ATV 05-04

December 2, 2005

Page 1 of 8

SERVICERECALL
MODEL: 2005 Brute Force™ 750 4x4i (KVF750-A1/B1)
TITLE: TIE-ROD END REPLACEMENT
Eligibility
Eligible Units
Kawasaki Action
Initiate Recall Campaign:
Kawasaki has initiated a Recall campaign
to repair all eligible units. The repair consists of
replacing the tie rod ends and related parts.
THIS BULLETIN IS OF THE HIGHEST PRIORITY AND MUST BE ACTED UPON
IMMEDIATELY TO ENSURE CUSTOMER SAFETY.
Model Vehicle Identification Number Range
KVF750-A1 JKAVFDA1v5B500001 thru 518688
KVF750-B1 JKAVFDB1v5B500001 thru 506051
Please check VSI (Vehicle Service Inquiry) in
K-dealer for other possible repair campaigns for
eligible units. See bulletin number ATV 04-02, ATV
04-03.

Kawasaki will repair some units prior to you
receiving them. Repair can be verified using VSI or
by the Repair Verification. See Repair Verification
section for details.

Subject

Tie rods connect the steering shaft to the left
and right steering knuckles. On eligible units, the
tie rod end could separate during operation due to
either wear or impact leading to a loss of steering
control and creating the potential for an accident
resulting in injury or death.

File behind the “ATV” tab in your Kawasaki
“Service and Warranty” binder
©2005, Kawasaki Motors Corp., U.S.A.
TIE ROD
ASSEMBLY
STEERING
SHAFT
Notify Registered Owners:

Kawasaki is sending a Recall letter to
registered owners of eligible units. A second
notification will be sent to owners the second
week of January 2006 when parts are available in
adequate quantities instructing them to contact a
Kawasaki ATV dealer to schedule the repair

Dealer Action

Repair Eligible Units:

Repair all eligible units including sold units in the
field and unsold units in your dealership inventory
prior to delivery to the retail purchaser. It is the
obligation of authorized Kawasaki retail Dealers to
repair eligible units in Dealer‘s possession prior to
retail sale. Failure to comply with this obligation to
repair all units eligible for Recall or FDM campaigns
by the Dealer constitutes a breach of the Dealer
Sales and Service Agreement. Refer to Service
Policies bulletin SP 05-01. Refer to the Repair
Procedure section of the bulletin for details.

Document Completed Repairs:

Federal law requires manufacturers to maintain
accurate follow-up records on repairs performed
on eligible units. Dealers MUST submit a Warranty
Claim for each repair. Refer to the Warranty
Information section of this bulletin for details.



NOTE: Steering Stem Bearing Removal:


o If you fail to submit a Warranty Claim for a new
unit that is subsequently sold and registered,
the new owner will receive the Recall letter
requesting the return of the vehicle to you for
repair.
Submit Product Registration:

Submit the product registration to Kawasaki
immediately after retail sale of any eligible unit.
Be sure to supply the correct customer name and
address. Kawasaki uses the product registration
information for customer notification.

Also, if you know that the customer has
moved, please submit a Customer Update to the
Warranty Department.

Repair Procedure

The repair will vary depending on VIN. Early
produced units require the replacement of the tie
rod assemblies and installation of a steering stop
damper. Later models require only the tie rod
assemblies. See the VIN range below to identify
the proper repair kit and make the appropriate
repair.

Refer to the appropriate sections of the
KVF750-A1/B1 Service Manual (P/N 99924-133401, -02, -03) for information and procedures
related to parts removal and installation.

Preparation:

• If necessary, clean the area around the tie rod
so that the work area is clean.
• Place the vehicle on a flat surface and set the
parking brake
• Loosen the wheel nuts at both sides.
• Elevate the front wheels and remove the
wheel nuts and wheels.
Tie-Rod Removal (All Units):

• Remove cotter pins, tie-rod end nuts and tie-
rod assembly [A] from both sides.
For KVF750-A1 500001 thru 517987
and KVF750-B1 500001 thru 505537 ONLY:

• Remove steering stem bearing joint bolts
[A].
Remove cotter pin [A], steering stem bottom
end nut [B] and collar [C], and remove the
steering stem bearing [D].
•
Steering Stem Bearing Installation:
For KVF750-A1 500001 thru 517987
and KVF750-B1 500001 thru 505537 ONLY:


(1) Rod-Assy, Tie (6) Nut, Lock, 6mm
(2) Washer, 10.2×20×1.5 (7) Bracket, Steering
(3) Pin-Cotter, 2.0×15 (8) Bolt, 8×35
(4) Holder-Steering (9) Pin-Cotter, 3.0×25
(5) Damper (10) Steering Stem Bearing
Page 2


• Liberally grease the seal grooves in the
steering stem bearing.
• Lift the steering stem and install the steering
stem bearing, collar, and tighten steering
stem bottom end nut.
Torque
Steering Stem Bottom End Nut:
62 N•m (6.3 kgf•m, 46 ft•lb)

• Place the new steering stem holder over the
steering stem bearing and tighten using the
new bolts [A].
Torque
Steering Stem Bearing Joint Bolts:
23 N•m (2.3 kgf•m, 17 ft•lb)

Install Damper
• Install new dampers [A] to the holder.
• Tighten dampers with the nuts [B].
Torque
Damper Nuts:
8 N•m (0.8 kgf•m, 6 ft•lb)
• Install new steering bracket [A] on top
of the bracket of the steering stem.
NOTE: This bracket is secured by the tie rod
ends [B].
Install Tie-Rod Assemblies (All Units):

• Install new tie rod assemblies and tighten
(both sides).
Torque

Tie-rod End Nuts:

42 N•m (4.3 kgf•m, 31 ft•lb)


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 cotter pins.
Check Wheel Alignment:

• Check handlebar alignment and toe-in of
front wheels.
Refer to the Wheel Alignment (page 11-6)
section of the Service Manual.

Toe-in of Front Wheels:

-10 ~ 10 mm (-0.39 ~ 0.39 in.) at 1G


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-rod 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.

Install Wheels:

• Install wheels and tighten wheel nuts.
Torque

Wheel-Nuts:

52 N•m (5.3 kgf•m, 38 ft•lb)

Destroy all original parts removed from
vehicles after the required 90-day retention
period.

Page 3


Parts Information

Parts needed to complete the Recall will be automatically allocated for 50% of affected units sold by
your dealership plus those in your dealership inventory.

Order numbers will begin with M1 through M7. Unshipped orders will appear on your K-Dealer back
order inquiry.

Please order additional required kits through normal channels. These orders will be shipped after
automatic allocations are complete.

• After the allocation is complete, order the appropriate repair kit using the VIN range in the table
below:
Kit, Rod-Assembly-Tie contents (P/N 99999-0084)
VIN Range: KVF750-A1 500001 thru 517987, KVF750-B1 500001 thru 505537


Description Part Number Qty Remark
Holder-Steering 13280-0200 1 STOPPER
Damper 92161-0385 2 FIT HOLDER
Nut, Lock, 6mm 92015-1603 2 FOR DAMPER
Bracket, Steering 11054-0589 1 STEERING SHAFT
Bolt, 8×35 92151-3763 2 STEERING LOWER BALL JOINT
Rod-Assembly, Tie 39110-0024 2
Washer, 10.2×20×1.5 92022-3742 6 TIE-ROD-END
Pin-Cotter, 2.0×15 550D2015 4 TIE-ROD-END
Pin-Cotter, 3.0×25 550D3025 1 STEERING LOWER END
Joint-Ball 59266-0016 1 STEERING LOWER END

Kit, Rod-Assembly-Tie contents (P/N 99999-0086)
VIN Range: KVF750-A1 517988 thru 518688, KVF750-B1 505538 thru 506051


Description Part Number Qty Remark
Rod-Assembly, Tie 39110-0024 2
Washer, 10.2×20×1.5 92022-3742 6 TIE-ROD-END
Pin-Cotter, 2.0×15 550D2015 4 TIE-ROD-END

Return any original 2005 KVF750-A1/B1 tie rods (P/N 39111-0012) or ends (P/N 39112-0006) in your
dealer inventory to KMC for credit. Use a Request for Credit form (P/N 99995-502) and reference Recall
ATV 05-04 in the Additional Information section.

Warranty Information


This is a safety Recall campaign. Repair is authorized regardless of ownership or warranty status.
Repairs MUST BE PERFORMED IMMEDIATELY ON ALL ELIGIBLE UNITS in the field and during initial
assembly and preparation. See the Warranty Policies and Procedures Manual (claim type 3 information)
for detailed instructions when submitting the Warranty Claim.

