The Brute Force 650 4x4i combines the luxurious ride quality offered by the front and rear independent suspension of the Brute Force 750 4x4i with a 650 cc engine.
SpecificationsEngine Type: 4-stroke 90 V-twin
Displacement: 633 cc
Bore and Stroke: 80 x 63 mm
Compression Ratio: 9.9:1
Valve System: SOHC, 4 valves per cylinder
Carburetor: Dual Keihin CVKR-34
Ignition: Digital DC-CDI
Starting: Electric with recoil back-up
Transmission: Dual range CVT with reverse
Primary Drive: Belt converter
Final Drive: Shaft, Electric 2WD / 4WD, rider controlled locking front differential
Primary Reduction Ratio: 3.122 ~ 0.635 (belt converter)
Overall Drive Ratio: Forward (High): 42.32 ~ 8.61
Forward (Low): 66.02 ~ 13.43
Reverse: 55.01 ~ 11.19
Frame Type: Double cradle, high-tensile tubular steel
Suspension: Front: Double wishbone, stepped spring preload adjustment
Suspention: Rear: Double wishbone, stepped spring preload adjustment
Wheel Travel: Front: 171 mm
Wheel Travel: Rear: 200 mm
Tires: Front: AT 25 x 8-12
Tires: Rear: AT 25 x 10-12
Tread (Front/Rear): 920 mm / 894 mm
Front Brake: Dual hydraulic with twin-piston calipers with 200 mm drilled discs
Rear Brake: Enclosed wet multi-plate
Parking Brake: Enclosed wet multi-plate
Battery: 12 V, 12 Ah, Maintenance Free
Charging Output: 24.2 A, 14 V @ 6,000 rpm
Headlights (High/Low): 12 V, 40/40 W x 2
Headlight Marker lights: 3/3 W x 2
Tail/Brake Light: 12 V, 5/21 W
Overall Length: 2,195 mm
Overall Width: 1,177 mm
Overall Height: 1,230 mm
Wheelbase: 1,279 mm
Seat Height: 907 mm
Curb Mass: 297 kg (654.8 lbs.)
Fuel Capacity: 20.5 litres
Colours: Smoky Blue, Sunbeam Red, Camouflage Realtree APG
Warranty: 12 months
Good Times Protection Plan: 24 or 36 months (Kawasaki GTPP begins after the standard limited warranty expires)
EngineThe ATV industries first V-twin receives its first substantial revisions in 2006 for the use in the Brute Force 650 4x4i. The liquid-cooled, 633 cm3, SOHC, 4-valve V-twin engine is more powerful than many competitors largest machines, churning out a substantial 46 PS @ 7,500 rpm.
Torque output 51.4 N m @ 5,500 rpm lets the KVF650F accelerate with ease.
High flow cylinder heads are based on the mighty the Brute Force 750 4x4i but feature a combustion chamber matched to the 650s 9.9:1 compression ratio.
KVF750 style, all-aluminum cylinders feature electrofusion-coated bores for light weight, long wear and excellent heat dispersion. The electrofusion bores save 1.5 pounds of engine weight compared to the iron liner cylinders of the other KVF650 models.
Other than jetting changes, the large bore, dual CVKR-34 mm, down-draft carburetors are lifted straight from the KVF750. Oriented for best flow into the straight intake tract, they deliver high intake efficiency and gutsy power across the rpm range.
Primer feature ensures easy starts no matter how cold the weather.
The four valve heads use large, 30 mm intake and 26 mm exhaust valves.
Efficient, SOHC (Single OverHead Cam) design operates forked rocker arms with screw type lash adjusters for ease of maintenance.
Vacuum-operated petcock automatically shuts off fuel flow when the engine is not running.
Offsetting the cylinders by 90 results in perfect primary balance, for low vibration levels and comfortable riding. Its so smooth theres no need for a separate extra engine balancer, saving power and weight.
Oversquare bore and stroke measure 80 x 63 mm (85 x 66 mm for the 750). Pistons and con rods are common with the other KVF650 models.
Aluminum exhaust pipe and muffler covers are lighter than steel components.
Oval, oiled foam air filter provides a large filtering surface for excellent breathing between routine cleanings.
