A] to the stopper [B].

•

Tighten:

Torque — Brake Hose Banjo Bolts: 23.5 N·m (2.4 kgf·m, 17 ft·lb)

•

Brake Pipe Nipple: 17.5 N·m (1.8 kgf·m, 13 ft·lb)

Bleed the brake line after master cylinder installation.

•

Adjust the brake pedal play (see Brake Pedal Play Inspection).

•

Check that the brake line has proper fluid pressure and no fluid leakage.

Front Master Cylinder Disassembly/Assembly

•

Refer to the Front Brake Master Cylinder Cup and Dust

Seal Replacement in the Periodic Maintenance chapter.

BRAKES 12-11

12-12 BRAKES

Brake Pedal and Master Cylinder

Front Master Cylinder Inspection

•

Disassemble the front master cylinder (see Front Brake

Master Cylinder Cup and Dust Seal Replacement in the

Periodic Maintenance chapter).

•

Check that there are no scratches, rust or pitting on the inside of the cylinder [A] and on the outside of the pistons

[B].

If the cylinder or piston shows any damage, replace them.

•

Inspect the primary cups [C] and secondary cups [D].

If a cup is worn, damaged, softened (rotted), or swollen, replace it.

If fluid leakage is noted at the brake push rod, the secondary cup of the rear piston should be replaced.

•

Check the dust cover [E] for damage.

If it is damaged, replace it.

•

Check that the relief [F] and supply [G] ports are not plugged.

If the small relief port becomes plugged, the brake shoes will drag on the drum. Blow the ports clean with compressed air.

•

Check the piston return springs [H] for any damage.

If the spring is damaged, replace it.

Rear Master Cylinder Removal

•

Remove:

Brake Pipe Nipple [A] (unscrew)

•

Immediately wipe up any brake fluid that spills.

NOTICE

Brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately.

•

Remove:

Rear Master Cylinder Mounting Bolts [B]

Rear Master Cylinder [C]

•

Rear Master Cylinder Installation

Apply specified oil to the rod end [A].

•

Apply grease to the O-ring [B].

•

Install:

Rear Master Cylinder [C]

•

Apply a non-permanent locking agent to the rear master cylinder mounting bolts.

•

Tighten:

Torque — Rear Master Cylinder Mounting Bolts: 27 N·m (2.8

kgf·m, 20 ft·lb)

•

Brake Pipe Nipple: 17.5 N·m (1.8 kgf·m, 13 ft·lb)

Bleed the brake line after master cylinder installation.

•

Check that the brake line has proper fluid pressure and no fluid leakage.

Rear Master Cylinder Disassembly/Assembly

•

Refer to the Rear Brake Master Cylinder Cup, O-ring and

Boot Replacement in the Periodic Maintenance chapter.

Brake Pedal and Master Cylinder

Rear Master Cylinder Inspection

•

Disassemble the rear master cylinder (see Rear Brake

Master Cylinder Cup, O-ring and Boot Replacement in the

Periodic Maintenance chapter).

•

Check that there are no scratches, rust or pitting on the inside of the cylinder [A] and on the outside of the pistons

[B].

If the cylinder or piston shows any damage, replace them.

•

Inspect the cup [C].

If a cup is worn, damaged, softened (rotted), or swollen, replace it.

If fluid leakage is noted at the push rod [D], the cup of the piston should be replaced.

•

Check the boot [E] for damage.

If it is damaged, replace it.

•

Check the piston return springs [F] for any damage.

If the spring is damaged, replace it.

BRAKES 12-13

12-14 BRAKES

Calipers

Front Brake Caliper Removal

•

Remove the front wheel (see Wheel Removal in the

Wheels/Tires chapter).

•

Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.

•

Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.

•

Unscrew the banjo bolt and remove the brake hose [D] from the caliper.

NOTICE

Immediately wash away any brake fluid that spills.

NOTE

○

If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Front Brake

Caliper Piston Seal and Dust Seal Replacement).

•

Front Brake Caliper Installation

Install the caliper and brake hose lower end.

○

Replace the washers that are on each side of hose fitting with new ones.

•

Touch the stopper of the brake hose to the stopper on the caliper.

•

Tighten:

Torque — Brake Caliper Mounting Bolts: 33 N·m (3.4 kgf·m,

25 ft·lb)

Brake Hose Banjo Bolt: 23.5 N·m (2.4 kgf·m, 17

•

ft·lb)

Check the fluid level in the brake reservoir.

•

Bleed the brake line (see Brake Line Air Bleeding).

•

Check the brake for good braking power, no brake drag, and no fluid leakage.

WARNING

After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death.

Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc.

Front Brake Caliper Disassembly

•

Refer to the Front Brake Caliper Piston Seal and Dust

Seal Replacement in the Periodic Maintenance chapter.

Front Brake Caliper Assembly

•

Refer to the Front Brake Caliper Piston Seal and Dust

Seal Replacement in the Periodic Maintenance chapter.

Calipers

Caliper Piston Seal Damage Inspection

The piston seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature.

•

Replace the piston seals in accordance with the Periodic

Maintenance Chart or under any of the following conditions.

○

Brake fluid leakage around the pad

○

Brakes overheat

○

There is a large difference in inner and outer pad wear.

○

The seal is stuck to the pistons.

If the piston seal is replaced, replace the dust seal as well. Also, replace all seals every other time the pads are changed.

Dust Seal and Friction Boot Damage Inspection

•

Replace the dust seals [A] in accordance with the Periodic Maintenance Chart or check that the dust seals and friction boots [B] are not cracked, worn swollen, or otherwise damaged.

If they show any damage, replace them.

Front Brake Caliper Piston and Cylinder Damage

Inspection

•

Visually inspect the piston [A] and cylinder surfaces [B].

Replace the caliper if the cylinder and piston are badly scored or rusty.

Front Brake Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.

•

Check to see that the caliper holder shafts are not badly worn or stepped, and that the rubber boots [B] are not damaged.

If the rubber boot is damaged, replace the rubber boot.

If caliper holder shaft is damaged, replace the caliper holder shaft and rubber boot as a unit.

BRAKES 12-15

12-16 BRAKES

Brake Pads

Front Brake Pad Removal

•

Remove the caliper with the hose installed (see Front

Brake Caliper Removal).

•

Remove the pad mounting bolts [A].

•

Remove the brake pads [A].

•

Front Brake Pad Installation

Push the caliper piston in by hand as far as it will go.

•

Be sure that the anti-rattle spring is in place.

•

Install:

Brake Pads

Pad Mounting Bolts

•

Tighten:

Torque — Front Brake Pad Mounting Bolts: 17.2 N·m (1.8

kgf·m, 13 ft·lb)

WARNING

After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death.

Do not attempt to ride the vehicle until a firm brake lever is obtained by pumping the lever until the pads are against the disc.

Front Brake Pad Wear Inspection

•

Refer to the Front Brake Pad Wear Inspection in the Periodic Maintenance chapter.

Brake Discs

Front Brake Disc Cleaning

Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone.

WARNING

These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings.

Front Brake Disc Removal

•

Remove:

Front Hub (see Front Hub Removal in the Wheels/Tires chapter)

Brake Disc Mounting Bolts [A]

Brake Disc [B]

Front Brake Disc Installation

•

The disc must be installed with the marked side [A] facing toward the steering knuckle.

•

Apply a non-permanent locking agent to the brake disc mounting bolts.

•

Tighten:

Torque — Front Brake Disc Mounting Bolts: 41.5 N·m (4.2

kgf·m, 31 ft·lb)

•

After installing the discs, check the disc runout. Completely clean off any grease that has gotten on either side of the disc with a high-flash point solvent. Do not use one which will leave an oily residue.

Front Brake Disc Wear Inspection

•

Measure the thickness of each disc at the point [A] where it has worn the most.

Replace the disc if it has worn past the service limit.

Disc Thickness

Standard: 4.6

∼

5.0 mm (0.18

∼

0.20 in.)

Service Limit: 4.3 mm (0.17 in.)

•

Front Brake Disc Runout Inspection

Jack up the vehicle so that the wheels are off the ground.

•

Remove the front wheels and turn the handlebar fully to one side.

•

Set up a dial gauge against the disc [A], and measure the disc runout.

If the runout exceeds the service limit, replace the disc.

Disc Runout

Standard: TIR 0.25 mm (0.010 in.) or less

Service Limit: TIR 0.3 mm (0.012 in.)

BRAKES 12-17

12-18 BRAKES

Brake Hoses and Pipes

Brake Hose and Pipe Inspection

•

Refer to the Brake Hose and Pipe Connections Inspection in the Periodic Maintenance chapter.

Brake Hose Replacement

•

Refer to the Brake Hose Replacement in the Periodic

Maintenance chapter.

Parking Brake Pedal and Cables

Parking Brake Pedal Inspection

•

Refer to the Parking Brake Pedal Inspection in the Periodic Maintenance chapter.

Parking Brake Pedal Removal

•

Remove:

Control Panel (see Control Panel Removal in the Frame chapter)

•

Cable Locknuts [A]

Remove the cable end from the pin [B].

•

Remove:

Spring [C]

Circlip [D]

Shim [E]

Parking Brake Pedal [F]

•

When removing the parking release lever [G], remove the following parts.

Spring [H]

Circlip and Washer [I]

Parking Brake Pedal Installation

•

Apply grease:

Parking Brake Pedal Pivot [A]

Parking Release Lever Pivot [B]

•

Install:

Parking Brake Pedal [C]

New Bushings [D] (press, if installing)

Pin [E]

Shim [F]

New Circlip [G]

Spring [H]

Parking Release Lever [I]

Washer [J]

New Circlip [K]

Spring [L]

If there is the excess play in right and left directions on the parking brake pedal, replace the shim [F] to one in the following shims.

Shims

Part Number Thickness

92180-0279

92180-0281

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

92180-0279

1.2 mm (0.047 in.)

•

When installing the parking brake indicator light switch

[M], install the washer [N] and tighten the parking brake indicator light switch screws [O].

Torque — Parking Brake Indicator Light Switch Screws: 0.4

N·m (0.04 kgf·m, 4 in·lb)

BRAKES 12-19

12-20 BRAKES

Parking Brake Pedal and Cables

Parking Brake Cable Removal

•

Remove:

Control Panel (see Control Panel Removal in the Frame chapter)

Cable Locknuts [A]

•

Loosen the cable mounting nuts [B] and remove the cable

[C] from the bracket.

•

Remove:

Adjuster [A]

Pin [B]

Washer

Spring [C]

•

Remove the cable from the bracket and remove it from the frame.

Parking Brake Cable Installation

•

Run the 2WD/4WD shift cable according to the Cable,

Wire and Hose Routing section in the Appendix chapter.

•

Install the front side of parking brake cable [A] as shown in the figure.

Cable Mounting Nut [B]

•

10 mm (0.39 in.) [C]

Install the rear side of parking brake cable [D] as follows.

•

Install the following parts in the lever [E] temporarily.

Rear End of Parking Brake Cable

Washer and Pin

Adjuster [F]

•

Push the lever toward cable as shown until the lever is stopped without lever return spring.

•

Setting Position [G]

•

Then tighten the adjuster until the pin touches the lever and return the adjuster 3

∼

5 rotations.

•

Install the return spring to the lever.

Check the parking brake for good braking power and when the parking brake released, no brake drag.

Parking Brake Cable Lubrication

Whenever the brake cable is removed, lubricate the cable as follows:

•

Lubricate the cable with a penetrating aerosol cable lubricant through the pressure cable luber.

Internal Wet Brake

Internal Wet Brake Disassembly

•

Refer to Rear Final Gear Case section in the Final Drive chapter.

Internal Wet Brake Assembly

•

Refer to Rear Final Gear Case section in the Final Drive chapter.

BRAKES 12-21

SUSPENSION 13-1

Suspension

Table of Contents

Exploded View…………………………………………………………………………………………………………

13-2

Specifications ………………………………………………………………………………………………………….

13-6

Special Tools …………………………………………………………………………………………………………..

13-7

Shock Absorbers (Other than KRF750S) …………………………………………………………………….

13-8

Front Shock Absorber Spring Preload Adjustment …………………………………………………..

13-8

Front Shock Absorber Removal…………………………………………………………………………….

Front Shock Absorber Installation………………………………………………………………………….

Front Shock Absorber Inspection…………………………………………………………………………..

13-8

13-8

13-9

Front Shock Absorber Scrapping…………………………………………………………………………..

13-9

Rear Shock Absorber Spring Preload Adjustment……………………………………………………

13-10

Rear Shock Absorber Removal …………………………………………………………………………….

13-10

Rear Shock Absorber Installation ………………………………………………………………………….

13-11

Rear Shock Absorber Inspection …………………………………………………………………………..

13-11

Rear Shock Absorber Scrapping …………………………………………………………………………..

13-12

Shock Absorbers (KRF750S) …………………………………………………………………………………….

13-13

Front Shock Absorber Rebound Damping Force Adjustment…………………………………….

13-13

Front Shock Absorber Compression Damping Force Adjustment ………………………………

13-13

Front Shock Absorber Spring Preload Adjustment …………………………………………………..

13-14

Front Shock Absorber Removal…………………………………………………………………………….

13-14

Front Shock Absorber Installation………………………………………………………………………….

13-14

Front Shock Absorber Inspection…………………………………………………………………………..

13-15

Front Shock Absorber Scrapping…………………………………………………………………………..

13-15

Rear Shock Absorber Rebound Damping Force Adjustment …………………………………….

13-16

Rear Shock Absorber Compression Damping Force Adjustment……………………………….

13-16

Rear Shock Absorber Spring Preload Adjustment……………………………………………………

13-17

Rear Shock Absorber Removal …………………………………………………………………………….

13-17

Rear Shock Absorber Installation ………………………………………………………………………….

13-18

Rear Shock Absorber Inspection …………………………………………………………………………..

13-18

Rear Shock Absorber Scrapping …………………………………………………………………………..

13-19

Suspension Arms …………………………………………………………………………………………………….

13-20

Front Suspension Arm Removal ……………………………………………………………………………

13-20

Front Suspension Arm Installation …………………………………………………………………………

13-21

Front Suspension Arm Disassembly………………………………………………………………………

13-22

Front Suspension Arm Assembly…………………………………………………………………………..

13-22

Rear Suspension Arm Removal…………………………………………………………………………….

13-23

Rear Suspension Arm Installation………………………………………………………………………….

13-24

Rear Suspension Arm Disassembly ………………………………………………………………………

13-24

Rear Suspension Arm Assembly …………………………………………………………………………..

13-25

Stabilizer Removal ………………………………………………………………………………………………

13-25

Stabilizer Installation ……………………………………………………………………………………………

13-26

Stabilizer Joint Inspection …………………………………………………………………………………….

13-26

Rear Knuckle Removal ………………………………………………………………………………………..

13-26

Rear Knuckle Installation ……………………………………………………………………………………..

13-27

Rear Knuckle Disassembly …………………………………………………………………………………..

13-27

Rear Knuckle Assembly……………………………………………………………………………………….

13-28

Bearing and Oil Seal…………………………………………………………………………………………………

13-29

Ball Bearing Inspection ………………………………………………………………………………………..

13-29

Oil Seal Inspection ………………………………………………………………………………………………

13-29

13

13-2 SUSPENSION

Exploded View

SUSPENSION 13-3

Exploded View

No.

Fastener

1 Front Shock Absorber Mounting Nuts

2 Front Suspension Arm Pivot Nuts

3 Steering Knuckle Joint Nuts

N·m

57.5

87.5

46.5

4. KRF750S

AG: Apply lithium grease (NLGI Grade No.2).

G: Apply grease.

LG: Apply liquid gasket (Liquid Gasket, TB1215: 92104-1065).

R: Replacement Parts

Torque kgf·m

5.9

8.9

4.7

ft·lb

42

65

34

Remarks

R

R

13-4 SUSPENSION

Exploded View

SUSPENSION 13-5

Exploded View

No.

Fastener

1 Rear Shock Absorber Mounting Nuts

2 Rear Suspension Arm Pivot Nuts

3 Rear Knuckle Mounting Nuts

4 Stabilizer Joint Nuts

5 Stabilizer Holder Bolts

N·m

95.5

87.5

57.5

57.5

31.5

6. KRF750S

AG: Apply lithium grease (NLGI Grade No.2).

G: Apply grease.

L: Apply a non-permanent locking agent.

LG: Apply liquid gasket (Liquid Gasket, TB1215: 92104-1065).

R: Replacement Parts

Torque kgf·m

9.7

8.9

5.9

5.9

3.2

ft·lb

70

65

42

42

23

Remarks

R

R

R

R

L

13-6 SUSPENSION

Specifications

Item

Shock Absorbers (Oher than KRF750S)

Spring Preload Setting Position:

Front

Rear

Shock Absorbers (KRF750S)

Rebound Damping Force Adjustment:

(Out from the fully tightened position)

Front

Rear

Compression Damping Force Adjustment:

(Out from the fully tightened position)

Front

Rear

Spring Preload Setting Position:

Front

Rear

Standard

No. 2

111.5 mm (4.390 in.)

Service Limit

(Usable Range)

1

∼

5

109.5

∼

127.5 mm

(4.311

∼

5.020 in.)

1 turn out

1 turn out

(Usable Range)

0

∼

2.5 turns out

1

∼

3 turns out

3.5 turns out

12 clicks out

(Usable Range)

0

∼

5 turns out

1

∼

20 clicks

(Usable Range)

82.5 mm (3.248 in.) 75.5

∼

95.5 mm (2.972

∼

3.760 in.)

116.0 mm (4.567 in.) 109.5

∼

127.5 mm

(4.311

∼

5.020 in.)

Special Tools

Inside Circlip Pliers:

57001-143

Outside Circlip Pliers:

57001-144

Steering Stem Nut Wrench:

57001-1100

Hook Wrench R37.5, R42:

57001-1101

Bearing Driver Set:

57001-1129

SUSPENSION 13-7

Jack:

57001-1238

Hook Wrench T=3.2 R37:

57001-1539

Knuckle Joint Driver:

57001-1640

13-8 SUSPENSION

Shock Absorbers (Other than KRF750S)

Front Shock Absorber Spring Preload Adjustment

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Using the nut wrench, turn the adjusting sleeve [A] to adjust the spring preload.

Special Tool — Steering Stem Nut Wrench: 57001-1100

○

The standard adjuster setting for average-build rider of 68 kg (150 Ib) with no passenger and no accessories is 2th position.

Spring Preload Setting

Standard Position: 2th position

Adjustable Range: 1st

∼

5th position

•

If the compression of the spring is not suited to the operating conditions, adjust it to an appropriate position by referring to the table below.

Spring Preload Adjustment

Adjuster

Position

1st

↑

↓

5th

Damping

Force

Shock

Absorber

Hardness

Weak

↑

↓

Strong

Soft

↑

↓

Hard

Load

Light

↑

↓

Heavy

Road

Conditions

Good

↑

↓

Bad

Driving

Speed

Low

↑

↓

High

Front Shock Absorber Removal

•

Support the vehicle on a stand or a jack so that the front wheels are off the ground.

Special Tool — Jack: 57001-1238

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

While holding the front wheels, remove the lower and upper shock absorber mounting bolts [A] and nuts.

•

Remove the front shock absorber [B].

Front Shock Absorber Installation

•

Apply grease to the inside of needle bearing [A] and grease seal lips [B].

•

Install the collar [C]

Shock Absorbers (Other than KRF750S)

•

Install the bushing [A] using a press.

•

Install the front shock absorber so that the label side [B] faces outside.

[C] Needle Bearing

[D] Collar

[E] Grease Seals

[F] New Nuts

•

Tighten:

Torque — Front Shock Absorber Mounting Nuts: 57.5 N·m

(5.9 kgf·m, 42 ft·lb)

SUSPENSION 13-9

Front Shock Absorber Inspection

•

Check the bushing in the upper pivot.

If bushing is worn, cracked, hardened, or otherwise damaged, replace it.

•

Check the needle bearing and grease seals in the lower pivot.

If they are damaged, replace them.

Front Shock Absorber Scrapping

WARNING

Since the front shock absorber contains nitrogen gas, do not incinerate or disassemble the front shock absorber. Before a front shock absorber is scrapped, drill a hole at a point about 15mm

(0.59 in.) [A] up from the bottom of the cylinder to release the nitrogen gas completely. Wear safety glasses when drilling the hole, as the gas may blow out bits of drilled metal when the hole opens.

13-10 SUSPENSION

Shock Absorbers (Other than KRF750S)

•

Rear Shock Absorber Spring Preload Adjustment

Loosen the locknut [A].

•

Turn the adjusting nut [B] to the desired position.

Special Tool — Hook Wrench T = 3.2, R37: 57001-1539

Adjusting Length [C]: from center of upper mounting bolt to lower surface of adjusting nut

○

The standard adjusting nut setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is 111.5 mm (4.390 in.) spring length.

Spring Preload Setting

Standard: Adjusting length 111.5 mm (4.390 in.)

Usable Range: Adjusting length 109.5

∼

127.5 mm

(4.311

∼

5.020 in.)

•

Tighten the locknut.

If the spring action feels too soft or too stiff, adjust it.

Spring Preload Adjustment

Adjusting

Length

Damping

Force

Setting

109.5 mm

(4.311 in.)

Weak Soft

Load

Light

Road

Good

Speed

Low

↑

↓

127.5 mm

(5.020 in.)

↑

↓

Strong

↑

↓

Hard

↑

↓

Heavy

↑

↓

Bad

↑

↓

High

Rear Shock Absorber Removal

•

Remove:

Rear Wheel (see Wheel Removal in the Wheels/Tires chapter)

Guard [A], Bolts and Washer

•

Remove:

Rear Shock Absorber Mounting Bolts [A] and Nuts

Rear Shock Absorber [B]

Shock Absorbers (Other than KRF750S)

Rear Shock Absorber Installation

•

Apply grease to the inside of needle bearing [A] and grease seal lips [B].

•

Install the collars [C].

SUSPENSION 13-11

•

Apply grease to the grease seal lips [A].

•

Install the collars [B].

•

When replacing the ball bearing [A], install the new circlip

[B].

[C] Grease Seals

[D] Collars

[E] New Nuts

[F] Needle Bearing

•

Tighten:

Torque — Rear Shock Absorber Mounting Nuts: 95.5 N·m

(9.7 kgf·m, 70 ft·lb)

•

Install the removed parts (see appropriate chapters).

Rear Shock Absorber Inspection

•

Check the ball bearing and grease seals in the upper pivot.

If they are damaged, replace them.

•

Check the needle bearing and grease seals in the lower pivot.

If they are damaged, replace them.

13-12 SUSPENSION

Shock Absorbers (Other than KRF750S)

Rear Shock Absorber Scrapping

WARNING

Pressurized nitrogen may explode when heated.

The rear shock contains nitrogen gas. To avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve.

•

Remove the rear shock absorber. (see Rear Shock Absorber Removal).

•

Drill the hole [A] of the reservoir tank using about 2 mm

(0.08 in.) drillbit.

WARNING

Drilling will release high pressure gas that may blow metal shavings at high speed and cause eye injury.

Wear safety goggles or face shield when drilling the reservoir tank.

Shock Absorbers (KRF750S)

Front Shock Absorber Rebound Damping Force

Adjustment

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

To adjust the rebound damping force, turn the rebound damping force adjuster [A] to the desired position.

○

The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 1 turn out from the fully clockwise position.

Rebound Damping Force Adjustment

Adjuster

Position

2.5 Turns

Out

↑

↓

0

Damping

Force

Weak

↑

↓

Strong

Setting

Soft

↑

↓

Hard

Load

Light

↑

↓

Heavy

Road

Good

↑

↓

Bad

Speed

Low

↑

↓

High

Front Shock Absorber Compression Damping

Force Adjustment

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

To adjust the compression damping force, turn the compression damping force adjuster [A] to the desired position.

○

The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 3.5 turns out from the fully clockwise position.

Compression Damping Force Adjustment

Adjuster

Position

5 Turns

Out

↑

↓

0

Damping

Force

Weak

↑

↓

Strong

Setting

Soft

↑

↓

Hard

Load

Light

↑

↓

Heavy

Road

Good

↑

↓

Bad

Speed

Low

↑

↓

High

SUSPENSION 13-13

13-14 SUSPENSION

Shock Absorbers (KRF750S)

•

Front Shock Absorber Spring Preload Adjustment

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Loosen the locknut [A].

Turn the adjusting nut [B] to the desired position.

Special Tool — Hook Wrench R37.5, R42: 57001-1539

Adjusting Length [C]: from center of upper mounting bolt to lower surface of adjusting nut

○

The standard adjusting nut setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is 82.5 mm (3.248 in.) spring length.

Spring Preload Setting

Standard: Adjusting length 8.25 mm (3.248 in.)

Usable Range: Adjusting length 75.5

∼

95.5 mm (2.972

∼

3.760 in.)

•

Tighten the locknut.

If the spring action feels too soft or too stiff, adjust it.

Spring Preload Adjustment

Adjusting

Length

Damping

Force

Setting

75.5 mm

(2.972 in.)

Weak Soft

Load

Light

Road

Good

Speed

Low

↑

↓

95.5 mm

(3.760 in.)

↑

↓

Strong

↑

↓

Hard

↑

↓

Heavy

↑

↓

Bad

↑

↓

High

Front Shock Absorber Removal

•

Support the vehicle on a stand or a jack so that the front wheels are off the ground.

Special Tool — Jack: 57001-1238

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

While holding the front wheels, remove the lower and upper shock absorber mounting bolts [A] and nuts.

•

Remove the front shock absorber [B].

Front Shock Absorber Installation

•

Apply grease to the inside of needle bearing [A] and grease seal lips [B].

•

Install the collar [C]

Shock Absorbers (KRF750S)

•

Install the bushing [A] using a press.

[B] Needle Bearing

[C] Collar

[D] Grease Seals

[E] New Nuts

•

Tighten:

Torque — Front Shock Absorber Mounting Nuts: 57.5 N·m

(5.9 kgf·m, 42 ft·lb)

SUSPENSION 13-15

Front Shock Absorber Inspection

•

Check the bushing in the upper pivot.

If bushing is worn, cracked, hardened, or otherwise damaged, replace it.

•

Check the needle bearing and grease seals in the lower pivot.

If they are damaged, replace them.

Front Shock Absorber Scrapping

WARNING

Pressurized nitrogen may explode when heated.

The rear shock contains nitrogen gas. To avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve.

•

Remove the front shock absorber. (see Front Shock Absorber Removal).

•

Drill the hole [A] of the reservoir tank using about 2 mm

(0.08 in.) drillbit.

