Kawasaki MULE 3010 TRANS 4 × 4, MULE 3010 TRANS 4x4 Service Manual

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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

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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.

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

1-2 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

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

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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

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

20 2.0 14

57 5.8 42

12 1.2 104 in·lb

44 4.5 33

120 12 87

Torque

Remarks

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

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

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

∼ 17

2-8 PERIODIC MAINTENANCE

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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

–––

––– –––

–––

PERIODIC MAINTENANCE 2-9

Property of www.SmallEngineDiscount.com - Not for Resale

Specifications

Item Standard Service Limit

Brakes

Brake Fluid:

Type DOT3 –––

Fluid Level Between upper and lower level lines ––– Brake Pedal Play BrakeDrumInsideDiameter 180.000 ∼ 180.160 mm

Brake Shoe Lining Thickness 4.5 mm (0.18 in.) 1.0 mm (0.04 in.) Parking Brake Lever Travel 8 ∼ 12 notches (clicks) at 200 N (20 kgf, 44 lb) –––

Steering

Steering Wheel Free Play 0 ∼ 20 mm (0 ∼ 0.79 in.)

Electrical System

Brake Light Switch Timing ON after 10 mm (0.39 in.) of pedal travel ––– Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

2 ∼ 10 mm (0.08 ∼ 0.39 in.)

(7.0866 ∼ 7.0929 in.)

–––

180.75 mm (7.116 in.)

–––

2-10 PERIODIC MAINTENANCE

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Special Tools

Inside Ci rclip Pliers: 57001-143

Rotor Puller, M16/M18/M20/M22 × 1.5: 57001-1216

Valve Adjusting Screw Holder: 57001-1217

Brake Drum Remover: 57001-1260

Brake Drum Pusher, M18 × 1.5: 57001-1261

Brake Drum Holder: 57001-1325

Oil Filter Wrench: 57001-1249

Brake Drum Remover Nuts: 57001-1326

Periodic Maintenance Procedures

Property of www.SmallEngineDiscount.com - Not for Resale

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.

Throttle Pedal Free Play

Standard: 5 ∼ 10 mm (0.2 ∼ 0.4 in.)

Throttle Pedal Free Play Adjustment

Remove:

•

Cargo Bed (tilt up)

Loosen the adjuster mounting nuts [A] at the cable lower

•

end. Slide the adjuster [B] until the proper amount of throttle

•

pedal free play is obtained. Tighten the mounting nuts securely.

•

Start the engine.

•

Withthe transmissionin neutral, operate the throttlepedal

•

a few times to make sure that the idle speed does not change. If the idle speed does change, the throttle cable may be improperly adjusted, incorrectly routed, or it may be damaged. Correct any of these conditions before operation.

•

WARNING

Operation with improperly adjusted, incorrectly routed, or a damaged cable could result in an unsafe operating condition.

PERIODIC MAINTENANCE 2-11

NOTE

If the throttle pedal free play cannot be adjusted by us-

○

ing the adjuster at the cable lower end, use the cable adjuster [A] at the cable upper end. Do not forget to securely tighten the adjuster mounting nuts [B].

2-12 PERIODIC MAINTENANCE

Property of www.SmallEngineDiscount.com - Not for Resale

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. Turn the throttle pedal stop bolt until the bolt head lightly

•

touches the bottom of the throttle pedal. Tighten the locknut securely.

•

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

Tilt up the cargo bed.

•

Check the idle speed with a tachometer.

•

If the idle speed is out of the specified range, adjust it.

Idle Sp eed

Standard: 850 ∼ 950 r/min (rpm)

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

Tilt up the cargo bed.

•

Loosen the accel lever stopper screw [A] on the control

•

panel. Turnthe idleadjusting screw [B] at the carburetor until the

•

idle speed is correct. Depress and release the throttle pedal a few times to

•

make sure that the idle speed is within the specified range. Readjust if necessary. After the adjustment, screw in the accel lever stopper

•

screw [A] until the screw lightly touches the accel lever [C].

Fuel System Cleanliness Inspection

WARNING

Gasoline is extremely flammable and can be explosive 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; this includes any appliance with a pilot light.

Remove:

•

Cargo Bed (tilt up)

Place a suitable container under the carburetor.

•

Turnout the drain screw [A] a few turns to drain some fuel

•

from the carburetor, and check for water or dirt in the fuel. If any water or dirt comes out, clean the carburetor and fuel tank (see Fuel Tank) and check the fuel filter. Tighten the drain screw securely.

•

Periodic Maintenance Procedures

Property of www.SmallEngineDiscount.com - Not for Resale

Fuel Filter Inspection

Visually inspect the fuel filter [A].

•

If the filter is clear with no signs of dirt or other contamination, it is OK and need not be replaced. If thefilter is dark or looks dirty,replace it. Also, check the rest of the fuel system for contamination.

Intake Chamber Water Draining

Lift the cargo bed to support it with the rod.

•

Remove the clamp then the drain hose [A] on the intake

•

chamber [B] to expel dust and/or water accumulated inside.

PERIODIC MAINTENANCE 2-13

External Carburetor Mechanism Cleaning

Lift the cargo bed to support it with the rod.

•

Remove the carburetor cover.

•

Clean and lubricate the throttle lever roller [A] and choke

•

lever cam [B], with a penetrating rust inhibitor, such as WD40 or BEL-RAY 6 in 1.

[C] Throttle Valve Lever

Fuel Hoses And Connections Inspection

Lift up the cargo bed and seat.

•

Check the fuel hoses and fittings for deterioration, cracks

•

and signs of leakage. Replace the fuel hose if any fraying, leak [A], cracks [B] or bulges [C] are noticed. Check thatthe hoses are securely connected and clamps

•

are installed correctly. When installing, route the hoses according to Cable,

•

Wire, and Hose Routing section in the Appendix chapter. When installing the fuelhoses, avoidsharp bending, kink-

•

ing, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed. Replace the hose if it has been sharply bent or kinked.

2-14 PERIODIC MAINTENANCE

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Periodic Maintenance Procedures

Fuel Hoses R eplacement

Tilt up the cargo bed.

•

Slide out the plate clamps [A].

•

Removethe hoses [B](seeExploded View inFuelSystem

•

chapter). When installing, route the hoses according to Cable,

•

Wire, and Hose Routing section in the Appendix chapter. Wheninstalling the fuel hoses, avoidsharp bending, kink-

•

ing, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.

Fit the fuel hose [A] onto the fitting fully and install the

•

plate clamp [B] beyond the raised rib [C].

1 ∼ 2 mm (0.0039 ∼ 0.0078 in.) [D]

The hose end must reach the filler [E] or be as near as

○

possible to the step [F].

Bleed the air from the fuel filter (see Next Section).

