PRAIRIE 360 4X4 (KVF360-A/C), PRAIRIE 360 2X4 (KVF360-B), PRAIRIE 650 4X4 (KVF650-A/B), PRAIRIE 700 4X4 (KVF700-A/B/D),

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1 SERVICE REPLACES: Please discard ATV dated 4/5/07 MODEL: 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/D/E/F), TITLE: DRIVE BELT CHECK/DRIVE BELT FAILURE DETECTION SYSTEM MEMORY CLEARING PROCEDURE SERVICE INFORMATION ATV First Issued: April 5, 2007 Revised: Octber 26, 2007 Page 1 f 7 Subject With numerus Kawasaki ATV mdels equipped with the Kawasaki Autmatic Pwerdrive System (KAPS) spanning several mdel years, keeping track f the different prcedures used t clear the Drive Belt Check/Drive Belt Failure Detectin systems memry can be difficult and cnfusing. Use this bulletin, alng with newlydevelped vide clips sn t be available n K-Dealer, t quickly find which prcedure applies t each mdel and t guide yu thrugh the resetting prcess. Backgrund Sme Kawasaki ATVs have a belt mnitring system that signals tw drive belt cnditins. One f these cnditins is when the belt has reached its 100-hur maintenance service pint. This cnditin is shwn by a light that cmes n and is cnstantly illuminated (n the KVF 360, the light flashes). The ther cnditin is when the belt failure switch has been tripped and causes the indicatr t flash. This alerts the peratr that a belt failure has ccurred. In either case, whether cnstantly n r flashing, the drive belt must be inspected and the warning light must be reset. Always inspect and service the belt as necessary befre resetting the belt warning indicatr. There are fur different methds f resetting the warning indicatr, depending n the ATV mdel and in sme cases, mdel year. Unfamiliarity with the Drive Belt Check and Drive Belt Failure Detectin systems n Prairie, Brute Frce and KFX700 ATV mdels can als cause nn-faulty igniters t be replaced instead f the memry being cleared. Read this bulletin fr a thrugh understanding f these systems t avid unnecessary igniter replacement. Applicable Vehicles Cmpnents Included (Symptm) Drive Belt Drive Belt Failure Mdel Check (Light Detectin Switch Stays On after (Light r LCD 100 hurs) Flashes) KVF360-B * 1 2WD KSV700-A/B KVF360-A/C KVF650-A1/B1 ** 2 4WD KVF650-A2/B2/D/E/F/G/H KVF700-A/B/D KVF750-A/B/C/D/E/F * 1 The KVF360-B des nt have a Belt Check indicatr light. An hur meter recrding key n time is prvided under the seat fr assistance in fllwing the Peridic Maintenance Chart. The meter cannt be reset. ** 2 The 2002 KVF650-A1/B1 is nt equipped with a Belt Check Indicatr light. The Reverse indictr light and LCD meter will flash indicating the Drive Belt Failure Detectin switch has been tripped. A. DRIVE BELT CHECK INDICATOR LIGHT File behind the ATV tab in yur Kawasaki Service and Warranty binder 2007, Kawasaki Mtrs Crp., U.S.A. TM

