SERVICE INFORMATION

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ATV 07-02
                SERVICE
 REPLACES: Please discard ATV 03-04 dated 12/12/03
                                                                                                                April 5, 2007


                                                                                                                             Page 1 of 7
  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 FORCETM 650 4X4i (KVF650-D/E/F/G),
                  BRUTE FORCETM 750 4X4i (KVF750-A/B/C),
  TITLE:          DRIVE BELT CHECK/DRIVE BELT FAILURE DETECTION
                  SYSTEM MEMORY CLEARING PROCEDURE

                                                SERVICE INFORMATION
Subject                                                                         Components

    Unfamiliarity with the Drive Belt Check and                                 Drive Belt Check System:
Drive Belt Failure Detection systems on Prairie,
                                                                                     The Drive Belt Check system consists of an
Brute Force and KFX700 ATV models is causing
                                                                                hour meter that records key ON or engine running
non-faulty igniters to be replaced instead of the
                                                                                time depending on model. If 100 hours accumulate
memory being cleared. Read this bulletin for a
                                                                                in the hour meter, the Belt Check Indicator light
thorough understanding of these systems to avoid
                                                                                in the dash will illuminate and stay on indicating
unnecessary igniter replacement.
                                                                                the drive belt should be inspected and replaced
                                                                                if necessary.

                                                                                Drive Belt Failure Detection System:
                                                                                    The Drive Belt Failure Detection system
                                                                                consists of a switch mounted in the CVT cover
                                                                                that can be tripped by a worn or damaged belt. If
                                                                                the Drive Belt Failure Detection switch is tripped,
                                                                                the Belt Check Indicator light will flash and the
                                                                                vehicle will enter "slow mode." In slow mode, the
                                                                                vehicle is limited to 3600 rpm, and the vehicle will
  A. DRIVE BELT CHECK INDICATOR LIGHT                                           not enter 4WD.

Applicable Vehicles                                                             Other Conditions

                                   Components Included (Symptom)                    The Drive Belt Failure Detection system can
                                     Drive Belt   Drive Belt Failure            be activated due to sudden changes in voltage.
             Model                  Check (Light Detection Switch               Several common conditions that can activate the
                                   Stays On after  (Light or LCD
                                     100 hours)       Flashes)
                                                                                system:
       KVF360-B                       *NOTE: 1                                  Disconnecting/connecting the battery with the
2WD
       KSV700-A/B                                        
                                                                                  key in the ON position, this is common for new
       KVF360-A/C                                        
       KVF650-A1/B1                  **NOTE: 2                                   units during initial setup.
4WD KVF650-A2/B2/D/E/F/G/H                                                     Use of accessories that have a significant draw
       KVF700-A/B/D                                      
                                                                                  on the battery.
       KVF750-A/B/C                                      
*NOTE: 1
The KVF360-B does not have a Belt Check indicator light. An hour meter
                                                                                    The Drive Belt Failure Detection switch sends
recording key on time is provided under the seat for assistance in following    voltage to the igniter. If the battery is connected or
the Periodic Maintenance Chart. The meter cannot be reset.
                                                                                disconnected when the key is in the ON position,
**NOTE: 2
The 2002 KVF650-A1/B1 is not equipped with a Belt Check Indicator light.        the igniter reads the sudden change in voltage as
The Reverse indictor light and LCD meter will flash indicating the Drive Belt
Failure Detection switch has been tripped.
                                                                                the switch being tripped.

File behind the "ATV" tab in your Kawasaki
"Service and Warranty" binder
                                                                                                                        TM

2007, Kawasaki Motors Corp., U.S.A.
      Kawasaki ships ATVs with the key in the          Service Manuals
ignition switch in the ON position so that the                 MODEL                 PART NUMBER
key cannot fall out. If the battery is charged and      KVF360-A/C               99924-1285-06
installed with the key in the ON position, the          KVF360-B                 99924-1302-04
sudden increase in voltage can trigger the igniter      KVF650-A/B               99924-1261-04
                                                        KVF650-D/E               99924-1348-03
to illuminate the Belt Check Indicator light.
                                                        KVF650-F/G/H             99924-1363-01
    Accessories, such as a winch, that create           KSV700-A/B               99924-1315-05
a large voltage draw on the battery can also            KVF700-A/B               99924-1319-04
trigger the igniter to illuminate the Belt Check        KVF750-A/B/C             99924-1334-04
Indicator light.                                           Once the drive belt has been inspected, the
     If battery voltage is drawn down significantly    Belt Check/Drive Belt Failure Detection system
during use of the accessory and the accessory          must be reset. Use the instructions that follow to
is turned off or disconnected, the sudden jump         reset the system.
in voltage may cause the indicator light to flash.
                                                       Warranty Information
     Occasionally the Belt Failure Toggle Switch
inside the CVT can become defective. Even while           This bulletin is service information only not
in the ON position, there could be no continuity       warranty authorization.
                                                           If the Belt Check Indicator light stays on after
                                                       completing the resetting procedure two or three
                                                       times, the igniter may need to be replaced. A
                                                       study of igniters replaced under warranty has
                                                       concluded that actual failure rate of the igniters
                                                       is extremely low, however.
                                                           Confirm that the Drive Belt Failure Detection
                                                       switch is ON and complete the resetting
                                                       procedure two or three times prior to requesting
                                                       warranty on any KVF360-A/C, KVF650-A/B/D/E/
                                                       F/G/H, KVF700-A/B/D, KSV700-A/B, and KVF750-
                                                       A/B/C igniters to make sure the unit is actually
                                                       malfunctioning. As of the original publication
                                                       date of this bulletin, any igniters replaced under
                                                       warranty for these models will be called back
 A.   SWITCH
 B.   ON POSITION                                      to Kawasaki and tested. If the igniter is working
 C.   CVT COVER                                        properly after resetting the Belt Check/Drive
 D.   FORWARD (OFF POSITION)                           Belt Failure Detection system, the dealer will be
                                                       charged back for the igniter and labor.
(open circuit), especially when riding in rough
terrain. To check, tap on the CVT cover near the
switch while the engine is idling. If the tapping
causes the Belt Check Indicator Light to flash,
the CVT cover needs to be replaced.

