Kawasaki MULE 3010 TRANS 4 × 4, MULE 3010 TRANS 4x4 Service Manual
MULE 3010 TRANS 4 × 4
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Utility Vehicle
Service Manual
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Quick Reference Guide
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General Information 1 j
Periodic Maintenance 2 j
Fuel System 3 j
Cooling System 4 j
Engine Top End 5 j
Converter System 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Engine Bottom End 9 j
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer tothesectional table of contents
for the exact pages to locate the specific topic required.
Transmission 10 j
Wheels/Tires 11 j
Final Drive 12 j
Brakes 13 j
Suspension 14 j
Steering 15 j
Frame 16 j
Electrical System 17 j
Appendix 18 j
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MULE 3010 TRANS 4 × 4
Property of www.SmallEngineDiscount.com - Not for Resale
Utility Vehicle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Department/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your dealer for the latest information on
product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2004 Kawasaki Heavy Industries. Ltd., First Edition (1): Nov. 1, 2004 (M)
LIST OF ABBREVIATIONS
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A ampere(s) lb pounds(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC
BTDC before top dead center
°C degree(s) Celsius
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
bottom dead center
PS
psi
r revolution
horsepower
pound(s) per square inch
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
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Toprotect the environment in which we all live, Kawasaki hasincorporated crankcaseemission
(1) and exhaust emission (2) control systems in compliance with applicable regulations of the
United States Environmental Protection Agency and California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system isused to eliminateblow-by gases. The blow
-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from
the crankcase, and then returned back to the bottom of the crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine family is engine modifications that
consist of a modifiedcarburetor andignition system having optimum ignitiontiming characteristics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum
fuel economy with a suitable air cleaner and exhaust system.
A maintenance free ignition system provides the most favorable ignition timing and helps main-
tain a thorough combustion process within the engine whichcontributes to a reduction of exhaust
pollutants entering the atmosphere.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairi ng, servicing, selling, leasing, or trading
motor v ehicles or motor vehicle engines, or who operates a fleet of motor v ehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."
(Continued on next page.)
NOTE
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The phrase "remove or render inoperative any device or element of design" has been generally
○
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the vehicle.
c.Addition ofcomponents or accessories thatresult in the vehicleexceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.
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.
Foreword
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This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However,itcontains enoughdetail andbasic informationto makeit useful to the owner who desiresto perform his own basicmaintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
beforestarting work, andthen dothe workcarefully in a c lean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
thisservice manual. Anyownermaintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
•
Service Manual.
Be alert for problems and non-scheduled
•
maintenance.
Useproper tools and genuine KawasakiVehi-
•
cle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are introduced by the Special Tool
Catalog or Manual. Genuine parts provided
as spare parts are listed in the Parts Catalog.
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Rememberto keep completerecords of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the firstpage of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
additiontoWARNINGand CAUTION) whichwill
help you distinguish different types of information.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
takebased onthe resultsof thetest orinspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which partsrequire specified tightening torque, oil, grease or a locking
agent during assembly.
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GENERAL INFORMATION 1-1
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General Information
Table of Contents
Before Servicing..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-8
Unit Conversion Table............................................................................................................ 1-11
1
1-2 GENERAL INFORMATION
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Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any service on the vehicle, disconnect
thebattery wires from thebattery to prevent the engine from
accidentally turning over. Disconnect the ground wire (–)
first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive
(+) terminal of the battery then the negative (–) wire to the
negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
otherforeign materialsentering intosealed areasduring vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Before Servicing
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Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
GENERAL INFORMATION 1-3
Inspection
Reuse of worn or damaged partsmay lead toserious accident. Visuallyinspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for s ervice limits on individualparts. Replace
the parts if any damage has been found or if the part is beyond its service limit.
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.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
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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 thespecified sequence to prevent case warpage or deformationwhich can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Often, the tightening sequence is followed twice initial
tightening and final tightening with torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive orhard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing performance. Remove old gaskets and c lean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling.
