Kawasaki KSV700A7F 2007 User manual

Category
Motorcycles
Type
User manual
KFX700
All Terrain Vehicle
Service Manual
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Referto the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
Quick Reference Guide
General Information 1
j
Periodic Maintenance 2
j
Fuel System 3
j
Cooling System 4
j
Engine Top End 5
j
Converter System 6
j
Engine Lubrication System 7
j
Engine Removal/Installation 8
j
Crankshaft/Transmission 9
j
Wheels/Tires 10
j
Final Drive 11
j
Brakes 12
j
Suspension 13
j
Steering 14
j
Frame 15
j
Electrical System 16
j
Appendix 17
j
KFX700
All Terrain 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/Consumer Products & Machinery
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.
© 2003 Kawasaki Heavy Industries, Ltd. 7th Edition (1) : Mar. 28, 2008 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pounds(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celcius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
Toprotecttheenvironment inwhich weall live, Kawasakihas incorporatedcrankcaseemission
(1) and exhaust emission (2) control systems in compliance with applicable regulations of the
United States Environmental Protection Agency and California Air Resources Board.
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
separatedfromthegaseswhilepassingthroughtheinsideofthebreatherchamberfromthecrankcase,
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 modified carburetor and an ignition system having optimum ignition timing characteristics.
The carburetor 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.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is com-
monly 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
titleprior to its sale and delivery to the ultimate purchaser,or for anymanufactureror 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 know-
ingly 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 follow-
ing its sale and delivery to the ultimate purchaser..."
NOTE
â—‹
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 de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components su
ch that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the vehicle.
c.Additionof componentsoraccessoriesthatresultinthevehicleexceedingthe stan-
dards.
d.Permanently removing, disconnect
ing, 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)
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:
•
Carburetor or internal parts
•
Spark Plug
•
Magneto ignition system
•
Air Cleaner element
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering
inoperativeby any person other than for purposes of maintenance, repair, orreplacement, of any
device or element of design incorporated into any new vehicle for the p
urpose of noise 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.
Among those acts presumed to constitute tampering are the acts listed below:
* Replacement of the original exhaust system or muffler with a compo
nent not in compliance
with Federal regulations.
* Removal of the muffler(s) or any internal portion of the muffler(s).
* Removal of the air box or air box cover.
* Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it containsenough detailand basic in-
formationtomake it usefulto the ownerwho de-
siresto performhisown basicmaintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
beforestartingwork, and then do thework ca
re-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurem
ents
can only be made if the proper instruments are
used, and the use of substitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in
accordance with
thisservicemanual. Anyowner maintenanceor
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 propertools and
genuineKawasaki Vehi-
cle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are i
ntroduced by the Service Man-
ual. Genuine parts provided as spare parts
are listed in the Parts Catalog.
•
Follow the p
rocedures in this manual care-
fully. Don’t take shortcuts.
•
Remembertokeepcompleterecordsofmain-
tenance a
nd 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 Ta-
ble of Contents.
For example, if you want ignition coil informa-
tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap-
ter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
additiontoWARNINGandCAUTION)whi
chwill
help you distinguish different types of informa-
tion.
NOTE
â—‹
This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
•
Indicates a procedural step or work to be
done.
â—‹
Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the te
xt of a NOTE.
Indicates a conditional step or what action to
takebasedon the resultsofthetestor inspec-
tion in the proced
ural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system com
ponents follows the Table of
Contents. In these illustrations you will find the
instructions indicatingwhich parts requirespec-
ified tighten
ing torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
1
General Information
Table of Contents
Before Servicing..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-9
