SERVICE
REPLACES: Please discard ATV 03-04 dated 12/12/03

ATV 07-02

April 5, 2007

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MODEL:

TITLE:

PRAIRIE 360 4X4 (KVF360-A/C), PRAIRIE 360 2X4 (KVF360-B), PRAIRIE 650 4X4 (KVF650-A/B), PRAIRIE 700 4X4 (KVF700-A/B/D), KFX700 (KSV700-A/B/C), BRUTE FORCE 650 4X4i (KVF650-D/E/F/G), BRUTE FORCE 750 4X4i (KVF750-A/B/C), DRIVE BELT CHECK/DRIVE BELT FAILURE DETECTION SYSTEM MEMORY CLEARING PROCEDURE

SERVICE INFORMATION

Subject Unfamiliarity with the Drive Belt Check and Drive Belt Failure Detection systems on Prairie, Brute Force and KFX700 ATV models is causing non-faulty igniters to be replaced instead of the memory being cleared. Read this bulletin for a thorough understanding of these systems to avoid unnecessary igniter replacement. Components Drive Belt Check System: The Drive Belt Check system consists of an hour meter that records key ON or engine running time depending on model. If 100 hours accumulate in the hour meter, the Belt Check Indicator light in the dash will illuminate and stay on indicating the drive belt should be inspected and replaced if necessary. Drive Belt Failure Detection System: The Drive Belt Failure Detection system consists of a switch mounted in the CVT cover that can be tripped by a worn or damaged belt. If the Drive Belt Failure Detection switch is tripped, the Belt Check Indicator light will flash and the vehicle will enter slow mode. In slow mode, the vehicle is limited to 3600 rpm, and the vehicle will not enter 4WD. Other Conditions
Components Included (Symptom) Drive Belt Drive Belt Failure Check (Light Detection Switch Stays On after (Light or LCD 100 hours) Flashes) *NOTE: 1 **NOTE: 2
A. DRIVE BELT CHECK INDICATOR LIGHT

Applicable Vehicles

The Drive Belt Failure Detection system can be activated due to sudden changes in voltage. Several common conditions that can activate the system: Disconnecting/connecting the battery with the key in the ON position, this is common for new units during initial setup. Use of accessories that have a significant draw on the battery. The Drive Belt Failure Detection switch sends voltage to the igniter. If the battery is connected or disconnected when the key is in the ON position, the igniter reads the sudden change in voltage as the switch being tripped.
KVF360-B KSV700-A/B KVF360-A/C KVF650-A1/B1
4WD KVF650-A2/B2/D/E/F/G/H KVF700-A/B/D KVF750-A/B/C
*NOTE: 1 The KVF360-B does not have a Belt Check indicator light. An hour meter recording key on time is provided under the seat for assistance in following the Periodic Maintenance Chart. The meter cannot be reset. **NOTE: 2 The 2002 KVF650-A1/B1 is not equipped with a Belt Check Indicator light. The Reverse indictor light and LCD meter will flash indicating the Drive Belt Failure Detection switch has been tripped.
File behind the ATV tab in your Kawasaki Service and Warranty binder
2007, Kawasaki Motors Corp., U.S.A.
Kawasaki ships ATVs with the key in the ignition switch in the ON position so that the key cannot fall out. If the battery is charged and installed with the key in the ON position, the sudden increase in voltage can trigger the igniter to illuminate the Belt Check Indicator light. Accessories, such as a winch, that create a large voltage draw on the battery can also trigger the igniter to illuminate the Belt Check Indicator light. If battery voltage is drawn down significantly during use of the accessory and the accessory is turned off or disconnected, the sudden jump in voltage may cause the indicator light to flash. Occasionally the Belt Failure Toggle Switch inside the CVT can become defective. Even while in the ON position, there could be no continuity

