Kawasaki Brute Force 750 4x4i service schedule

1. Work in a well-ventilated place away from sparks or flames. Never clean the foam with petrol or a low-flash-point solvent.
2. Take out the element (see the service manual for the cover).
3. Wash it in high-flash-point solvent, then squeeze it dry in a clean towel. Do not wring it or blow it dry; that tears the foam.
4. Replace it if it is torn, holed or hard.
5. Soak it in foam filter oil, squeeze out the excess, then wrap it in a clean rag and squeeze it as dry as possible.
6. Refit it. Check the air cleaner drain tube: if water or oil has collected, take off the tube plug, drain it, and refit the plug and clamp firmly.

Tools: Bath of high-flash-point solvent, Clean towels, Gloves

1. Park on level ground, engine off, key out.
2. Check the front reservoir level and the pad linings; replace pads at 1 mm (new is 4 mm).
3. Check the rear brake lever free play is 1–2 mm and the pedal free play is 15–25 mm; adjust if needed.
4. Check the brake light comes on after 10 mm of pedal travel.
5. Check the front brake hoses and joints for leaks or damage every 90 days or 1,700 km.

Tools: Torch, Rule, Spanners for the cable adjusters

1. Warm the engine up, then park so the quad is level side to side and front to back. Stop the engine and take the key out. Hot oil burns: wear gloves.
2. Take out the engine drain plug and let the oil drain. Remove the filter with the filter wrench to drain it too.
3. Fit a new gasket to the drain plug and tighten it to 20 N·m.
4. Oil the new filter's gasket, screw it on and tighten it with the filter wrench to 18 N·m.
5. Fill with 2.2 L of 10W-40 JASO MA oil.
6. Start the engine, check for leaks, stop it and check the level after a minute. Top up if needed.
7. Take the old oil and filter to a proper disposal point.

Tools: Drain tray (3 L), Kawasaki oil filter wrench 57001-1249 or similar, Torque wrench (18–20 N·m), Funnel, Gloves

1. Let the engine cool and take the key out.
2. Remove each plug and clean it, ideally in a plug sand-blaster, then brush off any abrasive.
3. Replace a plug with corroded or damaged electrodes or a cracked insulator.
4. Set the gap to 0.7–0.8 mm.
5. Screw the plugs in by hand and tighten to 13 N·m. Refit the caps.

Tools: Plug spanner, Wire feeler gauge, Torque wrench (13 N·m)

1. Engine off, key out, engine cool. Remove the converter cover (see the service manual).
2. Measure the belt width in several places: new 29.7–30.3 mm, replace below 28.0 mm. Check for cracks, breaks or peeling.
3. Turn the driven pulley to move the belt fully to the outside, then measure the deflection between the pulleys with a straightedge and ruler: 22–27 mm.
4. If it is outside this range, add or remove the shims as the service manual says. If it still cannot be set, replace the belt.
5. Whenever you replace the belt, check the drive and driven pulleys.
6. Measure the engine brake actuator lever guide shoe: replace the lever assembly if the worn area is wider than 6 mm.
7. Refit the cover, tightening the bolts in sequence to 8.8 N·m.

Tools: Socket set, Vernier caliper, Straightedge and ruler, Torque wrench (8.8 N·m)

1. Park on level ground, engine off, key out.
2. Wipe the grease fitting on the rear propeller shaft universal joint clean and grease it.
3. Wipe off any excess. Check the joint boots for splits at the same time.

Tools: Grease gun, Rag

1. This means opening the rear final gear case. Have a Kawasaki dealer do it unless you have the service manual and tools.
2. Refill with the correct tractor hydraulic fluid afterwards.

Tools: Service manual

1. Only check with the engine cold. Take the key out.
2. Follow the service manual to set each cylinder at top dead centre on compression and remove the valve adjusting caps.
3. Clearances: inlet 0.10–0.15 mm, exhaust 0.20–0.25 mm.
4. Adjust with the screw and locknut and tighten the locknut to 12 N·m; refit the caps at 8.8 N·m.
5. If you do not have the service manual, have a Kawasaki dealer do it.

Tools: Feeler gauges, Service manual, Socket set, Torque wrench (12 N·m)

1. Ride the quad so the oil is warm and picks up sediment, then park it level side to side and front to back. Stop the engine and take the key out.
2. Front: remove the front side cover, put the tray under the case and remove the drain plug. Refit it with a new aluminium gasket at 15 N·m.
3. Front: fill with 10W-40 to the bottom of the filler opening (about 0.40 L). Grease the O-ring and tighten the filler cap to 29 N·m.
4. Rear: remove the drain plug, drain, refit it with a new aluminium gasket at 13 N·m.
5. Rear: fill with tractor hydraulic fluid to the bottom of the filler opening (about 0.72 L). Grease the O-ring and tighten the filler cap to 29 N·m.
6. Keep oil off the tyres and rims; it damages the rubber and makes them slippery. Clean any off with high-flash-point solvent.

Tools: Small drain tray, Socket set, Torque wrench (13–29 N·m), Oil pump or squeeze bottle, Grease

1. Take off the reservoir cap and the rubber cap on the caliper bleed valve. Fit a clear tube to the bleed valve, running into a jar.
2. Fill the reservoir with new fluid.
3. Open the bleed valve, squeeze and hold the brake lever, close the valve, then release the lever. Repeat until clean fluid comes out, keeping the reservoir topped up.
4. Do the other caliper the same way, tighten the bleed valves to 5.4 N·m and fit the caps.
5. Brake fluid damages paint and plastics: wipe spills at once.

Tools: Clear bleed tube and jar, Ring spanner, Torque wrench (5.4 N·m)

1. Never take off the radiator cap or drain coolant while the engine is hot: wait until it cools.
2. Remove the left footboard, front fender, radiator cover and the reserve tank, and empty the tank.
3. Remove the drain plug at the bottom of the water pump, then take off the radiator cap in two steps.
4. Also remove the drain plugs on the front and rear cylinders.
5. Refit all drain plugs at 8.8 N·m, fill with 50/50 mix and bleed out air using the bleeder bolt as the service manual says.
6. Wash spilt coolant off the tyres at once (it makes them slippery) and dispose of old coolant safely.

Tools: Drain tray, Funnel, Socket set, Torque wrench (8.8 N·m), Antifreeze tester