Unit Conversion Table ............................................................................................................ 1-12
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly oper-
ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, 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 cables from the battery to prevent the engine
fromaccidentallyturningover. Disconnectthegroundcable
(–) first and then the positive (+). When completed with the
service, first connect the positive (+) cable to the positive
(+) terminal of the battery then the negative (–) cable 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
Useahighflushpointsol
vent 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
otherforeignmaterialsenteringintosealed areasduringve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
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.
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 ac-
cident. Visuallyinspect removed parts for corrosion, discol-
oration, 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 be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, 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 se-
quence 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 quar-
ter turn and them 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 disas
sembly and assembly,
excessiveforce can cause expensiveor hard to repair dam-
age. 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 per-
formance. 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
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
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
Donotremovepressedoilorgreasesealsunlessremoval
is necessary. Replace with new ones whenever removed.
Pressnew oilseals with manufactureand 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
Replacecirclipsorcotterpinsthatwereremovedwithnew
ones. Take care not to open the clip excessively when in-
stalling 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. Lubri-
cation 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. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Leads
A two-color lead is identifie
d first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
leads 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.
GENERAL INFORMATION 1-7
Model Identification
KSV700-A1 Left Side View
KSV700-A1 Right Side View
1-8 GENERAL INFORMATION
Model Identification
KSV700-B1LeftSideView
KSV700-B1 Right Side View
GENERAL INFORMATION 1-9
General Specifications
Items KSV700-A1 ∼ A2, A6F ∼/B1 ∼B2, B6F ∼/C6F
Dimensions
Overall Length 1 985 mm (78.15 in.)
Overall Width 1 195 mm (47.05 in.)
Overall Height 1 170 mm (46.06 in.)
Wheelbase 1 285 mm (50.60 in.)
Ground Clearance:
Rear Final Gear Case 160 mm (6.30 in.)
Center of Frame 245 mm (9.65 in.)
Seat Height 850 mm (33.46 in.)
Dry Mass (KSV700-A1 ∼ A8F/B1 ∼ B8F/C6F) 234 kg (516 lb)
Curb Mass: (KSV700A9F (US, AU)/B9F) 250 kg (551 lb)
(KSV700A9F (EUR)) 251 kg (553 lb)
Front 115 kg (254 lb)
(KSV700A9F (EUR)) 115.5 kg (255 lb)
Rear 135 kg (298 lb)
(KSV700A9F (EUR)) 135.5 kg (299 lb)
Fuel Tank Capacity 12 L (3.2 US gal)
Performance
Minimum Turning Radius 3.2 m (10.50 ft)
Engine
Type
4-stroke, SOHC, V2-cylinders
Cooling System
Liquid-cooled
Bore and Stroke 82.0 × 66.0 mm (3.23 × 2.60 in.)
Displacement 697 cm³ (42.5 cu in.)
Compression Ratio 9.9 : 1
Maximum Horsepower 36.3 kW (49.4 PS) @6 500 r/min (rpm), (US) -
Maximum Torque 59.2 N·m (6.04 kgf·m, 43.67 ft·lb) @5 000 r/min (rpm)
Carburetion System Carburetor, Keihin CVKR-D32
Starting System Electric Starter
Ignition System Digital DC-CDI
Timing Advance Electronically advanced
Ignition Timing From 5° BTDC @1 100 r/min (rpm) to 28° BTDC @5 000 r/min
(rpm)
Spark Plug NGK CR7E
Valve Timing:
Inlet
Open 20° BTDC
Close 44° ABDC
Duration 244°
Exhaust:
Open 44° BBDC
Close 20° ATDC
Duration 244°
Lubrication System Forced lubrication (wet sump)
1-10 GENERAL INFORMATION
General Specifications
Items KSV700-A1 ∼ A2, A6F ∼/B1 ∼B2, B6F ∼/C6F
Engine Oil:
Grade API SF or SG
API SH, or SJ with JASO MA, MA1 or MA2 (KSV700-A1 ∼ A6F/B1
∼ B6F/C6F)
API SH, SJ or SL with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 2.2L(2.33USqt)
Drive Train
Primary Reduction System:
Type Belt converter
Reduction Ratio 3.122 ∼ 0.635
Transmission:
Type 1-speed and reverse
Gear Ratios:
Forward: 2.416 (29/27 × 27/20 × 20/12)
Reverse 4.285 (16/12 × 20/14 × 27/20 × 20/12)
Final Drive System:
Type Shaft 2WD
Reduction Ratio 4.375 (35/8)
Overall Drive Ratio:
Forward: 32.999 ∼ 6.711
Reverse 58.527 ∼ 11.904
Final Gear Case Oil:
Type MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR
HYDRAULIC FLUID or EXXON HYDRAUL 560
Capacity 900 mL (0.95 US qt)
Frame
Type Double cradle, tubular steel
Caster (rake angle) 4.5°
Camber -0.5°
King Pin Angle 12.5°
Trail 20 mm (0.79 in.)
Tread:
Front 1 000 mm (39.37 in.)
Rear 900 mm (35.43 in.)
Rim Size:
Front 10 × 5.5
Rear 10 × 8.5
Front Tire:
Type Tubeless
Size AT22 X 7-10
Rear Tire:
Type Tubeless
Size AT22 X 11-10
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Kawasaki KSV700A7F 2007 User manual

Category
Motorcycles
Type
User manual

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