Service Manuals

MODEL KVF360-A/C KVF360-B KVF650-A/B KVF650-D/E KVF650-F/G/H KSV700-A/B KVF700-A/B KVF750-A/B/C PART NUMBER 99924-1285-06 99924-1302-04 99924-1261-04 99924-1348-03 99924-1363-01 99924-1315-05 99924-1319-04 99924-1334-04
Once the drive belt has been inspected, the Belt Check/Drive Belt Failure Detection system must be reset. Use the instructions that follow to reset the system. Warranty Information This bulletin is service information only not warranty authorization. If the Belt Check Indicator light stays on after completing the resetting procedure two or three times, the igniter may need to be replaced. A study of igniters replaced under warranty has concluded that actual failure rate of the igniters is extremely low, however. Confirm that the Drive Belt Failure Detection switch is ON and complete the resetting procedure two or three times prior to requesting warranty on any KVF360-A/C, KVF650-A/B/D/E/ F/G/H, KVF700-A/B/D, KSV700-A/B, and KVF750A/B/C igniters to make sure the unit is actually malfunctioning. As of the original publication date of this bulletin, any igniters replaced under warranty for these models will be called back to Kawasaki and tested. If the igniter is working properly after resetting the Belt Check/Drive Belt Failure Detection system, the dealer will be charged back for the igniter and labor.

A. B. C. D.

SWITCH ON POSITION CVT COVER FORWARD (OFF POSITION)
(open circuit), especially when riding in rough terrain. To check, tap on the CVT cover near the switch while the engine is idling. If the tapping causes the Belt Check Indicator Light to flash, the CVT cover needs to be replaced. Resetting Procedure If the Belt Check Indicator light is illuminated or blinking, first check the condition of the belt. Following the procedures in the appropriate Service Manual, inspect and replace the drive belt as necessary.

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All KVF Models (Except KVF650-A1/B1): KVF360-A/C, KVF650-A/B/D/E/F/G/H, KVF700A/B/D, and KVF750-A/B/C models have both an hour meter feature and a Drive Belt Failure Detection switch. KVF360-A/C
to completing the resetting procedure. To reset both the Belt Check system indicator and the Drive Belt Failure Detection system, follow these procedures: KVF360-A/C, KVF650-A2/B2/D/E/F/G/H, KVF700-A/B/D: If the Belt Check indicator light is illuminated or blinking, first check the condition of the belt. Following the procedures in the Service Manual applicable to the model being serviced, inspect and replace the drive belt as necessary. Once the drive belt has been inspected, the Belt Check/Drive Belt Failure Detection system must be reset. Use the instructions that follow to reset the system. o NOTE: The belt switch (toggle) inside the CVT cover must be at the ON position before performing this procedure. Turn ignition key to the OFF poison. Disconnect the 2-wire small black connector [A] by the right-front side of the engine.

BELT CHECK INDICATOR LIGHT
NOTE: On KVF360-A/C models, the Belt Check Indicator light is illuminated after 100 hours has accumulated.
KVF650-A/B/D/E/F/G/H, KVF700-A/B/D, and KVF750-A/B/C

KVF360 shown.

TRIP METER/ ODOMETER/ HOUR METER
Disconnect both black and gray 4-wire connectors [A] in the same vicinity (under the seat on KVF750 models).
NOTE: KVF650-A/B/D/E/F/G/H, KVF700-A/B/D, and KVF750-A/B/C models have a Belt Check Indicator light and a viewable hour meter in the LCD meter.
If 100 hours has accumulated, the Belt Check Indicator light will come on and stay on. If the Drive Belt Failure Detection switch is tripped, the Belt Check Indicator light will flash and go into slow mode. If the light is flashing, the switch must be placed back into the ON position prior

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Reconnect the gray plug (male) connector [A] to the black receptacle (female) connector [B].
10. Reconnect the 2-wire small black connector [B].
NOTE: Do not connect the gray receptacle (female) connector to the black plug (male connector) or the procedure will not work. Turn the ignition key to the ON position. Make sure that the belt light [A] flashes fast 5 times at an approximately 0.4-second interval, then slowly at an approximately 1second interval.
11. Turn the ignition key to the ON position. 12. Confirm the belt light is OFF.

7. 8. 9.

Wait two seconds or longer while the light flashes at a 1-second interval. Turn the ignition key OFF. Reconnect both gray and black connectors to their correct matching colored connectors.

