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Toggle Nav. Aircraft Aeroplanes Buses Golf Carts. Contact us Support. My Cart 0 Cart. Skip to the end of the images gallery. Skip to the beginning prairje the images gallery. Fast Download Speeds. Full Search Facility. Print one or all pages of your manual.
Add to Cart. PDF Secure transaction. This quick reference guide will assist you in locat ing a desired topic or procedure. NOTE o 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 rendering inoperative of devices or elements of design in order manuall perform maintenance.
Tampering could include: a. Maladjustment of vehicle components such that the emission standards are exceeded. Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle.
Addition of components or accessories that result in the vehicle exceeding the standards. Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.
US Model only To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these mqnual, 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 information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of 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 effici ently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever speci al 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 substi- tute tools servixe adversely affect safe operation.
For the duration of the warranty period, we recommend that all repairs 2002 kawasaki prairie 400 service manual scheduled maintenance be performed in accordance with this service manual.
Any owner maintenance or repair procedu re not performed in accordance with this manual may void the warranty. To get the longest life out of your Vehicle:. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Catalog or Manual. Genuine parts provided as spare parts are 2002 kawasaki prairie 400 service manual in the Parts Catalog.
Don't take shortcuts. How to Use this Manual In preparing this manual, we divided the product into its major systems. These systems 2002 kawasaki prairie 400 service manual the manual's chapters.
All information for a particular system from adjustment through disassembly and kawassaki is located in a single chapter. The Quick Reference Guide shows you all of 2002 kawasaki prairie 400 service manual product's system and assists in locating their chapters.
Each chapter in turn has its own compre- hensive Table of Contents. The chart gives a time schedule for required maintenance operations.
If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Always follow safe operating and maintenance practices. AWARNING This warning aervice identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. NOTE o This note symbol indicates points of partic- ular interest for more efficient and convenient operation. It also precedes the text of a NOTE. In most chapters an exploded view illustration of the system components follows the Table of Contents.
In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever kawwsaki.
Nevertheless, even a detailed account has limitations, 2002 kawasaki prairie 400 service manual certain amount of basic knowledge is also required for successful work. Especially note the following: 1 Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the vehicle.
For the same reason, before installing a new part, clean off any dust or metal filings. This prevents: a the possibility of accidentally turning the engine over while partially disassembled. But if this 2002 kawasaki prairie 400 service manual Manual has installation or assembly procedures, follow them. Then tighten them evenly in a cross pattern. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the prwirie, nuts, or screws must be tightened in the order and mxnual indicated. When torque values are given in this Service Manualuse them. Either too little or too much torque may lead to serious damage. 2002 kawasaki prairie 400 service manual a good quality, reliable torque wrench. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem.
Whenever tapping is necessary, tap lightly maual a rubber, 2002 kawasaki prairie 400 service manual, or plastic-faced mallet. Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads.
Protect your hands dervice gloves or a piece of thick cloth when lifting prairiee engine or turning it over. A commercial solvent commonly available in North America kawadaki Stoddard solvent generic name. Always follow manufacturer and container directions regarding the use of any solvent.
The mating surfaces around the gasket should be free of foreign matter and perfectly 2002 kawasaki prairie 400 service manual to avoid oil or compression leaks. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearings.
Only press on the race that forms the press fit with the base component to avoid damaging the bearings. This prevents severe stress servjce the balls or needles and races, and prevents races and balls or needles from being dented. Press a ball bearing until it stops at the stop in aervice hole or on the shaft. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out.
2002 kawasaki prairie 400 service manual should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with 2002 kawasaki prairie 400 service manual end of the hole. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.
During assembly, oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended.
This manual makes reference to molybdenum disulfide grease MOS2 in the assembly of certain engine and chassis parts. 2002 kawasaki prairie 400 service manual check manufacturer recommendations before using such special lubricants. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color.
These replacement parts will be damaged or lose their original function once removed. If there is 2002 kawasaki prairie 400 service manual doubt as to the condition of them, replace them with new ones. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts. You're Reading a Preview What's Included? Show prev pages. Instant of the factory repair manual for the Kawasaki Prairie atv. Covers all 2wd and 4x4 models. This is the same type of service manual your local dealer will use when doing a repair.
It also precedes the text of a NOTE. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
Especially note the following: 1 Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before installing a new part, clean off any dust or metal filings. This prevents: a the possibility of accidentally turning the engine over while partially disassembled. But if this Service Manual has installation or assembly procedures, follow them. Then tighten them evenly in a cross pattern.
Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. 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. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a rubber, wooden, or plastic-faced mallet. Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads.
Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. A commercial solvent commonly available in North America is Stoddard solvent generic name. Always follow manufacturer and container directions regarding the use of any solvent. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage.
Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearings. Only press on the race that forms the press fit with the base component to avoid damaging the bearings.
This prevents severe stress on the balls or needles and races, and prevents races and balls or needles from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out.
Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. During assembly, oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film.
CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. NOTE o This note symbol indicates points of partic- ular interest for more efficient and convenient operation. It also precedes the text of a NOTE. In most chapters an exploded view illustration of the system components follows the Table of Contents.
In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
Especially note the following: 1 Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before installing a new part, clean off any dust or metal filings. This prevents: a the possibility of accidentally turning the engine over while partially disassembled.
But if this Service Manual has installation or assembly procedures, follow them. Then tighten them evenly in a cross pattern. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. 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. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a rubber, wooden, or plastic-faced mallet. Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads.
Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. A commercial solvent commonly available in North America is Stoddard solvent generic name. Always follow manufacturer and container directions regarding the use of any solvent. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.
Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearings. Only press on the race that forms the press fit with the base component to avoid damaging the bearings.
This prevents severe stress on the balls or needles and races, and prevents races and balls or needles from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction.
Select Vehicle. HINs have 12 digits. They look like this: KAWJ Motorcycles You will find the VIN stamped on the steering head, below the handlebars. Mule Utility Vehicles You will find the VIN on the top edge of the front bench seat base, just below the seat cushion.
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