Brake Fluid Front Radiator Cap Danger Rear Brake Lever Parking Brake 9. Brake Lever Lock Reverse Power Assist Switch Override 3. Variable Front Differential Control Lever Engine Stop Switch 4. Starter Button Storage Box 5. Front Carrier Headlights Shock Absorbers Front Disc Brake Caliper Front Cylinder Spark Plug Front Final Gear Case Air Cleaner Oil Filler Plug Fuses Rear Final Gear Case Radiator Tool Kit Winch Bracket Fuel Tank Filler Cap Fuel Tank Rear Cylinder Spark Plug Shift Lever Rear Brake Pedal Coolant Reserve Tank All parts and With the exception of genuine Kawasaki Parts and accessories added to this vehicle should be Accessories, Kawasaki has no control over the de- genuine Kawasaki or equivalent components sign or application of accessories.
Try to maintain front to rear balance cially designed for use on Kawasaki vehicles. This ATV is not designed for carrying passengers on the carriers. The ignition switch also operates the power outlet circuit and this vehicle has an accessory fuse 15 A to protect this circuit. The connector has a cap. Remove it to connect an electrical accessory.
Al- ways install a fuse 5 A or less for the circuit. Fuel Level Gauge The hour display stops Odometer: blinking and the minute display starts blinking. The odometer shows the total distance in kilome- Push the Left button to advance the minutes. The meter cannot be reset. The 4WD and 2WD indicators will blink connected. Stop driving immediately and When the lead connector for the CVT check indi- see an authorized Kawasaki dealer to have the sys- cator is disconnected or the lead itself is cut and tem checked.
Do not let the engine continue running with a warning light staying on. The CVT Check Indicator Light goes on after hours of operation as a reminder that the drive belt must be inspected for wear.
Could result in ATV overturning. To lock the brake lever, first pull in the brake lever. Then pull in the lock lever and while holding it against the brake lever, release the brake lever. Rear Carrier A. Front Carrier Avoid filling the tank in the rain or where heavy dust is blow- ing so that the fuel does not get contaminated.
Page 50 Avoid using blends of unleaded gasoline and blends during refueling. Fuel system damage and -BIL with the gasoline in the fuel tank. It is a 2-position, key-operated switch. Remove the key to prevent unauthorized vehicle use. Included with the key is dealer may have the number in its records. If the key a key number, which is stamped on the key itself. If the The switch positions are identified on the housing. Back- This vehicle is equipped with a variable limited slip ing up without looking where you are going.
An unexpected change in direc- tion can cause the operator to lose control, resulting in an accident and injury. Pushing the lever forward increases en- gine speed.
When released, spring pressure returns the lever to the rear. Always check that the throttle lever returns normally before starting the engine. In addition, there must be adequate throttle cable play. The limiter functions by restricting the moving Increases your chances of losing control of distance of the throttle lever. Never try to adjust the limiter by racing the engine in neutral or in gear with brake on, or the engine may be damaged.
Make sure that the rear hooks align to their rear receivers. Push the seat with both hands around the rear hooks The storage box is located on the left side front and make sure there is a click sound to indicate that fender and upper side front fender. Remove the seat for the kit. The minor adjustments and replacement of parts explained in this manual can be performed with the tools in the kit. Storage Box B. A trailer hitch bracket is fitted at the rear end of the Overloading a trailer.
The winch and its installing brackets are not supplied this vehicle. Please con- tact a dealer if you need them. To avoid injury and property damage, observe the following precautions, not to exceed the spooling load equivalent to kg 1 lb. If the vehi- ately after starting it, even if the engine is already cle is not used carefully during this period, you may warm.
Check the following items each day before you ride. Enough fuel in tank, no leaks. Engine Oil Coolant level between level lines when engine is cold , no leaks. Air Pressure when cold : Front: 35 kPa 0. Repeat until the engine Starting the Engine starts. The starter Running the engine without ventilation. Reverse while moving. Changing operating mode while moving can cause a sudden change in handling performance which can cause the operator to lose control and have an acci Brake Control System.
It can assist the operator If parking inside a garage or other structure, be sure it is well ventilated and the vehicle is not close WARNING to any source of flame or sparks; this includes any appliance with a pilot light.
Page Stopping The Atv In An Emergency Stopping the ATV in an Emergency An improperly serviced or clogged air cleaner may allow dirt and dust to enter the throttle body Your Kawasaki vehicle has been designed and assembly and stick the throttle open. Study this manual with your child to be sure he This vehicle is not a toy.
It is an off-road motor or she fully understands all of the special safety vehicle. Op- eration on public streets, roads, and highways is not recommended and is not safe. ATV tires are not designed to operate on paved or concrete surfaces. The tires will not slip as neces- sary which may seriously affect control of the vehi- cle.
The proper clothing can make riding more comfortable and reduce the chance of injury If you take a spill. Long pants will also protect your legs from the hot exhaust system. Super Black. Fragment Camo Gray. Bright White. Warning: ATVs can be hazardous to operate. For your safety: Always wear a helmet, eye protection, and protective clothing. Never carry a passenger. Never ride under the influence of drugs or alcohol. Never ride on public roads or pavement.