Liquid Gasket, Locking Agent
For applications that require Liquid Gasket or a
Non-Permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket
or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious
damage.
Before Servicing
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Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact 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. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
GENERAL INFORMATION 1-5
Oil Seal, Grease Seal
Donot remove pressedoil or greaseseals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil sealswith manufacture andsize marks facing
out. Make sure the seal is aligned properlywhen installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replacecirclips or cotterpins that wereremoved with new
ones. Take care not to open the clip excessively when installing to prevent deformation.
1-6 GENERAL INFORMATION
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Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication 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. Rotate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructedotherwise, electrical
wires must be connected to those of the same color.
Model Identification
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KAF620-J1 Left Side View
GENERAL INFORMATION 1-7
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.
1-8 GENERAL INFORMATION
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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 177 mm (6.97 in.)
Seat Height:
Front 868 mm (34.17 in.)
Rear 896 mm (35.28 in.)
Dry Weight
Curb Weight:
Front
Rear 374 kg (825 lb)
Fuel Tank Capacity 24.2 L (6.4 US gal)
Cargo Bed (L × W × H):
Long Bed 1 280 × 1 212 × 287 mm (50.39 × 47.72 × 11.30 in.)
Short Bed 770 × 1 212 × 287 mm (30.31 × 47.72 × 11.30 in.)
Performance
Maximum Torque 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm), (US) –
Minimum Turning Radius 3.8 m (12.5 ft)
Engine
Type 4-stroke, OHV, 2 cylinder
Cooling System Liquid-cooled
Bore And Stroke 76 × 68 mm (2.99 × 2.68 in.)
Displacement 617 mL (37.6 cu in.)
Compression Ratio 10.3
Carburetion System MIKUNI BW26-18
Starting System Electric Starter
Ignition System
Ignition Timing
Spark Plug NGK BPR2ES
Cylinder Numbering Method Front to rear, 1-2
Firing Order Front to rear, 1-2
Valve Timing:
Inlet:
open #1 68° BTDC/#2 64° BTDC
close #1 76° ABDC/#2 80° ABDC
duration 324°
Exhaust:
open 94° BBDC
close 48° ATDC
668 kg (1 473 lb)
321 kg (708 lb)
Battery and transistor
3/900 ∼ 13/2 000 ∼ 18/2 500 ∼ 23/3 500 (BTDC°/rpm)
GENERAL INFORMATION 1-9
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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 Belt drive torque converter
Reduction Ratio 3.9 ∼ 0.85
Transmission Gear Ratio:
Forward:
High
Low
Reverse:
Low 4.220 (41/20 × 25/20 × 28/17)
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio:
Forward:
High 8.360
Low 17.212
Reverse:
Low 19.372
Front Final Gear Case Oil:
Type API GL-5 or GL-6 Hypoid gear oil for LSD
Capacity 0.4 L (0.4 US qt)
Transmission Oil:
Type API GL-5 Hypoid gear oil, SAE 90 (above 5°C, 41°F) or SAE
Capacity 2.5 L (2.6 US qt)
Frame
Type Steel tube, Ladder
Caster (Rake Angle) 7.5°
Camber 0.8°
Trail 35 mm (1.4 in.)
Tire:
Front And Rear 23 × 11.00-10, Tubeless
Steering Type
1.821 (51/28)
3.750 (51/28 × 25/20 × 28/17)
2-speed, automatic, reverse gear drive (4WD/2WD)
5.4 (81/15)
SAE 85W-140, SAE 90, or SAE 140
80 (below 5°C, 41°F)
Rack and pinion
1-10 GENERAL INFORMATION
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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
Parking Brake Type Drum (Mechanical internal expansion)
Electrical Equipment
Battery 12 V 18 Ah
Headlight:
Type
Bulb 12 V 30 W × 2
Tail/Brake Light 12 V 5/21 W
Alternator:
Type Three - phase AC
Rated Output 21 A /12 V @3 000 rpm
Load Capacity
Maximum Vehicle Load
(Including Occupants And Cargo) 603 kg (1330 lb)
Maximum Cargo Bed Load:
Long 363 kg (800 lb)
Short 182 kg (401 lb)
US: United States Model
Drum (Hydraulic)
Semi-sealed beam
Specifications are subject to change without notice, and may not apply to every country.