•

Air Cleaner Eleme n t Cleaning

Unlock the clamps [A].

•

Remove:

•

Air Cleaner Cover [B]

Remove:

•

Element [A]

Clean the element by tapping gently with the handle end

•

of a screwdriver. If the element is very dirty or damaged, replace the element. Carefully clean out the air cleaner cover.

•

Periodic Maintenance Procedures

Property of www.SmallEngineDiscount.com - Not for Resale

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).

PERIODIC MAINTENANCE 2-15

Air C leaner Hou s ing Dust and/or Water Inspection

Push open the drain tube [A] on the bottom of the air

•

cleaner housing.

Cooling System

Radiator Cleaning

CAUTION

Clean the radiator screen and the radiator in accordance with the Periodic Maintenance Chart. In dusty areas, they should be cleaned more frequently than the recommended interval. After riding through muddy terrains, the radiator screen and the radiator should be cleaned immediately.

Remove:

•

Front Fender Front Cover Radiator Screen Mounting Bolts [A] Radiator Screen [B]

Clean the radiator screen in a bath of tapwater, and then

•

dry it with compressed air or by shaking it.

2-16 PERIODIC MAINTENANCE

Property of www.SmallEngineDiscount.com - Not for Resale

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 surface. Run the steam gun following the core fin direction.

Radiator Hose and Connection Inspection

The high pressure inside the radiator hose can cause

○

coolant to leak or the hose to burst if the line is not properly maintained. Visually inspect the hoses [A] for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks or bulges are noticed. Check that the hoses are securely connected and clamps

•

are tightened correctly.

Coolant Draining

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wash away any coolant that spills on the frame, engine, or wheels. Since coolant is harmful to the humanbody, do not use for drinking.

Pull off the reservoir tank hose [A] and pour the coolant

•

into a container. Remove:

•

Radiator Cap [B]

Remove the radiator cap in two steps. First turn the cap

○

counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.

Remove:

•

Coolant Drain Plug [A] at Front Cylinder

Place a container under the drain plug.

○

Periodic Maintenance Procedures

Property of www.SmallEngineDiscount.com - Not for Resale

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

Place a container under the drain plugs.

○

PERIODIC MAINTENANCE 2-17

Coolant Filling

Tighten the drain plugs.

•

Torque - Coolant Drain Plugs (Cylinder): 17 N·m (1.7 kgf·m,

12 ft·lb)

Remove:

•

Radiator Cap Air Bleeder Bolts [A]

Pour the coolant slowly so that the air in the engine and

•

radiator can escape.

NOTE

Pour in the coolant slowly so that the air in the engine

○

and radiator can escape.

CAUTION

Soft or distilled water must be used with antifreeze (see Specifications in this chapter) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, considerably reducing the efficiency of the cooling system.

Water and Coolant Mixture Ratio (Recommended)

Soft Water Coolant Freezing Point Total Amount

50%

–35°C (–31°F)

4.6 L (4.9 US qt)

NOTE

Choose a suitable mixture ratio by referring to the

○

coolant manufacture’s directions.

When the coolant begins to flow out the air bleeder bolt

•

holes, tighten the air bleeder bolts.

2-18 PERIODIC MAINTENANCE

Property of www.SmallEngineDiscount.com - Not for Resale

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 withcoolant.

•

Bleed the air from the cooling system as follows.

•

Start the engine and run it until no more air bubbles can

○

be seen in the coolant in the reservoir tank (less than five minutes). Tap the radiator hoses to force any air bubbles caught

○

inside. Stop the engine andfill thereservoir tank up to theF (Full)

○

mark with coolant.

CAUTION

Do not add more coolant above the F (Full) mark.

Install the reservoir tank cap.

•

Coolant Filter Inspection

Visually inspect the coolant filter [A].

•

If the filter is cleaner with no signs of dirt or other contamination, it is OK and need not be replaced. If the filter is dark or looks dirty, replace it. Also, check the rest of the cooling system for contamination.

Converter System

Drive Belt Inspection

Measure the width [A] of the belt.

•

If any measurements exceed the servicelimit, replace the belt.

Belt Width

Standard: 30.3 mm (1.19 in.) Service Limit: 28.8 mm (1.13 in .)

Periodic Maintenance Procedures

Property of www.SmallEngineDiscount.com - Not for Resale

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.

Converter Driven Pulley Shoe Inspection

Remove the driven pulley (see Drive and Driven Pulley

•

Removal in the Converter System chapter). Disassembly the driven pulley.

•

If the ramps [A] or the wear shoes [B] are damaged or worn, replace the ramp or the shoes.

PERIODIC MAINTENANCE 2-19

If the wear shoe contact area width [A] is greater than the service limit, replace the shoe [B].

Wear Shoe Width

Service Limit: 16.3 mm (0.64 in.)

Air Cleaner Element Cleaning/Inspection

NOTE

In dusty areas, the element should be cleaned more

○

frequently than the recommended interval. Afterriding throughrain or onmuddy roads, the element

○

should be cleaned immediately.

WARNING

Clean the element in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean element.

2-20 PERIODIC MAINTENANCE

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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 it.

CAUTION

Do not use compressed air to clean the paper element. Do not oil the paper element.

Converter Dust or Water Draining

Unscrew the clamp screw [A] and remove the drain hose

•

[B] on the bottom of the converter housing to expel dust and/or water accumulated inside.

Engine Top End

Valve Clearance Inspection

NOTE

Valve clearance must be checked when the engine is

○

cold (at room temperature).

Remove:

•

Alternator Cover [A]

Remove:

•

Cylinder Head Covers [A] Spark Plugs

Periodic Maintenance Procedures

Property of www.SmallEngineDiscount.com - Not for Resale

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.

NOTE

The mark "1" is for the No. 1 cylinder, and "2" is for the

○

No. 2 cylinder.

PERIODIC MAINTENANCE 2-21

Usingathickness gauge[A],measure the valveclearance

•

between the rocker arm and the valve stem. If the valve clearance is incorrect, adjust it.

Valve Clearance (when cold)

Standard: 0.25 mm (0.010 in.)

Valve Clearance Adjustment

Loosen the valve adjusting screw locknut [A].

•

Turn the valve adjusting screw [B] until the correct clear-

•

ance is obtained. Holding the adjusting screw with the holder [C], tighten

•

the locknut.

Special Tool - Valve Adjusting Screw Holder: 57001-1217 Torque - Valve Adjusting Screw Locknut: 9.8 N·m (1.0

kgf·m, 87 in·lb)

2-22 PERIODIC MAINTENANCE

Property of www.SmallEngineDiscount.com - Not for Resale

Periodic Maintenance Procedures

Spark Arrester Cleaning

WARNING

To avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run during this procedure, the muffler will become hot.