WARNING

Drilling will release high pressure gas that may blow metal shavings at high speed and cause eye injury.

Wear safety goggles or face shield when drilling the reservoir tank.

13-16 SUSPENSION

Shock Absorbers (KRF750S)

Rear Shock Absorber Rebound Damping Force

Adjustment

•

To adjust the rebound damping force, turn the rebound damping force adjuster [A] to the desired position.

○

The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 1 turn out from the fully clockwise position.

Rebound Damping Force Adjustment

Adjuster

Position

3 Turns

Out

↑

↓

0

Damping

Force

Weak

↑

↓

Strong

Setting

Soft

↑

↓

Hard

Load

Light

↑

↓

Heavy

Road

Good

↑

↓

Bad

Speed

Low

↑

↓

High

Rear Shock Absorber Compression Damping

Force Adjustment

•

To adjust the compression damping force, turn the compression damping force adjuster [A] to the desired position until you feel a click.

○

The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 12th click from the 1st click of the fully clockwise position.

Compression Damping Force Adjustment

Adjuster

Position

20

↑

↓

1

Damping

Force

Weak

↑

↓

Strong

Setting

Soft

↑

↓

Hard

Load

Light

↑

↓

Heavy

Road

Good

↑

↓

Bad

Speed

Low

↑

↓

High

Shock Absorbers (KRF750S)

•

Rear Shock Absorber Spring Preload Adjustment

Loosen the locknut [A].

•

Turn the adjusting nut [B] to the desired position.

Special Tool — Hook Wrench R37.5, R42: 57001-1101

Adjusting Length [C]: from center of upper mounting bolt to lower surface of adjusting nut

○

The standard adjusting nut setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is 116.0 mm (4.567 in.) spring length.

Spring Preload Setting

Standard: Adjusting length 116.0 mm (4.567 in.)

Usable Range: Adjusting length 109.5

∼

127.5 mm

(4.311

∼

5.020 in.)

•

Tighten the locknut.

If the spring action feels too soft or too stiff, adjust it.

Spring Preload Adjustment

Adjusting

Length

Damping

Force

Setting

109.5 mm

(4.311 in.)

Weak Soft

Load

Light

Road

Good

Speed

Low

↑

↓

127.5 mm

(5.020 in.)

↑

↓

Strong

↑

↓

Hard

↑

↓

Heavy

↑

↓

Bad

↑

↓

High

Rear Shock Absorber Removal

•

Remove:

Rear Wheel (see Wheel Removal in the Wheels/Tires chapter)

Guard [A], Bolts and Washer

•

Remove:

Rear Shock Absorber Mounting Bolts [A] and Nuts

Rear Shock Absorber [B]

SUSPENSION 13-17

13-18 SUSPENSION

Shock Absorbers (KRF750S)

Rear Shock Absorber Installation

•

Apply grease to the inside of needle bearing [A] and grease seal lips [B].

•

Install the collars [C].

•

Apply grease to the grease seal lips [A].

•

Install the collars [B].

•

When replacing the ball bearing [A], install the new circlip

[B].

[C] Grease Seals

[D] Collars

[E] New Nuts

[F] Needle Bearing

•

Tighten:

Torque — Rear Shock Absorber Mounting Nuts: 95.5 N·m

(9.7 kgf·m, 70 ft·lb)

•

Install the removed parts (see appropriate chapters).

Rear Shock Absorber Inspection

•

Check the ball bearing and grease seals in the upper pivot.

If they are damaged, replace them.

•

Check the needle bearing and grease seals in the lower pivot.

If they are damaged, replace them.

Shock Absorbers (KRF750S)

Rear Shock Absorber Scrapping

WARNING

Pressurized nitrogen may explode when heated.

The rear shock contains nitrogen gas. To avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve.

•

Remove the rear shock absorber. (see Rear Shock Absorber Removal).

•

Drill the hole [A] of the reservoir tank using about 2 mm

(0.08 in.) drillbit.

WARNING

Drilling will release high pressure gas that may blow metal shavings at high speed and cause eye injury.

Wear safety goggles or face shield when drilling the reservoir tank.

SUSPENSION 13-19

13-20 SUSPENSION

Suspension Arms

Front Suspension Arm Removal

•

Remove:

Front Wheels (see Wheel Removal in the Wheels/Tires chapter)

Front Hub [A] (see Front Hub Removal in the

Wheels/Tires chapter)

Brake Caliper and Hose [B] (from Suspension Arm)

Front Shock Absorber Mounting Bolt [C] and Nut (lower)

•

Remove:

Cotter Pins

Tie-rod End Nut [A]

Knuckle Joint Nuts [B]

•

Remove the tie-rod end [A] from the knuckle using a suitable joint remover [B].

•

Remove:

Front Lower Suspension Arm Pivot Bolts, Caps and Nuts

[A]

Front Upper Suspension Arm Pivot Bolt, Caps and Nut

[B]

Knuckle [C] and Front Suspension Arms Assembly

•

Remove the knuckle joints [A] from the knuckle using a suitable joint remover [B].

Suspension Arms

Front Suspension Arm Installation

•

Clean the taper surface [A] of the knuckle [B] and shank of the knuckle joint, or the tapers will not fit snugly.

•

Apply lithium grease (NLGI Grade No.2) to the inside of the caps.

•

Install:

Front Upper Suspension Arm

Front Lower Suspension Arm

Suspension Arm Pivot Bolts, Caps and Nuts (temporary)

Front Shock Absorber Mounting Bolt and Nut (lower)

•

Install:

Knuckle [A], Washers [B] and Nuts

○

Install the washer as shown in the figure.

SUSPENSION 13-21

•

Tighten:

Torque — Front Suspension Arm Pivot Nuts: 87.5 N·m (8.9

kgf·m, 65 ft·lb)

Steering Knuckle Joint Nuts: 46.5 N·m (4.7 kgf·m,

34 ft·lb)

Front Shock Absorber Mounting Nut: 57.5 N·m

(5.9 kgf·m, 42 ft·lb)

•

Install:

New Cotter Pins [A]

NOTE

○

When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.

○

It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past the nearest hole.

•

Bend the cotter pin [A] over the nut [B].

•

Install the removed parts (see appropriate chapter).

13-22 SUSPENSION

Suspension Arms

Front Suspension Arm Disassembly

•

Remove:

Upper Suspension Arm [A]

Caps [B]

Bushings [C]

Sleeve [D]

O-rigs [E]

•

Remove:

Lower Suspension Arm [A]

Caps [B]

Bushings [C]

Sleeve [D]

O-rigs [E]

•

Remove:

Circlip [A]

Special Tool — Outside Circlip Pliers: 57001-144

•

Remove the knuckle joint [B] using a press.

Front Suspension Arm Assembly

•

Press the new knuckle joint using a press.

Special Tool — Knuckle Joint Driver [A]: 57001-1640

•

Install:

New Circlip

Special Tool — Outside Circlip Pliers: 57001-144

Suspension Arms

•

Apply adhesive (Three Bond: 1215) to outside of the bushing [A] and install it into the suspension arm [B].

•

Wipe off any extra adhesive.

•

Apply lithium grease (NLGI Grade No.2) to the inside [C] of the bushing and cap [D].

•

Apply lithium grease (NLGI Grade No.2) to the sleeves

[A] and new O-rings [B].

SUSPENSION 13-23

Rear Suspension Arm Removal

•

Remove:

Rear Wheel (see Wheel Removal in the Wheels/Tires chapter)

Axle Guard [A]

Stabilizer Joint [B] (see Stabilizer Removal)

•

Support the rear hub using a suitable jack or block [A].

•

Remove:

Rear Shock Absorber Bolt, Washer and Nut (lower)

Rear Knuckle Mounting Bolt [B], Washers, Shim and Nut

Rear Upper Suspension Arm Pivot Bolts [C], Caps and

Nuts

Rear Upper Suspension Arm [D]

•

Remove:

Rear Lower Suspension Arm Pivot Bolts [A], Washers,

Shim and Nut

Rear Lower Suspension Arm Pivot Bolts [B], Caps and

Nuts

Rear Lower Suspension Arm [C]

13-24 SUSPENSION

Suspension Arms

Rear Suspension Arm Installation

•

Apply lithium grease (NLGI Grade No.2) to the inside of the caps [A].

•

Install:

Rear Lower Suspension Arm [B]

Rear Lower Suspension Arm Pivot Bolts [C], Caps and

New Nuts [D] (temporary)

Rear Knuckle Mounting Bolt [E], Washers [F], Shim [G] and New Nuts [H] (temporary)

If there are over 0.5 mm (0.02 in.) gap between the knuckle and lower suspension arm, add the shim [G] to front side.

•

Support the rear hub using a suitable jack or block.

•

Apply lithium grease (NLGI Grade No.2) to the inside of the caps [A].

•

Install:

Rear Upper Suspension Arm [B]

Rear Upper Suspension Arm Pivot Bolts [C], Caps and

New Nuts [D] (temporary)

Rear Knuckle Mounting Bolt [E], Washers [F], Shim [G] and New Nuts [H] (temporary)

If there are over 0.5 mm (0.02 in.) gap between the knuckle and upper suspension arm, add the shim [G] to front side.

•

Install:

Rear Shock Absorber Mounting Bolt, Washer and Nut

(lower)

•

Tighten:

Torque — Rear Suspension Arm Pivot Nuts: 87.5 N·m (8.9

kgf·m, 65 ft·lb)

Rear Knuckle Mounting Nuts: 57.5 N·m (5.9 kgf·m,

42 ft·lb)

Rear Shock Absorber Mounting Nuts: 95.5 N·m

(9.7 kgf·m, 70 ft·lb)

•

Install:

Stabilizer Joint (see Stabilizer Installation)

Rear Wheel (see Wheel Installation in the Wheels/Tires chapter)

Rear Suspension Arm Disassembly

•

Remove:

Upper Suspension Arm [A]

Caps [B]

Bushings [C]

Sleeve [D]

O-rigs [E]

Suspension Arms

•

Remove:

Lower Suspension Arm [A]

Caps [B]

Bushings [C]

Sleeve [D]

O-rigs [E]

•

Rear Suspension Arm Assembly

•

Apply adhesive (Three Bond: 1215) to outside of the bushing [A] and install it into the suspension arm [B].

•

Wipe off any extra adhesive.

Apply lithium grease (NLGI Grade No.2) to the inside [C] of the bushing and cap [D].

•

Apply lithium grease (NLGI Grade No.2) to the sleeves [A] and New O-rings [B] of the upper and lower suspension arms.

SUSPENSION 13-25

Stabilizer Removal

•

Remove:

Rear Wheels (see Wheel Removal in the Wheels/Tires chapter)

Stabilizer Joint [A]

○

Hold the joint bolt with an Allen wrench [B], and remove the nut [C].

•

Remove:

Stabilizer Holder Bolts [A]

Stabilizer Holders [B]

Dampers and Stabilizer [C]

13-26 SUSPENSION

Suspension Arms

Stabilizer Installation

•

Install the stabilizer [A] so that the recess side [B] faces to lower side.

•

Install:

Stabilizer [A]

Dampers [B] (both sides)

Stabilizer Holders [C] and Bolts (both sides)

•

Apply a non-permanent locking agent to the stabilizer holder bolts.

•

Tighten:

Torque — Stabilizer Holder Bolts [D]: 31.5 N·m (3.2 kgf·m, 23 ft·lb)

•

Install:

Stabilizer Joints [E] (both sides)

New Stabilizer Joint Nuts [F]

○

Hold the joint bolt with an Allen wrench, and tighten the nut.

Torque — Stabilizer Joint Nuts [F]: 57.5 N·m (5.9 kgf·m, 42 ft·lb)

•

Install:

Rear Wheels (see Wheel Installation in the Wheels/Tires chapter)

Stabilizer Joint Inspection

•

Remove:

Stabilizer Joint (see stabilizer Removal)

•

Inspect each spherical bearing [A].

If roughness, excessive play, or seizure is found, replace the stabilizer joint.

•

Inspect each boot [B].

If damage, wear or deterioration is found, replace the stabilizer joint.

Rear Knuckle Removal

•

Remove:

Rear Wheel (see Wheel Removal in the Wheels/Tires chapter)

Rear Hub (see Rear Hub Removal in the Wheels/Tires chapter)

•

Remove:

Rear Knuckle Mounting Bolts [A], washers and Nuts

Rear Knuckle [B]

Suspension Arms

Rear Knuckle Installation

•

Install the rear knuckle [A] so that the TOP mark [B] faces upward.

•

Tighten:

Torque — Rear Knuckle Mounting Nuts: 57.5 N·m (5.9 kgf·m,

42 ft·lb)

Rear Knuckle Disassembly

•

Remove:

Rear Knuckle (see Rear Knuckle Removal)

Oil Seals [A]

Sleeve [B]

•

Remove:

Bushings [A]

○

Using a suitable bearing remover [B].

SUSPENSION 13-27

•

Remove:

Circlip [A]

Special Tool — Inside Circlip Priers [B]: 57001-143

•

Remove the ball bearing using a press [A].

Special Tool — Bearing Driver Set [B]: 57001-1129

13-28 SUSPENSION

Suspension Arms

Rear Knuckle Assembly

•

Install:

Ball Bearing (until bottomed)

Special Tool — Bearing Driver Set [A]: 57001-1129

•

Install:

New Circlip [A]

Special Tool — Inside Circlip Priers: 57001-143

•

Apply lithium grease (NLGI Grade No.2):

Sleeves [B]

Lips of Oil Seals [C]

•

Install:

Bushings [D] (until bottomed)

Special Tool — Bearing Driver Set: 57001-1129

•

Install:

Sleeve

Oil Seals

Bearing and Oil Seal

Ball Bearing Inspection

Since the bearings are made to extremely close tolerances, the clearance cannot normally be measured.

NOTICE

Do not remove any bearings for inspection.

•

Turn each bearing back and forth [A] while checking for plays, roughness, or binding.

If bearing play, roughness, or binding is found, replace the bearing.

SUSPENSION 13-29

Oil Seal Inspection

•

Inspect the oil seals.

Replace any if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.

STEERING 14-1

Steering

Table of Contents

Exploded View…………………………………………………………………………………………………………

14-2

Specifications ………………………………………………………………………………………………………….

14-4

Special Tools …………………………………………………………………………………………………………..

14-5

Steering Wheel and Main Shaft Assembly …………………………………………………………………..

14-6

Steering Wheel Position Adjustment………………………………………………………………………

14-6

Steering Wheel Free Play Inspection……………………………………………………………………..

14-6

Steering Wheel Centering…………………………………………………………………………………….

Steering Wheel Removal ……………………………………………………………………………………..

Steering Wheel Installation …………………………………………………………………………………..

14-6

14-6

14-7

Steering Shafts Removal ……………………………………………………………………………………..

Steering Shafts Installation …………………………………………………………………………………..

14-7

14-8

Steering Gear Assembly……………………………………………………………………………………………

14-9

Steering Gear Assembly Removal…………………………………………………………………………

Steering Gear Assembly Installation………………………………………………………………………

14-9

14-9

Tie-rod Length Adjustment……………………………………………………………………………………

14-11

Steering Joint Dust Boot Inspection……………………………………………………………………….

14-11

Steering Knuckles…………………………………………………………………………………………………….

14-12

Steering Knuckle Removal……………………………………………………………………………………

14-12

Steering Knuckle Installation…………………………………………………………………………………

14-12

Knuckle Bearing Removal…………………………………………………………………………………….

14-13

Knuckle Bearing Installation………………………………………………………………………………….

14-13

14

14-2 STEERING

Exploded View

STEERING 14-3

Exploded View

No.

1 Steering Wheel Mounting Nut

2 Steering Knuckle Joint Nuts

3 Main Shaft Mounting Bolts

4 Intermediate Shaft Clamp Bolts

5 Steering Gear Assembly Nuts

6 Tie-Rod End Locknuts

7 Tie-Rod End Nuts

Fastener

Torque

N·m kgf·m

54 5.5

46.5

41.5

21.5

95.5

44

41.5

4.7

4.2

2.2

9.7

4.5

4.2

G: Apply grease.

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

R: Replacement Parts

16

70

32

31

ft·lb

40

34

31

Remarks

R

R

14-4 STEERING

Specifications

Item

Steering Wheel

Steering Wheel Free Play

Steering Gear Assembly

Tie-Rod Length

(distance between boot end and locknut)

Standard

0

∼

20 mm (0

∼

0.79 in.)

80 mm (3.15 in.)

Service Limit

– – –

– – –

Special Tools

Outside Circlip Pliers:

57001-144

Bearing Driver Set:

57001-1129

STEERING 14-5

14-6 STEERING

Steering Wheel and Main Shaft Assembly

Steering Wheel Position Adjustment

•

Remove:

Control Panel (see Control Panel Removal in the Frame

• chapter)

Loosen the steering main shaft mounting bolts [A].

•

Adjust the steering wheel position.

•

Tighten:

Torque — Main Shaft Mounting Bolts: 41.5 N·m (4.2 kgf·m,

31 ft·lb)

Steering Wheel Free Play Inspection

•

Refer to Steering Wheel Free Play Inspection in the Periodic Maintenance chapter.

Steering Wheel Centering

•

Test ride the vehicle.

If the steering wheel is not straight when the vehicle is traveling in a straight line, do the following.

•

Check the tie-rod length and adjust it if necessary (see

Toe-in Adjustment in the Wheels/Tires chapter).

•

Remove:

Wheel Cap [A]

•

•

Loosen the steering wheel mounting nut [A].

•

Push the vehicle in a straight line with no one aboard, and stop it without turning the steering wheel.

•

Remount the steering wheel so that it is straight ahead.

Tighten:

Torque — Steering Wheel Mounting Nut: 54 N·m (5.5 kgf·m,

•

Install:

Wheel Cap

40 ft·lb)

Steering Wheel Removal

•

Remove:

Wheel Cap [A]

Steering Wheel Mounting Nut [B] and Spring Washer

Steering Wheel [C]

Steering Wheel and Main Shaft Assembly

Steering Wheel Installation

•

Install:

Steering Wheel [A]

Spring Washer [B]

New Steering Wheel Mounting Nut [C]

•

Install the steering wheel cap [A] so that the “Kawasaki” mark parallel to the line [B].

STEERING 14-7

Steering Shafts Removal

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Lift and hold the front fender rear (see Front Fender Rear

Removal in the Frame chapter).

•

Remove:

Control Panel (see Control Panel Removal in the Frame chapter)

Steering Wheel (see Steering Wheel Removal)

Washer

Intermediate Shaft Clamp Bolt [A]

Main Shaft Mounting Bolts [B] and Nut

Main Shaft [C]

Rubber Seal [D]

•

Remove:

Intermediate Shaft Clamp Bolt [A]

Intermediate Shaft [B]

14-8 STEERING

Steering Wheel and Main Shaft Assembly

Steering Shafts Installation

•

Apply grease to the dust cover lips [A].

•

Connect the intermediate shaft [A] to the main shaft [B] and the steering gear pinion [C] in any position.

•

Tighten:

Torque — Intermediate Shaft Clamp Bolts [D]: 21.5 N·m (2.2

•

kgf·m, 16 ft·lb)

Install the main shaft mounting bolts [E] and nut [F].

•

Tighten:

Torque — Main Shaft Mounting Bolts: 41.5 N·m (4.2 kgf·m,

•

31 ft·lb)

Install the washer [G].

•

Install the rubber seal [H] so that the recess side faces to front side.

Steering Gear Assembly

Steering Gear Assembly Removal

•

Remove:

Front Wheel (see Wheel Removal in the Wheel/Tires chapter)

Intermediate Shaft Clamp Bolt [A]

•

Remove:

Cotter Pins, Tie-rod End Nuts [A] and Washers (both sides)

NOTICE

Do not loosen the tie-rod end locknuts [B], or the toe-in of the front wheels will be changed.

•

Remove the tie-rod end [A] from the knuckle using a suitable joint remover [B].

STEERING 14-9

•

Remove:

Steering Gear Assembly Bracket Bolts [A]

Steering Gear Assembly Bolts [B], Washers and Nuts

Steering Gear Assembly [C]

Steering Gear Assembly Installation

•

Adjust if necessary:

Tie-rod Length Adjustment (see Toe-in Adjustment in the

Wheels/Tires chapter)

14-10 STEERING

Steering Gear Assembly

•

Apply a non-permanent locking agent (Three Bond

TB2471 (Blue)):

Steering Gear Assembly Bolts [A] M12, L = 60 mm (2.36

in.)

Steering Gear Assembly Bracket Bolts [B] M12, L = 25 mm (2.36 in.)

•

Install:

Steering Gear Assembly [C]

Damper [D]

Washer [E] and Steering Gear Assembly Bolts

Bracket [F] and Steering Gear Assembly Bracket Bolts

New Steering Gear Assembly Nuts [G]

•

Tighten:

Torque — Steering Gear Assembly Nuts [G]: 95.5 N·m (9.7

kgf·m, 70 ft·lb)

•

Clean the tapered portion of the tie-rod end joint [A] and the tapered hole of the steering knuckle [B], or the tapers will not fit snugly.

•

Install:

Washers [C] (both sides, as shown in the figure)

Tie-rod End Nuts [D] (both sides)

•

Tighten:

Torque — Tie-rod End Nuts: 41.5 N·m (4.2 kgf·m, 31 ft·lb)

•

Install:

New Cotter Pin [E]

NOTE

○

When inserting the cotter pin [A], if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.

○

It should be within 30 degrees.

○

Loosen once and tighten again when the slot goes past the nearest hole.

•

Bend the cotter pin [A] over the nut [B].

•

Install the removed parts (see appropriate chapter).

•

Check the toe-in of front wheels (see Toe-in Adjustment in the Wheels/Tires chapter).

Steering Gear Assembly

Tie-rod Length Adjustment

•

Refer to Toe-in Adjustment in the Wheels/Tires chapter.

Tie-rod Length [A]

Steering Joint Dust Boot Inspection

•

Refer to Steering Joint Dust Boot Inspection in the Periodic Maintenance chapter.

STEERING 14-11

14-12 STEERING

Steering Knuckles

Steering Knuckle Removal

•

Remove:

Front Wheel (see Wheel Removal in the Wheel/Tires chapter)

Front Hub (see Front Hub Removal in the Wheel/Tires chapter)

Front Suspension Arms (see Front Suspension Arm Removal in the Suspension chapter)

•

Remove the knuckle joint [A] from the suspension arm using a suitable joint remover [B].

Steering Knuckle Installation

•

Clean the taper surfaces [A] of the knuckle [B] and shank of the knuckle joint, or the tapers will not fit snugly.

•

Install:

Knuckle [A], Washers [B] and Nuts

○

Install the washer as shown in the figure.

•

Install:

Front Suspension Arm (see Front Suspension Arm Installation in the Suspension chapter)

Tie-rod End (see Steering Gear Assembly Installation)

Steering Knuckles

•

Install:

New Cotter Pins [A]

NOTE

○

When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.

○

It should be within 30 degrees.

○

Loosen once and tighten again when the slot goes past the nearest hole.

•

Bend the cotter pin [A] over the nut [B].

STEERING 14-13

•

Install the removed parts (see appropriate chapter).

Knuckle Bearing Removal

•

Remove:

Knuckle (see Steering Knuckle Removal)

Circlip [A]

Special Tool — Outside Circlip Pliers [B]: 57001-144

•

Drive the bearing [A] out using a suitable bearing driver.

Special Tool — Bearing Driver Set: 57001-1129

Knuckle Bearing Installation

•

Press in the bearing until it is bottomed.

Special Tool — Bearing Driver Set: 57001-1129

•

Replace the circlip with a new one.

Special Tool — Outside Circlip Pliers: 57001-144

FRAME 15-1

Frame

Table of Contents

Exploded View……………………………..

15-2

Seat and Seat Belts………………………

15-18

Seat Removal …………………………

15-18

Seat Installation ………………………

15-18

Seat Disassembly ……………………

15-18

Seat Assembly ………………………..

15-19

Seat Belt Removal

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)………………..

15-20

Seat Belt Removal

(KRF750ND/PD/RD/SD) ………..

15-21

Seat Belt Installation

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)………………..

15-22

Seat Belt Installation

(KRF750ND/PD/RD/SD) ………..

15-23

Control Panel……………………………….

15-24

Control Panel Removal …………….

15-24

Control Panel Installation ………….

15-26

Glove Compartment Removal……

15-26

Glove Compartment Installation…

15-27

Cupholder Removal

(KRF750P/R/S/V)………………….

15-27

Cupholder Installation

(KRF750P/R/S/V)………………….

15-30

Fenders ………………………………………

15-31

Front Fender Front Removal……..

15-31

Front Fender Front Installation…..

15-31

Front Fender Rear Removal ……..

15-31

Front Fender Rear Installation …..

15-32

Rear Fender Removal………………

15-32

Rear Fender Installation……………

15-33

Rear Flap Removal ………………….

15-33

Rear Flap Installation ……………….

15-33

Cargo Bed …………………………………..

15-34

Cargo Bed Removal…………………

15-34

Cargo Bed Installation………………

15-34

Cargo Bed Disassembly …………..

15-36

Cargo Bed Assembly ……………….

15-39

Bars ……………………………………………

15-44

Right and Left Bars Removal …….

15-44

Right and Left Bars Installation ….

15-44

Covers ………………………………………..

15-47

Engine Upper Cover Removal …..

15-47

Engine Upper Cover Installation ..

15-47

Center Cover Removal …………….

15-48

Center Cover Installation ………….

15-48

Frame Cover Removal……………..

15-48

Frame Cover Installation…………..

15-50

Seat Lower Cover Removal ………

15-50

Seat Lower Cover Installation ……

15-51

Seat Lower Right Plate Removal .

15-52

Seat Lower Right Plate

Installation ……………………………

15-52

Seat Lower Left Plate Removal …

15-52

Seat Lower Left Plate Installation 15-53

Right and Left Brackets Removal 15-53

Right and Left Brackets

Installation ……………………………

15-54

Center Bracket Removal…………..

15-54

Center Bracket Installation………..

15-55

Right Frame Pipe Removal……….

15-55

Right Frame Pipe Installation…….

15-56

Left Cover Removal …………………

15-56

Left Cover Installation ………………

15-57

Side Cover Removal

(KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD)……………………..

15-58

Side Cover Installation

(KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD)……………………..

15-58

Side Cover Inspection

(KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD)……………………..

15-59

Windshield Removal

(KRF750P/R/V) …………………….

15-59

Windshield Installation

(KRF750P/R/V) …………………….

15-60

Sun Top Cover Removal

(KRF750P/R/V) …………………….