TIE RODS AND STEERING BEARING
KVF750-A1 500001 thru 517987
KVF750-B1 500001 thru 505537
TIE RODS ONLY
KVF750-A1 517988 thru 518688
KVF750-B1 505538 thru 506051
Job Code 22181 22182
Flat Rate Time 1.2 hr 0.7 hr
Failure Date Same as Repair Date Same as Repair Date
Claim Type 3 3
Problem Part Number 99999-0084 99999-0086
Problem Part Kit, Rod-Assembly-Tie Kit, Rod-Assembly-Tie
Qty 1 1

Page 4


Repair Verification


After repair or inspection, make a small punch mark
at the top center of the VIN as shown.

NOTE:

o Repair verification is an essential part of the repair
procedure. Along with the physical repair verification
mark, check VSI (Vehicle Service Inquiry) in k-dealer.
com for other possible repair campaigns for eligible
units.

PUNCH MARK HERE
BRUTE FORCE® 750 4x4i TIE ROD END REPLACEMENT
WARNING AND RECALL NOTICE


Dear Kawasaki Brute Force 750 4x4i Owner:
This notice is sent to you in accordance with the requirements of the Consumer Product Safety Act.


The reason for this notice:

This letter is sent to notify you that Kawasaki, in cooperation with the U.S. Consumer Product Safety
Commission, has initiated a voluntary safety Recall Campaign to replace the steering tie rod ends on
2005 Brute Force® 750 4x4i (KVF750-A1/KVF750-B1) models.

Tie rods connect the steering shaft to the left and right steering knuckles. On eligible units, a tie rod
end could separate during operation due to either wear or impact, leading to a loss of steering control
and creating the potential for an accident resulting in injury or death. Our records indicate that you have
bought one of these units.

What Kawasaki and your dealer will do:

Your Kawasaki dealer will correct this problem for you at no charge. The correction will consist of replacing
the tie rod ends and related parts.

What you must do to ensure your safety:

Kawasaki strongly recommends that you do not ride your ATV until the repair has been completed. If you
must operate your vehicle prior to the repair, inspect the tie rods and ends prior to each ride according
to the procedure below. If you do not feel capable of performing the inspection, do not ride your ATV until
the repair has been completed.

Parts Availability:

Repair kits will begin to arrive at dealerships in January 2006 and will be available in limited quantities
initially. Kawasaki will send you another notice when you can contact your dealer to schedule the free
repair. The actual repair will take over one hour but may take longer due to scheduling at the dealership
and the time needed to obtain required parts.

Tie rod inspection procedure (Refer to attached procedure):

Place the vehicle on a flat, hard surface and lock the
parking brake. You will inspect both steering tie rods
and complete a visual and physical check of the four tie
rod ends. Use a flashlight to assist you in the inspection
and check both left and right sides. You will have to turn
the wheels fully left and right to inspect the tie rods and
ends.

Start by inspecting the tie rod and tie rod ends on the
left side. Turn the wheels fully to the right so that you
can look between the front fender and wheel to view the
tie rod clearly. Using a flashlight, inspect the tie rod for any signs of bending. Repeat on the right side. If
either of the rods are bent, do not operate the vehicle prior to repair.

Next, visually inspect the tie rods ends (inner and outer) for displacement or damage of the tie rod boot.
The boot should be properly in place so that dirt, water, or other contaminants cannot enter the joint. If
any of the tie rod boots are damaged or out of place, do not ride your vehicle.

BRACKETSTEERING
KNUCKLE
OUTER TIE
ROD END
INNER TIE
ROD END
Page 5


The final step is to check for movement between the tie rod end body and shaft. To check for movement,
attempt to move the tie rod end body up and down. There should be no movement between the body and
the shaft. Use the illustrations to assist in the inspection and check all four ends. If there is movement
between the tie rod end body and the shaft on any of the tie rods ends, the repair must be
completed prior to riding your vehicle.

A video demonstration can be viewed at http://www.kawasaki.com to assist you in the inspection. After entering
the Owner Information section, submit your Vehicle Identification Number (VIN) located at the top of this
letter and you will be able to view this letter and the video demonstration.

If you need help:

If you have questions or concerns that your dealer is not able to resolve, please contact Kawasaki’s
Consumer Services Department:

Kawasaki Motors Corp., U.S.A.

ATTN: Consumer Services Department

P.O. Box 25252
Santa Ana, California 92799-5252
(866) 802-9381 (toll-free) between 8:30 a.m. and 4:45 p.m. PT Monday through Friday.
If you received this notice in error:

Our records indicate you are the current owner of the Brute Force 750 4x4i described in this letter. If you
no longer have the vehicle described in this letter, or if it has been repaired, please help us to update our
records by calling Kawasaki toll free at (866) 802-9381.

