Segment:
Mid-size utility ATV, known for its balance of power, 4x4 capability, and rider comfort.
Target Audience:
Recreational riders, utility users, farmers, hunters, and individuals seeking reliable off-road transportation.
Key Competitors:
Polaris Sportsman 500/700, Yamaha Grizzly 660, Arctic Cat 650 H1.
Engine Configuration:
V-twin, liquid-cooled engine providing strong torque and power delivery.
Drivetrain:
Selectable 2WD/4WD with limited-slip front differential, providing excellent traction in varied terrain.
Suspension:
Independent suspension on all four wheels for a smoother ride and improved handling over rough ground.
Braking System:
Powerful dual front disc brakes and a sealed rear drum brake (or disc depending on specific sub-model) for reliable stopping power.
Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012
Variants Covered:
4x4i (4-wheel drive with independent suspension)
Estimated Pages:
Refer to actual manual for precise count; typically 300-500+ pages for a comprehensive factory service manual.
Type:
Factory Service Repair Workshop Manual
Engine:
Complete engine overhaul, tuning, diagnostics, fuel injection system, cooling system, lubrication system.
Transmission:
Automatic transmission (CVT), clutch operation, gearshift mechanism, differential, 4WD system.
Chassis:
Frame, suspension (front and rear independent), steering system, wheels, tires.
Brakes:
Hydraulic disc brakes (front and rear), brake system maintenance, bleeding, component replacement.
Electrical:
Wiring diagrams, battery, charging system (alternator/stator), ignition system, lighting, starting system, sensors, ECU.
Bodywork:
Plastic body panels, seat, handlebars, rack systems, fairings (if applicable), fenders.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body, EFI control.
Exhaust System:
Exhaust pipes, muffler, catalytic converter (if applicable).
Maintenance:
Routine maintenance tasks, fluid changes, filter replacements, spark plug service, lubrication points.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Diagnostics:
Engine diagnostic codes (DTCs), electrical system testing, component testing procedures.
Rebuilds:
Detailed instructions for complete engine and transmission rebuilds.
Adjustments:
Carburetor/throttle body synchronization, valve clearance adjustments, brake adjustments.
Depth:
Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Tools:
Information on necessary special tools, diagnostic equipment, and measurement specifications.
Torque Specifications:
Precise torque values for all critical fasteners and components.
Illustrations:
Detailed diagrams, exploded views, and step-by-step photographs for clarity.
Specifications Tables:
Extensive tables of specifications, tolerances, and performance data.
Engine Type:
4-stroke, V-twin, SOHC, 4 valves per cylinder
Displacement:
633 cc (38.6 cu. in.)
Bore X Stroke:
72.0 x 77.0 mm (2.83 x 3.03 in.)
Cooling System:
Liquid-cooled
Horsepower Est:
Approximately 48-50 HP (Varies by tuning and regulatory compliance)
Torque Est:
Approximately 38-40 lb-ft (Varies by tuning and regulatory compliance)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Fuel Tank Capacity:
4.1 US gallons (15.5 L)
Ignition System:
Digital CDI with electronic advance
Spark Plug Type:
NGK CR7E (example, verify with manual)
Oil Type:
SAE 10W-40 API SG or higher (verify with manual for specific viscosity and API rating)
Oil Capacity:
Approximately 2.4 US quarts (2.3 L) with filter change (verify with manual)
Type:
Automatic (CVT - Continuously Variable Transmission) with engine braking
Drive Modes:
2WD / 4WD (selectable)
Differential:
Front: Limited-slip, Rear: Locked
Gear Selection:
High, Low, Neutral, Reverse, Park
Transmission Fluid Type:
Kawasaki ATV Genuine Grease (verify with manual for specific part number and type)
Length:
Approx. 82.1 in. (2085 mm)
Width:
Approx. 46.7 in. (1185 mm)
Height:
Approx. 49.4 in. (1255 mm)
Wheelbase:
Approx. 50.4 in. (1280 mm)
Ground Clearance:
Approx. 8.7 in. (220 mm)
Dry Weight:
Approx. 575 lbs (261 kg)
Curb Weight:
Varies by model year, typically around 600-620 lbs (272-281 kg)
Front Rack Capacity:
Approx. 88 lbs (40 kg)
Rear Rack Capacity:
Approx. 176 lbs (80 kg)
Towing Capacity:
Approx. 1,250 lbs (567 kg)
Front Tire Size:
AT25x8-12 (examples: 25x8R-12)
Rear Tire Size:
AT25x10-12 (examples: 25x10R-12)
Wheel Bolt Pattern:
4x110 mm
Atv Safety Standards:
Complies with ANSI standards for recreational off-highway vehicles.
Braking System:
Dual hydraulic front disc brakes, sealed rear drum or disc brake, engine braking provided by CVT.
Traction Control:
Automatic front differential lock enhances traction in challenging conditions.
Lighting:
Dual 30W headlights, 8W taillight/brake light for visibility.
Chassis Design:
Robust frame construction and independent suspension contribute to stability and handling.
Ergonomics:
Comfortable seating and intuitive controls designed for rider control and reduced fatigue.
Display:
Digital instrument cluster featuring speedometer, odometer, trip meter, fuel gauge, 2WD/4WD indicator, engine hour meter, and clock.
Braking Assistance:
Engine braking via CVT assists in downhill control.
Accessory Power:
Typically includes a DC power outlet for charging accessories.
Oil Change Interval:
Every 100 hours or 6 months, whichever comes first (verify with manual).
Air Filter Cleaning:
Every 50 hours or 3 months, clean and re-oil (verify with manual).
Spark Plug Replacement:
Every 200 hours or 1 year (verify with manual).
Valve Clearance Check:
Every 200 hours or 1 year (verify with manual).
Brake Fluid Change:
Every 12 months (verify with manual).
Engine Oil:
SAE 10W-40 API SG or higher
Coolant:
Kawasaki Motorcycle Antifreeze (or equivalent ethylene glycol-based coolant with corrosion inhibitor) - 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (verify with manual).
Transmission Gear Oil:
Kawasaki ATV Genuine Grease (or specific recommended grease for final drive and gearbox).
Common Wear Items:
Brake pads, wheel bearings, tie rod ends, CV boots, drive belts (CVT).
Potential Fuel System Issues:
Clogged fuel injectors or fuel pump issues can occur with contaminated fuel or lack of regular use.
Electrical Connections:
Corrosion on electrical connectors, especially in wet environments, can lead to intermittent issues.
Manufacturer History:
Kawasaki Heavy Industries (KHI) has a long history of producing robust and reliable powersports vehicles, including a strong legacy in ATVs.
Brute Force Lineage:
The Brute Force line succeeded earlier Kawasaki ATV models, evolving to incorporate more advanced features like V-twin engines and fuel injection.
650 Engine Development:
The 650cc V-twin engine was a significant step, offering increased power and torque compared to its predecessors, making it competitive in the utility ATV market.
Production Period:
The Brute Force 650 4x4i was a popular model within the 2006-2012 timeframe, with minor updates and variations across these years.
