• Vin Location On Kawasaki Mule 3010
• Kawasaki Mule 3010 Specs

Look for the VIN on the right front frame rail behind the wheel. For most late-model Mule™ side x side, the VIN is located on the forward frame rail below the seat. Jan 31, 2018 - Best Answer: 'MULE™ Utility Vehicles: You will find the VIN on your Kawasaki utility vehicle stamped into the frame front cross member.

Vin Location On Kawasaki Mule 3010

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Summary of Contents for Kawasaki MULE 3010 TRANS 4 × 4

• Page 1 MULE 3010 TRANS 4 × 4 Utility Vehicle Service Manual Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 2 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Converter System Engine Lubrication System Engine Removal/Installation Engine Bottom End Transmission 10 j Wheels/Tires 11 j Final Drive 12 j Brakes 13 j Suspension 14 j Steering 15 j Frame...
• Page 4 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 5 Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. Property of www.SmallEngineDiscount.com - Not for Resale © 2004 Kawasaki Heavy Industries. Ltd., First Edition (1): Nov. 1, 2004 (M)
• Page 6 LIST OF ABBREVIATIONS ampere(s) pounds(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
• Page 7 EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
• Page 8 PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (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 systems, or alter them in any way which results in an increase in noise level.

• Page 9: How To Use This Manual

  • Use proper tools and genuine Kawasaki Vehi- cle parts. Special tools, gauges, and testers • Indicates a procedural step or work to be that are necessary when servicing Kawasaki done.
• Page 10 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 12: Before Servicing

  1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper- ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
• Page 13 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
• Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
• Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
• Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.

• Page 17: Model Identification

  GENERAL INFORMATION 1-7 Model Identification KAF620-J1 Left Side View KAF620-J1 Right Side View The KAF620-K1 is a camouflage-surface-treated model and identical to the KAF620-J1, the base model, in every other aspect: controls, features, and specifications. Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 18: General Specifications

  1-8 GENERAL INFORMATION General Specifications Items KAF620-J1/K1 Dimensions Overall Length 3 169 mm (124.76 in.) Overall Width 1 449 mm (57.05 in.) Overall Height 1 933 mm (76.10 in.) Wheelbase 2 165 mm (85.24 in.) Track: Front 1 160 mm (45.67 in.) Rear 1 180 mm (46.46 in.) Ground Clearance...
• Page 19 GENERAL INFORMATION 1-9 General Specifications Items KAF620-J1/K1 duration 322° Lubrication System Forced lubrication (wet sump) Engine Oil: Grade API SF or SG, API SH or SJ with JASO MA Viscosity 10W-40 Capacity 1.8 L (1.9 US qt) Coolant Capacity 4.6 L (4.9 US qt) Drive Train Primary Reduction System: Type...
• Page 20 1-10 GENERAL INFORMATION General Specifications Items KAF620-J1/K1 Suspension: Front: Type MacPherson strut Wheel Travel 100 mm (3.9 in.) Rear: Type De Dion axle Wheel Travel 70 mm (2.8 in.) Brake Type: Front And Rear Drum (Hydraulic) Parking Brake Type Drum (Mechanical internal expansion) Electrical Equipment Battery 12 V 18 Ah...

• Page 21: Unit Conversion Table

  GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 micro µ...
• Page 22 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 23: Table Of Contents

  PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Spark Arrester Cleaning....2-22 Torque and Locking Agent....Engine Lubrication ......2-22 Specifications ........Oil and/or Filter Change....2-22 Special Tools ........2-10 Oil Filter Removal ......2-23 Periodic Maintenance Procedures..

• Page 24: Periodic Maintenance Chart

  2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever First comes Regular Service Service first...
• Page 25 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever First comes Regular Service Service first → After 50 Every 250 Every h, or 1 h, or 5 500 h, or ↓ 000 km 000 km 10 000 Page Every OPERATION of use of use km of use CHASSIS...

• Page 26: Torque And Locking Agent

  2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1).
• Page 27 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cooling Fan Cover Bolts 0.90 78 in·lb Engine Lubrication System Engine Oil Drain Plug (M14) Engine Oil Drain Plug (M16) Oil Pressure Switch 87 in·lb Oil Filter –...
• Page 28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Bearing Holder Housing Locknut Bevel Gear Case Holder Nuts Drive Gear Nut Front Axle Cap Bolts 0.90 78 in·lb Drive Shaft Cap Bolts Brakes Bleed Valves 0.60 52 in·lb Push Rod Locknut Brake Hose Banjo Bolts...
• Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Bar Mounting Bolts And Nuts Rear End Sub-Frame Mounting Bolts Hood Latch Lever Mounting Bolt Tail Gate Fixing Lever Screw 0.45 39 in·lb Screen Fixing Lever Screw 0.45 39 in·lb Electrical System...

• Page 30: Specifications

  2-8 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System 5 ∼ 10 mm (0.2 ∼ 0.4 in.) Throttle Pedal Free Play – – – 850 ∼ 950 r/min (rpm) Idle Speed – – – Cooling System Coolant: Type Permanent type of antifreeze (Soft water –...
• Page 31 PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Brakes Brake Fluid: Type DOT3 – – – Fluid Level Between upper and lower level lines – – – 2 ∼ 10 mm (0.08 ∼ 0.39 in.) Brake Pedal Play – – – 180.000 ∼...

• Page 32: Special Tools

  2-10 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Brake Drum Remover: 57001-143 57001-1260 Rotor Puller, M16/M18/M20/M22 × 1.5: Brake Drum Pusher, M18 × 1.5: 57001-1216 57001-1261 Valve Adjusting Screw Holder: Brake Drum Holder: 57001-1217 57001-1325 Oil Filter Wrench: Brake Drum Remover Nuts: 57001-1249 57001-1326 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 33: Periodic Maintenance Procedures

  PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Fuel System Throttle Pedal Free Play Inspection • Check that the throttle pedal moves smoothly from full open to close. If the throttle pedal does not return properly, lubricate the throttle cable. • Check the throttle pedal free play [A]. If the free play is incorrect, adjust the throttle cable.

• Page 34: Full Throttle Pedal Position Adjustment

  2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Full Throttle Pedal Position Adjustment • Loosen the locknut [A]. • Screw in the throttle pedal stop bolt [B]. • Depress the throttle pedal until the throttle lever on the carburetor is in the fully opened position, and keep its position.

• Page 35: Fuel Filter Inspection

  PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Fuel Filter Inspection • Visually inspect the fuel filter [A]. If the filter is clear with no signs of dirt or other contami- nation, it is OK and need not be replaced. If the filter is dark or looks dirty, replace it. Also, check the rest of the fuel system for contamination.

• Page 36: Fuel Hoses Replacement

  2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hoses Replacement • Tilt up the cargo bed. • Slide out the plate clamps [A]. • Remove the hoses [B] (see Exploded View in Fuel System chapter). • When installing, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.

• Page 37: Air Cleaner Housing Dust And/or Water Inspection

  PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Install the cover [A] and lock the clamps. ○ Face the TOP mark [B] upward. • Reset the Air Filter Restriction Gauge [A] (push [B] its reset button). Air Cleaner Housing Dust and/or Water Inspection •...

• Page 38: Radiator Hose And Connection Inspection

  2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core . Hold the steam gun perpendicular to the core sur- face.

• Page 39: Coolant Filling

  PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Remove: Torque Converter Coolant Drain Plug [A] at Rear Cylinder ○ Place a container under the drain plug. • Remove: Front Final Gear Case Skid Plate Coolant Drain Plugs [A] at Water Pipes ○...

• Page 40: Coolant Filter Inspection

  2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Fill the cooling system up to the filler neck [A] in the radi- ator cap fitting with coolant. • Install the radiator cap. • Fill the reservoir tank up to the F (Full) mark with coolant. •...

• Page 41: Converter Driven Pulley Shoe Inspection

  PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Check the belt for wear, cracks, breaks or peeling. If necessary, replace the belt with a new one. Belt [A] Crack [B] Broken [C] NOTE ○ Whenever the belt is replaced, inspect the drive and the driven pulleys.

• Page 42: Converter Dust Or Water Draining

  2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the air cleaner element, and separate the foam element [A] from the paper element [B]. • Clean the foam element in a bath of a high flash-point solvent, and then dry it with compressed air or by shaking CAUTION Do not use compressed air to clean the paper ele- ment.

• Page 43: Valve Clearance Adjustment

  PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Turn the alternator rotor clockwise so that the mark '1' [A] or '2' [B] on the rotor aligns with the mark [C] on the crankcase breather cover. Check both rocker arms are free. If not, turn the rotor more one turn and free both rocker arms.

• Page 44: Spark Arrester Cleaning

  2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spark Arrester Cleaning WARNING To avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run dur- ing this procedure, the muffler will become hot. • Remove the drain plug [A] from the muffler [B]. •...

• Page 45: Oil Filter Removal

  PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures NOTE ○ Depending on the atmospheric temperature of your rid- ing area, the engine oil viscosity should be changed ac- cording to the chart: Oil Filter Removal • Tilt up the cargo bed. • Remove the oil filter [A].

• Page 46: Transmission

  2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Transmission Transmission Oil Change • Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle. • Place an oil pan beneath the transmission case. •...

• Page 47: Tire Inspection

  PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Tire Inspection • Examine the tire for damage and wear. If the tire is cut or cracked, replace it. ○ Lumps or high spots on the tread or sidewalls indicate internal damage, requiring tire replacement. ○...

• Page 48: Brakes

  2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake Fluid Level Inspection • With the vehicle on level ground, check that, through the inspection hole [A], the fluid level in the reservoir is be- tween the upper (MAX) and lower (MIN) level lines. If the fluid level is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line.

• Page 49: Brake Fluid Changing

  PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Brake Fluid Changing • Remove the maintenance cover. • Check that there is plenty of fluid in the reservoir. NOTE ○ The fluid level must be checked several times during the fluid changing and replenished as necessary. If the fluid in the reservoir runs completely out any time during fluid changing, air bleeding must be done since air will have entered the line.

• Page 50: Brake Master Cylinder Cup And Dust Seal Replacement

  2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the locknut [A] and turn the push rod [B] to obtain the correct amount of free play. • Tighten: Torque - Push Rod Locknut: 18 N·m (1.8 kgf·m, 13 ft·lb) • Check for brake drag and braking effectiveness. WARNING Incorrect adjustment with insufficient free play can cause brake heating and drag.

• Page 51: Brake Hose And Pipe Inspection

  PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Brake Hose and Pipe Inspection • The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not properly main- tained. Bend and twist the rubber hose while examining Replace it if any cracks or bulges are noticed.

• Page 52: Brake Wear Inspection

  2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures [A] Metal Pipes [B] Nipples [C] Hoses [E] Retainers Brake Wear Inspection • Remove the brake drum (see Brake Drum Removal in the Brakes chapter). • Measure the inside diameter of the drum at several points. If any measurement is greater than the service limit, re- place the drum.

• Page 53: Brake Wheel Cylinder Assembly Replacement

  PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake Wheel Cylinder Assembly Replacement • Remove: Brake Drum (see Brake Drum Removal) Brake Pipe Nipple [A] ○ Immediately wipe up any brake fluid that spills. CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up imme- diately.
• Page 54 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures (Rear Brake Panel) ○ Pry the ratchet lever [A] with a screwdriver [B] to reset the shoe clearance adjuster in its original position [C] • Grease (Amoco Rykon Premium Grease No. 2 EP Green): Brake Panel Seating Surface •...

• Page 55: Parking Brake Lever Travel Adjustment

  PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Parking Brake Lever Travel Adjustment • Check parking brake lever travel [A]. ○ Pull the parking brake lever [B] upward slowly all way. Count the number of notches (clicks) during lever travel. If lever travel is not correct, adjust it. Parking Brake Lever Travel 8 ∼...

• Page 56: Steering

  2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Wheel Free Play Inspection • Check steering wheel free play [A]. ○ Set the front wheels straight ahead. Gently turn [B] the steering wheel left and right. The steering wheel free play is the amount of travel in the steering wheel, before the front wheels begin to turn.

• Page 57: Electrical System

  PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Electrical System Brake Light Switch Adjustment • Check the operation of the brake light switch by depress- ing the brake pedal. The brake light should go on after 10 mm (0.4 in.) of pedal travel [A]. If it does not, adjust the brake light switch [A] up or down.
• Page 58 2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Pivots and Points: Lubricate with Grease. Seat Brackets Cargo Bed Mounting Pins Throttle Pedal Pivot Brake Pedal Pivot Transmission Shift Control Lever Pivot Differential Shift Cable Upper End 2WD/4WD Shift Lever Pivot Propeller Shaft Bearing [A] (under seat) ○...

• Page 59: Bolts, Nuts, And Fasteners

  PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Bolts, Nuts, and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ Check the engine fastener tightness when the engine is cold (at room temperature).
• Page 60 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering: Steering Wheel Mounting Nut Intermediate Shaft Clamp Bolts Tie-rod End Nuts and Cotter Pins Tie-rod End Locknuts Suspension Arm Joint Nuts and Cotter Pins Main Shaft Mounting Bolts and Nuts Frame: Front and Rear Bar Mounting Bolts and Nuts Front Guard Mounting Nuts Cargo Bed Hook Mounting Bolts Cargo Bed Mounting Pin Clips...
• Page 61 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........Choke Cable Lubrication....3-14 Specifications ........Choke Cable Inspection....3-15 Throttle Pedal and Cable....Carburetor ......... 3-16 Throttle Pedal Free Play Idle Speed Inspection ....3-16 Inspection........Idle Speed Adjustment....3-16 Throttle Pedal Free Play Fuel System Cleanliness...

• Page 62: Exploded View

  3-2 FUEL SYSTEM Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 63 Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Mounting Bolts Air Duct Clamps 0.98 0.10 8.7 in·lb 3. Approxmately 60° G: Apply grease. SS: Apply silicone sealant (Kawasaki Bond: 56019-120) around the tubes. Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 64 3-4 FUEL SYSTEM Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 65 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Float Bowl Screws 0.20 18 in·lb Cover Mounting Bolts 0.30 26 in·lb Chamber Case Cover Bolts 0.50 43 in·lb Governor Arm Mounting Nut 0.75 65 in·lb Carburetor Cover Bolts 0.90 78 in·lb Link Lever Mounting Bolts...