Remove the drain plug [A] from the muffler [B].

•

Apply the parking brake.

•

In an open area away from combustible materials, start

•

the engine with the gear shift lever in the N (neutral) position. Raise and lower engine speed while tapping on the muf-

•

fler with a rubber mallet until the carbon particles are purged from the muffler.

WARNING

Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas can lead to carbon monoxide poisoning, asphyxiation, and death.

Stop the engine.

•

Install the drain plug.

•

Engine Lubrication

Oil and/or Filter Change

Warm up the engine so that the oil will pick up any sedi-

•

ment and drain easily. Place an oil pan beneath the engine.

•

Remove the engine oil drain plug [A], and let the oil drain

•

completely. If the oil filter is to be changed, replace it with a new one. Check the gasket at the drain plug for damage.

•

Replace the gasket with a new one if it is damaged. After the oil has completely drained out, install the drain

•

plug with the gasket.

Torque - Engine Oil Drain Plug: 22 N·m (2.2 kgf·m, 16 ft·lb)

Fill the engine with a good quality motor oil as specified

•

in the table. Check the oil level.

•

Engine Oil

Grade: API SF or SG

API SH or SJ with JASO MA Viscosity: Capacity: 1.5 L (1.6 US qt) (when filteris not removed)

Oil level:

SAE 10W-40

1.8 L (1.9 US qt) (when filter is removed)

BetweenFandLlinesondipstick

Periodic Maintenance Procedures

Property of www.SmallEngineDiscount.com - Not for Resale

NOTE

Depending on the atmospheric temperature of your rid-

○

ing area, the engine oil viscosity should be changed according to the chart:

Oil Filter Removal

Tilt up the cargo bed.

•

Remove the oil filter [A].

•

When unscrewing the oil filter, cover thefilter bottom with

○

a clean cloth so as not to spill the engine oil out of the filter. Any split oil should be wiped up completely.

PERIODIC MAINTENANCE 2-23

Use the oil filter wrench [A] if the oil filter is tight.

○

Special Tool - Oil Filter Wrench: 57001-1249

Oil Filter Installation

Apply engine oil:

•

Oil Filter Gasket

Install the new filter.

•

Screwthe filter inuntilthe gasket touchestheengine, then

○

turn it 3/4 turn. Add the engine oil (see Oil Level Inspection).

•

Thoroughly warm up the engine, and check the oil leak-

•

age and the oil level. If necessary, add more engine oil.

2-24 PERIODIC MAINTENANCE

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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.

•

Remove the transmission oil drain plug [A], andlet the oil

•

drain completely. Check the gasket at the drain plug for damage.

•

Replace the gasket with a new one if it is damaged. After the oil has completely drained out, install the drain

•

plug with the gasket.

Torque - Transmission Oil Drain Plug: 15 N·m (1.5 kgf·m,

11 ft·lb)

Fill the transmission case with a good quality oil as spec-

•

ified in the table. Check the oil level.

•

Transmission Oil

Type: Viscosity:

Capacity: 2.5 L (2.6 US qt) Oil Level:

API "GL-5" Hypoid gear oil SAE 90: above 5°C (41°F) SAE 80: below 5°C (41°F)

Between H and L lines on dipstick

Wheels/Tires

Wheels Nuts Tightne ss Inspection

Check the tightness of all the wheel nuts.

•

If there are loose nut, first loosen by 1/2 turn, then retorque them to the specified torque.

Torque - Wheel Nuts: 137 N·m (14 kgf·m, 101 ft·lb)

Tighten the wheel nuts [1] ∼ [4] in a criss-cross pattern.

○

Periodic Maintenance Procedures

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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. Remove any foreign objects from the tread. After re-

○

moval, check for leaks with a soap and water solution. Measure the tread depth at the center of the tread with a

•

depth gauge [A]. Since the tire may wear unevenly, take measurements at several places. If any of the measurements is less than the service limit, replace the tire.

Tire Tread Depth

Standard: 13.2 mm (0.520 in.) Service Limit 3 mm (0.12 in.)

Standard Tire

Front and rear:

23 × 11.00-10 DUNLOP KT869 Tubeless

PERIODIC MAINTENANCE 2-25

Final Drive

Front Final Gear Case 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. Park the vehicle so that it is level, both side-to-side and

•

front-to-rear. Remove:

•

Front Final Gear Case Skid Plate

Place an oil pan beneath the front final gear case and

•

remove the drain plug [A].

WARNING

When draining or filling the final gear case, be careful that no oil gets on the tire or rim. Clean off any oil that inadvertently gets on them with a high-flash point solvent.

After the oil has completely drained out, i nstall the drain

•

plug with a new aluminum gasket, and tighten it.

Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb)

Fill the gear case up to the bottom of filler opening with

•

the oil specified below.

Front Final Gear Case Oil

Type:

Viscosity: Capacity: 0.4 L (0.4 US qt) Oil Level

API "GL-5 or GL-6" hypoid gear oil for LSD (Limited Slip Differential gears)

SAE 85W-140, SAE 90, or SAE 140

Filler opening level

NOTE

"GL-5 and GL-6" indicate a quality and additive rating.

○

Be sure the O-ring is in place, and tighten the filler cap.

•

Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb )

2-26 PERIODIC MAINTENANCE

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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 between 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.

WARNING

Change the fluid in the brake system completely if the fluid level is low but the type and brand of the fluid already in the reservoir are unknown.

Raise the front cargo hood (see Frame chapter).

•

Remove:

•

Rubber Cap [A]

Fill the reservoir to the upper level line [A].

•

Upper Level Line (MAX) Lower Level Line (MIN) [B]

Apply the brake forcefullyfor a fewseconds and check for

•

fluid leakage around the fittings.

WARNING

If the brake pedal has a soft or "spongy feeling" when it is applied, there might be air in the brake lines or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, have the brake system serviced immediately.

Periodic Maintenance Procedures

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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 fluidin the reservoir runs completely out any time during fluid changing, air bleeding must be done since air will have entered the line.

Remove the wheel for extra clearance.

•

Connect a clear plastic hose to the bleed valve at the

•

wheel cylinder, running the other end of the hose into a container.

NOTE

Start with the rear left or right wheel and finish with the

○

front left or right wheel.

Open the bleed valve, apply pressure to the brake pedal,

•

closethevalve whilethebrake isapplied, and thenquickly release the pedal. Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes.

1. Open bleed valve.

2. Apply brake pedal and hold it.

3. Close bleed valve.

4. Release brake pedal.

Tighten:

•

Torque - Bleed Valves: 5.9 N·m (0.60 kgf·m, 52 in·lb)

Repeat the previous step for each wheel.