Clever body styling has created a simple air box cover designed to allow access to the air filter by removing only one cover.
Air routed to the air filter (and to the CVT) enters a cavity located in front of the air box via a rear-facing intake passage under the handlebars. This helps prevent the ingress of water, mud, dust, etc.
A 3-piece shroud box further reduces the possibility of water and mud entering the air box and CVT cavity in harsh conditions. Insulators are attached to the left-hand shroud panel to reflect exhaust pipe heat and ensure cooler air flow into the air box for a denser intake charge to increase power at low speeds or under hot climate conditions.
Drains in the air box (one on the clean side and one on the dirty side of the filter) help remove water that accumulates in the airbox in harsh conditions.
Lightweight crankshaft reduces engine inertia for faster throttle response.
Powerful rare-earth magnets used in the AC generator are highly efficient and lighter weight than traditional magnets. Lighter flywheel effect aids in the quick revving engine character.
AC generator output at slower speeds is enhanced with the rare-earth magnets making more power available to run accessories when driving at slower speeds. Peak AC generator output is 340W.
A circuit breaker ensures the cooling fans motor does not overheat in the event the fan does become clogged with debris. The under-seat breaker switch can be reset without changing parts.
ChassisHigh-tensile steel, double-cradle frame is very rugged.
Compared to the riding position of the KVF700, which lends itself well to jumps and sliding the machine while standing up, the Brute Force 650 is suited to more of an upright, seated position.
Seat has thick foam padding and a wide, comfortable shape.
The Brute Force 650 features independant front and rear suspension. The suspension offers the best IRS sport riding potential keeping the sport in Sport/Utility.
Double wishbone, independant suspension used front and rear ensures high ride comfort and ground following ability, especially in the low and medium speed ranges.
Revised caster angle for the front A-arms (upper and lower) results in lighter steering.
New front and rear spring rates with revised initial preload settings improve rider comfort.
Upper and lower front A-arms and lower rear A-arms use a combination of needle bearings and spherical joints for high stability, smooth suspension action and superb ride comfort.
Tuned sway bar controls roll yet allows smooth independent movement of the rear wheels.
5-position adjustable spring preload, front and rear, allows tuning for varying loads.
The 4-bulb headlight cuts an impressive swath through dark nights.
Front guard and front guard cover give this 650 a rugged look distinct from that of its 750 big brother.
Instrument package mounts the instruments more vertically to suit the upright-seated riding position. Multi-purpose, digital instrumentation includes speedometer, odometer, tripmeter, fuel gauge, engine temperature indicator, clock, and hour meter.
Indicator lamps for neutral, reverse gear, 2WD/4WD, belt indicator, and oil warning are also fitted.
Fenders and body parts are made of thermo-plastic olefin (TPO) material featuring a scratch resistant finish for long-wearing good looks. Fit and finish is excellent.
Storage compartments in the left and right front fenders are handy for storing a variety of small items. Rubber nets keep items secure yet accessible.
High-quality aluminum wheels mount with automotive-style tapered lug nuts.
Dual-piston front brake calipers deliver powerful, progressive braking.
A vehicle down sensor automatically shuts off the fuel supply if the machines attitude becomes extreme. If the vehicle tips over or leans more than 65 degrees, the sensor operates, cutting the ignition spark. The system automatically resets once the ATV is upright again.
Electrical equipment is conveniently located under the seat for easy access.
Convenient 12 V accessory outlets are provided at the front (10 Amp switched, cigarette type) and rear (5 Amp unswitched, bullet type).
Large 20.5 L fuel tank is located beneath the rear fender and operates via a vaccuum-operated fuel pump. This location contributes to a low centre of gravity.
Convenient carriers hold 40 kg up front and 80 kg in the rear, and are ideal for work, camping and many other tasks.
Space to fit a winch is available inside the front guard. The sturdy frame can handle a 3,000lb class winch with the optional mounting bracket.
Standard equipment trailer hitch bracket is fitted with a standard bolt hole for a traditional trailer ball.
Final DriveEfficient through engine propeller shaft is lubricated using the same oil shared with the engine and transmission. The all-in-one case saves weight and controls the exacting tolerances between components.