• Page 66: Specifications

  3-6 FUEL SYSTEM Specifications Item Standard Service Limit Throttle Pedal and Cable 5 ∼ 10 mm (0.2 ∼ 0.4 in.) Throttle pedal free play – – – Governer Link Mechanism 0.05 ∼ 0.3 mm (0.002 ∼ 0.012 in.) Throttle link lever bolt/shim clearance –...

• Page 67: Throttle Pedal And Cable

  FUEL SYSTEM 3-7 Throttle Pedal and Cable Throttle Pedal Free Play Inspection • Refer to Throttle Pedal Free Play Inspection in the Peri- odic Maintenance chapter. Throttle Pedal Free Play Adjustment • Refer to Throttle Pedal Free Play Adjustment in the Peri- odic Maintenance chapter.

• Page 68: Governor Link Mechanism

  3-8 FUEL SYSTEM Governor Link Mechanism Control Panel Assembly Removal • Remove: Cargo Bed • Drill out the pop rivets [A] holding the control panel as- sembly shroud [B] with a drill bit of the 5 mm (0.02 in.) diameter. ○...
• Page 69 FUEL SYSTEM 3-9 Governor Link Mechanism 1. Governor Arm 2. Pivot Arm 3. Link 4. Hole 5. Turn the pivot arm. 6. Turn the governor arm. 7. Carburetor Throttle Full Open 8. Throttle Full Open 9. Governor Arm Clamp Nut 10.
• Page 70 3-10 FUEL SYSTEM Governor Link Mechanism • Turn the bushings [A] counterclockwise until fitting on the link with click [B]. • Fit the 4 bosses on the intake pipe of the engine with the carburetor cover after pass the link into the hole of the carburetor cover.

• Page 71: Governor Arm And Throttle Link Removal

  FUEL SYSTEM 3-11 Governor Link Mechanism Governor Arm and Throttle Link Removal • Remove: Cargo Bed Control Panel Assembly Shroud Carburetor Cover Bolts [A] Carburetor Cover [B] • Remove: Throttle Link [A] Governer Arm [B] Governor Arm Installation • Adjust the governor arm on the shaft. ○...

• Page 72: Governor Assembly Removal

  3-12 FUEL SYSTEM Governor Link Mechanism Governor Assembly Removal • Remove: Transmission Case (split) Governor Arm Governor Shaft Snap Pin [A] Governor Shaft [B] Washer (thin) [C] Washer (thick) [D] • Remove the governor assembly [A] with the sleeve [B] by prying the gear [C] with two suitable levers.

• Page 73: Throttle Link Lever Installation

  FUEL SYSTEM 3-13 Governor Link Mechanism Throttle Link Lever Installation • Measure the clearance [A] between the seating surface of the bolt head and shims. Throttle Link Lever Bolt/Shim Clearance 0.05 ∼ 0.3 mm (0.002 ∼ 0.012 in.) Standard: If the clearance is not within the specified range, adjust the clearance by adding or removing the shims.

• Page 74: Choke Cable

  3-14 FUEL SYSTEM Choke Cable Choke Cable Free Play Inspection • Push in the choke knob all the way. • Check the choke cable free play [A]. ○ Determine the amount of free play at the choke knob. Pull the choke knob until the starter lever [B] on the carburetor begins to turn;...

• Page 75: Choke Cable Inspection

  FUEL SYSTEM 3-15 Choke Cable Choke Cable Inspection • With the choke cable disconnected at both ends, the ca- ble should move freely [A] within the cable housing. If the cable does not move freely after lubricating, if the cable is frayed, or if the housing is kinked, replace the cable.

• Page 76: Carburetor

  3-16 FUEL SYSTEM Carburetor Idle Speed Inspection • Refer to Idle Speed Inspection in the Periodic Mainte- nance chapter. Idle Speed Adjustment • Refer to Idle Speed Adjustment in the Periodic Mainte- nance chapter. Fuel System Cleanliness Inspection • Refer to Fuel System Cleanliness Inspection in the Peri- odic Maintenance chapter.

• Page 77: Carburetor Installation

  FUEL SYSTEM 3-17 Carburetor • Remove: Carburetor [A] Choke Link [B] • After removing the carburetor, stuff pieces of lint-free, clean cloth into the carburetor holder and the air cleaner duct to keep dirt out of the engine and air cleaner. CAUTION If dirt gets through into the engine, excessive en- gine wear and possibly engine damage will occur.

• Page 78: Carburetor Disassembly

  ○ Apply silicone sealant [C] around the tube for filling the gap between the tube and duct. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Torque: Torque - Air Duct Clamp [D]: 0.98 N·m (0.10 kgf·m, 8.7 in·lb) •...

• Page 79: Carburetor Assembly

  FUEL SYSTEM 3-19 Carburetor • Remove: Pin [A] Float [B] • Remove: Pilot Jets [A] • Remove: Main Jets [A] Carburetor Assembly • Tighten: Torque - Float Bowl Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb) Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 80: Carburetor Cleaning

  3-20 FUEL SYSTEM Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash -point solvents to clean the carburetor.

• Page 81: Coolant Filter Cleaning

  FUEL SYSTEM 3-21 Carburetor • Check that the gasket [A] on the float bowl is in good condition. If the gasket is not in good condition, replace it. • Check the float [A] for cracks. If there are any cracks, replace the float. NOTE ○...

• Page 82: Air Cleaner

  ○ Apply silicone sealant [C] around the tube for filling the gap between the tube and duct. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Torque: Torque - Air Duct Clamp [D]: 0.98 N·m (0.10 kgf·m, 8.7 in·lb) Air Cleaner Housing Dust and/or Water Inspection •...

• Page 83: Fuel Pump And Fuel Filter

  FUEL SYSTEM 3-23 Fuel Pump and Fuel Filter Fuel Pump and Fuel Filter Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...

• Page 84: Fuel Tank

  3-24 FUEL SYSTEM Fuel Tank Fuel Tank Removal WARNING Fuel is extremely flammable and can be explosive under certain conditions. Turn the main switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

• Page 85: Fuel Tank Installation

  FUEL SYSTEM 3-25 Fuel Tank • Remove the fuel tank [A]. Fuel Tank Installation If the rubber dampers [A] were removed, install them onto the fuel tank with an adhesive. • Install the dampers on the collars, as shown. ○ Position the damper [A] so that its thicker side [B] faces the front side.
• Page 86 3-26 FUEL SYSTEM Fuel Tank ○ Push down the gasket [A] into the bottom of fuel tank cap [B], and insert the flange portions [C] of gasket to the cap threads. Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 87 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Sealant ........................... Flow Chart ..........................Coolant ........................... Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Water Pump..........................4-10 Water Pump Removal ....................... 4-10 Water Pump Installation ....................4-11 Water Pump Inspection.....................

• Page 88: Exploded View

  4-2 COOLING SYSTEM Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 89 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Reservoir Mounting Bolt 0.45 39 in·lb Radiator Screen Bolts 0.90 78 in·lb Radiator Mounting Bolts 0.90 78 in·lb Radiator Fan Switch Water Pipe Bolts 0.90 78 in·lb Coolant Temperature Warning Light Switch Coolant Drain Plugs (Cylinder ) Water Pump Cover Bolts (M6) 0.90...

• Page 90: Specifications

  4-4 COOLING SYSTEM Specifications Item Standard Service Limit Coolant Type Permanent type of antifreeze – – – (Soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green – – – Mixed ratio Soft water 50%, coolant 50% –...

• Page 91: Sealant

  COOLING SYSTEM 4-5 Sealant Kawasaki Bond (Silicone Sealant): 56019-120 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 92: Flow Chart

  4-6 COOLING SYSTEM Flow Chart Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 93 COOLING SYSTEM 4-7 Flow Chart 1. Radiator 2. Radiator Fan 3. Radiator Cap 4. Reservoir Tank 5. Water Pump 6. Cylinder 7. Thermostat 8. Coolant Temperature Warning Light Switch 9. Air Bleeder Bolt (Water Pipe) 10. Filter 11. Carburetor 12. Thermo Valve 13.
• Page 94 4-8 COOLING SYSTEM Flow Chart 1. Filter 2. Thermo Valve 3. White Mark 4. Coolant Inlet 5. Coolant Outlet 6. Level the tube to the inlet pipe. 7. Do not bulge the tube as a dotted line. 8. Face the projection on the valve body to the carburetor. Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 95: Coolant

  COOLING SYSTEM 4-9 Coolant Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room of ambi- ent temperature). CAUTION Do not check the level through the coolant filler by removing the radiator cap. If the cap is removed, the coolant will flow out from the reservoir tank.

• Page 96: Water Pump

  4-10 COOLING SYSTEM Water Pump Water Pump Removal • Remove: Torque Converter Coolant (drain) Water Hoses [A] Water Pump Cover Bolts [B] Water Pump Cover [C] • Remove: Water Pump Housing Bolt [A] Water Pump Housing [B] • Remove: Water Pump Drive Gear [A] •...

• Page 97: Water Pump Installation

  COOLING SYSTEM 4-11 Water Pump • Remove: Mechanical Seal [A] Oil Seal [B] Water Pump Installation • Clean the sliding surface of a new mechanical seal with a high-flash point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion.

• Page 98: Water Pump Inspection

  4-12 COOLING SYSTEM Water Pump Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the water pump body for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passages. Re- place the mechanical seal [A] or O-ring [B].

• Page 99: Radiator And Radiator Fan

  COOLING SYSTEM 4-13 Radiator and Radiator Fan Radiator Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.

• Page 100: Radiator Inspection

  4-14 COOLING SYSTEM Radiator and Radiator Fan Radiator Inspection • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparable de- formed fins, replace the radiator with a new one.

• Page 101: Radiator Cap

  COOLING SYSTEM 4-15 Radiator Cap The radiator cap at the reservoir tank has the pressure relief valve, and must be inspected. The cap at the radiator has no valve. CAUTION Do not change the positions of the radiator cap at the reservoir tank and the cap at the radiator.

• Page 102: Thermostat

  4-16 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant (drain) Hose [A] • Remove: Thermostat Housing Cap Bolts [A] Thermostat Housing Cap [B] Thermostat Installation • Install the thermostat [A] so that the jiggle valve [B] is on top. • Adjust: Coolant Thermostat Inspection...
• Page 103 COOLING SYSTEM 4-17 Thermostat • To check valve opening temperature, suspend the ther- mostat in a container of water and raise the temperature of the water. If the measurement is out of the specified range, replace the thermostat. Thermostat Valve Opening Temperature 80.5 ∼...

• Page 104: Hoses And Pipes

  4-18 COOLING SYSTEM Hoses and Pipes Hose and Pipe Installation • Install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting.

• Page 105: Radiator Fan Switch, Coolant Temperature Warning Light Switch

  Light Switch Installation • Apply silicone sealant to the threads of the coolant tem- perature warning light switch. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Apply grease to the O-ring of the radiator fan switch. • Tighten the fan switch and coolant temperature warning light switch.
• Page 106 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 107 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Cylinder Head ........................Cylinder Compression Measurement................Cylinder Head Removal ....................Cylinder Head Installation ....................Cylinder Head Disassembly and Assembly (Valve Mechanism Removal and Installation)........................

• Page 108: Exploded View

  5-2 ENGINE TOP END Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 109 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Intake Pipe Bolts 0.90 78 in·lb L (2) Valve Adjusting Screw Locknuts 87 in·lb Cylinder Head Bolts Coolant Temperature Warning Light Switch L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease.

• Page 110: Specifications

  5-4 ENGINE TOP END Specifications Item Standard Service Limit Cylinder Head Cylinder compression (Usable Range) 1 000 ∼ 1 520 kPa (10.2 ∼ 15.5 kgf/cm², – – – 145 ∼ 220 psi) @490 r/min (rpm) Cylinder head warp – – – 0.03 mm (0.001 in.) Valves Valve clearance (when cold)

• Page 111: Special Tools

  ENGINE TOP END 5-5 Special Tools Outside Circlip Pliers: Valve Seat Cutter, 45° - 30: 57001-144 57001-1187 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 32° - 33: 57001-1116 57001-1199 Valve Seat Cutter, 32° - 30: Valve Adjusting Screw Holder: 57001-1120 57001-1217 Valve Seat Cutter Holder Bar:...

• Page 112: Cylinder Head

  5-6 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Tilt up the cargo bed. • Thoroughly warm up the engine so that the engine oil be- tween the piston and the cylinder wall will help seal com- pression as it does during normal running. •...
• Page 113 ENGINE TOP END 5-7 Cylinder Head • Remove: Choke Cable Bracket Bolt [A] Choke Cable Bracket [B] Breather Hose [C] Coolant Hose [D] • Remove: Bands [A] Intake Manifold Bolts [B] Intake Manifold [C] Muffler and Exhaust Pipe Alternator Cover [D] •...

• Page 114: Cylinder Head Installation

  5-8 ENGINE TOP END Cylinder Head • Remove: Cylinder Head Bolts [A] Cylinder Head [B] Cylinder Head Gasket Rocker Arm Push Rods Cylinder Head Installation • Clean the mating surface of the cylinder head and the cylinder. • Replace the gasket with a new one. •...

• Page 115: Cylinder Head Disassembly And Assembly (valve Mechanism Removal And Installation)

  ENGINE TOP END 5-9 Cylinder Head • Tighten the cylinder head bolts in the order shown. Torque - Cylinder Head Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb) • Tighten the intake manifold bolts in the order shown. • Adjust: Valve Clearance Adjustment •...

• Page 116: Cylinder Head Warp

  5-10 ENGINE TOP END Cylinder Head • Remove: Valve Spring Retainers [A] Split Keepers [B] Valve Springs Valves ○ Press down the valve spring retainer holding the valve head, and remove the split keepers. • Remove: Oil Seals [A] Spring Seats [B] •...

