Foreword DANGER WARNING NOTICE NOTE

Transcription

1 TERYX4

2

3 Foreword In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most commonly removed parts have a direct bearing on a vehicle s reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers. This Assembly and Preparation Manual explains step by step procedures of the following items for all Kawasaki TERYX4. 1. Crate Handling 2. Uncrating 3. Assembly 4. Preparation The selling dealer assumes sole responsibility for any unauthorized modifications prior to sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale. Whenever you see the following symbols heed their instructions! Always follow safe operating and maintenance practices. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE NOTICE is used to address practices not related to personal injury. NOTE NOTE indicates information that may help or guide you in the operation or service of the vehicle. Kawasaki Heavy Industries, Ltd. accepts no liability for any inaccuracies or omissions in this publication, although every possible measure has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without notice Kawasaki Heavy Industries, Ltd. May, 2015

4 Table of Contents Crate Handling... 3 Crate Handling Precautions for RSC (Returnable Steel Crate)(US Model only)... 3 Crate Handling Precautions (Other than US Model)... 3 Uncrating... 4 Opening Crate (US Model only)... 4 Opening Crate (Other than US Model)... 8 Parts Check Assembly Steering Wheel Cargo Bed Rear Fenders Bars and Handhold Front Seats and Front Seat Belts Rear Seats and Rear Seat Belts Sun Top (KRT800G/H Model only) Front Guard French Labels (Canadian Model only) Brake Disc Cleaning Preparation Charged Battery Service (US Model) Uncharged Battery Service (Other than US Model) Engine Oil Front Final Gear Case Oil Rear Final Gear Case Oil Brakes Brake Pedal Brake Light Switch Parking Brake Lever Steering Wheel Front Shock Absorber Rear Shock Absorber Tire Air Pressures Fuel Coolant Throttle Pedal Idle Speed Adjustment Headlight Beam Wheel Alignment Digital Meter Fastener Check Standard Torque Table Test Ride Checklist... 59

5 CRATE HANDLING 3 Crate Handling Crate Handling Precautions for RSC (Returnable Steel Crate) (US Model only) Crate Position: Always place the crate upright on its base. The crate has been designed to carry the weight of the vehicle only in that position. The sides and top of the crate are not strong enough to act as the base of the crate. If the crate is tilted very far or set on its end or side, loose parts may be dislodged and fall inside the crate. Loading and Unloading Trucks for RSC: To load or unload crates, use a fork lift. Never attempt to unload crates by hand. NEVER DROP crates off a truck. Be sure to use the proper handling equipment for safe unloading, storing and stacking of crated Teryx utility vehicles. The weight of a large Teryx utility vehicle plus the RSC exceeds 950 kg (2 100 lbs.), therefore, two stacked crates will weigh approximately kg (4 190 lbs.). Use forklifts with at least lb. lifting capacity and 60-inch tapered fork blades not greater than 1-1/2 inch thick. Forklifts should also be equipped with all safety items, such as operator cages and fork back rests. Pulling Crate from Trucks for RSC: If pulling is necessary to unload from trailer, please put rope or chain on fork pocket area at end. A. Pull chain around fork pocket area. Stacking Returnable Steel Crates: The number of crates that may be stacked on top of one another depends on the condition of the crates and your forklift s capacity. Teryx utility vehicle RSCs are designed for integrated stacking. Do not stack any other type of crate or any other materials atop a Teryx RSC. In any case, do not stack returnable steel crates more than two high for trucking, and three high for storage. Crate Handling Precautions (Other than US Model) Crate Position: Always place the crate upright on its base. The crate has been designed to carry the weight of the vehicle only in that position. The sides and top of the crate are not strong enough to act as the base of the crate. If the crate is tilted very far or set on its end or side, loose parts may be dislodged and fall inside the crate.

6 4 UNCRATING Moving Crated Vehicle: WARNING Crate bands are only designed to hold the cardboard cover in place. If used as handles they can snap, causing you or the crate to fall resulting in injury. Do not move or lift the crate using the crate bands. Whenever moving the crate from one place to another, use a fork lift or flat bed hand truck. Vehicle crates are too big and heavy to be moved by hand. While moving a crate, never stand it on end or tip it over on its side. DO NOT DROP crated vehicles. Loading and Unloading Trucks: To load or unload crates, use a fork lift, a lift -type tail gate, or a ramp. Never unload crates by hand. NEVER DROP crates off a truck. Stacking Disposable Wooden Crates: The number of crates that may be stacked on top of one another depends on the condition of the crates more than any other single factor. Also, take into consideration the weight of the upper crate(s), the sizes of all the crates in a stack, and the strength of the bottom crate(s) base on the type of crate construction (steel, wood, bracing, etc.). In any case, do not stack crates more than two high for trucking, and three high for storage. Uncrating Opening Crate (US Model only) WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear protective gloves, boots and eye protection when uncrating to prevent injury. TyingDownCrates: Always tie down crates when transporting them. Put the tie downs across the crate at the crate s internal vertical braces. Do not use any hooks on the crate. WARNING The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection when uncrating to prevent injury.

7 UNCRATING 5 Clear a space about 6 m (20 ft.) square to give yourself plenty of space to work. Place the crate upright on its base. Remove the outer cover and inspect the unit for concealed damage. If concealed damage is evident, document the damage as outlined in the Kawasaki Warranty Policies and Procedures Manual before proceeding to uncrate the unit. Remove the cardboard cover. To work efficiently, start work at the rear of the crate. Remove the bolts (2) of the diagonal brace and locknuts (2) of the diagonal brace to disconnect the rear diagonal braces (2) from the rear upright. Repeat these steps for the front upright. Discard the bolts (4) of the diagonal brace and locknuts (4) of the diagonal brace. Allow the diagonal braces to pivot out and down to the ground. They remain attached to the pallet. NOTICE Remove the pivot bolts of the front upright and detach the front upright before rolling the vehicle off the crate base. If the front upright is left attached to the crate base, the pivot bolts of the front upright could damage the tires. Remove the pivot bolts (2) of the front upright, locknuts (2) of the front upright and the front upright. A. Front Upright B. Locknut of Front Upright C. Pivot Bolt of Front Upright After rolling off the vehicle, reinstall the front upright to the crate base for return shipment. Lay down the rear upright. To do so, lift up on the upright to disengage its sockets from the pallet. Now the upright may be pivoted down to the ground. (It remains attached to the pallet.) Be careful not to drop it on anyone. A. Rear Upright B. Bolt of Diagonal Brace C. Locknut of Diagonal Brace A. Upright Sun Top Removal (KRT800G/H Model only) Cut the tie-bands that retain the sun top, and remove the sun top from the unit.