2 Cmpnents Drive Belt Check System: The Drive Belt Check system cnsists f an hur meter that recrds key ON r engine running time depending n mdel. If 100 hurs accumulate in the hur meter, the Belt Check Indicatr light in the dash will illuminate and stay n indicating the drive belt shuld be inspected and replaced if necessary.. Drive Belt Failure Detectin System: The Drive Belt Failure Detectin system cnsists f a switch munted in the CVT cver that can be tripped by a wrn r damaged belt. If the Drive Belt Failure Detectin switch is tripped, the Belt Check Indicatr light will flash and the vehicle will enter slw mde. In slw mde, the vehicle is limited t 3600 rpm, and the vehicle will nt enter 4WD. KVF360-A/C, KVF650-A/B/D/E/F/G/H, KVF700- A/B/D, and KVF750-A/B/C/D/E/F mdels have bth an hur meter feature and a Drive Belt Failure Detectin switch. BELT CHECK INDICATOR LIGHT KVF360-A/C On KVF360-A/C mdels, the Belt Check Indicatr light is illuminated after 100 hurs has accumulated. KVF650-A/B/D/E/F/G/H, KVF700-A/B/D, and KVF750-A/B/C BELT CHECK INDICATOR LIGHT TRIP METER/ ODOMETER/ HOUR METER KVF650-A/B/D/E/F/G/H, KVF700-A/B/D, and KVF750-A/B/C/D/E/F mdels have a Belt Check Indicatr light and a viewable hur meter in the LCD meter. If 100 hurs has accumulated, the Belt Check Indicatr light will cme n and stay n. If the Drive Belt Failure Detectin switch is tripped, the Belt Check Indicatr light will flash and the vehicle will g int slw mde. If the light is flashing, the switch must be placed back int the ON psitin prir t cmpleting the resetting prcedure. T reset bth the Belt Check system indicatr and the Drive Belt Failure Detectin system, fllw these prcedures: If the Belt Check indicatr light is illuminated r blinking, first check the cnditin f the belt. Fllwing the prcedures in the Service Manual applicable t the mdel being serviced, inspect and replace the drive belt as necessary. Once the drive belt has been inspected, the Belt Check/Drive Belt Failure Detectin system must be reset. Use the instructins that fllw t reset the system. Other Cnditins The Drive Belt Failure Detectin system can be activated due t sudden changes in vltage. Several cmmn cnditins that can activate the system: Page 2

3 Discnnecting/cnnecting the battery with the key in the ON psitin, this is cmmn fr new units during initial setup. Use f accessries that have a significant draw n the battery. The Drive Belt Failure Detectin switch sends vltage t the igniter. If the battery is cnnected r discnnected when the key is in the ON psitin, the igniter reads the sudden change in vltage as the switch being tripped. Kawasaki ships ATVs with the key in the ignitin switch in the ON psitin s that the key cannt fall ut. If the battery is charged and installed with the key in the ON psitin, the sudden increase in vltage can trigger the igniter t illuminate the Belt Check Indicatr light. Accessries, such as a winch, that create a large vltage draw n the battery can als trigger the igniter t illuminate the Belt Check Indicatr light. If battery vltage is drawn dwn significantly during use f the accessry and the accessry is turned ff r discnnected, the sudden jump in vltage may cause the indicatr light t flash. Occasinally the Belt Failure Tggle Switch inside the CVT can becme defective. Even while in the ON psitin, there culd be n cntinuity (pen circuit), especially when riding in rugh terrain. T check, tap n the CVT cver near the switch while the engine is idling. If the tapping causes the Belt Check Indicatr Light t flash, the CVT cver needs t be replaced. Resetting Prcedure If the Belt Check Indicatr light is illuminated r blinking, first check the cnditin f the belt. Fllwing the prcedures in the apprpriate Service Manual, inspect and replace the drive belt as necessary. Service Manuals MODEL PART NUMBER 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 KVF750-D/E Once the drive belt has been inspected, the Belt Check/Drive Belt Failure Detectin system must be reset. Use the instructins that fllw t reset the system. Warranty Infrmatin This bulletin is service infrmatin nly, nt warranty authrizatin. If the Belt Check Indicatr light stays n after cmpleting the resetting prcedure tw r three times, the igniter may need t be replaced. A study f igniters replaced under warranty has cncluded that actual failure rate f the igniters is extremely lw, hwever. Cnfirm that the Drive Belt Failure Detectin switch is ON and cmplete the resetting prcedure tw r three times prir t requesting warranty n any KVF360-A/C, KVF650-A/B/D/E/ F/G/H, KVF700-A/B/D, KSV700-A/B, and KVF750- A/B/C igniters t make sure the unit is actually malfunctining. As f the riginal publicatin date f this bulletin, any igniters replaced under warranty fr these mdels will be called back t Kawasaki and tested. If the igniter is wrking prperly after resetting the Belt Check/Drive Belt Failure Detectin system, the dealer will be charged back fr the igniter and labr. A. SWITCH B. ON POSITION C. CVT COVER D. FORWARD (OFF POSITION) Page 3