• Page 117: Valves

  ENGINE TOP END 5-11 Valves Valve Clearance Inspection • Refer to Valve Clearance Inspection in the Periodic Main- tenance chapter Valve Clearance Adjustment • Refer to Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Seat Inspection • Remove the valve. •...
• Page 118 5-12 ENGINE TOP END Valves Seat Cutter Operating Cares 1. The valve seat cutter [A] is designed only for valve seat repair. Therefore the cutter must not be used for other purposes. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off.
• Page 119 ENGINE TOP END 5-13 Valves Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter to the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
• Page 120 5-14 ENGINE TOP END Valves Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 121: Valve Spring Free Length

  ENGINE TOP END 5-15 Valves Valve Spring Free Length • Measure the valve spring free length. If the free length is less than the service limit, replace the valve spring with a new one. Valve Spring Free Length Standard: 34.3 mm (1.35 in.) Service Limit: 32.6 mm (1.28 in.) Valve Head Thickness •...

• Page 122: Valve Guide Inside Diameter

  5-16 ENGINE TOP END Valves Valve Guide Inside Diameter • Measure the inside diameter [A] of the valve guide. If the valve guide has worn past the service limit, replace the cylinder head. Valve Guide Inside Diameter 6.000 ∼ 6.015 mm (0.2362 ∼ 0.2368 in.) Standard: Service Limit: 6.08 mm (0.239 in.) Measuring Valve/Guide Clearance (Wobble Method)

• Page 123: Rocker Arm Push Rod Inspection

  ENGINE TOP END 5-17 Valves • Measure the inside diameter [A] of the rocker arm. If the bearing has worn past the service limit, replace the rocker arm with a new one. Rocker Arm Inside Diameter 12.006 ∼ 12.024 mm (0.4727 ∼ 0.4734 Standard: in.) Service Limit:...

• Page 124: Exhaust Pipe And Muffler

  5-18 ENGINE TOP END Exhaust Pipe and Muffler Exhaust Pipe Removal • Remove: Exhaust Pipe Cover Screws [A] Exhaust Pipe Cover [B] • Remove: Exhaust Pipe Holder Nuts [A] Exhaust Pipe Clamp Bolts [B] Exhaust Pipes [C] Muffler Removal • Remove: Exhaust Pipe Clamp Bolts [A] Muffler Mounting Bolts [B]...

• Page 125: Exhaust Pipe And Muffler Inspection

  ENGINE TOP END 5-19 Exhaust Pipe and Muffler Exhaust Pipe and Muffler Inspection • Before removing, check for signs of leakage at the ex- haust pipe gasket in the cylinder head and at the muffler clamp. If there are signs of leakage around the exhaust pipe gas- ket, it should be replaced.
• Page 126 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 127 CONVERTER SYSTEM 6-1 Converter System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Air Cleaner..........................Air Cleaner Housing Removal................... Air Cleaner Element Removal................... Air Cleaner Element Cleaning/Inspection ................. Torque Converter........................Torque Converter Removal ....................Torque Converter Installation .................... 6-10 Torque Converter Case Removal..................

• Page 128: Exploded View

  6-2 CONVERTER SYSTEM Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 129 CONVERTER SYSTEM 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Driven Pulley Bolt Wear Shoe Mounting Screws 0.11 10 in·lb Drive Pulley Bolt (New) Cooling Fan Cover Bolts 0.90 78 in·lb Drive Pulley Cover Bolts 113 in·lb Spider Ramp Weight Nuts 0.70 61 in·lb L: Apply a non-permanent locking agent.
• Page 130 6-4 CONVERTER SYSTEM Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 131 CONVERTER SYSTEM 6-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Converter Cover Botls 0.15 13 in·lb 2. Fit the joint location of the seal with the top of the case. 3. Fit the seal into groove of the case. Do not twist the seal. Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 132: Specifications

  6-6 CONVERTER SYSTEM Specifications Item Standard Service Limit Drive Belt 28 ∼ 33 mm (1.1 ∼ 1.3 in.) Belt Deflection – – – Belt Width 30.3 mm (1.19 in.) 28.8 mm (1.13 in.) Drive Pulley 0 ∼ 0.4 mm (0 ∼ 0.16 in.) Spider Wear Guide Clearance –...

• Page 133: Special Tools

  CONVERTER SYSTEM 6-7 Special Tools Outside Circlip Pliers: Drive Pulley Puller Bolt: 57001-144 57001-1429 Drive Pulley Wrench: Driven Pulley Holder: 57001-1411 57001-1465 Drive & Driven Pulley Holder: 57001-1412 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 134: Air Cleaner

  6-8 CONVERTER SYSTEM Air Cleaner Air Cleaner Housing Removal • Loosen: Clamps [A] • Remove: Air Duct [B] Bracket Bolt [C], Collar and Nut Air Cleaner Housing [D] • After removing the housing, stuff pieces of lint-free, clean cloth into the torque converter cover duct to keep dirt out of the torque converter.

• Page 135: Torque Converter

  CONVERTER SYSTEM 6-9 Torque Converter Torque Converter Removal • Remove: Left Rear Shock Absorber [A] (see Suspension chapter) Air Cleaner Housing for Torque Converter (see Air Cleaner Housing Removal) Exhaust Pipe (see Engine Top End chapter) Outer Cover Bolts Torque Converter Cover [B] •...

• Page 136: Torque Converter Installation

  6-10 CONVERTER SYSTEM Torque Converter Torque Converter Installation • Clean the following portions with an oil-less cleaning fluid such as trichloroethylene or acetone. Fixed Sheave Tapered Portion [A] Crankshaft Tapered Portion [B] WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods.

• Page 137: Torque Converter Case Removal

  CONVERTER SYSTEM 6-11 Torque Converter When installing the new trim seal [A], install it according to the following procedure. ○ Fit the joint [B] of the trim seal with the top of the case [C]. ○ Fit the seal into the groove of the case. NOTE ○...

• Page 138: Drive Belt

  6-12 CONVERTER SYSTEM Drive Belt Drive Belt Removal • Remove the torque converter cover (see Torque Con- verter Removal). • Pull the parking brake lever up and to the rear to apply the parking brake. WARNING Wear gloves to protect your hands from sharp edges during the following steps.

• Page 139: Drive Belt Deflection Inspection

  CONVERTER SYSTEM 6-13 Drive Belt Drive Belt Deflection Inspection • Remove the torque converter cover (see Torque Con- verter Removal). • Put the transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley.

• Page 140: Drive Pulley

  6-14 CONVERTER SYSTEM Drive Pulley Drive Pulley Disassembly • Hold the drive pulley with the drive & driven pulley holder [A] in a vise. Special Tool - Drive & Driven Pulley Holder: 57001-1412 ○ Mount the pulley holder base plate chamfered side up in a vise, with the short guide (L = 41 mm) (1.614 in.) and short stoppers (L = 16 mm) (0.630 in.) installed.

• Page 141: Drive Pulley Assembly

  CONVERTER SYSTEM 6-15 Drive Pulley Drive Pulley Assembly • Install the ramp weight [A] as shown. • Tighten: Torque - Ramp Weight Nuts [B]: 6.9 N·m (0.70 kgf·m, 61 in·lb) • Check the ramp weights swing smoothly. • Install: Roller [A] Spacers [B] Pin [C] ○...

• Page 142: Spider/wear Guide Clearance Adjustment

  6-16 CONVERTER SYSTEM Drive Pulley • Tighten: Special Tool - Drive Pulley Wrench [A]: 57001-1411 Torque - Spider: 275 N·m (28 kgf·m, 203 ft·lb) • Put the spring [A] in the groove of the spider. • Align the arrows [B] on the drive pulley cover and spider. •...
• Page 143 CONVERTER SYSTEM 6-17 Drive Pulley • Replace any sheave which has uneven wear on the belt contacting surface. [A] Sheave Surface [B] Straight Edge If the guide bushings are damaged or worn, replace them. Cover Bushing Inside Diameter [A] 28.075 ∼ 28.175 mm (1.105 ∼ 1.109 in.) Standard: Service Limit: 28.21 mm (1.111 in.) Sheave Bushing Inside Diameter [B]...

• Page 144: Bushing Installation

  6-18 CONVERTER SYSTEM Drive Pulley If the spring is damaged, replace the spring. Spring Free Length [A] Standard: 65.02 mm (2.56 in.) Bushing Installation • Press the cover bushing [A] into the cover [B] with a suit- able driver until it stops at the shoulder in the hole. •...

• Page 145: Driven Pulley

  CONVERTER SYSTEM 6-19 Driven Pulley Driven Pulley Disassembly • Hold the driven pulley [A] with the drive & driven pulley holder and driven pulley holder in a vise. Special Tools - Drive & Driven Pulley Holder: 57001-1412 Driven Pulley Holder: 57001-1465 ○...

• Page 146: Driven Pulley Assembly

  6-20 CONVERTER SYSTEM Driven Pulley • Remove: Circlip [A] Spacer [B] Ramp [C] Spring [D] Movable Sheave [E] Spacers [F] Fixed Sheave [G] • Remove: Screws [A] Wear Shoes [B] Driven Pulley Assembly • Install the wear shoe [A] on the movable sheave [B] as shown.

• Page 147: Driven Pulley Inspection

  CONVERTER SYSTEM 6-21 Driven Pulley • Install: Movable Sheave [A] Spring [B] ○ Insert the spring end into the hole “C”. NOTE ○ The fixed/movable sheave assembly has several differ- ent spring locations which affect shifting characteristics of the torque converter. •...

• Page 148: Bushing Installation

  6-22 CONVERTER SYSTEM Driven Pulley If the splines [A] are damaged or worn, replace them. If the spring is damaged, replace the spring. Spring Free Length [A] Standard: 112.6 mm (4.43 in.) If the tabs on the spring are misaligned or the spring coils are distorted, replace the spring.
• Page 149 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Engine Oil Flow Chart......................Engine Oil and Oil Filter......................Oil Level Inspection......................Oil and/or Filter Change....................Oil Filter Removal ......................Oil Filter Installation ......................Oil Pump and Relief Valve......................

• Page 150: Exploded View

  7-2 ENGINE LUBRICATION SYSTEM Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 151 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch 87 in·lb Engine Oil Drain Plug (M16) Engine Oil Drain Plug (M14) Crankcase Cover Bolt G: Apply grease to the wire terminal. O: Apply engine oil. SS: Apply silicone sealant.

• Page 152: Specifications

  7-4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Service Limit Engine Oil and Oil Filter Engine oil: Grade API SF or SG – – – API SH or SJ with JASO MA Viscosity SAE 10W-40 – – – Capacity 1.5 L (1.6 US qt) (when filter is not removed) – – – 1.8 L (1.9 US qt) (when filter is removed) –...

• Page 153: Special Tools And Sealant

  ENGINE LUBRICATION SYSTEM 7-5 Special Tools and Sealant Oil Filter Wrench: 57001-1249 Kawasaki Bond (Silicone Sealant): 56019-120 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 154: Engine Oil Flow Chart

  7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Filter 5. Oil Pressure Switch 6. Crankshaft 7. Camshaft 8. Rocker Arm Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 155: Engine Oil And Oil Filter

  ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Oil Level Inspection NOTE ○ If the vehicle has just been used, wait several minutes for all the oil to drain down.
• Page 156 7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter • Apply engine oil to the rubber seal lip [A] on the dipstick. • Face the recess side [A] of the dipstick upward, and insert CAUTION Do not insert the dipstick except the specified di- rection.

• Page 157: Oil And/or Filter Change

  ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter If the oil level is too high, remove the excess oil, using a syringe or some other suitable device, or removing the engine oil drain plug, drain the excess oil. If the oil level is too low, add the correct amount of oil through the oil filler opening.

• Page 158: Oil Pump And Relief Valve

  7-10 ENGINE LUBRICATION SYSTEM Oil Pump and Relief Valve Oil Pump and Relief Valve Removal • Remove: Engine Crankcase Cover Oil Pump Cover Bolts [A] Oil Pump Gear [B] and Oil Pump Cover [C] Oil Pump Inner Rotor [D] Oil Pump Outer Rotor [E] Relief Valve Spring [F] Steel Ball [G] Oil Pump and Relief Valve Installation...

• Page 159: Engine Lubrication System

  ENGINE LUBRICATION SYSTEM 7-11 Oil Pump and Relief Valve • Visually inspect the relief valve spring [A], and steel ball [B]. If any rough spots are found during the above inspection, wash the valve clean with a high flash-point solvent and blow out any foreign particles that may be in the valve with compressed air.
• Page 160 7-12 ENGINE LUBRICATION SYSTEM Oil Pump and Relief Valve Inner Rotor Shaft Bearing Inside Diameter [A] 11.000 ∼ 11.011 mm (0.4331 ∼ 0.4335 Standard: in.) Service Limit: 11.07 mm (0.436 in.) Outer Rotor Housing Inside Diameter [B] 40.680 ∼ 40.701 mm (1.6016 ∼ Standard: 1.6024 in.) Service Limit:...

• Page 161: Oil Screen

  ENGINE LUBRICATION SYSTEM 7-13 Oil Screen Oil Screen Removal • Remove: Engine Crankcase Cover Oil Screen Cover Screws [A] Oil Screen Cover [B] • Remove: Oil Screen [A] Oil Screen Installation • Clean the oil screen thoroughly whenever it is removed. Oil Screen Cleaning/Inspection •...

• Page 162: Oil Pressure Switch

  • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Connect the wire to the oil pressure switch.
• Page 163 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 164: Exploded View

  8-2 ENGINE REMOVAL/INSTALLATION Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 165 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Positioning Plate Bolts Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 166: Engine Removal/installation

  8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Disconnect: Battery Terminal Wires (see Electrical System chapter) • Remove: Engine Oil (drain) Coolant (drain) Cargo Bed (see Frame chapter) Exhaust Pipe (see Engine Top End chapter) Torque Converter and Case (see Torque Converter Sys- tem chapter) Water Hoses [A] Air Ducts [B]...

• Page 167: Engine Installation

  ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Installation • Adjust the engine mounting position for alignment of the torque converter. ○ Mount the engine and install the engine mounting bolts loosely. ○ Install the engine positioning plate [A] onto the transmis- sion case and crankcase as shown.
• Page 168 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 169 ENGINE BOTTOM END 9-1 Engine Bottom End Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Crankcase Cover........................Crankcase Cover Removal ....................Crankcase Cover Installation .................... Camshaft and Tappets......................Camshaft Removal ......................Camshaft Installation ......................Camshaft Inspection ......................Cam Wear......................... Camshaft Bearing/Journal Wear..................

