2008 Kawasaki Brute Force 650 4x4 Owners Manual

2008 Kawasaki Brute Force 650 4x4 Manual

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  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 1
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 2
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 3
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION BREAK-IN HOW TO RIDE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE j j j j j j j A Table of Contents is included after the Foreword.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 4
    not avoided, will result in death or serious injury. HOW TO AVOID THE DANGER Read all DANGERS in this manual carefully and for your safety be sure to follow their instructions. NOTICE NOTICE is used to address practices not related to personal injury. WARNING HAZARD Failure to heed WARNING. WHAT
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 5
    this manual carefully and completely before starting your new Kawasaki. It contains important safety information. Never operate an ATV without proper instruction. , the sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 6
    to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: żRead this manual and all labels carefully and follow the operating procedures described. żThe Owner's Manual should be kept in the waterproof plastic bag and stored in the storage case provided
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 7
    sharply to one side. Go straight down the hill where possible. żAlways follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around
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    tached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for may affect vehicle handling. Refer to the Loading Information chapter in this manual. żNever exceed the stated load capacity for an ATV. Cargo should be properly distributed
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 9
    and limitations. This manual offers many safe riding tips, but its purpose is not to provide instruction in all the trouble-free life for your ATV, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their ATVs, a Service Manual
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 10
    The illustrations in this Owner's Manual are based on the KVF650D. The KVF650E is a camouflage-surface -treated model and identical to the KVF650D, the base model, in every other aspect: controls,
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 11
    /4WD Shifting ...Variable Limited Slip Front Differential ...Braking ...Stopping the Engine ...Parking the ATV...Stopping the ATV in an Emergency...SAFE OPERATION ...Read the Owner's Manual...52 52 52 53 54 54 54 54 56 57 58 59 60 61 61 62 63 64 65 65 67 68 69 70 71
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 12
    Beam ...Battery ...Fuse ...Breaker...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...Preparation for Storage ...Removal from Storage ...TRANSPORTING THE ATV ...TROUBLESHOOTING GUIDE... 131 132 135 135 140 142 143 144 145 146 148 150 152 153 153 155 158 159 159 159 162 163
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    OWNER SATISFACTION...181 ENVIRONMENTAL PROTECTION ...182 MAINTENANCE RECORD ...183
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    12 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance Rear final gear case Center of frame Curb Mass ENGINE Type Displacement Bore x Stroke Compression Ratio Starting
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 15
    SPECIFICATIONS 13 Capacity Coolant Capacity DRIVE TRAIN Driving System: Primary Final Transmission Type Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio: Forward Reverse Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil: Type Capacity Rear Final Gear Case Oil: Type
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    14 SPECIFICATIONS Tire Size: Front Rear Rim Size: Front Rear Brake: Front Rear Parking Brake Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light AT25X8-12 Tubeless AT25X10-12 Tubeless 12 × 6.0 12 × 7.5 Disc Enclosed Wet Multi-Plate Enclosed Wet Multi-Plate 18 L (4.8 US gal) 12
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 17
    SERIAL NUMBER LOCATIONS 15 SERIAL NUMBER LOCATIONS The frame and engine serial numbers are used to register the vehicle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 18
    16 LOCATION OF LABELS LOCATION OF LABELS All warning labels which are on your ATV are repeated here. Read them and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your ATV. Therefore, it is very important that all
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 19
    LOCATION OF LABELS 17 6. Front Carrier Maximum Load 7. Rear Carrier Maximum Load 8. Passenger Warning 9. Tire Pressure & Maximum Loading Warning 10. Transmission Warning 16. Trailer Towing Warning
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    18 LOCATION OF LABELS 11. Vehicle Emission Control Information 12. Battery Danger/Poison (On the backside) 13. Important Air Cleaner Information 14. Shock Absorber Caution
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    LOCATION OF LABELS 19 (1) (2) (3)
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    20 LOCATION OF LABELS (4) (6) (7) (5) (KVF650D) (8) (5) (KVF650E)
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    LOCATION OF LABELS 21 (9) (11) (KVF650D) (10) (11) (KVF650E)
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    22 LOCATION OF LABELS (12)
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    LOCATION OF LABELS 23 (13) (15) (14) (16)
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    24 LOCATION OF PARTS LOCATION OF PARTS 1. Rear Brake Lever (Parking Brake) 2. Brake Lever Lock 3. Variable Front Differential Control Lever 4. Starter Button 5. Multifunction Meter 6. Front Brake Reservoir 7. Selectable 2WD/4WD Shift Switch 8. Front Brake Lever 9. Light/Dimmer Switch 10. Reverse
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 27
    LOCATION OF PARTS 25 16. Front Carrier 17. Shock Absorber 18. Front Cylinder Spark Plug 19. Air Cleaner 20. Battery 21. Fuses 22. Seat Latch 23. Rear Carrier 24. Headlights 25. Front Final Gear Case 26. Disc Brake Caliper 27. Oil Filler Plug 28. Coolant Reserve Tank 29. Rear Brake 30. Rear Final
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 28