8 6 UNCRATING Front Side Bar and Middle Side Bar Removal (Both Sides) Cut the tie-band that retains the front side bar and middle side bar. Remove the bolt (D = 12, L = 55) (1) and nut (D = 12) (1) that tightens the front side bar, and remove the front side bar from the unit. Remove the bolt (D = 12, L = 20) (1) and nut (D = 12) (1) that tightens the middle side bar, and remove the middle side bar from the unit. A. Tie-bands B. Sun Top Remove the part box from the unit. A. Part Box Removing the Bars and Parts from the Unit Rear Side Bars and Front Guard Removal Cut the tie-bands that retain the rear side bars and front guard. Remove the rear side bars and front guard from the unit. A. Tie-band B. Front Side Bar C. Middle Side Bar D. Bolt (D = 12, L = 20) and Nut (D = 12) E. Bolt (D = 12, L = 55) and Nut (D = 12) Seats Removal Remove the seat backs, seat frames and seat bottoms from the unit. A. Seat Backs B. Seat Frames C. Seat Bottoms Remove the part box. A. Tie-bands B. Rear Side Bars C. Front Guard

9 UNCRATING 7 A. Part Box Upper Bars and Handhold Removal Remove the screws (D = 6, L = 20) (5) and collars (L = 4) (5). Remove the rear seat lower cover. Remove the screws (D = 6, L = 16) (4). Remove the cargo bed. A. Tie-bands B. Taillight Lead Connector C. Bolts D. Cargo Bed Frame E. Upper Bars F. Handhold Back Bars and Front Tie-downs Removal Cut the tie-bands that retain the back bars at the stabilizer, and remove the back bars from the stabilizer. Remove the front tie-downs by opening fully and disengaging latch. Take care to undo these evenly as there is heavy tension in the tie-down. A.Screws(D=6,L=20),Collars(L=4) B. Rear Seat Lower Cover C.Screws(D=6,L=16) D. Cargo Bed Cut the tie-bands that retain the cargo bed frame, upper bars and handhold. Disconnect the taillight lead connector located under the cargo bed frame. Remove the bolts (4), and discard them. Remove the cargo bed frame and upper bars. A. Tie-bands B. Back Bars C. Tie-downs (Front) Rear Tie-down Removal Remove rear tie-downs by opening fully and disengaging latch. Take care to undo these evenly as there is heavy tension in the tie -down.

10 8 UNCRATING A. Tie-downs (Rear) Roll the vehicle off the crate base after installing the steering wheel (see Steering Wheel section on page 24 in the assembly chapter). RETURN SHIPMENT Prepare the crate for return shipment. Fold braces in so they lay on the crate pallet. These items are discarded: - Outer Cover, Tie-downs (Qty. 4), Bolts (Qty. 4) of Diagonal Brace, Locknuts (Qty. 4) of Diagonal Brace Opening Crate (Other than US Model) WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear protective gloves, boots and eye protection when uncrating to prevent injury. A. Braces Reinstall the front upright, pivot bolts (2) of the front upright and locknuts (2) of the front upright and tighten the bolts and locknuts. Lift the rear upright to disengage its sockets. Pivot it down onto the crate pallet. Be careful not to drop on anyone. A. Uprights Repeat these steps for the other upright. Clear a space about 6 m (20 ft.) square to give yourself plenty of space to work. Place the crate upright on its base. Remove the outer cover and inspect the unit for concealed damage. If concealed damage is evident, document the damage as outlined in the Kawasaki Warranty Policies and Procedures Manual before proceeding to uncrate the unit. Remove the cardboard cover. Removing Panels Using a BPS3 square drive bit (ex. IM- PORT APEX Square Recess Power Bits- 1/4 Hex-size #3 or MAGNA Insert Bits-size #3 with quick change holder), remove the screws from the sides and ends into the top.

11 UNCRATING 9 A. Power Bit (APEX) WARNING Staples, nails and other fasteners have sharp points that can cause injury. Remove or bend into the wood all staples, nails or other fasteners in the crate base. Take out all the bolts, nuts, screws, and fasteners and remove the top and side panels of the wood crate. Top panel can be lifted from the unit. Have a second person help to remove this piece as it can be awkward to handle. Discard this assembly. Take care when letting the screen and center bar assembly down from the top, it is heavy and may fall. Side Panel Removal Remove the screws (18) shown below. The panel should come loose without excess force; check for any missed screws if the panel will not come off easily. NOTE Trying to break the panels off can result in damage to the unit. Top Panel Removal Remove the screws from the top panel. There are two screws in every corner. Remove two screws in every cross member. Repeat procedure for the other side of the unit. Discard these panels. End Panel Removal Remove the screws shown below. The panel should come loose without excess force, check for any missed screws if panel will not come off easily. NOTE Trying to break the panels off can result in damage to the unit.

12 10 UNCRATING Repeat as above for the rear panel. Discard these panels. A. Part Box Removing the Bars and Parts from the Unit Rear Side Bars and Front Guard Removal Cut the tie-bands that retain the rear side bars and front guard. Remove the rear side bars and front guard from the unit. Sun Top Removal (KRT800G/H Model only) Cut the tie-bands that retain the sun top, and remove the sun top from the unit. A. Tie-bands B. Rear Side Bars C. Front Guard A. Tie-bands B. Sun Top Remove the part box from the unit. Front Side Bar and Middle Side Bar Removal (Both Sides) Cut the tie-band that retains the side front bar and middle side bar. Remove the bolt (D = 12, L = 55) (1) and nut (D = 12) (1) that tightens the front side bar, and remove the front side bar from the unit. Remove the bolt (D = 12, L = 20) (1) and nut (D = 12) (1) that tightens the middle side bar, and remove the middle side bar from the unit.

13 UNCRATING 11 Upper Bars and Handhold Removal Remove the screws (D = 6, L = 20) (5) and collars (L = 4) (5). Remove the rear seat lower cover. Remove the screws (D = 6, L =16) (4). Remove the cargo bed. A. Tie-bands B. Front Side Bar C. Middle Side Bar D. Bolt (D = 12, L = 20) and Nut (D = 12) E. Bolt (D = 12, L = 55) and Nut (D = 12) Seats Removal Remove the seat backs, seat frames and seat bottoms from the unit. A.Screws(D=6,L=20)andCollars(L=4) B. Rear Seat Lower Cover C.Screws(D=6,L=16) D. Cargo Bed Cut the tie-bands that retain the cargo bed frame, upper bars and handhold. Disconnect the tail light lead connector located under the cargo bed frame. Remove the bolts (4), and discard them. Remove the cargo bed frame and upper bars. A. Seat Backs B. Seat Frames C. Seat Bottoms Remove the part box. A. Tie-bands B. Tail Light Lead Connector C. Bolts D. Cargo Bed Frame E. Upper Bars F. Handhold A. Part Box

14 12 UNCRATING Back Bars and Front Tie-downs Removal Cut the tie-bands that retain the back bars at the stabilizer, and remove the back bars from the stabilizer. Remove the front tie-downs by opening fully and disengaging latch. Take care to undo these evenly as there is heavy tension in the tie-down. NOTICE Be careful not to puncture a tire with sharp fasteners when rolling off the vehicle from the crate base. Roll the vehicle off the crate base after installing the steering wheel (see Steering Wheel section in the Assembly chapter). A. Tie-bands B. Back Bars C. Tie-downs (Front) Rear Tie-down Removal Remove rear tie-downs by opening fully and disengaging latch. Take care to undo these evenly as there is heavy tension in the tie -down. A. Tie-downs (Rear) NOTE It is important to remove the top panel as the unit will rise when the tie-downs are undone. Failure to do so will result in damage to the unit. Remove any nails from the crate base that might puncture a tire.

15 This page intentionally left blank. UNCRATING 13

16 14 UNCRATING Parts Check NOTE There may be minor differences in appearance between these illustrations and the actual vehicle parts. Remove the parts and check the crate base and packaged materials carefully for lost parts. Order any parts that are missing from the crate. Check the parts against the illustrations. In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters. In the following charts under Qty, ( ) = component of assembly parts.