4 All KVF Mdels (Except KVF650-A1/A2, B1/ B2 and KVF700-A1/B1): The belt switch (tggle) inside the CVT cver must be at the ON psitin befre perfrming this prcedure. 1. Turn ignitin key t the OFF pisn. 2. Discnnect bth black and gray 4-wire cnnectrs [A] in the same vicinity (under the seat n KVF750 mdels). 6. Discnnect the 2-wire small black cnnectr [A] by the right-frnt side f the engine. KVF360 shwn. KVF360 shwn. 3. Recnnect the gray plug (male) cnnectr [A] t the black receptacle (female) cnnectr [B]. 7. Observe the belt light, it shuld be flashing slwly at an apprximately 1-secnd 8. Wait five secnds r lnger while the light flashes at a 1-secnd 9. Turn the ignitin key 10. Recnnect bth gray and black cnnectrs t their crrect matching clred cnnectrs. 11. Recnnect the 2-wire small black cnnectr [B]. D nt cnnect the gray receptacle (female) cnnectr t the black plug (male cnnectr) r the prcedure will nt wrk. 4. Turn the ignitin key t the ON psitin. 5. Make sure that the belt light [A] flashes fast 5 times at an apprximately 0.4-secnd KVF360 shwn. 12. Turn the ignitin key t the ON psitin. 13. Cnfirm the belt light is KVF360 shwn. Page 4

5 KSV700-A/B/C: 6. Turn n the ignitin switch. KFX700 mdels stre engine running time in the igniter and the Belt Check Indicatr light is illuminated after 100 hurs f engine running time. When the Belt Check Indicatr light cmes n, fllw these prcedures t reset the hur meter: 1. Turn the ignitin switch 2. Inspect and replace the drive belt as necessary accrding t the Service Manual (P/N ). 3. Remve the seat. 4. Lcate the tw, 4-pin cnnectrs (A) under the seat. One cnnectin is black and the ther is gray. The hur meter resets immediately when the key is turned ON. A A. BELT CHECK INDICATOR LIGHT 4-PIN CONNECTORS A 7. The Belt Check Indicatr light shuld be flashing. 8. Turn ff the ignitin switch. 9. Discnnect the mismatched 4-pin cnnectr sets and recnnect them nrmally (blackt-black, gray-t-gray). 10. Turn n the ignitin switch and cnfirm that the indicatr light is n lnger n. 5. Discnnect bth sets f 4-pin cnnectrs, and recnnect the 4-pin cnnectrs t their ppsite clr, i.e., gray-t-black and blackt-gray. A A. GRAY-TO-BLACK; BLACK-TO-GRAY Page 5

6 KVF650-A2/B2 and KVF700-A1/B1: 1. Turn ff the ignitin switch. 2. Inspect and replace the drive belt as necessary accrding t the apprpriate Service Manual. 3. Discnnect bth sets f 4- r 5-pin cnnectrs [B] lcated abve the trque cnverter cver. 14. Turn n the ignitin switch and cnfirm that the Belt Check Indicatr light is n lnger flashing. The first versins f the service manuals shwed an incrrect prcedure. The crrect prcedure was printed in subsequent manuals. KVF650-A1/B1: A. 2-Pin Cnnectr B. 4-Pin Cnnectr KVF650-A/B, KVF700-A/B 5-Pin Cnnectr KVF360-A/C 4. Recnnect these cnnectrs t their ppsite clr, i.e. gray t black and black t gray KVF650 mdels have a Drive Belt Failure Detectin Switch lcated in the CVT cver and an hur meter in the LCD meter. If the switch is tripped, the LCD meter and indicatr lights in the dash will all flash rapidly. If the LCD meter and lights are flashing, it may be pssible t return the belt failure tggle switch t the ON psitin. 1. Turn ff the ignitin switch. 2. Remve the CVT cver. 3. Inspect and replace the drive belt as necessary accrding t the Service Manual (P/N ). 4. Inspect the belt failure tggle switch. If the switch functins prperly and the cnverter cver is nt damaged, reset the switch t the ON psitin. If the switch is brken r malfunctining, and/r the cver is damaged, the switch/cver must be replaced as a set since the switch husing is attached t the cver. 5. Reset the Drive Belt Failure Detectin switch t the ON psitin. 5. Turn n the ignitin switch. 6. Discnnect the belt switch at the 2-pin cnnectr [A] abve the trque cnverter cver. 7. The Belt Check Indicatr light shuld be flashing. Let it flash fr at least seven secnds. Mre than seven secnds is OK. 8. Turn ff the ignitin switch. 9. Turn n the ignitin switch again. 10. The Belt Check Indicatr light shuld be flashing. Let it flash fr at least seven secnds. 11. Turn ff the ignitin switch. 12. Discnnect the mismatched cnnectr sets and recnnect them nrmally (black t black, gray t gray). 13. Cnnect the belt switch 2-pin cnnectr. A. SWITCH B. ON POSITION C. CVT COVER D. FORWARD (OFF POSITION) 6. Turn the key t the ON psitin and cnfirm that the LCD meter and lights are n lnger flashing. Page 6