Unit Conversion Table
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GENERAL INFORMATION 1-11
Prefixes for Units:
Prefix Symbol Power
mega M ×1000000
kilo k × 1 000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001
Units of Mass:
kg ×2.205=lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 =
L × 0.2200 = gal (imp)
L × 1.057 = qt (US)
L × 0.8799 = qt (imp)
L × 2.113 = pint (US)
L × 1.816 =
mL × 0.03381 =
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in
gal (US)
pint (imp)
oz (US)
Units of Length:
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in
Units of Torque:
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
Units of Pressure:
kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cmHg
kgf/cm² × 98.07 = kPa
kgf/cm²
cmHg × 1.333 = kPa
× 14.22 = psi
Units of Speed:
km/h × 0.6214 = mph
Units of Force:
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
Units of Temperature:
Units of Power:
kW × 1.360 = PS
kW × 1.341 = HP
PS
PS × 0.9863 = HP
× 0.7355 = kW
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PERIODIC MAINTENANCE 2-1
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Periodic Maintenance
Table of Contents
Periodic Maintenance Chart .............. 2-2
Torque and Locking Agent................. 2-4
Specifications .................................... 2-8
Special Tools ..................................... 2-10
Periodic Maintenance Procedures..... 2-11
Fuel System.................................... 2-11
Throttle Pedal Free Play
Inspection.................................. 2-11
Throttle Pedal Free Play
Adjustment................................ 2-11
Full Throttle Pedal Position
Adjustment................................ 2-12
Idle Speed Inspection .................. 2-12
Idle Speed Adjustment................. 2-12
Fuel System Cleanliness
Inspection.................................. 2-12
Fuel Filter Inspection.................... 2-13
Intake Chamber Water Draining .. 2-13
External Carburetor Mechanism
Cleaning.................................... 2-13
Fuel Hoses And Connections
Inspection.................................. 2-13
Fuel Hoses Replacement............. 2-14
Air Cleaner Element Cleaning...... 2-14
Air Cleaner Housing Dust and/or
Water Inspection....................... 2-15
Cooling System............................... 2-15
Radiator Cleaning........................ 2-15
Radiator Hose and Connection
Inspection.................................. 2-16
Coolant Draining.......................... 2-16
Coolant Filling.............................. 2-17
Coolant Filter Inspection .............. 2-18
Converter System........................... 2-18
Drive Belt Inspection.................... 2-18
Converter Driven Pulley Shoe
Inspection.................................. 2-19
Air Cleaner Element
Cleaning/Inspection................... 2-19
Converter Dust or Water Draining 2-20
Engine Top End .............................. 2-20
Valve Clearance Inspection ......... 2-20
Valve Clearance Adjustment........ 2-21
2
Spark Arrester Cleaning............... 2-22
Engine Lubrication.......................... 2-22
Oil and/or Filter Change............... 2-22
Oil Filter Removal ........................ 2-23
Oil Filter Installation ..................... 2-23
Transmission .................................. 2-24
Transmission Oil Change............. 2-24
Wheels/Tires................................... 2-24
Wheels Nuts Tightness
Inspection.................................. 2-24
Tire Inspection ............................. 2-25
Final Drive....................................... 2-25
Front Final Gear Case Oil
Change...................................... 2-25
Brakes............................................. 2-26
Brake Fluid Level Inspection ....... 2-26
Brake Fluid Changing .................. 2-27
Brake Pedal Free Play
Adjustment................................ 2-27
Brake Master Cylinder Cup and