15-61

Sun Top Cover Installation

(KRF750P/R/V) …………………….

15-61

Guards………………………………………..

15-63

Front Guard Removal ………………

15-63

Front Guard Installation ……………

15-63

Front Bottom Guard Removal ……

15-63

Front Bottom Guard Installation …

15-64

Middle Bottom Guard Removal….

15-64

Middle Bottom Guard Installation.

15-64

Engine Bottom Guard Removal …

15-64

Engine Bottom Guard Installation 15-65

Rear Bottom Guard Removal…….

15-65

Rear Bottom Guard Installation….

15-65

Floorboard …………………………………..

15-66

Floorboard Removal ………………..

15-66

Floorboard Installation ……………..

15-69

15

15-2 FRAME

Exploded View

FRAME 15-3

Exploded View

1. The seal ends should be at lower area and the gap is less than 3 mm (0.12 in.).

2. KRF750N/T

3. KRF750P/R/S/V

4. KRF750NA/PA/RA/SA/TA

5. KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD

AD: Apply adhesive agent.

R: Replacement Parts

15-4 FRAME

Exploded View

KRF750NA/PA/RA/SA/TA

∼

NB/PB/RB/SB/VB

Exploded View

No.

Fastener

1 Right and Left Bar Mounting Bolts

2 Upper Bar Mounting Bolts

3 Back Bar Mounting Bolts

4 Bottom Guard Bolts

5 Front Guard Bolts

R: Replacement Parts

FRAME 15-5

N·m

98

46.5

46.5

8.8

31.5

Torque kgf·m

10

4.7

4.7

0.90

3.2

ft·lb

72

34

34

78 in·lb

23

Remarks

15-6 FRAME

Exploded View

KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD

FRAME 15-7

Exploded View

No.

Fastener

1 Right and Left Bar Mounting Bolts

2 Upper Bar Mounting Bolts

3 Back Bar Mounting Bolts

4 Bottom Guard Bolts

5 Front Guard Bolts

6. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

R: Replacement Parts

N·m

98

46.5

46.5

8.8

31.5

Torque kgf·m

10

4.7

4.7

0.90

3.2

ft·lb

72

34

34

78 in·lb

23

Remarks

15-8 FRAME

Exploded View

Exploded View

1. Apply sealing material to the hatched area and holes.

2. For the square dampers, install them so that the UP mark faces to upper side.

3. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

AD: Apply adhesive agent.

G: Apply grease.

FRAME 15-9

15-10 FRAME

Exploded View

FRAME 15-11

Exploded View

No.

Fastener

1 Right and Left Bar Mounting Bolts

2 Seat Belt Case Mounting Nuts

3 Seat Belt Mounting Bolts

4 Seat Belt Buckle Mounting Bolts

5 Seat Plate Bolts

6 Seat Belt Bracket Mounting Bolts

7 Right Frame Pipe Mounting Bolts

8 Bracket Bolts

9. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

10. KRF750ND/PD/RD/SD

L: Apply a non-permanent locking agent.

R: Replacement Parts

N·m

98

46.5

41.5

46.5

8.8

46.5

34.3

47

Torque kgf·m

10

4.7

4.2

4.7

0.90

4.7

3.5

4.8

ft·lb

72

34

31

34

78 in·lb

34

25

35

Remarks

L

15-12 FRAME

Exploded View

FRAME 15-13

Exploded View

No.

Fastener

1

2

Brake Pedal Bracket Mounting Bolts, L = 20 mm (0.79 in.)

Brake Pedal Bracket Mounting Bolts, L = 30 mm (1.2 in.)

3 Center Bracket Mounting Bolts

4 Bracket Bolts

5 Heat Guard Bolts

6. KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD

7. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

AD: Apply adhesive agent.

L: Apply a non-permanent locking agent.

N·m

34.3

34.3

22

47

8.8

Torque kgf·m

3.5

3.5

2.2

4.8

0.9

ft·lb

25

25

16

35

78 in·lb

Remarks

L

15-14 FRAME

Exploded View

Canada Model

Exploded View

1. Reflector (Yellow)

2. Reflector (Red)

FRAME 15-15

15-16 FRAME

Exploded View

KRF750P/R/V

Exploded View

No.

Fastener

1 Upper Bar Mounting Bolts

2. Sun Top Cover

FRAME 15-17

N·m

46.5

Torque kgf·m

4.7

ft·lb

34

Remarks

15-18 FRAME

Seat and Seat Belts

•

Seat Removal

Pull the seat lock lever [A] upward.

•

Lift the front edge of the seat [B], and then slide the seat forward and up.

Seat Installation

•

Insert the projections [A] at the rear of the seat into the seat holders [B].

•

Push down on the seat at the front and insert the pin [A] into the seat lock.

○

The seat lock clicks.

WARNING

A loose seat could cause the operator to lose control or the passenger to fall out of the vehicle during operation, causing severe injury or death. Make sure the seat is securely latched before operating vehicle.

•

When installing the pin [A], set the length 24.5 mm (0.965

in.) [B] as shown in the figure.

Washers [C]

Nut [D]

New Self Lock Nut [E]

Seat Disassembly

•

Remove:

Seat (see Seat Removal)

Seat Plate Bolts [A]

Seat Plate [B]

Dampers [C]

Seat and Seat Belts

•

Remove:

Pipe Bolts [A], Washers and Nuts

Pipe [B]

Seat Lock Bolts and Nuts [C]

Seat Lock [D]

Seat Assembly

•

Install:

Seat Lock [A]

Seat Lock Bolts [B] and New Nuts [C]

Dampers [D]

•

Install:

Pipe [A]

Pipe Bolts [B], Washers [C] and New Nuts [D]

FRAME 15-19

15-20 FRAME

Seat and Seat Belts

•

Install:

Seat [A]

Seat Plate [B]

•

Apply a non-permanent locking agent to the seat plate bolts [C].

•

Tighten:

Torque — Seat Plate Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Seat Belt Removal (KRF750NA/PA/RA/SA/TA

NC/PC/RC/SC/VC)

•

Open the cover [A].

•

Remove:

Seat Belt Mounting Bolt [B]

Upper Seat Bracket [C]

∼

•

Lift up the cargo bed.

•

Remove:

Seats (see Seat Removal)

•

Open the cover [A] upward.

•

Remove:

Seat Belt Case Mounting Bolt [A] and Nut

Seat Belt Case [B]

Rear Bar Mounting Bolt [C]

Lower Seat Belt Bracket [D] and Seat Belt

Seat and Seat Belts

•

Remove:

Seat Belt Buckle Mounting Bolt [A]

Seat Belt Buckle [B]

•

Seat Belt Removal (KRF750ND/PD/RD/SD)

Open the cover [A].

•

Remove:

Seat Belt Mounting Bolt [B]

Upper Seat Bracket [C]

•

Lift up the cargo bed.

•

Remove:

Seats (see Seat Removal)

•

Remove:

Seat Belt Case Mounting Bolt and Nut [A]

Seat Belt Case [B]

•

Remove:

Frame Cover (see Frame Cover Removal)

Seat Belt Bracket Mounting Bolt [A]

Lower Seat Belt Bracket [B] and Seat Belt

FRAME 15-21

15-22 FRAME

Seat and Seat Belts

•

Remove the engine upper cover (see Engine Upper

Cover Removal).

•

For the right seat belt buckle, disconnect the seat belt use reminder sensor lead connector [A].

•

Remove:

Seat Belt Buckle Mounting Bolt [B]

Seat Belt Buckle [C]

Seat Belt Installation (KRF750NA/PA/RA/SA/TA

NC/PC/RC/SC/VC)

•

Install:

Seat Belt Buckle [A] (as shown in the figure)

∼

•

Tighten:

Torque — Seat Belt Buckle Mounting Bolt [B]: 46.5 N·m (4.7

kgf·m, 34 ft·lb)

•

Fit the projection [A] on the recess of the frame and install the seat belt case [B].

•

Install:

Seat Belt Case Mounting Bolt [C] and Nut

•

Tighten:

Torque — Seat Belt Case Mounting Nut: 46.5 N·m (4.7 kgf·m,

34 ft·lb)

•

Fit the cover in the case securely.

•

Install:

Lower Seat Belt Bracket [A] (as shown in the figure)

Bar Mounting Bolt [B]

•

Tighten:

Torque — Right and Left Bar Mounting Bolt: 98 N·m (10 kgf·m, 72 ft·lb)

•

Install:

Upper Seat Bracket [A]

Seat Belt Mounting Bolt [B]

•

Tighten:

Torque — Seat Belt Mounting Bolt: 41.5 N·m (4.2 kgf·m, 31 ft·lb)

•

Fit the cover on the bracket securely.

Seat and Seat Belts

Seat Belt Installation (KRF750ND/PD/RD/SD)

•

Install:

Seat Belt Buckle [A]

•

Tighten:

Torque — Seat Belt Buckle Mounting Bolt [B]: 46.5 N·m (4.7

kgf·m, 34 ft·lb)

[C] 30

∼

40°

•

For the right seat belt buckle, connect the seat belt use reminder sensor lead connector [D].

•

Fit the projection [A] on the recess of the frame and install the seat belt case [B].

•

Install:

Seat Belt Case Mounting Bolt and Nut [C]

•

Tighten:

Torque — Seat Belt Case Mounting Nut: 46.5 N·m (4.7 kgf·m,

34 ft·lb)

•

Install:

Lower Seat Belt Bracket [A] (as shown in the figure)

Seat Belt Mounting Bolt [B]

•

Tighten:

Torque — Seat Belt Bracket Mounting Bolt: 46.5 N·m (4.7

kgf·m, 34 ft·lb)

•

Install:

Upper Seat Bracket [A]

Seat Belt Mounting Bolt [B]

•

Tighten:

Torque — Seat Belt Mounting Bolt: 41.5 N·m (4.2 kgf·m, 31

•

ft·lb)

•

Fit the cover on the bracket securely.

Install the removed parts (see appropriate chapters).

FRAME 15-23

15-24 FRAME

Control Panel

Control Panel Removal

•

Lift and hold the front fender rear (see Front Fender Rear

Removal).

•

Remove:

Steering Wheel (see Steering Wheel Removal in the

Steering chapter)

•

Disconnect:

Ignition Switch Lead Connector [A]

2WD/4WD Shift Switch Lead Connector [B]

Power Outlet Connector Lead Connectors [C]

•

Remove:

Quick Rivets [A]

Cover [B]

•

Remove:

Plug [A]

•

Remove:

Screw [A]

Knob [B]

Control Panel

•

Remove:

Mounting Nut [A]

Light Switch [B]

•

Remove:

Quick Rivets [A]

•

Remove:

Quick Rivets [A]

•

Open the cover [A].

•

Remove:

Screws [B] and Collars

•

Remove:

Screws [A], Washers and Collars [B]

Screws [C] and Collars

Control Panel [D]

FRAME 15-25

15-26 FRAME

Control Panel

Control Panel Installation

•

Install:

Control Panel [A]

Screws [B] L = 16 mm (0.63 in.)

Collars [C] L = 4 mm (0.16 in.)

Screws [D] L = 56 mm (2.20 in.)

Collars [E] L = 40 mm (1.57 in.)

Washers [F]

Collars [G] L = 4.7 mm (0.19 in.)

Quick Rivets [H]

Quick Rivets [I]

Cover [J]

•

Fit the projection [A] on the light switch [B] into the recess in the control panel.

•

Install:

Mounting Nut

Screw

Knob

Plug

•

Install removed parts.

Glove Compartment Removal

Right Glove Compartment Cover

•

Remove:

Clips [A]

Pins [B]

Right Glove Compartment Cover [C]

Center Glove Compartment (KRF750N/T)

•

Remove:

Control Panel (see Control Panel Removal)

Screws [A]

Center Glove Compartment [B]

Control Panel

Glove Compartment Installation

Right Glove Compartment Cover

•

Install:

Right Glove Compartment Cover [A]

Pins [B]

•

Install the clips [C] as shown in the figure.

Up [D]

Forward [E]

•

When installing the cover [F], install the following parts.

Pin [G] and Bracket [H]

Screws [I]

•

When installing the trim seal [J], the seal ends [K] should be at lower area and the gap is less than 3 mm (0.12 in.).

Center Glove Compartment (KRF750N/T)

•

Install:

Center Glove Compartment [A]

Screws [B]

Cupholder Removal (KRF750P/R/S/V)

•

Remove:

Control Panel (see Control Panel Removal)

Tapping Screws [A]

Cupholder Assembly [B]

•

Remove:

Bolts [A]

Holder [B]

•

Pull out the cupholder case [C] from the cupholder bracket

[D].

FRAME 15-27

15-28 FRAME

Control Panel

•

Remove:

Rivets [A]

○

Drill the rivets and remove them.

•

Remove the cupholder [A] from the cupholder case [B].

•

When removing the roller [A], remove the bolt [B].

•

When removing the roller bracket [A], remove the screws

[B].

•

When removing the plate [A], remove the tapping screws

[B] (both sides).

Control Panel

•

When removing the guide [A], remove the rivets [B].

○

Drill the rivets and remove them.

FRAME 15-29

15-30 FRAME

Control Panel

Cupholder Installation (KRF750P/R/S/V)

•

Install:

Cupholder Case [A]

Cupholder [B]

Trim [C]

Rivets [D]

Washers [E]

Guides [F]

Damper [G]

Plate [H]

Tapping Screws [I], L = 8 mm (0.31 in.)

Roller Brackets [J]

Screws [K]

Rollers [L]

Bolts [M], L = 13 mm (0.51 in.)

•

Install the cupholder case to the cupholder bracket [N].

•

Install:

Holder [O]

•

Bolts [P], L = 10 mm (0.39 in.)

Install the cupholder assembly to the control panel.

•

Tighten the tapping screws [Q] (both sides), L = 12 mm

(0.47 in.).

Fenders

Front Fender Front Removal

•

Remove:

Band [A] (both sides)

•

Clear the four hook portions from the slots, lift up the front fender front [A].

•

Support it in the tilted position with the supporting rod [B].

•

Disconnect:

Headlight Lead Connector [A] (both sides)

•

Remove the harness [B] from the clamps [C] (both sides)

•

Remove:

Snap Pin [D] (both sides)

Front Fender Front Mounting Pin [E] and Washer [F]

(both sides)

Front Fender Front [G]

•

Front Fender Front Installation

Installation is the reverse of removal.

•

Insert the front fender front hooks [A] into the receivers

[B] in the front fender rear (both sides).

Front Fender Rear Removal

•

Remove:

Tilt up and hold the front fender front (see Front Fender

Front Removal).

Quick Rivets [A]

Cover [B]

FRAME 15-31

15-32 FRAME

Fenders

•

Remove:

Quick Rivets [A] (both sides)

Screws [B] (both sides)

•

Remove:

Screws [A] and Collars

•

When holding the front fender rear [A] at upper position, lift and hold it with a suitable belt [B] firmly.

•

When removing the front fender rear from the frame, remove the right and left bar (see Right and Left Bars Removal).

•

Remove the front fender rear.

Front Fender Rear Installation

•

Installation is the reverse of removal.

Rear Fender Removal

•

Remove:

Screw Rivets [A]

Fenders

•

Remove:

Screw [A] and Collar

Screw Rivets [B]

Rear Fender [C]

Rear Fender Installation

•

Install:

Rear Fender [A]

Screw [B] and Collar [C]

Screw Rivets [D]

Rear Flap Removal

•

Remove:

Rear Wheel (see Wheel Removal in the Wheels/Tires chapter)

Quick Rivets [A]

Tapping Screws [B] and Collars

Rear Flap [C]

Rear Flap Installation

•

Install:

Rear Flap [A]

Tapping Screws [B] and Collars [C]

•

Install:

Quick Rivets [A]

Rear Wheel (see Wheel Installation in the Wheels/Tires chapter)

FRAME 15-33

15-34 FRAME

Cargo Bed

Cargo Bed Removal

•

Remove:

Rear Fenders (see Rear Fender Removal)

Tail/Brake Light Lead Connectors [A]

•

Remove:

Tail/Brake Light Lead Connectors [A]

•

Remove the harness [B] from the clamps.

•

Remove the gas spring dampers [A] following procedure as follows.

○

Lift up the cargo bed.

○

Insert the standard tip screwdriver [B] between the clamp

[C] and recess, and pry the clamp.

○

Lift up stronger and hold the cargo bed at full position.

○

Remove the gas spring damper from the stud.

○

Repeat the same procedure for other side and remove the gas spring damper.

•

Remove:

Snap Pins [A] (both sides)

Cargo Bed Mounting Pins [B] and Washers [C] (both sides)

Cargo Bed [D]

Cargo Bed Installation

•

When installing the dampers [A], apply an adhesive [B] and install them so that the “UP” mark [C] faces upward.

Frame [D]

Left Side View [E]

Cargo Bed

•

When replacing the studs [A], do the following procedures.

○

Remove:

Studs

Bolts [B] and Bracket [C] (for both Upper Sides)

○

Install:

Bracket [A] and Bolts [B] (for Upper Side)

Studs [C]

Nuts [D]

FRAME 15-35

•

Grease to the cargo bed mounting pins [A].

•

Install:

Cargo Bed

Cargo Bed Mounting Pins, Washers [B] and Snap Pins

[C]

15-36 FRAME

Cargo Bed

•

Install the gas spring dampers following procedure as follows.

○

Push the both clamps [A] of the gas spring damper until they are bottomed as shown in the figure.

○

Position the cylinder [A] to upper side.

○

Push and fit the gas spring damper [B] on the stud [C].

•

Install the harness into the clamps.

•

Install:

Tail/Brake Light Lead Connectors

Rear Fenders (see Rear Fender Installation)

Cargo Bed Disassembly

•

Remove:

Rear Fenders (see Rear Fender Removal)

Bolts [A]

Hook Lever [B] Bracket

•

Remove:

Screws [A]

Cargo Bed

•

Remove:

Screw Rivets [A]

Tail Gate Cover [B]

•

Remove:

Screws [A]

Reinforce [B]

Screws [C] and Stoppers (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Screws [D] and Stoppers

•

Remove:

Tail Gate [A]

•

Disconnect the taillight lead connectors [A].

•

Remove:

Bolt [B] and Nut

Bolts [C]

Taillight Bracket [D]

•

Remove:

Bolts [A] (both sides)

Wires [B] (both sides)

Dampers [C] (both sides)

Collar (both sides)

FRAME 15-37

15-38 FRAME

Cargo Bed

•

Remove:

Bolts [A] and Collars (both sides)

Screws [B] and Collars (both sides)

Middle Rear Fenders [C] (both sides)

•

Remove:

Quick Rivets [A]

Bolts [B]

Bolt [C] and Nut

Plate [D]

•

Remove:

Bolt [A] (both sides)

Bolts [B] and Nuts (both sides)

Plates [C] (both sides)

•

Remove:

Bolts [A] (both sides)

Hook Lever Assembly [B]

•

Remove:

Bolts [A] (both sides)

Brackets [B] (both sides)

Spring [C] (both sides)

Hook Lever [D]

Cargo Bed

•

Remove:

Bolts [A] and Nuts

Plate [B]

•

Remove:

Quick Rivets [A]

Flaps [B]

•

Remove:

Cargo Bed (see Cargo Bed Removal)

Bolts [A]

Tapping Screws [B]

Heat Guard Plate [C]

Cargo Bed Assembly

•

Install:

Heat Guard Plate [A]

Tapping Screws [B]

Bolts [C]

•

When installing the insulators [A] to the heat guard plate

[B], install them as shown in the figure.

FRAME 15-39

15-40 FRAME

Cargo Bed

•

Apply adhesive agent to the cargo bed rubber dampers

[A].

•

Install:

Cargo Bed Rubber Dampers

Clamps [B]

•

Install the hook lever following procedure as follows.

○

Install:

Hook Lever [A]

Bracket [B] (both sides)

Spring [C] (as shown in the figure, both sides)

Cargo Bed

○

Install:

Hook Lever [A]

Springs [B]

Brackets [C]

Bolts [D]

Bolts [E]

○

When installing the hook [F], position it as shown in the figure and tighten the bolts [G].

Upper Side [H]

Front Side [I]

FRAME 15-41

15-42 FRAME

Cargo Bed

•

Install:

Cargo Bed Base [A]

Front Plate [B]

Side Plates [C] (both sides)

Bolts [D]: M6, L = 16 mm (0.63 in.)

Nuts [E]

Cargo Net [F]

Bolts [G]: M6, L = 14 mm (0.55 in.)

Hooks [H]

Stopper [I]

Bolts [J]: M6, L = 14 mm (0.55 in.)

Covers [K]

Bands [L]

Cargo Bed

•

Install:

Tail Gate [A]

Stoppers [B]

Stoppers [C]

NC/PC/RC/SC/VC)

Screws [D]

Reinforce [E]

Tail Gate Cover [F]

Screw Rivets [G]

Hook Levers [H]

Brackets [I]

(KRF750NA/PA/RA/SA/TA

Bolts [J]: M6, L = 65 mm (2.56 in.)

Grommet [K]

Taillight Bracket [L] (both sides)

Bolts [M]: M6, L = 14 mm (0.55 in.)

Nuts [N]

Hooks [O] (both sides)

Dampers [P] (both sides)

Wires [Q] (both sides)

Collars [R]

Bolts [S]: M6, L = 18 mm (0.71 in.)

Stopper [U]

NC/PC/RC/SC/VC)

(KRF750NA/PA/RA/SA/TA

Rear Fenders (see Rear Fender Installation)

∼

∼

FRAME 15-43

15-44 FRAME

Bars

•

Right and Left Bars Removal

•

Remove:

Seats (see Seat Removal)

•

Open the cover [A].

Remove:

Seat Belt Mounting Bolt [B]

Upper Seat Bracket [C]

•

Remove:

Upper Bar Mounting Bolts [A]

Front Upper Bars [B]

Rear Upper Bars [C]

•

Remove:

Breather Hoses

Back Bar Mounting Bolts [A]

Back Bar Mounting Bolts [B]

Upper Back Bar [C]

Back Bar Mounting Bolts [D]

Lower Back Bar [E]

•

Remove:

Mounting Bolts [A] (Both Sides)

Lower Seat Bracket [B] (Both

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Right Bar [C]

Left Bar [D]

Sides,

Right and Left Bars Installation

•

Install:

Right and Left Bar [A]

Lower Seat Belt Bracket [B] (Both Sides,

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Mounting Bolts [C] (temporarily)

Bars

•

Install:

Lower Back Bar [A]

Upper Back Bar [B]

Back Bar Mounting Bolts [C] (temporarily)

•

Install:

Rear Upper Bar [A]

Front Upper Bar [B]

Upper Bar Mounting Bolts [C] (temporarily)

○

Install the rear upper bar [A] so that the hand grip [B] faces forward.

•

When installing the fittings [A], install them to lower back bar [B] as shown in the figure.

•

Tighten:

Torque — Right and Left Bar Mounting Bolts: 98 N·m (10 kgf·m, 72 ft·lb)

Back Bar Mounting Bolts: 46.5 N·m (4.7 kgf·m, 34 ft·lb)

Upper Bar Mounting Bolts: 46.5 N·m (4.7 kgf·m, 34

•

ft·lb)

•

Install the upper seat bracket (see Seat Belt Installation).

Install the removed parts.

FRAME 15-45

15-46 FRAME

Bars

[A] Right Bar

[B] Left Bar

[C] Lower Seat Brackets (both sides)

[D] Right and Left Bar Mounting Bolts

[E] Lower Back Bar

[F] Upper Back Bar

[G] Back Bar Mounting Bolts

[H] Rear Upper Bar

[I] Front Upper Bar

[J] Upper Bar Mounting Bolts

Covers

Engine Upper Cover Removal

•

Remove:

Seats (see Seat Removal)

Small Quick Rivet [A]

Quick Rivet [B]

Screw [C] and Collar

○

When removing the small rivet, insert thin driver [A] between the pin [B] and socket.

○

Remove the pin [A] and socket [B] from the cover.

•

Remove:

Small Quick Rivets [A]

Quick Rivet [B]

Screw [C] and Collar

Engine Upper Cover [D]

Engine Upper Cover Installation

•

Install:

Engine Upper Cover [A]

Small Quick Rivets [B]

Quick Rivets [C] (both sides)

Collars [D] (both sides)

Screws [E]: L = 22 mm (0.87 in.)

FRAME 15-47

15-48 FRAME

Covers

•

When installing the insulators, install them as shown in the figure.

○

Do not protrude the insulators beyond the edge of the engine upper cover [A].

Insulator [B] (P/No. 16073-0118)

Insulator [C] (P/No. 16073-0117)

Insulator [D] (P/No. 16073-0116)

Air Cleaner Housing Cap [E]

Insulator [F] (P/No. 16073-0115)

Center Cover Removal

•

Remove:

Quick Rivets [A]

Quick Rivets [B] (both sides)

Center Cover [C]

Center Cover Installation

•

Install:

Center Cover [A]

Quick Rivets [B]

Quick Rivets [C] (both sides)

Frame Cover Removal

Right Frame Cover

•

Remove:

Right Seat (see Seat Removal)

Screws [A]

Quick Rivet [B]

Covers

•

Remove:

Screw [A] and Collar

•

Remove:

Screws [A] and Collars

Screws [B]

Guard [C]

Quick Rivets [D]

•

Remove:

Screw [A] and Collar

Quick Rivets [B]

Fuel Tank Cap [C]

Right Frame Cover [D]

Left Frame Cover

•

Remove:

Left Seat (see Seat Removal)

Screws [A]

Quick Rivet [B]

•

Remove:

Screw [A] and Collar

FRAME 15-49

15-50 FRAME

Covers

•

Remove:

Screws [A] and Collars

Screws [B]

Guard [C]

Quick Rivets [D]

•

Remove:

Screw [A] and Collar

Quick Rivets [B]

Left Frame Cover [C]

Frame Cover Installation

•

Install:

Right Frame Cover [A]

Quick Rivets [B]

Collars [C]: L = 4 mm (0.16 in.)

Screws [D]: M6, L = 16 mm (0.63 in.)

Collars [E]: L = 7.2 mm (0.28 in.)

Screws [F]: M6, L = 22 mm (0.87 in.)

Guard [G]

Screws [H]: M5

•

Install the left frame cover according to the same procedure as the right frame cover.

•

Install:

Fuel Tank Cap (Right Side)

Seat Lower Cover Removal

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal)

Center Cover (see Center Cover Removal)

Screw [A] and Collar

Covers

•

Remove:

Quick Rivets [A] (both sides)

Seat Lower Cover [B]

Seat Lower Cover Installation

•

Insert the projection [A] of the cover into the hole [B]. (both sides).