    26 LOCATION OF PARTS 32. Tail/Brake Light 33. Storage Case/Tool Kit 34. Rear Cylinder Spark Plug 35. Carburetor 36. Shift Lever 37. Fuel Tank 38. Fuel Tank Filler Cap 39. Belt Drive Transmission (CVT) 40. Rear Brake Pedal 41. Fuel Tap 42. Radiator 43. Winch Installing Position
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    distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions provided in this section for carrying cargo or pulling a trailer. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 30
    28 LOADING INFORMATION żKawasaki Parts and Accessories have been spe- NOTE cially designed for use on Kawasaki vehicles. We strongly recommend that all parts and accessories you add to your vehicle be genuine Kawasaki components. • • • Because an all terrain vehicle is sensitive to increases in
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 31
    GENERAL INFORMATION 29 GENERAL INFORMATION Power Outlet Connector The power outlet connector is located under the left handlebar. The ignition switch also operates the power outlet circuit and this vehicle has an accessory fuse (10A) to protect this circuit. The connector has a cap. Remove it to
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 32
    30 GENERAL INFORMATION j Auxiliary Electrical Accessory Connector The auxiliary electrical accessory connector is located at the rear side under the rear fender. The connector has a cover. Remove it to connect an electrical accessory. A. Auxiliary Electrical Accessory Connector A. Connector Cover
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 33
    GENERAL INFORMATION 31 NOTICE Do not connect more than a 60 W load to the auxiliary electrical accessory terminals or the battery may become discharged. Always install a fuse rated 5 A or less in the auxiliary electric accessory circuit. The ATV has one fuse (30 A) to protect the electrical system.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 34
    32 GENERAL INFORMATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. "SET/RESET" Button Belt Check Indicator Light Neutral Indicator Light Reverse indicator Light Oil Pressure Warning Light "4WD" Indicator Light "2WD" Indicator Light Coolant Temperature Warning Symbol Fuel Level Gauge "TIME SET"
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    GENERAL INFORMATION 33 Speedometer: The speedometer shows the speed of the vehicle. j Fuel Level Gauge Symbol: The fuel in the fuel tank is shown in segments. All 7 segments are displayed when the fuel tank is full. As fuel is consumed the segments go out accordingly. The bottom segment begins
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 36
    34 GENERAL INFORMATION j NOTICE Do not let the engine continue running with a warning symbol flashing. Prolonged engine operation can result in engine damage from overheating. Clock: żWhen you touch the cooling fan, be sure to discon- NOTE nect the (-) cable of the battery, since the cooling
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 37
    GENERAL INFORMATION 35 żPushing the "SET/RESET" button momentarily ad- NOTE j vances the hour or minute step by step. Pushing and holding the button advances the hour or minute continuously. żThe clock works normally from the back-up power while the ignition switch is turned off. żWhen the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 38
    36 GENERAL INFORMATION Odometer: The odometer shows the total distance in miles that the vehicle has been ridden. The meter cannot be reset. j żThe data is maintained even if the battery is disconnected. żWhen the figures come to 99999, they turn back NOTE żThe data is maintained even if the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 39
    GENERAL INFORMATION 37 żThe data is maintained by the back-up power if the ignition switch is turned off. żWhen the trip meter is reset while the vehicle is NOTE j stopped, it starts counting as soon as the vehicle starts moving. żWhen the trip meter reaches 999.9 when the vehicle is running, it
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 40
    38 GENERAL INFORMATION 2WD/4WD Indicator Light: This ATV can be driven in either "2WD" or "4WD". When the selectable 2WD/4WD shift switch is in "4WD", the "4WD" indicator light will be lit and vice -versa. After shifting there is a momentary delay before the indicator lights change. Flashing 2WD/4WD
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 41
    GENERAL INFORMATION 39 Failure Parts and Failure Indication Patterns j A. B. C. D. Belt Check Indicator Light Neutral Indicator Light Reverse Indicator Light Oil Pressure Warning Symbol Neutral: When the transmission is in neutral, the neutral indicator light is lit. Reverse: When the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 42
    40 GENERAL INFORMATION Oil Pressure Warning Symbol: The "LED" (Light Emitting Diode) oil pressure symbol flashes to warn the operator whenever the oil pressure is dangerously low or the ignition key is in the "ON" position with the engine not running, and goes off when the engine oil pressure is
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 43
    GENERAL INFORMATION 41 j Brake Levers and Pedal The lever on the right side of the handlebar operates the front brake. A. Brake Lever (Parking Brake) B. Brake Lever Lock The foot pedal on the right side also operates the rear brake. A. Brake Lever The lever on the left side of the handlebar
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 44
    the front or rear brakes. Apply both front and rear brakes gradually. Refer to the HOW TO RIDE and SAFE OPERATION chapters for more instructions on braking. If you begin rolling backwards: Keep weight uphill. Never apply either front or rear brakes suddenly while rolling backwards. Apply both front
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 45
    GENERAL INFORMATION 43 (For "2WD") j WARNING HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use low gearing and maintain steady speed when climbing a hill. If you lose all forward speed:
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 46
    44 GENERAL INFORMATION j Brake Lever Lock (Parking Brake) If the brake lever lock is used, the rear brake lever can be used as a parking brake. To lock the brake lever, first pull in the brake lever. Then pull in the lock lever and while holding it against the brake lever, release the brake lever.