17 UNCRATING 15 No. Part Name Qty Remarks 1 Steering Wheel 1 2 Washer (1) D = Nut, Steering Wheel (1) D=12 4 Steering Wheel Cap 1 5 Front Seat Belt 2 6 Bolt, Seat Belt 4 D = 10, L = 16 7 Rear Seat Belt 2 8 Seat Belt Buckle 2 9 Flanged Bolt, Seat Belt 8(2) D = 12, L = Front Guard 1 11 Bolt, Front Guard 4 D = 10, L = Front Guard Cover 1 13 Screw, Front Guard Cover 2 D = 6, L = Front Side Bar (Left) (1) 15 Flanged Bolt, Upper Bar, Back Bar, Handhold 20 D=10, L = Upper Bar (Front) 1 17 Front Side Bar (Right) (1) 18 Middle Side Bar (Right) (1) 19 Rear Side Bar (Right) 1 20 Middle Side Bar Pad 2 21 Flanged Bolt, Side Bar 10 (2) D = 12, L = Nut, Side Bar 12 (4) D=12 23 Flanged Bolt, Middle Side Bar (Upper) 4 D = 12, L = Middle Side Bar (Left) (1) 25 Upper Bar (Center) 1 26 Rear Side Bar (Left) 1 27 Washer, Handhold 4 D = Handhold 1 29 Flanged Bolt, Back Bar 2 D = 8, L = Washer, Back Bar 2 D= Back Bar (Upper) 1 32 Back Bar (Lower) 1

18 16 UNCRATING

19 UNCRATING 17 No. Part Name Qty Remarks 1 Rear Seat Lower Cover (1) 2 Screw, Tapping, Rear Seat Lower Cover (5) D = 6, L = 20 3 Collar, Rear Seat Lower Cover (5) L=4 4 Clip Nut, Rear Seat Lower Cover (5) 5 Cargo Bed (1) 6 Flanged Bolt, Cargo Bed 4 D = 6, L = 22 7 Hook, Cargo Bed 4 8 Collar, Cargo Bed 4 L=4 9 Screw, Tapping, Cargo Bed (4) D = 6, L = Flanged Bolt, Cargo Bed Frame 4 D = 8, L = Collar, Cargo Bed Frame 4 L= Cargo Bed Frame (1) 13 Damper, Cargo Bed Frame (2) 14 Band, Taillight Lead 1 L = Screw, Tapping, Rear Fender 4 D = 6, L = Washer, Rear Fender 4 D= Collar, Rear Fender 4 L=3 18 Collar, Rear Fender 2 L= Screw, Tapping, Rear Fender 12 D = 6, L = Collar, Rear Fender 10 L=4 21 Clip Nut, Rear Fender 4 22 Cover, Rear Fender (Left) (1) 23 Rivet, Cover (8) 24 Rear Fender (Left) 1 25 Cover, Rear Fender (Light) (1) 26 Rear Fender (Right) 1 27 Clip Nut, Rear Fender 12

20 18 UNCRATING

21 UNCRATING 19 No. Part Name Qty Remarks 1 Seat Back 4 2 Seat Bottom 2 3 Damper, Seat Bottom (8) 4 Spring, Seat Bottom (2) 5 Hook, Seat Bottom (2) 6 Front Seat Assy (Right) 1 7 Flanged Bolt, Seat Frame 8 D = 8, L = 25 8 Washer, Seat Frame 4 D=8.2 9 Flanged Bolt, Seat Back 16 D = 6, L = Inner Pad, Seat Back Cover, Seat Back 2 12 Rivet, Cover, Inner Pad 8 13 Front Seat Assy (Left) 1 14 Rear Seat Frame (Right) 1 15 Spacer, Rear Seat Frame 8 16 Rear Seat Frame (Left) 1

22 20 UNCRATING

23 UNCRATING 21 No. Part Name Qty Remarks (KRT800G/H) 1 Bracket, Upper Bar 2 2 Damper Screw 8 D = 6, L = 18 4 Collar 6 L=5.1 5 Damper 6 D=24 6 Sun Top 1 7 Damper Damper Clamp, Back Bar 2 10 Damper Bracket, Back Bar (Right) 1 12 Bracket, Back Bar (Left) 1 13 Clamp, Upper Bar 2 14 Locknut 10 D=6

24 22 UNCRATING

25 UNCRATING 23 No. Part Name Qty Remarks French Labels and Instruction (Canadian Models only) 1 Label, Warning, General 1 2 Instruction, Label 1 3 Label, Important Information, Air Cleaner 1 4 Label, Specification, ROPS 1 5 Label, Notice, Shifting 1 6 Label, Notice, Dipstick 1 7 Label, Warning, Tire and Overload 1 8 Label, Important Information, Drive Belt 1 9 Cover, Certification, Emission 1 10 Label, Certification, Emission 1 11 Label, Warning, Refueling 1 12 Label, Warning, Cargo Bed 1 13 Label, Trailer Towing 1 14 Battery Electrolyte (Other than US model) 1 YTX20L-BS, 12 V 18 Ah 15 Owner s Manual 1

26 24 ASSEMBLY Assembly Steering Wheel Steering Wheel Installation Remove the steering wheel nut (D = 12) and the washer (D = 12.1) from the steering shaft. A. Steering Wheel Cap B. Steering Wheel Check the Kawasaki mark of the steering wheel parallel to the line. A. Steering Wheel Nut (D = 12) B. Steering Wheel Washer (D = 12.1) C. Steering Shaft Set the front wheels straight ahead. Mount the steering wheel on the steering shaft as shown below and reinstall the steering wheel nut (D = 12) and washer (D = 12.1). Tighten the wheel nut to the specified torque. Torque : 54 N m (5.5 kgf m, 40 ft lb) A. Kawasaki Mark B. Line Steering Position Adjustment (KRT800F/G/H) Move the steering wheel up or down while pulling up the tilt lock lever under the steering wheel. Release the tilt lock lever to lock the steering wheel in position. A. Washer (D = 12.1) B. Nut (D = 12) C. Steering Wheel Check the direction to install the steering wheel cap. To install the steering wheel cap, insert the projections of steering wheel into the holders. A. Tilt Lock Lever B. Pull Up C. Adjust Steering Wheel

27 ASSEMBLY 25 NOTE Make sure you have securely locked the steering wheel in place by moving it up and down. Install the rear seat lower cover with the tapping screws (D = 6, L = 20) (5) and collars (L =4)(5). Cargo Bed Cargo Bed Frame Installation Install the cargo bed frame with the cargo bed frame bolts (D = 8, L = 25) (4) and collars (L = 8.2) (4). Connect the tail/brake light lead connector. Tighten the cargo bed frame bolts to the specified torque. Torque:35 N m (3.6 kgf m, 26 ft lb) A. Rear Seat Lower Cover B. Tapping Screws (D = 6, L = 20) and collars (L = 4) Rear Fenders Install the clip nuts (6) to the cargo bed and rear seat lower cover. A. Cargo Bed Frame B. Bolts (D = 8, L = 25) and Collars (L = 8.2) C. Tail/Brake Light Lead Connector Cargo Bed Installation Install the cargo bed with the bolts (D = 6, L = 22) (4), tapping screws (D = 6, L = 16) (4), hooks (4) and collars (L = 4) (4). Install the clip nuts (5) to the cargo bed. A. Clip Nuts B. Cargo Bed C. Rear Seat Lower Cover Install the clip nuts (2) to the rear fender. A. Cargo Bed B. Bolts (D = 6, L = 22), Hooks and Collars (L = 4) C. Tapping Screws (D = 6, L = 16) D. Clip Nuts

