This is the Kawasaki factory service manual for the 2008 Teryx 750 4x4 recreation utility vehicle, publication 99924-1397-01, running to 575 pages. It is written for trained mechanics but carries enough detail for owners who service their own machine.
The manual covers the full vehicle: general information and periodic maintenance, the fuel and cooling systems, engine top end, the CVT converter system, engine lubrication, engine removal, crankshaft and transmission, wheels and tires, final drive, brakes, suspension, steering, frame, the electrical system, and a troubleshooting appendix.
With this PDF you can set spark plug gap and idle speed, measure and replace the CVT drive belt, torque wheel nuts and pulley bolts, bleed the brakes, test the charging system, and work through the appendix to trace hard starting, overheating, or converter faults. Torque values and service limits are listed throughout.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 7-17 | 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, Instrument) |
| Periodic Maintenance | 18-69 | Scheduled Maintenance Must Be Done in Accordance with This C, Following Tables List the Tightening Torque for the Major Fa, Inside Circlip Pliers: |
| Fuel System | 70-103 | Fuel Level Gauge: |
| Cooling System | 104-122 | Permanent Type Antifreeze Is Used As a Coolant to Protect the Co, Bearing Driver Set: |
| Engine Top End | 123-169 | Inside Circlip Pliers:, Camshaft Chain Tensioner Removal (Camshaft Chain Tensioner Installation) |
| Converter System | 170-196 | Outside Circlip Pliers: |
| Engine Lubrication System | 197-210 | 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 | 211-216 | Engine Removal (Engine Installation) |
| Crankshaft/Transmission | 217-245 | Outside Circlip Pliers:, Crankcase Disassembly (Crankcase Assembly) |
| Wheels/Tires | 246-260 | Rotor Puller, M16/M18/M20/M22 × 1.5:, Toe-In Is the Amount That the Front Wheels Are Closer Together I (Toe-In Adjustment) |
| Final Drive | 261-353 | Dummy Page, Bearing Puller: |
| Brakes | 354-374 | Warning (Front Brake Fluid Recommendation, Front Brake Fluid Level Inspection, Front Brake Fluid Change, Brake Line Air Bleeding) |
| Suspension | 375-395 | Inside Circlip Pliers: |
| Steering | 396-408 | Outside Circlip Pliers: |
| Frame | 409-459 | Seat Removal (Installation, Disassembly, Assembly, Belt Removal, Belt Installation) |
| Electrical System | 460-532 | Ignition Switch [a], Bearing Driver Set:, There Are a Number of Important Precautions That Should Be Taken |
| Appendix | 533-575 | 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 System Malfunction:, Battery Discharged:, Battery Overcharged:) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Wheel Nuts Torque | 137.3 N·m (14 kgf·m, 101 ft·lb) | p. 50 |
| Converter Cover Bolts Torque | 8.8 N·m (0.90 kgf·m, 78 in·lb) | p. 23 |
| Drive Belt Width Standard | 30.0 ∼ 30.6 mm (1.181 ∼ 1.205 in.) | p. 29 |
| Drive Belt Width Service Limit | 28.3 mm (1.114 in.) | p. 29 |
| Battery Type | Sealed Battery | p. 471 |
| Battery Capacity (CA Model) | 12 V 12 Ah | p. 471 |
| Spark Plug Gap Standard | 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) | p. 29 |
| Spark Plugs Torque | 13 N·m (1.3 kgf·m, 113 in·lb) | p. 468 |
| Air Cleaner Element Oil | High-quality foam air filter oil | p. 29 |
| Air Cleaner Mounting Bolts Torque | 8.8 N·m (0.90 kgf·m, 78 in·lb) | p. 22 |
| Pad Lining Thickness Standard | 3.9 mm (0.15 in.) | p. 30 |
| Pad Lining Thickness Service Limit | 1 mm (0.04 in.) | p. 30 |
