Print Preview C 2004 Kawasaki KFX 700 V Force Service Manual
Kawasaki KFX700 V-Force 2003 Service Manual Kawasaki KFX700 V-Force 2003 Service Manual
User Manual: 2004 Kawasaki KFX 700 V Force Service Manual
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Page Count: 445 [warning: Documents this large are best viewed by clicking the View PDF Link!]
- tables
- LIST OF ABBREVIATIONS
- Units of Mass:
- Units of Volume:
- Units of Force:
- Units of Length:
- Units of Torque:
- Units of Pressure:
- Units of Speed:
- Units of Power:
- Basic Torque for General Fasteners of Engine Parts
- Basic Torque for General Fasteners of Frame Parts
- Throttle Lever Free Play
- Choke Lever Free Play [B]
- Idle Speed
- Water and Coolant Mixture Ratio (when shipping)
- Valve Clearance (when cold)
- Valve Clearance (when cold)
- Belt Height (Paralle Portion)
- Belt Deflection
- Spacers
- Engine Oil
- Shift Control Cable Grip Free play [A]
- Tire Tread Depth
- Standard Tire
- Final Gear Case Oil
- Pad Lining Thickness
- Rear Brake Lever Free Play
- Brake Pedal Free Play
- Spark Plug Gap
- Brake Light Timing
- Carburetor Pilot Screw Setting
- Service Fuel Level
- Float Height
- Carburetor Synchronization Vacuum
- Radiator Cap Relief Pressure
- Thermostat Valve Opening Temperature
- Valve Closing Temperature (for reference)
- Rocker Arm Inside Diameter
- Rocker Shaft Diameter
- Cam Height
- Camshaft Bearing Clearance (x618)
- Camshaft Bearing Clearance (x622)
- Camshaft Journal Diameter (x618)
- Camshaft Journal Diameter (x622)
- Cylinder Compression (Usable Range)
- Cylinder Head Warp
- Valve/Valve Guide Clearance (Wobble Method)
- Valve Seating Surface Outside Diameter
- Valve Seating Surface Width
- Piston Diameter
- Piston/Cylinder Clearance
- Piston Ring/Groove Clearance
- Piston Ring Groove Width
- Piston Ring Thickness
- Piston Ring End Gap
- Cover Bushing Inside Diameter [A]
- Sheave Bushing Inside Diameter [A]
- Spring Free Length [A]
- Shoe Side Clearance
- Sheave Bushing Inside Diameter
- Spring Free Length [A]
- Oil Pressure
- Connecting Rod Bend
- Connecting Rod Twist
- Connecting Rod Big End Side Clearance
- Connecting Rod Big End Bearing, Insert/Crankpin Clearance
- Crankpin Diameter
- Crankpin Diameter Marks
- Connecting Rod Big End Inside Diameter Marks
- Big End Bearing Insert Selection
- Crankshaft Runout
- Crankshaft Main Journal Diameter
- Crankcase Main Bearing Bore Diameter
- Shift Fork Ear Thickness
- Shifter Groove Width
- Toe-in of Front Wheels
- Maximum Tire Air Pressure (to seat beads when cold)
- Tire Air Pressure (when cold)
- Drive Bevel Gear Shims for Tooth Contact Adjustment
- Driven Bevel Gear Shims for Backlash Adjustment
- Output Bevel Gear Backlash
- Rear Axle Shaft Runout
- 6. Pinion Gear Shims for Tooth Contact Adjustment
- 7. Ring Gear Shims for Backlash Adjustment
- Recommended Disc Brake Fluid
- Disc Thickness
- Disc Runout
- Pedal Position [C]
- Spring Action
- Compression Damping
- Spring Preload Setting Position
- Spring Action
- Tie-Rod Length
- Battery Terminal Voltage
- Terminal Voltage: 11.5 less than 12.5 V
- Terminal Voltage : less than 11.5 V
- Regulator/Rectifier Output Voltage
- Alternator Output Voltage
- Stator Coil Resistance
- Rectifier Circuit Inspection
- Ignition Coil Arcing Distance
- Ignition Coil Winding Resistance
- Ignition Coil Primary Peak Voltage
- Crankshaft Sensor Resistance
- Connections:
- Crankshaft Sensor Peak Voltage
- Ignition Timing
- Vehicle-down Sensor Power Source Voltage
- Vehicle-down Sensor Power Source Voltage
- Vehicle-down Sensor Power Output Voltage
- Vehicle-down Sensor Power Output Voltage
- Commutator Diameter
- Starter Motor Brush Length
- Testing Relay
- Testing Relay
- Radiator Fan Motor Leads
- Fuel Pump Supply Voltage
- Fuel Pump Pressure
- Fuel Indicator Light [A]:
- Neutral Indicator Light (LED) [B]:
- Reverse Indicator Light (LED) [C]:
- Water Temperature Warning Light (LED) [D]:
- Oil Pressure Warning Light (LED) [E]:
- Belt Indicator Light (LED) [F]:
- Radiator Fan Switch Resistance
- Coolant Temperature Warning Light Switch Resistance
- toc
- Read OWNER'S MANUAL before operating.
