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How to Troubleshoot and Reset the Flashing Belt Light on a Kawasaki Brute Force 750?

Asked Jul 10, 20131 view1 answer
I recently installed a new belt on my vehicle, but I'm experiencing issues. It backfires and won't rev fully open. Can anyone help me troubleshoot this problem?

Troubleshooting the Belt Light Flashing on a Kawasaki Brute Force 750

If you are experiencing a flashing belt light on your Kawasaki Brute Force 750, it typically indicates that there is an issue with the drive belt or its adjustment. This can often occur after a belt installation or adjustment. Below is a comprehensive guide to help you troubleshoot and reset the belt light successfully.

Understanding the Belt Light

The belt light serves as a warning system for your ATV, indicating that the belt requires inspection or adjustment. A flashing light may indicate:

  • Belt wear or damage
  • Improper belt tension
  • Belt alignment issues

Step-by-Step Instructions to Reset the Belt Light

  1. Preparation

    • Ensure that your ATV is on a flat surface.
    • Turn off the ignition and remove the key.
    • Gather the necessary tools:
      • Torque wrench,
      • Flathead screwdriver,
      • 10mm and 19mm sockets,
      • Circlip remover,
      • Spring compressor,
      • Broomstick or similar tool for stabilization.

  2. Access the Belt Area

    • Remove the seat of your ATV to access the electrical connectors.
    • Unplug the black and grey connectors located at the rear right corner under the seat. The grey connector is a reset plug.

  3. Swap the Connectors

    • Swap the grey and black connectors:
      • Connect the grey plug to the black connector.
      • Connect the black plug to the grey connector.

  4. Turn on Ignition

    • Turn the ignition key to the "ON" position without starting the engine.
    • You should observe the belt light begin to flash rapidly.

  5. Disconnect the 2-Pin Belt Switch

    • Locate the 2-pin connector at the top of the CVT cover.
    • Disconnect this connector while the grey and black connectors are still swapped.
    • The belt light should now begin to flash slowly.

  6. Allow Flashing Time

    • Let the belt light flash slowly for at least 5 seconds. This indicates that the reset process is underway.

  7. Turn Off Ignition

    • Turn the ignition key to the "OFF" position.

  8. Reconnect the Connectors

    • Reconnect the grey and black connectors to their original positions:
      • Grey back to grey
      • Black back to black
    • Reconnect the 2-pin belt switch connector.

  9. Final Check

    • Turn the ignition key back to the "ON" position again and check if the belt light is now off.

Tips and Best Practices

  • Inspect the Belt: Before resetting the light, ensure the belt is in good condition. Look for signs of wear, cracks, or fraying.
  • Check Belt Tension: Proper belt tension is crucial for optimal performance. Refer to the specifications for deflection measurements:
    • Normal deflection: 22mm to 27mm (0.87 to 1.06 inches)
    • Aim for about 22mm to 25mm for best performance.

Common Pitfalls

  • Incorrect Connector Swapping: Make sure you are swapping the correct connectors. Swapping the wrong connectors will not reset the light and could lead to further issues.
  • Not Allowing Enough Time: Ensure to let the belt light flash slowly for a sufficient duration. Skipping this step may result in an unsuccessful reset.
  • Ignoring Belt Condition: Always check the belt’s physical condition before resetting any lights to prevent recurring warnings.

Additional Troubleshooting for Backfiring and Poor Performance

If you’re experiencing backfiring and your vehicle won’t rev fully open, consider the following troubleshooting steps:

  1. Check Fuel Flow:

    • Ensure that there’s no blockage in the fuel line.
    • Inspect the fuel filter and replace it if necessary.

  2. Inspect the Air Filter:

    • A clogged air filter can restrict airflow, leading to poor performance. Clean or replace the air filter as needed.

  3. Electrical Connections:

    • Verify that all electrical connections are secure and free from corrosion.
    • Inspect the ignition system components, including spark plugs and coils.

  4. Throttle Position Sensor (TPS):

    • Ensure that the TPS is functioning correctly and is properly calibrated.

  5. Seek Professional Help:

    • If you are unable to resolve the issues after following these steps, consider seeking help from a professional mechanic or your local dealership.

By following these guidelines, you should be able to effectively troubleshoot the belt light issue on your Kawasaki Brute Force 750, as well as address any performance problems you may be facing. If you have any further questions or need assistance, feel free to reach out for additional support.

Expert Answers
AP
Abe Pastor
Answered Jul 10, 2013
✓ Accepted
To address the flashing belt light on your Kawasaki Brute Force 750, you’ll want to start by checking the belt deflection. You can do this by placing a straight edge, like a ruler, across the belt from the primary to the secondary sheave. Apply about 13 lbs of pressure in the center and measure how far the belt dips down from the straight edge. Ideally, the deflection should be between 22mm and 27mm, with 22mm to 25mm being optimal. If you're closer to 27mm, it’s time to tighten the belt. To tighten it, you’ll need to remove a shim from the secondary sheave. The thickness of the shim affects the belt deflection, so you’ll want to measure how many millimeters you need to decrease. For reference, a change of 0.1mm in spacer thickness results in about a 1.3mm change in belt deflection. There are various shim thicknesses available, ranging from 0.3mm to 1.4mm. For this process, you’ll need some specific tools: a spring compressor, a circlip remover, and a primary puller, along with standard metric tools. Once you have everything ready, remove the primary clutch and the belt, then take out the secondary sheave. Compress it using the spring compressor, remove the circlip, and decompress the spring to access the shims. Make sure to mark the sheaves for proper reassembly. After adjusting the shims, you’ll need to reset the belt light. Turn off the ignition and pull the CVT cover. Inside, switch the reset switch to the "on" position. Then, disconnect the two connectors under the seat—swap the grey and black connectors. With the grey connected to the black and the black disconnected, turn the ignition on without starting the quad. Watch the belt light; when it stops flashing quickly and starts flashing slowly, the reset is successful. Turn off the ignition, reconnect everything, and you should be good to go. If the light is flashing due to a 100-hour service reminder, you can skip removing the CVT cover. Just swap the plugs and follow the rest of the reset procedure. If you encounter any issues, unplug the connector on the right side of the motor that goes to the relay, then unplug the black connector behind the CDI box and connect the grey one instead. Turn the key on for about 30 seconds, then turn it off and reconnect everything. This should give you an additional 100 hours before the light comes back on.

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