•

When brake fluid changing is finished, add the fluid to the

•

upper level in the reservoir. Apply the brake forcefully for a few seconds, and check

•

for fluid leakage around the fittings.

PERIODIC MAINTENANCE 2-27

WARNING

If the brake pedal has a soft or "sponge feeling" when it is applied, there might be air in the brake line or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, bleed the air from the brake lineimmediately.

Install the removed parts.

•

Brake Pedal Free Play Adjustment

Check brake pedal free play [A].

•

Brake Pedal Free Play

Standard: 2 ∼ 10 mm (0.08 ∼ 0.39 in.)

If free play is not correct, adjust it.

2-28 PERIODIC MAINTENANCE

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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. Skidding and loss of control may result.

Brake Master Cylinder Cup and Dust Seal Replacement

Remove the master cylinder (see Master Cylinder Re-

•

moval in the Brakes chapter). Push the pistons in all the way with a screwdriver and

•

remove the piston stop bolt. Remove the retainer with the circlip pliers and remove the

•

pistons.

Special Tool - Inside Circlip Pliers: 57001-143

Remove the pistons by lightly applying compressed air to

○

where the brake pipe fits into the cylinder.

Dust Cover [A] Retainer [B] Pistons [C] Springs [D] Secondary Cup [E] Primary Cup [F] Piston Stop Bolt [G] Master Cylinder [H] Be careful of the secondary cup direction [I]

Before assembly, clean all parts including the master

•

cylinder 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 alcohol, for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the brake.

Push the pistons in all the way with a screwdriver and

•

install the piston stop bolt. Tighten:

•

Torque - Piston Stop Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Reservoir Clamp Bolt: 5.9 N·m (0.60 kgf·m, 52

in·lb)

Periodic Maintenance Procedures

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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 maintained. Bend and twist the rubber hose while examining it. Replace it if any cracks or bulges are noticed. The metal pipe will rust if the plating i s damaged.

•

Replace the pipe if it is rusted, cracked (especially check the fittings), or if the plating is badly scratched.

Brake Hose and Pipe Replacement

To remove the metal pipes [A], unscrew the nipples [B].

•

To remove the hoses [C], remove the banjo bolts [D]

•

and/or pull out the retainers [E] (see below). Immediately wipe up any brake fluid that spills.

•

CAUTION

Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.

Use a new aluminum washer for each side of the hose

•

fittings at the master cylinder.

Apply brake fluid:

Brake Pipe Nipple Threads

Tighten:

•

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf· m, 18

ft·lb)

Brake Pipe Nipples: 18 N·m (1.8 kgf·m, 13 ft·lb)

Check that the brake line has proper fluid pressure and

•

no fluid leakage.

PERIODIC MAINTENANCE 2-29

2-30 PERIODIC MAINTENANCE

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Periodic Maintenance Procedures

[A] Metal Pipes [B] Nipples [C] Hoses [E] Retainers

Brake Wear Inspection

Remove the brake drum (see Brake Drum Removal inthe

•

Brakes chapter). Measurethe inside diameterof the drumat several points.

•

If any measurement is greater than the service limit, replace the drum. If the drum is worn unevenly or scored, lightly turn the drum on a brake drum lathe or replace it. Do not turn the drum beyond the service limit.

BrakeDrumInsideDiameter

Standard: 180.000 ∼ 180.160 mm (7.0866 ∼ 7.0929

in.)

Service Limit: 180.75 mm (7.116 in.)

Measure the lining thickness at several points.

•

Brake Shoe Lining Thickness

Standard: 4.5 mm (0.18 in.) Service Limit: 1.0 mm (0.04 in.)

If any measurement is less than theservice limit,replace both shoes as a set. If the lining thickness is greater than the service limit, do the following before installing the shoes. File or sand down any high spots on the surface on the

•

lining. Use a wire brush to remove any foreign particles from the

•

lining. Wash off any oil or grease with an oilless solvent.

•

CAUTION

Do not use a solvent which willleave onoily residue or the shoes will have to be replaced.

Periodic Maintenance Procedures

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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 immediately.

Loosen the brake wheel cylinder mounting bolts [B] for cylinder removal.

Remove:

•

Brake Shoe Spring [A] Brake Shoe [B]

Push the shoe hold-down springs [C] and twist the pins

○

[D] to remove the shoes.

NOTE

Hold the brake shoes with a clean cloth to protect the

○

linings from grease or dirt.

PERIODIC MAINTENANCE 2-31

Remove the collar [E] on the rear brake panel.

•

Replace the rear wheel cylinder with a new one.

•

Set the brake s hoe clearance adjuster so that the drum

•

can be reinstalled on the panel assembly.

(Front Brake Panel)

Turn one of the wheel cylinder ends [A] while pushing it

○

in. Keep the other end [B] fromturning until both the ends of the pistons are back in the cylinder completely.

2-32 PERIODIC MAINTENANCE

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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

Apply a non-permanent locking agent:

•

Brake Panel Mounting Bolts

Apply brake fluid:

•

Brake Pipe Nipple Threads

Tighten:

•

Torque - WheelCylinderMountingBolts: 11N·m (1.1 kgf·m,

95 in·lb)

Wheel Cylinder Mounting Nuts: 7.8 N·m (0.80

kgf·m, 69 in·lb)

Brake Panel Mounting Bolts: 44 N·m (4.5 kgf·m,

33 ft·lb)

BrakePipeNipple:18N·m(1.8kgf·m,13ft·lb)

Grease [A]:

•

Brake Panel and Brake Shoe Contact Points Wheel Cylinder Piston Ends Brake Shoe Anchor Ends

Grease (rear brake only) [B]:

•

Shoe Clearance Adjuster Pivots Shoe Clearance Adjuster and Shoe Contact Points

Periodic Maintenance Procedures

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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

Standard: 8 ∼ 12 notches (clicks) at 200 N (20 kg, 44

lb)

Release the parking brake and return the lever to its rest

•

position. Loosen the locknut [A] and turn the adjusting nut [B] to

•

obtain the correct amount of lever travel. Tighten the locknut.

•

Check for brake drag and braking effectiveness.

•

WARNING

Incorrect adjustment with insufficient free play can cause brakes to overheat and drag. Skidding and loss of control may result.

PERIODIC MAINTENANCE 2-33

NOTE

If the parking brake lever travel cannot be adjusted by

○

using the adjusting nut at the lever, use the adjusters [A] at the parking brake lever and rear wheels. Do not forget to adjust boththe left and right cablesevenly,and then securely tighten the adjuster mounting nuts [B].

2-34 PERIODIC MAINTENANCE

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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 w heel left and right. Thesteering wheel free play is the amount of travel in the steering wheel, before the front wheels begin to turn.

Steering Wheel Free Play

Standard: 0 ∼ 20 mm (0 ∼ 0.79 in.)