28 26 ASSEMBLY Hold the tail/brake light lead with band (L = 292.1) as shown. A. Clip Nuts B. Rear Fender Install the rear fender with the tapping screws (D = 6, L = 20) (6), collars (L = 4) (5) and collar (L = 7.2) (1). A. Tail/Brake Light Lead B. Band (L = 292.1) Connect the tail/brake light lead connector. A. Rear Fender B. Tapping Screws (D = 6, L = 20) and Collars (L = 4) C. Tapping Screw (D = 6, L = 20) and Collar (L = 7.2) Install the rear seat lower cover and cargo bed with the tapping screws (D = 6, L = 18) (2), washers (D = 6.5) (2) and collars (L = 3) (2). A. Tail/Brake Light Lead Connector Install another side rear fender in the same way. Bars and Handhold Side Bars Installation Install the front side bar with the side bar mounting bolts (D = 12, L = 55) (2) and nuts (D = 12) (2). A. Cargo Bed B. Tapping Screws (D = 6, L = 18), washers (D = 6.5) and Collars (L = 3)

29 ASSEMBLY 27 A. Front Side Bar B. Side Bar Mounting Bolts (D = 12, L = 55) and Nuts (D = 12) Install the rear side bar with the side bar mounting bolts (D = 12, L = 55) (2) and nuts (D = 12) (2). A. Front Side Bar B. Rear Side Bar C. Middle Side Bar D. Side Bar Mounting Bolts (D = 12, L = 65) and Nuts (D = 12) Install the middle side bar with the side bar mounting bolts (D = 12, L = 55) (2) and nuts (D = 12) (2) while pushing the middle bar down. A. Rear Side Bar B. Side Bar Mounting Bolts (D = 12, L = 55) and Nuts (D = 12) Install the middle side bar to the front and rear side bars with the side bar mounting bolts (D = 12, L = 65) (2) and nuts (D = 12) (2). A. Middle Side Bar B. Push down. C. Side Bar Mounting Bolts (D = 12, L = 55) and Nuts (D = 12) Install another side bars in the same way. Upper Bar Installation Install the upper bar (front) with the upper bar mounting bolts (D = 10, L = 14) (4). Be sure to install the upper bar (front) so that the triangular plate comes upper side.

30 28 ASSEMBLY A. Upper Bar (Front) B. Upper Bar Mounting Bolts (D = 10, L = 14) (Both Sides) C. Triangular Plate of Upper Bar (Front) Install the upper bar (center) with the upper bar mounting bolts (D = 10, L = 14) (4). Be sure to install the upper bar (center) so that the triangular plate comes upper side. A. Handhold B. Handhold Mounting Bolts (D = 10, L = 14) and Washers (D = 10.2) (Both Sides) C. Middle Side Bar Back Bar Installation Install the back bars with the back bar mounting bolts (D = 10, L = 14) (8). A. Upper Bar (Center) B. Upper Bar Mounting Bolts (D = 10, L = 14) (Both Sides) C. Triangular Plate of Upper Bar (Center) Handhold Installation Install the handhold with the handhold mounting bolts (D = 10, L = 14) (4) and washers (D = 10.2) (4). A. Back Bar (Upper) B. Back Bar (Lower) C. Back Bar Mounting Bolts (D = 10, L = 14) (Both Sides) Install the back bar joint bolts (D = 8, L = 16) (2) and washers (D = 8.5) (2). A. Back Bar Joint Bolts (D = 8, L = 16) and Washers (D = 8.5)

31 ASSEMBLY 29 Tighten the side bar mounting nuts, upper bars, handhold and back bars mounting bolts and nuts to the specified torque. When torquing the front side bar mounting nuts, hold the side bar mounting bolt head and tighten the nut with an open end wrench type torque wrench. NOTE There is not enough space around the front side bar mounting nuts to apply a general socket wrench to them. Use an open end wrench type torque wrench to torquing the side bar mounting nuts. Enough bolt tension is not available if the side bar mounting bolt head is tightened. Side Bar Mounting Nuts Torque: 69 N m (7.0 kgf m, 51 ft lb) Side Bar Joint Nuts: 82 N m (8.4 kgf m, 60 ft lb) Upper Bar Mounting Bolts Torque: 44.5 N m (4.54 kgf m, 32.8 ft lb) Handhold Mounting Bolts Torque: 44.5 N m (4.54 kgf m, 32.8 ft lb) A. Front Seat Belt B. Rear Seat Belt C. Seat Belt Bracket (Silver) D. Seat Belt Bracket (Black) Install the front seat belt case on the mounting bracket on the middle side bar with the seat belt case mounting bolt (D = 12, L = 20) (1). The seat belt case has a small projection which fits into a hole in the mounting bracket. Tighten the seat belt case mounting bolt to the specified torque. Seat Belt Case Mounting Bolt Torque: 46.5 N m (4.74 kgf m, 34.3 ft lb) Back Bar Mounting Bolts Torque: 44.5 N m (4.54 kgf m, 32.8 ft lb) Back Bar Joint Bolts Torque: 22.5 N m (2.29 kgf m, 16.6 ft lb) Front Seats and Front Seat Belts Seat Belt Installation NOTE The front seat belt and the rear seat belt differ in seat belt bracket color. A. Seat Belt Case B. Projection C. Hole D. Middle Side Bar Install the seat belt without twisting. Install the seat belt bracket on the middle side bar with upper seat belt mounting bolt (D = 10, L = 16) (1). Tighten the upper seat belt mounting bolt to the specified torque. Upper Seat Belt Mounting Bolt Torque: 37 N m (3.8 kgf m, 27 ft lb)

32 30 ASSEMBLY A. Seat Belt Bracket B. Upper Seat Belt Mounting Bolt (D = 10, L=16) C. Middle Side Bar Install the seat belt without twisting. Install the seat belt bracket on the middle side frame with lower seat belt mounting bolt (D = 12, L = 20) (1) as shown. Tighten the lower seat belt mounting bolt to the specified torque. Lower Seat Belt Mounting Bolt Torque: 46.5 N m (4.74 kgf m, 34.3 ft lb) A. Seat Back B. Seat Frame C. Holes D. Bolts (D = 6, L = 14) Peel off each sheet of release paper and stick the inner pads ( ) (3) on the seat back cover. A. Seat Belt Bracket (Bent end faces outward.) B. Lower Seat Belt Mounting Bolt (D = 12, L=20) C. Middle Side Frame A. Inner Pads ( ) B. Seat Back Cover C. 5 mm (0.2 in.) D. Align the edge of the inner pad with the quick rivet hole Install the seat back cover with the quick rivets (4). Seat Installation Insert the seat frame ends into the holes of the seat back. Install the bolts (D = 6, L = 14) (4) and tighten them. A. Seat Back Cover B. Quick Rivets

33 ASSEMBLY 31 The front seats can be adjusted within 3 positions to suit the occupant s preference. To adjust the operator seat position, remove the seat and pull up the lock pin. Move the seat frame forward or backward to select the desired position [1 ~ 3], and release the lock pin. Make sure the lock pin has been inserted into the locking hole in position. Rear Seats and Rear Seat Belts Seat Belt Installation Install the seat belt buckle on the seat frame so that the mounting angle is 60 degrees, and tighten the seat belt buckle mounting bolt (D = 12, L = 20) to the specified torque. Seat Belt Buckle Mounting Bolt Torque: 46.5 N m (4.74 kgf m, 34.3 ft lb) A. Lock Pin B. Seat Frame C. Locking Holes (3 Positions) To adjust the passenger seat position, remove the seat and remove the seat frame mounting bolts and washers under the seat, and install them in the positions to suit the occupant s preference. A. Seat Frame B. Seat Belt Buckle C. Seat Belt Buckle Mounting Bolt (D = 12, L = 20) D. 60 degrees E. Release button faces to the outside of seat frame. Install the rear seat belt case on the mounting bracket on the rear seat with the seat belt case mounting bolt (D = 12, L = 20) (1). The seat belt case has a small projection which fits into a hole in the mounting bracket. Tighten the seat belt case mounting bolt to the specified torque. Seat Belt Case Mounting Bolt Torque: 46.5 N m (4.74 kgf m, 34.3 ft lb) A. Seat Frame Mounting Bolts and Washers B. Seat Frame C. Mounting Holes (3 Positions) Tighten the seat frame mounting bolts.

