2005 - 2011 Kawasaki Brute Force 650 Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: Brute Force 650 4x4 Model Code Internal: KVF650 Platform: Brute Force Vehicle Type: All-Terrain Vehicle (ATV) Codes Chassis Codes: KVF650-D, KVF650-E 👋 Introduction...

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类型: Atv

斯库: 41615

标签: 2005 2006 2007 2008 2009 2010 2011 ATV Brute Force 650 Brute Force Models Kawasaki Powersports

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Brute Force 650 4x4

Model Code Internal:

KVF650

Platform:

Brute Force

Vehicle Type:

All-Terrain Vehicle (ATV)

Codes

Chassis Codes:

KVF650-D, KVF650-E

👋 Introduction

Market Position

Market Position:

A robust and capable utility ATV, positioned for serious work and recreational trail riding.

Competitive Analysis

Competitive Analysis:

Competed directly with other 650cc-class utility ATVs from manufacturers like Yamaha (Grizzly 660) and Polaris (Sportsman 700). Known for its powerful engine and reliable 4x4 system.

Key Features

Key Features:

Liquid-cooled V-twin engine, selectable 4WD with limited-slip front differential, independent rear suspension, robust chassis, powerful braking system, and ample cargo capacity.

📋 Manual Details

Coverage

Covered Years:

2005, 2006, 2007, 2008, 2009, 2010, 2011

Covered Models:

KVF650-D1 (2005), KVF650-E1 (2005), KVF650D6F (2006), KVF650E6F (2006), KVF650D7F (2007), KVF650E7F (2007), KVF650D8F (2008), KVF650E8F (2008), KVF650D9F (2009), KVF650E9F (2009), KVF650DAF (2010), KVF650DBF (2010)

Page Count

Page Count:

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Systems Covered:

• General Information

• Periodic Maintenance

• Fuel System

• Cooling System

• Engine Top End

• Clutch

• Engine Lubrication System

• Engine Removal/Installation

• Crankshaft/Transmission

• Wheels/Tires

• Final Drive

• Brakes

• Suspension

• Steering

• Frame

• Electrical System

• Wiring Diagrams

• Appendix

Procedures Included

Procedures Included:

• Diagnostic procedures

• Repair procedures

• Maintenance procedures

• Troubleshooting

• Component disassembly and reassembly

• Torque specifications

• Adjustment procedures

• Component testing

• Electrical system diagnostics

• Engine tuning

Technical Depth

Technical Depth:

Comprehensive (from basic maintenance to advanced diagnostics and complete overhaul)

📊 Manual Specifications

File Format

File Format:

Compatibility:

All Versions of Windows & Mac

Requirements:

Adobe PDF Reader

Print Quality

Print Quality:

High-resolution, clear diagrams and text

Binding Type

Binding Type:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, V-twin, SOHC, 4-valve per cylinder

Displacement:

633 cc

Bore X Stroke:

76.0 x 73.0 mm

Compression Ratio:

8.3:1

Ignition:

Lubrication:

Forced lubrication, wet sump

Performance

Horsepower:

Approximately 45-50 HP (Estimated, varies by tuning and region)

Torque:

Approximately 38-42 ft-lbs (Estimated)

Fuel System

Fuel Delivery:

Carburetor (Dual Mikuni BNS36)

Fuel Type:

Unleaded gasoline, 87 octane minimum

Fuel Tank Capacity:

4.1 US gal (15.5 L)

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT)

Transmission Features:

High and Low range, Reverse, Neutral, Park

Optional

Optional Transmission:

Features

Drive System:

Shaft drive, selectable 4WD with limited-slip front differential

📐 Dimensions

Exterior

Length:

80.7 in (2050 mm)

Width:

45.5 in (1155 mm)

Height:

45.5 in (1155 mm)

Wheelbase:

50.6 in (1285 mm)

Ground Clearance:

10.4 in (265 mm)

Weights

Dry Weight:

600 lbs (272 kg)

Curb Weight:

617 lbs (280 kg) - Estimated

Cargo

Front Rack Capacity:

120 lbs (55 kg)

Rear Rack Capacity:

265 lbs (120 kg)

Towing Capacity:

1,250 lbs (567 kg)

🛡️ Safety Features

Ratings

Safety Ratings:

ATV safety is primarily governed by rider skill and adherence to safe operating practices. Not subject to automotive crash testing standards.

Active Features

Active Features:

• Engine Braking (CVT)

• Selectable 4WD

• Limited-Slip Front Differential

Passive Features

Passive Features:

• Ergonomic seating

• Handlebar controls

• Handguards (standard on some models)

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Utility ATV, typically no infotainment system)

Driver Assistance

Driver Assistance Features:

N/A (Utility ATV, focus is on mechanical and chassis components)

Connectivity

Connectivity Features:

N/A (Utility ATV)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 1,000 miles or 12 months, whichever comes first. Initial break-in oil change recommended sooner.

Spark Plug Replacement:

Refer to manual, typically around 3,000-6,000 miles or annually, depending on usage.

Air Filter Cleaning Or Replacement:

Inspect every 6 months or 500 miles, clean or replace as needed. More frequent inspection in dusty conditions.

Valve Adjustment:

Refer to manual, typically every 6,000 miles or as specified by performance changes.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil

Engine Oil Capacity:

Approx. 3.7 US qt (3.5 L) with filter change

Coolant Type:

Pre-mixed ethylene glycol coolant (50/50 solution), antifreeze/coolant suitable for aluminum engines

Brake Fluid Type:

DOT 4

Final Drive Oil Type:

API GL-5, SAE 80W-90 gear oil

Transmission Fluid Type:

CVT fluid specific to Kawasaki or compatible brands (refer to manual for exact specification)

Known Issues

Known Issues:

• CVT belt wear and failure (common to all CVT systems, inspect regularly)

• Carburetor jetting issues (may require adjustment for altitude or modifications)

• Starter motor solenoid issues (less common)

• Water pump seal leaks (rare, but possible with age/mileage)

📚 Vehicle History

Brand Heritage

Brand Heritage:

Kawasaki has a long-standing reputation for producing high-quality, durable, and performance-oriented powersports vehicles, including ATVs.

Model Evolution

Model Evolution:

The Brute Force 650 4x4 was introduced as a successor to earlier Kawasaki 4x4 models, building on their foundation with a larger, more powerful V-twin engine and improved suspension and chassis design. It served as a key model in Kawasaki's ATV lineup during its production run.

Production

Production Years:

2005-2011

Manufacturing Location:

Japan (Kawasaki Heavy Industries)

🏆 Awards & Recognition

Recognitions

Recognitions:

While specific awards are not widely publicized for individual model years of ATVs, the Brute Force 650 4x4 was generally well-regarded by enthusiasts and media for its power, capability, and reliability in its class.