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    for each carrier. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo. Allow greater distance for braking. Always follow the instructions in your Owner's Manual for carrying cargo. Maximum Load Front Rear A. Front Carrier 40 kg (88 lb) 80 kg (176 lb)
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 48
    46 GENERAL INFORMATION j Fuel Tank Filling the Tank: Only use gasoline with the recommended octane rating (See next page.) Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. Never fill the tank completely to the top. As the fuel expands in
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 49
    : j A. Fuel Tank B. Filler Neck C. Top Level Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps in the U.S.A. The
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 50
    damage. Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under your warranty. NOTICE Avoid using blends
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    the fuel system. Before storage it is recommended that you drain all fuel from the fuel tank and carburetors. See the Storage section in this manual. j Fuel Tap The fuel tap is located under the seat. A. Fuel Tap B. "ON" position C. "PRI" position żThe tap is kept in the ON position all
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 52
    50 GENERAL INFORMATION carburetor is completely empty, turn the fuel tap from the "ON" to the "PRI" position. When the engine has started, turn the fuel tap to "ON". j Ignition Switch The ignition switch is located on the right front fender. It is a 2-position, key-operated switch. The key can be
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 53
    GENERAL INFORMATION 51 j Write your key number here. A. Ignition Switch B. "ON" position C. "OFF" position Blank keys are available at your Kawasaki dealer. Ask your dealer to make any additional spare keys you may need, using your original key as a master, or using the key code on the tag with
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 54
    Assist Switch only if additional power is needed. Starter Button: Refer to the "Starting the Engine" section of the "How to Ride" chapter for starting instructions. Engine Stop Switch: In addition to the ignition switch, the engine stop switch must be in the "RUN" position for the engine
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 55
    GENERAL INFORMATION 53 To start the engine, push the starter button with the front or rear brake applied in any shift position. j Choke Lever The choke lever on the left handlebar provides a rich mixture for cold starting conditions. Pull the choke lever all the way to the left to start the engine.
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    54 GENERAL INFORMATION j Shift Lever This vehicle is equipped with a sub-transmission and a reverse gear. The shift lever is located at the right side of the engine and it has four positions: "H" (High), "L" (Low), "N" (Neutral), and "R" (Reverse). To shift into high range, stop the vehicle
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 57
    GENERAL INFORMATION 55 WARNING HAZARD Shifting into "H" (High) or "L" (Low) or "R" (Reverse) while moving. WHAT CAN HAPPEN Shifting the transmission while the vehicle is moving can cause abrupt changes in speed and direction resulting in loss of control and accident with severe personal injury or
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 58
    56 GENERAL INFORMATION j Variable Front Differential Control Lever This vehicle is equipped with a variable limited slip differential (LSD) for the front wheels. The differential control lever is located on the left side of the handlebar. When one front wheel loses traction, it can slip reducing
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 59
    GENERAL INFORMATION 57 Selectable 2WD/4WD Shift Switch You can select "2WD" or "4WD" to suit various riding conditions. To shift, first stop the vehicle completely, then press the electrically selectable 2WD/4WD shift switch up or down. The switch is located on the right handlebar switch housing.
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    58 GENERAL INFORMATION j Throttle Lever The throttle lever is located on the right side of the handlebar. Pushing the lever forward increases engine speed. When released, spring pressure returns the lever to the rear. Always check that the throttle lever returns normally before starting the engine.
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    maximum engine power. j WARNING HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased in the course and the operating techniques described in the Owner's Manual. For more information about the training course, contact an authorized
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 62
    60 GENERAL INFORMATION j NOTICE If the throttle limiter is adjusted, verify the changes in throttle in an open, non-traffic area. Never try to adjust the limiter by racing the engine in neutral or in gear with brake on, or the engine may be damaged. Seat To remove the seat, pull the latch lever
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 63
    GENERAL INFORMATION 61 j Storage Case The storage case is located under the seat. Keep this Owner's Manual in the storage case. Here is where you will find a tool kit. Keep only light items in this storage case. To open the case lid,
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 64
    62 GENERAL INFORMATION j Trailer Hitch Bracket A trailer hitch bracket is fitted at the rear final gear case. To avoid injury and property damage, observe the following precautions while towing a trailer: WARNING HAZARD Improperly attaching and loading a trailer. Overloading a trailer. WHAT CAN
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 65
    vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Do not operate or install winch without reading and understanding the operator's manual supplied with the winch. A. Winch-installing position
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    engine while the transmission is in neutral. żIt is important to perform the initial service after the first 10 hours (100 km, 60 mi) of operation as described in this manual and the service manual for this vehicle. See the Periodic Maintenance Chart in the MAINTENANCE AND ADJUSTMENT chapter. NOTE
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    . If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition. DANGER HAZARD Running the engine without ventilation. WHAT CAN HAPPEN
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 68
    66 HOW TO RIDE Fuel ...Engine Oil ...Coolant ...Tires ...Enough fuel in tank, no leaks. Oil level between "H" (High) and "L" (Low) lines, no leaks. Coolant level between level lines (when engine is cold), no leaks. Air Pressure (when cold): Front: 28 kPa (0.28 kgf/cm², 4 psi) Rear: 35 kPa (0.35 kgf/
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 69
    HOW TO RIDE 67 Starting the Engine the engine is cold (same as outside temper• When ature), pull the choke lever all the way to the left. Keep the throttle completely closed. DANGER HAZARD Running the engine without ventilation. WHAT CAN HAPPEN Breathing exhaust gas leads to carbon monoxide
