Kawasaki Teryx Owner's manual

Quick Reference Guide

GENERAL INFORMATION j

BREAK-IN j

HOW TO OPERATE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

This Quick Reference Guide will assist you in

finding the in

formation you’re looking for.

A Table of Contents is included after the

Foreword.

Whenever you see the symbols shown below,

heed their instructions! Always follow safe operat-

ing and maintenance

practices.

DANGER

DANGER indicates a hazardous situation

which, if not avoided, will result in death or

serious injury.

WARNING

WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

NOTICE

NOTICE is used to

address practices not re-

lated to personal injury.

NOTE

○

NOTE indicates information that may help or guide

you in the opera

tion or service o f the vehicle.

WARNING

Engine exhaust, some of its constituents,

and certain vehicle components contain or

emit chemicals known to the State of Cali-

fornia to cause cancer and birth defects or

other reproductive harm.

BASIC SAFE DRIVING

Knowing and following these rules f or s afe oper-

ation will increase your satisfac tio n with your new

Kawasaki vehicle.

Read the Ow ner’s M

anual

Read and understand this Owner’s Manual. This

is especially important for inexperienced operators.

Keep this Owner’

s Manual with this vehicle and refer

to it if you have any questions.

Obey Local Laws

Know and obey all laws and regulations govern-

ing the use of off

-highway vehicles in your area. Re-

spect private property. Always try to preserve nature

and the environment.

Maximum Seating Capacity

Do not exceed sea

ting capacity: 2 occupants.

Occupants shall only ride in designated seating

positions and with only one pe rson in e ach s eat.

Do not carry smal

l children o n lap.

Occupant Capaci

ty

Make sure operators are 16 years or older with a

valid driver ’s license.

Each occupant m u

st be able to sit with back

against seat, feet flat on floor, and hands on steer-

ing w heel, handgrip or handhold.

The operator sh

ould be tall enough to wear the

seat belt properly and reach all controls.

Passenger(s) should also be tall enough for the

seat belt to fit properly and to be able to brace them-

selves, as necessary, by placing both feet firmly on

the floor while gripping the handhold. Stay com-

pletely inside the vehicle.

Off-Highway Use Only

This vehicle is not an all-terrain vehicle; it is de-

signed and equipped to be a multiuse u tility vehicle

for off-highway use only. Use of this vehicle on pub-

lic roads and paved surfaces is hazardous. Do not

operate this vehicle o n public roads or paved sur-

faces.

Dress Properly

Proper clothing can reduc e the severity of injury in

the event of an accident.

Always wear appropriate eye protection, protec-

tive clothing, and properly fitting D.O.T. approved

helmet.

Wearing Seat Belts

Both the operator and passenger(s) should al-

ways wear their seat belts properly. Seat belts

cannot c ompletely protect you in every accident,

but in many cases a seat belt can reduce the risk

of serious injury. Also, to avoid injury, do not put

any part of your body outside of the vehicle for any

reason.

Close the Doors

Be sure all doors are securely closed during oper-

ation and ne ver rem ov

e a door.

The doors prevent branches, gravel, and debris

from getting inside the passe nger compartment.

Drive Carefully and w ith Good Judgement

Wewantyoutobesatis

fied with your new

Kawasaki vehicle, so drive carefully, safely, and ex-

ercise good judgement. Practice basic maneuvers

so you can drive c onf

idently and safely.

Improper use of this vehicle can be hazardous.

Never operate at sp ee ds too fast for your skills or

conditions. Handli

ng characteristics of this vehicle

change depending upon cargo load and driving

modes.

Never D rink and Drive

Alcohol and drugs i

mpair your judgement and slow

your reactions. Even drugs prescribed by a physi-

cian can be dangerous. Check with your doctor.

Before Starting the Engine

Three “musts” befo

re starting the engine are:

1. Apply the parkin g brake,

2. Put the shift lever in the “N” (neutral) position,

3. Check the t hro ttle pedal for prope r o p erat ion. It

should return to its rest position when released.

Use the Parking Brake

Always apply parking brake before exiting your ve-

hicle.

Modifications and Accessories

Installation of accessories may affect the handling

of your vehicle. See t

he “LOADING INFORMATION”

chapter o f this manual for more detailed information.