Through engine design allows for very short, light, rigid driveshafts for the front and rear final drives. Straight alignment of the drive shaft to the front final drive case delivers power through sealed splines with no U-joints required.
Compact final gear case design contributes to incredible ground clearance allowing the KVF650 to go where others fear to tread.
The rear final drive housing carries Kawasakis renowned, internal, wet brake system. The brake operates in the final drives oil bath completely sealing it from wear causing mud, dust, water, etc.
External brake lever return spring replaces the internal brake lever return spring to provide better and more consistent brake feel at the lever.
Dual Cardan joints to the rear drive absorb torque fluctuations and reduce vibration through the rear drive shaft.
Front and rear final drives use sturdy CV joints to feed power to the wheels.
Front outboard CV joints have an operating range of 50.
Front CV joints can be independently disassembled, greatly easing outboard CV boot replacements.
Electrically selectable 2WD/4WD system allows fast, easy switching between two and four wheel drive to suit changing terrain and applications.
Rider controlled, variable front differential makes it much easier to get the ATV through difficult or slippery situations.
With the hand lever released, the system functions as a light limited slip differential providing excellent steering feel.
Pulling the lever increases the torque on the limited slip plates until the differential effectively locks. This fast acting, wide range offine-tuning ability is a technological feature unseen in other industries, let alone on competitors ATVs.
Lever operation puts the rider in control. The rider decides how strong the system functions. Also, theres no delay as in some electrically switched systems; the system engages and disengages immediately as the rider pulls or releases the lever.
Reverse limiter (3600 rpm) automatically engages when reverse is selected to prevent excessive speeds or acceleration in reverse. An override pushbutton on the left handlebar control assembly allows the rider to easily increase to full power if needed.
TransmissionConvenient mono-shifter enables quick shifting between Reverse, Neutral, High, and Low range thanks to the unique single sliding detent mechanism inside the transmission case .
The engine can be started in any gear if one of the brakes is applied.
The KAPS (Kawasaki Automatic Powerdrive System) is a high-durability automatic CVT combined with a straight shifting High/Low/Reverse transmission designed to handle the strong power output of the Brute Force 650 engine.
KAPS takes advantage of the Brute Force 650s strong low end torque by engaging just off idle (approximately 1500 rpm) which contributes to the relaxed low speed riding and very smooth belt engagement.
The drive converter uses a four-finger spider that distributes loads better than a traditional three-finger spider. With the reduced loads per finger, CVT response is smoother and wear is reduced.
Hard chrome plating on the drive converter shaft improves surface texture to reduce bushing wear and to further improve CVT action.
Cooling fan cast into the drive sheave draws air from a cavity located below the handlebars via a rear-facing intake passage. This helps prevent the ingress of water, mud, dust, etc.
A 3-piece shroud box further reduces the possibility of water and mud entering the air box and CVT cavity in harsh conditions.
The driven converters movable sheave slides on sealed, greased bushings for smoothest operation and longest wear. Four steel guide pins also operate within the sealed grease.
The two power pulses of the Brute Force 650s V-twin engine reduce stress on the CVT components compared to the one large power pulse of a big-bore single cylinder engine extending belt and CVT service life.
CVT sheaves are manufactured of high-pressure cast, high silicon aluminum (same as pistons) for best durability.
Kawasaki Engine Brake Control uses speed and direction sensors along with an electric servo for smooth operation. This system detects the ATVs speed, direction, and deceleration electrically. When the conditions are satisfied, the electric servo moves out to hold the CVT drive pulley closed thereby connecting the driving pulley with the driven pulley through the belt and then generating braking force from the engine.
The Kawasaki Engine Brake Control is an automatic engaging system. Theres no need to apply throttle for the system to engage. Coasting forward in gear, the Kawasaki Engine Brake Control automatically engages to provide engine braking force. Additionally, whenever the key is turned off, a learner program in the engine brake controller measures and then self adjusts for belt wear to ensure consistent engine braking operation.
Kawasaki Engine Brake Control safety features ensure that the engine braking force only works when the ATV is moving forward and vehicle speed is more than 3 km/h.