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    68 HOW TO RIDE żIf the starter does not turn, the battery will be al- j most fully discharged. It is possible to start with the recoil starter. żUsing the recoil starter with the battery disconnected will cause the belt failure detection system to activate. Once activated it must be reset by a
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 71
    HOW TO RIDE 69 Shifting Gears the vehicle completely. • Stop Move the shift lever into the "H" (High) or "L" (Low) • position. you intend to operate the vehicle in reverse, • If move the shift lever into the "R" (Reverse) posi- WARNING HAZARD Shifting into "H" (High) or "L" (Low) or "R" (Reverse)
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    70 HOW TO RIDE 2WD/4WD Shifting the vehicle completely. • Stop Press • down. the selectable 2WD/4WD shift switch up or WARNING HAZARD Changing from "2WD" to "4WD" or from "4WD" to "2WD" while the ATV is moving. WHAT CAN HAPPEN The handling characteristics of this ATV differ between "2WD" and "4WD"
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 73
    HOW TO RIDE 71 Variable Limited Slip Front Differential WARNING HAZARD Increasing limited slip differential (LSD) traction while turning or before entering a turn. WHAT CAN HAPPEN Pulling the front differential control lever can reduce steering response, increasing the effort to turn. An
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 74
    72 HOW TO RIDE Braking the throttle completely. • Close Under most conditions stop by pulling in the front • brake lever and pressing down the rear brake stop while riding in reverse, close the throttle • To and gradually apply the brakes. Sudden application of the rear brake or the front brake (
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    HOW TO RIDE 73 (For "4WD") WARNING HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use low gearing and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight
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    74 HOW TO RIDE (For "2WD") WARNING HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use low gearing and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 77
    HOW TO RIDE 75 Parking the ATV parking inside a garage or other structure, be • If sure it is well ventilated and the vehicle is not close to any source of flame or sparks; this includes any appliance with a pilot light. • Stop the vehicle on a level surface. WARNING HAZARD Parking on a steep
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    . Improper maintenance can create a dangerous situation known as throttle failure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust to enter the carburetor and stick the throttle open. 2. During removal of the air cleaner
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    ride there without the express written permission of the owner. Always try to preserve nature and the environment. Read the Owner's Manual Read and understand this Owner's Manual, and carry it with you when you ride. This is especially important for younger riders and beginners. Refer to this Owner
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    to reach to put their feet on the footboards and their hands on the handlebars. Study this manual with your child to be sure he or she fully understands all of the special safety instructions. WARNING HAZARD Failure to follow the age recommendations for this ATV. Failure to supervise children 16
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    are designed for off-road use only. WARNING HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the and the operating techniques described in the Owner's Manual. For more information about the training course, contact an authorized ATV
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    80 SAFE OPERATION Off-Road Use Only This vehicle is designed for off-road use only. Operation on public streets, roads, and highways is not recommended and is not safe. ATV tires are not designed to operate on paved or concrete surfaces. The tires will not slip as necessary which may seriously
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    SAFE OPERATION 81 Dress Properly Always wear an approved helmet, eye protection, and protective clothing. The proper clothing can make riding more comfortable and reduce the chance of injury If you take a spill. Long pants will also protect your legs from the hot exhaust system. j
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    82 SAFE OPERATION WARNING HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating
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    SAFE OPERATION 83 WARNING HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Passengers affect balance and steering and increase risk of losing control. Carrying a passenger could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a
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    84 SAFE OPERATION WARNING HAZARD Attempting wheelies, stunts. jumps, and other Never Drink and Drive Alcohol and drugs impair your judgement and slow your reactions. Even drugs prescribed by a physician can be dangerous. Check with your doctor. WHAT CAN HAPPEN Increases the chance of an accident,
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    SAFE OPERATION 85 Keep Your Feet on the Footboards and Hands on the Handlebars Always ride with your feet on the footboards. If your feet touch the ground while you are moving, you could be injured. It is possible to have the rear wheel run over your foot. If you have a lot of motorcycle experience
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 88
    86 SAFE OPERATION Before Starting the Engine Three "musts" before starting the engine are: 1) Set the parking brake, 2) Put the transmission in neutral, Use the Parking Brake Always apply the parking brake before getting off your vehicle. If it should roll, it might be damaged or cause injury. j
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    affect the handling of your ATV. See the Loading Information chapter of this manual for more detailed information. Kawasaki does not recommend that you modify your ATV in this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. j
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    88 SAFE OPERATION Loading Your ATV Never ride with passengers on the carrier. This vehicle is not designed for carrying passengers on the carriers. Make sure all cargo is securely attached. Don't carry heavy or bulky items that exceed the cargo maximum load capacity. Also, don't overload your ATV.
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    vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Do not operate or install winch without reading and understanding the operators manual supplied with the winch. j
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    90 SAFE OPERATION Refer to the instructions in the Loading Information chapter of this manual. Overloading this ATV or carrying or towing cargo improperly will adversely affect vehicle handling and could cause an accident. Perform the Daily Safety Checks Refer