• Page 170: Exploded View

  9-2 ENGINE BOTTOM END Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 171 ENGINE BOTTOM END 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Connecting Rod Big End Cap Bolts Oil Filter Stud Bolt Crankcase Cover Bolts Coolant Drain Plugs (Cylinder) G: Apply grease. O: Apply engine oil. Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 172: Specifications

  9-4 ENGINE BOTTOM END Specifications Item Standard Service Limit Camshaft and Tappets Cam height: 25.719 ∼ 25.809 mm Inlet 25.62 mm (1.009 in.) (1.0126 ∼ 1.0161 in.) 25.962 ∼ 26.052 mm Exhaust 25.86 mm (1.018 in.) (1.0221 ∼ 1.0257 in.) 15.957 ∼...
• Page 173 ENGINE BOTTOM END 9-5 Specifications Item Standard Service Limit 34.004 ∼ 34.015 mm 34.05 mm Connecting rod big end (1.3387 ∼ 1.3392 in.) bearing inside diameter (1.341 in.) Crankshaft runout Less than 0.02 mm 0.05 mm (0.0008 in.) TIR (0.002 in.) TIR 33.959 ∼...

• Page 174: Special Tools

  9-6 ENGINE BOTTOM END Special Tools Piston Pin Puller Assembly: 57001-910 Piston Ring Compressor Grip: 57001-1095 67 ∼ 79: Piston Ring Compressor Belt, 57001-1097 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 175: Crankcase Cover

  ENGINE BOTTOM END 9-7 Crankcase Cover Crankcase Cover Removal • Remove: Engine Water Pump Crankcase Cover Bolts [A] Crankcase Cover [B] NOTE ○ If the crankcase cover sticks, tap lightly with a mallet on the alternator side near the knock pins. Crankcase Cover Installation •...

• Page 176: Camshaft And Tappets

  9-8 ENGINE BOTTOM END Camshaft and Tappets Camshaft Removal • Remove: Engine Cylinder Heads Crankcase Cover Camshaft [A] Tappets [B] ○ Turn the engine upside down to keep the tappets from catching the cam lobes. Camshaft Installation • Apply engine oil: Tappets Camshaft Journals Cam Surfaces...

• Page 177: Camshaft Bearing/journal Wear

  ENGINE BOTTOM END 9-9 Camshaft and Tappets Camshaft Bearing/Journal Wear • Measure the diameter [A] of the camshaft journals. If any journal has worn past the service limit, replace the camshaft with a new one. Camshaft Journal Diameter 15.957 ∼ 15.975 mm (0.6282 ∼ 0.6289 in.) Standard: Service Limit: 15.93 mm (0.627 in.) •...

• Page 178: Cylinders And Pistons

  9-10 ENGINE BOTTOM END Cylinders and Pistons Piston Removal • Remove: Engine Cylinder Heads Crankcase Cover Camshaft • Turn the crankshaft to expose the two connecting rod big end cap bolts. • Remove: Connecting Rod Big End Cap Bolts [A] Connecting Rod Big End Caps [B] •...

• Page 179: Piston Installation

  ENGINE BOTTOM END 9-11 Cylinders and Pistons • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove • Remove the 3-piece oil ring with your thumbs in the same manner.
• Page 180 9-12 ENGINE BOTTOM END Cylinders and Pistons • Assemble the pistons onto the connecting rods as shown. ○ No. 1 cylinder piston, align the arrow on the top of the piston with 'MADE IN JAPAN' on the connecting rod. ○ No.

• Page 181: Piston Ring, Piston Ring Groove Wear

  ENGINE BOTTOM END 9-13 Cylinders and Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to the groove sur- faces. If not, the piston must be replaced. •...

• Page 182: Boring, Honing

  9-14 ENGINE BOTTOM END Cylinders and Pistons Boring, Honing When boring and honing a cylinder, note the following. ○ Oversize piston requires oversize rings. Oversize Piston and Rings 0.50 mm (0.02 in.) Oversize ○ Before boring a cylinder, first measure the exact diame- ter of the oversize piston, and the, according to the stan- dard clearance in the Specifications, determine the rebore diameter.

• Page 183: Crankshaft And Connecting Rods

  ENGINE BOTTOM END 9-15 Crankshaft and Connecting Rods Connecting Rod Removal • Remove the connecting rods during the piston removal. Connecting Rod Installation • Install the connecting rods during the piston installation. Crankshaft Removal • Remove: Engine Cylinder Head Alternator Rotor and Stator Crankcase Cover Camshaft Pistons and Connecting Rods...

• Page 184: Connecting Rod Big End Side Clearance

  9-16 ENGINE BOTTOM END Crankshaft and Connecting Rods • Measure the connecting rod twist. ○ With the big-end arbor [A] still on the V blocks [C], hold the connecting rod horizontally and measure the amount that the small end arbor [B] varies from being parallel with the surface plate over a 100 mm (3.937 in.) length of the arbor to determine the amount of connecting rod twist.

• Page 185: Crankshaft Runout

  ENGINE BOTTOM END 9-17 Crankshaft and Connecting Rods ○ Remove the connecting rod big end cap, and measure the plastigauge width [A] to determine the bearing/crankpin clearance. Connecting Rod Big End Bearing/Crankpin Clearance 0.024 ∼ 0.048 mm (0.0009 ∼ 0.0019 in.) Standard: Service Limit: 0.08 mm (0.0031 in.)

• Page 186: Crankshaft Main Bearing/journal Wear

  9-18 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Main Bearing/Journal Wear • Measure the diameter [A] of the crankshaft main journal. If the journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft Main Journal Diameter 33.959 ∼...

• Page 187: Breather Valve

  ENGINE BOTTOM END 9-19 Breather Valve Breather Valve Removal • Remove: Alternator and Stator Breather Cover Bolts [A] Breather Cover [B] • Remove: Breather Valve [A] Breather Valve Installation • Place the reed valve on the seat so that there is a slight gap between the valve and the seat.
• Page 188 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 189 TRANSMISSION 10-1 Transmission Table of Contents Exploded View........10-2 2WD/4WD Shift Cable Specifications ........10-8 Lubrication......... 10-24 Special Tools and Sealant ....10-9 2WD/4WD Shift Cable Inspection 10-24 Transmission Oil........ 10-10 2WD/4WD Shift Mechanism Transmission Oil Level Inspection 10-10 Removal ........10-24 Transmission Oil Change.....

• Page 190: Exploded View

  10-2 TRANSMISSION Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 191 TRANSMISSION 10-3 Exploded View G: Apply grease. Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 192 10-4 TRANSMISSION Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 193 TRANSMISSION 10-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift Shaft Stop Bolts 0.80 69 in·lb Differential Gear Housing Bolts Shift Arm Positioning Bolt G: Apply grease. L: Apply a non-permanent locking agent. O: Apply engine oil. Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 194 10-6 TRANSMISSION Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 195 TRANSMISSION 10-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Transmission Case Bolts 0.90 78 in·lb Transmission Oil Drain Plug Engine Positioning Plate Bolts Governor Pivot Arm Stopper Bolt Shift Shaft Lever Clamp Bolts 104 in·lb Hi/Low Gear Case Bolts Bearing Holder Neutral Switch Transmission Case Mounting Bolts...

• Page 196: Specifications

  10-8 TRANSMISSION Specifications Item Standard Service Limit Transmission Oil Type API 'GL-5' Hypoid gear oil – – – Viscosity SAE 90: above 5°C (41°F) – – – SAE 80: below 5°C (41°F) – – – Capacity: 2.5 L (2.6 US qt) –...

• Page 197: Special Tools And Sealant

  TRANSMISSION 10-9 Special Tools and Sealant Outside Circlip Pliers: Hexagon Wrench, Hex 32: 57001-144 57001-1194 Oil Seal & Bearing Remover: Kawasaki Bond (Liquid Gasket - Silver): 57001-1058 92104-002 Bearing Driver Set: 57001-1129 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 198: Transmission Oil

  10-10 TRANSMISSION Transmission Oil CAUTION Vehicle operation with insufficient, deteriorated or contaminated transmission oil will cause acceler- ated wear and may result in transmission failure. Transmission Oil Level Inspection NOTE ○ If the vehicle has just been used wait several minutes for all the oil to settle down.

• Page 199: Transmission Case

  TRANSMISSION 10-11 Transmission Case Transmission Case Removal • Remove: Transmission Oil (drain) Cargo Bed Propeller Shafts (see Final Drive chapter) Torque Converter Case (see Converter System) Drive Shafts and Axles (see Final Drive chapter) Neutral Switch Terminal Lead (disconnect) Transmission Shift Cable Lower End [A] Hi/Low Shift Cable Lower End [B] 2WD/4WD Shift Cable Lower End [C] Differential Shift Cable Lower End [D]...

• Page 200: Transmission Case Splitting

  If any one of them has been removed, re- place it with a new one. • Apply liquid gasket: Transmission Case Mating Surface Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104 - • Apply grease: Oil Seal Lips •...

• Page 201: Transmission And Shift Mechanism

  TRANSMISSION 10-13 Transmission and Shift Mechanism Transmission and Hi/Low Shift Cables Installation • Remove one side of the spring [A] from the shift shaft lever assembly. • Put the shift lever [A] in the 'L' (LOW) position. • Using the shift shaft lever [B] temporarily set the shift arm [A] in forward or reverse position as shown.
• Page 202 10-14 TRANSMISSION Transmission and Shift Mechanism • Screw the joint [A] of the shift shaft lever [B] fully into the hi/low shift cable [C] end, and install the cable onto the bracket [D]. • Line up the punch mark [A] on the shift arm, projection [B] on the transmission case and slit opening in the shift shaft lever [C].
• Page 203 TRANSMISSION 10-15 Transmission and Shift Mechanism • Screw the joint [A] of the shift shaft lever [B] fully into the transmission shift cable [C] end, and install the cable onto the bracket [D]. • Line up the punch mark [A] on the shift arm, projection [B] on the transmission case and slit opening in the shift shaft lever [C].

• Page 204: Shift Lever Position Inspection

  10-16 TRANSMISSION Transmission and Shift Mechanism Shift Lever Position Inspection • Start the engine and put the shift lever in 'N' (NEUTRAL) or 'L' (LOW) position. • Move the shift lever [A] slowly to the direction of the arrow on the figure. At this time, increase the engine speed slightly.

• Page 205: Transmission Shift Cable Inspection

  TRANSMISSION 10-17 Transmission and Shift Mechanism Transmission Shift Cable Inspection • With the cable disconnected at both ends, the cable should move freely within the cable housing. If the cable movement is not free, if the cable is frayed, or if the housing is kinked, replace the cable.

• Page 206: Transmission Installation

  10-18 TRANSMISSION Transmission and Shift Mechanism • Remove: Circlips [A] Driven Shaft Reverse Sprocket [B] Driven Shaft Forward Gear [C] Driven Shaft [D] Special Tool - Outside Circlip Pliers: 57001-144 Transmission Installation • Replace all circlips that were removed with new ones. NOTE ○...

• Page 207: Transmission And Shift Mechanism Inspection

  TRANSMISSION 10-19 Transmission and Shift Mechanism Transmission and Shift Mechanism Inspection • Visually inspect the forward gears, reverse sprockets, gear and shaft bushings [A], drive chains, and shifter. • Replace parts worn beyond the service limit. Shift Arm Pin Diameter [A] 7.95 ∼...

• Page 208: Hi/low Gears And Shift Mechanism

  10-20 TRANSMISSION Hi/Low Gears and Shift Mechanism Hi/Low Shift Cable Installation • See Transmission and Hi/Low Shift Cables Installation. Hi/Low Shift Cable Inspection • With the cable disconnected at both ends, the cable should move freely within the cable housing. If the cable movement is not free, if the cable is frayed, or if the housing is kinked, replace the cable.

• Page 209: Hi/low Gear And Shift Mechanism Installation

  TRANSMISSION 10-21 Hi/Low Gears and Shift Mechanism • Remove: Circlip [A] Washer [B] Low Gear [C] Collar Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Bolt [A] Holder [B] • Remove: Retaining Pin [A] Shift Shaft and Arm [B] Hi/Low Gear and Shift Mechanism Installation •...

• Page 210: Hi/low Gear And Shift Mechanism Inspection

  10-22 TRANSMISSION Hi/Low Gears and Shift Mechanism • Install: Reduction Gear [A] High Gear [B] Washer [C] Shifter [D] • Check to see that the hi/low gear case knock pins [E] are in place on the transmission case. If any one of them has been removed, replace it with a new one.

• Page 211: 2wd/4wd Shift Mechanism

  TRANSMISSION 10-23 2WD/4WD Shift Mechanism 2WD/4WD Shift Cable Adjustment • Put the shift lever [A] in the 2WD position. • Install the 2WD/4WD shift cable [A] to the shift shaft lever [B] and cable bracket [C]. • Put the shift lever [A] in the 4WD position. •...

• Page 212: 2wd/4wd Shift Cable Lubrication

  10-24 TRANSMISSION 2WD/4WD Shift Mechanism NOTE ○ If the 2WD/4WD shift cable cannot be adjusted by using the adjuster at the shift shaft lever, use the adjuster [A] at the shift lever. Do not forget to tighten the adjuster nuts [B]. 2WD/4WD Shift Cable Lubrication Whenever the shift cable is removed, lubricate the cable as follows.

• Page 213: 2wd/4wd Shift Mechanism Installation

  TRANSMISSION 10-25 2WD/4WD Shift Mechanism • Remove: Shifter [A] Circlip [B] Speedometer Gear [C] Collar Special Tool - Outside Circlip Pliers: 57001-144 2WD/4WD Shift Mechanism Installation • Apply grease: Shift Shaft O-ring • Install the shift shaft lever [A] to the shift shaft arm [B] as shown.

• Page 214: Differential Gears And Shift Mechanism

  10-26 TRANSMISSION Differential Gears and Shift Mechanism Differential Shift Cable Adjustment • Put the shift lever [A] in the UNLOCK position. • Set the shift shaft lever [A] in the UNLOCK position. • Loosen the adjuster nut [B] until the inner cable is slightly loosened.

• Page 215: Differential Shift Mechanism Installation

  TRANSMISSION 10-27 Differential Gears and Shift Mechanism Differential Shift Mechanism Installation • Apply grease: Shift Shaft O-ring • Install the shift shaft lever [A] to the shift arm [B] as shown. Torque - Shift Shaft Stop Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb) Differential Shift Mechanism Inspection •...

