Kawasaki KFX 700V Force - Repair, Service Manual, Parts Catalog and Wiring Diagrams

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KAWASAKI KFX 700V FORCE - WORKSHOP, SERVICE, REPAIR MANUAL - PARTS CATALOGUE - WIRING DIAGRAMS

- English Service Manual, Parts Catalogue and Wiring Diagrams, for ATV Kawasaki KFX 700V Force.
 
CONTENTS:

SERVICE MANUAL

Foreword
General Information
- Before starting to perform an inspection service or carry out a
- Especially note the following:
- Two-Color Electrical
- KSV700 A1 Left Side View
- KSV700 A1 Right Side View
- Prefixes for Units:
- Units of Temperature:
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
- Suspension
- Steering
- Electrical System
- General Lubrication
- Bolts and Nuts Tightening
- Wheels:
- Brakes:
- Others:
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
- Throttle Lever Free Play Adjustment
- Throttle Case Removal/Disassembly
- Throttle Case Assembly/Installation
- Throttle Cable Installation
- Throttle Case Inspection
- Throttle Cable Lubrication
- Throttle Cable Inspection
- Choke Lever Free Play Check
- Choke Lever Free Play Adjustment
- Choke Lever and Cable Removal
- Choke Lever and Cable Installation
- Choke Cable Lubrication
- Choke Cable Inspection
- 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
- Air Cleaner Element Cleaning and Inspection
- Air Cleaner Draining
- Air Cleaner Housing Removal
- Air Cleaner Housing Installation
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tank Cleaning
- Fuel Tap Removal
- Fuel Tap Installation
- Fuel Tap Inspection
- Fuel Pump Removal
- Pump Filter Cleaning
- Fuel Pump Installation
- Fuel Pump Inspection
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
- Coolant Level Inspection
- Coolant Draining
- Coolant Filling
- Pressure Testing
- Water Pump Cover Removal
- Water Pump Cover Installation
- Impeller Removal
- Water Pump Impeller Installation
- Water Pump Impeller Inspection
- Mechanical Seal Replacement
- Radiator Removal
- Radiator Fan Removal
- Radiator Fan Installation
- Radiator Inspection
- Radiator Cleaning
- Radiator Cap Inspection
- Thermostat Removal
- Thermostat Installation
- Thermostat Inspection
- Radiator Fan Switch Removal
- Radiator Fan Switch Installation
- Radiator Fan Switch Inspection
- Coolant Temperature Warning Light Switch Removal
- Coolant Temperature Warning Light Switch Installation
- Coolant Temperature Warning Light Switch Inspection
- Coolant Filter Cleaning
- Coolant Valve Inspection
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
- Camshaft Chain Tensioner Installation
- Rocker Case Removal
- Rocker Case Installation
- Rocker Arm Removal
- Rocker Arm Installation
- Rocker Arm Inspection
- Rocker Shaft Diameter Measurement
- Camshaft Removal
- Camshaft Installation
- Camshaft Assembly
- Cam Wear
- Camshaft Bearing Wear
- KACR Inspection
- KACR Removal
- KACR Installation
- Camshaft Chain Removal
- Camshaft Chain Installation
- Cylinder Compression Measurement
- Cylinder Head Removal
- Cylinder Head Installation
- Cylinder Head Cleaning
- Cylinder Head Warp
- 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 Removal
- Piston Removal
- Cylinder, Piston Installation
- Cylinder Wear
- Piston Wear
- Piston/Cylinder Clearance
- Piston Ring, Piston Ring Groove Wear
- Piston Ring Groove Width
- Piston Ring Thickness
- Piston Ring End Gap
- This vehicle is equipped with a spark arrester approved for off-
- Spark Arrester Cleaning
- Muffler and Exhaust Pipe Removal
- Muffler and Exhaust Pipe Installation
- Exhaust System Inspection