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    to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. Tire Air Pressure This vehicle is equipped with low pressure tires. Tire inflation and type can affect the vehicle's handling characteristics
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    an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this vehicle. Always maintain proper tire pressure as described in the Owner's Manual. Riding Terrain Before riding in a new area be sure to check for hidden obstacles or hazards. Keep your
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    ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner's Manual. j
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 96
    94 SAFE OPERATION WARNING HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 97
    SAFE OPERATION 95 To stop while riding in reverse, close the throttle and gradually apply the brakes. Sudden application of the rear brake or the front brake (For "4WD") can cause the front end of the vehicle to lift off the ground. To shift out of reverse, first stop vehicle completely. Then move
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 98
    96 SAFE OPERATION Riding in "4WD" "4WD" gives greater traction when you are climbing steep inclines, or driving on bumpy, sandy or slippery surfaces. If maximum torque is needed in these situations, shift into the low position with the shift lever. Refer to the "Shift Lever" section and "2WD/4WD
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 99
    SAFE OPERATION 97 Remember: żUse "4WD" on steep inclines or loose surfaces, or when stuck in the mud. żFor maximum torque shift into low range. żDo not drive in "4WD" on paved surfaces. żUse the variable front differential control lever to increase traction. Turning the Vehicle The new rider must
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 100
    98 SAFE OPERATION seat and shifting body weight onto the outside footboard, helps the rear wheels turn easier and improve front wheel steering. WARNING HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 101
    loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 102
    100 SAFE OPERATION Don't attempt to climb hills that are too steep for the ATV or for your abilities. When climbing a hill, lean forward to keep the front wheels from lifting. On steeper hills you may need to stand and lean forward for even more weight transfer. The front wheels must be kept on the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 103
    TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this manual on level ground. Be very careful when turning on any hill. This ATV is equipped with the electrically selectable 2WD/4WD. When driving in "4WD
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 104
    brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 105
    SAFE OPERATION 103 Remember: żSome hills are too steep. Use common sense. żNever ride past your limit of visibility. If you can't see what is on the other side of the crest of a hill, slow down until you can get a clear view. żUse low gearing. żDon't let the vehicle roll backward. If it does, avoid
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 106
    THE HAZARD Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. j
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 107
    loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this manual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 108
    106 SAFE OPERATION Normally you should descend straight down a hill, since riding at an angle could cause the vehicle to lean to one side and possibly tip over. Select low gearing before beginning your descent. Sit back on the seat and brace yourself by straightening your arms. Hold your speed down
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 109
    SAFE OPERATION 107 Sliding and Skidding On slippery or loose surfaces, special care is required. Sliding may be hazardous because the wheels may suddenly regain traction and cause the vehicle to tip or overturn and have an accident. Therefore, never ride "over your head" when you are unprepared for
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 110
    108 SAFE OPERATION żDon't ride on public streets, roads, or highways. Riding in Water Choose a location to enter and exit the water where the banks are not too steep or slippery. Check the water before entering for rocks, holes or other obstacles which may cause you to overturn or become stuck or
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 111
    SAFE OPERATION 109 WARNING HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 112
    110 SAFE OPERATION If the water inside transmission is not drained, drain the water in accordance with following procedures. Loosen the air duct clamps to remove the air duct. the bolts to remove the belt drive trans• Loosen mission cover. • Wipe the water off with a clean, lint-free towel. • j
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 113
    SAFE OPERATION 111 Remember: żDon't ride in fast flowing water. żStay out of water deeper than the lower end of the axle cap. żDry out the brakes. żCheck the air cleaner for water. żCheck the engine and gear case oils for water. j Wash the vehicle in fresh water if it is exposed to salt water or
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 114
    112 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Periodic Maintenance Chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 115
    repair recommendations specified in the appropriate Kawasaki Service Manual. Refer to MAINTENANCE AND ADJUSTMENT chapter for make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record for
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 116
    read your Kawasaki Limited Emission Control Systems Warranty delivered with this Owner's Manual carefully and keep it valid by complying with the owner's obligations it contains. To obtain warranty service, the Kawasaki Limited Emission Control Systems Warranty requires that you return your vehicle
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 117
    MAINTENANCE AND ADJUSTMENT 115 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits 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
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 118
    more frequently when operated in mud, dust, or other harsh riding conditions, or when carrying heavy loads or pulling a trailer. FREQUENCY First Service Regular Service Every 90 days of vehicle use, 1,700 km (1 100 Every ml), or when year Belt indicator of light turns on use (100 hours of use
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 119
    mi) of use Every 10 days or 200 km (120 mi) of use Every 30 days or 600 km (360 mi) of use Air cleaner-service* Throttle lever play-inspect Choke lever play-inspect Valve clearance-inspect* Idle speed-inspect Fuel system cleanliness-inspect* Engine oil-change* Oil filter-replace* Spark
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 120
    118 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 90 days of vehicle use, 1,700 km (1 100 Every ml), or when year Belt indicator of light turns on use (100 hours of use)
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 FREQUENCY First Service Regular Service Every 90 days of vehicle use, 1,700 km (1 100 Every ml), or when year Belt indicator of light turns on use (100 hours of use)