• Page 216: Differential Gear Installation

  10-28 TRANSMISSION Differential Gears and Shift Mechanism • Remove: Differential Gear Housing Bolts [A] Final Gear [B] • Remove: Housing Cover [A] Knock Pin [B] Side Gear [C] Spacer [D] • Remove: Knock Pins [A] Retaining Pin [B] Pinion Gear Shaft [C] Pinion Gears [D] Spacers Side Gear [E]...

• Page 217: Bearings And Oil Seal

  TRANSMISSION 10-29 Bearings and Oil Seal Bearing Replacement • Using a press, a puller, the oil seal & bearing remover, or the bearing driver set, remove the bearings. Special Tools - Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 •...

• Page 218: Transmission Sectional Figure

  10-30 TRANSMISSION Transmission Sectional Figure Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 219 TRANSMISSION 10-31 Transmission Sectional Figure Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 220 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 221 WHEELS/TIRES 11-1 Wheels/Tires Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Wheel Alignment ........................11-5 Toe-in Adjustment ......................11-5 Wheels (Rims) ........................11-7 Wheel Removal......................... 11-7 Wheel Installation......................11-7 Wheel (Rim) Inspection..................... 11-7 Wheel (Rim) Replacement....................11-7 Tires ............................11-9 Tire Removal ........................

• Page 222: Exploded View

  11-2 WHEELS/TIRES Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 223 WHEELS/TIRES 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Wheel Nuts Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 224: Specifications

  11-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheel Alignment Caster 7.5° (non-adjustable) – – – Camber 0.8° (non-adjustable) – – – 0 ∼ 20 mm (0 ∼ 0.79 in.) Toe-in – – – Tires Standard tire: Front and Rear 23 × 11.00-10 –...

• Page 225: Wheel Alignment

  WHEELS/TIRES 11-5 Wheel Alignment Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A (Rear) is greater than B (Front) as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground.
• Page 226 11-6 WHEELS/TIRES Wheel Alignment NOTE ○ The toe-in will be near the specified range, if the length of the tie-rod distance between the dust boot end [A] of steering gear assembly and the locknut [B] is 43.5 mm (1.71 in.) [C] on both the left and right tie-rods. •...

• Page 227: Wheels (rims)

  WHEELS/TIRES 11-7 Wheels (Rims) Wheel Removal • Loosen the wheel nuts [A] (Do not remove). • Lift the wheel(s) off the ground. • Remove: Wheel Nuts Wheel(s) Wheel Installation • Position the wheel so that the valve stem [A] is toward the outside of the vehicle.
• Page 228 11-8 WHEELS/TIRES Wheels (Rims) • Install a new air valve in the new rim. ○ Remove the valve cap, lubricate the stem with a soap and water solution, and pull the stem [A] through the rim from the inside out until it snaps into place. CAUTION Do not use engine oil or petroleum distillates to lu- bricate the stem because they will deteriorate the...

• Page 229: Tires

  WHEELS/TIRES 11-9 Tires Tire Removal • Remove: Wheel (see Wheel Removal) Valve Core (let out the air) • Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water [A]. This helps the tire beads slip off the rim flanges.

• Page 230: Tire Inspection

  • Check the tire pressure using an air pressure gauge. NOTE ○ Kawasaki provides the air pressure gauge (P/N 52005 -1031) as the owner’s tool. Tire Air Pressure (when cold) Front: 69 kPa (0.7 kgf/cm², 10 psi) Rear: 167 kPa (1.7 kgf/cm², 24 psi)
• Page 231 FINAL DRIVE 12-1 Final Drive Table of Contents Exploded View........12-2 Bevel Gear Case ....... 12-21 Specifications ........12-6 Bevel Gear Case Removal ..12-21 Special Tools ........12-7 Bevel Gear Case Installation ..12-21 Front Final Gear Case ....... 12-8 Bevel Gear Case Disassembly ..

• Page 232: Exploded View

  12-2 FINAL DRIVE Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 233 FINAL DRIVE 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Case Bracket Bolts Gear Case Mounting Nuts Oil Filler Cap Oil Drain Plug Front Axle Cap Bolts 0.90 78 in·lb Differential Case Torx Bolts Pinion Gear Slotted Nut Pinion Gear Bearing Housing Nuts Ring Gear Bolts 10 Ring Gear Cover Bolts (M10)
• Page 234 12-4 FINAL DRIVE Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 235 FINAL DRIVE 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bevel Gear Case Holder Nuts Housing Locknut Bearing Holder Driven Gear Shaft Nut Bevel Gear Case Bolts Drive Gear Nut Drive Shaft Cap Bolts G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum dislfide grease in a weight ratio 10:1).

• Page 236: Specifications

  12-6 FINAL DRIVE Specifications Item Standard Service Limit Front Final Gear Case Gear case oil: Type API 'GL-5 or GL-6' hypoid gear oil for – – – LSD (Limited Slip Differential gears) Viscosity SAE85W-140, SAE90, or SAE140 – – – Capacity 0.4 L (0.4 US qt) –...

• Page 237: Special Tools

  FINAL DRIVE 12-7 Special Tools Bearing Puller: Socket Wrench: 57001-135 57001-1283 Outside Circlip Pliers: Pinion Gear Holder: 57001-144 57001-1285 Oil Seal & Bearing Remover: Hexagon Wrench, Hex 40: 57001-1058 57001-1324 Bearing Driver Set: Socket Wrench: 57001-1129 57001-1363 Pinion Gear Holder: Transmission Gear Holder: 57001-1281 57001-1364...

• Page 238: Front Final Gear Case

  12-8 FINAL DRIVE Front Final Gear Case Front Final Gear Case Oil Level Inspection • Park the vehicle so that it is level, both side-to-side and front-to-rear. • Remove: Front Final Gear Case Skid Plate Bolts [A] Front Final Gear Case Skid Plate [B] •...

• Page 239: Front Final Gear Case Removal

  FINAL DRIVE 12-9 Front Final Gear Case Front Final Gear Case Removal • Remove: Front Final Gear Case Oil (drain) Radiator (see Cooling System chapter) Propeller Shafts (see Propeller Shaft Removal) Front Axles (see Front Axle Removal) Front Final Gear Case Mounting Bolts [A] and Nuts [B] Collar [C] •...

• Page 240: Front Final Gear Case Disassembly

  12-10 FINAL DRIVE Front Final Gear Case Front Final Gear Case Disassembly • Remove: Front Final Gear Case (see Front Final Gear Case Re- moval) Bearing Housing Nuts [A] Pinion Gear Unit [B] • Remove: Spacers [A] (both sides) • Remove the ring gear cover bolts, starting with the smaller bolts [B].

• Page 241: Differential Unit And Ring Gear Disassembly

  FINAL DRIVE 12-11 Front Final Gear Case • Install the pinion gear unit with the ring gear side of the case facing down. • Align the air vent passage [A] with the hose nipple [B]. ○ First tighten the 10 mm (0.39 in.) bolts, then tighten the 8 mm (0.31 in.) bolts.

• Page 242: Lsd Clutch Torque Inspection

  12-12 FINAL DRIVE Front Final Gear Case • Be sure to assemble the differential unit and inspect the clutch torque (see LSD Clutch Torque Inspection). Tapped Holes [A] for Ring Gear Mark [B] for assembly • Install the front axles [C] to center the steel plates. •...

• Page 243: Lsd Clutch Plate Inspection

  FINAL DRIVE 12-13 Front Final Gear Case LSD Clutch Plate Inspection • Visually inspect the friction plates and steel plates to see if they show any signs of seizure, overheating, or uneven wear. If any plates show signs of damage, or if the friction plates have worn past the service limit, replace the friction plates and steel plates as a set.

• Page 244: Front Final Bevel Gear Adjustment

  12-14 FINAL DRIVE Front Final Gear Case • Fit the toothed washer claw [A] into the shaft. • Apply molybdenum disulfide oil to the threads and seating surface of the pinion gear slotted nut, and tighten it. Torque - Pinion Gear Slotted Nut: 120 N·m (12 kgf·m, 87 ft·lb) If none of the toothed washer tabs [B] align, tighten the nut further just enough to align one of the tabs with a slot...
• Page 245 FINAL DRIVE 12-15 Front Final Gear Case Bearing Preload Adjustment: • Check and adjust the bearing preload in the following cases. ○ When any of the parts listed below are replaced with new ones. Pinion Gear Collar Shim Tapered Roller Bearings Pinion Gear Bearing Housing [A] Oil Seal Collar ○...
• Page 246 12-16 FINAL DRIVE Front Final Gear Case Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 247 FINAL DRIVE 12-17 Front Final Gear Case If the preload is out of the specified range, replace the collar and/or shim(s). ○ To increase preload, decrease the size of the shim(s) or collar. To decrease preload, increase the size of the shim(s) or collar.
• Page 248 12-18 FINAL DRIVE Front Final Gear Case • Move the front axle back and forth [A]. Special Tool - Pinion Gear Holder: 57001-1285 [B] Dial Gauge [C] Bevel Gear Backlash 0.09 ∼ 0.20 mm (0.035 ∼ 0.0079 in.) (at Standard: ring gear tooth) Tooth Contact Adjustment •...
• Page 249 FINAL DRIVE 12-19 Front Final Gear Case Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 250: Bevel Gear Inspection

  12-20 FINAL DRIVE Front Final Gear Case Bevel Gear Inspection • Visually check the bevel gears [A] for scoring, chipping, or other damage. Replace the bevel gears as a set if either gear is dam- aged. Differential Gear Inspection • Visually check the differential gears [A] for scoring, chip- ping, or other damage.

• Page 251: Bevel Gear Case

  FINAL DRIVE 12-21 Bevel Gear Case Bevel Gear Case Removal • Remove: Transmission Oil (drain) Cargo Bed (see Frame chapter) Propeller Shafts (see Propeller Shaft Removal) Bevel Gear Case Bolts [A] Bevel Gear Case [B] Bevel Gear Case Installation • Check and adjust the bevel gear backlash and tooth con- tact when any of the backlash-related parts are replaced (see Bevel Gear Adjustment).

• Page 252: Bevel Gear Case Assembly

  12-22 FINAL DRIVE Bevel Gear Case • Remove: Housing Locknut Bearing Housing [A] Special Tools - Pinion Gear Holder: 57001-1281 [C] Socket Wrench: 57001-1363 [B] • Remove: Driven Gear Shaft Nut [A] Special Tool - Pinion Gear Holder: 57001-1281 [B] ○...

• Page 253: Drive Bevel Gear Removal

  FINAL DRIVE 12-23 Bevel Gear Case Drive Bevel Gear Removal • Remove: Hi/Low Gear Case Drive Gear Nut [A] Special Tool - Transmission Gear Holder [B]: 57001-1364 • Remove: Drive Gear [A] Drive Gear Shim(s) [B] Drive Gear Shaft [C] Drive Bevel Gear Installation •...
• Page 254 12-24 FINAL DRIVE Bevel Gear Case • Set up a dial gauge [A] against one of the grooves in the locknut [B]. • To measure the backlash, turn the shaft clockwise and counterclockwise while holding the drive bevel gear steady. The difference between the highest and lowest gauge readings is the amount of backlash.

• Page 255: Bevel Gear Inspection

  FINAL DRIVE 12-25 Bevel Gear Case Tooth Contact Adjustment • Clean any dirt and oil off the bevel gear teeth. • Apply checking compound to 4 or 5 teeth on the driven bevel gear. NOTE ○ Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush.
• Page 256 12-26 FINAL DRIVE Bevel Gear Case Incorrect Tooth Contact Patterns Example 1: Increase the thickness of the drive bevel gear shim(s) by 0.05 mm (0.002 in.), and/or increase the thick- ness of the driven bevel gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown below.

• Page 257: Ball Bearing Inspection

  FINAL DRIVE 12-27 Bevel Gear Case Bevel Gear Inspection • Visually check the bevel gears [A] for scoring, chipping, or other damage. Replace the bevel gears as a set if either gear is dam- aged. Ball Bearing Inspection • Since the ball bearings are made to extremely close toler- ances, the wear must be judged by feel rather than mea- surement.

• Page 258: Propeller Shafts

  12-28 FINAL DRIVE Propeller Shafts Propeller Shaft Removal • Remove: Fuel Tank (see Fuel System chapter) Plate Screws [A] Plate [B] • Remove: Water Pipe Bracket Bolts [A] • Remove: Propeller Shaft Bearing Housing Mounting Bolts [A] and Nuts • Move the water pipe [A] and the propeller shaft bearing housing [B] to the outside [C].

• Page 259: Propeller Shaft Installation

  FINAL DRIVE 12-29 Propeller Shafts Propeller Shaft Installation • Wipe the old grease off the splines of the propeller shafts, and grease to them. • Inspect the propeller shafts. • Apply grease to the O-ring [A] on the front pinion gear. •...

• Page 260: Propeller Shaft Inspection

  12-30 FINAL DRIVE Propeller Shafts Propeller Shaft Inspection • Visually inspect the splines of the propeller shafts. If they are twisted, badly worn, or chipped, replace the shafts. • Check that the universal joint works smoothly without rat- tling or sticking. If it does not, the bearings of the joint are damaged.

• Page 261: Drive Shaft And Axles

  FINAL DRIVE 12-31 Drive Shaft and Axles Front Axle Removal • Remove: Steering Knuckle (see Steering chapter) Radiator Side Cover Front Axle Cap Bolts [A] Front Axle [B] Front Axle Installation • Wipe the old grease off the splines of the axle and cap oil seal, and grease them.

• Page 262: Rear Drive Shaft And Axle Installation

  12-32 FINAL DRIVE Drive Shaft and Axles • Remove: Drive Shaft Cap Bolts [A] Drive Shaft [B] and Cap [C] ○ Set the differential shift lever into the UN-LOCK position. Rear Drive Shaft and Axle Installation • Wipe the old grease off the splines of the drive shafts, axles, and cap oil seals, and grease them.