- EMISSION CONTROL INFORMATION
- PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only)
- Foreword
- General Information
- Periodic Maintenance
- The scheduled maintenance must be done in accordance with this c
- The following tables list the tightening torque for the major fa
- Oil Filter Wrench : 57001 1249
- Carburetor Drain Plug Wrench, Hex 3 : 57001 1269
- Flywheel & Pulley Holder : 57001 1343
- Pulley Holder Attachment : 57001 1472
- Filler Cap Driver: 57001 1454
- Fuel System
- Throttle Lever Free Play Inspection
- Throttle Lever Free Play Adjustment
- Choke Lever Free Play Check
- Choke Lever Free Play Adjustment
- Idle Speed Inspection
- Idle Speed Adjustment
- Fuel System Cleanliness Inspection
- Air Cleaner Element Cleaning and Inspection
- Air Cleaner Draining
- Fuel Hoses and Connections Inspection
- Fuel Hose and Fuel Filter Replacement
- Cooling System
- Engine Top End
- Converter System
- Engine Lubrication System
- Crankshaft/Transmission
- Wheels/Tires
- Final Drive
- Brakes
- Front Brake Pad Wear Inspection
- Front Brake Hoses and Connections Inspection
- Front Brake Hose Replacement
- Brake Fluid Level Inspection
- Brake Fluid Change
- Brake Line Air Bleeding
- Master Cylinder Inspection (Visual Inspection)
- Caliper Fluid Seal Replacement
- Caliper Dust Seal and Friction Boot Replacement
- Rear Brake Plates Replacement
- Rear Brake Lever Free Play Inspection
- Rear Brake Pedal Free Play Inspection
- Rear Brake Lever and Pedal Free Play Adjustment
- Suspension
- Steering
- Electrical System
- General Lubrication
- Bolts and Nuts Tightening
- Fuel System
- Fuel Level Gauge : 57001 1017
- Pilot Screw Adjuster, A : 57001 1239
- Carburetor Drain Plug Wrench, Hex 3 : 57001 1269
- Throttle Lever Free Play Inspection
- Choke Lever Free Play Check
- Idling Speed Inspection
- Idle Speed Adjustment
- Pilot Screw Adjustment
- Service Fuel Level Inspection
- Service Fuel Level Adjustment
- Carburetor Synchronization Inspection
- Carburetor Synchronization Adjustment
- Fuel System Cleanliness Inspection
- Carburetor Removal
- Carburetor Installation
- Carburetor Disassembly
- Carburetor Assembly
- Carburetor Separation
- Carburetor Joining
- Carburetor Cleaning
- Carburetor Inspection
- Air Cleaner Element Removal
- Fuel Tank Removal
- Fuel Pump Removal
- Cooling System
- Permanent type antifreeze is used as a coolant to protect the co
- Bearing Driver Set : 57001 1129
- Bearing Remover Shaft, x69 : 57001 1265
- Bearing Remover Head, x610 x x612 : 57001 1266
- Kawasaki Bond (Silicone Sealant) : 56019 120
- Coolant Deterioration Inspection
- Water Pump Cover Removal
- Radiator Removal
- Thermostat Removal
- Radiator Fan Switch Removal
- Coolant Temperature Warning Light Switch Removal
- Coolant Filter Cleaning
- Engine Top End
- Outside Circlip Pliers : 57001 144
- Compression Gauge : 57001 221
- Valve Spring Compressor Assembly : 57001 241
- Piston Pin Puller Assembly : 57001 910
- Valve Seat Cutter, 45° x627.5 : 57001 1114
- Valve Seat Cutter, 32° x628 : 57001 1119
- Valve Seat Cutter, 60° x630 : 57001 1123
- Valve Seat Cutter Holder Bar : 57001 1128
- Valve Seat Cutter, 45° x630 : 57001 1187
- Valve Seat Cutter, 32° x633 : 57001 1199
- Valve Spring Compressor Adapter, x622 : 57001 1202
- Valve Guide Arbor, x65 : 57001 1203
- Valve Guide Reamer, x65 : 57001 1204
- Valve Seat Cutter Holder, x65 : 57001 1208
- Piston Pin Puller Adapter : 57001 1211
- Filter Cap Driver: 57001 1454
- Compression Gauge Adapter, M10 × 1.0 : 57001 1486
- Kawasaki Bond (Silicone Sealant) : 56019 120
- Camshaft Chain Tensioner Removal
- Rocker Case Removal
- Camshaft Removal
- Cylinder Compression Measurement
- Valve Clearance Inspection
- Cylinder Removal
- This vehicle is equipped with a spark arrester approved for off-
- Converter System
- Circlip Pliers : 57001 154
- Flywheel & Pulley Holder : 57001 1343
- Drive & Driven Pulley Holder : 57001 1412
- Drive Pulley Puller Bolt : 57001 1429
- Pulley Holder Attachment : 57001 1472