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 122
    120 MAINTENANCE AND ADJUSTMENT Engine Oil In order for the engine and transmission to function properly, maintain the engine oil at the proper level, and change the oil and replace the oil filter in accordance with the Periodic Maintenance Chart. Not only do dirt and metal particles collect in the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 123
    MAINTENANCE AND ADJUSTMENT 121 the plug and check the oil level. The • Unscrew oil level should be between the "H" (High) and "L" (Low) lines on the dipstick. WARNING HAZARD Engine or transmission seizure. WHAT CAN HAPPEN Can lock the front and rear wheels (For "2WD": rear wheels) causing an
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 124
    122 MAINTENANCE AND ADJUSTMENT the oil filter is to be replaced, remove the oil filter • If cartridge and replace it with a new one. j A. Drain Plug the oil completely drain with the vehicle on • Let level ground. A. Cartridge WARNING HAZARD Improper disposal of used motor oil. WHAT CAN HAPPEN
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 125
    MAINTENANCE AND ADJUSTMENT 123 Engine Oil Grade: Viscosity: Capacity: API SG, SH, SJ, SL, or SM with JASO MA, MA1 or MA2 SAE 10W-40 1.54 L (1.63 US qt) [when filter is not removed] 1.75 L (1.85 US qt) [when filter is removed] 2.05 L (2.17 US qt) [when engine is completely dry] j A. Gasket •
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 126
    124 MAINTENANCE AND ADJUSTMENT Front and Rear Final Gear Case Oil In order for the differential, pinion, and ring gears to function properly, check the oil level and change the oil in accordance with the Periodic Maintenance Chart. WARNING HAZARD Operating this vehicle with insufficient,
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 127
    MAINTENANCE AND ADJUSTMENT 125 Oil Level Inspection the vehicle level front-to-rear and side-to • With -side, remove the filler caps from the front and rear final gear cases. j A. Rear Final Gear Case B. Filler Cap NOTICE A. Front Final Gear Case B. Filler Cap Be careful not to allow any dirt
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 128
    126 MAINTENANCE AND ADJUSTMENT j A. Front Final Gear Case B. Filler Opening C. Bottom Thread A. Rear Final Gear Case B. Filler Opening C. Bottom Thread • Install each filler cap. żFront and rear final gear cases use different types NOTE of oils. Use the specified type and brand of oil in each
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 129
    MAINTENANCE AND ADJUSTMENT 127 the vehicle level, place an oil pan beneath • With each gear case. • Remove each filler cap and drain plug j A. Rear Final Gear Case B. Drain Plug A. Drain Plug WARNING HAZARD Improper disposal of used gear case oil. WHAT CAN HAPPEN Used gear case oil is a toxic
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 130
    128 MAINTENANCE AND ADJUSTMENT the oil has completely drained out, install the • After drain plugs and gaskets. Replace the damaged gaskets with new ones. Tightening Torque Front Final Gear 15 N·m (1.5 kgf·m, 11 ft·lb) Case Rear Final Gear Case 20 N·m (2.0 kgf·m, 15.0 ft·lb) Front Final Gear Case
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 131
    MAINTENANCE AND ADJUSTMENT 129 NOTICE The front and rear final gear cases require different oils. To ensure correct performance and durability, use only the recommended oils. •The front final gear case uses engine oil; the same oil you use in the engine. The front gear case contains the variable
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 132
    130 MAINTENANCE AND ADJUSTMENT Coolant: Coolant absorbs heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer damage. Check the coolant level each day before operating the vehicle, and replenish coolant if the level is
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 133
    MAINTENANCE AND ADJUSTMENT 131 żIn an emergency you can add water alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible. żA permanent type of antifreeze is installed in the cooling system when
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 134
    132 MAINTENANCE AND ADJUSTMENT Spark Plug The standard spark plug is shown in the table. The spark plugs should be taken out in accordance with the Periodic Maintenance Chart for cleaning, inspection, and resetting of the plug gap. Maintenance If the plugs are oily or have carbon build up on them,
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 135
    MAINTENANCE AND ADJUSTMENT 133 Spark Plug Removal Front Cylinder Carefully pull the spark plug cap from the spark plug. • j Spark Plug Standard Plug Plug Gap Tightening Torque NGK CR7E, DENSO U22ESR-N 0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.) 11 ∼ 15 N·m (1.1 ∼ 1.5 kgf·m, 8.1 ∼ 11 ft·lb) A. Spark Plug Cap
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 136
    134 MAINTENANCE AND ADJUSTMENT Rear Cylinder Remove the rubber air duct of belt drive transmission. • j A. Spark Plug Cap A. Rubber Air Duct B. Clamps C. Screws pull the spark plug cap from the spark • Carefully plug. • Unscrew the spark plug. Spark Plug Fitting the plugs into the plug holes. •
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 137
    and stick the throttle open. This could cause an accident. HOW TO AVOID THE HAZARD Clean the air cleaner regularly and according to the instructions in this section. j NOTICE A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possibly engine damage. The
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 138
    136 MAINTENANCE AND ADJUSTMENT Element Cleaning the knobs and remove the air cleaner upper • Turn cover. j A. Air Cleaner Housing Cap B. Snaps A. Air Cleaner Upper Cover B. Knobs the air cleaner element up and take it out of • Pull the air cleaner housing. up the snaps and remove the air cleaner
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 139
    MAINTENANCE AND ADJUSTMENT 137 WARNING HAZARD Dirt or dust allowed into the carburetor. WHAT CAN HAPPEN Can cause the throttle to stick open. This could cause an accident. HOW TO AVOID THE HAZARD Be sure to cover the air cleaner opening to the carburetor after removing the element. Clean the air
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 140
    138 MAINTENANCE AND ADJUSTMENT WARNING HAZARD Cleaning the air cleaner element with gasoline or low flash-point solvent. WHAT CAN HAPPEN Gasoline or low flash-point solvents are extremely flammable and can be explosive under certain conditions. A fire or explosion can cause severe injury or death.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 141
    MAINTENANCE AND ADJUSTMENT 139 then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element. Remove the towel from the inlet tract. Install the element in the air cleaner housing to avoid the edges of the element from turning over. Clamp the air cleaner housing
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 142
    140 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. Spark Arrester
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 143