•

When installing the insulators, install them as shown in the figure.

○

Wipe the seat lower cover by alcohol before sticking the insulators.

○

Do not protrude the insulators beyond the edge of the seat lower cover [A].

Insulator [B] (P/No. 16073-0119)

Insulator [C] (P/No. 16073-0120)

Insulator [D] (P/No. 16073-0121)

Insulator [E] (P/No. 16073-0122)

Standard Line to Stick [F]

Frame [E]

Rear View (Inside of Seat Lower Cover) [G]

•

Stick the insulator [E] so that the press line matches the corner [H].

FRAME 15-51

15-52 FRAME

Covers

•

Install:

Seat Lower Cover [A]

Quick Rivets [B]

Collar [C]: L = 4 mm (0.16 in.)

Screw [D]: L = 16 mm (0.63 in.)

Seat Lower Right Plate Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal)

Bolts [A] and Brackets

Bolts [B]

Seat Lower Right Plate [C]

Seat Lower Right Plate Installation

•

Install:

Seat Lower Right Plate [A]

Bolts [B] and Brackets [C]

Seat Lower Left Plate Removal

•

Removal:

Seat Lower Cover (see Seat Lower Cover Removal)

Tapping Screw [A]

Bolts [B] and Bracket [C]

Clamp [D]

•

Removal:

Bolt [A]

Seat Lower Left Plate [B]

Covers

Seat Lower Left Plate Installation

•

When installing the insulators and damper on the seat lower left plate [A], install them as shown in the figure.

Damper [B] (P/No. 92161-0273)

15 mm (0.59 in.) [C]

Insulator [D] (P/No. 16073-0112)

Insulator [E] (P/No. 16073-0113)

○

Match the center of the hole to the center of the nut [F].

○

Match the edges of the insulators [G].

•

Install:

Bracket [H]

Clamp [I]

○

Install the clamp in the right angle direction of the pipe [J].

•

Install:

Bolts [K]

Tapping Screw [L]

Right and Left Brackets Removal

Right Bracket

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal)

Right Frame Cover (see Frame Cover Removal)

Center Bracket Mounting Bolt [A]

Bracket Bolts [B]

Right Bracket [C]

Left Bracket

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal)

Left Frame Cover (see Frame Cover Removal)

Seat Lower Left Plate (see Seat Lower Left Plate Removal)

Ignition Coil [A]

Center Bracket Mounting Bolt [B]

Bracket Bolts [C]

Left Bracket [D]

•

Remove the leads [A] from the clamp.

FRAME 15-53

15-54 FRAME

Covers

Right and Left Brackets Installation

•

Install:

Right and Left Brackets

Bracket Bolts

•

Tighten:

Torque — Bracket Bolts: 47 N·m (4.8 kgf·m, 35 ft·lb)

Center Bracket Mounting Bolts: 22 N·m (2.2 kgf·m,

16 ft·lb)

•

Install the removed parts.

Center Bracket Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Seat Lower Left Plate (see Seat Lower Left Plate Removal in the Frame chapter)

Seat Lower Right Plate (see Seat Lower Right Plate Removal in the Frame chapter)

Right Bracket (see Right and Left Brackets Removal in the Frame chapter)

(For Center Bracket Assembly Removal)

•

Remove:

Throttle Cable Rear End [A]

Center Bracket Mounting Bolt [B]

•

Remove:

ISC Valve [A] (ISC Valve Removal in the Fuel System

(DFI) chapter)

Breather Hoses [B]

•

Remove:

Spring [A]

Shift Lever Tie-rod End [B]

Covers

•

Remove:

Rubber Cover [A]

Center Bracket Mounting Bolts [B]

Center Bracket [C]

(For Center Bracket Unit Removal)

•

Remove:

Throttle Cable Rear End [A]

Differential Shift Cable Rear End [B]

Center Bracket Mounting Bolt [C]

Differential Shift Lever Removal (see Differential Shift

Lever Removal in the Final Drive chapter)

Shift Lever (see Shift Lever Removal in the Crankshaft/Transmission chapter)

•

Remove:

Band and Harnesses

Rubber Cover [A]

Center Bracket Mounting Bolts [B]

Center Bracket [C]

Center Bracket Installation

•

Install:

Center Bracket Assembly [A]

Center Bracket Mounting Bolts [B]

•

Tighten:

Torque — Center Bracket Mounting Bolts: 22 N·m (2.2 kgf·m,

16 ft·lb)

•

Install the removed parts.

Right Frame Pipe Removal

•

Remove:

Fuel Tank (Fuel Tank Removal in the Fuel System chapter)

Solenoid Valve Bracket Bolts [A] and Bracket Assembly

[B]

Vacuum Actuator Bracket Bolts [C] and Bracket Assembly [D]

FRAME 15-55

15-56 FRAME

Covers

•

Remove:

Right Frame Pipe Mounting Bolt [A] and Nut

Right Frame Pipe Mounting Bolt [B]

Right Frame Pipe [C]

•

Right Frame Pipe Installation

Replace the right frame pipe mounting nut with a new one.

•

Install:

Right Frame Pipe and Bolts

•

Tighten:

Torque — Right Frame Pipe Mounting Bolts: 34.3 N·m (3.5

kgf·m, 25 ft·lb)

Vacuum Actuator Bracket Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

Solenoid Valve Bracket Bolts: 8.8 N·m (0.90 kgf·m,

78 in·lb)

•

Install the removed parts.

Left Cover Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal)

Left Bracket (see Right and Left Brackets Removal)

Battery (see Battery Removal in the Electrical System chapter)

Vehicle-down Sensor [A] (see Vehicle-down Sensor Removal in the Fuel System (DFI) chapter)

Quick Rivet [B] and Cover [C]

Tapping Screws [D] and Collars

Electric Parts Case [E]

•

Remove:

Bolts [A]

Battery Mounting Plate [B]

Covers

•

Remove:

Tapping Screws [A] and Washers

Tapping Screws [B]

Left Cover [C]

○

Remove the bolts [D] and plate, if necessary.

Left Cover Installation

•

When installing the trim seal [A] to the left cover [B], push the trim seal to the corner [C], and apply adhesive to the trim seal and install it as shown in the figure.

24 ±1 mm (0.94 ±0.04 in.) [D]

•

Install:

Left Cover

Tapping Screws [E]

Washers [F]

FRAME 15-57

(For US Model)

•

Install:

Battery Mounting Plate [A]

Bolts [B]

•

When the following part is removed, install it.

Damper [C]

•

Install the removed parts.

(For CA Model)

•

Install:

Battery Mounting Plate [A]

Bolts [B]

•

When the following parts are removed, install them as shown in the figure.

Dampers [C]

Brackets [D]

Bolts [E]

•

Install the removed parts

15-58 FRAME

Covers

Side Cover Removal (KRF750NC/PC/RC/SC/VC

ND/PD/RD/SD)

•

Lower Side Cover

Separate the upper and lower side covers.

•

Remove:

Screw [A]

Belt [B]

Collars [C]

∼

•

Remove:

Bolts [A]

Washer [B]

Collars [C]

Lower Side Cover [D]

Upper Side Cover

•

Remove the three belts of the upper cover from the hooks

•

[A].

•

Remove the belts from the buckles [B].

Remove the upper side cover [C].

Side Cover Installation (KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD)

Lower Side Cover

•

Install:

Lower Side Cover [A]

Collars [B]

Washer [C]

Bolts [D]

•

Install:

Collars [A]

Belt [B]

Washer [C]

Screw [D]

Covers

Upper Side Cover

•

Set up the upper side cover [A] at inside of the shoulder guard [B].

•

Fix the belts of the upper side cover to the shoulder guard using the center buckles [C].

•

Fix the belts of the upper side cover to the lower and middle hooks [D].

•

Connect the latch plate [E] of the upper side cover to the buckle [F] of the lower side cover.

•

Fix the belt of the upper side cover to the upper hook [G].

Side Cover Inspection (KRF750NC/PC/RC/SC/VC

∼

ND/PD/RD/SD)

•

Check the following parts for damage or tear.

Belt Attachments and Belts [A]

Covers [B]

Adjusters [C]

Buckles [D]

Damper [E]

If necessary, replace the covers with new ones.

•

Check the operation of the buckle [A].

○

Set the plate [B] in the buckle, and confirm the plate does not come off when pulling it.

○

Set the plate in the buckle, and confirm the plate comes off when the release buttons [C] is pushed.

If the operation is not correct, replace the upper and lower side covers with new ones.

•

Connect the upper and lower side covers.

If the three belts [A] have the slack, remove the slack of the three belts using the adjusters [B] attached to the three positions as shown in the figure.

Windshield Removal (KRF750P/R/V)

•

Remove:

Bolts [A] and Washers

Brackets [B], Dampers and Collars

Windshield [C]

FRAME 15-59

15-60 FRAME

Covers

Windshield Installation (KRF750P/R/V)

•

Install:

Windshield [A]

Trim [B]

Collars [C]

Washers [D]

○

Thick side [E] is front side [F].

•

Install:

Dampers [G]

Brackets [H]

Bolts [I]

[J] Fit the trim on the front fender rear.

Covers

Sun Top Cover Removal (KRF750P/R/V)

•

Remove:

Screws [A] and Collars

Sun Top Cover [B]

Sun Top Cover Installation (KRF750P/R/V)

•

Install:

Sun Top Cover [A]

Screws [B] and Collars [C]

•

When installing the brackets, install them with the upper bar mounting bolts [D].

Small Bracket [E]

Large Bracket [F]

Front Side [G]

○

Tighten:

Torque — Upper Bar Mounting Bolts: 47 N·m (4.8 kgf·m, 35 ft·lb)

FRAME 15-61

15-62 FRAME

Covers

•

When installing the pads [A], install them on the rib of the front fender as shown in the figure.

Sun Top Cover [B]

49 mm (1.93 in.) [C]

Guards

Front Guard Removal

•

Remove:

Tapping Screws [A] and Collars

Screws [B] and Collars

Front Guard Cover [C]

•

Remove:

Bolts [A] (both sides)

Front Guard [B]

Front Guard Installation

•

Install:

Front Guard [A]

Bolts [B]

•

Install:

Front Guard Cover [A]

Screws [B] and Collars [C]

Tapping Screws [D]

Front Bottom Guard Removal

•

Remove:

Bottom Guard Bolts [A] and Collars

Front Bottom Guard [B]

FRAME 15-63

15-64 FRAME

Guards

Front Bottom Guard Installation

•

Install:

Front Bottom Guard [A]

Bottom Guard Bolts [B] and Collars [C]

Middle Bottom Guard Removal

•

Remove:

Bottom Guard Bolts [A] and Collars

Middle Bottom Guard [B]

Middle Bottom Guard Installation

•

Install:

Middle Bottom Guard [A]

Bottom Guard Bolts [B] and Collars [C]

Engine Bottom Guard Removal

•

Remove:

Bottom Guard Bolts [A]

Engine Bottom Guard [B]

Guards

Engine Bottom Guard Installation

•

Install:

Engine Bottom Guard [A]

Bottom Guard Bolts [B]

•

When installing the following parts, install them as shown in the figure.

Guard [C]

Bottom Guard Bolts [D]

Damper [E]

Insulator [F]

FRAME 15-65

Rear Bottom Guard Removal

•

Remove:

Bottom Guard Bolts [A] and Collars

Rear Bottom Guard [B]

Rear Bottom Guard Installation

•

Install:

Rear Bottom Guard [A]

Bottom Guard Bolts [B] and Collars [C]

15-66 FRAME

Floorboard

Floorboard Removal

Left Floorboard

•

Remove:

Control Panel (see Control Panel Removal)

Steering Shafts (see Steering Shafts Removal in the

Steering chapter)

Seat Lower Cover (see Seat Lower Cover Removal)

Front Brake Master Cylinder (see Front Brake Master

Cylinder Removal in the Brakes chapter)

•

Remove:

Parking Brake Cable [A]

Parking Brake Light Switch Lead Connectors [B]

•

Remove:

Throttle Cable [A]

•

Remove:

Brake Light Switch Lead Connectors [A]

Brake Pedal Bracket Mounting Bolts [B]

•

Remove:

Brake Pedal Bracket Mounting Bolts [A]

Brake Pedal Bracket [B]

Floorboard

•

Remove:

Plate Bolts [A] and Washers

•

Remove:

Bracket Bolts [A]

Bracket [B] and Plate

•

Remove:

Tapping Screws [A] and Collars

•

Remove:

Screws [A] and Collars

•

Remove:

Tapping Screws [A] and Collars

Screws [B] and Collars

Quick Rivets [C]

Left Floorboard [D]

FRAME 15-67

15-68 FRAME

Floorboard

Right Floorboard

•

Remove:

Left Floorboard

Coolant Reserve Tank (see Coolant Change in the Cooling System chapter)

Tapping Screws [A] and Collars

Clamp [B]

•

Remove:

Grommet [A]

•

Remove:

Tapping Screws [A] and Collars

Screws [B] and Collars

Quick Rivets [C]

Right Floorboard [D]

Floorboard

Floorboard Installation

•

Install:

Right Floorboard [A]

Left Floorboard [B]

Tapping Screws [C] and Collars [D]: L = 4 mm (0.16 in.)

Screws [E] and Collars [D]: L = 4 mm (0.16 in.)

Screws [F] and Collars [G]: L = 7.2 mm (0.28 in.)

Quick Rivets [H]

Well Nuts [I]

Caps [J]

FRAME 15-69

•

Install:

Coolant Reserve Tank (see Coolant Change in the Cooling System chapter)

•

Install the grommet [A] to the right floorboard [B] so that the large diameter [C] side faces forward.

Harness [D]

Front Side [E]

15-70 FRAME

Floorboard

•

Apply sealing material to the mating surface of the floorboard and plate [A].

•

Install:

Plate

Bracket [B]

Bolts [C]: M6, L = 18 mm (0.71 in.)

Washers [D]: Outside Diameter 15 mm (0.59 in.)

•

Apply a non-permanent locking agent to the brake pedal bracket mounting bolts [A].

•

Install:

Brake Pedal Bracket [B]

Washers [C]: Thickness 1.6 mm (0.063 in.)

Washers [D]: Thickness 3.2 mm (0.126 in.)

•

Tighten:

Torque — Brake Pedal Bracket Mounting Bolts: 34.3 N·m

(3.5 kgf·m, 25 ft·lb)

•

Install:

Throttle Cable (see Throttle Cable Installation in the Fuel

System chapter)

Parking Brake Cable (see Parking Brake Cable Installation in the Brakes chapter)

Parking Brake Light Switch Lead Connectors

Front Brake Master Cylinder (see Front Brake Master

Cylinder Installation in the Brakes chapter)

Steering Shafts (see Steering Shafts Installation in the

Steering chapter)

Control Panel (see Control Panel Installation)

Seat Lower Cover (see Seat Lower Cover Installation)

ELECTRICAL SYSTEM 16-1

Electrical System

Table of Contents

Parts Location………………………………

Exploded View……………………………..

16-3

16-6

Specifications ………………………………

16-12

Special Tools ……………………………….

16-14

Wiring Diagram

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) ………………….

16-16

Wiring Diagram

(KRF750ND/PD/RD/SD)……………..

16-18

Precautions………………………………….

16-20

Electrical Wiring……………………………

16-21

Wiring Inspection …………………….

16-21

Battery ………………………………………..

16-22

Battery Removal ……………………..

16-22

Battery Installation …………………..

16-22

Battery Activation (CA Model)……

16-25

Precautions …………………………….

16-27

Interchange …………………………….

16-28

Charging Condition Inspection…..

16-28

Refreshing Charge ………………….

16-29

Charging System ………………………….

16-31

Alternator Cover Removal…………

16-31

Alternator Cover Installation………

16-32

Alternator Rotor Removal ………..

16-34

Alternator Rotor Installation ………

16-35

Alternator Stator Removal…………

16-36

Alternator Stator Installation………

16-36

Regulator/Rectifier Output

Voltage Inspection…………………

16-36

Alternator Inspection ………………..

16-37

Regulator/Rectifier Removal ……..

16-38

Regulator/Rectifier Installation …..

16-38

Regulator/Rectifier Inspection……

16-39

Ignition System …………………………….

16-41

Spark Plug Removal ………………..

16-41

Spark Plug Installation ……………..

16-41

Spark Plug Cleaning/Inspection…

16-41

Spark Plug Gap Inspection ……….

16-41

Ignition Coil Removal ……………….

16-41

Ignition Coil Installation …………….

16-42

Ignition Coil Inspection……………..

16-43

Ignition Coil Primary Peak Voltage

Inspection…………………………….

16-44

Crankshaft Sensor Removal ……..

16-45

Crankshaft Sensor Installation …..

16-45

Crankshaft Sensor Inspection……

16-45

Crankshaft Sensor Peak Voltage

Inspection…………………………….

16-46

Alternator Rotor Inspection ……….

16-46

Ignition Timing Test ………………….

16-46

Electric Starter System ………………….

16-51

Starter Motor Removal……………..

16-51

Starter Motor Installation…………..

16-51

Starter Motor Disassembly………..

16-52

Starter Motor Assembly ……………

16-53

Brush Inspection ……………………..

16-55

Commutator Cleaning and

Inspection…………………………….

16-55

Armature Inspection…………………

16-55

Brush Lead Inspection ……………..

16-56

Right-hand End Cover Inspection 16-56

Starter Relay Inspection……………

16-56

Starter Relay Installation…………..

16-56

Starter Control Relay Inspection ..

16-56

Starter Motor Clutch Removal……

16-59

Starter Motor Clutch Installation…

16-59

Starter Motor Clutch Inspection …

16-59

Torque Limiter Inspection………….

16-60

Lighting System ……………………………

16-61

Headlight Beam Vertical

Adjustment …………………………..

16-61

Headlight Bulb Replacement …….

16-61

Tail/Brake Light Bulb

Replacement ………………………..

16-62

Radiator Fan System…………………….

16-65

Radiator Fan Circuit Inspection….

16-65

Radiator Fan Motor Inspection…..

16-65

Radiator Fan Breaker Inspection .

16-65

Radiator Fan Breaker Installation 16-66

Radiator Fan Relay Inspection…..

16-66

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) …………………….

16-68

Multifunction Meter Unit Removal 16-68

Multifunction Meter Unit

Installation ……………………………

16-68

Multifunction Meter Unit

Inspection…………………………….

16-69

Meter (KRF750ND/PD/RD/SD) ………

16-77

Multifunction Meter Unit Removal 16-77

Multifunction Meter Unit

Installation ……………………………

16-77

Multifunction Meter Operation

Inspection…………………………….

16-78

Multifunction Meter System

Inspection…………………………….

16-78

Multifunction Meter Unit

Inspection…………………………….

16-80

Actuator Control System………………..

16-84

Engine Brake Actuator Removal..

16-84

16

16-2 ELECTRICAL SYSTEM

Engine Brake Actuator

Installation ……………………………

16-84

Actuator Control System Outline..

16-85

Engine Brake Actuator Inspection 16-85

Speed Sensor Circuit Inspection..

16-86

Controller Unit Inspection………….

16-87

Forward/Reverse Detecting

Sensor Inspection …………………

16-88

2WD/4WD Solenoid Valve……………..

16-91

2WD/4WD Solenoid Valve

Inspection…………………………….

16-91

Relay ………………………………………….

16-94

Relay Inspection ……………………..

16-94

Switches and Sensor…………………….

16-95

Brake Light Switch Adjustment ….

16-95

Water Temperature Switch

Inspection…………………………….

16-95

Fuel Level Sensor Inspection…….

16-95

Speed Sensor Removal/Installa-

tion ……………………………………..

16-95

Speed Sensor Inspection………….

16-96

Switch Inspection …………………….

16-96

Fuses …………………………………………

16-98

Fuse Removal…………………………

16-98

Fuse Installation………………………

16-98

Fuse Inspection……………………….

16-99

Parts Location

Ignition Switch [A]

2WD/4WD Shift Switch [B]

Multifunction Meter [C]

Accessory Connector (12 V 120 W) (Power Outlet) [D]

ELECTRICAL SYSTEM 16-3

Lighting Switch [A]

Parking Brake Position Switch [A]

Brake Light Switch [B]

Starter Motor [A]

Engine Ground [B]

Crankshaft Sensor [C]

Alternator [D]

Forward/Reverse Detecting Sensor [E]

Reverse Position Switch [F]

Neutral Position Switch [G]

Battery [A]

Fuse Box [B]

Starter Relay [C]

Actuator Controller [D]

Vehicle-down Sensor [E]

Starter Control Relay [F]

Radiator Fan Relay [G]

Fuel Pump Relay [H]

Frame Ground [I]

Radiator Fan Breaker [J]

ECU (Electronic Control Unit) [K]

16-4 ELECTRICAL SYSTEM

Parts Location

Regulator/Rectifier [A]

Frame Ground 2 [B]

Radiator Fan [C]

4WD Position Switch [D]

Spark Plug (Front Cylinder) [A]

Starter Motor [B]

Oil Pressure Switch [C]

Ignition Coil #1 (Front Cylinder) [D]

Spark Plug (Rear Cylinder) [A]

ISC Valve [B]

Throttle Sensor [C]

Water Temperature Sensor [D]

Ignition Coil #2 (Rear Cylinder) [A]

Engine Brake Actuator [B]

2WD/4WD Solenoid Valve [C]

Fuel Pump and Fuel Level Sensor [D]

Speed Sensor [A]

Parts Location

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Multifunction Meter [A]

“SET/RESET” Button [B]

CVT Belt Check Indicator Light [C]

Neutral Indicator Light [D]

Reverse Indicator Light [E]

Oil Pressure Warning Indicator Light [F]

“4WD” Indicator Symbol [G]

“2WD” Indicator Symbol [H]

Water Temperature Warning Symbol [I]

FI Indicator Symbol [J]

Fuel Level Gauge [K]

“TIME SET” Button [L]

Clock [M]

Speedometer/“P” Parking Brake Symbol [N]

Trip Meter/Odometer/Hour Meter [O]

“MODE” Button [P]

(KRF750ND/PD/RD/SD)

Multifunction Meter [A]

Yellow Engine Warning Indicator Light (LED) [B]

Red CVT Belt Check Indicator Light (LED) [C]

Speedometer [D]

Fuel Level Gauge [E]

Red Parking Brake Indicator Light (LED) [F]

Red Reverse Indicator Light (LED) [G]

Green Neutral Indicator Light (LED) [H]

Right Button [I]

Odometer/Trip Meter/Hour Meter [J]

Clock [K]

Left Button [L]

2WD Indicator Symbol [M]

Red Seat Belt Use Reminder (LED) [N]

Red Coolant Temperature Warning Indicator Light (LED)

[O]

Red Oil Pressure Warning Indicator Light (LED) [P]

4WD Indicator Symbol [Q]

ELECTRICAL SYSTEM 16-5

16-6 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-7

Exploded View

No.

Fastener

1 Starter Motor Mounting Bolts

2 Starter Motor Terminal Locknut

3 Starter Motor Cable Mounting Nut

4 Starter Motor Through Bolts

5 Starter Motor Clutch Bolts

6 Left Engine Cover Bolts

7 Alternator Rotor Bolt

8 Alternator Cover Plugs

9 Crankshaft Sensor Mounting Bolts

10 Alternator Stator Bolts

11 Alternator Cover Bolts, L = 55 mm (2.17 in.)

12 Alternator Cover Bolts, L = 30 mm (1.18 in.)

13 Breather Plate Screws

14. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

M: Apply molybdenum dislfide grease.

R: Replacement Parts

17.5

5.9

13.5

8.8

8.8

2.9

N·m

8.8

11

6.8

5.0

34

5.9

127

0.60

13.0

1.8

0.60

1.4

0.90

0.90

0.30

Torque kgf·m

0.90

1.1

0.69

0.51

3.5

ft·lb

78 in·lb

97 in·lb

60 in·lb

44 in·lb

25

52 in·lb

94

13

52 in·lb

10

78 in·lb

78 in·lb

26 in·lb

Remarks

L

L

L

16-8 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-9

Exploded View

No.

Fastener

1 Ignition Coil Mounting Bolts

2 Spark Plugs

3 Vacuum Actuator Bracket Bolts

4 Solenoid Valve Bracket Bolts

5 ECU Mounting Bolts

6 Engine Brake Actuator Mounting Bolts

7 Engine Brake Actuator Cover Bolt

8 Forward/Reverse Detecting Sensor Mounting Bolt

9 Speed Sensor Mounting Bolt

10 Reverse Position Switch

11 Neutral Position Switch

12 4WD Position Switch

13. 2WD/4WD Solenoid Valve

14. Lighting Switch

15. Ignition Switch

16. 2WD/4WD Shift Switch

17. Accessory Connector (12 V 120 W) (Power Outlet)

18. Actuator Controller

19. Air Temperature Sensor

20. Brake Light Switch

G: Apply grease.

S: Follow the specific tightening sequence.

8.8

6.9

8.8

8.8

N·m

5.9

13

8.8

14.9

8.8

15

15

15

Torque kgf·m ft·lb

0.60

52 in·lb

1.3

115 in·lb

0.90

78 in·lb

0.90

78 in·lb

0.70

61 in·lb

0.90

78 in·lb

0.90

78 in·lb

1.5

11

0.90

78 in·lb

1.5

1.5

1.5

11

11

11

Remarks

S

S

16-10 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-11

Exploded View

No.

Fastener

1 Water Temperature Sensor

2 Radiator Fan Assembly Bolts

3 Oil Pressure Switch

4 Battery Holder Mounting Bolts

5 Regulator/Rectifier Mounting Bolts

N·m

12

8.3

15

16

8.8

6. Fuse Box

7. Radiator Fan Breaker 15 A

8. Fuse Pump Relay

9. Radiator Fan Relay

10. Starter Control Relay

11. US Model

12. CA Model

13. KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).

Torque kgf·m

1.2

0.85

1.5

1.6

0.90

ft·lb

106 in·lb

73 in·lb

11

12

78 in·lb

Remarks

SS

16-12 ELECTRICAL SYSTEM

Specifications

Item Standard

Battery

Type

Model Name

Capacity

Gross Weight

Electrolyte Volume

Sealed Battery

KMX14-BS (CA Model)

12 V 12 Ah (CA Model)

12 V 14 Ah (US Model)

4.7 kg (10.4 lb) (CA Model)

7.0 kg (15.4 lb) (US Model)

0.69 L (42 cu in.) (CA Model)

2.18 L (133 cu in.) (US Model)

Charging System

Alternator Type

Charging Voltage

(Regulator/Rectifier Output Voltage)

Alternator Output Voltage

Stator Coil Resistance

Ignition System

Spark Plug:

Spark Plug Gap

Spark Plug Cap Resistance

Ignition Coil:

3 Needle Arcing Distance

Primary Winding Resistance

Secondary Winding Resistance

Primary Peak Voltage

Crankshaft Sensor Resistance

Crankshaft Sensor Peak Voltage

Electric Starter System

Starter Motor:

Brush Length

Fuel Level Sensor

Fuel Level Sensor Resistance:

Full Level Position

Empty Level Position

Actuator Control System

Actuator Resistance

Three-phase AC

14

∼

15 V

52

∼

78 V at 4 000 r/min (rpm)

0.24

∼

0.36 Ω

0.7

∼

0.8 mm (0.028

∼

0.031 in.)