- Drive Pulley Holder : 57001 1473
- Drive Pulley Wrench : 57001 1474
- Spring Holder Set : 57001 1483
- Drive Pulley Holder : 57001 1520
- WARNING
- Drive Belt Removal
- Drive Pulley Removal
- Driven Pulley Removal
- Specifications
- Engine Lubrication System
- Engine Removal/Installation
- Crankshaft / Transmission
- Wheels / Tires
- Final Drive
- Bearing Puller : 57001 135
- Outside Circlip Pliers : 57001 144
- Oil Seal & Bearing Remover : 57001 1058
- Bearing Driver Set : 57001 1129
- Socket Wrench : 57001 1363
- Damper Spring Compressor Set : 57001 1475
- Holder & Guide Arbor : 57001 1476
- Socket Wrench, Hex 50 : 57001 1478
- Output Shaft Holder & Spacer : 57001 1479
- Pinion Gear Holder : 57001 1480
- Nut Holding Bolts : 57001 1481
- Socket Wrench : 57001 1482
- Socket Wrench, Hex 41 : 57001 1484
- Pinion Gear Holder : 57001 1485
- Oil Seal Driver: 57001 1487
- Hexagon Wrench, Hex 41 : 57001 1491
- Output Drive Bevel Gear Removal
- Output Drive Bevel Gear Installation
- Output Drive Bevel Gear Disassembly
- Output Drive Bevel Gear Assembly
- Output Driven Bevel Gear Removal
- Output Driven Bevel Gear Installation
- Output Driven Bevel Gear Disassembly
- Output Driven Bevel Gear Assembly
- Output Bevel Gears Adjustment
- Output Bevel Gear (Backlash-related Parts)
- Propeller Shaft Removal
- Rear Axle Removal
- Final Gear Case Oil Level Inspection
- Ball or Needle Bearing Inspection
- Brakes
- Inside Circlip Pliers : 57001 143
- WARNING
- Master Cylinder Removal
- Caliper Removal
- Brake Pad Removal
- Disc Cleaning
- Brake Hose Inspection
- Brake Pedal Position Inspection
- Brake Pedal Position Adjustment
- Rear Brake Lever Free Play Inspection
- Brake Pedal Free Play Inspection
- Rear Brake Lever and Pedal Free Play Adjustment
- Brake Pedal Removal
- Brake Pedal Installation
- Brake Cable Removal
- Brake Cable Installation
- Brake Cable Lubrication
- Brake Pedal Shaft Removal
- Brake Pedal Shaft Installation
- Internal Wet Brake Disassembly
- Suspension
- Inside Circlip Pliers : 57001 143
- Outside Circlip Pliers : 57001 144
- Oil Seal & Bearing Remover : 57001 1058
- Hook Wrench : 57001 1101
- Bearing Driver Set : 57001 1129
- Jack : 57001 1238
- Front Shock Absorber Inspection
- Suspension Arm Removal
- Swingarm Removal
- Steering
- Frame
- Electrical System
- Hook Wrench : 57001 1101
- Timing Light : 57001 1241
- Compression Gauge Gasket : 57001 1314
- Hand Tester : 57001 1394
- Flywheel Puller Assembly : 57001 1405
- Needle Adapter Set : 57001 1457
- Light/Dimmer Switch [A]
- There are a number of important precautions that should be taken
- Wiring Inspection
- Battery Removal
- Alternator Cover Removal
- WARNING
- Spark Plug Removal
- Spark Plug Installation
- Spark Plug Cleaning/Inspection
- Spark Plug Gap Inspection
- Ignition Coil Removal
- Ignition Coil Installation
- Ignition Coil Inspection
- Ignition Coil Primary Peak Voltage Inspection
- Crankshaft Sensor Removal
- Crankshaft Sensor Installation
- Crankshaft Sensor Inspection
- Crankshaft Sensor Peak Voltage Inspection
- Alternator Rotor Inspection
- Ignition Timing Test
- Vehicle-down Sensor Outline
- Vehicle-down Sensor Removal
- Vehicle-down Sensor Installation
- Vehicle-down Sensor Inspection
- Ignition System Troubleshooting
- Ignition System Circuit
- Starter Motor Removal
- Headlight Beam Vertical Adjustment
- Radiator Fan Circuit Inspection
- Fuel Pump Inspection
- Indicator Unit Removal
- Brake Light Switch Adjustment
- 30 A Main Fuse Removal
- Appendix
- NOTE
- Engine Doesn't Start, Starting Difficulty:
- Poor Running at Low Speed:
- Poor Running or No Power at High Speed:
- Overheating:
- Over Cooling:
- Converter Operation Faulty:
- Gear Shifting Faulty:
- Abnormal Engine Noise:
- Abnormal Drive Train Noise:
- Abnormal Frame Noise:
- Exhaust Smokes Excessively:
- Handling and/or Stability Unsatisfactory
- Brake Doesn't Hold
- Battery Discharged:
- Battery Overcharged:
- NOTE
- Read OWNER'S MANUAL before operating.