    MAINTENANCE AND ADJUSTMENT 141 an open area away from combustible materials, • In start the engine with the transmission in neutral. DANGER HAZARD Running the engine without ventilation. WHAT CAN HAPPEN Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. Exhaust gases
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 144
    142 MAINTENANCE AND ADJUSTMENT Throttle Cable There must be free play in the throttle mechanism. Measure the distance the throttle lever moves before the engine begins to pick up speed. Free play should be 2 ∼ 3 mm (0.08 ∼ 0.12 in.). j A. Adjuster B. Locknut If the free play cannot be set by
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 145
    MAINTENANCE AND ADJUSTMENT 143 Carburetor Carburetor adjustment is done with the idle adjusting screw. Adjustment WARNING HAZARD Hot engine and exhaust pipe. WHAT CAN HAPPEN Can burn your hands. HOW TO AVOID THE HAZARD Never touch a hot engine or an exhaust pipe during carburetor adjustment. the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 146
    144 MAINTENANCE AND ADJUSTMENT WARNING HAZARD Failure to maintain the control cable. WHAT CAN HAPPEN Can result in control malfunction and an accident. Without proper maintenance the cable can become frayed, kinked, pinched, and damaged so that it can break or jam. HOW TO AVOID THE HAZARD Be sure
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 147
    MAINTENANCE AND ADJUSTMENT 145 out the drain screws a few turns to drain the • Turn carburetor, and check to see if water or dirt has accumulated in the carburetor. The fuel tank vent hoses must be routed as specified. The engine may stall or lose power if the fuel tank vent is plugged or if the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 148
    146 MAINTENANCE AND ADJUSTMENT Choke Lever Pulling the choke lever to the left makes the carburetor provide a richer mixture for easy starting when the engine is cold. If starting difficulty or richer fuel mixture occurred, inspect the choke lever to adjust it if necessary. Inspection if the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 149
    MAINTENANCE AND ADJUSTMENT 147 j A. Handlebar Cover B. Screws A. Choke Cable B. Locknut C. Adjuster the locknut at the middle of choke cable. • Loosen the adjuster until the cable has the proper • Turn amount of play. • Tighten the locknut after adjustment.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 150
    148 MAINTENANCE AND ADJUSTMENT Variable Differential Control Lever By pulling the control lever toward the handlebar, the driving force of the front wheels equalizes providing more traction. If the differential control lever has excessive play, adjust the differential control cable. Inspection
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 151
    MAINTENANCE AND ADJUSTMENT 149 j A. Handlebar Cover B. Screws A. Differential Control Cable B. Cable Locknut C. Adjuster the locknut at the middle of the differential • Loosen control cable. the adjuster until the cable has the proper • Turn amount of play. • Tighten the locknut after adjustment.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 152
    150 MAINTENANCE AND ADJUSTMENT Belt Drive Transmission (CVT) The vehicle is equipped with a belt-driven Continuously Variable Transmission (CVT). This automatic drive system, although simple to operate, does require periodic inspection since the drive belt wears with normal use. Inspection should
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 153
    MAINTENANCE AND ADJUSTMENT 151 Causes of accelerated Belt Wear Avoid these hard usage conditions to obtain maximum belt life and prevent accelerated belt wear and deterioration. Operating the vehicle in high range while climbing hills, carrying heavy loads, or pulling a trailer. Exceeding maximum
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 154
    152 MAINTENANCE AND ADJUSTMENT High Altitude Use The original belt drive transmission settings for this vehicle are best for sea level use. When the vehicle is used at high altitude the engine performance will decrease. This is why readjustment of both weights and spring preload of transmission are
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 155
    MAINTENANCE AND ADJUSTMENT 153 Brakes Front Brake: Disc and brake pad wear is automatically compensated for and has no effect on the brake lever action. There are no parts that require adjustment on the front brake. WARNING HAZARD Air in brake line. WHAT CAN HAPPEN Can make the brake feel mushy or
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 156
    154 MAINTENANCE AND ADJUSTMENT WARNING HAZARD Contaminated brake fluid. WHAT CAN HAPPEN Can reduce braking performance or cause brake failure, resulting in an accident. HOW TO AVOID THE HAZARD Do not use brake fluid from a container that has been left open or that has been unsealed for a long time.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 157
    MAINTENANCE AND ADJUSTMENT 155 Maintenance Chart. Replacement should be done by an authorized Kawasaki Dealer. Brake Pedal Position Adjustment from the top center of the brake pedal • Measure in its rest position to the upper surface of the right footboard. The brake pedal should be 60 ∼ 65 mm
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 158
    156 MAINTENANCE AND ADJUSTMENT WARNING HAZARD Incorrect adjustment of the brake pedal and/or brake lever free play. WHAT CAN HAPPEN Can cause brake damage or malfunction and result in an accident. HOW TO AVOID THE HAZARD Always maintain proper pedal and/or lever free play. A. Adjusting Bolt B.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 159
    MAINTENANCE AND ADJUSTMENT 157 j A. Brake Lever Adjuster B. Brake Pedal Adjuster A. 1 ∼ 2 mm (0.04 ∼ 0.08 in.) B. Locknut C. Adjuster Brake Lever Free Play Adjustment the locknut and turn the adjuster at the • Loosen brake lever in as far as it will go. the locknut. • Tighten Turn the adjuster at
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 160
    158 MAINTENANCE AND ADJUSTMENT Brake Light Switch Only the switch at the rear brake pedal can be adjusted. When the brake pedal is depressed, the brake light goes on. The brake light switch should be inspected in accordance with the Periodic Maintenance Chart. The brake light switches of the front
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 161
    MAINTENANCE AND ADJUSTMENT 159 Wheels Rims: The rims are a drop-center, tubeless tire design. Take care not to damage the sealing surfaces of the tire or rim when removing or installing tires. Note that the rims, like automotive rims, are not symmetrical and should be installed in one direction
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 162
    rims requires compressed air and is normally recommended as a dealer service operation. However, a tube can be inserted into the tire by tires specified in the Owner's Manual for this vehicle. Always maintain proper tire pressure as described in this Owner's Manual. Maximum Tire Air Pressure for
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 163
    MAINTENANCE AND ADJUSTMENT 161 Tire Wear, Damage As tire tread wears down, tires become more susceptible to puncture and failure. In accordance with the Periodic Maintenance Chart, measure the depth of the tread with a depth gauge, and replace any tire that has worn down to the minimum allowable
