Kawasaki BRUTE FORCE 4i Service manual

Kawasaki BRUTE FORCE 4i · service manual · 594 pages

Kawasaki BRUTE FORCE 4i
Service manual
594 pages
ATV

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Cylinder Head Bolts (M10), first	25 N·m	2.5 kgf·m · 18 ft·lb	p. 27
Cylinder Head Bolts (M10), final	49 N·m	5 kgf·m · 36 ft·lb	p. 27
Rocker Shaft Bolts	22 N·m	2.2 kgf·m · 16 ft·lb	p. 28
Camshaft Chain Tensioner Cap Bolts	22 N·m	2.2 kgf·m · 16 ft·lb	p. 28
Front Cylinder Camshaft Chain Guide Bolt	20 N·m	2 kgf·m · 15 ft·lb	p. 28
Rear Cylinder Camshaft Chain Guide Bolt	20 N·m	2 kgf·m · 15 ft·lb	p. 28
Exhaust Pipe Holder Nuts	17 N·m	1.7 kgf·m · 12 ft·lb	p. 28
Muffler Mounting Nuts	20 N·m	2 kgf·m · 14 ft·lb	p. 28
Muffler Mounting Locknuts	31 N·m	3.2 kgf·m · 23 ft·lb	p. 28
Drive Pulley Bolt	93 N·m	9.5 kgf·m · 68 ft·lb	p. 28
Driven Pulley Nut	93 N·m	9.5 kgf·m · 68 ft·lb	p. 28
Oil Filter	17.5 N·m	1.8 kgf·m · 13 ft·lb	p. 28
Engine Lubrication System	15 N·m	1.5 kgf·m · 11 ft·lb	p. 28
Engine Oil Drain Bolt	20 N·m	2 kgf·m · 15 ft·lb	p. 28
Oil Pressure Relief Valve	15 N·m	1.5 kgf·m · 11 ft·lb	p. 28
Oil Pump Drive Chain Tensioner Bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 28
Engine Mounting Bracket Bolts	72 N·m	7.3 kgf·m · 53 ft·lb	p. 28
Engine Mounting Bolt	72 N·m	7.3 kgf·m · 53 ft·lb	p. 28
Engine Mounting Nut	100 N·m	10 kgf·m · 74 ft·lb	p. 28
Connecting Rod Big End Cap Nuts	34.3 N·m	3.5 kgf·m · 25 ft·lb	p. 28
Shift Lever Assembly Bracket Bolts	19.6 N·m	2 kgf·m · 14 ft·lb	p. 29
Tie-rod End Nut	19.6 N·m	2 kgf·m · 14 ft·lb	p. 29
Shift Lever Assembly Nut	19.6 N·m	2 kgf·m · 14 ft·lb	p. 29
Shift Shaft Positioning Bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 29
Shift Shaft Spring Bolt	25 N·m	2.5 kgf·m · 18 ft·lb	p. 29
Tie-rod End Locknut	19.6 N·m	2 kgf·m · 14 ft·lb	p. 29
Shift Lever Guide Mounting Nut	19.6 N·m	2 kgf·m · 14 ft·lb	p. 29
Wheel Nuts	15 N·m	1.5 kgf·m · 11 ft·lb	p. 29
Wheel Nuts	76 N·m	7.7 kgf·m · 56 ft·lb	p. 29
Front Axle Nuts	197 N·m	20 kgf·m · 145 ft·lb	p. 29
Rear Axle Nuts	265 N·m	27 kgf·m · 195 ft·lb	p. 29
Output Driven Bevel Gear Housing Bolts	26 N·m	2.7 kgf·m · 20 ft·lb	p. 29
Output Drive Bevel Gear Housing Bolts	26 N·m	2.7 kgf·m · 20 ft·lb	p. 29
Bevel Gear Holder Nut	157 N·m	16 kgf·m · 116 ft·lb	p. 29
Bearing Holder	120 N·m	12 kgf·m · 88 ft·lb	p. 29
Output Shaft Holder Nut	157 N·m	16 kgf·m · 116 ft·lb	p. 29
Front Final Gear Case Left Cover Bolts	9.8 N·m	87 in·lb	p. 29
Ring Gear Bolts	57 N·m	5.8 kgf·m · 42 ft·lb	p. 29
Front Final Gear Case Center Cover Bolts	24 N·m	2.4 kgf·m · 17 ft·lb	p. 30
Front Final Gear Case Oil Filler Cap	29 N·m	3 kgf·m · 22 ft·lb	p. 30
Pinion Gear Bearing Holder Nut	127 N·m	13 kgf·m · 94 ft·lb	p. 30
Pinion Gear Bearing Holder	137 N·m	14 kgf·m · 101 ft·lb	p. 30
Front Final Gear Case Coupling Nut	25 N·m	2.5 kgf·m · 18 ft·lb	p. 30
Front Final Gear Case Oil Drain Bolt	15 N·m	1.5 kgf·m · 11 ft·lb	p. 30
Variable Differential Control Cable Locknut	17 N·m	1.7 kgf·m · 12 ft·lb	p. 30
Rear Final Gear Case Front Cover Bolts	24 N·m	2.4 kgf·m · 18 ft·lb	p. 30
Pinion Gear Bearing Holder Nut	157 N·m	16 kgf·m · 116 ft·lb	p. 30