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
- Torque Converter Cover Removal
- Torque Converter Cover Installation
- Converter Exhaust Duct Removal
- Converter Exhaust Duct Installation
- Converter Intake Duct Removal
- Converter Intake Duct Installation
- Drive Belt Removal
- Drive Belt Installation
- Drive Belt Inspection
- Drive Belt Deflection Inspection
- Drive Belt Deflection Adjustment
- Drive Pulley Removal
- Drive Pulley Disassembly
- Drive Pulley Inspection
- Spider Shoe Side Clearance Adjustment
- Drive Pulley Assembly
- Drive Pulley Installation
- Driven Pulley Removal
- Driven Pulley Disassembly
- Driven Pulley Inspection
- Driven Pulley Assembly
- Driven Pulley Installation
- Specifications
Engine Lubrication System
- Oil Pressure Gauge, 10 kgf/cm : 57001 164
- Oil Pressure Gauge Adapter, PT 1/8 : 57001 1033
- Kawasaki Bond (Silicone Sealant) : 56019 120
- WARNING
- Oil Level Inspection
- Engine Oil Change
- Oil Filter Change
- Oil Screen Removal
- Oil Screen Cleaning
- Oil Pressure Measurement
- Oil Pressure Relief Valve Removal
- Oil Pressure Relief Valve Installation
- Oil Pressure Relief Valve Inspection
- Oil Pump Removal
- Oil Pump Installation
- Oil Pipe Removal
- Oil Pipe Installation
Engine Removal/Installation
- Engine Removal
- Engine Installation
Crankshaft / Transmission
- Outside Circlip Pliers : 57001 144
- Bearing Driver Set : 57001 1129
- Crankcase Disassembly
- Crankcase Assembly
- Crankshaft Removal
- Crankshaft Installation
- Connecting Rod Removal
- Connecting Rod Installation
- Crankshaft/Connecting Rod Cleaning
- Connecting Rod Bend
- Connecting Rod Twist
- Connecting Rod Big End Side Clearance
- Connecting Rod Big End Bearing/Crankpin Wear
- Crankshaft Runout
- Crankshaft Main Bearing/Journal Wear
- Shift Lever Removal
- Shift Lever Installation
- Shift Control Cables Removal
- Shift Control Cables Installation
- Reverse Lock Cable Removal
- Reverse Lock Cable Installation
- Transmission Removal
- Transmission Installation
- Shift Fork Bending
- Shift Fork/Gear and Shifter Groove Wear
- Transmission and Shift Mechanism Inspection
- Ball and Needle Bearing Replacement
- Ball and Needle Bearing Wear
- Oil Seal Inspection
Wheels / Tires
- Jack : 57001 1238
- Toe-in is the amount that the front wheels are closer together i
- Toe-in Inspection
- Toe-in Adjustment
- Wheel Removal
- Wheel Installation
- Wheel (Rim) Inspection
- Wheel (Rim) Replacement
- Tire Removal
- Tire Installation
- Tire Inspection
- Front Hub Removal
- Front Hub Installation
- Front Hub Disassembly/Assembly
- Rear Hub Removal
- Rear Hub Installation
- Rear Hub Disassembly/Assembly
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
- Propeller Shaft Installation
- Propeller Shaft Joint Boot Inspection
- Propeller Shaft Inspection
- Rear Axle Removal
- Rear Axle Installation
- Ball Bearing Wear
- Rear Axle Runout Inspection
- Final Gear Case Oil Level Inspection
- Final Gear Case Oil Change
- Final Gear Case Removal
- Final Gear Case Installation
- Final Gear Case Disassembly
- Final Gear Case Assembly
- Oil Seal Installation
- Final Bevel Gear Adjustment
- Final Gear Case (Backlash-related Parts)
- Ball or Needle Bearing Inspection
- Oil Seal Inspection
Brakes
- Inside Circlip Pliers : 57001 143
- WARNING
- Brake Fluid Recommendation
- Brake Fluid Level Inspection
- Brake Fluid Change
- Brake Line Air Bleeding
- Master Cylinder Removal
- Master Cylinder Installation
- Master Cylinder Disassembly
- Master Cylinder Assembly
- Master Cylinder Inspection (Visual Inspection)
- Caliper Removal