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 164
    rod ends (4 pieces), steering knuckles (2 pieces), and propeller shaft (3 pieces) for cracks, holes, damage or deterioration. If there is any indication of these troubles, have the joint boot replaced by an authorized Kawasaki dealer. To inspect the boots at the engine, remove the left engine cover
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 165
    MAINTENANCE AND ADJUSTMENT 163 Suspension The rear shock absorber can be adjusted by changing the spring preload for various riding and loading conditions. If the spring action feels too soft or too stiff, have it adjusted by an authorized Kawasaki dealer. j A. Boot A. Rear Shock Absorber B.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 166
    sealed type, and the sealing strip should not be removed at any time after the specified electrolyte has been installed in the battery for initial service. It is not necessary to check the battery electrolyte level or add distilled water. However, in order to maximize battery life and ensure that it
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 167
    MAINTENANCE AND ADJUSTMENT 165 periods of time, the battery is more likely to discharge. Due to their internal composition, batteries continually self discharge. The discharge rate depends on the type of battery and ambient temperature. As temperatures rise, so does the discharge rate. Every 15°C (
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 168
    166 MAINTENANCE AND ADJUSTMENT Current Drain (Y50-N18L-A) Days from 100% DischargCharged to 50% ing Ampere Discharged 7 mA 10 mA 15 mA 20 mA 30 mA 60 Days 42 Days 28 Days 21 Days 14 Days Days from 100 % Charged to 100 % Discharged 119 Days 83 Days 56 Days 42 Days 28 Days Battery Maintenance It is
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 169
    properly. żIf you charge the sealed battery, never fail to observe the instructions shown on the label on the battery. NOTE j A. B. C. D. parts that contain lead and lead compounds WHAT CAN HAPPEN Could cause health problem. HOW TO AVOID THE HAZARD Wash hands after handling battery. the cables
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 170
    168 MAINTENANCE AND ADJUSTMENT the battery in place. • Put Securely connect the cable with protective cap to • the (+) terminal, and then securely connect the Fuse The main fuse and the fuse for the POWER OUTLET are located under the seat, and the spare fuses next to them. If the electrical systems
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 171
    MAINTENANCE AND ADJUSTMENT 169 Breaker The breaker for the radiator fan is located under the seat near the fuse case. If the fan does not function, inspect the breaker. In order to reset the breaker, push the button at the side of the breaker case. Before resetting, however, check that the radiator
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 172
    170 MAINTENANCE AND ADJUSTMENT General Lubrication Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions, and especially after using a high-pressure spray
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 173
    MAINTENANCE AND ADJUSTMENT 171 Cleaning For the prolonged life of your vehicle, wash it down immediately after it has been splashed with seawater or exposed to the sea breeze, or operated on rainy days, rough terrain, or in dusty areas. Preparations for Washing Before washing, these precautions
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 174
    Bolt and Nut Tightening Every day before riding, check the tightness of the nuts and bolts listed here. Please refer to the Service Manual or ask your authorized dealer for the torque values. j 1. Front Carrier Mounting Bolts 2. Brake Lever Pivot Nut 3. Brake Lever Holder Screws 4. Variable
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 175
    MAINTENANCE AND ADJUSTMENT 173 j 12. 13. 14. 15. Throttle Case Screws Brake Master Cylinder Clamp Bolts Brake Lever Pivot Nut Exhaust Pipe Holder Nuts
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 176
    174 STORAGE STORAGE Preparation for Storage the entire vehicle thoroughly. • Clean Run the for about five minutes to warm the • oil, shut engine it off and drain the engine oil. left in for a long time, the fuel will break down and could clog the carburetor.) Close the drain screw when finished.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 177
    STORAGE 175 WARNING HAZARD Improper disposal of gasoline. WHAT CAN HAPPEN Gasoline is a toxic substance, which can pollute the environment. HOW TO AVOID THE HAZARD Contact your local authorities for approved disposal methods and follow those methods at all times. the spark plug and spray fogging
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 178
    176 STORAGE NOTICE Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged a battery becomes, the more easily it freezes. a plastic bag over the muffler to prevent mois• Tie ture from entering. a cover over the
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 179
    TRANSPORTING THE ATV 177 TRANSPORTING THE ATV Note the following points for transporting the vehicle. Turn the fuel tap to the "OFF"position. Drain the carburetor float bowls by loosening the drain screws. Hold a suitable container under the drain hose to catch the fuel. Tighten the screws when
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 180
    178 TRANSPORTING THE ATV WARNING HAZARD Transporting this ATV tipped up on its rear end. WHAT CAN HAPPEN Can cause gasoline to leak from the fuel tank causing a fire hazard. HOW TO AVOID THE HAZARD Never tip this vehicle up on end for transporting.
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 181
    TROUBLESHOOTING GUIDE 179 TROUBLESHOOTING GUIDE Starter Motor Not Rotating Engine stop switch "OFF" Fuse failed Battery leads do not make good electrical contact with battery terminals. Battery discharged Engine Cranks,
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 182
    180 TROUBLESHOOTING GUIDE filter clogged or inlet blocked • Air Spark dirty or worn • Chokeplug left on • Engine oil incorrect • in fuel • Water Drive belt slipping • Water in belt
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 183
    receipt of your correspondence we will contact the dealership and work with them in resolving your problem. In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence. Please send your correspondence to:. CONSUMER RELATIONS KAWASAKI
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 184
    182 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION To protect our environment, properly discard used tire, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 185
    MAINTENANCE RECORD 183 MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Traveled Distance Maintenance Performed
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 186
    184 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 187
    MAINTENANCE RECORD 185 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 188
    186 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 189
    MAINTENANCE RECORD 187 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki Brute Force 650 4x4 | Owners Manual - Page 190
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