• Page 263: Dust Boot Inspection

  FINAL DRIVE 12-33 Drive Shaft and Axles Dust Boot Inspection • Visually inspect the boots [A] in accordance with the Peri- odic Maintenance Chart or if the drive shafts or axles are noisy during operation. If the dust boot is torn, worn, deteriorated, or leaks grease, replace it.
• Page 264 12-34 FINAL DRIVE Drive Shaft and Axles • Remove the steel balls [A] with a screwdriver [B]. • Wipe the old grease. CAUTION Do not reuse the old grease. • Move the steel ball holder [C] toward the outboard joint. •...
• Page 265 FINAL DRIVE 12-35 Drive Shaft and Axles • Check the universal joints. If any joint does not work smoothly without rattling or stick- ing, the joint bearing is damaged. Replace the axle. • Visually inspect the splines on the shaft. If they are badly worn or chipped, replace the axle.
• Page 266 12-36 FINAL DRIVE Drive Shaft and Axles • Install: Small Boot Band [A] Inboard Boot [B] Steel Ball Holder [C] Steel Ball Base [D] ○ Install the steel ball holder [A] as shown. ○ Face the chamfered side [B] of the steel ball base [C] to the boot.

• Page 267: Ball Bearing Inspection

  FINAL DRIVE 12-37 Drive Shaft and Axles • Install the retaining ring [A] so that the opening [B] is aligned with one of the projections [C]. • Install the inboard boot [A] on the outboard joint and shaft [B] properly as shown. [C] 119 mm (4.69 in.) •...

• Page 268: Grease Seal Inspection

  12-38 FINAL DRIVE Drive Shaft and Axles Grease Seal Inspection • Visually inspect the grease seals. Replace if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been oth- erwise damage. Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 269 BRAKES 13-1 Brakes Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Brake Fluid ..........................13-8 Brake Fluid Recommendation................... 13-8 Brake Fluid Level Inspection..................... 13-8 Brake Fluid Changing ....................... 13-8 Brake Line Air Bleeding ....................13-9 Brake Pedal and Master Cylinder ..................

• Page 270: Exploded View

  13-2 BRAKES Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 271 BRAKES 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.60 52 in·lb Wheel Cylinder Mounting Bolts 95 in·lb Brake Panel Mounting Bolts Front Axle Nuts Brake Pipe Nipples Brake Hose Banjo Bolts Piston Stop Bolt 0.90 78 in·lb Reservoir Clamp Bolt 0.60 52 in·lb...
• Page 272 13-4 BRAKES Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 273 BRAKES 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.60 52 in·lb Wheel Cylinder Mounting Nuts 0.80 69 in·lb Brake Panel Mounting Bolts Rear Axle Nuts Brake Pipe Nipples F: Apply brake fluid. G: Apply grease. HG: Apply grease (Amoco Rykon Premium Grease No. 2 EP Green). RL: Apply rubber lubricating oil.

• Page 274: Specifications

  13-6 BRAKES Specifications Item Standard Service Limit Brake Fluid Type DOT3 – – – Fluid level Between upper and lower level lines – – – Brake Pedal 2 ∼ 10 mm (0.08 ∼ 0.39 in.) Brake pedal free play – – – Brake Drums 180.000 ∼...

• Page 275: Special Tools

  BRAKES 13-7 Special Tools Inside Circlip Pliers: Brake Drum Pusher, M18 × 1.5: 57001-143 57001-1261 Rotor Puller, M16/M18/M20/M22 × 1.5: Brake Drum Holder: 57001-1216 57001-1325 Brake Drum Remover: Brake Drum Remover Nuts: 57001-1260 57001-1326 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 276: Brake Fluid

  13-8 BRAKES Brake Fluid Brake Fluid Recommendation Use extra heavy-duty brake fluid only from a container marked DOT3. Recommended Brake Fluid Type: DOT3 WARNING Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time.

• Page 277: Brake Line Air Bleeding

  BRAKES 13-9 Brake Fluid Brake Line Air Bleeding • Remove the maintenance cover. • Check that there is plenty of fluid in the reservoir. NOTE ○ The fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservoir runs completely out any time dur- ing bleeding, the bleeding operation must be done over again from the beginning since air will have entered the...

• Page 278: Brake Pedal And Master Cylinder

  13-10 BRAKES Brake Pedal and Master Cylinder Brake Pedal Free Play Adjustment • Refer to Brake Pedal Free Play Adjustment in the Periodic Maintenance chapter. Master Cylinder Removal • Remove: Front Fender Upper (see Frame chapter) Brake Hose Banjo Bolts [A] Brake Pipe Nipple [B] (unscrew) •...

• Page 279: Master Cylinder Inspection

  BRAKES 13-11 Brake Pedal and Master Cylinder Master Cylinder Inspection • Check that there are no scratches, rust or pitting on the inside of the cylinder and on the outside of the piston. If the cylinder or piston shows any damage, replace them. •...

• Page 280: Brake Hoses And Pipes

  13-12 BRAKES Brake Hoses and Pipes Brake Hose and Pipe Inspection • Refer to Brake Hose and Pipe Inspection in the Periodic Maintenance chapter. Brake Hose and Pipe Replacement • Refer to Brake Hose and Pipe Replacement in the Peri- odic Maintenance chapter.

• Page 281: Brake Drums

  BRAKES 13-13 Brake Drums Brake Drum Removal • Remove: Wheel (see Wheel Removal) Cotter Pin [A] Axle Nut [B] ○ Loosen the axle nut, while applying the brake, and release the brake. • The brake drums are press-fitted on the axles. Use the brake drum remover, stud nuts, and rotor puller (special tools) to remove the drums.
• Page 282 13-14 BRAKES Brake Drums • Grease (Amoco Rykon Premium Grease No.2 EP Green): Front Brake Drum Grease Seal Lips [A] • Tighten: • Do not press the drum bolts out. If a drum bolt is damaged, replace the drum. Torque - Front Axle Nuts: 200 N·m (20 kgf·m, 140 ft·lb) Rear Axle Nuts: 300 N·m (31 kgf·m, 220 ft·lb) •...

• Page 283: Brake Panel Assemblies

  BRAKES 13-15 Brake Panel Assemblies Brake Panel Removal • Remove: Brake Drum (see Brake Drum Removal) Brake Pipe Nipple [A] ○ Immediately wipe up any brake fluid that spills. CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up imme- diately.

• Page 284: Brake Panel Installation

  13-16 BRAKES Brake Panel Assemblies • Remove the following for the rear brake panel removal. Cotter Pin [A] Clevis Pin [B] Parking Brake Lever Linkage [C] • Remove: Brake Panel Mounting Bolts [A] Brake Panel [B] Brake Panel Installation • Set the brake shoe clearance adjuster so that the drum can be re-installed on the panel assembly.
• Page 285 BRAKES 13-17 Brake Panel Assemblies • Grease (Amoco Rykon Premium Grease No. 2 EP Green): Brake Panel Seating Surface • Apply a non-permanent locking agent: Brake Panel Mounting Bolts • Apply brake fluid: Brake Pipe Nipple Threads • Tighten: Torque - Wheel Cylinder Mounting Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) Wheel Cylinder Mounting Nuts: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Page 286: Wheel Cylinder Assembly

  13-18 BRAKES Brake Panel Assemblies Wheel Cylinder Assembly • Before assembly, clean all parts including the wheel cylin- der with brake fluid or alcohol, and apply brake fluid to the removed parts and the inner wall of the cylinder. CAUTION Use only brake fluid, isopropyl alcohol, or ethyl al- cohol, for cleaning brake parts.

• Page 287: Brake Shoe Spring Inspection

  BRAKES 13-19 Brake Panel Assemblies Brake Shoe Spring Inspection • Visually inspect the brake shoe springs [A] for breaks or distortion. If the springs are damaged in any way, replace them. Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 288: Parking Brake Lever And Cables

  13-20 BRAKES Parking Brake Lever and Cables Parking Brake Lever Travel Adjustment • Refer to Parking Brake Lever and Cables in the Periodic Maintenance chapter. Parking Brake Cable Lubrication Whenever the parking brake cables are removed, lubri- cate the cables as follows. •...
• Page 289 SUSPENSION 14-1 Suspension Table of Contents Exploded View........................14-2 Specifications ......................... 14-4 Special Tool ..........................14-5 Struts and Rear Shock Absorbers ..................14-6 Strut (Front Shock Absorber) Removal................14-6 Strut (Front Shock Absorber) Installation................14-6 Strut Spring Replacement....................14-7 Rear Shock Absorber Preload Adjustment ............... 14-8 Rear Shock Absorber Removal ..................

• Page 290: Exploded View

  14-2 SUSPENSION Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 291 SUSPENSION 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Strut Locknut Strut Mounting Nuts Strut Clamp Nut Tie-rod End Nuts Front Suspension Arm Pivot Bolts Front Suspension Arm Joint Nut Leaf Spring Mounting Nuts (Rear) Leaf Spring Mounting Nuts (Front) Damper Bracket Mounting Nuts 10 Rear Shock Absorber Mounting Nuts G: Apply grease.

• Page 292: Specifications

  14-4 SUSPENSION Specifications Item Standard Service Limit Rear Shock Absorbers (Usable Range) 1 ∼ 5 positions Spring Preload Setting Position 3rd position Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 293: Special Tool

  SUSPENSION 14-5 Special Tool Steering Stem Nut Wrench: 57001-1100 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 294: Struts And Rear Shock Absorbers

  14-6 SUSPENSION Struts and Rear Shock Absorbers Strut (Front Shock Absorber) Removal • Remove: Front Fender Upper (see Frame chapter) Front Wheel (see Wheels/Tires chapter) Brake Panel (see Brakes chapter) Brake Hose Retainer [A] Brake Hose [B] (from Bracket) Strut Clamp Bolt and Nut [C] •...

• Page 295: Strut Spring Replacement

  SUSPENSION 14-7 Struts and Rear Shock Absorbers • Bend the cotter pin [A] over the nut [B]. Strut Spring Replacement In addition to the standard springs, hard springs are avail- able. The hard springs stiffen the strut action and accelerate the rebound damping.

• Page 296: Rear Shock Absorber Preload Adjustment

  14-8 SUSPENSION Struts and Rear Shock Absorbers • Apply grease to the upper and lower side on the following parts, and install them. Dust Seal [A] Thrust Washer [B] ○ Face the projection on the thrust washer downward. • Install: Holder [A] Large Washer [B] Small Washer [C]...

• Page 297: Rear Shock Absorber Removal

  SUSPENSION 14-9 Struts and Rear Shock Absorbers Rear Shock Absorber Removal • Remove: Rear Wheel (see Wheels/Tires chapter) • Remove: Rear Shock Absorber Mounting Bolts and Nuts [A] (while moving the frame up or down with a jack) Rear Shock Absorber [B] Rear Shock Absorber Installation •...

• Page 298: Front Suspension Arms

  14-10 SUSPENSION Front Suspension Arms Front Suspension Arm Removal • Remove: Front Wheel (see Wheels/Tires chapter) • Hold the front brake drum and panel assembly in position. • Remove: Front Suspension Arm Pivot Bolts [A] • Remove: Front Suspension Arm Joint Nut [A] Front Suspension Arm Joint from Steering Knuckle ○...

• Page 299: Front Suspension Arm Inspection

  SUSPENSION 14-11 Front Suspension Arms • Bend the cotter pin [A] over the nut [B]. Front Suspension Arm Inspection • Visually inspect the front suspension arm for breaks or distortion. If the front suspension arm is damaged in any way, re- place it.

• Page 300: Leaf Springs And Dampers

  14-12 SUSPENSION Leaf Springs and Dampers Leaf Spring Removal • Remove: Rear Wheel (see Wheels/Tires chapter) • Hold the rear brake drum and panel assembly in position. • Free the brake hose [A], pipe, and cable from the leaf spring. ○...

• Page 301: Leaf Spring Inspection

  SUSPENSION 14-13 Leaf Springs and Dampers Leaf Spring Inspection • Visually inspect the leaf spring for breaks or distortion. If the leaf spring is damaged in any way, replace it. • Check the rubber bushings in the mounts and the damper. Replace any bushings or damper that are worn, cracked, hardened, or otherwise damaged.
• Page 302 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 303 STEERING 15-1 Steering Table of Contents Exploded View........................15-2 Specifications ......................... 15-4 Steering Wheel and Main Shaft Assembly ................15-5 Steering Wheel Position Adjustment................. 15-5 Steering Wheel Free Play Inspection................15-5 Steering Wheel Centering....................15-5 Steering Wheel and Steering Shaft Removal ..............15-5 Steering Wheel and Main Shaft Installation ..............

• Page 304: Exploded View

  15-2 STEERING Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 305 STEERING 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Steering Wheel Mounting Nut Intermediate Shaft Clamp Bolts Tie-rod End Locknuts Rack Guide Spring Cap Locknut Steering Gear Assembly Bracket Bolts Strut Clamp Nut Tie-rod End Nuts 8. Apply grease on contact plate. G: Apply grease.

• Page 306: Specifications

  15-4 STEERING Specifications Item Standard Service Limit Steering Wheel 0 ∼ 20 mm (0 ∼ 0.79 in.) Steering wheel free play – – – Steering Gear Assembly Tie-rod length 43.5 mm (1.71in.) – – – (distance between boot end and locknut) Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 307: Steering Wheel And Main Shaft Assembly

  STEERING 15-5 Steering Wheel and Main Shaft Assembly Steering Wheel Position Adjustment • Loosen the steering main shaft bracket mounting nuts [A]. • Adjust the steering wheel position. • Tighten the main shaft bracket mounting nuts securely. Steering Wheel Free Play Inspection •...

• Page 308: Steering Wheel And Main Shaft Installation

  15-6 STEERING Steering Wheel and Main Shaft Assembly • Remove: Steering Gear Shaft Clamp Bolt [A] Intermediate Shaft [B] Steering Wheel and Main Shaft Installation • Grease: Dust Cover Lips [A] • Connect the intermediate shaft [A] to the main shaft and the steering gear pinion in any position.

• Page 309: Steering Gear Assembly

  STEERING 15-7 Steering Gear Assembly Steering Gear Assembly Removal • Remove: Front Fender Upper (see Frame chapter) Steering Wheel and Main Shaft Assembly Front Radiator (see Cooling System chapter) Tie-rod End Nuts [A] Tie-rod Ends [B] from Steering Knuckles ○ Install a suitable nut on the stud of the tie-rod end joint and tap the nut to free the joint from the steering knuckle.