We are sorry for any inconvenience this may cause, but we have taken this action in the interest of your
safety and continued satisfaction with your Kawasaki ATV. Please contact your dealer if you have any
questions.

Sincerely,
KAWASAKI MOTORS CORP., U.S.A.


Follow-Up Postcard:

BRUTE FORCE® 750 4x4i TIE ROD END REPLACEMENT

Dear Kawasaki Brute Force 750 4x4i Owner:

Parts Availability Notice:

Recently you received a letter from Kawasaki informing you of a Recall on your Kawasaki Brute Force 750
4x4i. On eligible units, a steering tie rod end could separate during operation due to either wear or impact,
leading to a loss of steering control and creating the potential for an accident resulting in injury or death.


Parts required to complete the repair are now being shipped to authorized Kawasaki ATV dealers. Parts


will be available in limited quantities initially but will be widely available soon.
Your authorized Kawasaki ATV dealer will correct this for you free of charge. Please call your authorized
Kawasaki ATV dealer to schedule an appointment for repair and take this postcard with you at the time of
your appointment.


We are sorry for any inconvenience this may cause, but we have taken this action in the interest of your
safety and continued satisfaction with your Kawasaki ATV. Please contact your dealer if you have any
questions.


Sincerely,
KAWASAKI MOTORS CORP., U.S.A.


Page 6


December 2005
Page 1 of 2

Brute Force® 750 4x4i Tie Rod End Replacement Safety Recall Campaign

Affected Units: 2005 Brute Force 750 4x4i (KVF750-A1)
2005 Brute Force 750 4x4i Hardwoods (KVF750-B1)

What you must do to ensure your safety:

Kawasaki strongly recommends that you do not ride your ATV until the repair has been
completed. If you must operate your vehicle prior to the repair, inspect the steering tie rods and
ends prior to each ride and ride at a low speed. If you do not feel capable of performing the
inspection, do not ride your ATV until the repair has been completed.

Inspection Procedure:

You will inspect both steering tie rods and then complete a visual and physical check of the
four tie rod ends. Use a flashlight to assist you in the inspection and check both left and right

sides.
Do not ride the vehicle if the tie rods are not
straight or there is movement between the tie
rod end body and shaft on any of the tie rods
ends.
Tie Rod Inspection
1. Place the vehicle on a flat, hard surface and lock the parking brake.
2. Turn the wheels fully to the right so that you can look between the front fender and wheel to
view the LEFT tie rod clearly. STEERING SHAFT
3. Using a flashlight, inspect the tie rod for any signs
of bending.
4. Now, turn the wheels fully to the left so you can
inspect the right tie rod. If either of the tie rods
are bent, do not operate the vehicle prior to
repair.
Tie Rod End Visual Inspection

1. Visually inspect all four tie rods ends (inner and
outer) for displacement of the tie rod boot. The boot
should be properly in place so that dirt, water, or
other contaminants cannot enter the joint. If any
of the tie rod boots are out of place, do not ride
your vehicle.
STEERING
KNUCKLE
BRACKET
INNER TIE
ROD END
OUTER TIE
ROD END
TIE ROD
END BODY
TIE ROD
BOOT
Page 7


Page 2 of 2


Proper Condition of Boot

The rubber boot should be securely in place around the
entire circumference of the aluminum body.

Displaced Boot


PROPER
POSITION
OF BOOT
LOOSE BOOT
DO NOT RIDE
Tie Rod End Physical Inspection

1. Check for movement between the tie rod end body and shaft (both inner and outer tie rod
ends). To check for movement, attempt to move the tie rod body up and down.
TIE ROD

If there is movement between the tie rod end
body and the shaft on any of the tie rods ends,
the repair must be completed prior to riding
your vehicle.

If you operate the vehicle prior to the repair:

o Perform the inspection prior to each ride
o Operate the ATV at a low speed.
o If you feel any loseness in the steering, do not ride the
vehicle.
NOTE:

o A video demonstration can be viewed at http://www.kawasaki.com to assist you in the inspection.
After entering the Owner Information section, submit your Vehicle Identification Number
(VIN) located at the top of this page and you will be able to view this letter and the video
demonstration.
NO MOVEMENT
TIE ROD
END SHAFT
END BODY
Page 8