This is the factory Kawasaki service manual for the 2005 Brute Force 750 4x4i and KVF 750 4x4 all terrain vehicle, publication number 99924-1334-02. It runs 531 pages and downloads as a PDF you can open on a phone, tablet, or shop computer.
The manual carries every system on the machine: periodic maintenance, the fuel system, cooling, the engine top end, the converter (CVT) drive, engine lubrication, crankshaft and transmission, final drive, brakes, suspension, steering, and the full electrical system with wiring. Procedures include specifications, service limits, and step by step teardown and reassembly.
With it you can diagnose a no start, set valve clearances, service the CVT, bleed the brakes, or trace a charging fault yourself instead of paying dealer labor. Print the pages you need or keep the whole file on hand for reference.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Toc | 1 | |
| Tables | 1-5 | List of Abbreviations |
| Emission Control Information | 6 | 1., 2. |
| Please Do Not Tamper with Noise Control System (Us Model Only) | 7 | |
| General Information | 10-21 | Before Starting to Perform an Inspection Service or Carry Out a (Battery Ground, Edges of Parts, Solvent, Cleaning Vehicle Before Disassembly, Arrangement and Cleaning of Removed Parts, Storage of Removed Parts, Replacement Parts, Assembly Order, Tightening Sequence, Tightening Torque, Force, Gasket, O-Ring, Liquid Gasket, Locking Agent, Press, Ball Bearing and Needle Bearing, Oil Seal, Grease Seal, Circlips, Cotter Pins, Lubrication, Direction of Engine Rotation, Electrical Wires) |
| Periodic Maintenance | 22-63 | Scheduled Maintenance Must Be Done in Accordance with This C, Following Tables List the Tightening Torque for the Major Fa, Oil Filter Wrench: |
| Fuel System | 64-99 | Fuel Level Gauge: |
| Cooling System | 100-119 | Permanent Type Antifreeze Is Used As a Coolant to Protect the Co, Bearing Driver Set: |
| Engine Top End | 120-165 | Outside Circlip Pliers:, Camshaft Chain Tensioner Removal (Camshaft Chain Tensioner Installation) |
| Converter System | 166-193 | Circlip Pliers: |
| Recoil Starter | 194-197 | Recoil Starter Removal (Installation, Inspection) |
| Engine Lubrication System | 198-209 | Oil Pressure Gauge, 10 kgf/cm :, Warning (Oil Level Inspection, Engine Oil Change, Oil Filter Change, Oil Screen Removal, Oil Screen Cleaning, Oil Pressure Measurement) |
| Engine Removal/Installation | 210-215 | Engine Removal (Engine Installation) |
| Crankshaft/Transmission | 216-243 | Outside Circlip Pliers:, Crankcase Disassembly (Crankcase Assembly) |
| Wheels/Tires | 244-259 | Jack:, Toe-In Is the Amount That the Front Wheels Are Closer Together I (Steering Centering Inspection, Steering Centering Adjustment, Toe-In Inspection, Toe-In Adjustment) |
| Final Drive | 260-333 | Blank Page, Bearing Puller: |
| Brakes | 334-357 | Inside Circlip Pliers:, Warning (Brake: Fluid Recommendation, Fluid Level Inspection, Fluid Change, Line Air Bleeding) |
| Suspension | 358-375 | Inside Circlip Pliers: |
| Steering | 376-391 | Inside Circlip Pliers: |
| Frame | 392-413 | Seat Removal (Seat Installation) |
| Electrical System | 414-503 | Light/Dimmer Switch [a], Timing Light:, There Are a Number of Important Precautions That Should Be Taken, Wiring Inspection (Special Tool -) |
| Appendix | Note (Engine Doesn't Start, Starting Difficulty:, Poor Running at Low Speed:, Poor Running or No Power at High Speed:, Overheating:, Over Cooling:, Converter Operation Faulty:, Gear Shifting Faulty:, Abnormal Engine Noise:, Abnormal Drive Train Noise:, Abnormal Frame Noise:, Exhaust Smokes Excessively:, Handling and/or Stability Unsatisfactory, Brake Doesn't Hold, Kawasaki Engine Brake Control and Selectable 2WD/4WD System Malf, Battery Discharged:, Battery Overcharged:) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Basic Torque for General Fasteners of Engine Parts (6 mm (0.24 in.) 9T bolt head) | 12 ~ 15 N·m (1.2 ~ 1.5 kgf·m, 104 ~ 130 in·lb) | p. 31 |
| Fuel Pump Mounting Nuts Torque | 7.8 N·m (0.80 kgf·m, 69 in·lb) | p. 68 |
| Fuel Pump Replacement Condition (damaged hose connection areas) | Replace the fuel pump | p. 97 |
| Battery Type | Sealed Battery | p. 425 |
| Battery Capacity | 12 V 12 Ah | p. 425 |
| Valve Clearance (Exhaust) | 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.) | p. 127 |
| Valve Clearance (Inlet) | 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) | p. 127 |
| Alternator Type | Three-phase AC | p. 425 |
| Charging Voltage (Regulator/Rectifier Output Voltage) | 14 ~ 15 V | p. 425 |
| Troubleshooting: Engine Doesn’t Start, Starting Difficulty: No fuel flow | Fuel pump damaged or circuit open/short | p. 505 |
| Overall Length | 2192 mm | p. 17 |