34 32 ASSEMBLY A. Seat Belt Case B. Projection C. Hole D. Seat Frame E. Seat Belt Case Mounting Bolt Install the seat belt without twisting. Install the seat belt bracket on the seat frame with lower seat belt mounting bolt (D = 12, L = 20) (1) as shown. Tighten the lower seat belt mounting bolt to the specified. Lower Seat Belt Mounting Bolt Torque: 46.5 N m (4.74 kgf m, 34.3 ft lb) A. Seat Back B. Seat Frame C. Holes D. Bolts (D = 6, L = 14) Install the spacers (4). A. Spacers Install the seat frame on the frame body with bolts (D = 8, L = 25) (4) and washers (D = 8.2) (2). A. Seat Belt Bracket (Bent end faces inward.) B. Lower Seat Belt Mounting Bolt (D = 12, L=20) C. Seat Frame Seat Installation Insert the seat frame ends into the holes of the seat back. Install the bolts (D = 6, L = 14) (4) and tighten them. A. Seat Frame B. Bolts (D = 8, L = 25) and Washers (D = 8.2) C. Bolts (D = 8, L = 25)

35 ASSEMBLY 33 Install the seat belt without twisting. Install the seat belt bracket on the rear side bar with upper seat belt mounting bolt (D = 10, L = 16) (1). Tighten the upper seat belt mounting bolt to the specified torque. Upper Seat Belt Mounting Bolt Torque: 37 N m (3.8 kgf m, 27 ft lb) A. Seat Belt Bracket B. Upper Seat Belt Mounting Bolt (D = 10, L=16) C. Rear Side Bar Install the seat bottom. Sun Top (KRT800G/H Model only) Sun Top Installation Install the dampers on the brackets as shown. A. Dampers (40 x 40 x 10) (2 pieces) B. Rear Upper Bar C. 453 mm (17.8 in.) D. 378 mm (14.9 in.) E. 40 mm (1.6 in.) Install the dampers on the underside of the sun top as shown. A. Bracket (for Back Bar) (Left and Right) B. Bracket (for Upper Bar) (4 pieces) C. Collar (L = 5.1) D. Damper ( ) E. Damper ( ) F. Damper (D = 24) Attach the dampers on the top side of the rear upper bar as shown. A. Sun Top B. Dampers ( ) (2 pieces) C. Front Side Install the sun top with the screws (D = 6, L = 18) (4), collars (L = 5.1) (4) and dampers (D = 24) (4). Install the brackets.

36 34 ASSEMBLY Install the brackets with the screws (D = 6, L = 18) (2), collars (L = 5.1) (2) and dampers (D = 24) (2). Install the clamps with the screws (D = 6, L = 18) (2). A. Screws(D=6,L=18),Collars(L=5.1) and Dampers (D = 24) (Both Sides) B. Brackets (for Upper Bar) (Both Sides) C. Front Side Install the locknuts (D = 6) (2). A. Bracket (Both Sides) B. Screw (D = 6, L = 18), Collar (L = 5.1) and Damper (D = 24) (Both Sides) C. Locknut (D = 6) D. Screw (D = 6, L = 18) (Both Sides) E. Clamp (Both Sides) F. Back Bar A. Locknuts (D = 6) (Both Sides) B. Upper Bar (Front) C. Upper Bar (Center) Install the clamps with the locknuts (D = 6) (4). Front Guard Install the front guard with tighten the front guard bolts (D= 10, L= 16) (4). Tighten the front guard bolts to the specified torque. Front Guard Bolts Torque: 44.5 N m (4.54 kgf m, 32.8 ft lb) A. Clamp (for Upper Bar) (Both Sides) B. Locknuts (D = 6) (Both Sides) C. Upper Bar (Front) A. Front Guard B. Front Guard Bolt (Both Sides) Install the front guard cover with tighten the front guard cover screws (D= 6, L= 16) (2).

37 ASSEMBLY 35 A. Front Guard Cover B. Front Guard Cover Screws 3. Drive Belt Information 4. Tire and Overload Warning French Labels (Canadian Model only) NOTE Apply the French labels over the English labels on the unit when required. Wipe off any oil or grease from the English labels. Refer to the following photographs in the label locations. Peel each French label off the backing sheet and apply it over the English label. 5. Emission Certification 6.Dipstick Notice 1. General Warning 2. Shifting Notice 7. Refueling Warning 8. Air Cleaner Information

38 36 PREPARATION 9. ROPS Specification 10. Cargo Bed Warning A. Front Brake Disc (Both Sides) Preparation Charged Battery Service (US Model) Pre-filled, Pre-charged Battery 11. Trailer Towing Warning Brake Disc Cleaning Jack up the vehicle so that the wheels are off the ground. Using oilless solvent, clean the front brake discs while turning the wheels. WARNING Oilless solvent is usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer s warnings. WARNING An anticorrosive treatment applied to the brake discs will increase braking distance and can cause an accident resulting in serious injury or death. Remove the anticorrosive treatment using an oilless solvent. The battery used in this RUV is a pre-filled, pre -charged, sealed battery, eliminating the need for dealers to prepare the battery by filling it with electrolyte. However, dealers should still check each battery s state of charge periodically to be sure it meets the minimum 12.6 volts specification and charge it to 100% state of charge during Assembly & Preparation. The new battery is built to automotive industry standards and should hold a charge of 75% or above for approximately six months at C (72 77 F). Because the battery will discharge at different rates based on varying conditions, it is recommended that it be checked every three months on any inventory unit. Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage. The battery is located under the air cleaner housing. Remove the protective caps on the battery terminals and discard them.

39 PREPARATION 37 A. Protective Caps Measure the battery terminal voltage. NOTE Measure with a digital meter that can be read to at least one decimal place voltage. Battery Terminal Voltage Standard: 12.6 V or more If the reading is above the specification refreshing charge is not required. Go on to the next step (see Battery Cable Installation). A. Protective Cap (Red) B. Protective Cap (Black) C. Positive Cable (+) D. Negative Cable ( ) Cover the positive terminal (+) with its red protective cap. Cover the negative terminal ( ) with its black protective cap. Battery Removal Remove the bolts and nuts. Remove the battery holder and collars, and take the battery and battery cover out of the battery case. A. Digital Meter If the reading is below the specification refreshing charge is required. See the Battery Removal and Refreshing Charge section. Battery Cable Installation Turn the ignition switch off. Run the battery cables as shown, and first connect the red protective capped positive cable to the battery positive terminal (+), then connect the black protective capped negative cable to the negative terminal ( ). Put a light coat of grease on the terminals to prevent corrosion. A. Nuts B. Battery Holder C. Battery Cover D. Battery E. Collars F. Bolts Battery Specifications Battery Capacity 12 V 14 Ah Battery P/No

40 38 PREPARATION Refreshing Charge DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. NOTICE Always remove the battery from the vehicle for charging. If the battery is charged while still installed, battery electrolyte may spill and corrode the frame or other parts of the vehicle. Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting. Higher-than-normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause internal shorting. If the temperature of the electrolyte rises above 45 C (113 F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately. NOTE Neverattempttochargeafrozenbattery. Allow it to warm up to room temperature before charging. Never leave a battery on a trickle charger longer than 48 hours. Serious damage to the battery will occur. A. Seal Sheet or Cap Refer to the Battery Charging Time Table for the charging. Determine battery condition after charging. Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria Judgement 12.6 V or more Good 12.0 less than 12.6 V less than 12.0 V Battery Installation Turntheignitionswitchoff. Charge insufficient Recharge Unserviceable Replace WARNING This battery is sealed battery type. Never remove seal sheet or cap even at charging. Never add water. Charge with current and time as stated below.

