Market Segment:
High-performance utility ATV (All-Terrain Vehicle).
Key Competitors:
Polaris Sportsman 6x6, Arctic Cat 650 H1, Yamaha Grizzly 660, Can-Am Outlander 650.
Distinguishing Features:
Kawasaki's V-twin engine technology, robust 4x4 system, independent rear suspension (IRS), and strong utility focus for hauling and towing.
Systems Covered:
Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Drivetrain (Transmission, Driveshafts, Differentials), Suspension (Front & Rear), Steering, Brakes, Electrical System (Wiring Diagrams, Lighting, Starting, Charging), Frame, Bodywork, Body Panels, Seat, Handlebars, Storage Compartments
Estimated Pages:
500-700 (typical for comprehensive ATV service manuals of this era)
Type:
Factory Service Manual / Repair Manual
Engine And Components:
Detailed disassembly, inspection, assembly, and troubleshooting of the 650cc V-twin engine, including valve timing, piston rings, cylinder head, crankshaft, connecting rods, and oil pump.
Fuel And Ignition:
Comprehensive coverage of the fuel injection system (EFI), throttle body, fuel pump, injectors, ECU, ignition coils, spark plugs, and timing.
Drivetrain And Transmission:
Detailed procedures for the automatic transmission, CVT (Continuously Variable Transmission) clutch system, high/low range gearbox, selectable 2WD/4WD system, front and rear differentials, driveshafts, and CV joints.
Suspension And Steering:
Front and rear independent suspension systems, shock absorbers, springs, control arms, ball joints, bushings, tie rods, steering column, and steering rack.
Brakes:
Front and rear brake caliper service, master cylinders, brake lines, brake fluid replacement, bleeding procedures, and parking brake adjustments.
Electrical System:
Complete wiring diagrams, troubleshooting guide for electrical issues, battery service, starter motor, alternator (stator), lighting system (headlights, taillights, brake lights), instrument panel, and safety switches.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug inspection/replacement, brake pad inspection, tire pressure checks, coolant checks and replacement, drive belt inspection, and general lubrication.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues, including starting problems, engine performance issues, transmission engagement issues, and electrical faults.
Major Repairs:
Complete engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls, and electrical component diagnostics/replacement.
Technical Specifications:
Torque specifications for all fasteners, clearance measurements, fluid capacities, electrical resistance values, and diagnostic trouble codes (DTCs).
Depth Of Coverage:
Comprehensive: Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed exploded views, diagrams, and diagnostic flowcharts.
Engine Type:
4-stroke, liquid-cooled, V-twin, SOHC, 4 valves per cylinder
Bore X Stroke:
76.0 x 70.0 mm
Horsepower:
Approx. 49 HP @ 6500 RPM (Varies by specific model year and tuning)
Torque:
Approx. 41.7 lb-ft @ 5500 RPM (Varies by specific model year and tuning)
Fuel Delivery:
Fuel Injection (EFI)
Throttle Body:
Dual 32mm throttle bodies
Oil Type Specification:
SAE 10W-40 API SG or higher (Refer to manual for precise specification and capacity)
Coolant Type Specification:
Ethylene glycol-based antifreeze with distilled water (50/50 mix) (Refer to manual for precise specification and capacity)
Overall Length:
Approx. 82.1 inches (2085 mm)
Overall Width:
Approx. 46.5 inches (1180 mm)
Overall Height:
Approx. 45.7 inches (1160 mm)
Wheelbase:
Approx. 50.6 inches (1285 mm)
Ground Clearance:
Approx. 9.1 inches (230 mm)
Curb Weight:
Approx. 653 lbs (296 kg) (Varies slightly by year and configuration)
Towing Capacity:
1250 lbs (567 kg)
Cargo Capacity Rack Front:
44 lbs (20 kg)
Cargo Capacity Rack Rear:
176 lbs (80 kg)
Front Tire Size:
AT25 x 8-12
Rear Tire Size:
AT25 x 10-12
Wheel Bolt Pattern:
5x114.3mm (5x4.5 inches)
Safety Ratings:
N/A (ATVs are not typically crash-tested by standard automotive safety organizations like NHTSA or IIHS. Safety is determined by design and operator responsibility.)
Braking System:
Hydraulic disc brakes, front and rear
Engine Braking:
Integrated engine braking via CVT system
Handlebars:
Ergonomic handlebars with thumb throttle and grip controls.
Lighting:
Dual Halogen 35W headlights, LED taillight/brake light.
Engine Oil Change:
Every 25 hours or 6 months (whichever comes first); More frequently under severe use (Refer to manual for exact intervals).
Air Filter Cleaning:
Every 25 hours or 6 months; clean more frequently in dusty conditions.
Spark Plug Inspection:
Every 100 hours or 1 year.
Brake Fluid Replacement:
Every 2 years or as needed.
Cv Belt Inspection:
Every 100 hours or 1 year.
Engine Oil Capacity:
Approx. 2.4 US qt (2.3 L) (Refer to manual for exact capacity with filter change).
Transmission Fluid Capacity:
Refer to manual for precise capacity and type.
Coolant Capacity:
Approx. 2.5 US qt (2.4 L) (Refer to manual for exact capacity).
Common Wear Items:
CVT belt wear, front and rear differential seals, ball joints, tie rod ends due to heavy use and off-road conditions.
Electrical Component Reliability:
While generally robust, older models may experience issues with charging systems (stator) or fuel pump reliability if not maintained.
Maintenance Schedule Guidance
Schedule Detail:
The manual provides a detailed maintenance schedule covering all intervals, critical checks, and fluid replacements necessary for optimal performance and longevity.