3.75

∼

6.25 kΩ

7 mm (0.28 in.) or more

1.84

∼

2.76 Ω

10.4

∼

15.6 kΩ

160 V or more

110

∼

140 Ω

2 V or more

12 mm (0.47 in.)

10 Ω

120 Ω

3

∼

15 Ω (between R and BK leads)

3.5

∼

6.5 kΩ (between O and BL leads)

630

∼

5 330 Ω (between Y and BL leads)

1.2

∼

1.6 kΩ Forward/Reverse Detecting Sensor

Resistance

2WD/4WD Solenoid Valve

Solenoid Valve Resistance

Switches

Brake Light Switch Timing

37

∼

43 Ω at 20°C (68°F)

ON after 10 mm (0.4 in.) of pedal travel

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

6.5 mm (0.26 in.)

– – –

– – –

– – –

– – –

– – –

– – –

ELECTRICAL SYSTEM 16-13

Specifications

Item Standard

Water Temperature Sensor Resistance *18.80 ±2.37 kΩ at –20°C (–4°F)

*about 6.544 kΩ at 0°C (32°F)

1.136 ±0.095 kΩ at 40°C (104°F)

0.1553 ±0.0070 kΩ at 100°C (212°F)

*: Reference Information

Service Limit

– – –

– – –

– – –

– – –

16-14 ELECTRICAL SYSTEM

Special Tools

Bearing Driver Set:

57001-1129

Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:

57001-1405

Timing Light:

57001-1241

Flywheel Holder:

57001-1313

Peak Voltage Adapter:

57001-1415

Needle Adapter Set:

57001-1457

Hand Tester:

57001-1394

Drive Pulley Holder:

57001-1620

Special Tools

This page intentionally left blank.

ELECTRICAL SYSTEM 16-15

16-16 ELECTRICAL SYSTEM

Wiring Diagram (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

ELECTRICAL SYSTEM 16-17

Wiring Diagram (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

16-18 ELECTRICAL SYSTEM

Wiring Diagram (KRF750ND/PD/RD/SD)

Wiring Diagram (KRF750ND/PD/RD/SD)

ELECTRICAL SYSTEM 16-19

16-20 ELECTRICAL SYSTEM

Precautions

There are a number of important precautions that should be taken when servicing electrical systems. Learn and observe all the rules below.

○

Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts.

○

Always check battery condition before condemning other parts of an electrical system. A fully charged battery is required for conducting accurate electrical system tests.

○

The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.

○

To prevent damaging electrical parts, do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running.

○

Because of the high current, never keep the ignition switch key turned “START” position when the starter motor will not turn over, or the current may burn out the starter motor windings.

○

Take care not to short the leads that are directly connected to the battery positive (+) terminal to chassis ground.

○

Troubles may involve one or in some cases all items.

Never replace a defective part without determining what

CAUSED the failure. If the failure was caused by some other item or items, they too must be repaired or replaced, or the new replacement will soon fail again.

○

Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Defective wires and bad connections will affect electrical system operation.

○

Measure coil and winding resistance when the part is cold

(at room temperature).

○

Color Codes:

BK Black

BL Blue

GY Gray

LB Light blue

R

V

Red

Violet

BR Brown

CH Chocolate

DG Dark green P

LG Light green W

O Orange Y

Pink

G Green PU Purple

White

Yellow

Electrical Wiring

Wiring Inspection

•

Visually inspect the wiring for signs of burning, fraying, etc.

If any wiring is defective, replace the damaged wiring.

•

Pull each connector [A] apart and inspect for corrosion, dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

• is damaged, replace it.

Check the wiring for continuity.

○

Use the wiring diagram to find the ends of the lead which is suspected of being a problem.

○

Connect the hand tester between the ends of the leads.

Special Tool — Hand Tester: 57001-1394

○

Set the tester to the ×1 Ω range.

If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness [B] if necessary.

ELECTRICAL SYSTEM 16-21

16-22 ELECTRICAL SYSTEM

Battery

○

In this model, two batteries are prepared.

Pre-charged Sealed Type Battery [A] (US model)

Sealed Type Battery [A] (CA model)

•

Battery Removal

Turn off the ignition switch.

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

•

Disconnect the battery negative (–) cable [A] first, and then the positive (+) cable [B].

NOTICE

Be sure to disconnect the negative (–) cable first.

US Model [C]

CA Model [D]

•

Remove:

Battery Holder Mounting Nuts [E]

Battery Holder [F]

Battery [G]

Battery Installation

(For US Model)

•

Check that the damper [A] on the plate [B] is properly in place.

Battery

•

Check that the damper [A] on the battery holder [B] is properly in place.

ELECTRICAL SYSTEM 16-23

•

Check that the dampers [A] on the battery [B] are properly in place.

•

Install:

Battery [A]

Collars [B]

Battery Holder [C]

•

Tighten:

Torque — Battery Holder Mounting Bolts [D]: 16 N·m (1.6

kgf·m, 12 ft·lb)

•

Connect the positive (+) cable first, and then negative (–) cable.

Positive Terminal [E]

•

Do not run the positive (+) cable between the left cover and collar (see Cable, Wire, and Hose Routing in the Appendix chapter).

•

Put a light coat of grease on the terminals to prevent corrosion.

•

Install the terminal cap on the positive terminal.

(For CA Model)

•

Check that the dampers [A] on the plate [B] and bracket

[C] are properly in place.

16-24 ELECTRICAL SYSTEM

Battery

•

Check that the damper [A] on the battery holder [B] is properly in place.

•

Check that the damper [A] on the battery [B] is properly in place.

•

Check that the damper [A] on the battery bracket [B] is properly in place.

•

Install:

Battery Brackets [A]

Battery Bracket Mounting Bolts [B]

Battery [C]

Collars [D]

Battery Holder [E]

•

Tighten:

Torque — Battery Holder Mounting Bolts [F]: 16 N·m (1.6

kgf·m, 12 ft·lb)

•

Connect the positive (+) cable first, and then negative (–) cable.

Positive Terminal [G]

•

Put a light coat of grease on the terminals to prevent corrosion.

•

Install the terminal cap on the positive terminal.

Battery

Battery Activation (CA Model)

Electrolyte Filling

•

Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These names must be the same.

Battery Model Name

KRF750N/P/R/S: KMX14-BS

NOTICE

Each battery comes with its own specific electrolyte container; using the wrong container may overfill the battery with incorrect electrolyte, which can shorten battery life and deteriorate battery performance. Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type.

NOTICE

Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume.

DANGER

Sulfuric acid in battery electrolyte can cause severe burns. To prevent burns, wear protective clothing and safety glasses when handling electrolyte. If the electrolyte comes in contact with your skin or eyes, wash the area with liberal amounts of water and seek medical attention for more severe burns.

•

Place the battery on a level surface.

•

Check to see that the sealing sheet has no peeling, tears, or holes in it.

•

Remove the sealing sheet.

NOTE

○

The battery is vacuum sealed. If the sealing sheet has leaked air into the battery, it may require a longer initial charge.

•

Remove the electrolyte container from the vinyl bag.

•

Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery.

NOTE

○

Do not pierce or otherwise open the sealed cells [B] of the electrolyte container. Do not attempt to separate individual cells.

ELECTRICAL SYSTEM 16-25

16-26 ELECTRICAL SYSTEM

Battery

•

Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.

NOTE

○

Do not tilt the electrolyte container.

•

Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times.

NOTE

○

Be careful not to have the battery fall down.

•

Keep the container in place. Don’t remove the container from the battery, the battery requires all the electrolyte from the container for proper operation.

NOTICE

Removal of the container before it is completely empty can shorten the service life of the battery.

Do not remove the container until it is completely empty.

•

After filling, let the battery sit for 20

∼

60 minutes with the electrolyte container kept in place, which is required for the electrolyte to fully permeate into the plates.

•

Make sure that the container cells have emptied completely, and remove the container from the battery.

•

Place the strip of caps [A] loosely over the filler ports, press down firmly with both hands to seat the strip of caps into the battery (don’t pound or hammer). When properly installed, the strip of caps will be level with the top of the battery.

NOTICE

Once the strip of caps is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery.

NOTE

○

Charging the battery immediately after filling can shorten service life.

ELECTRICAL SYSTEM 16-27

Battery

Initial Charge

•

Newly activated sealed batteries require an initial charge.

Standard Charge: 1.2 A × 5

∼

10 hours

If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers:

Battery Mate 150-9

OptiMate PRO 4-S/PRO S/PRO2

Yuasa MB-2040/2060

Christie C10122S

If the above chargers are not available, use equivalent one.

•

Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. (Voltage immediately after charging becomes temporarily high. For accurate measuring, let the battery sit for given time.)

NOTE

○

Charging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. If voltage is not at least 12.8 V, repeat charging cycle.

○

To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds.

Re-check voltage and if less than 12.8 V repeat the charging cycle and load test. If still below 12.8 V the battery is defective.

Precautions

1) No need of topping-up

No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that.

2) Refreshing charge

If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification

(see Refreshing Charge).

When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.

NOTICE

This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above.

Never remove the seal caps during refresh charge.

If by chance an excessive amount of gas is generated due to overcharging, the safety valve operates to keep the battery safe.

3) When you do not use the vehicle for months

Give a refresh charge before you store the vehicle and store it with the negative cable removed.

Give a refresh charge once a month during storage.

4) Battery life

If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it. (Provided, however, the vehicle’s starting system has no problem.)

16-28 ELECTRICAL SYSTEM

Battery

DANGER

Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water and seek medial attention for more severe burns.

Interchange

A sealed battery can fully display its performance only when combined with a proper vehicle electrical system. Therefore, replace a sealed battery only on a vehicle which was originally equipped with a sealed battery.

Be careful, if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.

Charging Condition Inspection

Battery charging condition can be checked by measuring battery terminal voltage.

•

Remove the battery (see Battery Removal).

NOTICE

Be sure to disconnect the negative (−) cable first.

•

Measure the battery terminal voltage.

NOTE

○

Measure with a digital voltmeter [A] which can be read to one decimal place voltage.

If the reading is below the specified, refreshing charge is required.

Battery Terminal Voltage (US model)

Standard: 12.6 V or more

Battery Terminal Voltage (CA model)

Standard: 12.8 V or more

Battery

•

Refreshing Charge

Remove the battery [A] (see Battery Removal).

•

Refresh-charge by following method according to the battery terminal voltage.

WARNING

This battery is sealed type. Never remove sealing cap [B] even at charging. Never add water. Charge with current and time as stated below.

ELECTRICAL SYSTEM 16-29

(US model)

Terminal Voltage: 11.8

∼

less than 12.6 V

Standard Charge (see following chart)

2 A × 4

∼

12 h

6 A × 2

∼

6 h

(CA model)

Terminal Voltage: 11.5

∼

less than 12.8 V

Standard Charge

1.2 A × 5

∼

10 h (see following chart)

Quick Charge

6.0 A × 1.0 h

NOTICE

If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do the standard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method: 1.2 A × 20 h

NOTE

○

Increase the charging voltage to a maximum voltage of

25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current [D], decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 minutes, replace the battery.

Battery [A]

Battery Charger [B]

Standard Value [C]

16-30 ELECTRICAL SYSTEM

Battery

•

Determine battery condition after refreshing charge.

○

Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal voltage according to the table below.

(US model)

Criteria

12.6 V or higher

12.0

∼

12.5 V or lower

12.0 V or lower

Judgement

Good

Charge insufficient → Recharge

Unserviceable → Replace

(CA model)

Criteria

12.8 V or higher

12.0

∼

12.7 V or lower

12.0 V or lower

Judgement

Good

Charge insufficient → Recharge

Unserviceable → Replace

Charging System

Alternator Cover Removal

•

Drain:

Coolant (see Coolant Change in the Periodic Maintenance chapter)

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)

•

Remove

NC/PC/RC/SC/VC):

(KRF750NA/PA/RA/SA/TA

Torque Converter Cover (see Torque Converter Cover

∼

Removal in the Converter System chapter)

•

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Remove the three bolts of the drive pulley cover [A].

•

Install the drive pulley holder [B], tightening the removed three bolts [C].

Special Tool — Drive Pulley Holder: 57001-1620

ELECTRICAL SYSTEM 16-31

•

Remove:

Left Cover (see Left Cover Removal in the Frame chapter)

Water Pump Impeller (see Water Pump Impeller Removal in the Cooling System chapter)

Bolts [A] and Left Engine Cover [B]

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Holding the drive pulley with the drive pulley holder, remove the alternator rotor bolt [A].

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Remove:

Collar [A]

○

Install a M6 bolt [B] to the collar, and remove it.

16-32 ELECTRICAL SYSTEM

Charging System

•

Remove:

Engine Ground Terminal Bolt [A]

•

Remove the main harness [B] from the clamp [C].

•

Disconnect:

Alternator Lead Connectors [A]

Crankshaft Sensor Lead Connector [B]

•

Remove:

Alternator Cover Bolts [A]

Alternator Cover [B]

Alternator Cover Installation

•

When installing the oil seals [A], press the oil seals in the alternator cover so that each oil seal surface is flush with the cover end as shown in the figure.

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) [B]

•

Apply grease to the oil seal lips.

•

When installing the ball bearing [C], press the ball bearing until it is bottomed.

Special Tool — Bearing Driver Set: 57001-1129

•

Be sure all of the old gasket has been removed from the alternator cover and the left crankcase sealing surfaces.

•

Check that the dowel pins [A] are in place, and fit a new gasket [B] on the crankcase.

•

Check that the bearing [C] is in place

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC).

Charging System

•

•

Fit the grommets [A] into the notch in the cover (see

Crankshaft Sensor Installation).

•

Apply grease to the alternator cover oil seal.

•

Install the alternator cover.

Tighten:

Torque — Alternator Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

ELECTRICAL SYSTEM 16-33

•

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Replace the O-ring [A] with a new one.

•

Apply grease to the O-ring.

•

Install the collar [B] and O-ring on the alternator cover.

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Hold the drive pulley with the drive pulley holder [A].

Special Tool — Drive Pulley Holder: 57001-1620

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Tighten:

Torque — Alternator Rotor Bolt [A]: 127 N·m (13.0 kgf·m, 94 ft·lb)

•

Apply a non-permanent locking agent to the left engine cover bolts.

•

Tighten:

Torque — Left Engine Cover Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)

•

Install the removed parts (see appropriate chapter).

•

Pour:

Coolant (see Coolant Change in the Periodic Maintenance chapter)

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)

16-34 ELECTRICAL SYSTEM

Charging System

Alternator Rotor Removal

•

Remove:

Alternator Cover (see Alternator Cover Removal)

Ball Bearing [A] (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

(KRF750ND/PD/RD/SD)

•

Remove the torque converter (see Torque Converter

Cover Removal in the Converter System chapter).

•

Remove the three bolts of the drive pulley cover [A].

Install the drive pulley holder [B], tightening the removed three bolts [C].

Special Tool — Drive Pulley Holder: 57001-1620

(KRF750ND/PD/RD/SD)

•

Holding the drive pulley with the drive pulley holder, remove the alternator rotor bolt [A].

•

Screw the flywheel puller [A] onto the alternator rotor.

Special Tool — Flywheel Puller Assembly, M38 × 1.5/M35 ×

1.5: 57001-1405

•

Holding the flywheel puller, turn the rotor puller bolt until the alternator rotor is forced off the end of the crankshaft.

NOTICE

If the rotor is difficult to remove, turn the puller while tapping the end of the puller. Do not strike the alternator rotor. Striking the rotor can cause the magnets to lose magnetism.

Charging System

Alternator Rotor Installation

•

When installing the starter clutch gear [A], apply molybdenum disulfide grease to the crankshaft [B].

ELECTRICAL SYSTEM 16-35

•

Using a cleaning fluid, clean off any oil or dirt on the following portions and dry them with a clean cloth.

Crankshaft Tapered Portion [A]

Alternator Rotor Tapered Portion [B]

•

Fit the rotor onto the crankshaft so that woodruff key [C] fits into the groove [D] in the hub of the rotor.

•

Install the alternator rotor [A] while turning the starter clutch gear [B].

•

Apply molybdenum disulfide grease to the shaft of the torque limiter [C].

•

Install the torque limiter.

(KRF750ND/PD/RD/SD)

•

Hold the drive pulley with the drive pulley holder [A].

Special Tool — Drive Pulley Holder: 57001-1620

(KRF750ND/PD/RD/SD)

•

Tighten:

Torque — Alternator Rotor Bolt [A]: 127 N·m (13.0 kgf·m, 94 ft·lb)

16-36 ELECTRICAL SYSTEM

Charging System

Alternator Stator Removal

•

Remove:

Alternator Cover (see Alternator Cover Removal)

Crankshaft Sensor [A] (see Crankshaft Sensor Removal)

Bolts [B] and Alternator Stator [C]

Alternator Stator Installation

•

Tighten:

Torque — Alternator Stator Bolts: 13.5 N·m (1.4 kgf·m, 10 ft·lb)

•

Install:

Crankshaft Sensor (see Crankshaft Sensor Installation)

•

Fit the lead grommets into the notch on the alternator cover.

Grommets [A] for Alternator Leads

Grommets [B] for Crankshaft Sensor Leads

○

Run the alternator stator leads under the crankshaft sensor leads.

○

Fit the grommet for alternator leads first and then install the one of crankshaft sensor leads to the notch of the alternator cover.

•

Regulator/Rectifier Output Voltage Inspection

•

Remove the left seat (see Seat Removal in the Frame chapter).

•

Check the battery condition (see Battery section).

Warm up the engine to obtain actual alternator operating conditions.

Charging System

•

Check that the ignition switch is turned off, and connect a hand tester [A] to the battery terminals.

Special Tool — Hand Tester: 57001-1394

•

Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off.

The readings should show nearly battery voltage when the engine speed is low, and as the engine speed increases, the readings should also increase.

Regulator/Rectifier Output Voltage

Connections

Tester Range Reading

Tester (+) to Tester (–) to

25 V DC Battery (+) Battery (–) 14

∼

15 V

•

Turn off the ignition switch, and disconnect the hand tester.

If the regulator/rectifier output voltage is between the values given in the table, the charging system is working normally.

If the output voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open.

If the battery voltage does not increase as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective.

Alternator Inspection

There are three types of alternator failures: short, open, or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output.

•

To check the alternator output voltage, perform the following procedures.

○

Disconnect the alternator lead connectors [A].

○

Connect a hand tester [B] as shown in the table.

○

Start the engine.

○

Run it at the rpm given in the table.

○

Note the voltage readings (total 3 measurements).

Alternator Output Voltage

Tester Range

250 V AC

Connections Reading

Tester (+) to Tester (–) to at 4 000 rpm

One black lead

Another black lead

52

∼

78 V

If the output voltage is within the values in the table, the alternator is operating correctly, and the regulator/rectifier is damaged. A much lower reading indicates that the alternator is defective.

ELECTRICAL SYSTEM 16-37

16-38 ELECTRICAL SYSTEM

Charging System

•

Check the stator coil resistance as follows:

○

Stop the engine.

○

Disconnect the alternator connector.

○

Connect a hand tester as shown in the table.

○

Note the readings (total 3 measurement).

Stator Coil Resistance at 20°C (68°F)

Tester Range

× 1 Ω

Connections

Tester (+) to Tester (–) to

One black lead

Another black lead

Reading

0.24

∼

0.36 Ω

If there is more resistance than shown in the table, or no reading (infinity) for any two leads, the stator has an open and must be replaced. Much less resistance means the stator is shorted and must be replaced.

•

Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground.

Any reading less than infinity (∞) indicates a short, necessitating stator replacement.

If the stator coils have normal resistance, but the voltage check shows the alternator to be defective; then the rotor magnetism has probably weakened, and the rotor must be replaced.

Special Tool — Hand Tester: 57001-1394

Regulator/Rectifier Removal

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Remove:

Regulator/Rectifier Mounting Bolts [A]

Regulator/Rectifier [B]

•

Disconnect the regulator/rectifier lead connector [C].

•

Regulator/Rectifier Installation

Connect the regulator/rectifier lead connector.

•

Install:

Regulator/Rectifier

•

Tighten:

Torque — Regulator/Rectifier Mounting Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

Charging System

Regulator/Rectifier Inspection

•

Remove:

Regulator/Rectifier (see Regulator/Rectifier Removal)

•

Set the hand tester to the × 1 kΩ range and make the measurements shown in the table.

Special Tool — Hand Tester: 57001-1394

•

Connect the hand tester to the regulator/rectifier.

If the tester readings are not as specified, replace the regulator/rectifier.

NOTICE

Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings.

If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.

ELECTRICAL SYSTEM 16-39

Regulator/Rectifier Resistance

(–)*

Terminal

A

B

C

D

E

A

Tester (+) Lead Connection

B C D

–

2

∼

26

2

∼

26

∞

–

∞

∞

∞

∞

∞ – ∞

2

∼

26 ∞ ∞ –

2

∼

50 2

∼

26 2

∼

26 2

∼

26

(−)*: Tester (−) Lead Connection

(Unit: kΩ)

∞

∞

–

E

∞

∞

16-40 ELECTRICAL SYSTEM

Charging System

Charging System Circuit

1. Ignition Switch

2. Fuse Box

3. Main Fuse 30 A

4. Regulator/rectifier

5. Engine Ground

6. Battery

7. Alternator

8. Loads

9. Frame Ground 2

Ignition System

WARNING

The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil or spark plug lead while the engine is running, or you could receive a severe electrical shock.

NOTICE

Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent igniter damage.

Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the diodes and igniter.

Use the standard regulator/rectifier, or the igniter will be damaged.

Spark Plug Removal

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Rubber Covers

Spark Plug Cap [A]

•

Using a spark plug wrench, remove the spark plug [B].

ELECTRICAL SYSTEM 16-41

•

Spark Plug Installation

•

Tighten:

Torque — Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)

•

Fit the spark plug caps securely.

Pull up the spark plug caps lightly to make sure of the installation of the spark plug caps.

Spark Plug Cleaning/Inspection

•

Refer to the Spark Plug Cleaning/Inspection in the Periodic Maintenance chapter.

Spark Plug Gap Inspection

•

Refer to the Spark Plug Gap Inspection in the Periodic

Maintenance chapter.

Ignition Coil Removal

Front Side

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Rubber Cover

Clamps [A] and [B]

Spark Plug Cap [C]

Primary Lead Connectors [D]

Bolts [E]

Ignition Coil [F]

16-42 ELECTRICAL SYSTEM

Ignition System

Rear Side

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Rubber Cover

•

Spark Plug Cap [A]

Open the clamp [B].

•

Remove:

Primary Lead Connectors [C]

Bolts [D]

Ignition Coil [E]

Ignition Coil Installation

•

Install:

Ignition Coil

Torque — Ignition Coil Mounting Bolts: 5.9 N·m (0.60 kgf·m,

52 in·lb)

•

Connect the primary leads to the ignition coil terminals as shown.

Front Side

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

G/W Lead → (–) Terminal [A] (Green)

BR Lead → (+) Terminal [B] (Black)

(KRF750ND/PD/RD/SD)

G/W Lead → (–) Terminal [A] (Green)

BR/BL Lead → (+) Terminal [B] (Black)

Rear Side

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

BL/W Lead → (–) Terminal [A] (Green)

BR Lead → (+) Terminal [B] (Black)

(KRF750ND/PD/RD/SD)

W Lead → (–) Terminal [A] (Green)

BR/BL Lead → (+) Terminal [B] (Black)

Ignition System

•

Ignition Coil Inspection

Remove the ignition coil.

•

Measure the arcing distance with a coil tester [A] to check the condition of the ignition coil [B].

•

Connect the ignition coil (with the spark plug cap left attached at the end of the spark plug lead) to the tester in the manner prescribed by the manufacturer and measure the arcing distance.

Ignition Coil 3 Needle Arcing Distance

7 mm (0.28 in.) or more

WARNING

To avoid extremely high voltage shocks, do not touch the coil body or leads.

If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective.

•

To determine which part is defective, measure the arcing distance again with the spark plug cap removed from the ignition coil. Remove the cap by turning it counterclockwise.

If the arcing distance is as before, the trouble is with the ignition coil. If the arcing distance is normal, the trouble is with the spark plug cap.

If a coil tester is not available, the coil can be checked for a broken or badly shorted winding with a hand tester.

Special Tool — Hand Tester: 57001-1394

NOTE

○

The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage.

•

Measure the primary winding resistance [A] as follows:

○

Connect the tester between the coil terminals.

○

Set the tester to the × 1 Ω range.

•

Measure the secondary winding resistance [B] as follows:

○

Remove the plug cap by turning it counterclockwise.

○

Connect the tester between the spark plug lead and terminal.

○

Set the tester to the × 1 kΩ range.

Ignition Coil Winding Resistance

Primary Windings: 1.84

∼

2.76 Ω

Secondary Windings: 10.4

∼

15.6 kΩ

If the hand tester does not read as specified, replace the coil.

○

To install the plug cap, turn it clockwise.

ELECTRICAL SYSTEM 16-43

16-44 ELECTRICAL SYSTEM

Ignition System

Ignition Coil Primary Peak Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

•

Remove the spark plug cap (see Spark Plug Removal),

• but do not remove the spark plug.

Measure the primary peak voltage as follows.

○

Connect a commercially peak voltage adapter [A] to the hand tester [B] (1 000 V DC range). Install the needle adapter [C] on the peak voltage adapter leads.

Special Tools — Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

○

For KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC models, insert the needle adapter into the terminal of the G/W

(front) or BL/W (rear) primary lead [D].

○

For KRF750ND/PD/RD/SD models, insert the needle adapter into the terminal of the G/W (front) or W (rear) primary lead.

○

Install a new spark plug [E] into the spark plug cap, and ground it to the engine.

Ignition Coil [F]

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC [G]

KRF750ND/PD/RD/SD [H]

WARNING

To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections.

