1999-2002 Kawasaki Prairie 300 KVF300 Service & Repair Manual

PRAIRIE 3004 x 4 Kawasaki PRAIRIE 300 All Terrain Vehicle Service Manual

This quick reference guide will ass ist you !n locating a desired topic or procedure. _Send the pages back to match the black tab of the desired chapter number wlth the black tab on the edge at each table of contents page. _ Refer to the sectional table of contents for the exact pages to loc ate the specific top ic required. Quick Reference Guide I General Information I Fuel System I Engine Top End I Converter System I Recoil Starter Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission WheelslTires Final Drive I Brakes I Suspension I Steering I Frame I Electrical System I Appendix

Kawasaki - PRAIRIE 300 4x4 PRAIRIE 300 All Terrain Vechicle Service Manual

LIST OF ABBREVIATIONS A ampere(s) Ib pounds (s) ABDC afler bottom dead center m meter(s) AC alternating current min minute(s) ATDC afler top dead center N ne'NI on (s) BBDC bef ore bott om dead center p, pascal(s) BDC bott om dead center PS horsepower BTDC bef ore l op dead canter psi pound{s) per square inch ·C degree(s) Celcius , revolution DC direct current 'I'm revolu tion(s) per minute F farad(s) TOC top dead center ·F degree(s) Fahrenheit T IR tolal indicator readi ng « foot, feel V vol t(s) 9 gram(s) W watt(s) h hour(s) n ohm(s) L liter(s ) Read OWNER'S MANUAL before operating.

EMISSION CONTROL INFORMATION To protect the environment in which we allliv8, Kawasaki has Incorporated crankcase emission (I ) and exhaust emission (2) control systems In compliance wi th applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. 1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase. Then. iI is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of crankcase. 2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist 01 a modified carburetor and an ignition system having optimum ignition timing characteristics. The carburetor has been calibrated to provide lean airlfuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system. A maintenance free Igniti on system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains What is commonly referred to as the Act's "tampering provisions.' ·Sec. 203(a) The following acts and the causing thereof are prohibited... (3)(A) for any person to remove or render Inoperative any device or element of design installed on or In a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render Inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperatlve any device or element 01 design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser. .. • NOTE ..) The phrase "remove or render inoperative any device or element of design ~ has been generally interpreted as follows : 1. Tampering does not include the temporary removal or render ing inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include: a. Maladjustment of vehicle components such that the emission standards are exceeded. b. Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. c. Addition of components or accessories that result in the vehicle exceeding the standards. d. Permanently removing, disconnecting, or rendering inopera tive any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WH ICH IS PUNISHABLE BY CI VI L PENALTIES NOT EXCEEDING S10,000 PER VIOLATION.

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only) To minimize the noise emissions from th is product, Kawasaki has equipped it wi th etleclive intake and althausl silencing systems. They are designed to give optimum performance wh ile maintaining a low noise lellel. Please do not remove these systems, or alter them in any which results in an increase in noise leveL

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in formation to make it useful to the owner who desires to perlorm his own basic maintenance and repair work. A basic knowledge 01 mechanics, the proper use of tools. and workshop procedures must be understood In order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work. all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with Ihe procedures before starling work. and Ihen do the work carefully in a clean area. Whenever special tools or equipment are specified. do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used. and the use of substitute tools may adversely affect safe operation. For Ihe duration 01 the warrant y period, we recommend that all repairs and scheduled maintenance be performed in accordance with th is service manual. Any o wner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest lile out of your vehicle: • Follow the Periodic Maintenance Chart in the Service Manua l. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers tha t are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Catalog or Manua l. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual carefully. Don't lake shortcuts. • Remember 10 keep complete records 01 maintenance and repair with dates and any new parts installed. How to Use This Manual In preparing this manual. we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Qu i ck Aeference Guide shows you all of the product's system and assists in locating their chapters. Each Chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart Is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug informa ti on, for example. go to the Periodic Maintenance Chart first. The charI tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table 01 Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARNING and CAUTION symbols. heed their instructronsl Always lollow safe operating and maintenance practices. , AWARNING This warni ng s ymbol ident ifies special instructions or procedu res which , il not correctly fol- lowed , could result in perso nal injury, or lo ss of lIIe. CAUTION Thi s cauti on symbol i dentifies special instruc - tions or procedures which , ;, not strictly ob- served, co uld result In damage to or destru ction of equi pment . This manual contains lour more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of Information. NOTE u Th Is note symbol indicates points of particular in- terest for more efficient and convenient operation. • Indicates a procedural step or work to be done. o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. * Indicates a conditional step or what action to take based on the resu lt s of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components lollows the Table of Content s. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil. grease or a locking agent during assembl y.