• Page 310: Steering Gear Preload Adjustment

  15-8 STEERING Steering Gear Assembly • Install the boot [A] so that the mark (F, Arrow) [B] faces forward. • Tighten: Torque - Steering Gear Assembly Bracket Bolts: 52 N·m (5.3 kgf·m, 38 ft·lb) Tie-rod End Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) •...

• Page 311: Tie-rod Length Adjustment

  STEERING 15-9 Steering Gear Assembly Tie-rod Length Adjustment • Check the length [A] of the tie-rod distance between the dust boot end [B] of steering gear assembly and the lock- nut [C]. This distance should be the specified value for both the left and right tie-rods.

• Page 312: Steering Knuckles

  15-10 STEERING Steering Knuckles Steering Knuckle Removal • Remove: Front Wheel (see Wheels/Tires chapter) Front Brake Drum (see Brakes chapter) Front Brake Panel Assembly (see Brakes chapter) Tie-rod End Nut [A] Tie-rod End [B] from Steering Knuckle ○ Install a suitable nut on the stud of the tie-rod end joint and tap the nut to free the joint from the steering knuckle.
• Page 313 STEERING 15-11 Steering Knuckles • Bend the cotter pin [A] over the nut [B]. • Check: Toe-in of Front Wheels (see Wheels/Tires chapter) Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 314 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 315 FRAME 16-1 Frame Table of Contents Exploded View........................16-2 Seat and Seat Belts........................ 16-8 Front Seat Removal ......................16-8 Front Seat Installation ....................... 16-8 Rear Seat Removal......................16-9 Rear Seat Installation......................16-10 Seat Belt Removal ......................16-10 Seat Belt Installation ......................16-11 Control Panel..........................

• Page 316: Exploded View

  16-2 FRAME Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 317 FRAME 16-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Hood Latch Lever Mounting Bolt 2. Damper 3. Carburetor Cover 4. 10 mm (0.39 in.) AD: Apply adhesive agent. G: Apply grease. Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 318 16-4 FRAME Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 319 FRAME 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Seat Belt Mounting Bolts Seat Belt Buckle Mounting Bolts Front Bar Mounting Bolts (Lower) Front Bar Mounting Bolts (Upper) Top Bar Mounting Bolts Center Bar Mounting Bolts and Nuts Rear Bar Mounting Bolts and Nuts Rear End Sub-frame Mounting Bolts Screen Fixing Lever Screw 0.45...
• Page 320 16-6 FRAME Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 321 FRAME 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Tail Gate Fixing Lever Screw 0.45 39 in·lb 2. Large Corner Side 3. Fix the bolt to inside from outside. AD: Apply adhesive agent. G: Apply grease. L: Apply a non-permanent locking agent. Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 322: Seat And Seat Belts

  16-8 FRAME Seat and Seat Belts Front Seat Removal • Remove: Seat Bracket Nuts [A] Seat Brackets [B] Seat [C] • Remove: Seat Back Mounting Nuts [A] Seat Back [B] Front Seat Installation • Grease: Seat Bracket Inside Surfaces [A] •...

• Page 323: Rear Seat Removal

  FRAME 16-9 Seat and Seat Belts Rear Seat Removal • Fold the rear seat and push its assembly into the stored position. • Tilt up the cargo bed. • Remove the pivot bolt [A] and nut [B]. • Remove the rear seat [C]. •...

• Page 324: Rear Seat Installation

  16-10 FRAME Seat and Seat Belts Rear Seat Installation • Install the rear seat back [A] so that its thicker side [B] faces upward. Seat Belt Removal • Remove: Front Seat Belt Mounting Bolts [A] Front Seat Belts [B] • Remove: Front Seat Belt Buckle Mounting Bolts [A] Front Seat Belt Buckles [B]...

• Page 325: Seat Belt Installation

  FRAME 16-11 Seat and Seat Belts Seat Belt Installation • Tighten: Torque - Seat Belt Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) ○ Install the front [A] and rear seat belts so that their instal- lation angle is 40° ∼ 60° [B]. •...

• Page 326: Control Panel

  16-12 FRAME Control Panel Control Panel Removal • Remove: Front Cargo Compartment (see Front Cargo Compart- ment Removal) • Disconnect: Light Switch Wire Connector Hour Meter Wire Connector Ignition Switch Wire Connector Power Outlet Connector Wire Connector Coolant Temperature Warning/Parking Brake Indicator Light Wire Connector •...

• Page 327: Front Cargo Compartment

  FRAME 16-13 Front Cargo Compartment Front Cargo Hood Removal • Remove: Rear Snap Pins [A] Mounting Pins [B] Front Snap Pins [C] • Slide the front cargo hood [D] to the right and remove it. • Remove: Arm Assembly Bolts [A] Arm Assembly [B] Stay Front Cargo Compartment Removal...

• Page 328: Cargo Bed

  16-14 FRAME Cargo Bed Cargo Bed Removal • Unlock the hooks [A] • Raise the rear seat and push it toward the front seat back to store. • Remove: Rear Fenders Mounting Screws [A] Rear Fenders [B] • Remove: Tail/Brake Light Wires [A] Tail/Brake Light Mounting Bolts [B] Tail/Brake Light Assemblies [C] •...

• Page 329: Cargo Bed Installation

  FRAME 16-15 Cargo Bed Cargo Bed Installation • Grease: Cargo Bed Mounting Pins • Apply adhesive agent: Cargo Bed Rubber Dampers (Bottom) [A] Frame Rubber Dampers (Upper) [B] Tail Gate Pivot Rubber Dampers (Left and Right) • When the cargo bed is disassembled, note the following when installing the plates and tail gate.

• Page 330: Front, Center And Rear Bars

  16-16 FRAME Front, Center and Rear Bars Front Bar Removal • Remove: Front Bar Mounting Bolts [A] Front Bar [B] Front Bar Installation • Tighten: Torque - Front Bar Mounting Bolts (Lower): 98 N·m (10 kgf·m, 72 ft·lb) Front Bar Mounting Bolts (Upper): 44 N·m (4.5 kgf·m, 33 ft·lb) Rear Bar Removal •...

• Page 331: Rear Bar Installation

  FRAME 16-17 Front, Center and Rear Bars Rear Bar Installation • Be sure the rubber plates [A] are in position. ○ Plug one hole [B] and plug only half about another hole [C], using the rubber plate. • Tighten: Torque - Rear Bar Mounting Bolts and Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb) Center Bar Removal •...

• Page 332: Cargo Bed Latch Position Inspection

  16-18 FRAME Front, Center and Rear Bars Cargo Bed Latch Position Inspection • Cargo bed must be latched securely on the cargo bed or the rear seat hooks [B] without rattling. [A] Latch If there is rattling or not snug enough, adjust the latch positions.

• Page 333: Front Fender Assembly

  FRAME 16-19 Front Fender Assembly Front Cover Removal • Remove: Front Cargo Hood (see Front Cargo Hood Removal) Guard Bolts [A] Collars [B] Guard [C] • Remove: Screws [A] Guard [B] • Remove: Screws [A] • Remove: Rivets [A] • Remove: Rivets [A] Screws [B]...

• Page 334: Front Fender Removal

  16-20 FRAME Front Fender Assembly Front Fender Removal • Remove: Screws [A] Guard [B] • Remove: Coolant Reserve Tank from Frame Rivets [A] • Remove: Screws [A] Plugs [B] and Screws Screws [C] and Nuts Front Fender [D] Radiator Side Cover Removal •...

• Page 335: Radiator Side Cover Installation

  FRAME 16-21 Front Fender Assembly Radiator Side Cover Installation • Apply adhesive agent: Radiator Side Cover Trims [A] Radiator Side Cover Flap Removal • Remove: Radiator Side Cover (see Radiator Side Cover Removal) Screw [A], Nut and Washer Radiator Side Cover Flap [B] Floor Center Panel Removal •...
• Page 336 16-22 FRAME Front Fender Assembly • Remove: Screws [A] Floor Center Panel (Rear Side) [B] Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 337: Rear End Sub-frame

  FRAME 16-23 Rear End Sub-frame Rear End Sub-frame Removal • Remove: Engine (see Engine Removal/Installation chapter) Transmission Case (see Transmission chapter) Rear End Sub-frame Mounting Bolts [A] and Nuts Rear End Sub-frame [B] Rear End Sub-frame Installation • Tighten: Torque - Rear End Sub-frame Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb) Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 338 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 339 ELECTRICAL SYSTEM 17-1 Electrical System Table of Contents Exploded View........17-2 Starter Motor Removal....17-31 Specifications ........17-6 Starter Motor Installation....17-31 Special Tools ........17-7 Starter Motor Disassembly... 17-31 Parts Location........17-8 Starter Motor Assembly ....17-33 Precautions........17-11 Carbon Brush Inspection .....

• Page 340: Exploded View

  17-2 ELECTRICAL SYSTEM Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 341 ELECTRICAL SYSTEM 17-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Igniter Mounting Bolts 0.90 78 in·lb Regulator/Rectifier Mounting Bolts 0.90 78 in·lb Spark Plugs Alternator Rotor Nut Starter Motor Mounting Bolts L: Apply a non-permanent locking agent. G: Apply grease. Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 342 17-4 ELECTRICAL SYSTEM Exploded View Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 343 ELECTRICAL SYSTEM 17-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch 87 in·lb Neutral Switch Radiator Fan Switch Coolant Temperature Warning Light Switch Battery Holder Nuts 6. Battery Holder 7. Damper 8. 10 ∼ 15 mm (0.39 ∼ 0.59 in.) G: Apply grease to the wire terminal.

• Page 344: Specifications

  17-6 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Sealed battery – – – Capacity 12 V 18 Ah – – – Voltage 12.8 V or more – – – Charging System Type Three-phase AC – – – Battery voltage ∼ 15 V Regulator/rectifier output voltage –...

• Page 345: Special Tools

  ELECTRICAL SYSTEM 17-7 Special Tools Crankcase Splitting Tool Assembly: Peak Voltage Adapter: 57001-1098 57001-1415 Hand Tester: Needle Adapter Set: 57001-1394 57001-1457 Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 346: Parts Location

  17-8 ELECTRICAL SYSTEM Parts Location Horn [A] Radiator Fan Switch [B] Radiator Fan [C] Brake Light Switch [A] Horn Button [A] Light Switch [B] Hour Meter [C] Ignition Switch [D] Coolant Temperature Warning Indicator Light [E] Parking Brake Indicator Light [F] Battery [A] Starter Circuit Relay [A] Regulator/Rectifier [B]...
• Page 347 ELECTRICAL SYSTEM 17-9 Parts Location Fuse Box [A] Ground Wire (Frame) [B] Coolant Temperature Warning Indicator Light Switch [A] Spark Plugs [A] Ignition Coils [B] Ground Wire (Engine) [A] Starter Motor [B] Neutral Switch [A] Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 348 17-10 ELECTRICAL SYSTEM Parts Location Oil Pressure Switch [A] Alternator [A] Pickup Coil [B] Fuel Pump [C] Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 349: Precautions

  ELECTRICAL SYSTEM 17-11 Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○...
• Page 350 17-12 ELECTRICAL SYSTEM Precautions Male Connectors [B] Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 351: Battery

  ELECTRICAL SYSTEM 17-13 Battery Battery Removal • Remove: Mounting Rivets [A] Screws [B] Battery Cover [C] • Remove: Left Side Cover (see Frame chapter) Battery Holder Nuts [A] Battery Holder [B] • Disconnect the negative terminal wire [A] first, and then positive terminal wire [B].

• Page 352: Battery Activation

  17-14 ELECTRICAL SYSTEM Battery • Put the battery in place on the rubber damper. • Connect the three positive wires [A] first, and then con- nect the negative wire [B]. • Put a light coat of grease on the terminals to prevent cor- rosion.
• Page 353 Newly activated sealed batteries require an initial charge. Standard Charge 1.8 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150–9 If the above chargers are not available, use equivalent one.

• Page 354: Precautions

  17-16 ELECTRICAL SYSTEM Battery • After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don’t pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery. CAUTION Once the strip of the caps [A] is installed onto the battery, never remove the caps, nor add water or...

• Page 355: Charging Condition Inspection

  ELECTRICAL SYSTEM 17-17 Battery a sealed battery. Be careful, if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened. Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage.
• Page 356 17-18 ELECTRICAL SYSTEM Battery NOTE ○ Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current [D], decrease the voltage and charge by the standard charging method described on the battery case.

• Page 357: Charging System

  ELECTRICAL SYSTEM 17-19 Charging System Alternator Rotor and Stator Removal • Remove, if the engine is mounted on the frame: Cargo Bed Propeller Shafts • Remove: Alternator Cover Bolts [A] Alternator Cover [B] • Remove: Pickup Coil (see Pickup Coil Removal) Alternator Rotor Nut [A] ○...

• Page 358: Alternator Rotor And Stator Installation

  17-20 ELECTRICAL SYSTEM Charging System • Disconnect the alternator wire connector [A]. • Remove: Alternator Stator Mounting Screws [A] Alternator Stator [B] Alternator Rotor and Stator Installation • Apply non-permanent locking agent: Alternator Stator Mounting Screws • Clean [A] the inside of the alternator rotor [B] and end of the crankshaft [C] or the taper will not fit snugly.

• Page 359: Charging System Operational Inspection

  ELECTRICAL SYSTEM 17-21 Charging System • Install: Pickup Coil (see Pickup Coil Installation) • Route the electrical wires as shown. Alternator Wire [A] Pickup Coil Wires [B] Bands [C] Charging System Operational Inspection • Check battery condition. NOTE ○ Always check battery condition before condemning other parts of the charging system.

• Page 360: Stator Coil Resistance

  17-22 ELECTRICAL SYSTEM Charging System Stator Coil Resistance • Disconnect the alternator wire connector. • Measure the stator coil resistance. ○ Connect an ohmmeter between the alternator wires. Stator Coil Resistance Standard: 0.2 ∼ 0.4 Ω If the meter does not read as specified, replace the alter- nator stator.
• Page 361 ELECTRICAL SYSTEM 17-23 Charging System Regulator Circuit Test-1st Step: • Connect the test light and the 12 V battery to the regula- tor/rectifier as shown. • Check BK1, BK2, and BK3 terminals respectively. CAUTION The test light limits the current flow through the reg- ulator/rectifier.
• Page 362 17-24 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. 30 A Fuse 6. Load Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 363: Ignition System

  ELECTRICAL SYSTEM 17-25 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, high tension coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is...