•

Turn the ignition switch ON, rotate the engine for 4

∼

5 seconds with the transmission in neutral to measure the primary peak voltage.

•

Repeat the measurements 5 times for one ignition coil.

Ignition Coil Primary Peak Voltage

Standard: 160 V or more

•

Repeat the test for the other ignition coil.

If the reading is less than the specified value, check the following.

Ignition Coils (see Ignition Coil Inspection)

Crankshaft Sensor (see Crankshaft Sensor Inspection)

If the ignition coils and crankshaft sensor are normal, see the Ignition System Troubleshooting chart on page 16-42.

Ignition System

Crankshaft Sensor Removal

•

Remove:

Alternator Cover (see Alternator Cover Removal)

Crankshaft Sensor Mounting Bolts [A]

Plate [B]

Crankshaft Sensor [C]

ELECTRICAL SYSTEM 16-45

Crankshaft Sensor Installation

•

Install:

Stator Coil Leads [A]

Crankshaft Sensor [B]

Plate [C]

•

Tighten:

Torque — Crankshaft Sensor Mounting Bolts: 5.9 N·m (0.60

kgf·m, 52 in·lb)

•

Fit the lead grommets into the notch on the alternator cover.

Grommets [A] for Alternator Leads

Grommets [B] for Crankshaft Sensor Leads

○

Position the blue lead of the crankshaft sensor to outside.

Crankshaft Sensor Inspection

•

Remove the seat (see Seat Removal in the Frame chapter).

•

Disconnect the crankshaft sensor lead connector [A].

•

Measure the crankshaft sensor resistance.

○

Connect a hand tester [B] between the BK/W lead and the

BL lead.

○

Set the tester to the × 10 Ω range.

Special Tool — Hand Tester: 57001-1394

Crankshaft Sensor Resistance

110

∼

140 Ω

If the tester does not read as specified, replace the crankshaft sensor.

16-46 ELECTRICAL SYSTEM

Ignition System

Crankshaft Sensor Peak Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Disconnect:

Crankshaft Sensor Lead Connector [A]

•

Set the hand tester [B] to the 10 V DC range.

•

Connect the peak voltage adapter [C] to the hand tester and crankshaft sensor leads in the connector.

Special Tools — Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Connections:

Crankshaft Sensor

Lead

Adapter Hand Tester

BK/W

←

R

→

(+)

BL ← BK → (–)

•

Turn the ignition switch on, and rotate the engine for 4

∼

5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage.

•

Repeat the measurement 5 or more times.

Crankshaft Sensor Peak Voltage

Standard: 2 V or more

If the peak voltage is lower than the standard, inspect the crankshaft sensor.

Alternator Rotor Inspection

•

Check the timing projection [A] for damage such as chipping or grooving.

If the timing projection on the rotor is visibly damaged, replace the alternator rotor.

Ignition Timing Test

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

Ignition Timing Inspection Plug [A]

Ignition System

•

Attach a timing light [A] and a tachometer in the manner prescribed by the manufacturer.

Special Tool — Timing Light: 57001-1241

•

Start the engine and aim the timing light at the timing mark on the alternator rotor.

•

Run the engine at the speeds specified and note the alignment of the timing marks.

ELECTRICAL SYSTEM 16-47

[A] F or R mark

Ignition Timing

Engine speed r/min (rpm)

1 100 and below

Slot [B] aligned with:

Advanced mark [C] on alternator rotor

NOTE

○

Do not mix up the timing marks with mark [A].

If the ignition timing is incorrect, replace the ECU and the crankshaft sensor.

16-48 ELECTRICAL SYSTEM

Ignition System

Ignition System Troubleshooting

ELECTRICAL SYSTEM 16-49

Ignition System

Ignition System Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. Throttle Sensor

2. Ignition Switch

3. Reverse Position Switch

4. Neutral Position Switch

5. Speed Sensor

6. Frame Ground 1

7. Fuse Box

8. Main Fuse 30 A

9. ECU (Electronic Control Unit)

10. Vehicle-down Sensor

11. Engine Ground

12. Battery

13. Spark Plugs

14. Ignition Coils

15. Water Temperature Sensor

16. Crankshaft Sensor

17. Intake Air Temperature Sensor

18. Intake Air Pressure Sensor

16-50 ELECTRICAL SYSTEM

Ignition System

Ignition System Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Frame Ground 2

3. Engine Ground

4. Battery

5. Spark Plugs

6. Ignition Coils

7. Crankshaft Sensor

8. Waterproof Joint 1

9. Waterproof Joint 2

10. Ignition Switch

11. Vehicle-down Sensor

12. Water Temperature Sensor

13. Intake Air Temperature Sensor

14. Intake Air Pressure Sensor

15. Throttle Sensor

16. Neutral Position Switch

17. Reverse Position Switch

18. Speed Sensor

19. Fuse Box

20. Ignition Fuse 10 A

21. Main Fuse 30 A

Electric Starter System

Starter Motor Removal

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Seat Lower Left Plate (see Seat Lower Left Plate Removal in the Frame chapter)

Air Intake Duct [A]

ELECTRICAL SYSTEM 16-51

•

Remove:

Joint Duct [A], Bolts and Collars

•

Remove:

Starter Motor Cable [A] and Nut

Starter Motor Mounting Bolts [B]

Starter Motor [C]

NOTICE

Do not tap the end of the starter motor shaft or the motor may be damaged.

Starter Motor Installation

•

Clean the starter motor lugs [A] and crankcase [B] where the starter motor is grounded.

•

Replace the O-ring [A] with a new one.

•

Apply grease to the O-ring.

•

Install the starter motor.

NOTICE

Do not tap the end of the starter motor shaft or the motor may be damaged.

16-52 ELECTRICAL SYSTEM

Electric Starter System

•

Install the starter motor cable [A] at the angle as shown in the figure.

[B] about 20°

•

Tighten:

Torque — Starter Motor Mounting Bolts: 8.8 N·m (0.90 kgf·m,

78 in·lb)

Starter Motor Cable Mounting Nut: 6.8 N·m (0.69

kgf·m, 60 in·lb)

•

Apply grease to the O-ring [A] in the joint duct [B].

•

Install:

Joint Duct and Collars [C]

•

Tighten:

Torque — Joint Duct Bolts [D]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Fit the projection [A] of the air intake duct into the groove

[B] of the rubber duct, and tighten the clamp screw.

•

Starter Motor Disassembly

Remove the starter motor (see Starter Motor Removal).

•

Take off the starter motor through bolts [A] and remove the both end covers [B].

•

Pull out the armature [A] out of the yoke [B].

NOTE

○

Do not remove the circlip [C] from the shaft.

Electric Starter System

•

Remove:

Starter Motor Terminal Locknut [A]

Washer [B]

Collar [C]

•

Pull out the brushes from the brush holder [A].

•

Remove:

Brush Springs [B]

Starter Motor Terminal [C]

Positive Brush Assy [D] and O-ring

Screw [E]

Negative Brush Assy [F]

Brush Holder

Starter Motor Assembly

•

Align the hole [A] of the brush holder [B] to the boss [C] of the end cover [D].

ELECTRICAL SYSTEM 16-53

•

Install the negative brush assy [A] to the brush holder [B].

•

Tighten the screw [C] securely.

•

Install the positive brush assy [D] to the brush holder.

•

Install the starter motor terminal.

•

Replace the O-ring [A] with a new one.

•

Install the following parts to the starter motor terminal [B].

O-ring

Collar [C]

Washer [D]

Starter Motor Terminal Locknut [E]

○

Install the collar so that stepped side faces outward.

•

Tighten:

Torque — Starter Motor Terminal Locknut: 11 N·m (1.1

kgf·m, 97 in·lb)

16-54 ELECTRICAL SYSTEM

Electric Starter System

•

Install the brush springs [A].

•

Insert the brushes [B] to the brush holder.

•

Apply thin coat of grease to the oil seal [A].

•

Replace the O-rings [A] with new ones.

•

Insert the armature [B] so that commutator side [C] faces hollow side [D] of the yoke.

•

Align the marks [A] to assembly the yoke and the end cover [B] as shown.

•

Tighten:

Torque — Starter Motor Through Bolts [A]: 5.0 N·m (0.51

kgf·m, 44 in·lb)

Electric Starter System

Brush Inspection

•

Measure the length of each brush [A].

If any is worn down to the service limit, replace the brush assy.

Starter Motor Brush Length

Standard: 12 mm (0.47 in.)

Service Limit: 6.5 mm (0.26 in.)

ELECTRICAL SYSTEM 16-55

Commutator Cleaning and Inspection

•

Clean the metallic debris off the between commutator segments [A].

NOTE

○

Do not use emery or sand paper on the commutator.

•

Check the commutator for damage or abnormal wear.

Replace the starter motor with a new one if there is any damage or wear.

•

Visually inspect the commutator segments for discoloration.

Replace the starter motor with a new one if discoloration is noticed.

Armature Inspection

•

Using the × 1 Ω hand tester range, measure the resistance between any two commutator segments [A].

Special Tool — Hand Tester: 57001-1394

If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.

•

Using the highest hand tester range, measure the resistance between the segments and the shaft [B].

If there is any reading at all, the armature has a short and the starter motor must be replaced.

NOTE

○

Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.

16-56 ELECTRICAL SYSTEM

Electric Starter System

Brush Lead Inspection

•

Using the × 1 Ω hand tester range, measure the resistance as shown.

Terminal Bolt and Positive Brushes [A]

Right-hand End Cover and Negative Brushes [B]

Special Tool — Hand Tester: 57001-1394

If there is not close to zero ohms, the brush lead has an open. Replace the brush plate assy.

Right-hand End Cover Inspection

•

Using the highest hand tester range, measure the resistance as shown.

Terminal Bolt and Right-hand End Cover [A]

Terminal Bolt and Negative Brushes [B]

Special Tool — Hand Tester: 57001-1394

If there is any reading, the brush assy and/or terminal bolt assy have a short. Replace the starter motor.

Starter Relay Inspection

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Battery (Negative Cables)

•

Disconnect:

Starter Motor Cable [A]

Battery Positive Cable [B]

Connector [C]

•

Remove:

Starter Relay [D]

•

Connect the hand tester [A] and a 12 V battery [B] to the starter relay as shown.

If the relay does not work as specified, the relay is defective. Replace the relay.

Testing Relay

Hand Tester Range: × 1Ω range

Criteria: When battery is connected

⇒ 0 Ω

When battery is disconnected

⇒

∞

Ω

Starter Relay Installation

•

Connect the cables to the starter relay [A] as follows.

Starter Motor Cable [B]

Battery Positive Cable [C]

Damper [D]

30

∼

45° [E]

Starter Control Relay Inspection

•

Refer to the Relay Inspection.

ELECTRICAL SYSTEM 16-57

Electric Starter System

Electric Starter Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. Ignition Switch

2. Neutral Position Switch

3. Brake Light Switch

4. Fuse Box

5. Main Fuse 30 A

6. Frame Ground 1

7. ECU (Electronic Control Unit)

8. Starter Control Relay

9. Engine Ground

10. Battery

11. Starter Relay

12. Starter Motor

16-58 ELECTRICAL SYSTEM

Electric Starter System

Electric Starter Circuit (KRF750ND/PD/RD/SD)

1. ECU (Electronic Control Unit)

2. Starter Control Relay

3. Engine Ground

4. Frame Ground 2

5. Battery

6. Starter Relay

7. Starter Motor

8. Ignition Switch

9. Neutral Position Switch

10. Brake Light Switch

11. Fuse Box

12. Ignition Fuse 10 A

13. Main Fuse 30 A

Electric Starter System

Starter Motor Clutch Removal

•

Remove the alternator rotor (see Alternator Rotor Removal).

•

Hold the rotor with the flywheel holder and take out the starter motor clutch bolts [A].

Special Tool — Flywheel Holder: 57001-1313

ELECTRICAL SYSTEM 16-59

•

Take out the one-way clutch [A].

•

Starter Motor Clutch Installation

Apply engine oil to around the cams of the one-way clutch.

•

Install the one-way clutch so that the flange [A] fits on the recess [B] of the race.

•

Apply a non-permanent locking agent:

Starter Motor Clutch Bolts

•

Tighten:

Torque — Starter Motor Clutch Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

Starter Motor Clutch Inspection

•

Remove:

Alternator Rotor (see Alternator Rotor Removal)

•

Fit the starter clutch gear into the starter motor clutch.

If the alternator rotor turns counterclockwise [A] freely from the starter clutch gear, but not clockwise [B], the clutch is operating correctly.

If the clutch does not operate correctly, or if it makes noise, disassemble it and examine each part visually. Replace any worn or damaged parts.

NOTE

○

Examine the starter clutch gear [A]. Replace it if it is worn or damaged.

16-60 ELECTRICAL SYSTEM

Electric Starter System

Torque Limiter Inspection

•

Remove:

Alternator Rotor (see Alternator Rotor Removal)

•

Remove the torque limiter [A] and visually inspect it.

If the limiter has wear, discoloration, or other damage, replace it as a unit.

Lighting System

Headlight Beam Vertical Adjustment

•

Turn the adjusting screw [A] on each headlight rim in or out to adjust the headlight vertically.

NOTE

○

On high beam, the brightest point should be slightly below horizontal with the vehicle on its wheels and the rider seated. Adjust both headlights to the same angle.

ELECTRICAL SYSTEM 16-61

Headlight Bulb Replacement

•

Tilt up and hold the front fender front (see Front Fender

Front Removal in the Frame chapter).

•

Remove:

Headlight Lead Connector [A]

Clamps [B]

•

Remove:

Screws [A]

•

Remove:

Headlight Connector [A]

Vertical Adjustment Screw [B], Spring, and Nut

Bolts [C] (both sides)

•

Turn the headlight bulb [A] counterclockwise and pull out the bulb from the headlight.

NOTICE

When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.

NOTE

○

Clean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution.

16-62 ELECTRICAL SYSTEM

Lighting System

•

Replace the headlight bulb.

•

Fit the projections [A] of the bulb in the hollows [B] of the headlight.

•

Turn the headlight bulb [A] clockwise.

•

Install the removed parts.

[A] Screw [M5, L = 10 mm (0.39 in.)]

[B] Screw [M6, L = 25 mm (0.98 in.)]

•

Connect the headlight lead connector [A] and install the champs [B].

•

After installation, adjust the headlight aim (see Headlight

Beam Vertical Adjustment).

Tail/Brake Light Bulb Replacement

•

Remove:

Rear Fender (see Rear Fender Removal in the Frame chapter)

Tail/Brake Light Mounting Nuts [A] and Washers

Tail/Brake Light Assembly [B]

Lighting System

•

Remove:

Tail/Brake Light Lens Mounting Screws [A] and Nuts

Tail/Brake Light Lens [B]

ELECTRICAL SYSTEM 16-63

•

Push and turn the bulb [A] counterclockwise and remove it.

○

Turn the bulb about 15°.

•

Insert the new bulb by aligning its upper and lower pins

[A] with the upper and lower grooves [B] in the socket, and turn the bulb clockwise.

•

Fit the projections [A] of the gasket and lens into the recess [B] of the housing.

•

Install:

Screws and Nuts (Part No. 92015-1550) [A]

○

Install the nuts so that the flat side faces to the housing

[B].

•

Install:

Washers [C]

Bracket [D]

Washers [E] and Nuts (Part No. 311AA0400) [F]

•

Install the removed parts.

16-64 ELECTRICAL SYSTEM

Lighting System

Lighting System Circuit

1. Lighting Switch

2. Brake Light Switch

3. Ignition Switch

4. Fuse Box

5. Main Fuse 30 A

6. Headlight (Right) 12 V 35/35 W

7. Headlight (Left) 12 V 35/35 W

8. Brake/Tail Lights 12 V 27/8 W

9. Battery

10. Engine Ground

11. Frame Ground 1

Radiator Fan System

Radiator Fan Circuit Inspection

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Radiator Fan Relay [A]

•

Disconnect the 4-pin connector [B].

ELECTRICAL SYSTEM 16-65

•

Using an auxiliary leads [A], connect BL/R and BL/W terminals in the relay lead connector of the harness side.

NOTE

○

The ignition switch need not be turned on.

If the fan does not rotate, inspect the following.

Main Fuse 30 A

Radiator Fan Breaker (see Radiator Fan Breaker Inspection)

Fan Motor (see Fan Motor Inspection)

When the fan system is abnormal even if the above inspection is normal, check the following items.

Water Temperature Sensor (see Water Temperature

Sensor Inspection)

Radiator Fan Relay (see Relay Circuit Inspection)

Wiring (see Wiring Inspection)

If their parts are normality, replace the ECU (see ECU

Removal/Installation in the Fuel System (DFI) chapter).

•

Radiator Fan Motor Inspection

•

Lift and hold the front fender (see Front Fender Removal in the Frame chapter).

•

Disconnect the connector [A] in the fan lead.

Using two auxiliary wires, supply battery [B] voltage to the fan motor.

If the fan does not rotate, the fan motor is defective and must be replaced.

Radiator Fan Motor Leads

BL → Battery (+)

BK → Battery (–)

Radiator Fan Breaker Inspection

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Connectors [A] (disconnect)

Radiator Fan Breaker [B]

16-66 ELECTRICAL SYSTEM

Radiator Fan System

•

Inspect the breaker for operation.

•

Connect:

12 V Battery [A]

0.6 Ω Resistance [B]

Radiator Fan Breaker [C]

Switch [D]

If the circuit in the breaker will not open within 60 seconds, replace the breaker.

•

When resetting the breaker, push the reset button after ten seconds or more pass.

•

Radiator Fan Breaker Installation

Connect the radiator fan breaker lead connector.

•

Install:

Radiator Fan Breaker

Radiator Fan Relay Inspection

•

Refer to the Relay Inspection.

Radiator Fan Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. Radiator Fan Motor

2. Frame Ground 1

3. Radiator Fan Breaker

4. Fuse Box

5. Main Fuse 30 A

6. ECU

7. Radiator Fan Relay

8. Engine Ground

9. Battery

Radiator Fan System

Radiator Fan Circuit (KRF750ND/PD/RD/SD)

ELECTRICAL SYSTEM 16-67

1. ECU

2. Radiator Fan Relay

3. Engine Ground

4. Battery

5. Frame Ground 1

6. Radiator Fan Motor

7. Radiator Fan Breaker

8. Fuse Box

9. Main Fuse 30 A

16-68 ELECTRICAL SYSTEM

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Multifunction Meter Unit Removal

•

Tilt up the front fender front (see Front Fender Front Removal in the Frame chapter).

•

Remove the cover (see Front Fender Rear Removal in the Frame chapter).

•

Disconnect:

Meter Lead Connector [A]

•

Remove:

Meter Bracket Bolts [B]

Meter Assembly [C] and Upper Damper

•

Remove:

Multifunction Meter Mounting Nuts [A] and Washers

Meter Bracket [B]

Multifunction Meter Unit [C]

NOTICE

Do not drop the meter unit.

Multifunction Meter Unit Installation

•

Install:

Multifunction Meter Unit [A]

Upper Damper [B]

Lower Dampers [C]

Bracket [D]

Washers [E]

Multifunction Meter Mounting Nuts [F]

•

Install:

Meter Assembly and Upper Damper

Meter Bracket Screws

•

Connect:

Meter Lead Connector

•

Install:

Cover (see Front Fender Rear Installation in the Frame chapter)

ELECTRICAL SYSTEM 16-69

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Multifunction Meter Unit Inspection

•

Remove:

Multifunction Meter Unit (see Multifunction Meter Unit

Removal)

NOTICE

Do not drop the meter unit.

[A] Meter Unit Lead Connectors

[1] Speed Sensor Pulse

[2] Belt Indicator Light (LED) (–)

[3] Water Temperature Warning Symbol (–)

[4] 2WD/4WD Position Indicator Symbols (LCD) (–)

[5] Fuel Level Gauge Segments (LCD)

[6] Meter Illumination (+)

[7] Reverse Indicator Light (LED) (–)

[8] Neutral Indicator Light (LED) (–)

[9] Ignition (+)

[10] Battery (+)

[11] Oil Pressure Warning Indicator Light (LED) (–)

[12] Battery (–)

[13] Parking Brake Indicator Symbol (LED) (–)

[14] FI Indicator Symbol (LCD)

[15] Unused

[16] Unused

LED: Light Emitting Diode

LCD: Liquid Crystal Display

Check 1: LCD Segments Check

•

Using auxiliary wires, connect a 12 V battery to the meter unit connector as follows.

•

Connect the battery positive (+) terminal to terminal [10].

•

Connect the battery negative (–) terminal to terminal [12].

•

Connect terminal [9] to the battery (+) terminal.

○

When the terminal [9] is connected, all the LCD segments appear for one second.

○

When the terminal [9] is disconnected, all the LCD segments disappear.

If the display function does not work, replace the meter unit.

NOTE

○

When the oil switch is turned off, the hour meter begins count.

○

Therefore, when connecting the check 1 circuit, the hour meter begins count because the circuit of the oil switch is opened.

○

To stop the count of the hour meter, connect the battery negative (–) terminal to terminal [11] (see Check 12).

○

The hour meter cannot be reset.

16-70 ELECTRICAL SYSTEM

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Check 2: MODE and TIME SET Buttons Operation

•

Check

Connect the wires in the same manner as Check 1.

•

Check that when the MODE button [A] is pushed and held continuously, the display [B] cycles through the three modes.

ODO → TRIP A → TRIP B → Hour → ODO

If the display function does not work, replace the meter unit.

•

Cycle the meter to TRIP A or TRIP B mode.

•

Check that when the SET/RESET button [A] is pushed, the display turns to 0.0.

If the display function does not indicate 0.0 [B], replace the meter unit.

•

Check that when the TIME SET [A] and SET/RESET [B] buttons are pushed, the time [C] will reset.

If the meter function does not work, replace the meter unit.

•

Indicate the ODO mode.

•

Check that the display [A] change to the mile and km display each time by pushing the SET/RESET [B] bottom while MODE [C] bottom pushed in.

NOTE

○

Mile/Km Display can alternate between English and metric modes (mile and km) in the digital meter. Make sure that km or mile according to local regulations is correctly displayed before riding.

If the display function does not work and adjust, replace the meter unit.

ELECTRICAL SYSTEM 16-71

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Check 3: Speedometer Check

Connect the wires in the same manner as Check 1.

•

The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal

[1].

○

Indicates approximately 40 mph if the input frequency is approximately 789 Hz.

○

Indicates approximately 40 km/h if the input frequency is approximately 526 Hz.

If the meter function does not work, replace the meter unit.

NOTE

○

The input frequency of the oscillator adds the integrated value of the odometer.

○

The integrated value of the odometer cannot be reset.

•

Check 4: Odometer Check

Connect the wires in the same manner as Check 3.

•

Pushing the MODE button [A], cycle the odometer [B].

•

Raise the input frequency of the oscillator to see the result of this inspection.

If the value indicated by the odometer does not increase, replace the meter unit.

NOTE

○

The integrated value of the odometer cannot be reset.

•

Check 5: Trip Meter A/B Check

Connect the wires in the same manner as Check 3.

•

Pushing the MODE button [A], cycle the trip meter A or B

[B].

•

Raise the input frequency of the oscillator to see the result of this inspection.

If the value indicated by the trip meter A or B does not increase, replace the meter unit.

NOTE

○

The integrated value of the odometer cannot be reset.

•

Check 6: Belt Check Indicator Light Check

•

Connect the wires in the same manner as Check 1.

Connect terminal [2] to the battery (–) terminal.

16-72 ELECTRICAL SYSTEM

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

○

The belt check indicator light (LED) [A] should go on.

If the LED light does not go on, replace the meter unit.

•

Check 7: Water Temperature Warning Symbol Check

•

Connect the wires in the same manner as Check 1.

Connect terminal [3] to the battery (–) terminal.

○

The water temperature warning symbol (LCD) [A] should flash.

If the symbol does not flash, replace the meter unit.

•

Check 8: 2WD/4WD Indicator Symbols Check

Connect the wires in the same manner as Check 1.

○

The 2WD indicator Symbol (LCD) [A] should appear.

•

Connect terminal [4] to the battery (–) terminal.

ELECTRICAL SYSTEM 16-73

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

○

The 4WD indicator Symbol (LCD) [A] should appear.

If the display function does not work, replace the meter unit.

•

Check 9: Fuel Level Gauge Check

Connect the wires in the same manner as Check 1.

○

The first segment (LCD) [A] should flash.

It the segment (LCD) does not flash, replace the meter unit.

•

Connect terminal [5] to the battery (–) terminal.

○

When terminal [5] is connected, one segment in the fuel gauge should appear every 15 seconds.

NOTICE

When all segments appeared, disconnect the terminal [5].

If the display function does not work, replace the meter unit.

•

Check 10: Reverse Indicator Light Check

•

Connect the wires in the same manner as Check 1.

Connect terminal [7] to the battery (–) terminal.

○

The reverse indicator light (LED) [A] should go on.

If the LED light does not go on, replace the meter unit.

16-74 ELECTRICAL SYSTEM

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

•

Check 11: Neutral Indicator Light Check

•

Connect the wires in the same manner as Check 1.

Connect terminal [8] to the battery (–) terminal.

○

The neutral indicator light (LED) [A] should go on.

If the LED light does not go on, replace the meter unit.

•

Check 12: Oil Pressure Warning Light Check

•

Connect the wires in the same manner as Check 1.

Connect terminal [11] to the battery (–) terminal.

○

The oil pressure warning light (LED) [A] should flash.

If the LED light does not flash, replace the meter unit.

•

Check 13: FI Indicator Light Check

•

Connect the wires in the same manner as Check 1.

Connect terminal [14] (R/Y) to the battery (–) terminal.

ELECTRICAL SYSTEM 16-75

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

○

The FI indicator symbol (LCD) [A] should go on for 3 seconds, and flash after that.

If the symbol does not flash, replace the meter unit.

•

Check 14: Parking Brake Indicator Symbol Check

•

Connect the wires in the same manner as Check 1.

Connect terminal [13] (G) to the battery (–) terminal.

○

The parking brake indicator symbol “P” (LCD) [A] should appear.

If the symbol does not appear, replace the meter unit.

•

Check 15: Meter Illumination Check

•

Connect the wires in the same manner as Check 1.

Connect terminal [6] to the battery (+) terminal.

○

The meter illumination [A] should go on.

If the illumination does not go on, replace the meter unit.