41 PREPARATION 39 Put the battery and battery cover in the battery case. Reinstall the bolts, nuts and collars in the reverse of removal. Be sure not to pinch the cables with the battery holder. Run the battery cables as shown, and first connect the red protective capped positive cable to the battery positive terminal (+), then connect the black protective capped negative cable to the negative terminal ( ). Put a light coat of grease on the terminals to prevent corrosion. Cover the positive terminal (+) with its red protective cap. Cover the negative terminal ( ) with its black protective cap. new battery to ensure the best possible battery performance. Activating the battery requires two steps, filling the battery with electrolyte, and charging. Read the Battery Safety Label shown below and following procedures carefully before battery activation. NOTICE Incorrect Battery Activation will reduce battery performance and service life. Be sure to strictly follow the Battery Service instructions in this Manual. DANGER Heed the battery safety label shown here. A. Protective Cap (Red) B. Protective Cap (Black) C. Positive Cable (+) D. Negative Cable ( ) Uncharged Battery Service (Other than US Model) Battery Removal Remove the bolts and nuts. Remove the battery holder and collars, and take the battery and battery cover out of the battery case. Be careful that any rubber dampers are not pulled out of position. A. Battery The battery used in this RUV is a sealed type and the battery electrolyte is supplied in a container. Follow the procedure for activating a A. Nuts B. Battery Holder C. Battery Cover D. Battery E. Collars F. Bolts

42 40 PREPARATION Battery Activation Electrolyte Filling Make sure that the model name of the electrolyte container matches the model name of the battery. These names must be the same. Battery Model Name KRT800E/F/G/H: YTX20L-BS Place the battery on a level surface. peeling, tears, or holes in it. Remove the sealing sheet. Check to see that the sealing sheet has no NOTE The battery is vacuum sealed. If the sealing sheet has leaked air into the battery, it may require a longer initial charge. A. Model Name of the Electrolyte B. Model Name of the Battery NOTICE Each battery comes with its own specific electrolyte container; using the wrong container may overfill the battery with incorrect electrolyte, which can shorten battery life and deteriorate battery performance. Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type. A. Sealing Sheet B. Filler Ports Remove the electrolyte container from the vinyl bag. Detach the strip of caps from the container and set aside, these will be used later to seal the battery. NOTE Do not pierce or otherwise open the sealed cells of the electrolyte container. Do not attempt to separate individual cells. NOTICE Do not remove the aluminum sealing sheet from the filler ports until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. DANGER Sulfuric acid in battery electrolyte can cause severe burns. To prevent burns, wear protective clothing and safety glasses when handling electrolyte. If the electrolyte comes in contact with your skin or eyes, wash the area with liberal amounts of water and seek medical attention for more severe burns. A. Strip of Caps B. Sealed Cells Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.

43 PREPARATION 41 NOTE Do not tilt the electrolyte container. After filling, let the battery sit for minutes with the electrolyte container kept in place, which is required for the electrolyte to fully permeate into the plates. Make sure that the container cells have emptied completely, and remove the container from the battery. Place the strip of caps loosely over the filler ports, press down firmly with both hands to seat the strip of caps into the battery (don t pound or hammer). When properly installed, the strip of caps will be level with the top of the battery. Check the electrolyte flow. If no air bubbles are coming up from the filler ports, or if the container cells have not emptied completely, tap the container a few times. NOTE Be careful not to have the battery fall down. A. Strip of Caps A. Air Bubbles B. Tap the Container Keep the container in place. Don t remove the container from the battery, the battery requires all the electrolyte from the container for proper operation. NOTICE Removal of the container before it is completely empty can shorten the service life of the battery. Do not remove the container until it is completely empty. NOTICE Once the strip of caps is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery. NOTE Charging the battery immediately after filling can shorten service life. Initial Charge Newly activated sealed batteries require an initial charge. Standard Charge: 1.8 A 5 10 hours

44 42 PREPARATION If using a recommended battery charger, follow the charger s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate OptiMate PRO 4-S/PRO S/PRO 2 Yuasa MB-2040/2060 Christie C10122S If the above chargers are not available, use equivalent one. Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. (Voltage immediately after charging becomes temporarily high. For accurate measuring, let the battery sit for given time.) NOTE Charging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. If voltage is not at least 12.8 volts, repeat charging cycle. To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 volts repeat the charging cycle and load test. If still below 12.8 volts the battery is defective. Battery Installation Turn the ignition switch off. Check that the rubber dampers on the battery holder and the battery case are properly in place. Put the battery and battery cover in the battery case. Reinstall the bolts, nuts and collars in the reverse of removal. Run the battery cables as shown, and first connect the red protective capped positive cable to the battery positive terminal (+), then connect the negative cable to the negative terminal ( ). Hold the positive cable with the clamp. Put a light coat of grease on the terminals to prevent corrosion. Cover the positive terminal (+) with its red protective cap. A. Positive Cable (+) and Red Cap B. Battery Cover C. Clamp D. Battery E. Negative Cable ( ) Engine Oil Engine Oil Level Inspection DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area. NOTE This vehicle s engine is filled with 10W-40 oil from the factory. DO NOT DRAIN and refill the crankcase before use. Check oil level and drain bolt tightness. Engine Oil Drain Bolt Torque: 20 N m (2.0 kgf m, 15 ft lb) A. Engine Oil Drain Bolt

45 PREPARATION 43 Park the vehicle so that it is level, both side-to -side and front-to-rear. Before starting the engine, check that the engine has oil. Remove the operator s seat bottom. Unhook the upper part of rubber cover from the hooks and open the cover. A. Hook Portions B. Rubber Cover Unscrew the oil filler plug on the left lower side of the engine and wipe the dipstick dry. Then screw it in again. Unscrew the plug and check that the engine has oil. A. Oil Filler Plug When installing the plug, be sure the O-ring is in place, and screw the plug in finger tight. NOTICE If the engine is run without oil, it will be severely damaged. Start the engine and run it for several minutes at idle speed. Stop the engine, then wait several minutes until the oil settles. Unscrew the oil filler plug, wipe its dipstick dry, and screw it in again. Unscrew the plug and check the oil level. The oil level should be between the mesh portion on the dipstick. A. Screw in the oil filler plug fully to inspect the oil level. B. Mesh Portion If the oil level is too high, remove the excess oil through the oil filler opening using a syringe or some other suitable device. If the oil level is too low, add the oil to reach the correct level. Screw the plug in finger tight. Recommended Engine Oil Type: APISG,SH,SJ,SLorSMwith JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 3.4 L (3.6 US qt) [when filter is not removed] 3.6L(3.8USqt) [when filter is removed] NOTE Do not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch. Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Install the removed parts.