Kawasaki does not recommend that you modify your

vehicleinanyway.U

nauthorized modifications may

produce dangerous handling conditions or adversely

affect veh icle reliability.

Perform the Daily Checks

Refer to the Daily C

hecks section for a list of items

to check each day before use. Habitual performance

of these checks will help to insure safer, more re-

liable usage. Be su

re that any irregularities found

during these checks are corrected before operating

the vehicle.

Tire Air Pressure

Tire inflation an

d type can affect the vehicle’s han-

dling characteristics. Check the tire pressure fre-

quently. Use only the recommended tires for re-

placement.

Refueling

Before refueling the vehicle, shut the engine off

and make sure the area is well ventilated and free

of an y source of f

lame or sparks. Gasoline is very

flammable.

EMISSION CONTROL I NFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust

emission (2), and evaporative emission (3) control systems in compliance with applicable regulations of the

United States Environmental Protections Agency and C alifornia Air Resources Board.

1. Crankcase Emiss

ion Control System

A sealed-type crankcase emission control system is used to eliminate blow-by gases. The b low-by gases

are led to the breather chamber through the crankcase. Then, it is led to the air intake chamber.

Oil is separated fr

om the gases while passing through the inside of the breather chamber from the crankcase,

and then returned back to the bottom of the crankcase.

2. Exhaust Emission Control System

The exhaust emission control system applied to this engine family is engine modifications that consist of a

fuel injection and

ignition system having optimum ignition timing characteristics.

The fuel injection has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel econ-

omy with a suitable air cleaner and exhaust system.

A maintenance free

ignition system provides the most favorable ignition timing and helps maintain a thor-

ough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the

atmosphere.

3. Evaporative Emission Control System

The evaporative em

ission control system for this vehicle consists of low permeation fuel hoses and a fuel

tank.

Maintenance and Warranty

Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels. This

Owner ’s Manual conta

ins those maintenance recommendations for your vehicle. Those items identified by the

Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards.

As the owner of this vehicle, you have the responsibility to make sure that the recommended maintenance is

carried out accordi

ng to the instructions in this Owner’s Manual at your own expense.

You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have pro-

vided space at the end of this manual where an authorized Kawasaki dealer, or someone equally competent,

can record the maint

enance. You should also retain co pie s of maintenance work orders, bills, etc ., as verifica -

tion of this maintenance.

Tampering with Emission Control System Prohibited

Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by

any person other tha

n 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 render

ed inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

Do not tamper with the original emission related parts:

•

Throttle body and internal parts

•

Spark plugs

•

Magneto or elec

tronic battery ignition system

•

Fuel filter/Fuel injector/Fuel pump

•

Air cleaner element

•

Electronic C

ontrol Unit (ECU)

PLEASE DO NOT TAMPER WITH N OISE CONTROL SYSTEM

To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust

silencing systems. They are designed t o give optimum pe rformance while maintaining a low noise level. Please

do not remove

these systems, or alte r the m in any wa y which results in an inc rease in n oise le vel.

FOREWORD

Congratulations on you r purchase of a new Kawasaki Recre a tio n Utility Vehicle (RUV). It is the result of

Kawasaki’s engineering expertise and a tradition of manufacturing high-quality consumer products.

Please read this Owner ’s Manual carefully before starting your new Recreation Utility Vehicle (RUV) so

that you will be thoroughly familiar with th e proper operation of your ve hicle’s contro ls, its features, capabilities,

and limita tions.

To ensure a long, trouble–free life for your vehicle, give it the proper care and maintenance described in this

manual.

For those who would like more detailed information on their vehicle, a Service Manual is available for purchase

from any authorized Kawasaki dealer. The Service Manual contains detailed disassembly and maintenance

information. Those who plan to do their own work should, of course, be competent mechanics and possess

the special tools described in the Service Manual.

Keep this Owner ’s M anual aboard your vehicle at all times so that you can refer to it whenever you need

information.

This manual should be considered a permanent part of the vehicle and should remain with the vehicle when

it is sold.