If steering wheel free play is not correct, inspect the following:

Steering Wheel Mounting Nut (see Steering chapter) Intermediate Shaft Clamp Bolts (see Steering chapter) Steering Gear Assembly Mounting Bracket Bolts (see Steering chapter) Steering Gear Assembly Mounting Rubber Dampers Tie-rod End Nuts (see Wheels/Tires chapter) Steering Gear Preload Adjustment (see Steering chap-

ter) If the inspections above check out good but the free play is outof the specified, the steering gear assembly is damaged and should be replaced as a unit.

Steering Joint Dust Boot Inspection

Visually inspect the dust boots [A] at boththe ends of the

•

steering gear assembly.

Front [B] If there is any signs of deterioration, cracks, or damage, replace the steering gear assembly together with these boots.

Frame

Seat Belt Inspection

Check that each seat belt functions properly.

•

Push the latch plate [A] intothe buckle [B] until itclicks the

○

latch plate must slide smoothly into the buckle, the click sound shows it is securely latched. Push the red button [C] in the buckle to make sure it re-

○

lease freely. Check the belt webbing for wear, cuts or damage.

•

If any irregularities are found, replace the seat belt.

Periodic Maintenance Procedures

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Electrical System

Brake Light Switch Adjustment

Check the operation of the brake light switchby 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. To change the switch position, turn the adjusting nut [B].

Brake Light Switch Timing

Standard: ON after 10 mm (0.4 in.) of pedal travel

CAUTION

To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.

PERIODIC MAINTENANCE 2-35

Spark Plug Cleaning/Inspection

Remove the spark plug (see Electrical System chapter).

•

Clean thespark plug, preferably in a sandblasting device,

•

and then clean off any abrasive particles. The plug may also be cleaned using a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.

Spark Plug Gap Inspection

Measure the gap [A] with a wire-type thickness gauge.

•

If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

Standard: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

General Lubrication

Before lubricating each part, clean offany rustyspots with

•

rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.

2-36 PERIODIC MAINTENANCE

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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)

Greasethe propellershaft bearingusing the grease nip-

○

ple [B].

Cables: Lubricate with Rust Inhibitor.

Throttle Cable Differential Shift Cable 2WD/4WD Shift Cable

Cables: Lubricate with Motor Oil.

Parking Brake Cables

With the cable disconnect at both ends, the cable should

•

move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or ifthe cable housing is kinked[C], replace the cable.

Periodic Maintenance Procedures

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Bolts, Nuts, and Fasteners

Tightness Inspection

Checkthe tightness ofthebolts andnutslisted here. Also,

•

check to see that each cotter pin is in place and in good condition.

NOTE

Check theengine fastener tightness when the engine is

○

cold (at room temperature).

If there are loose fasteners, first loosen by 1/2 turn, then retorque them to the specifiedtorque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the basic torque table (see Torque and Locking Agent in this chapter). If cotter pins are damaged, replace them with new ones.

Nut, Bolt, and Fasteners to be checked Engine:

Engine Mounting Bolts Exhaust Pipe Holder Nuts Exhaust Pipe and Muffler Clamp Bolt Muffler Mounting Bolts Throttle Pedal Pivot Clip Fuel Tank Holder Nuts

PERIODIC MAINTENANCE 2-37

Transmission/Final Drive:

Axle Nuts and Cotter Pins Drive Shaft Bracket Mounting Nuts Transmission Shift Cable Upper End Clip Transmission Shift Lever Clamp Bolt Differential Shift Lever Pivot Clip Differential Shift Cable Upper End Clip Differential Shift Lever Mounting Nut Propeller Shaft Bearing Mounting Nuts 2WD/4WD Shift Lever Pivot Clip 2WD/4WD Shift Lever Mounting Nut Hi/Low Shift Lever Pivot Clip Hi/Low Shift Cable Upper End Clip Hi/Low Shift Lever Mounting Nut

Wheels:

Wheel Nuts

Brakes:

Master Cylinder Mounting Bolts Master Cylinder Push Rod Clevis Pin Clip Parking Brake Lever Assembly Mounting Bolts Parking Brake Cable Lower End Clevis Pin Cotter Pins Brake Pedal Pivot Shaft Cotter Pin

Suspension:

Suspension Arm Pivot Bolts Strut Mounting Nuts Strut Clamp Nuts and Cotter Pins Leaf Spring Mounting Nuts Shock Absorber Mounting Nuts

2-38 PERIODIC MAINTENANCE

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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 Screen Mounting Nuts Seat Bracket Nuts Seat Back Mounting Nuts Seat Belt Mounting Bolts Battery Holder Nuts Skid Plate Mounting Bolts Rear End Sub-frame Mounting Nuts

Fuel System

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Table of Contents

Exploded View................................... 3-2

Specifications .................................... 3-6

Throttle Pedal and Cable................... 3-7

Throttle Pedal Free Play

Inspection.................................. 3-7

Throttle Pedal Free Play

Adjustment................................ 3-7

Full Throttle Pedal Position

Adjustment................................ 3-7

Throttle Cable Installation ............ 3-7

Throttle Cable Lubrication............ 3-7

Throttle Cable Inspection............. 3-7

Governor Link Mechanism................. 3-8

Control Panel Assembly Removal 3-8 Control Panel Assembly

Installation................................. 3-8

Governor Arm and Throttle Link

Removal ................................... 3-11

Governor Arm Installation ............ 3-11

Governor Assembly Removal ...... 3-12

Governor Assembly Installation ... 3-12

Governor Assembly Inspection.... 3-12

Throttle Link Lever Installation ..... 3-13

Maximum Engine Speed

Inspection.................................. 3-13

Choke Cable...................................... 3-14

Choke Cable Free Play

Inspection.................................. 3-14

Choke Cable Free Play

Adjustment................................ 3-14

Choke Cable Installation.............. 3-14

FUEL SYSTEM 3-1

Choke Cable Lubrication .............. 3-14

Choke Cable Inspection............... 3-15

Carburetor ......................................... 3-16

Idle Speed Inspection .................. 3-16

Idle Speed Adjustment................. 3-16

Fuel System Cleanliness

Inspection.................................. 3-16

Carburetor Removal..................... 3-16

Carburetor Installation.................. 3-17

Carburetor Disassembly .............. 3-18

Carburetor Assembly................... 3-19

Carburetor Cleaning..................... 3-20

Carburetor Inspection .................. 3-20

Coolant Filter Cleaning ................ 3-21

Coolant Valve Inspection ............. 3-21

Air Cleaner......................................... 3-22

Air Cleaner Element Cleaning...... 3-22

Air Cleaner Housing Removal...... 3-22

Air Cleaner Housing Installation... 3-22 Air Cleaner Housing Dust and/or

Water Inspection....................... 3-22

Fuel Pump and Fuel Filter................. 3-23

Fuel Pump and Fuel Filter

Removal.................................... 3-23

Fuel Pump Installation ................. 3-23

Fuel Filter Installation................... 3-23

Fuel Filter Inspection.................... 3-23

Fuel Tank........................................... 3-24

Fuel Tank Removal...................... 3-24

Fuel Tank Installation................... 3-25

Fuel Tank Cleaning/Inspection..... 3-25

3-2 FUEL SYSTEM

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Exploded View

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FUEL SYSTEM 3-3

No. Fastener

Air Cleaner Housing Mounting Bolts

2 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.