7 DRIVE BELT WARNING LIGHT CLEARING PROCEDURES 2002 KVF650-A1/B KSV700-A/B/C KVF650-A2/B2 and KVF700-A1/B1 Other KVF MODELS 1. Turn the ignitin switch 1. Turn the ignitin switch 1. Turn the ignitin switch 1. Turn the ignitin switch 2. Remve the CVT cver. 2. Inspect and replace the drive belt as necessary accrding t the Service Manual (P/N ). 2. Inspect and replace the drive belt as necessary. 2. Discnnect bth black and gray 4-wire cnnectrs in the same vicinity (under the seat n KVF750 mdels). 3. Inspect and replace the drive belt as necessary accrding t the Service Manual (P/N ). 4. Reset the Drive Belt Failure Detectin switch t the ON psitin. 5. Turn the key t the ON psitin and cnfirm that the LCD meter and lights are n lnger flashing. 3. Remve the seat. 3. Access the tw sets f 4- r 5-pin cnnectrs (black and gray) abve the CVT cver and discnnect them. 4. Lcate the tw, 4-pin cnnectrs under the seat. One cnnectin is black and the ther gray. 5. Discnnect bth sets f 4-pin cnnectrs, and recnnect the 4- pin cnnectrs t their ppsite clr, i.e., grayt-black and black- tgray. 6. Turn the ignitin switch ON. The indicatr light resets immediately when the key is turned ON. 7. The Belt Check Indicatr light shuld be flashing. 8. Turn the ignitin switch 9. Discnnect the mismatched 4-pin cnnectr sets and recnnect them nrmally (black-t-black, gray-t-gray). 10. Turn the ignitin switch ON and cnfirm that the indicatr light is n lnger n. Page 7 4. Recnnect these cnnectrs t their ppsite clrs, i.e. gray t black and black t gray. 3. Recnnect the gray plug (male) cnnectr t the black receptacle (female) cnnectr. D nt cnnect the gray receptacle (female) cnnectr t the black plug (male cnnectr) r the prcedure will nt wrk. 4. Turn the ignitin switch ON. 5. Turn the ignitin switch ON. 5. Make sure that the belt light flashes fast 5 times at an apprximately 0.4-secnd interval, then slwly at an apprximately 1-secnd 6. Discnnect the 2-pin belt switch cnnectr lcated abve the CVT cver. 7. The Belt Check indicatr light shuld be flashing. Let it flash fr at least seven secnds. 6. Discnnect the 2-wire small black cnnectr by the right-frnt side f the engine. 7. Observe the belt light, it shuld be flashing slwly at an apprximately 1- secnd Mre than 7 secnds is OK. 8 Turn the ignitin key 8. Wait tw secnds r lnger while the light flashes at a 1-secnd 9 Turn the ignitin key ON 9. Turn the ignitin switch again. 10 The Belt Check indicatr light shuld be flashing. Let it flash fr at least seven secnds. 10. Recnnect bth gray and black cnnectrs t their crrect matching clred cnnectrs. Mre than 7 secnds is OK. 11. Turn ff the ignitin switch. 11. Recnnect the 2-wire small black cnnectr. 12. Discnnect the mis-matched cnnectrs and recnnect them t their crrect matching clred cnnectrs. 13. Recnnect the 2-wire small black cnnectr. 14. Turn the ignitin key t the ON psitin. 15. Cnfirm the belt light is 12. Turn the ignitin switch ON. 13. Cnfirm the belt light is