kvf750 tie rod recall info
Contents
1. EE 2AN E E Kawasaki Category Factory Directed Modification SERVICE maa KVF750 A1 B1 INFORMATION DC8971A 2A Dec 13 2005 Subject Tie rod End Ball Separation RECALL Discard the previous one REVISED Subject sss Tie rod separation caused by either wear or impact can occur during operation This can disconnect the front wheel from the steering control and could result in an accident with Tle rod assy risk of injury or death to the ATV operator Units within the V I N ranges listed below are eligible for repair Eligible units JKAVEDA1 5BXXXXXX All other than 500001 thru 518688 KVF750 A1 Europe JKAVE750AABXXXXXX 600008 thru 600969 KVF750 B1 JKAVFDB1V5BXXXXXX an con 500001 thru 506051 V Check digit XXXXXX Serial Number Kawasaki has initiated a Factory Directed Modification RECALL campaign to repair all eligible units according to the Required Action in Field section of this Service Information Repair all eligible units including sold units in field and unsold units in Dealer Also repair all Tie rod Ends and Tie rod sold as spare parts in fields and unsold parts in Dealer and Distributor Page 1 of 6 Quality Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd E E Kawasaki 1 Notify Registered Owners Notify all owners of eligible units of modifying the designated all terrain vehicle by means of sending letters or any other else Kawasaki s2. Tie lt Preparation gt f necessary clean the area around the knuckle and suspension arm so that the work area is clean Place the vehicle on a flat surface Loosen the wheel nuts A at both sides Lift up the front wheels and remove the wheel nuts and wheels lt Remove Tie rod gt Remove cotter pins tie rod end nuts washers and tie rod assy A DC8971A 2A Page 3 of 6 for Kit Rod Assy Tie P N 99999 0084 lt Remove Steering Stem Bearing gt Remove steering stem bearing joint bolts A Lift the steering stem Remove cotter pin A steering stem bottom end nut B and collar C Remove steering stem bearing D lt Install Steering Stem Bearing gt Fill grease up the seal grooves in new steering stem bearing Lift the steering stem and install the steering stem bearing Install the collar Tighten steering stem bottom end nut 5108004B51 C Steering Stem Bottom End Nut 62 N m 6 3 kgf m 46 ft Ib Install new holder damper A on the steering stem bearing Tighten new steering stem bearing and new holder with new joint bolts B both sides Steering Stem Bearing Joint Bolts 23 N m 2 3 kgf m 17 ft lb lt Install Damper gt Install new dampers A to the holder Tighten dampers with new damper nuts B both sides Damper Nuts 8 N m 0 8 kgf m 6 ft Ib lt Install New Bracket gt Install new bracket A on the old b
3. od locknuts and make sure the tie rod ends are aligned 180 opposed Handlebar misalignment or unequal tie rod adjustment can cause the vehicle to drift left or right or mishandle which could lead to an accident Operate the vehicle slowly after handlebar alignment and toe in adjustment to check that the steering responds correctly and the handlebar is straight when the vehicle is traveling in a straight line If not re check the handlebar alignment and toe in adjustment DC8971A 2A Page 5 of 6 Make a small punch mark up the V I N as a verification mark A V I N B Front Axis left side C Punch Mark The labor cost will be reimbursed upon your warranty request All other than Europe market Model KVF750A1 KVF750B1 KVF750A1 KVF750B1 517987 505537 518688 506051 ee Quantity 1 Special Claim ID No DC8971A DC8972A Ooo 3 O Claim Type 3 Europe market Model KVF750A1 _ _ _ KVF750A1 600861 thru 600969 Quantity fF S S 0 Please issue invoice of total cost incurred for repair in case distributor carries out rework their inventory before shipping DC8971A 2A Page 6 of 6
4. racket of the steering stem DC8971A 2A Page 4 of 6 E E Kawasaki for All Kit Rod Assy Tie lt Install Tie rod Assy gt CAUTION Do not loosen the tie rod end locknuts on the new tie rod assy before installing tie rod assy Tie rod ends and tie rods are pre assembled at the proper length and angle Install new tie rod assy and washers refer to first illustration Hold the flat surface A of the tie rod end with a thin wrench B and tighten the tie rod end nut C Tie rod End Nuts 42 N m 4 3 kgf m 31 ft lb AWARNING Be careful not to damage the rubber seal during installation Hold the tie rod end shaft with a 17mm wrench while tightening the tie rod end nuts Damage could occur to the tie rod end if the tie rod assembly is allowed to hang by one end Support the tie rod assembly during installation Install new cotter pins Install front wheels Tighten the wheel nuts in a criss cross pattern Wheel Nuts 57 N m 5 8 kgf m 42 ft Ib lt Check Toe in gt Check toe in of front wheels If the toe in is not in the specified range the vehicle needs to be adjusted Toe in of Front Wheels 10 10 mm 0 39 0 39 in at 1G AWARNING Allowing the tie rod end body to contact the shaft while loosening or tightening the tie rod locknuts can cause damage to the tie rod end and result in failure of steering components Hold the tie rod end with a wrench when loosening or tightening the tie r
5. trongly recommends customer 1 Do not ride the vehicle until it has been repaired 2 Perform the Tie rod End Free Play Inspection as instructed on the separate sheets prior to each ride if customer must ride the vehicle prior to repair 2 Modify the vehicles By following the repair procedure repair all eligible units including sold units in the field and unsold units in your inventory The following parts are required for this repair V I N serial number range a Remark KVF750 A1 900001 thru 517987 Kit Rod Assy Tie 99999 0084 1 600008 thru 600860 900001 thru 505537 KVF750 A1 917988 thru 518688 Kit Rod Assy Tie 99999 0086 1 600861 thru 600969 005538 thru 506051 Kit Rod Assy Tie contents 99999 0084 1 Rod Assy Tie 39110 0024 2 2 Washer 10 2x20x1 5 92022 3742 6 TIE ROD END Kit Rod Assy Tie contents 99999 0086 1 Rod Assy Tie 39110 0024 2 2 Washer 10 2x20 1 5 92022 3742 6 TIE ROD END 3 Pin Cotter 2 0x15 550D2015 4 TIE ROD END DC8971A 2A Page 2 of 6 Kawasaki 1 Rod Assy Tie 2 Washer 10 2x20x1 5 3 Pin Cotter 2 0x15 4 Holder Damper 5 Damper 6 Nut Lock 6mm 7 Bracket Steering 8 Bolt 8x35 9 Pin Cotter 3 0x25 10 Joint Ball Refer to the appropriate sections of the Service Manual P No 99924 1334 01 02 03 for information and procedures related to parts removal and installation for All Kit Rod Assy
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