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KSV700-A/B/C: KFX700 models store engine running time in the igniter and the Belt Check Indicator light is illuminated after 100 hours of engine running time. When the Belt Check Indicator light comes on, follow these procedures to reset the hour meter: 1. 2. Turn the ignition switch OFF. Inspect and replace the drive belt as necessary according to the Service Manual (P/N 999241315-05). Remove the seat. Locate the two, 4-pin connectors (A) under the seat. One connection is black and the other is gray.
Turn on the ignition switch. NOTE: The hour meter resets immediately when the key is turned ON.

A. BELT CHECK INDICATOR LIGHT
The Belt Check Indicator light should be flashing. Turn off the ignition switch. Disconnect the mismatched 4-pin connector sets and reconnect them normally (black-toblack, gray-to-gray).

4-PIN CONNECTORS

10. Turn on the ignition switch and confirm that the indicator light is no longer on.
Disconnect both sets of 4-pin connectors, and reconnect the 4-pin connectors to their opposite color, i.e., gray-to-black and blackto-gray.
A. GRAY-TO-BLACK; BLACK-TO-GRAY

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KVF650-A1/B1: 2002 KVF650 models have a Drive Belt Failure Detection Switch located in the CVT cover and an hour meter in the LCD meter. If the switch is tripped, the LCD meter and indicator lights in the dash will all flash rapidly. If the LCD meter and lights are flashing, return the switch to the ON position. 1. 2. 3. Turn off the ignition switch. Remove the CVT cover. Inspect and replace the drive belt as necessary according to the Service Manual (P/N 999241261-04). Reset the Drive Belt Failure Detection switch to the ON position.
Turn the key to the ON position and confirm that the LCD meter and lights are no longer flashing.

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DRIVE BELT WARNING LIGHT CLEARING PROCEDURES
2002 KVF650-A1/B1 1. Turn the ignition switch OFF. 2. Remove the CVT cover. 2004-2007 KSV700-A/B/C 1. Turn the ignition switch OFF. ALL KVF MODELS (Except KVF650-A1/B1) 1. Turn the ignition switch OFF.
2. Inspect and replace the drive belt 2. Disconnect the 2-wire small black connector by the right-front side of as necessary according to the the engine. Service Manual (P/N 99924-131505). 3. Disconnect both black and gray 4-wire connectors in the same vicinity (under the seat on KVF750 models).
3. Inspect and replace the drive belt 3. Remove the seat. as necessary according to the Service Manual (P/N 99924-126104).
4. Reset the Drive Belt Failure 4. Locate the two, 4-pin connectors 4. Reconnect the gray plug (male) Detection switch to the ON under the seat. One connection is connector to the black receptacle position. black and the other is gray. (female) connector.
o Do not connect the gray receptacle (female) connector to the black plug (male connector) or the procedure will not work.
5. Turn the key to the ON position and 5. Disconnect both sets of 4-pin 5. Turn the ignition switch ON. confirm that the LCD meter and connectors, and reconnect the 4lights are no longer flashing. pin connectors to their opposite color, i.e., gray-to-black and blackto-gray. 6. Turn the ignition switch ON. 6. Make sure that the belt light flashes fast 5 times at an approximately 0.4-second interval, then slowly NOTE: at an approximately 1-second The hour meter resets immediately interval. when the key is turned ON.

7. The Belt Check Indicator light 7. Wait two seconds or longer while should be flashing. the light flashes at a 1-second interval. 8. Turn the ignition switch OFF. 8. Turn the ignition switch OFF. 9. Disconnect the mismatched 4- 9. Reconnect both gray and black connectors to their correct pin connector sets and reconnect matching colored connectors. them normally (black-to-black, gray-to-gray). 10. Turn the ignition switch ON and 10. Reconnect the 2-wire small black confirm that the indicator light is connector. no longer on. 11. Turn the ignition switch ON. 12. Confirm the belt light is OFF.

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Workhorse KVF360
A dependable and affordable mid-size ATV with great towing and load capacities. Electric starter, multi-function meter, fuel gauge and electrical accessory sockets are just some of the convenient features.