N·m kgf·m ft·lb

20 2.0 14

Torque

Remarks

3-4 FUEL SYSTEM

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Exploded View

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FUEL SYSTEM 3-5

No. Fastener

Float Bowl Screws 2 Cover Mounting Bolts 2.9 0.30 26 in·lb L 3 Chamber Case Cover Bolts 4.9 0.50 43 in·lb 4 Governor Arm Mounting Nut 7.4 0.75 65 in·lb 5 Carburetor Cover Bolts 8.8 0.90 78 in·lb 6 Link Lever Mounting Bolts 8.8 0.90 78 in·lb L

AD: Apply adhesive agent.

L: Apply a non-permanent locking agent.

N·m kgf·m ft·lb

2.0 0.20 18 in·lb

Torque

Remarks

3-6 FUEL SYSTEM

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Specifications

Item Standard Service Limit

Throttle Pedal and Cable

Throttle pedal free play 5 ∼ 10 mm (0.2 ∼ 0.4 in.) –––

Governer Link Mechanism

Throttle link lever bolt/shim clearance 0.05 ∼ 0.3 mm (0.002 ∼ 0.012 in.) –––

Choke Cable

Choke cable free play 0 ∼ 1mm(0∼ 0.04 in.) –––

Carburetor

Idle speed 850 ∼ 950 r/min (rpm) ––– Carburetor specifications:

Make/type Mikuni/BW26-18 ––– Main jet Pilot jet #41.3 ––– Throttle valve #165 –––

Optional Parts:

Main Jet:

Altitude:

0 ∼ 500 m (0 ∼ 1 600 ft):

Front #90 (92063-2403) ––– Rear #92.5 (92063-2402) –––

500 ∼ 1 500 m (1 600 ∼ 4 900 ft):

Front #88.8 (92063-2413) ––– Rear #91.3 (92063-2407) –––

1 500 ∼ 2 500 m (4 900 ∼ 8 200 ft):

Front #87.5 (92063-2405) ––– Rear #90 (92063-2403) –––

2 500 ∼ 3 500 m (8 200 ∼ 11 000 ft):

Front #86.3 (92063-2363) ––– Rear #88.8 (92063-2413) –––

3 500 ∼ 4 500 m (11 000 ∼ 14 000 ft):

Front #85 (92063-2376) ––– Rear #87.5 (92063-2405) –––

Front: #90, Rear: #92.5

–––

Throttle Pedal and Cable

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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.

Full Throttle Pedal Position Adjustment

Refer to Full Throttle Pedal Position Adjustment in the

•

Periodic Maintenance chapter.

Throttle Cable Installation

Route the throttle cable correctly (see Appendix chapter).

•

Adjust:

•

Throttle Pedal Free PlayAdjustment (seePeriodic Maintenance chapter)

WARNING

Operation with incorrectly routed or improperly adjusted cable could result in an unsafe operating condition.

FUEL SYSTEM 3-7

Throttle Cable Lubrication

Whenever the throttle cable is removed, lubricate the ca-

ble as follows.

Apply a thin coating of grease to the cable upper and

•

lower ends. Lubricate the cable with a penetrating rust inhibitor

•

through a pressure cable lubber.

Throttle Cable Inspection

With the throttle 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.

3-8 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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. Drill only until the rivet head comes off. Do not drill

○

through the hole.

Remove:

•

Control Panel Assembly Mounting Bolts [A], Collars and Washers Control Panel Assembly [B]

Control Panel Assembly Installation

Install the governor arm [A] on the governor arm pivot [B].

•

Insert the bushings [A] in the holes of the governor arm

•

and throttle lever on the carburetor from upper side with click [B].

Insertthe link [A]in thehole of thebushings [B] fromupper

•

side.

Governor Link Mechanism

Property of www.SmallEngineDiscount.com - Not for Resale

FUEL SYSTEM 3-9

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. Pin

11. Front-Reverse Shift Cable

3-10 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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. Insert a suitable rod in the hole on the pivot arm, and turn

•

the pivot arm clockwise until it cannot rotate.

Install the panel comp with bolts, collars, and washers, on

•

the gear case while turning right counterclockwise. Make sure that the throttle lever onthe carburetor isin the

•

fully opened and closed position. Hook the spring for thegovernor and the spring for return.

•

Install the throttle cable to the accelerator lever on the

•

panel comp.

1. Collar

2. Washer

3. Boss on Gear Case

4. Governor Spring

5. Return Spring

6. Throttle Cable

7. Panel Comp

8. Accelerator Lever

Install the control panel assembly shroud and pop rivet

•

the shroud to the control panel assembly.

Loosen (temporally):

•

Accel Lever Stopper Screw [A] Throttle Cable Mounting Nuts [B]

Screw in the accel leverstopper screw untilthat the clear-

•

ance [C] between oblong hole of the resin rod [D] connected on the carburetor and joint-ball [E] of the throttle lever of the carburetor is about 1 mm (0.04 in.). Tighten the throttle cable mounting nuts. In this case, do

•

not extend the cable too much. Adjust:

•

Throttle Pedal Free Play Adjustment Idle Speed Adjustment

Governor Link Mechanism

Property of www.SmallEngineDiscount.com - Not for Resale

Governor Arm and Throttle Lin k Removal

Remove:

•

Cargo Bed Control Panel Assembly Shroud Carburetor Cover Bolts [A] Carburetor Cover [B]

Remove:

•

Throttle Link [A] Governer Arm [B]

FUEL SYSTEM 3-11

Governor Arm Installation

Adjust the governor arm on the shaft.

•

Loosen the nut [A].

○

Turn the governor shaft [B] clockwise as far as possible

○

and hold it there. Turn the governor arm [C] clockwise as far as possible

○

(to make it fully openthe throttle valve), hold itthere, and tighten the nut.

Check that the governor arm [A] and the accel lever pin

•

[B] fit together or there is a slight clearance between the governor arm and the accel lever pin, when the throttle lever is fully opened.