16-76 ELECTRICAL SYSTEM

Meter (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Meter Circuit

1. Multifunction Meter

2. 4WD Position Switch

3. Neutral Position Switch

4. Reverse Position Switch

5. Speed Sensor

6. Frame Ground 1

7. Parking Brake Light Switch

8. Fuse Box

9. Main Fuse 30 A

10. Fuel Level Sensor

11. ECU

12. Engine Ground

13. Battery

14. Oil Pressure Switch

15. Lighting Switch

16. Ignition Switch

Meter (KRF750ND/PD/RD/SD)

Multifunction Meter Unit Removal

•

Tilt up the front fender front (see Front Fender Front Removal in the Frame chapter).

•

Remove the cover (see Front Fender Rear Removal in the Frame chapter).

•

Disconnect:

Meter Connector [A]

•

Remove:

Meter Bolts [B]

Meter Assembly [C] and Upper Damper

•

Remove:

Multifunction Meter Mounting Nuts [A] and Washers

Meter Bracket [B]

Multifunction Meter Unit [C]

NOTICE

Do not drop the meter unit.

ELECTRICAL SYSTEM 16-77

Multifunction Meter Unit Installation

•

Install:

Multifunction Meter Unit [A]

Upper Damper [B]

Lower Dampers [C]

Bracket [D]

Washers [E]

Multifunction Meter Mounting Nuts [F]

•

Install:

Meter Assembly and Upper Damper

Meter Bracket Screws

•

Connect:

Meter Connector

•

Install:

Cover (see Front Fender Rear Installation in the Frame chapter)

16-78 ELECTRICAL SYSTEM

Meter (KRF750ND/PD/RD/SD)

Multifunction Meter Operation Inspection

NOTE

○

Be sure the battery is fully charged.

•

Check 1: Switching Inspection

Turn the ignition switch to ON and check the following.

○

The all LCD segments [A] appear for 3 seconds.

○

The seat belt use reminder [B] goes on for 10 seconds.

○

Other LED indicator lights [C] go on for 3 seconds.

○

After the LED lights go off, the following indications appear in the LCD.

2WD or 4WD Indicator Symbol

Speedometer

Fuel Level Gauge

Clock

Odometer, Trip Meter A/B or Hour Meter

If the meter does not work, replace the multifunction meter unit.

•

By pushing the left button [A] each time, check that the display [B] changes as follows.

ODO → TRIP A → TRIP B → HOUR → ODO

○

This display is ordinary indication.

If the display function does not work, check the wiring (see

Meter unit Circuit).

If the wiring is good, replace the multifunction meter unit.

•

Indicate the ODO mode.

•

Check that the display [A] change to the “km/h” and “mph” display each time by pushing the right button [B] while left button [C] pushed in.

NOTE

○

Mile/Km Display can alternate between English and metric modes (mile and km) in the digital meter. Make sure that km or mile according to local regulations is correctly displayed before riding.

If the display function does not work, replace the multifunction meter unit.

Multifunction Meter System Inspection

NOTE

○

Be sure the battery is fully charged.

•

Check 2-1: Gear Position Indication Inspection

Turn the ignition switch to ON.

○

The neutral indicator light (LED) [A] goes on when the shift lever is in “N” (Neutral).

○

The reverse indicator light (LED) [B] goes on when the shift lever is in “R” (Reverse).

Meter (KRF750ND/PD/RD/SD)

•

Turn the ignition switch to OFF.

If the display function does not work, check the following parts.

Neutral Position Switch (see Switch Inspection)

Reverse Position Switch (see Switch Inspection)

Wiring (see Meter Unit Circuit)

If above parts are good, inspect the ECU (see ECU Power

Supply Inspection in the Fuel System (DFI) chapter).

If the ECU is good, replace the multifunction meter unit.

•

Check 2-2: Parking Brake Indication Inspection

Turn the ignition switch to ON.

○

The parking brake indicator light (LED) [A] goes on when the parking brake lever is applying.

•

Turn the ignition switch to OFF.

If the display function does not work, check the following parts.

Parking Brake Position Switch (see Switch Inspection)

Wiring (see Meter Unit Circuit)

If above parts are good, inspect the ECU (see ECU Power

Supply Inspection in the Fuel System (DFI) chapter).

If the ECU is good, replace the multifunction meter unit.

•

Check 2-3: 2WD/4WD Indication Inspection

Turn the ignition switch to ON.

○

The 2WD indicator symbol [A] (“2WD” and 2 tires) appears when the 2WD/4WD shift switch is in “2WD”.

○

The 4WD indicator symbol [B] (“4WD” and 4 tires) appears when the 2WD/4WD shift switch is in “4WD”.

ELECTRICAL SYSTEM 16-79

•

Turn the ignition switch to OFF.

If the display function does not work, check the following parts.

4WD Position Switch (see Switch Inspection)

Wiring (see Meter Unit Circuit)

If above parts are good, inspect the ECU (see ECU Power

Supply Inspection in the Fuel System (DFI) chapter).

If the ECU is good, replace the multifunction meter unit.

16-80 ELECTRICAL SYSTEM

Meter (KRF750ND/PD/RD/SD)

Multifunction Meter Unit Inspection

•

Remove:

Multifunction Meter Unit (see Multifunction Meter Unit

Removal)

NOTICE

Do not drop the meter unit.

1. 2WD/4WD Indicator (LCD) (–)

2. Seat Belt Use Reminder Sensor (–)

3. Fuel Level Gauge Segments

4. Unused

5. Unused

6. ECU Communication Signal

7. Unused

8. Unused

9. Battery (+)

10. Ignition (+)

11. Red Oil Pressure Warning Indicator Light (LED) (–)

12. Battery (–)

Check 3-1: Red Engine Warning Indicator Light (LED)

Inspection

•

Using the auxiliary leads, connect the 12 V battery to the multifunction meter unit connector as follows.

○

Connect the battery positive (+) terminal to the terminal

[9] [10].

○

Connect the battery negative (–) terminal to the terminal

[12].

•

Check that the engine warning indicator light (LED) [A] goes on after the seat belt use reminder goes off.

If the engine warning indicator light (LED) does not go on, replace the multifunction meter unit.

Check 3-2: Red Oil Pressure Warning Indicator Light

(LED) Inspection

•

Using the auxiliary leads, connect the 12 V battery to the multifunction meter unit connector as follows.

○

Connect the battery positive (+) terminal to the terminal

[9] [10].

○

Connect the battery negative (–) terminal to the terminal

[12].

•

Connect the terminal [11] to the battery negative (–) terminal.

Meter (KRF750ND/PD/RD/SD)

•

Check that the oil pressure warning indicator light (LED)

[A] blinks.

If the oil pressure warning indicator light (LED) does not blink, replace the multifunction meter unit.

ELECTRICAL SYSTEM 16-81

Check 3-3: Red Seat Belt Use Reminder (LED) Inspection

•

Using the auxiliary leads, connect the 12 V battery to the multifunction meter unit connector as follows.

○

Connect the battery positive (+) terminal to the terminal

[9] [10].

○

Connect the battery negative (–) terminal to the terminal

[12].

•

Check that the seat belt use reminder (LED) [A] goes on for 10 seconds.

○

When the battery is connected, the seat belt use reminder

(LED) will goes on and stay on for 10 seconds, even if the terminal [2] is not connected.

•

After 10 seconds, connect the terminal [2] to the battery negative (–) terminal.

•

Check that the seat belt use reminder (LED) [A] goes on.

If the seat belt use reminder (LED) does not work, replace the multifunction meter unit.

Check 3-4: Fuel Level Gauge Inspection

•

Using the auxiliary leads, connect the 12 V battery to the multifunction meter unit connector as follows.

○

Connect the battery positive (+) terminal to the terminal

[9] [10].

○

Connect the battery negative (–) terminal to the terminal

[12].

•

Connect the variable rheostat [A] to the terminal [3].

16-82 ELECTRICAL SYSTEM

Meter (KRF750ND/PD/RD/SD)

•

Check that the number of segments matches the resistance value of the variable rheostat.

○

The fuel level gauge is updated every 10 seconds.

Variable Rheostat

Resistance (Ω)

10

20

Display Segments [A]

6 segments go on

5 segments go on

35

45

55

70

90

4 segments go on

3 segments go on

2 segments go on

1 segment goes on

1 segment blinks

If the display function does not work, replace the multifunction meter unit.

Check 3-5: Other Inspection

○

The following items are displayed while running.

Speedometer

Odometer

Trip A/B Meter

Hour Meter

Clock

CVT Belt Check Indicator Light (LED)

Water Temperature Warning Indicator Light (LED)

•

When the above item is faulty indication, check the following items.

Wiring (see Wiring Inspection)

Speed Sensor (see Speed Sensor Input Voltage Inspection in the Fuel System (DFI) chapter)

Water Temperature Sensor (see Water Temperature

Sensor Output Voltage Inspection in the Fuel System

(DFI) chapter)

If the above items are good, replace the multifunction meter unit and/or ECU.

Meter (KRF750ND/PD/RD/SD)

Meter Circuit

ELECTRICAL SYSTEM 16-83

1. ECU

2. Seat Belt Use Reminder Sensor

3. Frame Ground 2

4. Engine Ground

5. Battery

6. Waterproof Joint 1

7. Oil Pressure Switch

8. Frame Ground 1

9. Ignition Switch

10. Multifunction Meter

11. 4WD Position Switch

12. Fuse Box

13. Ignition Fuse 10 A

14. Main Fuse 30 A

15. Fuel Level Sensor

16-84 ELECTRICAL SYSTEM

Actuator Control System

Engine Brake Actuator Removal

•

Remove:

Torque Converter Cover (see Torque Converter Cover

Removal in the Converter System chapter)

Actuator Cover Bolt [A]

Actuator Mounting Bolts [B]

Actuator [C]

Actuator Cover [D]

Engine Brake Actuator Installation

•

Apply grease and Install:

O-ring [A]

•

Apply molybdenum disulfide grease to the pin [B].

•

Apply grease to the trim seal [A] and install the cover [B].

•

Insert the pin into the collar [A] of the engine brake lever assembly [B].

•

Wipe off any protruding grease.

•

Install the clamp [A] in this area [B] (about 30 mm (1.2

in.)).

•

Tighten the actuator mounting bolts following the tightening sequence [1

∼

4].

Torque — Engine Brake Actuator Mounting Bolts: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

Engine Brake Actuator Cover Bolt: 8.8 N·m (0.90

kgf·m, 78 in·lb)

Actuator Control System

Actuator Control System Outline

The actuator controller has a microprocessor that detects vehicle speed, ignition switch, and the forward/reverse movement of the vehicle in order to control the engine brake actuator.

Actuator Control System

ELECTRICAL SYSTEM 16-85

Engine Brake Actuator Inspection

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

Actuator Lead Connector [A]

16-86 ELECTRICAL SYSTEM

Actuator Control System

•

Measure the resistance between the following terminals in the actuator lead connector [A].

Special Tool — Hand Tester: 57001-1394

Actuator Internal Resistance

4 (Red) — 6 (Black):

1 (Orange) — 3 (Blue):

2 (Yellow) — 3 (Blue):

3

∼

15 Ω

3.5

∼

6.5 kΩ

630

∼

5 330 Ω

If any reading is not within the specified range, replace the engine brake actuator.

Speed Sensor Circuit Inspection

NOTE

○

Be sure the battery is fully charged.

•

Support the vehicle on a stand or a jack so that the wheels are off the ground.

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

•

Connect:

Controller Connector [A]

Hand Tester [B] (range: DC 25 V)

Tester (+) → Connector (P) Terminal [5]

Tester (–) → Connector (BK/Y) Terminal [10]

○

Install the needle adapters on the tester leads.

Special Tools — Hand Tester: 57001-1394

•

Needle Adapter Set: 57001-1457

•

Turn ON the ignition switch.

Spin a rear wheel, measure the voltage.

Speed Sensor Output Voltage

Standard: repeat from 0 to 5 V

If the reading is not standard, check the wiring.

If the wiring is good, check the speed sensor (see Speed

Sensor Inspection).

Actuator Control System

Controller Unit Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove:

Seat Lower Cover (see Seat Lower Cover Removal in the Frame chapter)

•

Connect:

Controller Connector [A]

Hand Tester [B] (range: DC 25 V)

Tester (+) → Connector (BR) Terminal [9]

(KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

Tester (+) → Connector (BR/BL) Terminal [9]

(KRF750ND/PD/RD/SD)

Tester (–) → Connector (BK/Y) Terminal [10]

○

Install the needle adapters on the tester leads.

Special Tools — Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

•

Turn ON the ignition switch.

Controller Power Supply Voltage

Standard: near Battery Voltage

If the reading is not battery voltage, check the wiring harness, 30 A fuse, or ignition switch.

•

Connect:

Controller Connector [A]

Hand Tester [B] (range: DC 10 V)

Tester (+) → Connector (O) Terminal [2]

Tester (–) → Connector (BK/Y) Terminal [10]

○

Install the needle adapters on the tester leads.

Special Tools — Hand Tester: 57001-1394

•

Needle Adapter Set: 57001-1457

•

Turn ON the ignition switch.

Measure the controller output voltage for the actuators.

Controller Output Voltage (to Actuators)

Standard: 4.8 ±0.2 V

If the reading is not standard, replace the actuator controller unit.

ELECTRICAL SYSTEM 16-87

16-88 ELECTRICAL SYSTEM

Actuator Control System

•

Support the vehicle on a stand or a jack so that the wheels are off the ground.

•

Connect:

Controller Connector [A]

Hand Tester [B] (range: DC 25 V)

Tester (+) → Connector (W/R) Terminal [15]

Tester (–) → Connector (BK/Y) Terminal [10]

○

Install the needle adapters on the tester leads.

Special Tools — Hand Tester: 57001-1394

•

Needle Adapter Set: 57001-1457

Turn ON the ignition switch.

•

Spin a rear wheel as forward rotation.

•

After the wheels stop and one second elapses, turn OFF the ignition switch.

•

After two seconds elapses, measure the controller output voltage for the engine brake actuator until the actuator stops.

Controller Output Voltage (to engine brake actuator)

Standard: 5

∼

12 V

If the reading is not standard, check the forward/reverse detecting sensor.

If the forward/reverse detecting sensor is normal, replace the actuator controller unit.

Forward/Reverse Detecting Sensor Inspection

•

Remove:

Engine Upper Cover (see Engine Upper Cover Removal in the Frame chapter)

•

Disconnect forward/reverse detecting sensor lead connector [A].

•

Measure the forward/reverse detecting sensor resistance.

○

Connect the hand tester between the BK lead and the W lead.

○

Set the tester to the × 10 Ω range.

Special Tool — Hand Tester: 57001-1394

Forward/Reverse Detecting Sensor Resistance

Standard: 1.2

∼

1.6 kΩ

If the reading is not within the specified range, replace the forward/reverse detecting sensor.

•

Using the highest resistance, measure the resistance between forward/reverse detecting sensor leads and chassis ground.

If the tester reading is less than infinity (∞) indicates a short, replace the forward/reverse detecting sensor.

ELECTRICAL SYSTEM 16-89

Actuator Control System

Actuator Control System Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. Engine Brake Actuator

2. Actuator Controller

3. Speed Sensor

4. Forward/Reverse Detecting Sensor

5. Ignition Switch

6. Fuse Box

7. Actuator Controller Fuse 10 A

8. Main Fuse 30 A

9. Frame Ground 1

10. Engine Ground

11. Battery

16-90 ELECTRICAL SYSTEM

Actuator Control System

Actuator Control System Circuit (KRF750ND/PD/RD/SD)

1. Speed Sensor

2. Fuse Box

3. Ignition Fuse 10 A

4. Actuator Controller Fuse 10 A

5. Main Fuse 30 A

6. Actuator Controller

7. Engine Brake Actuator

8. Frame Ground 2

9. Engine Ground

10. Battery

11. Forward/Reverse Detecting Sensor

12. Waterproof Joint 1

13. Ignition Switch

2WD/4WD Solenoid Valve

2WD/4WD Solenoid Valve Inspection

•

Remove:

Right Bracket (see Right Bracket Removal in the Frame chapter)

2WD/4WD Solenoid Valve Lead Connector [A]

Bracket Bolts [B]

Bracket [C] with 2WD/4WD Solenoid Valve [D]

Hose Ends (from each part)

ELECTRICAL SYSTEM 16-91

•

Set the hand tester [A] to × 10 Ω range and connect the tester leads to the terminals in the 2WD/4WD solenoid valve connector [B].

Special Tool — Hand Tester: 57001-1394

2WD/4WD Solenoid Valve Resistance

Standard: 37

∼

43 Ω at 20°C (68°F)

If the reading is out of the standard, replace the

2WD/4WD solenoid valve.

If the reading is standard resistance, check the operation of the 2WD/4WD solenoid valve as follows.

•

Connect the 12 V battery [A] to the terminals in the

2WD/4WD solenoid valve connector as shown in the figure.

•

When the battery is connected, check that the 2WD/4WD solenoid valve makes a clicking sound (operating sound).

If the 2WD/4WD solenoid valve does not click, replace it.

•

When the battery is connected, check that the 2WD/4WD solenoid valve operates the air flow (arrows) as shown in the figure.

[A] Battery is connected.

[B] Battery is disconnected.

If the 2WD/4WD solenoid valve does not work, replace it

16-92 ELECTRICAL SYSTEM

2WD/4WD Solenoid Valve

2WD/4WD Solenoid Valve Circuit (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

1. 2WD/4WD Shift Switch

2. Frame Ground 1

3. Fuse Box

4. Main Fuse 30 A

5. 2WD/4WD Solenoid Valve

6. ECU

7. Engine Ground

8. Battery

9. Ignition Switch

ELECTRICAL SYSTEM 16-93

2WD/4WD Solenoid Valve

2WD/4WD Solenoid Valve Circuit (KRF750ND/PD/RD/SD)

1. ECU

2. Engine Ground

3. Battery

4. Waterproof Joint 1

5. Ignition Switch

6. 2WD/4WD Shift Switch

7. Fuse Box

8. Ignition Fuse 10 A

9. Main Fuse 30 A

10. 2WD/4WD Solenoid Valve

16-94 ELECTRICAL SYSTEM

Relay

Relay Inspection

•

Remove:

Left Seat (see Seat Removal in the Frame chapter)

Starter Control Relay [A]

Radiator Fan Relay [B]

Fuel Pump Relay [C]

○

The relays are identical.

•

Connect the hand tester [A] and a 12 V battery [B] to the relay [C] as shown.

Special Tool — Hand Tester: 57001-1394

If the relay does not work as specified, the relay is defective. Replace the relay.

Testing Relay

Hand Tester Range: × 1 Ω

Criteria: When battery is connected

⇒ 0 Ω

When battery is disconnected

⇒ ∞ Ω

Relay Coil Terminals: [1] and [2]

Relay Switch Terminals: [3] and [4]

Switches and Sensor

Brake Light Switch Adjustment

•

Refer to the Brake Light Switch Inspection and Adjustment in the Periodic Maintenance chapter.

Water Temperature Switch Inspection

•

Refer to the Water Temperature Sensor Inspection in the

Fuel System (DFI) chapter.

Fuel Level Sensor Inspection

•

Remove:

Fuel Pump (see Fuel Pump Removal in the Fuel System

(DFI) chapter)

•

Check that the float moves up and down smoothly without binding. It should go down under its own weight.

If the float does not move smoothly, replace the fuel pump assembly.

•

Using a hand tester [A], measure the resistance across the terminals in the fuel pump lead connector [B].

Special Tool — Hand Tester: 57001-1394

NOTE

○

In contrast to the normal measuring method, the current that flows through the gauge when measuring it with a tester is very low, thus making the measurement easily affected by the oxidized film of the resistance plate, and resulting in excessive resistance. Therefore, make sure to wipe the resistance plate with alcohol before taking a measurement.

If the readings are not as specified, replace the fuel pump assembly.

Fuel Level Sensor Resistance

Standard: Full Level Position [C]: 10 Ω

Empty Level Position [D]: 120 Ω

ELECTRICAL SYSTEM 16-95

•

Speed Sensor Removal/Installation

•

Drain the engine oil (see Engine Oil Change in the Periodic Maintenance Chapter).

•

Disconnect the speed sensor Connector [A].

Remove:

Bolt [B]

•

Speed Sensor [C]

Replace the O-ring with a new one.

•

Apply grease to the O-ring.

•

Install the speed sensor to the fully seated position before tightening the mounting bolt.

NOTE

○

If the sensor is not fully seated before tightening the bolt, the O-ring can be damaged and oil may leak.

•

Tighten:

Torque — Speed Sensor Mounting Bolt: 8.8 N·m (0.90 kgf·m,

78 in·lb)

16-96 ELECTRICAL SYSTEM

Switches and Sensor

•

Speed Sensor Inspection

Remove the speed sensor (see Speed Sensor Removal).

•

Connect the speed sensor connector [A] with the battery

[B], 10 kΩ resistor [C] and hand tester [D] as shown.

•

Set the tester to the DC 25 V range.

Special Tool — Hand Tester: 57001-1394

•

Trace [A] each side of the speed sensor surface with the screwdriver.

○

Then the tester indicator should flick [B].

If the tester indicator does not flick, replace the speed sensor.

Switch Inspection

•

Using the hand tester, check to see that only the connections shown in the table have continuity.

○

For the ignition switch and headlight switch, refer to tables in the Wiring Diagram.

If the switch has an open or short, repair or replace it with a new one.

Switches and Sensor

Neutral Position Switch Connection

[A] Neutral Position Switch

Reverse Position Switch Connection

[B] Reverse Position Switch

4WD Position Switch Connection

2WD/4WD Shift Switch Connection

Brake Light Switch Connection

Parking Brake Position Switch Connection

Oil Pressure Switch Connection*

Seat Belt Use Reminder Sensor Connection

(KRF750ND/PD/RD/SD)

*: Engine Iubrication system is in good condition

ELECTRICAL SYSTEM 16-97

16-98 ELECTRICAL SYSTEM

Fuses

Fuse Removal

•

Remove:

•

Left Seat (see Seat Removal in the Frame chapter)

•

Push the central pin [A] of the quick rivet and remove it.

Slide the cover [B] rearward and remove it.

•

Remove:

Fuse Box Lid [A]

•

Pull the fuses [A] straight out of the fuse box with needle nose pliers.

Fuse Installation

If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.

•

Install the fuses on the original position as specified on the fuse box lid [A].

•

Insert the projection [A] of the cover [B] under the electric parts case [C] and install the cover.

Fuses

Fuse Inspection

•

Inspect the fuse element.

If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.

Housing [A]

Fuse Element [B]

Terminals [C]

Blown Element [D]

NOTICE

When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit.

Installation of a fuse with a higher rating may cause damage to wiring and components.

ELECTRICAL SYSTEM 16-99

APPENDIX 17-1

Appendix

Table of Contents

Troubleshooting Guide ……………………………………………………………………………………………..

17-2

Cable, Wire, and Hose Routing ………………………………………………………………………………….

17-6

17

17-2 APPENDIX

Troubleshooting Guide

NOTE

○

Refer to the Fuel System chapter for most of DFI trouble shooting guide.

○

This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.

Engine Doesn’t Start, Starting Difficulty:

Starter motor not rotating:

Neutral switch trouble

Starter motor trouble

Battery voltage low

Starter and circuit relays not contacting or operating

Starter button not contacting

Wiring open or shorted

Ignition switch trouble

Fuse blown

Starter motor rotating but engine doesn’t turn over:

Starter motor clutch trouble

Engine won’t turn over:

Valve seizure

Rocker arm seizure

Cylinder, piston seizure

Crankshaft seizure

Connecting rod small end seizure

Connecting rod big end seizure

Transmission gear or bearing seizure

Camshaft seizure

No fuel flow:

No fuel in tank

Fuel tank air vent obstructed

Fuel line clogged

Fuel pump damaged or circuit trouble

Fuel/air mixture incorrect:

Bypass screw maladjusted

Air cleaner clogged, poorly sealed, or missing

No spark; spark weak:

Spark plug dirty, broken, or maladjusted

Spark plug cap or spark plug lead trouble

Spark plug cap shorted or not in good contact

Spark plug incorrect

Crankshaft sensor trouble

ECU trouble

Ignition coil trouble

Battery voltage low

Ignition switch shorted

Wiring shorted or open

Fuse blown

Compression Low:

Spark plug loose

Cylinder head not sufficiently tightened down

No valve clearance

Cylinder, piston worn

Piston ring bad (worn, weak, broken, or sticking)

Piston ring/groove clearance excessive

Cylinder head gasket damaged

Cylinder head warped

Valve spring broken or weak

Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)

Compression release (KACR) cam sticks open (Engine stalls when moving off)

Poor Running at Low Speed:

Spark weak:

Spark plug dirty, broken, or maladjusted

Spark plug cap or spark plug lead trouble

Spark plug cap shorted or not in good contact

Spark plug incorrect

ECU trouble

Crankshaft sensor trouble

Ignition coil trouble

Battery voltage low

Fuel/air mixture incorrect:

Bypass screw maladjusted

Air cleaner clogged, poorly sealed, or missing

Fuel tank air vent obstructed

Fuel pump trouble

Throttle body holder loose

Air cleaner duct loose

Compression low:

Spark plug loose

Cylinder head not sufficiently tightened down

No valve clearance

Cylinder, piston worn

Piston ring bad (worn, weak, broken, or sticking)

Piston ring/groove clearance excessive

Cylinder head gasket damaged

Cylinder head warped

Valve spring broken or weak

Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)

Compression release (KACR) cam sticks open (Engine stalls when moving off)

Other:

Engine oil viscosity too high

Brake dragging

ECU trouble

Front or rear final gear case oil viscosity too high

APPENDIX 17-3

Troubleshooting Guide

Poor Running or No Power at High Speed:

Firing incorrect:

Spark plug dirty, broken, or maladjusted

Spark plug cap or spark plug lead trouble

Spark plug cap shorted or not in good contact

Spark plug incorrect

Crankshaft sensor trouble

ECU trouble

Ignition coil trouble

Fuel/air mixture incorrect:

Air cleaner clogged, poorly sealed, or missing

Water or foreign matter in fuel

Throttle body holder loose

Air cleaner duct loose

Fuel tank air vent obstructed

Fuel line clogged

Fuel pump trouble

Compression low:

Spark plug loose

Cylinder head not sufficiently tightened down

No valve clearance

Cylinder, piston worn

Piston rings bad (worn, weak, broken, or sticking)

Piston ring/groove clearance excessive

Cylinder head gasket damaged

Cylinder head warped

Valve spring broken or weak

Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface.)