• Page 364: Ignition Coil Installation

  17-26 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation • Install: Tube [A] (for rear ignition coil wire) Ignition Coil Inspection • Measure the ignition coil [C] resistance. Measure primary winding resistance [A] Measure secondary winding resistance [B] Ignition Coil Winding Resistance 1.87 ∼...

• Page 365: Pickup Coil Removal

  ELECTRICAL SYSTEM 17-27 Ignition System • Turn the ignition switch ON, and run the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage. • Repeat the measurements 5 times for one ignition coil. Ignition Coil Primary Peak Voltage Standard: 264 V or more •...

• Page 366: Pickup Coil Peak Voltage Inspection

  17-28 ELECTRICAL SYSTEM Ignition System Pickup Coil Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the spark plug caps, but do not the spark plugs. • Remove: Pickup Coil Wire Connector [A] • Set the hand tester [B] to the 10 V DC range. •...

• Page 367: Ignition System Inspection

  ELECTRICAL SYSTEM 17-29 Ignition System Ignition System Inspection Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 368 17-30 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. 30 A Fuse 3. Battery 4. Igniter 5. Ignition Coils 6. Spark Plugs 7. Pickup Coil Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 369: Electric Starter System

  ELECTRICAL SYSTEM 17-31 Electric Starter System Starter Motor Removal • Remove: Torque Converter Case (see Converter System chapter) Starter Motor Wires (from Starter Motor) [A] Starter Motor Mounting Bolts [B] Starter Motor [C] Starter Motor Installation • Clean the mating surface [A] of the starter motor and the crankcase where the starter motor is grounded [B].
• Page 370 17-32 ELECTRICAL SYSTEM Electric Starter System • Remove: Armature [A] Positive Brushes [B] Brush Plate [C] • Remove: Drive End Cover Screws [A] Drive End Cover [B] • Remove: Starter Clutch [A] Idle Gear [B] Steel Ball [C] • Remove: Retainer [A] and Rollers [B] •...

• Page 371: Starter Motor Assembly

  ELECTRICAL SYSTEM 17-33 Electric Starter System Starter Motor Assembly • Grease: Retainer and Rollers Starter Clutch Steel Ball Return Spring Armature Bearing • Install the retainer [A] and rollers [B] on the drive end cover shaft [C]. • Install: Starter Clutch [A] Idle Gear [B] •...

• Page 372: Carbon Brush Inspection

  17-34 ELECTRICAL SYSTEM Electric Starter System • Fit the projection [A] on the yoke [B] into the notch [C] in the magnetic switch [D]. • Install the magnetic switch wire and tighten the nut se- curely. Carbon Brush Inspection • Measure the carbon brush length [A].

• Page 373: Armature Inspection

  ELECTRICAL SYSTEM 17-35 Electric Starter System • Measure the diameter [A] of the commutator. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator Diameter Standard: 30 mm (1.18 in.) Service Limit: 29 mm (1.14 in.) Armature Inspection •...

• Page 374: Starter Circuit Relay Inspection

  17-36 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection • Remove: Starter Circuit Relay [A] Starter Circuit Relay Connector [B] • Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defec- tive.
• Page 375 ELECTRICAL SYSTEM 17-37 Electric Starter System Electric Starter Circuit 1. Starter Motor 2. Starter Circuit Relay 3. Neutral Switch 4. Battery 5. 30 A Fuse 6. Ignition Switch Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 376: Fuel Pump And Relay

  17-38 ELECTRICAL SYSTEM Fuel Pump and Relay The fuel pump does not operate when the ignition switch is turned on alone. The pump operates when the engine is running. When fuel level in the float chamber is low, the fuel pump operates to supply fuel into the float chamber.
• Page 377 ELECTRICAL SYSTEM 17-39 Fuel Pump and Relay Fuel Pump and Relay Circuit 1. Ignition Switch 2. Battery 3. 30 A Fuse 4. Fuel Pump Relay 5. Fuel Pump 6. Igniter Property of www.SmallEngineDiscount.com - Not for Resale...

• Page 378: Radiator Fan

  17-40 ELECTRICAL SYSTEM Radiator Fan Radiator Fan Circuit Inspection • Disconnect the wires from the radiator fan switch [A]. • Using an auxiliary wire [B], connect the radiator fan switch wires. If the radiator fan rotates, inspect the radiator fan switch. If the radiator fan does not rotate, inspect the following.

• Page 379: Lighting System

  ELECTRICAL SYSTEM 17-41 Lighting System Headlight Beam Adjustment • Turn the adjusting screw [A] on each headlight rim in or out to adjust the headlight vertically. Headlight Bulb Replacement • Remove: Front Cargo Bed Compartment (see Frame chapter) Dust Cover [A] •...

• Page 380: Tail/brake Light Replacement

  17-42 ELECTRICAL SYSTEM Lighting System Tail/Brake Light Replacement • Remove the lock pin type bulb [A]. ○ Remove the tail/brake light lens. ○ Push the bulb in, turn it counterclockwise, and pull it out of the socket. CAUTION Do not use bulbs rated for greater wattage than the specified value.
• Page 381 ELECTRICAL SYSTEM 17-43 Lighting System Lighting System Circuit 1. Headlights 2. Tail/Brake Lights 3. Light Switch 4. Brake Light Switch 5. Coolant Temperature Warning Light Switch 6. Parking Brake Light Switch 7. Parking Brake Indicator Light 8. Coolant Temperature Warning Indicator Light 9.

• Page 382: Switches

  17-44 ELECTRICAL SYSTEM Switches Brake Light Switch Adjustment • Refer to Brake Light Switch Adjustment in the Periodic Maintenance chapter. Switch Inspection • Using a hand tester, check to see that only the connec- tions shown in the table (see Wiring Diagram) have con- tinuity (about zero ohms).

• Page 383: Coolant Temperature Warning Light Switch Inspection

  ELECTRICAL SYSTEM 17-45 Switches Coolant Temperature Warning Light Switch Inspection • Remove: Coolant Temperature Warning Light Switch (see Cooling System chapter) • Suspend the switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged.

• Page 384: Fuses

  17-46 ELECTRICAL SYSTEM Fuses Fuse Removal • Unlock the hook to lift up the lid [A]. • Pull the fuses [B] straight out of the fuse box with a needle nose pliers. Fuse Installation If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage.

• Page 385: Electrical Wiring

  ELECTRICAL SYSTEM 17-47 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.

• Page 386: Wiring Diagram

  17-48 ELECTRICAL SYSTEM Wiring Diagram Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 387 ELECTRICAL SYSTEM 17-49 Wiring Diagram Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 388 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 389 APPENDIX 18-1 Appendix Table of Contents Troubleshooting Guide ......................18-2 Cable, Wire, and Hose Routing ....................18-6 Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 390 18-2 APPENDIX Troubleshooting Guide NOTE Cylinder head not sufficiently tightened ○ This is not an exhaustive list, giving every down possible cause for each problem listed. It No valve clearance is meant simply as a rough guide to assist Cylinder, piston worn the troubleshooting for some of the more Piston ring bad (worn, weak, broken, or common difficulties.
• Page 391 APPENDIX 18-3 Troubleshooting Guide Poor Running or No Power at High Speed: Carburetor holder loose Firing incorrect: Air cleaner clogged, poorly sealed, or miss- Spark plug dirty, broken, or maladjusted Spark plug cap shorted or not in good con- Compression high: tact Carbon built up in combustion chamber Spark plug incorrect...
• Page 392 18-4 APPENDIX Troubleshooting Guide Shifting too quickly: Piston seizure or damaged Drive pulley spring weak Cylinder head gasket leaking Driven pulley spring weak or incorrectly in- Exhaust pipe leaking at cylinder head con- stalled (too loose) nection Shifting too slowly: Crankshaft runout excessive Belt dirty or worn Engine mounts loose...
• Page 393 APPENDIX 18-5 Troubleshooting Guide Brown smoke: Battery Discharged: Main jet too small Battery faulty (e.g., plates sulphated, Fuel level too low shorted through sedimentation, elec- Air cleaner poorly sealed or missing trolyte level too low) Handling and/or Stability Unsatisfactory: Battery leads making poor contact Steering wheel hard to turn: Load excessive (e.g., bulb of excessive Steering shaft bearing damaged...
• Page 394 18-6 APPENDIX Cable, Wire, and Hose Routing 1. Headlight Wire 2. Main Harness 3. Band (Do not tighten band on wire connector joint.) 4. Black/Yellow Wire 5. Red/Black Wire 6. Red/Yellow Wire Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 395 APPENDIX 18-7 Cable, Wire, and Hose Routing 1. Water Temperature Warning/Parking Brake Indicator Lights 2. Oil Pressure Warning Indicator Light Wire (for Option) 3. Power Outlet Connector 4. Ignition Switch 5. Hour Meter 6. Speedometer Cable (Option) 7. Horn Switch Wire 8.
• Page 396 18-8 APPENDIX Cable, Wire, and Hose Routing 1. Radiator Fan Motor 2. Radiator Fan Motor Wire 3. Radiator Fan Switch 4. Horn Wire 5. Front Final Gear Case Breather Hose 6. Radiator Fan Motor Tube 7. Brake Light Switch 8. Speedometer Cable (Option) 9.
• Page 397 APPENDIX 18-9 Cable, Wire, and Hose Routing 1. Brake Master Cylinder 2. Keep hose away from steering intermediate shaft. 3. Install clamp in this direction. 4. Brake Hose (Left) Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 398 18-10 APPENDIX Cable, Wire, and Hose Routing 1. Main Harness 9. Hi/Low Shift Cable 2. Choke Cable 10. Radiator Fan Switch Wire 3. Differential Shift Cable 11. Horn Wires 4. Brake Light Switch 12. Front Final Gear Case Breather Hose 5.
• Page 399 APPENDIX 18-11 Cable, Wire, and Hose Routing 1. Ignition Switch Wire 2. Headlight Wire (Left) 3. Headlight Wire (Right) 4. Main Harness 5. Band 6. 110 mm (4.3 in.) 7. 80 mm (3.2 in.) 8. 170 mm (6.7 in.) 9. 300 mm (11.8 in.) 10.
• Page 400 18-12 APPENDIX Cable, Wire, and Hose Routing 1. Breather Tube 2. Brake Hose 3. Brake Pipe 4. Clamp 5. Band Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 401 APPENDIX 18-13 Cable, Wire, and Hose Routing 1. Front Brake Master Cylinder 2. Brake Hose 3. Harness 4. Clamp 5. Band 6. Parking Brake Lever Boot Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 402 18-14 APPENDIX Cable, Wire, and Hose Routing 1. Right Brake Drum 2. Right Frame 3. Breather Tube 4. Brake Pipe 5. Brake Cable 6. Left Brake Drum 7. Left Frame 8. Band Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 403 APPENDIX 18-15 Cable, Wire, and Hose Routing 1. Run the cables straight to front. 9. Clamp 2. Trims 10. Differential Shift Cable: Keep 25 mm 3. Run the cables under the main harness (0.98 in.) or more clearance between the and fuel hose.
• Page 404 18-16 APPENDIX Cable, Wire, and Hose Routing 1. Right Parking Brake Cable 2. Left Parking Brake Cable 3. Clamp 4. Right Side Round Pipe End of Frame 5. Plug Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 405 APPENDIX 18-17 Cable, Wire, and Hose Routing 1. Accessory Connectors 10. Water Temperature Warning Indicator 2. Headlight Wire (Left) Light Wire 3. Ground Wire (Steering Gear Assembly) 11. Ignition Switch Wire 4. Radiator Fan Motor Wire 12. Hour Meter Wire 5.
• Page 406 18-18 APPENDIX Cable, Wire, and Hose Routing 1. Brake/Tail Light Wire 2. Clamp 3. Band 4. Neutral Switch Wire 5. 80 mm (3.2 in.) 6. Neutral Switch Cap 7. 0 ∼ 20° 8. Frame Pipe 9. Carburetor 10. Carburetor Air Vent Tube 11.
• Page 407 APPENDIX 18-19 Cable, Wire, and Hose Routing 1. Floor Center Covers 12. Upper Side 2. Position the rubber protector for the (+) 13. Inside wire lead. 14. Parking Brake Switch Wire 3. Fuel Pump Wire 15. Battery 4. Band 16. Black Tape 5.
• Page 408 18-20 APPENDIX Cable, Wire, and Hose Routing 1. Regulator/Rectifier 2. Starter Circuit Relay 3. Fuel Pump Relay 4. Igniter 5. Fuel Filter 6. Run the harness between the frame and the fuel filter. 7. Fuel Pump 8. (–) Wire Lead 9.
• Page 409 APPENDIX 18-21 Cable, Wire, and Hose Routing 1. Fuel Tank 13. Frame 2. Cross Pipe 14. Breather Hose 3. Fuel Hose 15. Fuel Pump 4. Protector 16. Install the fuel hose so that its bent portion 5. To Fuel Filter faces inside.
• Page 410 18-22 APPENDIX Cable, Wire, and Hose Routing 1. Horn Button 2. Horn Switch Contact 3. Ground Wire 4. to Main Harness 5. Band 6. Front 7. Installation condition of horn switch contact Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 411 APPENDIX 18-23 Cable, Wire, and Hose Routing 1. Speedometer Cable 9. Speedometer Gear 2. Clamp the speedometer cable with other 10. Plain Washer 6 mm (0.24 in.) cables, harness and brake pipe. 11. O-ring 3. Clamp the speedometer cable with other 12.
• Page 412 18-24 APPENDIX Cable, Wire, and Hose Routing 1. Differential Shift Cable 2. Cable Bracket 3. 100 mm (3.9 in.) 4. Cable Clamp 5. 2WD/4WD Shift Cable Property of www.SmallEngineDiscount.com - Not for Resale...
• Page 413 MODEL APPLICATION Year Model Beginning Frame No. □ 2005 KAF620-J1 JK1AFCJ1 5B500001 □ 2005 KAF620-K1 JK1AFCK1 5B500001 □ :This digit in the frame number changes from one machine to another. Property of www.SmallEngineDiscount.com - Not for Resale Part No.99924-1350-01 Printed in Japan...