Dust Seal Replacement ............ 2-28
Brake Hose and Pipe Inspection.. 2-29
Brake Hose and Pipe
Replacement............................. 2-29
Brake Wear Inspection................. 2-30
Brake Wheel Cylinder Assembly
Replacement............................. 2-31
Parking Brake Lever Travel
Adjustment ............................... 2-33
Steering .......................................... 2-34
Steering Wheel Free Play
Inspection.................................. 2-34
Steering Joint Dust Boot
Inspection.................................. 2-34
Frame ............................................. 2-34
Seat Belt Inspection..................... 2-34
Electrical System............................ 2-35
Brake Light Switch Adjustment.... 2-35
Spark Plug Cleaning/Inspection... 2-35
Spark Plug Gap Inspection.......... 2-35
General Lubrication ........................ 2-35
Bolts, Nuts, and Fasteners............. 2-37
Tightness Inspection.................... 2-37
2-2 PERIODIC MAINTENANCE
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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
OPERATION
ENGINE
Converter belt - check*
Converter driven pulley shoe - check*
Converter air cleaner element - clean*
Converter dust or water - drain*
Valve clearance - check
Engine oil - change* 1 year
Oil filter - replace*
Throttle pedal play - check
Idle speed - adjust
External carburetor mechanism (Throttle
lever roller and choke lever cam) - clean*
Fuel hose and connections - check*
Fuel hose - replace 4 years 2-14
Fuel filter - change*
Fuel system cleanliness - check*
Air cleaner element - clean*
Intake chamber water - drain*
Spark plug - clean and gap
Spark arrester - clean
Radiator - clean*
Radiator hoses and connections - check 1 year
Coolant - change 2 years 2-16
Coolant filter - clean 1 year 2-18
: Clean, adjust, lubricate, torque, or replace parts as necessary.
•
*: Service more frequently when operated in mud, dust, or other harsh riding conditions.
Whichever
comes
first
→
↓
Every
First
Service
After50 h,
or 1 000
km of use
Regular Service
Every 250
h,or 5000
km of use
•
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
•
•
• •
• •
Every
500 h, or
10 000
kmofuse
•
•
•
•
See
Page
2-18
2-19
2-19
2-20
2-20
2-22
2-23
2-11
2-12
2-13
2-13
2-13
2-12
2-14
2-13
2-35
2-22
2-15
2-16
Periodic Maintenance Chart
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PERIODIC MAINTENANCE 2-3
FREQUENCY Whichever
comes
first
↓
OPERATION
CHASSIS
Steering - check
Steering and axle shaft joint dust boots -
check
Brake pedal play - check*
Parking brake lever - check
Brake hose and pipe - check
Brake fluid level - check
Brake wear - check*
Tire wear - check*
Brake light switch - check
Seat belt - check
General lubrication - perform*
Bolts, nuts, and fasteners tightness -
check
Wheel nuts tightness - check
Front final gear case oil and transmission
oil - change*
Brake fluid - change 2 years 2-27
Brake master cylinder cup and dust seal
- replace
Brake wheel cylinder assembly - replace 2 years 2-31
Brake hose - replace 4 years 2-29
: Clean, adjust, lubricate, torque, or replace parts as necessary.
•
*: Service more frequently when operated in mud, dust, or other harsh riding conditions.
Every
1 year
2 years 2-28
→
First
Service
After 50
h, or 1
000 km
of use
Regular Service
Every250
h, or 5
000 km
of use
• •
• •
• •
• •
• •
• •
•
• •
• •
•
•
• •
• •
• •
Every
500 h, or
10 000
km of use
See
Page
2-34
2-35
2-27
2-33
2-29
2-26
2-30
2-25
2-35
2-34
2-35
2-37
2-24
2-25
2-4 PERIODIC MAINTENANCE
Property of www.SmallEngineDiscount.com - Not for Resale
Torque and Locking Agent
The following tables list the tightening torque forthe majorfasteners, 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).
O: Apply an oil to the threads, seated surface, or washer.
R: Replacement Part
S: Tighten the fasteners following the specified sequence.