Tighten:

•

Torque - Carburetor Cover Bolts: 8.8 N·m (0.90 kgf·m, 78

in·lb)

3-12 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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.

CAUTION

Do not remove the governor assembly unless it is necessary. Once it has been removed, it must be replaced.

Remove the washer.

•

Governor Assembly Installation

Fitthe sleeveinto the governorassembly,and install them

•

as a set.

NOTE

The sleeve and the governor assembly cannot be in-

○

stalled separately. Push the set onto the shaft until the step fits into the

○

groove securely.

Sleeve [A] Governor Assembly [B] Step [C] Washer [D] Groove [E] Shaft [F] 32 mm (1.26 in.) [G]

Check that the gear turns freely and the weights move

•

smoothly.

Governor Assembly Inspection

Visually check the governor assemblyfor wearand dam-

•

age. If any part is worn or damaged, replace the assembly.

Governor Link Mechanism

Property of www.SmallEngineDiscount.com - Not for Resale

Throttle Link Lever Installation

Measure the clearance [A] between the seating surface

•

of the bolt head and shims.

Throttle Link Lever Bolt/Shim Clearance

Standard: 0.05 ∼ 0.3 mm (0.002 ∼ 0.012 in.)

If the clearance is not within the specified range, adjust the clearance by adding or removing the shims.

[B] Throttle Link Lever Bolt [C] Shims [D] Washers [E] Throttle Link Lever [F] Intake Pipe

Shims

Part No. Thickness 92180-2055 92180-2056 92180-2057 92180-2060 92180-2061

Apply a non-permanent locking agent:

•

Link Lever Mounting Bolt

Tighten:

•

Torque - Link Lever Mounting Bolt: 8.8 N·m (0.90 kgf·m, 78

in·lb)

0.5 mm (0.020 in.)

0.4 mm (0.016 in.)

0.3 mm (0.012 in.)

0.6 mm (0.024 in.) Green

0.7 mm (0.028 in.)

Color

Yellow

Black

White

FUEL SYSTEM 3-13

Maximum Engine Speed Inspection

Apply the parking brake.

•

Put the shift lever in the neutral position.

•

When the throttle pedal isfully depressed, make sure that

•

the maximum engine speed is as follows.

Maximum Engine

Speed

about 3 600 rpm 39129-1011 Yellow

If the engine maximum speed is not the specified value, check the governor spring and governor control system.

Part No.

Governor Spring

Color

Free Length [A]

53.0 mm (2.09 in.)

3-14 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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 offree play at the chokeknob. Pull

○

the choke knob until the starter lever [B] on the carburetor begins to turn; the amount of choke knob travel is the amount of free play. If the free play is not correct, adjust the choke cable.

Choke Cable Free Play

Standard: 0 ∼ 1mm(0∼ 0.04 in.)

Choke Cable Free Play Adjustment

Remove:

•

Cargo Bed (tilt up)

Loosen the mounting nuts [A] and slide the adjuster [B]

•

until the cable has the proper amount of free play. Tighten the mounting nuts securely.

•

Choke Cable Installation

Route the choke cable correctly(see the Appendixchap-

•

ter). Adjust:

•

Choke Cable Free Play Adjustment

WARNING

Operation with incorrectly routed or improperly adjusted cable could result in an unsafe operating condition.

Choke Cable Lub rication

Wheneverthe choke cableis removed, lubricatethe cable

as follows.

Lubricate the cable with a penetrating rust inhibitor

•

through the pressure cable luber.

Choke Cable

Property of www.SmallEngineDiscount.com - Not for Resale

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.

FUEL SYSTEM 3-15

3-16 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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.

Carburetor Removal

WARNING

Remove:

•

Cargo Bed (tilt up) Coolant (drain) Carburetor Cover (See Governor Arm and Throttle Link Removal) Fuel Hose [A] Air Vent Tube [B] Coolant Hoses [C] Breather Hose [D] Link [E] Chamber Cover [F]

Remove:

•

Carburetor Mounting Bolts [A] Chamber Case [B]

Carburetor

Property of www.SmallEngineDiscount.com - Not for Resale

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 engine wear and possibly engine damage will occur.

Carburetor Installation

Install:

•

Pins [A] New Gasket [B] Choke Link [C] Carburetor

FUEL SYSTEM 3-17

Install:

•

Pins [A] New Gasket [B]

Install:

•

Chamber Case [A]

Carburetor Mounting Bolts [B] When installing the cover [C], note the following. Apply a non permanent locking agent:

○

Cover Mounting Bolts [D] Tighten:

○

Torque - Cover Mounting Bolts: 2.9 N·m (0.30 kgf·m, 26

in·lb)

3-18 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

Carburetor

Install:

•

Chamber Case Cover [A] Clamp [B]

Tighten:

•

Torque - Chamber Case Cover Bolts [C]: 4.9 N·m (0.50

kgf·m, 43 in·lb)

Wheninstallingthe air duct[A]to thetube[B] on thecham-

•

ber case cover, note the following. Strip off the old sealant around the tube and inside of the

○

air duct. Apply silicone sealant [C] around the tube for filling the

○

gap between the tube and duct.

Sealant - Kawasaki Bond (Silicone Sealant): 560 19-120

Torque:

○

Torque - Air Duct Clamp [D]: 0.98 N·m (0.1 0 kgf·m, 8.7 in·lb)

Install the parts removed.

•

Adjust:

•

Throttle Pedal Free Play Adjustment Choke Cable Free Play Adjustment Idle Speed Adjustment

Carburetor Disassembly

WARNING

Remove:

•

Carburetor (see Carburetor Removal) Float Bowl Screws [A] Float Bowl [B]

Carburetor

Property of www.SmallEngineDiscount.com - Not for Resale

Remove:

•

Pin [A]

Float [B]

Remove:

•

Pilot Jets [A]

FUEL SYSTEM 3-19

Remove:

•

Main Jets [A]

Carburetor Assembly

Tighten:

•

Torque - Float Bowl Screws: 2.0 N·m (0.20 kgf·m, 18 in·l b )

3-20 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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.

CAUTION

Do not use compressed air on an assembled carburetor, the float may be crushed by the pressure. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetorcleaning solutionwhich could attack these parts; instead, use a mild high flash point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.

Disassemble the carburetor.

•

Immerse all the metal parts in a carburetor cleaning solu-

•

tion. Rinse the parts in water.

•

When the parts are clean, dry them with compressed air.

•

Blow through the air and fuel passages with compressed

•

air. Assemble the carburetor.

•

Carburetor Inspection

WARNING

Turnthethrottle and chokeshafts tocheck that thethrottle

•

and choke valves move smoothly.

Throttle Valves [A]

Choke Valves [B] If the valves do not more smoothly, replace the damaged parts.