GENERAL INFORMATION 1-1 General Information Table of Contents Belore Servicing................ ..................... ................................................. .. ... .............................. .. . .......... .. 1-2 Model Identification...................................... .. ......... ....................................................... ,. ... .. ............ 1-4 General Specifications .............................. .... .. ...... .... .. .... .. ....... . ................. ............................. ................ ..... 1-6 Periodic Maintenance Chart...... .............. ............ .......... " .................... ... .. ... .. ......................... .. ............... 1-10 Technicallnlormation 1 - Torque Converter ....... .. .. .................................................................................... ... ................ 1-11 Technical Information 2 - Reverse Power Control System ......................... .......................................... .. .. . 1·14 Torque and Locking Agent ................ ....................... ..................... .. ....................... .. ................ ... .. ...... , ... ... ....... 1-15 Special Tools, Sealan!.................................. ...................................................................................................... .. 1-19 Cable, Wire. and Hose Routing .............................. ......... ................................ ................. .. .............. .. ........................... 1-24

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations. notes, illustrations. photographs, cautions. and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and re installation or disassembly and reassembly of general parts. Especially note the following: (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine wil l shorten the li fe of the motorcycle. For the same reason, before installing a new par t, clean oft any dust or metal filings. (2) Battery Ground Disconnect the ground H wire from Ihe battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidental ly turning over while work is being carried out , sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connecllhe positive wire to Ihe positive (+) terminal of the battery (3 ) Installation. Assembly Generally, installation or assembly is the reverse of removal or disassembly_ However, if installalion or assembly sequence is given in this Service Manual, follow it. NOle parts locations and cable, wir e, and hose routing during removal or disassembly so they can be Installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible. (4 ) TIghtening Sequence When installing bolls, nuts, or screws for which a lightening sequence is given in this Service Manual, ma ke sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and lighten them to a snug lit, thus ensuring that the part has been Installed in ils proper location. Then, tighten them to the speCified torque in the tightening sequence and method indicated_ If tightening sequence instructions are not given, lighten them evenly in a cross pattern, Conversely, to remove a pat. first loosen all the bolts, nuts, or screws that are retaining the part a lI 4-turn before removing them. (5) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (6) Force Common sense should dictate how much f orce is necessary in assembly and disassembly. II a part seems especially difficult to remove or Inslall, stop and eKamine what may be causing the problem. Whenever tapping Is necessary, lap lightly using a wooden or plastic-faced mallet. Use an impacl driver lor screws (particularly f or the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads. (7) Edges Wat ch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over. (8 ) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger . A commerci al solvenl commonly available in North America is standard solvent (generic name). Always follow manufacturer and conl ainer directions regarding the use of any solvent. (9) Gasket. O-Ring Replace a gasket or an C-ring with a new part when disassembling_ Remove any foreign matler from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface 10 prevent 011 or compression leaks. (10) Liquid Gasket. Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage. ( 11 ) Press When usirlg a press or driver to install a pari such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contaci to ensure a smooth lit. (12) Ball Bearing and Needle Bearing 00 not remove a ball bearing or a needle bearing unless il is absolutely necessary. Replace any ball or needle bearings that were removed with new ones_ Install bea ri ngs with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only 10 the end of the race I hat coni acts the press fit portion , and press it evenly over Ihe base component. (13) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed inlo place using a suitable driver, applying a force uniformly to the end of seal until Ihe lace 01 the seal is even With the end 01 the hole, unless instructed otherv.rise_ When pressing in an oil or grease seal which has manufacturer's marks, press it in wi lh the marks facing out.

GENERAL INFORMATION 1-3 Before Servicing (14) Circlip, Retaining Ring. and Cotter Pin When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with Its chamfered side facing load side as well. Replace any eire lips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading 10 a major problem. (IS) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply cil lo any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost ils lubricative quality and may contain foreign particles Ihal act as abrasives; therefore. make sure to wipe it oft and apply fresh grease or oil. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application f or which they are not intended. ( t6) Direction of Engine Rotation To rotate the crankshaft manually. make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the leh side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine In the direction of positive rotation as well. ( 17) Replacement Parts When there is a replacement instruction, replace these pans wi th new ones every time they are removed. Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these par ts with new ones every time they are removed. Although the previously mentioned gasket. O·ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement pans . (18) Electrical Wires All the electrical wires are either one·color or two·color. A two·color wire is identified first by the primary color and then the stripe color. For example. a yellow wire with thin red stripes is referred to as a ·yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed. Unless instructed otherwise, electrical wires must be connected to wires of the same color. Two-Color Electrical Wi re ( cro s s-s e ction) Co l o. Indlo.tld on t n4 II .. &. 1 .'10"" ... . ' ... 11· [.'0 1 .... . Ye I lo w/ Red ---'Y/ R--- .. .. .... . , c (19) Inspection When parts have been disassembled. visually inspect these parts tor the following conditions or other damage. If there is any doubt as to the condition of them, repiace them with new ones. Abrasion Bent Crack Dent Hardening Scratch Color change Deterioration Seizure (20) Specifi cations Specification terms are defined as follows: "Standards' show dimensions or performances which brand·new parts or systems have. Warp Wear 'Service Limits' indicate the usable limits. If the measurement shows excessive wear or deteriorated performance. replace the damaged parts.

1999-2002 Kawasaki Prairie 300 KVF300 Service & Repair Manual

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