KEY FEATURES

Sealed rear brake system is unaffected by water, mud, dust and debris.
Front and rear load carrying racks.
Head, tail and brake lights.
Independent front suspension allows each wheel to track over uneven ground for maximum traction with light steering effort.
Low maintenance single cylinder 4stroke engine with Kawasaki Automatic Power-Drive System (KAPS).

Warranty: 12 months

Kawasaki 2009
SPECIFICATIONS: KVF360B9F
NOTE: Specifications subject to change without notice

FEATURES & BENEFITS

ENGINE The cylinder is set at 45 for a lower centre of gravity with better ground clearance, as well as providing easy access to the spark plug. A standard oil cooler with fan provides optimum temperature control. Electric starter with recoil backup allows you to start the ATV even if the battery is low. Fuel system
Engine type. 4-stroke, single cylinder, SOHC, air cooled, 2-valve cylinder head Displacement. 362 cm3 Bore & stroke. 80.0 x 72.0 mm Compression ratio. 8.3:1 Maximum power. 15.7 kW (21.4 PS) / 7,000 r/min Maximum torque. 26.1 Nm / 4,500 r/min Minimum turning radius. 3.2 m Fuel system. Keihin CVK34 carburettor Starting. electric starter with auxiliary recoil Towing capacity. 500 kg (trailer and cargo) Load capacity, F / R. 40 kg / 70 kg Transmission.. CVT with reverse Frame type.. double cradle, tubular steel Suspension, F / R.. MacPherson strut / swingarm with single shock absorber Wheel travel, F / R. 170 / 180 mm Tyre, F / R. AT25 X 8-12 / AT25 X10-12 Brakes, F / R.. 166 mm discs with single piston calipers / sealed multiplate system L x W x H.. 2,065 x 1,205 x 1,175 mm Wheelbase.. 1,255 mm Track, F / R. 900 / 895 mm Ground clearance.. 260 / 195 (at centre of chassis / at rear final drive Seat height.. 910 mm Curb mass. 277 kg Fuel capacity.. 13.5 L Battery.. 12V, 14Ah Colours.Sunbeam Red
Single damper with coil spring and 5-way pre-load adjustment. Dual front disc brakes
Dual front disc brakes assure quick, sure stops. Sealed rear brake system
CV carburettor provides excellent throttle response, power and torque across the rpm range. Snorkel air intake draws cleaner, drier and cooler air for more power and reduced air filter maintenance. Air box features a dual-layer foam filter to minimise engine wear.
Multi-plate rear brake system is totally enclosed within the swingarm. Operates in a sealed oil bath so that brake is unaffected by water, mud, dust and debris. Compact design provides more ground clearance at the rear axle. Detail features
TRANSMISSION Kawasaki Automatic Power-Drive System (KAPS)
Belt driven Constantly Variable Transmission (CVT) is fully automatic. High and Low range with simple shifter design. Cooling air flows in from a snorkel in front of the steering head to keep out water and dust for reduced wear. Kawasaki Engine Brake Control (KEBC)
Applies engine braking under certain conditions for added slowing power down hills. Automatically compensates for CVT belt wear for consistent performance.
Spacious layout lets even larger riders feel comfortable. Automotive type spin on oil filter helps ease maintenance. Multi-function meter includes speedometer, odometer, trip meter, hour meter, neutral and reverse indicator lamps. Brake lights are triggered by the hand and foot brakes. Convenient electrical accessory outlets at the front (120W) and rear (60W). Adjustable footpeg position increases comfort and offers great traction for the riders boots. Front and rear racks can carry a combined load of 110 kgs. Rear trailer hitch bracket is standard with a 500 kg towing capacity. Optional parts include carburettor jets, large capacity battery, high altitude converter ramp weights and front and rear suspension springs.
CHASSIS MacPherson strut independent front suspension
Provides a comfortable ride with 170 mm of suspension travel. Twin dampers with coil springs. Swingarm rear suspension
More than 180 mm of rear wheel travel.