SS: Apply a silicone sealant to the threads.
Fastener
Fuel System
Air Duct Clamps 1.0 0.10 8.7
Cover Mounting Bolts 2.9 0.30 26 in·lb L
Chamber Case Cover Bolts 4.9 0.50 43 in·lb
Float Bowl Screws 2.0 0.20 18 in·lb
Air Cleaner Housing Mounting Bolts 20 2.0 14
Governor Arm Mounting Nut
Link Lever Mounting Bolts 8.8 0.90 78 in·lb L
Carburetor Cover Bolts 8.8 0.90 78 in·lb
Cooling System
Water Pump Cover Bolts (M6) 8.8 0.90 78 in·lb S
Water Pump Cover Bolt (M8) 25 2.5 18 S
Radiator Fan Switch 25 2.5 18
Radiator Screen Bolts 8.8 0.90 78 in·lb
Radiator Mounting Bolts 8.8 0.90 78 in·lb
Water Pipe Bolts 8.8 0.90 78 in·lb
Coolant Temperature Warning Light Switch 23 2.3 17 SS
Coolant Reservoir Mounting Bolt 4.4 0.45 39 in·lb
Coolant Drain Plugs (Cylinder) 17 1.7 12
Engine Top End
Cylinder Head Bolts 22 2.2 16 S
Intake Pipe Bolts 8.8 0.90 78 in·lb L(2)
Valve Adjusting Screw Locknuts 9.8 1.0 87 in·lb
Coolant Temperature Warning Light Switch 23 2.3 17 SS
Intake Manifold Bolts
Muffler Mounting Bolts – – – L
Converter System
Drive Pulley Bolt (New) 76 7.7 56 R
Driven Pulley Bolt 93 9.5 69 L
Converter Cover Bolts 1.5 0.15 13 in·lb
Ramp Weight Nuts 6.9 0.70 61 in·lb
Spider 275 28 203
Drive Pulley Cover Bolts 13 1.3 113 in·lb
Wear Shoe Mounting Screws 1.1 0.11 10 in·lb
N·m kgf·m ft·lb
7.4 0.75 65 in·lb
– – –
Torque
Remarks
S
Torque and Locking Agent
Property of www.SmallEngineDiscount.com - Not for Resale
PERIODIC MAINTENANCE 2-5
Fastener
Cooling Fan Cover Bolts 8.8 0.90 78 in·lb
Engine Lubrication System
Engine Oil Drain Plug (M14) 22 2.2 16
Engine Oil Drain Plug (M16)
Oil Pressure Switch 9.8 1.0 87 in·lb SS
Oil Filter – – – see text
Engine Removal/Installation
Engine Positioning Plate Bolts 20 2.0 14
Engine Bottom End
Crankcase Cover Bolts
Connecting Rod Big End Cap Bolts 21 2.1 15 O
Coolant Drain Plugs (Cylinder) 17 1.7 12
Oil Filter Stud Bolt 18 1.8 13
Transmission
Transmission Oil Drain Plug 15 1.5 11
Transmission Case Mounting Bolts 44 4.5 33
Transmission Case Bolts 8.8 0.90 78 in·lb
Shift Arm Positioning Bolt 37 3.8 27
Hi/Low Gear Case Bolts
Shift Shaft Stop Bolt 7.8 0.80 69 in·lb
Differential Gear Housing Bolts
Bearing Holder 120 12 87 MO
Neutral Switch 15 1.5 11
Governor Pivot Arm Stopper Bolt 15 1.5 11
Shift Shaft Lever Clamp Bolts
Wheels/Tires
Tie-Rod End Locknuts 49 5.0 36
Wheel Nuts 137 14 101
Final Drive
Front Final Gear Case:
Oil Filler Cap 29 3.0 22
Oil Drain Plug 20 2.0 14
Gear Case Bracket Bolts 44 4.5 33 L
Gear Case Mounting Nuts
Ring Gear Cover Bolts (M10) 47 4.8 35
Ring Gear Cover Bolts (M8) 25 2.5 18
Pinion Gear Bearing Housing Nuts 25 2.5 18
Differential Case Torx Bolts 32 3.3 24 L
Ring Gear Bolts 49 5.0 36
Pinion Gear Slotted Nut
Bevel Gear Case:
Bevel Gear Case Bolts 22 2.2 16
Driven Gear Shaft Nut 110 11 80 L
N·m kgf·m ft·lb
25 2.5 18
25 2.5 18
20 2.0 14
57 5.8 42
12 1.2 104 in·lb
44 4.5 33
120 12 87
Torque
Remarks
MO
2-6 PERIODIC MAINTENANCE
Property of www.SmallEngineDiscount.com - Not for Resale
Torque and Locking Agent
Fastener
Bearing Holder 120 12 87 L
Housing Locknut 120 12 87 L
Bevel Gear Case Holder Nuts 25 2.5 18
Drive Gear Nut 120 12 87 MO
Front Axle Cap Bolts 8.8 0.90 78 in·lb
Drive Shaft Cap Bolts 20 2.0 14
Brakes
Bleed Valves 5.9 0.60 52 in·lb
Push Rod Locknut 18 1.8 13
Brake Hose Banjo Bolts 25 2.5 18
Brake Pipe Nipples 18 1.8 13
Piston Stop Bolt 8.8 0.90 78 in·lb
Reservoir Clamp Bolt 5.9 0.60 52 in·lb
Front Axle Nuts 200 20 140
Rear Axle Nuts 300 31 220
Wheel Cylinder Mounting Bolts
Wheel Cylinder Mounting Nuts 7.8 0.80 69 in·lb
Brake Panel Mounting Bolts 44 4.5 33 L
Suspension
Strut M ounting Nuts 44 4.5 33
Strut Clamp Nut 98 10 72
Strut Lock Nut 49 5.0 36
Rear Shock Absorber Mounting Nuts 59 6.0 43
Front Suspension Arm Pivot Bolts 98 10 72
Front Suspension Arm Joint Nut
Damper Bracket Mounting Nuts 44 4.5 33
Leaf Spring Mounting Nuts (Front) 98 10 72
Leaf Spring Mounting Nuts (Rear)
Tie-rod End Nuts 34 3.5 25
Steering
Steering Wheel Mounting Nut
Intermediate Shaft Clamp Bolts 20 2.0 14
Steering Gear Assembly Bracket Bolts 52 5.3 38 L
Tie-rod End Nuts 34 3.5 25
Rack Guide Spring Cap Locknut 39 4.0 29
Tie-Rod End Locknuts 49 5.0 36
Strut Clamp Nut
Frame
Seat Belt Mounting Bolts 34 3.5 25
Front Bar Mounting Bolts (Lower)
Front Bar Mounting Bolts (Upper) 44 4.5 33
Top Bar Mounting Bolts 44 4.5 33
Center Bar Mounting Bolts and Nuts
N·m kgf·m ft·lb
11 1.1 95 in·lb
78 8.0 58
59 6.0 43
52 5.3 38
98 10 72
98 10 72
44 4.5 33
Torque
Remarks
Torque and Locking Agent
Property of www.SmallEngineDiscount.com - Not for Resale
PERIODIC MAINTENANCE 2-7
Fastener
Rear Bar Mounting Bolts And Nuts 44 4.5 33
Rear End Sub-Frame Mounting Bolts 44 4.5 33
Hood Latch Lever Mounting Bolt 39 4.0 29
Tail Gate Fixing Lever Screw
Screen Fixing Lever Screw 4.4 0.45 39 in·lb L
Electrical System
Alternator Rotor Nut 120 12 87
Spark Plugs 17 1.7 12
Starter Motor Mounting Bolts 22 2.2 16
Regulator/Rectifier Mounting Bolts 8.8 0.90 78 in·lb
Igniter M ounting Bolts 8.8 0.90 78 in·lb
Alternator Stator Mounting Screws - - - L
Coolant Temperature Warning Light Switch 23 2.3 17 SS
Oil Pressure Switch 9.8 1.0 87 in·lb SS
Neutral Switch 15 1.5 11
Radiator Fan Switch
Battery Holder Nuts 17 1.7 12
The table below, relating tightening torque to thread diameter,lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
N·m kgf·m ft·lb
4.4 0.45 39 in·lb L
25 2.5 18
Torque
Remarks
Basic Torque for General Fasteners of Engine Parts
Threads dia. Torque
mm (in.)