Rear Final Gear Case Right Cover Bolts	95 N·m	9.7 kgf·m · 70 ft·lb	p. 30
Rear Final Gear Case Right Cover Bolts	49 N·m	5 kgf·m · 36 ft·lb	p. 30
Rear Final Gear Case Right Cover Bolts	24 N·m	2.4 kgf·m · 18 ft·lb	p. 30
Rear Final Gear Case Oil Filler Cap	29 N·m	3 kgf·m · 22 ft·lb	p. 30
Rear Final Gear Case Oil Drain Bolt	15 N·m	1.5 kgf·m · 11 ft·lb	p. 30
Rear Final Gear Case Nuts	91 N·m	9.3 kgf·m · 67 ft·lb	p. 30
Front Bake Hose Banjo Bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 30
Front Brake Caliper Mounting Bolts	25 N·m	2.5 kgf·m · 18 ft·lb	p. 30
Front Brake Disc Mounting Bolts	37 N·m	3.8 kgf·m · 27 ft·lb	p. 30
Front Brake Caliper Holder Shaft	17 N·m	1.7 kgf·m · 12 ft·lb	p. 30
Front Brake Pad Mounting Bolts	17 N·m	1.7 kgf·m · 12 ft·lb	p. 30
Front Shock Absorber Mounting Nuts	34 N·m	3.5 kgf·m · 25 ft·lb	p. 30
Front Suspension Arm Pivot Nuts	42 N·m	4.3 kgf·m · 31 ft·lb	p. 30
Steering Knuckle Joint Nuts	29 N·m	3 kgf·m · 21 ft·lb	p. 31
Rear Shock Absorber Mounting Nuts	34 N·m	3.5 kgf·m · 25 ft·lb	p. 31
Stabilizer Holder Bolts	22 N·m	2.2 kgf·m · 16 ft·lb	p. 31
Stabilizer Joint Nuts	46 N·m	4.7 kgf·m · 34 ft·lb	p. 31
Rear Suspension Arm Pivot Nuts	46 N·m	4.7 kgf·m · 34 ft·lb	p. 31
Rear Knuckle Mounting Nuts	46 N·m	4.7 kgf·m · 34 ft·lb	p. 31
Handlebar Holder Bolts	29 N·m	3 kgf·m · 21 ft·lb	p. 31
Steering Stem Clamp Bolts	25 N·m	2.5 kgf·m · 18 ft·lb	p. 31
Tie-rod End Nuts	42 N·m	4.3 kgf·m · 31 ft·lb	p. 31
Steering Stem Bearing Joint Bolts	22 N·m	2.2 kgf·m · 16 ft·lb	p. 31
Steering Stem Bottom End Nut	62 N·m	6.3 kgf·m · 46 ft·lb	p. 31
Front Guard Bolts	46 N·m	4.7 kgf·m · 34 ft·lb	p. 31
Front Carrier Bracket Bolts	32 N·m	3.3 kgf·m · 24 ft·lb	p. 31
Rear Carrier Bracket Bolts	46 N·m	4.7 kgf·m · 34 ft·lb	p. 31
Footboard Bracket Bolts	46 N·m	4.7 kgf·m · 34 ft·lb	p. 31
Hitch Bracket Bolts	82 N·m	8.3 kgf·m · 60 ft·lb	p. 31
Rear Final Gear Case Mounting Bracket Bolts	59 N·m	6 kgf·m · 44 ft·lb	p. 31
Starter Motor Clutch Bolts	34 N·m	3.5 kgf·m · 25 ft·lb	p. 31
Alternator Cover Plugs	17.5 N·m	1.8 kgf·m · 13 ft·lb	p. 31
Alternator Rotor Bolt	127 N·m	13 kgf·m · 94 ft·lb	p. 31
Forward/Reverse Detecting Sensor Mounting Bolt	15 N·m	1.5 kgf·m · 11 ft·lb	p. 32
Mark of bolt head	2.6 N·m	23 in·lb	p. 32
Mark of bolt head	14.7 N·m	130 in·lb	p. 32
Mark of bolt head	9.8 N·m	87 in·lb	p. 32
Oil Filter Change	20 N·m	2 kgf·m · 14 ft·lb	p. 49
Banjo bolts	34 N·m	3.5 kgf·m · 25 ft·lb	p. 54
Radiator Fan Assembly	4.9 N·m	0.5 kgf·m · 43 in·lb	p. 177
Rocker Shafts and Copper Washers	22 N·m	2.2 kgf·m · 16 ft·lb	p. 199
Washers	25 N·m	2.5 kgf·m · 18 ft·lb	p. 212
Washers	49 N·m	5 kgf·m · 36 ft·lb	p. 212
Exhaust System	8.8 N·m	0.9 kgf·m · 78 in·lb	p. 227
Actuator Lever Assembly	8.8 N·m		p. 239
Drive Pulley Cover	13 N·m	1.3 kgf·m · 115 in·lb	p. 247
Engine Mounting Bolts	100 N·m	10 kgf·m · 74 ft·lb	p. 276

Capacities

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Fuel tank	19 L		p. 19

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	PDF page
E8F	—	p. 19
M10	—	p. 210
M38	—	p. 492

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