Compression release cam (K.A.C.R.) sticks open (Engine stalls when moving off)

Knocking:

Carbon built up in combustion chamber

Fuel poor quality or incorrect

Spark plug incorrect

ECU trouble

Miscellaneous:

Throttle valve won’t fully open

Brake dragging

Engine overheating

Engine oil level too high

Engine oil viscosity too high

Front or rear final gear case oil viscosity too high

Overheating:

Firing incorrect:

Spark plug dirty, broken, or maladjusted

Spark plug incorrect

ECU trouble

Fuel/air mixture incorrect:

Throttle body holder loose

Air cleaner poorly sealed, or missing

Air cleaner duct loose

Air cleaner clogged

Fuel pump trouble

Compression high:

Carbon built up in combustion chamber

Engine load faulty:

Engine oil level too high

Engine oil viscosity too high

Drive train trouble

Brake dragging

Lubrication inadequate:

Engine oil level too low

Engine oil poor quality or incorrect

Front or rear final gear case overheating:

Insufficient oil

Bevel gears maladjusted

LSD clutches in front final gear case maladjustment

Coolant incorrect:

Coolant level too low

Coolant deteriorated

Wrong coolant mixed ratio

Cooling system component incorrect:

Radiator fin damaged

Radiator clogged

Thermostat trouble

Radiator cap trouble

ECU trouble

Water temperature sensor trouble

Fan motor broken

Fan blade damaged

Water pump not turning

Water pump impeller damaged

Over Cooling:

Cooling system component incorrect:

ECU trouble

Water temperature sensor trouble

Thermostat trouble

Converter Operation Faulty:

Belt slipping:

Belt dirty, worn, or wetted

Drive or driven pulley sheave dirty or worn

Drive pulley spring broken or weak

Converter engagement speed too low:

Drive pulley spring broken or weak

Converter engagement speed too high:

Belt dirty or worn

Drive or driven pulley sheave dirty or worn

Drive pulley weight doesn’t move smoothly

Drive pulley movable sheave doesn’t move smoothly

Drive or driven pulley movable sheave bush worn

Drive pulley weight or roller worn

Shifting too quickly:

Drive pulley spring weak

17-4 APPENDIX

Troubleshooting Guide

Driven pulley spring weak or incorrectly installed (too loose)

Shifting too slowly:

Belt dirty or worn

Drive or driven pulley sheave dirty or worn

Drive pulley weight doesn’t move smoothly

Drive pulley movable sheave doesn’t move smoothly

Drive pulley spring incorrect installed (too tight)

Driven pulley movable sheave doesn’t move smoothly

Gear Shifting Faulty:

Doesn’t go into gear:

Shift fork bent or seized

Gear stuck on the shaft

Shift tie-rod maladjusted

Shift tie-rod damaged

Jumps out of gear:

Shifter groove worn

Gear dogs worn

Shift fork worn, bent

Shift arm positioning bolt spring weak or broken

Shift tie-rod maladjusted

Drive shaft, output shaft, and/or gear splines worn

Overshifts:

Shift arm positioning bolt spring weak or broken

Shift tie-rod maladjusted

Abnormal Engine Noise:

Knocking:

ECU trouble

Carbon built up in combustion chamber

Fuel poor quality or incorrect

Spark plug incorrect

Overheating

Piston Slap:

Cylinder/piston clearance excessive

Cylinder, piston worn

Connecting rod bent

Piston pin, piston holes worn

Valve noise:

Valve clearance incorrect

Valve spring broken or weak

Camshaft bearing worn

Rocker arm worn

Other noise:

Connecting rod small end clearance excessive

Connecting rod big end clearance excessive

Piston ring worn, broken, or stuck

Piston seizure, damage

Cylinder head gasket leaking

Exhaust pipe leaking at cylinder head connection

Crankshaft runout excessive

Engine mounts loose

Crankshaft bearing worn

Camshaft chain tensioner trouble

Camshaft chain, sprocket, guides worn

Alternator rotor loose

Abnormal Drive Train Noise:

Converter noise:

Belt worn

Drive or driven pulley sheave worn

Drive or driven pulley movable sheave bush worn

Drive or driven pulley mount loose

Driven pulley shoe worn

Drive pulley weight or roller side washer worn

Drive pulley weight or roller worn

Wear guides worn

Transmission noise:

Bearing worn

Transmission gears worn or chipped

Metal chips jammed in gear teeth

Engine oil insufficient or too thin

Front or rear final gear case noise:

Insufficient lubricant

Incorrect oil (Front final gear case)

Bevel gear bearings worn

Bevel gears worn or chipped

Bevel gears maladjusted

Worn LSD clutch friction plate (Front final gear case)

Damaged side gears or pinions (Front final gear case)

Abnormal Frame Noise:

Shock absorber noise:

Shock absorber damaged

Disc brake noise:

Pad installed incorrectly

Pad surface glazed

Disc warped

Caliper trouble

Rear brake noise:

Foreign matter in hub

Brake not properly adjusted

Other noise:

Bracket, nut bolt, etc. not properly mounted or tightened

Exhaust Smokes Excessively:

White smoke:

Piston oil ring worn

Cylinder worn

Valve oil seal damaged

Valve guide worn

Cylinder head gasket damaged

Engine oil level too high

APPENDIX 17-5

Troubleshooting Guide

Black Smoke:

Air cleaner clogged

Brown smoke:

Air cleaner duct loose

Air cleaner poorly sealed or missing

Handling and/or Stability Unsatisfactory

Steering wheel hard to turn:

Tire air pressure too low

Steering shaft damaged

Steering shaft lubrication inadequate

Steering shaft bent

Steering gear assembly damaged

Steering knuckle joint damaged

Tie-rod end damaged

LSD clutch maladjusted (front final gear case)

Noise when turning:

Side gear or pinion damaged (front final gear case)

LSD clutch friction plates damaged (Front final gear case)

Steering wheel shakes or excessively vibrates:

Tire worn

Wheel rim warped

Suspension arm bushing worn

Tie-rod joint worn

Axle shaft bearing worn

Steering wheel mount loose

Steering bolt or nut loose

Steering wheel pulls to one side:

Frame bent

Wheel maladjustment

Suspension arm bent or twisted

Steering shaft bent

Steering gear assembly damaged

Front or rear tire air pressure unbalanced

Shock absorber unbalanced

Shock absorption unsatisfactory:

Too hard:

Tire air pressure too high

Shock absorber damaged

Too soft:

Shock absorber oil leaking

Shock absorber spring weak

Tire air pressure too low

Shock absorber damaged

Brake Doesn’t Hold

Front brake:

Air in the brake line

Brake fluid leakage

Brake fluid deteriorated

Primary or secondary cup trouble

Master cylinder scratched inside

Pad overworn or worn unevenly

Oil, grease on pads and disc

Disc worn or warped

Brake overheated

Rear Brake:

Brake not properly adjusted

Plates worn

Brake parts worn or damaged

Kawasaki Engine Brake Control System

Malfunction:

Actuators failed

Speed sensor short or open

Forward/Reverse detecting sensor short or open

Actuator controller failed

Controller 10 A fuse blown

Battery disconnected

Battery Discharged:

Battery faulty (e.g., plates sulphated, shorted through sedimentation, electrolyte level too low)

Battery leads making poor contact

Load excessive (e.g., bulb of excessive wattage)

Ignition switch trouble

Regulator/rectifier trouble

Alternator trouble

Wiring faulty

Battery Overcharged:

Regulator/rectifier trouble

Battery trouble

17-6 APPENDIX

Cable, Wire, and Hose Routing

1. Tube

2. Clamp

3. Align the white paint mark on the tube with the adjustment mark on the crankcase.

4. Starter Motor

5. Starter Motor Cable

6. about 20°

Cable, Wire, and Hose Routing

APPENDIX 17-7

1. Clamps

2. about 45°

17-8 APPENDIX

Cable, Wire, and Hose Routing

1. ISC Valve

2. ISC Valve Tube (Front)

3. Resonator

4. Fuel Hose

5. Breather Hose

6. ISC Valve Tube (Rear)

7. Clamp

8. Position the clamp so that its edge must not contact to adjacent tube.

Cable, Wire, and Hose Routing

APPENDIX 17-9

1. Fuel Hose

2. Clamp (Bend the end of clamp to secure the tube.)

3. Fuel Pump

4. Harness

5. Water Temperature Sensor

6. Keep the clearance between the fuel tube and the water temperature sensor at least 5 mm (0.2

in.).

17-10 APPENDIX

Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing

1. ISC Valve

2. ISC Valve Tube (Front)

3. ISC Valve Tube (Primary)

4. ISC Valve Tube (Rear)

5. Breather Hose

6. Clamp (Clamp the ISC valve tube (Primary) and breather hose.)

7. White Marks

8. Clamp

9. Main Harness

10. Clamps (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

11. Drain Tube (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

12. Drain Plug (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

13. View P

APPENDIX 17-11

17-12 APPENDIX

Cable, Wire, and Hose Routing

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

1. Front Gear Case Breather Hose

2. Bands

3. Clamp

4. Reserve Tank Overflow Hose

5. Fan Motor Breather Hose

6. Frame Clamp

Cable, Wire, and Hose Routing

KRF750ND/PD/RD/SD

APPENDIX 17-13

1. Front Gear Case Breather Hose

2. Band

3. Clamp

4. Reserve Tank Overflow Hose

5. Fan Motor Breather Hose

17-14 APPENDIX

Cable, Wire, and Hose Routing

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

1. Fan Motor Lead Connector

2. Band

3. Fan Motor Breather Hose

4. Front Gear Case Breather Hose

5. Reserve Tank Hose

6. Reserve Tank Overflow Hose

7. Bands

8. Clamps

9. Frame Clamp

10. Run the radiator fan motor lead between the bracket and the radiator hose.

11. to Radiator

Cable, Wire, and Hose Routing

KRF750ND/PD/RD/SD

APPENDIX 17-15

1. Fan Motor Lead Connector

2. Band

3. Fan Motor Breather Hose

4. Front Gear Case Breather Hose

5. Reserve Tank Hose

6. Reserve Tank Overflow Hose

7. Band

8. Clamps

9. Run the radiator fan motor lead between the bracket and the radiator hose.

10. to Radiator

17-16 APPENDIX

Cable, Wire, and Hose Routing

1. Clamp

2. Insert the breather hose to outside (lower) fitting.

3. Band (Install the band so that the position is about middle in the area [C] and it must avoid the damper of the cargo bed.)

4. Rear Gear Case Breather Hose

5. Damper of Cargo Bed

6. Direction of Breather Hose Installation

7. to Gear Case

8. to Frame

9. View A

10. View B

Cable, Wire, and Hose Routing

APPENDIX 17-17

1. Filter

2. Breather Hose

3. Vent Hose

4. 2WD/4WD Solenoid Valve

5. Vacuum Hose

6. Vacuum Hose

7. Clamp

8. Vacuum Hose

9. Clamp

10. Cover

11. Run the vacuum hose under the cover.

12. Run the hoses into the hole.

13. Band

14. View A

15. Vacuum Actuator

17-18 APPENDIX

Cable, Wire, and Hose Routing

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

APPENDIX 17-19

Cable, Wire, and Hose Routing

1. Water Pipes

2. Lower Radiator Hose

3. Upper Radiator Hose

4. Cooling Hose

5. Clamps

6. Bracket

7. Keep clearance of 20 mm (0.8 in.) between the cooling hose and the edge of bracket.

8. View A

9. Align the white paint mark on the cooling hose with the index mark on the pump cover.

10. View B

11. Tighten the clamp screw to the direction as shown in the figure.

12. Connect the cooling hoses with its white mark facing up.

17-20 APPENDIX

Cable, Wire, and Hose Routing

KRF750ND/PD/RD/SD

APPENDIX 17-21

Cable, Wire, and Hose Routing

1. Water Pipes

2. Lower Radiator Hose

3. Upper Radiator Hose

4. Cooling Hose

5. Clamps

6. Bracket

7. Keep clearance of 20 mm (0.8 in.) between the cooling hose and the edge of bracket.

8. View A

9. Align the white paint mark on the cooling hose with the index mark on the pump cover.

10. View B

11. Tighten the clamp screw to the direction as shown in the figure.

12. Connect the cooling hoses with its white mark facing up.

13. Bands

14. Front Gear Case Breather Hose

15. Fan Motor Breather Hose

16. White Marks

17-22 APPENDIX

Cable, Wire, and Hose Routing

1. Rear Ignition Coil

2. Run the rear ignition coil lead over the shift lever tie-rod.

3. Front Ignition Coil

4. Clamps

5. Run the front ignition coil lead over the center bracket pipe.

6. Harness

7. Black Connector

8. White Connector

9. Black Terminal

10. Green Terminal

Cable, Wire, and Hose Routing

APPENDIX 17-23

1. Front Master Cylinder

2. Brake Hose

3. Clamps

4. Brake Pipes

5. Brake Pipe Joint

17-24 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 17-25

Cable, Wire, and Hose Routing

1. Front Brake Master Cylinder

2. Retainer

3. Brake Pipe

4. Brake Hoses

5. Clamp

6. Grommet

7. Clamp

8. Clamp (Right clamp has red paint. Left clamp is no paint.)

9. Stopper (Hold the brake hose with the stopper.)

10. Brake Hose Stopper (Touch the stopper of the brake hose to the stopper on the caliper.)

11. Caliper Stopper

12. Detail A

13. Clamp (Push the clamp to make the no gap between brake hose and steering knuckle.)

14. Steering Knuckle

15. No gap

17-26 APPENDIX

Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing

1. Parking Brake Cable

2. Differential Shift Cable

3. Band (Secure the differential shift cable and the throttle cable.)

4. 2WD/4WD Shift Cable

5. Throttle Cable

6. Clamp

7. Brake Pipe

8. Main Harness

9. Clamp (Clamp the parking brake cable at the white mark.)

APPENDIX 17-27

17-28 APPENDIX

Cable, Wire, and Hose Routing

1. Taping

2. Differential Shift Cable

3. 2WD/4WD Shift Cable

4. Holder

5. Vacuum Actuator

Cable, Wire, and Hose Routing

APPENDIX 17-29

1. Grommet

2. Parking Brake Cable

3. Main Harness

4. Bands (Secure the differential shift cable and the throttle cable.)

5. Differerntial Shift Cable

6. Throttle Cable

7. Clamp

17-30 APPENDIX

Cable, Wire, and Hose Routing

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

Cable, Wire, and Hose Routing

1. Main Harness

2. Top View

3. Bands

4. to 2WD/4WD Shift Switch (Apply grease to the terminals.)

5. Clamps

6. Side View (Section A-A)

7. Push the pre-installed clamp into the hole of frame.

8. Band (Clamp the wire harnesses at the taped areas.)

9. to Radiator Fan Motor

10. 20

∼

40 mm (0.8

∼

1.6 in.), Right and Left side

11. 40

∼

60 mm (1.6

∼

2.4 in.), Right and Left side

12. 70

∼

90 mm (2.8

∼

3.5 in.)

13. 140

∼

160 mm (5.5

∼

6.3 in.)

14. 30 mm (1.2 in.) maximum

APPENDIX 17-31

17-32 APPENDIX

Cable, Wire, and Hose Routing

KRF750ND/PD/RD/SD

Cable, Wire, and Hose Routing

1. Main Harness

2. Top View

3. Bands

4. to 2WD/4WD Shift Switch (Apply grease to the terminals.)

5. Clamps

6. Side View (Section A-A)

7. Push the pre-installed clamp into the hole of frame.

8. Band (Clamp the wire harnesses at the taped areas.)

9. to Radiator Fan Motor

10. 20

∼

40 mm (0.8

∼

1.6 in.), Right and Left side

11. 40

∼

60 mm (1.6

∼

2.4 in.), Right and Left side

12. 70

∼

90 mm (2.8

∼

3.5 in.)

13. 140

∼

160 mm (5.5

∼

6.3 in.)

14. 30 mm (1.2 in.) maximum

15. Kawasaki Diagnostic System Connector

16. Section B-B

17. View C

APPENDIX 17-33

17-34 APPENDIX

Cable, Wire, and Hose Routing

US model (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

APPENDIX 17-35

Cable, Wire, and Hose Routing

1. Intake Air Pressure Sensor

2. Intake Air Temperature Sensor

3. Forward/Reverse Detecting Sensor Connector

4. Neutral Position Switch

5. Reverse Position Switch

6. Apply lithium grease (NLGI Grade No.2) to the connectors.

7. Battery Positive (+) Cable

8. Battery Negative (–) Cable

9. Clamp the alternator lead, crankshaft sensor lead and oil pressure sensor lead with clamps.

10. Clamp the main harness with clamp as shown.

11. Engine Ground

12. Clamp the alternator lead, crankshaft sensor lead, oil pressure sensor lead, battery negative (–) cable and starter cable with band.

13. Clamp the connector so that the connector does not touch to the engine.

14. Clamp

15. Main Harness

16. Engine

17-36 APPENDIX

Cable, Wire, and Hose Routing

US model (KRF750ND/PD/RD/SD)

APPENDIX 17-37

Cable, Wire, and Hose Routing

1. Intake Air Pressure Sensor

2. Intake Air Temperature Sensor

3. Forward/Reverse Detecting Sensor Connector

4. Neutral Position Switch

5. Reverse Position Switch

6. Apply lithium grease (NLGI Grade No.2) to the connectors.

7. Battery Positive (+) Cable

8. Battery Negative (–) Cable

9. Clamp the alternator lead, crankshaft sensor lead and oil pressure sensor lead with clamps.

10. Clamp the main harness with clamp as shown.

11. Engine Ground

12. Clamp the alternator lead, crankshaft sensor lead, oil pressure sensor lead, battery negative (–) cable and starter cable with band.

13. Clamp the connector so that the connector does not touch to the engine.

14. Clamp

15. Main Harness

16. Engine

17. Clamp the inlet air temperature sensor lead with clamp.

18. Seat Belt Use Reminder Sensor Lead Connector

19. Seat Belt Use Reminder Sensor Lead

20. Clamp the battery positive (+) cable with clamp.

17-38 APPENDIX

Cable, Wire, and Hose Routing

CA model (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

APPENDIX 17-39

Cable, Wire, and Hose Routing

1. Intake Air Pressure Sensor

2. Intake Air Temperature Sensor

3. Forward/Reverse Detecting Sensor Connector

4. Neutral Position Switch

5. Reverse Position Switch

6. Apply lithium grease (NLGI Grade No.2) to the connectors.

7. Battery Positive (+) Cable

8. Battery Negative (–) Cable

9. Clamp the alternator lead, crankshaft sensor lead and oil pressure sensor lead with clamps.

10. Clamp the main harness with clamp as shown.

11. Engine Ground

12. Clamp the alternator lead, crankshaft sensor lead, oil pressure sensor lead, battery negative (–) cable and starter cable with band.

13. Clamp the connector so that the connector does not touch to the engine.

14. Clamp

15. Main Harness

16. Engine

17-40 APPENDIX

Cable, Wire, and Hose Routing

US model (KRF750ND/PD/RD/SD)

APPENDIX 17-41

Cable, Wire, and Hose Routing

1. Intake Air Pressure Sensor

2. Intake Air Temperature Sensor

3. Forward/Reverse Detecting Sensor Connector

4. Neutral Position Switch

5. Reverse Position Switch

6. Apply lithium grease (NLGI Grade No.2) to the connectors.

7. Battery Positive (+) Cable

8. Battery Negative (–) Cable

9. Clamp the alternator lead, crankshaft sensor lead and oil pressure sensor lead with clamps.

10. Clamp the main harness with clamp as shown.

11. Engine Ground

12. Clamp the alternator lead, crankshaft sensor lead, oil pressure sensor lead, battery negative (–) cable and starter cable with band.

13. Clamp the connector so that the connector does not touch to the engine.

14. Clamp

15. Main Harness

16. Engine

17. Clamp the inlet air temperature sensor lead with clamp.

18. Seat Belt Use Reminder Sensor Lead Connector

19. Seat Belt Use Reminder Sensor Lead

17-42 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 17-43

Cable, Wire, and Hose Routing

1. ISC Valve Harness

2. Water Temperature Sensor

3. 2WD/4WD Solenoid Valve Connector

4. Clamp the fuel hose and harness with clamp.

5. Fuel Pump/Fuel Level Sensor

6. Clamp the engine brake actuator harness with the clamp.

7. Engine Bake Actuator

8. Clamp the main harness with clamp.

9. Throttle Position Sensor

10. Fuel Injector #2 (Rear)

11. Fuel Injector #1 (Front)

12. Breather Hoses

13. Clamp the harnesses and breather hoses with the clamp.

14. Run the branched harnesses under the pipe.

15. Band (Secure the main harness to the pipe.) (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

16. Band (Secure the main harness to the pipe.)

17. Secure the main harness at the front of pipe within this area with the bands.

17-44 APPENDIX

Cable, Wire, and Hose Routing

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

APPENDIX 17-45

Cable, Wire, and Hose Routing

1. Regulator/Rectifier

2. Cover the regulator/rectifier connector with cover.

3. Band (Secure the regulator/rectifier lead with the front gear case breather tube and the fan motor breather tube.)

4. to the Left Headlight

5. Speed Sensor

6. Ignition Switch

7. 2WD/4WD Shift Switch

8. Multifunction Meter Harness

9. Bands (Secure the ignition switch, 2WD/4WD shift switch and mutifunction meter harnesses.)

10. Run the brake line and the harnesses above the frame.

11. Clamps

12. Lighting Switch

13. Bands (Secure the lighting switch harness to the brake bracket.)

14. Accessory Connector

15. Clamps

16. Grommet (Large Diameter)

17. Floorboard

18. Brake Light Switch Lead

19. Parking Brake Light Switch Lead

20. Frame Ground 2

17-46 APPENDIX

Cable, Wire, and Hose Routing

KRF750ND/PD/RD/SD

APPENDIX 17-47

Cable, Wire, and Hose Routing

1. Regulator/Rectifier

2. Cover the regulator/rectifier connector with cover.

3. Band (Secure the regulator/rectifier lead with the front gear case breather tube and the fan motor breather tube.)

4. to the Left Headlight

5. Speed Sensor

6. Ignition Switch

7. 2WD/4WD Shift Switch

8. Multifunction Meter Connector

9. Bands (Secure the ignition switch, 2WD/4WD shift switch and mutifunction meter harnesses.)

10. Run the brake line and the harnesses above the frame.

11. Clamps

12. Lighting Switch

13. Bands (Secure the lighting switch harness to the brake bracket.)

14. Accessory Connector

15. Clamps

16. Grommet (Large Diameter)

17. Floorboard

18. Brake Light Switch Lead

19. Parking Brake Light Switch Lead

20. Frame Ground 1

17-48 APPENDIX

Cable, Wire, and Hose Routing

1. Left Headlight Cover

2. Left Headlight Lead

3. Clamps

4. Holder (Hold headlight lead to the headlight cover.)

5. Frame

6. Right Headlight Cover

7. Right Headlight Lead

8. Run the radiator fan motor harness between the bracket and the radiator hose.

9. Run the right headlight harness above the radiator reserve tank hose.

Cable, Wire, and Hose Routing

APPENDIX 17-49

1. Band (Right and Left sides)

2. Clamp the tail light lead (each sides) and reverse light lead (right side only,

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC) to the bar.

3. Clamp (Clamp the tail light lead.)

4. Reverse Light Lead Connector (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

5. Cover (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

6. Band (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

7. Installation of Cover (KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC)

17-50 APPENDIX

Cable, Wire, and Hose Routing

KRF750NA/PA/RA/SA/TA

∼

NC/PC/RC/SC/VC

Cable, Wire, and Hose Routing

1. Kawasaki Diagnostic System Connector

2. Clamp the frame and main harness with band.

3. Place the frame ground 1 terminal horizontally as shown.

4. Clamp the ignition coil lead with clamp.

5. Ignition Coil #1 (Front)

6. Front

7. Crankshaft Sensor Connector (Grease to the inside of the connector.)

8. Alternator Lead Connectors (Free Location)

9. Oil Pressure Switch Lead Connector

10. Starter Relay

11. 30

∼

45°

12. Detail T

13. View W

APPENDIX 17-51

17-52 APPENDIX

Cable, Wire, and Hose Routing

KRF750ND/PD/RD/SD

Cable, Wire, and Hose Routing

1. Kawasaki Diagnostic System Connector

2. Clamp the frame and main harness with band.

3. Place the frame ground 2 terminal horizontally as shown.

4. Clamp the ignition coil lead with clamp.

5. Ignition Coil #1 (Front)

6. Front

7. Crankshaft Sensor Connector (Grease to the inside of the connector.)

8. Alternator Lead Connectors (Free Location)

9. Oil Pressure Switch Lead Connector

10. Starter Relay

11. 30

∼

45°

12. Detail T

13. View W

APPENDIX 17-53

17-54 APPENDIX

Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing

1. Rubber Cover

2. Rubber Cover

3. Rubber Cover

4. Bands

5. Bands

6. for Bracket

7. for Breather Hose

8. for Fuel Hose

9. for CVT Duct

10. Frame Pipe

11. for Harness

12. for Harness Clamp

13. for Drain Tube

14. for Engine Intakes

15. for Clamp

16. Pass the clamp through the cover.

17. Clamp

18. Seat Rail

19. Harness

20. For Seat Belt Buckle (KRF750ND/PD/RD/SD)

APPENDIX 17-55

2011

2011

2011

2011

2012

2012

2012

2012

Year

2010

2010

2010

2010

2010

2011

2012

2013

2013

2013

2013

MODEL APPLICATION

Model

KRF750NA

KRF750PA

KRF750RA

KRF750SA

KRF750TA

KRF750NB

KRF750PB

KRF750RB

KRF750SB

KRF750VB

KRF750NC

KRF750PC

KRF750RC

KRF750SC

KRF750VC

KRF750ND

KRF750PD

KRF750RD

KRF750SD

Beginning Frame No.

JKARFDN1

JKARFDP1

□

AB500001

□

AB500001

JKARFDR1

JKARFDS1

□

AB500001

□

AB500001

JKARFDT1

JKARFDN1

□

AB500001

□

BB502601

JKARFDP1

JKARFDR1

□

BB501801

□

BB501001

JKARFDS1

JKARFDV1

JKARFDN1

JKARFDP1

□

BB501401

□

BB500001

□

CB503401

□

CB502901

JKARFDR1

JKARFDS1

□

CB501901

□

CB502801

JKARFDV1

JKARFDN1

□

CB500901

□

DB505201

JKARFDP1

JKARFDR1

JKARFDS1

□

DB504001

□

DB502601

□

DB503701

□

:This digit in the frame number changes from one machine to another.

Part No.99924-1434-06

Printed in Japan