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2006-2010 Kawasaki Brute Force 650, KVF650 4x4i repair manual Preview image 1
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2006-2010 Kawasaki Brute Force 650, KVF650 4x4i repair manual

Models covered in this manual:

Brute Force 650, KVF650 / Kawasaki Motorcycle & Engine Company

  • 2006 Kawasaki Brute Force 650, KVF650 4x4i
  • 2007 Kawasaki Brute Force 650, KVF650 4x4i
  • 2008 Kawasaki Brute Force 650, KVF650 4x4i
  • 2009 Kawasaki Brute Force 650, KVF650 4x4i
  • 2010 Kawasaki Brute Force 650, KVF650 4x4i

Engine: 633 cc, liquid-cooled, 90-degree, 4-stroke V-twin, SOHC, four valves, 80 x 63 mm, 9.9:1

File specifications

File size: 111.29 MB
File type: PDF
Language: English
Number of pages: 562

Printable: Yes
Estimated download time: 2.28 Minutes
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Product Information

Table of Contents

Quick Reference Guide

General Information

  • Model Identification
  • General Specifications
  • Vehicle Specifications
  • Location of Labels

Periodic Maintenance

  • Maintenance Schedule
  • Engine Oil and Filter Change
  • Air Filter Maintenance
  • Spark Plug Inspection and Replacement
  • Valve Clearance Adjustment
  • Brake System Inspection
  • Tire Inspection
  • Battery Maintenance
  • Periodic Torque Specifications

Fuel System

  • Fuel Tank Removal and Installation
  • Fuel Line Inspection
  • Fuel Pump Operation Check
  • Carburetor/Throttle Body Disassembly, Inspection, and Assembly
  • Fuel Injection System Diagnosis
  • Fuel System Cleaning and Inspection

Cooling System

  • Coolant Replacement
  • Radiator and Hoses Inspection
  • Thermostat Inspection and Replacement
  • Water Pump Inspection and Repair
  • Cooling Fan Operation Check

Engine Top End

  • Cylinder Head Removal and Installation
  • Valve and Valve Spring Inspection
  • Camshaft Inspection
  • Cylinder and Piston Inspection
  • Timing Chain and Tensioner Inspection
  • Compression Test

Converter System

  • CVT Belt Inspection and Replacement
  • Primary and Secondary Pulley Inspection
  • CVT Operation Check
  • Drive Belt Tension Adjustment

Recoil Starter

  • Recoil Starter Mechanism Inspection
  • Recoil Spring Inspection
  • Starter Rope Replacement

Engine Lubrication System

  • Oil Pump Removal and Inspection
  • Oil Screen Cleaning
  • Oil Line Inspection
  • Lubrication System Troubleshooting

Engine Removal/Installation

  • Engine Removal Procedure
  • Engine Installation Procedure
  • Engine Mount Inspection and Replacement

Crankshaft/Transmission

  • Crankshaft Inspection
  • Transmission Gear Inspection
  • Shift Fork and Drum Inspection
  • Bearing and Oil Seal Replacement
  • Transmission Assembly

Wheels/Tires

  • Wheel Removal and Installation
  • Tire Inspection and Replacement
  • Wheel Bearing Inspection and Replacement
  • Tire Pressure Adjustment

Final Drive

  • Differential Inspection and Replacement
  • Drive Shaft Inspection
  • U-Joint Inspection
  • Final Drive Oil Replacement

Brakes

  • Brake Pad Inspection and Replacement
  • Brake Disc Inspection
  • Brake Line Inspection
  • Master Cylinder Inspection and Repair
  • Brake Bleeding Procedure

Suspension

  • Front Suspension Inspection and Adjustment
  • Rear Suspension Inspection and Adjustment
  • Shock Absorber Inspection
  • Suspension Arm Bushings Replacement

Steering

  • Steering Shaft Inspection
  • Steering Knuckle Inspection and Replacement
  • Tie Rod End Inspection
  • Steering Alignment Adjustment

Frame

  • Frame Inspection and Repair
  • Subframe Inspection
  • Frame Bolt Torque Specifications
  • Footpeg and Handlebar Inspection

Electrical System

  • Battery Inspection and Replacement
  • Charging System Check
  • Starter Motor Inspection
  • Ignition System Inspection
  • Lighting System Inspection
  • Electrical Component Testing and Replacement
  • Wiring Diagram

Appendix

  • Troubleshooting Guide
  • Special Tools List
  • Torque Specifications
  • Wiring Diagrams
  • Maintenance Records

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