46 44 PREPARATION Front Final Gear Case Oil Front Final Gear Case Oil Level Inspection With the vehicle level front-to-rear and side-to -side, remove the filler cap from the front final gear case. NOTE Front and rear final gear cases use different types of oils. Use the specified type and brand of oil in each final gear case. Front Final Gear Case Oil Type: API GL-5 Hypoid gear oil Viscosity: above 5 C (41 F) SAE 90 below 5 C (41 F) SAE 80 Capacity: 0.92 L (0.97 US qt) Install the filler cap and tighten it to the specified torque. Front Final Gear Case Oil Filler Cap Torque: 17.5 N m (1.78 kgf m, 12.9 ft lb) A. Front Final Gear Case B. Filler Cap C. Front Axle Shaft NOTICE Be careful not to allow any dirt or foreign materials to enter the front final gear case. Check the oil level. The oil level should come to the bottom of the filler opening. If it is insufficient, add oil through the oil filler opening as necessary. Rear Final Gear Case Oil Rear Final Gear Case Oil Level Inspection With the vehicle level front-to-rear and side-to -side, remove the filler cap from the rear final gear case. A. Rear Final Gear Case B. Filler Cap C. Rear Axle Shaft A. Bottom of Filler Opening NOTICE Be careful not to allow any dirt or foreign materials to enter the rear final gear case. Check the oil level. The oil level should come to the bottom of the filler opening. If it is insufficient, add oil through the oil filler opening as necessary.

47 PREPARATION 45 A. Bottom of Filler Opening NOTE Front and rear final gear cases use different types of oils. Use the specified type and brand of oil in each final gear case. Do not use front final gear case oil into the rear final gear case. Use only the specified oil. The rear final gear case contains brake plates which require a special oil type. Also the two different oil types for the rear gear case oil must not be mixed in use. Rear Final Gear Case Oil Type: Mobil Fluid 424, Citgo Transgard Tractor Hydraulic Fluid, Exxon Hydraul 560 Capacity: 0.98 L (1.04 US qt) Install the filler cap and tighten it to the specified torque. Rear Final Gear Case Oil Filler Cap Torque: 29 N m (3.0 kgf m, 21 ft lb) Brakes Brake Fluid Level Inspection WARNING When working with the disc brake, observe the precautions listed below. Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate. Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid. Don t change the fluid in the rain or when a strong wind is blowing. Brake fluid quickly damages painted surfaces; any spilled fluid should be completely wiped up immediately. If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE LINE. With the vehicle on level ground. Check that the fluid level in the reservoir is between the upper (MAX) and lower (MIN) level lines. A. Brake Fluid Reservoir B. Upper Level Line (MAX) C. Lower Level Line (MIN)

48 46 PREPARATION If the fluid level in the reservoir is lower than the lower level line, check for fluid leaks in the front brake lines and fill the reservoir. Remove the brake fluid reservoir cap. Fill the reservoir to the upper level line with DOT3 brake fluid, and reinstall the reservoir cap and tighten it to the specified torque. Reservoir Cap Torque: 3.5 N m (0.36 kgf m, 31 in lb) Pump the brake pedal a few times until it becomes hard, and then holding the pedal depressed, quickly open (turn counterclockwise) and close the bleed valve. Then release the pedal. Repeat this operation until no more air can be seen coming out into the plastic hose. A. Hold the brake pedal applied. B. Release the brake pedal. A. Brake Fluid Reservoir B. Reservoir Cap Operate the brake pedal several times. If it feels spongy, there might be air in the brake lines. If necessary, bleed the air in the brake line. Also check for fluid leakage around the fittings. Brake Line Air Bleeding With the brake reservoir horizontal, remove the brake reservoir cap and diaphragm, and check that there is plenty of fluid in the reservoir. NOTE The fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. Start with the rear master cylinder and finish with the front left or right caliper. Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container. With the reservoir cap off, slowly pump the brake pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir. This bleeds the air from the front brake master cylinder end of the line. A. Quickly open and close the bleed valve. Repeat the previous step one more time for the other front disc brake. When air bleeding is finished, check that the fluid is between the upper and lower level lines. Install the diaphragm and the reservoir cap. Tighten the bleed valve(s) to the specified torque. Brake Caliper Bleed Valve Torque: 5.4 N m (0.55 kgf m, 48 in lb) Rear Master Cylinder Bleed Valve Torque: 5.4 N m (0.55 kgf m, 48 in lb) Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.

49 PREPARATION 47 Brake Pedal Brake Pedal Free Play Inspection Depress the brake pedal lightly by hand. There should be 2 10 mm ( in.) of free play. If it does not, adjust the brake pedal play. Brake Pedal Free Play: 2 10 mm ( in.) WARNING Insufficient free play can cause brake heating and drag, resulting in skidding and loss of control which could cause an accident resulting in serious injury or death. Be sure the brake free play is adjusted to the specification. Brake Light Switch Brake Light Switch Inspection Turn the ignition switch on. Depress the brake pedal. The brake light should go on after about 10 mm (0.39 in.) of pedal travel. A. Brake Pedal B mm ( in.) Brake Pedal Free Play Adjustment Loosen the locknut and turn the push rod to obtain the correct amount of free play. A. 10 mm (0.39 in.) If it does not, adjust the brake light switch. Brake Light Switch Adjustment To adjust the brake light switch, move the switch up or down by turning the adjusting nut. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. A. Locknut B. Push Rod Tighten the locknut to the specified torque. Front Master Cylinder Push Rod Locknut Torque: 17.2 N m (1.75 kgf m, 12.7 ft lb) Check for brake drag and braking effectiveness.

50 48 PREPARATION A. Brake Light Switch B. Adjusting Nut C. Light Turns on Sooner D. Light Turns on Later Parking Brake Lever Parking Brake Lever Inspection Pull the parking brake lever upward slowly all the way. After 8 to 9 clicks of lever travel, the vehicle should not roll while parked. A. Adjuster Steering Wheel Steering Wheel Free Play Inspection Check steering wheel free play. Set the front tires straight ahead. Gently turn the steering wheel left and right. The steering wheel free play is the amount of travel in the steering wheel, before the front wheels begin to turn. Steering Wheel Free Play: 0 20 mm ( in.) A. 8 9 clicks B. Parking Brake Lever If it rolls, adjust the parking brake lever. Parking Brake Lever Travel Adjustment Turn the adjuster on the parking brake cable rear end to obtain the correct amount of lever travel. A mm ( in.) B. Gently turn. If the free play is incorrect, check and tighten the steering wheel mounting nut and the steering system parts, and adjust the steering gear preload. NOTE If the Steering Wheel Free Play Inspection/Adjustment is necessary, refer to the Service Manual.

51 PREPARATION 49 Front Shock Absorber Front Shock Absorber Spring Preload Adjustment Lift the wheel off the ground. Check the spring length from lower surface of adjusting nut to upper surface of lower spring seat on the front shock absorbers. STD Spring Preload Setting Length: mm (10.24 in.) A. Compression Damping Force Adjuster Compression Damping Force Setting A. Spring Preload Setting Length Refer to the Front Shock Absorber Preload Adjustment procedure in the Service Manual. Compression Damping Force Adjustment Check the position of the compression damping force adjuster on the top of each front shock absorber. NOTICE Do not force to turn the compression damping force adjuster from the fully seated position or the adjusting mechanism may be damaged. STD Compression Damping Force Setting: clicks (Turn out from the fully seated (turned fully clockwise) position) To adjust the front shock absorber compression damping force, turn the adjuster knob all the way clockwise to make the damping greatest. Turn the adjuster counterclockwise to decrease damping. Adjust the compression damping to the standard setting position. The right and left front shock absorbers must be adjusted evenly. Rear Shock Absorber Rear Shock Absorber Spring Preload Adjustment Lift the wheel off the ground. Check the spring length from lower surface of adjusting nut to upper surface of lower spring seat on the rear shock absorbers. STD Spring Preload Setting Length: mm (10.98 in.) A. Spring Preload Setting Length Refer to the Rear Shock Absorber Preload Adjustment procedure in the Service Manual.