This publication includes the latest information available at the time of printing. However, there may be minor

differences betwee n the actual prod uct and illustra tions and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

TABLE OF CONTENTS

SPECIFICATIONS.................................... ........ 12

SERIAL NUMBER LOCATIONS.. ............... ..... 16

LOCATION OF PARTS .................................... 17

LOCATION OF LABELS.. ............... ............... .. 20

LOADING INFORMATION............................... 30

GENERAL INFORMATION.............................. 32

Power Outlet Sockets

......................... ...........

32

Brake Pedal............. .............................. ........ 33

Cargo Bed .......................................... ........... 33

Tailgate: .......... ............... ............... .............. 33

Tailgate Remo v al:....................................... 34

Tailgate Installation:................... ................. 35

Cargo Bed: ................................... .............. 36

Multifunction Meter .. ............... ....................... 38

Speedometer:........................................... .. 39

Fuel Level Gauge S

ymbol: .................... .....

40

Clock: ......................................................... 40

Odometer: ..................... ............... .............. 41

Trip Meters A/B:

......................... .................

42

Hour Meter: ............. ............... .................... 42

2WD/4 WD/DIFF-LO CK Indicator:............... 43

Red Differenti

al Gear Lock Indicator Light:

44

Yellow Engine Warning Indicator Light: ...... 44

Red EPS Warning Indicator Light:.............. 44

Red Parking Br

ake Indicator Light:..... ........

44

Red Reverse Indicator Light:................. ..... 45

Green Neutra l Indica tor Light: ... ............... .. 45

Red Seat-Bel

t Us e Rem i nder: ............ ........

45

Red Coolant Temperature Warning

Indicator Light:...... ............... ............... ..... 45

Red Oil Pres

sure Warning Indicator Light: .

45

Fuel ..................................... .......................... 46

Glove Compartment ............ ............... ........... 48

Cupholders ................................... ............... .. 49

Compartm en t Side Cove

rs ............................

49

Storage Case ................................................ 50

Carrier Tray ................................................... 51

Ignition Switc h ............................................... 52

Keys ....................................... ....................... 53

Light Switch ............. ............... ....................... 54

Shift Lever ... .............................. ............... ..... 54

Selectable 2WD/4WD/DIFF-LOCK Shift

Switch............................ ............... .............. 55

Belt Drive Transmi

ssion................... ..............

57

Parking Brake Lever ........................ .............. 57

Doors............................. ............... ................. 58

Seats ............................................ ............... .. 59

Seat Be lts ..................................... ................. 61

Steering Whee l ....................... ....................... 63

Throttle Pedal ................................................ 63

Trailer Hitch Bracket ...................................... 64

Winch Installa tion .... ............... ............... ........ 65

BREAK-IN ...... .............................. ............... ..... 67

HOW TO OPERATE......................................... 68

Daily Checks ..... .............................. .............. 68

Starting the E

ngine............................. ...........

70

Jump Starting .......... ............... ....................... 71

Moving Off ............ .............................. ........... 73

Braking .......................... ............... ................. 73

Stopping the Engine ........................... ........... 74

Parking the Vehicle..... .............................. ..... 74

Shifting Ge

ars. ............... .............................. ..

76

2WD/4WD/Differential Shifting .............. ........ 77

When Stuck .......... ............... .......................... 79

Catalytic Converte

r........................................

79

SAFE OPERATION..................................... ..... 81

Read t he Owner’s Ma nual... ............... ........... 81

Obey Local Laws......................................... .. 81

Operator and Passenger Requirements........ 82

Beginning Operators ........ ............... .............. 83

Off-Highway Use O

nly ........... ............... ........

84

Dress Properly............ .............................. ..... 84

Closing Doors .......... ............... ....................... 85

Wearing Seat Bel

ts........................................

85

Drive Carefully and with Good Judgement.... 86

Never Drink and D rive ................................... 86

Before Startin

g the Engine ............................

87

Use the Par k ing Bra ke ........... ....................... 87

Modifications and Accessories ...................... 88

Loading Your R

UV................................. ........

88

Unfamiliar Terrain .......................................... 90

Driving in Re v erse ... ............... ............... ........ 90

Driving in “4W

D” ... .............................. ...........

91

Turning the Vehicle....................... ............... .. 91

Hills................................................................ 92

Climbing Hi

lls............................................... ..

