Target User:
Kawasaki Brute Force 650 4x4i ATV owners, independent repair shops, and service technicians.
Value Proposition:
Provides comprehensive, factory-level repair and maintenance information to save time and money on servicing.
Competitor Manuals:
This manual offers the depth and accuracy typically found in OEM (Original Equipment Manufacturer) service manuals, exceeding generic online guides.
Coverage Breadth:
Covers the entire lifespan of the model from 2006 to 2012, ensuring relevance for a broad range of vehicles.
Detail Level:
Focuses on precise technical procedures and specifications essential for professional-quality repairs.
Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly of the engine.
Fuel System:
Carburetor/fuel injection system diagnosis, cleaning, and adjustment.
Ignition System:
Spark plugs, ignition coils, CDI unit, and timing checks.
Drivetrain:
Transmission, clutch, drive shafts, CV joints, and differentials.
Suspension Steering:
Front and rear suspension components, steering assembly, wheel alignment.
Braking System:
Brake calipers, master cylinder, brake lines, pads, rotors, and bleeding procedures.
Electrical System:
Battery, charging system, lighting, starter, wiring diagrams, and component testing.
Cooling System:
Radiator, fan, thermostat, coolant hoses, and fluid specifications.
Exhaust System:
Muffler, pipes, and heat shields.
Body Chassis:
Frame inspection, body panel removal/installation, seat, racks, and guards.
Routine Maintenance:
Oil changes, filter replacements, lubrication points, and general inspection.
Troubleshooting Guides:
Diagnostic flowcharts for common problems and symptoms.
Component Repair:
Detailed step-by-step instructions for repairing or replacing individual parts.
Rebuild Instructions:
Comprehensive rebuild procedures for major components like the engine and transmission.
Wiring Diagrams:
Detailed electrical schematics for all systems.
Diagnostic Capabilities:
Advanced diagnostics, including electrical system testing and component troubleshooting.
Repair Scope:
Full spectrum from basic maintenance to complete engine and transmission overhauls.
Specifications Data:
Includes torque specifications, clearances, fluid capacities, and electrical data.
Searchability:
Text-searchable for quick information retrieval.
Graphic Resolution:
High-resolution for clear diagrams and illustrations.
Printable:
Yes, pages can be printed for field use.
Digital Binding:
N/A (Digital Download)
Digital Paper Simulation:
N/A (Digital Download)
Engine Type:
V-twin, liquid-cooled, 4-stroke, SOHC
Displacement:
633 cc (38.6 cubic inches)
Bore X Stroke:
76.0 x 69.0 mm
Horsepower Estimate:
Approximately 48-50 HP (actual figures vary)
Torque Estimate:
Approximately 36-38 lb-ft (actual figures vary)
Fuel Delivery:
Carbureted (Mikuni BSR32 x 2) or Electronic Fuel Injection (EFI) depending on specific sub-model/year. Manual will cover the specific system.
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
4.1 US gal (15.5 L)
Oil Type:
API SG, SF, or SH SAE 10W-40 or 20W-50 (refer to manual for exact spec based on temperature)
Oil Capacity:
Approximately 2.0-2.2 US qt (1.9-2.1 L) with filter change (verify in manual)
Spark Plug Type:
NGK CR9E / DPR9EA-9 (verify in manual)
Spark Plug Gap:
0.8 - 0.9 mm (0.031 - 0.035 in) (verify in manual)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with selectable 2WD/4WD
Drive Select:
Electric engageable 4-wheel drive with limited-slip front differential
Gear Reduction:
High and Low range, Neutral, Reverse
Cvtf Fluid Specification:
Kawasaki Genuine Belt Fluid (or equivalent approved CVT fluid - verify in manual)
Cvtf Capacity:
Approximately 1.1 US qt (1.0 L) (verify in manual)
Atv Safety Standards:
Complies with ANSI/SVIA 1-2004 and SAE J1212 (typical for US models, verify specific market compliance).
Braking System Type:
Hydraulic disc brakes front and rear.
Parking Brake:
Mechanical type, typically integrated with rear brake caliper or transmission.
Lighting:
Dual 30W headlights, 15W taillight/brake light.
Seatbelt Provision:
Not applicable to ATVs; rider restraint typically via handlebars and footpegs.
Display Panel:
Digital meter with speed, odometer, trip meter, fuel gauge, clock, 2WD/4WD indicator, and neutral/reverse indicators.
4Wd System:
Electronically selectable 2WD/4WD with limited-slip front differential for enhanced traction.
Charging System:
Alternator with battery charging for electrical systems and accessories.
Engine Oil Change:
Every 100 hours or 6 months (recommend verification in manual).
Air Filter Cleaning:
Every 20 hours or annually (recommend verification in manual).
Spark Plug Inspection:
Every 100 hours or annually (recommend verification in manual).
Belt Inspection Cvtf Change:
Inspect belt every 100 hours; CVT fluid change typically every 12-24 months or per manual recommendation.
Engine Oil Viscosity Range:
10W-40 or 20W-50 (based on ambient temperature, consult manual)
Coolant Type:
Kawasaki Motorcycle Coolant or equivalent ethylene glycol-based coolant (50/50 mix with distilled water).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
CVT belt wear, suspension bushings, brake pads, wheel bearings, and tie rod ends are common wear items on ATVs.
Electrical Connections:
Corrosion on electrical connectors can be an issue in wet or muddy conditions; the manual will guide inspection and cleaning.
Kawasaki Atv Legacy:
Kawasaki has a long history of producing rugged and reliable ATVs, known for their performance and durability in off-road conditions.
Brute Force Lineage:
The Brute Force 650 4x4i succeeded earlier models and was a popular mid-to-large displacement ATV in Kawasaki's lineup, known for its V-twin power and 4WD capability.
Manufacturing Origin:
Likely manufactured in Lincoln, Nebraska, USA, or Japan (verify specific VIN location).
Industry Acclaim:
While specific awards for this exact model year are not readily cited, the Brute Force line consistently received positive reviews for its power, handling, and utility in the ATV market.
Performance Reputation:
Known for strong V-twin engine performance and capable off-road handling, making it a popular choice for utility and recreational riding.