52 50 PREPARATION Compression Damping Force Adjustment Check the position of the compression damping force adjuster on the top of each rear shock absorber. NOTICE Do not force to turn the compression damping adjuster from the fully seated position or the adjusting mechanism may be damaged. STD Compression Damping Force Setting: clicks (Turn out from the fully seated (turned fully clockwise) position) To adjust the rear shock absorber compression damping force, turn the adjuster knob all the way clockwise to make the damping greatest. Turn the adjuster counterclockwise to decrease damping. Adjust the compression damping to the standard setting position. The right and left rear shock absorbers must be adjusted evenly. Tire Air Pressures Tire Air Pressure Adjustment Adjust the pressures to the specified values in the front and rear, and make sure to tighten the caps securely. Tire Air Pressure (when cold): Front: 78.4 kpa (0.80 kgf/cm², 11.4 psi) Rear: 110 kpa (1.12 kgf/cm², 16 psi) A. Air Pressure Gauge NOTE To accurately measure the pressure, use a low air pressure gauge included in the tool kit of RUV. Do not use an automotive air pressure gauge because the specified tire air pressures of RUV is too low. Fuel A. Compression Damping Force Adjuster Compression Damping Force Setting WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch off. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.

53 PREPARATION 51 Open the fuel tank cap, and check for debris in the fuel tank. Fill the fuel tank with one gallon or four liters of unleaded gasoline. Use a gasoline with a minimum octane rating shown below. Fuel Type Unleaded Gasoline Octane Rating Method Antiknock Index (RON + MON) 2 Minimum Rating 87 Close the fuel tank cap and check for any leaks and correct them. Coolant Coolant Reservoir Tank Level Check Situate the vehicle on level ground. Check the coolant level through the coolant level gauge on the reserve tank. The coolant level should be between the F (Full) and L (Low) marks. NOTE Check the level when the engine is cold (room or atmospheric temperature). A. Reserve Tank B. Cap C. F (Full) Mark D. L (Low) Mark If the amount of coolant is insufficient, add coolant. Turn the knobs in direction as shown to release the locks. Pull up the front access cover and disengage 4 tabs at left and right side. Slide the front access cover forward to disengage 2 front tabs from the front grill and then remove the cover. A. Front Access Cover B. Knobs C. Tabs D. Pull up E. Slide forward F. Front Grill Unscrew the cap from the reserve tank and add coolant through the filler opening to the F (Full) mark. Install the cap. Recommended Coolant Solution Coolant Mixture Ratio: Water 50%: Antifreeze 50% (1:1) Recommended Antifreeze: Permanent type antifreeze (ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiator). NOTE A permanent type of antifreeze is installed in the cooling system when shipped. It is colored green and contains ethylene glycol. It is mixed at 50% and has the freezing point of 35 C ( 31 F). Insert the 2 front tabs of the front access cover to the front grill and the slits of the front fender. Fit the 4 tabs at left and right side into the slits and close the front access cover.

54 52 PREPARATION A. Front Access Cover B. Tab (Both Sides) C. Tabs (Both Sides) Turn the knobs in direction as shown in the picture to lock the front access cover. Throttle Pedal Throttle Pedal Free Play Inspection Apply the parking brake. Put the shift lever in the N (Neutral) position. Start the engine, and warm it up thoroughly. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Throttle Pedal Free Play: mm ( in.) A. Throttle Pedal B mm ( in.) A. Front Access Cover B. Knobs Pull up the rear of the front access cover to confirm the cover is securely locked. WARNING An open front access cover can distract or impair visibility of the operator, causing loss of vehicle control and potential serious injury or death. Lock the front access cover securely before operating the vehicle. Throttle Pedal Free Play Adjustment NOTE If the throttle pedal free play adjustment is necessary, refer to the Service Manual. Idle Speed Adjustment Idle speed is controlled by the ECU (electronic control unit) and cannot be adjusted. Idle speed after the engine is thoroughly warmed up is shown below. Idle Speed: ±50 r/min (rpm) Headlight Beam The headlight beams can be adjusted vertically. Turn the adjusting screw at the back of the each headlight rim in or out to adjust the headlight vertically.

55 PREPARATION 53 A. Headlight Cover B. Adjusting Screw (Outer) C. Adjusting Screw (Inner, KRT800G/H) Toe-in Inspect and Adjustment Lift the front wheels off the ground. Apply a heavy coat of chalk near the center of the front tires. Using a needle nose scriber, make a thin mark near the center of the chalk coating while turning the wheel. Set the wheels so that the marks on the tires are at the front side and at the level of the axle height. Ground the front wheels. Set the steering wheel straight ahead. At the level of the axle height, measure the distance between the scribed lines with a measure. Wheel Alignment Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A (Rear) is greater than B (Front) as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. If toe-in is incorrect, the front wheels will be dragged along the ground, scuffing and wearing the tread knobs. Caster and camber are built-in and require no adjustment. A (Rear) B (Front) = Amount of Toe-in (Distance A and B are measured at hub height) Move the vehicle rearward until the marks on the front tires are at the rear side and at the same level as the axle. Measure the distance between the scribed lines. Subtract the measurement of the front from the measurement of the rear to get the toe-in. Toe-in of Front Wheels Standard: mm ( in.) at 1G If the length is out of specification adjust the tie-rod length. Loosen the locknuts on each tie-rod and turn the adjusting rods the same number of turns and the same direction on both sides to achieve the specified toe-in.

56 54 PREPARATION NOTE Do not operate the vehicle with the digital meter displaying in the wrong unit (mile or km) of the digital meter. Shift the mph km/h display in the digital meter as follows. Turntheignitionswitchon. Display the odometer in the digital meter. The mph km/h display shifts by pushing the Right button while the Left button is pushed in. A. Locknuts B. Adjusting Rods NOTE The toe-in will be near the specified range, if the length of the tie-rod distance between the rod groove and the locknut is 97 mm (3.81 in.) on both the left and right tie-rods. A. mph km/h Display B. Left Button C. Right Button The mph km/h display shifts as follows. A. Rod Groove B. Locknut C. 97 mm (3.81 in.) Check the toe-in again. Tighten the tie-rod end locknuts to the specified torque. Tie-rod End Locknut Torque: 45 N m (4.6 kgf m, 33 ft lb) Test drive the vehicle. Digital Meter Check the Display Unit Setting in the Digital Meter The display unit setting can alternate between mile and km modes in the digital meter. Make sure that mile or km is correctly displayed according to local regulations before delivering to your customer. NOTE The data is maintained even if the battery is disconnected. Clock Adjustment Turntheignitionswitchon. The odometer is displayed. Push the Right button for more than two seconds. Both the hour and minute displays start blinking. A. Hour Display B. Minute Display

57 PREPARATION 55 Push the Right button. The hour display only blinks. Push the Left button to advance the hours. A. Hour Display Push the Right button. The hour display stops blinking and the minute display starts blinking. Push the Left button to advance the minutes. A. Minute Display Push the Right button. Both the hour and minute displays start blinking again. Push the Left button. The displays stop blinking and the clock starts working. NOTE Pushing the Left button momentarily advances the hour or minute step by step. Pushing and holding the button advances the hour or minute continuously. The clock works normally from the back-up power while the ignition switch is turned off. When the battery is disconnected, the clock resets to 1:00, and starts working again when the battery is connected.

58 56 PREPARATION Fastener Check The torque values listed are for assembly and preparation items only, see the appropriate Service Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery. Also check to see that each cotter pin or circlip is in place.

59 PREPARATION 57