92

Antenna Flag ......................................... ........ 93

Descending Hills............................................ 94

Traversing

Hillsides .......................................

95

Sliding a nd Skidding.................. .................... 95

Driving through Water.................................. .. 96

MAINTENAN

CE AND ADJUSTMENT .............

98

Periodic Mainten ance Chart ... ....................... 98

Engine Oil............................... ....................... 102

Front and

Rear Final Gear Case Oil..............

107

Cooling System ............................................. 112

Spark Plugs .. ............... ............... ................... 114

Valve Clearance ................... ............... .......... 115

Engine Air Cle aner ... ............... ............... ....... 116

Spark Arrester .......... ............... ............... ....... 120

Throttle Pedal ................................................ 123

Idle Adjustment............... .............................. . 124

Fuel Pump Filter .... .............................. .......... 124

Fuel Hose ..... ............... .............................. .... 125

Fuel Tank Vent............. ............... ................... 125

Belt Drive Transmission (CVT) ...................... 126

Brakes ............. .............................. ............... . 127

Brake Pedal:..................................... .......... 127

Front Brake:........ .............................. .......... 129

Rear Brake: ....................... ......................... 129

Brake Light Swi

tch.........................................

130

Steering Whee l ......... .............................. ....... 131

Power Ste erin g System (KRF800B /C/D).... 1 31

Wheels .................. ............... ......................... 132

Rims: ........................ .............................. .... 132

Wheel Nuts:.................... ............................ 132

Tires: ................................................... ....... 132

Joint B oots............................... ............... ....... 134

Suspension...... .............................. ............... . 135

Front Shock

Absorber: ............ ...................

135

Rear Shock Absorb er: ............................... . 137

Seat Be lts ...................................... ............... . 140

Headlight B

eam.............. ............... ................

141

Battery . ............... ............... ............................ 141

Fuse .................................................... .......... 145

Breaker........................... ............... ................ 147

General Lubric ation ................................ ....... 147

Cleaning ......................... .............................. . 148

Bolt and N

ut Tightening ........... ............... .......

149

STORAGE.................................................... .... 150

TROUBLESHOOTING GUIDE........... .............. 152

YOUR WARRANTY/OW NER SATISFACTION

.......................... .............................. .............. 154

ENVIRONMENTAL PROTECTION.................. 158

MAINTENANCE RECORD .............................. 159

12 SPECIFICATIONS

SPECIFICATIONS

PERFORMANCE

Maximum Torque

64 N·m (6.5 kgf·m, 47 ft·lb) at 5 500 r/min (rpm )

Minimum Turning Radius

5.1 m (16.7 ft)

DIMENSIONS

Overall Length: KRF800A/B/D 2 980 mm (117.32 in.)

KRF800C 3 125mm (123.03 in.)

Overall Width 1 565 mm (61.61 in.)

Overall Height: KRF800A/B 1 900 mm (74.80 in.)

KRF800C/D 1 950mm (76.77 in.)

Wheelbase

2 180 mm (85.83 in.)

Tread: Front

1 290 mm (50.79 in.)

Rear

1 275 mm (50.20 in.)

Ground Clearance 280 mm (11.0 in.)

Curb M a ss:

KRF800A

689kg(1519lb)

KRF800B

700kg(1544lb)

KRF800C 704 kg (1 552 lb)

KRF800D

707kg(1559lb)

Cargo Bed [L × W × H (Front/Rear)] 700 × 1 100 × 265/300 mm (27.56 × 43.31 × 10.43/11.81 in.)

ENGINE

Type

4-stroke, V2-cylinder, SOHC liquid-cooled

Displacement

783cm³(47.8cuin.)

SPECIFICATIONS 13

Bore × Stroke 85.0 × 69.0 mm (3. 35 × 2. 72 in.)