Resetting Procedure

    If the Belt Check Indicator light is illuminated
or blinking, first check the condition of the belt.
Following the procedures in the appropriate
Service Manual, inspect and replace the drive
belt as necessary.




                                                   Page 2
All KVF Models (Except KVF650-A1/B1):                   to completing the resetting procedure. To reset
                                                        both the Belt Check system indicator and the
    KVF360-A/C, KVF650-A/B/D/E/F/G/H, KVF700-
                                                        Drive Belt Failure Detection system, follow these
A/B/D, and KVF750-A/B/C models have both an
                                                        procedures:
hour meter feature and a Drive Belt Failure Detection
switch.                                                 KVF360-A/C, KVF650-A2/B2/D/E/F/G/H,
                                                        KVF700-A/B/D:
KVF360-A/C
                                                            If the Belt Check indicator light is illuminated
                                                        or blinking, first check the condition of the belt.
                                                        Following the procedures in the Service Manual
                                                        applicable to the model being serviced, inspect
                                                        and replace the drive belt as necessary.
                                                            Once the drive belt has been inspected, the
                                                        Belt Check/Drive Belt Failure Detection system
                                                        must be reset. Use the instructions that follow to
BELT CHECK                                              reset the system.
INDICATOR
LIGHT                                                                         NOTE:
                                                        o    The belt switch (toggle) inside the CVT
                                                             cover must be at the "ON" position before
                       NOTE:
                                                             performing this procedure.
o    On KVF360-A/C models, the Belt Check
     Indicator light is illuminated after 100 hours     1.   Turn ignition key to the OFF poison.
     has accumulated.                                   2.   Disconnect the 2-wire small black connector
                                                             [A] by the right-front side of the engine.
KVF650-A/B/D/E/F/G/H, KVF700-A/B/D, and
KVF750-A/B/C
    BELT CHECK
    INDICATOR
    LIGHT




                                                             KVF360 shown.


                                                        3.   Disconnect both black and gray 4-wire
                                       TRIP METER/           connectors [A] in the same vicinity (under
                                       ODOMETER/             the seat on KVF750 models).
                                       HOUR METER


                       NOTE:
o    KVF650-A/B/D/E/F/G/H, KVF700-A/B/D, and
     KVF750-A/B/C models have a Belt Check
     Indicator light and a viewable hour meter in
     the LCD meter.

    If 100 hours has accumulated, the Belt
Check Indicator light will come on and stay on. If
the Drive Belt Failure Detection switch is tripped,
the Belt Check Indicator light will flash and go
                                                             KVF360 shown.
into slow mode. If the light is flashing, the switch
must be placed back into the ON position prior
                                                    Page 3
4.   Reconnect the gray plug (male) connector         10. Reconnect the 2-wire small black connector
     [A] to the black receptacle (female)                 [B].
     connector [B].




                                                           KVF360 shown.

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




     KVF360 shown.


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




                                                  Page 4
KSV700-A/B/C:                                          6.    Turn on the ignition switch.
     KFX700 models store engine running time in                                NOTE:
the igniter and the Belt Check Indicator light is
                                                       o     The hour meter resets immediately when the
illuminated after 100 hours of engine running time.
                                                             key is turned ON.
When the Belt Check Indicator light comes on,
follow these procedures to reset the hour meter:
1.   Turn the ignition switch OFF.
2.   Inspect and replace the drive belt as necessary
     according to the Service Manual (P/N 99924-
     1315-05).
3.   Remove the seat.
4.   Locate the two, 4-pin connectors (A) under the
     seat. One connection is black and the other is                   A
     gray.


                                                           A. BELT CHECK INDICATOR LIGHT

                                                       7.    The Belt Check Indicator light should be
                                                             flashing.
                                                       8.    Turn off the ignition switch.
                          A                            9.    Disconnect the mismatched 4-pin connector
                                                             sets and reconnect them normally (black-to-
                                                             black, gray-to-gray).
                                                       10. Turn on the ignition switch and confirm that the
 4-PIN CONNECTORS                                          indicator light is no longer on.

5.   Disconnect both sets of 4-pin connectors,
     and reconnect the 4-pin connectors to their
     opposite color, i.e., gray-to-black and black-
     to-gray.




                           A




A. GRAY-TO-BLACK; BLACK-TO-GRAY




                                                  Page 5
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