6 (0.24) 4T 3.9 ∼ 4.9 0.40 ∼ 0.50 35 ∼ 43 in·lb
6 (0.24) 7T 7.8 ∼ 9.8 0.80 ∼ 1.0 69 ∼ 87 in·lb
6 (0.24) 9T 12 ∼ 15 1.2 ∼ 1.5 104 ∼ 130 in·lb
8 (0.31) 4T 10 ∼ 14 1.0 ∼ 1.4 87 ∼ 120 in·lb
8 (0.31)
10 (0.39)
10 (0.39) 7T 39 ∼ 44 4.0 ∼ 4.5 29 ∼ 33
Mark of bolt head
7T 18 ∼ 22 1.8 ∼ 2.2 13 ∼ 16
4T 20
N·m kgf·m ft·lb
∼ 24
2.
0 ∼ 2.4
Basic Torque for General Fasteners of Frame Parts
Threads dia. Torque
mm (in.) N·m kgf·m ft·lb
5 (0.20) 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 (0.24) 5.8 ∼ 7.9 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 (0.31)
10 (0.39)
12 (0.47) 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 ∼ 19 1.4 ∼ 1.9 10 ∼ 14
26 ∼ 34 2.6 ∼ 3.5 19 ∼ 25
14
∼ 17
2-8 PERIODIC MAINTENANCE
Property of www.SmallEngineDiscount.com - Not for Resale
Specifications
Item Standard Service Limit
Fuel System
Throttle Pedal Free Play 5 ∼ 10 mm (0.2 ∼ 0.4 in.) –––
Idle Speed 850 ∼ 950 r/min (rpm) –––
Cooling System
Coolant:
Type
Color Green –––
Mixed Ratio Soft water 50% × coolant 50% –––
Freezing Point –35°C (–31°F) –––
Total Amount 4.6L(4.9USqt) –––
Fan Belt Deflection 9.5 ∼ 11.5 mm/10 kgf (22 lb)
Converter System
Belt Width 30.3 mm (1.19 in.) 28.8 mm (1.13 in.)
Wear Shoe Width ––– 16 mm (0.64 in.)
Engine Top End
Valve Clearance (When Cold) 0.25 mm (0.010 in.) –––
Engine Lubrication System
Engine Oil:
Grade API SF or SG
Viscosity SAE 10W-40 –––
Capacity 1.5 L (1.6 US qt) (when filter is not removed)
Oil Level Between F and L marks on dipstick –––
Transmission
Transmission Oil:
Type API "GL-5" Hypoid gear oil –––
Viscosity SAE90: above 5°C (41°F) or
Capacity 2.5L(2.6USqt) –––
Oil Level Between H and L lines on dipstick –––
Wheels/Tires
Tire Tread Depth 13.2 mm (0.520 in.) 3 mm (0.12 in.)
Final Drive
Front Final Gear Case Oil:
Type
Viscosity
Capacity 0.4L(0.4USqt) –––
Oil Level Filler opening level –––
Permanent type of antifreeze (Soft water
and ethylene glycol plus corrosion and rust
inhibitor chemicals for aluminum engine and
radiators)
API SH or SJ with JASO MA
1.8 L (1.9 US qt) (when filter is removed)
SAE80: below 5°C (41°F)
API "GL-5 or GL-6" hypoid gear oil for LSD
(Limited Slip Differential gears)
SAE85W-140, SAE90 or SAE140
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