Compression Ratio

10.7 : 1

Starting System

Electric starter

Cylinder Nu m b ering Method

Front to rear, 1-2

Firing Order

1-2

Fuel System Fuel Injection (Mikuni

36 × 2)

Ignition System Battery and Coil (Transistorized Ignition)

Ignition Timing

7° BTDC at 1 270 r/min (rpm)

Spark Plug NGK CPR7EA-9

Lubrication System Forced lubrication (wet sump)

Engine Oil:

Type

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity

SAE 10W-40

Capacity 4.0 L (4.2 US qt)

Coolant Capacity 4.0 L (4.2 US qt)

DRIVE TRAIN

Clutch Type Wet, centrifugal

Driving Type: Primary

Belt drive torqu

e converter (CVT)

Final

Shaft 2WD/4WD

Transmission Type

2-speed & revers

e, Automatic

Primary Reduction Ratio 3.04 ∼ 0.78

Final Reduction Ratio: Front 4.375

Rear 4.400

14 SPECIFICATIONS

Overall Drive Ratio:

Forward

40.282 ∼ 10.336 (High)

68.209 ∼ 17.501 (Low)

Reverse 56.108 ∼ 14.396

Transmission Gear R

atio:

Forward

3.012 (High)

5.099 (Low)

Reverse 4.195

Front Final Gear Case Oil

Type

API GL-5 Hypoid gear oil, SAE 90 [above 5°C (41°F)]

SAE 80 [below 5°C (41°F)]

Capacity 0.92 L ( 0 .9 7 US qt)

Rear Final Gear Case O il

Type

Mobil Fluid 424, Citgo Transgard Tractor Hydraulic Fluid,

Exxon Hydraul 560

Capacity 0.88 L ( 0 .9 3 US qt)

FRAME

Type

Steel tube Double-X frame

Steering: KRF800B/C/D Assisted with Electric Power Steering (EPS) System

Caster 4.2°

Tire Size:

Front 26×9.00R12 Tubeless

Rear 26×11.00R12 Tubeless

Rim Size:

Front 12 × 6.0-AT

Rear 12 × 8.0-AT

Fuel Tank Capacit

y

30 L (7.9 US gal)

ELECTRICAL EQUI

PMENT

Battery 12 V 14 Ah

SPECIFICATIONS 15

Headlight:

KRF800A/B 12 V 35/35 W × 2

KRF800C/D

LED × 2

Tail/Brake Light 12 V 5/21 W × 2

LOAD CAPACITY

Maximum Vehicle Load (Including

occupants and cargo

)

503kg(1110lb)

Maximum Cargo Bed L

oad

272kg(600lb)

Maximum Storage Ca

se Load (Each)

18 kg (40 lb)

Seating Capacity

2 persons

Specifications are subject to change without notice.

16 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the vehicle. They are the only means of identifying

your particular mac hin e

from others of the same model type. These serial numbers may be needed by your

dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well

as the model type and any peculiar features of your machine that can help them identify it.

Frame No.

A. Frame Number

B. Front Axle Shaft

Engine No.

A. Engine Number

B. Exhaust Pipe

NOTE

○

Remove the engine

bottom guard under the en-

gine.

LOCATION OF PARTS 17

LOCATION OF PARTS

1. Front Shock Absorber

2. Headlight

3. Coolant Reserve Tank

4. Air Cleaner

5. Steering Wheel

6. ROPS (Roll Over Protective Structure)

7. Operator’s Seat

8. Operator’s Seat Belt

9. Cargo Bed Latch Handle

10. Cargo Bed

11. Brake Fluid Reservoir

12. D oor

13. Compartment Side Cover

14. S torage Case

15. Carrier Tray

16. Rear Shock Absorber

17. Tail/Brake Light

18 LOCATION OF PARTS

1. Passenger Seat Belt

2. Passenger Seat

3. Handgrips

4. Dashboard

5. Fuse Box/Breaker

6. Radiator

7. Trai ler Hitch Bracket

8. Muffler

9. Fuel Tank Cap

10. Belt Drive Torque Converter

11. Battery

LOCATION OF PARTS 19

1. Light Switch

2. Ignition Switch

3. Selec tab le 2WD/4WD/DIFF-LOCK Shift Switch

4. Shift Lever

5. Multifunction Meter

6. Power Outlet Socket (Front)

7. Glove Compartment

8. Cupholders

9. Parking Brake Lever

10. Throttle Pedal

11. Brake Pedal

12. P ower Outlet Socket (Rear)

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Kawasaki Teryx Owner's manual

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