Avoid excessive speeds and stunt driving. Be extra careful on difficult terrain. Kawasaki ATVs with engines over 90cc are recommended for use only by persons 16 years of age or older. If there are signs of leakage around the exhaust pipe gas- ket, it should be replaced. Special Tools Torque Converter Torque Converter Cover Removal Torque Converter Cover Installation M: Apply molybdenum disulfide grease. R: Replacement Part S: Follow the specific tightening sequence.
Drive Belt Belt Width Belt Deflection — If it is done, the learning control of Kawasaki Engine Brake Control system works and the engine brake actuator works an error operation. Cover Bushing Inside Diameter [A] Standard: Service Limit: If the sheave bushing is damaged or worn, replace it.
Sheave Bushing Inside Diameter [A] Spring Free Length [A] Standard: Sheave Bushing Inside Diameter If seals are damaged, replace the movable sheave. Recoil Starter Recoil Starter Removal Recoil Starter Installation Recoil Starter Inspection Engine Oil Flow Chart Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Change Oil Screen Removal Oil Screen Cleaning L: Apply a non-permanent locking agent.
O: Apply engine oil. Front Camshaft 8. Transmission Idle Shaft 2. Oil Filter 9. Oil Screen 3. Crankshaft Transmission Driven Shaft 4. Oil Pressure Switch Rear Camshaft 5. Oil Pipes Breather Hose 6. Engine Removal Engine Installation Page Face the seal of the bearing to the left side outward. G: Apply grease. MO: Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1. Crankpin Diameter Marks None: If the measurement exceeds the service limit, replace the crankshaft.
Driven Shaft Drive Low Gear 20T 2. Spacer Reverse Idle Shaft 3. Reverse Gear 12T Reverse Driven Gear 16T 4. Reverse Driven Output Gear 16T 5. Removal may damage them. W: Apply water or soap and water solution. 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 slip- ping or scuffing action between the tires and the ground.
Now the front wheels are parallel to each other and to the center line of the vehicle. Un- even thread length could cause tie-rod damage. Smooth the sealing sur- faces with fine emery cloth if necessary. This helps the tire beads slip off the rim flanges. Page Tire Inspection Deflate the tire to the specified pressure.
Tire Air Pressure when cold Front: 35 kPa 0. Ball Bearings 4. Bearing Housings 6. Output Driven Shaft 2. Drive Bevel Gear Shims 5. Output Driven Bevel Gear 7. Driven Bevel Gear Shims 3. Repeat in 0. Replace the bevel gears as a set if either gear is dam- aged. 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.
They must be re- placed as a set. Pinion Gear Shim s 2. Ring Gear Right Shim s 3. Ring Gear Left Shim s 4. 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. Standard Length of Assembling: Outboard: Standard Length of Assembling: Inboard: Pinion Gear 2.
Pinion Gear Bearing Holder 3. Gear Case Right Cover 4. Ball Bearings 5. Ring Gear 6. Pinion Gear Shim s 7. Ring Gear Shim s 8. To increase backlash, increase the thickness of the shim s. To decrease backlash, decrease the thickness of the shim s. Change the thickness a little at a time. Replace any if the lips are misshapen, discolored indicat- ing that the rubber has deteriorated , hardened, or been otherwise damaged.
Bend both hooks after installing the spring. Disc thickness 3 mm 0. Disc runout Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Take care that nei- ther the cylinder nor the piston skirt gets scratched. Replace the caliper if the cylinder and piston are badly scored or rusty.
Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone. R: Replacement Parts Property of www. If the spring action feels too soft or too stiff, adjust it in accordance with the following table. If bushings are worn, cracked, hardened, or otherwise damaged, replace them. If it is found, replace the knuckle joint. Tie-rod Length Standard: If the steering stem is bent, replace the steering stem. If roughness or binding is found, replace the bearing.
Learn and ob- serve all the rules below. This will burn out the diodes in the electrical parts. If any wiring is defective, replace the damaged wiring. If the connector is corroded or dirty, clean it carefully. Be sure to use the dedicated electrolyte container for correct electrolyte volume.
Page Precautions 1. Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge. 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.
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 electromag- netic field, or just by aging, will result in low output.
Ignition Switch 2. Fuse Box 3. Main Fuse 30 A 4. Load 5. Alternator 6. Starter Relay 8. Battery 12 V12 Ah 9. Engine Ground Terminal Property of www. 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. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. Shock to the sensor can damage it.
Ignition Switch 9. Reset Connector 2. Reverse Switch Crankshaft Sensor 3. Speed Sensor Ignition Coils 4. Fuse Box Main Fuse 30 A Spark Plugs 5. Multifunction Meter Battery 6. Starter Motor Brush Length Standard: Service Limit: 5 mm 0. If any is worn down to the service limit, replace the brush plate assembly. Starter Button 2.
Engine Stop Switch 3. Parking Brake Light Switch 4. Front Brake Light Switch 5. Rear Brake Light Switch 6. Main Fuse 30 A 7. Starter Circuit Relay Brake 8. If the limiter has wear, discoloration, or other damage, replace it as a unit. Headlight Left 2.
0コメント