- Caliper Installation
- Caliper Disassembly
- Caliper Assembly
- Piston and Cylinder Damage
- Caliper Holder Shaft Wear Inspection
- Brake Pad Removal
- Brake Pad Installation
- Brake Pad Wear Inspection
- Disc Cleaning
- Disc Removal
- Disc Installation
- Disc Wear
- Disc Runout
- Brake Hose Inspection
- Brake Hose Replacement
- 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
- Internal Wet Brake Assembly
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
- Front Shock Absorber Preload Adjustment
- Front Shock Absorber Removal
- Front Shock Absorber Installation
- Rear Shock Absorber:
- Suspension Arm Removal
- Suspension Arm Installation
- Suspension Arm Disassembly
- Suspension Arm Assembly
- Swingarm Removal
- Swingarm Installation
- Swingarm Disassembly
- Swingarm Assembly
- Swingarm Bearing Inspection
- Swingarm Bearing Lubrication
Steering
- Steering Stem Removal
- Steering Stem Installation
- Knuckle Removal
- Knuckle Installation
- Tie-Rod Removal
- Tie-Rod Installation
- Tie-Rod End Removal
- Tie-Rod End Installation
- Steering Inspection
- Steering Stem Straightness
- Steering Lubrication
- Steering Stem Clamp Inspection
- Steering Stem Bearing Inspection
- Steering Knuckle Bearing Inspection
- Tie-Rod End and Steering Knuckle Joint Inspection
- Handlebar Removal
- Handlebar Installation
Frame
- Seat Removal
- Seat Installation
- Front Fender Removal
- Front Fender Installation
- Rear Fender Removal
- Rear Fender Installation
- Side Inner Cover Removal
- Side Inner Cover Installation
- Air Cleaner Cover Removal
- Air Cleaner Cover Installation
- Radiator Cover Removal
- Front Guard Removal
- Front Guards Installation
- Engine Bottom Guard Removal
- Engine Bottom Guard Installation
- Rear Bottom Guard Removal
- Rear Bottom Guard Installation
- Foot Guard and Stay Removal
- Foot Guard and Stay Installation
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
- Battery Installation
- Electrolyte Filling
- Initial Charge
- Precautions
- Interchange
- Alternator Cover Removal
- Alternator Cover Installation
- Alternator Rotor Removal
- Alternator Rotor Installation
- Alternator Stator Removal
- Alternator Stator Installation
- Regulator/Rectifier Output Voltage Inspection
- Alternator Inspection
- Regulator/Rectifier Inspection
- Charging System Circuit
- 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
- Starter Motor Installation
- Starter Motor Disassembly
- Starter Motor Assembly
- Commutator Cleaning/Inspection
- Armature Inspection
- Starter Motor Brush Length
- Brush Assembly Inspection
- Brush Plate and Terminal Bolt Inspection
- Starter Relay Inspection
- Starter Circuit Relay Inspection
- Electric Starter Circuit
- Headlight Beam Vertical Adjustment
- Headlight Bulb Replacement
- Taillight Bulb Replacement
- Lighting System Circuit
- Radiator Fan Circuit Inspection
- Radiator Fan Motor Inspection
- Radiator Fan Circuit
- Fuel Pump Inspection
- Fuel Reserve Switch Inspection (1)
- Fuel Reserve Switch Inspection (2)
- Fuel Pump/Fuel Reserve Switch Circuit
- Indicator Unit Removal
- Indicator Unit Installation
- Indicator Unit Inspection
- Indicator Unit Circuit
- Brake Light Switch Adjustment
- Radiator Fan Switch Inspection
- Coolant Temperature Warning Light Switch Inspection
- Switch Inspection
- Neutral Switch Connection
- Reverse Switch Connections
- Oil Pressure Switch Connections*
- 30 A Main Fuse Removal
- Radiator Fan Fuse Removal
- Main Fuse Inspection
- Radiator Fan Fuse Inspection
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:

PARTS CATALOGUE