Carburetor

Property of www.SmallEngineDiscount.com - Not for Resale

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

Float height can not be adjusted.

○

FUEL SYSTEM 3-21

Check the tip [A] of the float valve needle [B]. It should be

•

smooth, without any grooves, scratches, or tears. If the tip is damaged [C], replace the valve needle. Push the rod [D] into the valve needle, and then release [E] it. If the rod does not spring out, replace the valve needle.

Coolant Filter Clean ing

Before winter season starts, clean the filter of carburetor

system.

Drain the coolant (see Cooling System chapter).

•

Remove the filter [A] from the cooling hoses [B].

•

Blow off dirt and sediment on the filter with compressed

•

air.

Coolant Valve Inspection

Drain the coolant (see Cooling System chapter).

•

Remove the coolant valve [A].

•

Inspect the coolant valve at room temperature.

•

If the valve is closed, replace the valve with a new one. To check valve opening just blow through the valve.

○

Valve Closing Temperature (for reference)

Standard: 70°C (158°F) or more at 25 kPa (0.25

kgf/cm², 3.6 psi)

3-22 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

Air Cleaner

Air Cleaner Eleme n t Cleaning

Refer to Air Cleaner Element Cleaning in the Periodic

•

Maintenance chapter.

Air Cleaner Housing Removal

Remove:

•

Air Ducts [A]

Mounting Bolts [B]

Air Cleaner Housing [C]

Air Cleaner Housing Installation

Tighten:

•

Torque - Air Cleaner Housing Mounting Bolts: 20 N·m (2.0

kgf·m, 14 ft·lb)

Wheninstallingthe air duct[A]to thetube[B] on thecham-

•

ber case cover, note the following. Strip off the old sealant around the tube and inside of the

○

air duct. Apply silicone sealant [C] around the tube for filling the

○

gap between the tube and duct.

Sealant - Kawasaki Bond (Silicone Sealant): 560 19-120

Torque:

○

Torque - Air Duct Clamp [D]: 0.98 N·m (0.1 0 kgf·m, 8.7 in·lb)

Air Cleane r Housing Dust and/or Water Inspection

Refer to Air Cleaner Housing Dust a nd/or Water Inspec-

•

tion in the Periodic Maintenance chapter.

Fuel Pump and Fuel Filter

Property of www.SmallEngineDiscount.com - Not for Resale

Fuel Pump and Fuel Filter Removal

WARNING

Remove:

•

Cargo Bed (tilt up) Fuel Hoses (disconnect) Fuel Pump [A] Fuel Filter [B]

FUEL SYSTEM 3-23

Fuel Pump Installation

Install the rubber damper [A] tothe pump so that thepro-

•

jection [B] on the damper aligns with the paint mark [C] on the pump. Connect the fuel hose from the filter to the fitting marked

•

INLET, and the hose to the carburetor to the another fitting.

Fuel Filter Installation

Install the fuel filter [A] so that the arrow [B] on it shows

•

the fuel flow from the fuel tank to the fuel pump.

Fuel Filter Inspection

Referto Fuel FilterInspectionin the PeriodicMaintenance

•

chapter.

3-24 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

Fuel Tank

Fuel Tank Removal

WARNING

Fuel is extremely flammable and can be explosive undercertain conditions. Turnthemain 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.

Remove:

•

Mounting Rivets [A]

Screws [B] Tilt up the front seat [A].

•

Remove the fuel tank cap [B].

•

Remove:

•

Mounting Rivets [C]

Screws [D]

Fuel Tank Cover [E]

Front Seat Lower Cover (Front Side) [F]

Remove:

•

Screws [A]

Front Seat Lower Cover (Rear Side) [B]

Disconnect the fuel hose [A].

•

Remove the fuel tank mounting bolt [B].

•

Remove the fuel tank mounting bolts [A].

•

Fuel Tank

Property of www.SmallEngineDiscount.com - Not for Resale

Remove the fuel tank [A].

•

Fuel Tank Installation

If the rubber dampers [A] were removed, install them onto the fuel tank with an adhesive.

FUEL SYSTEM 3-25

Install the dampers on the collars, as shown.

•

Position the damper [A] so that its thicker side [B] faces

○

the front side. Position the dampers [C] so that its thicker side [D] faces

○

downward.

Fuel Tank Cleaning/Inspection

WARNING

Clean the tank in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash point solvents to clean the tank.

Remove the fuel tank and drain it.

•

Remove the fuel level gauge [A].

•

Remove the seal [A] with the fitting [B] and hose [C].

•

Pour some high flash-point solvent into the fuel tank and

•

shake the tank to remove dirt and fuel deposits. Pour the solvent out of the tank.

•

Dry the tank with compressed air.

•

Visually inspect the following for any damage.

•

Fuel Tank Cap Gasket Fuel Level Gauge Cap Fuel Hose Seal on Fuel Tank

Replace them if they are damaged.

•

3-26 FUEL SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

Fuel Tank

Push down the gasket [A] into the bottom of fuel tank cap

○

[B], and insert the flange portions [C] ofgasket to the cap threads.

COOLING SYSTEM 4-1

Property of www.SmallEngineDiscount.com - Not for Resale

Cooling System

Table of Contents

Exploded View........................................................................................................................ 4-2

Specifications ......................................................................................................................... 4-4

Sealant ................................................................................................................................... 4-5

Flow Chart.............................................................................................................................. 4-6

Coolant................................................................................................................................... 4-9

Coolant Level Inspection................................................................................................... 4-9

Coolant Draining............................................................................................................... 4-9

Coolant Filling................................................................................................................... 4-9

Pressure Testing............................................................................................................... 4-9

Water Pump............................................................................................................................ 4-10

Water Pump Removal....................................................................................................... 4-10

Water Pump Installation.................................................................................................... 4-11

Water Pump Inspection..................................................................................................... 4-12

Radiator and Radiator Fan..................................................................................................... 4-13

Radiator Removal............................................................................................................. 4-13

Radiator Inspection........................................................................................................... 4-14

Radiator Cleaning............................................................................................................. 4-14

Radiator Cap .......................................................................................................................... 4-15

Radiator Cap Inspection ................................................................................................... 4-15

Thermostat ............................................................................................................................. 4-16

Thermostat Removal......................................................................................................... 4-16

Thermostat Installation...................................................................................................... 4-16

Thermostat Inspection ...................................................................................................... 4-16

Hoses and Pipes ...................................................................................................................4-18

Hose and Pipe Installation................................................................................................ 4-18

Hose Inspection................................................................................................................ 4-18

Radiator Fan Switch, Coolant Temperature Warning Light Switch......................................... 4-19

Radiator Fan Switch, Coolant Temperature Warning Light Switch Removal.................... 4-19

Radiator Fan Switch, Coolant Temperature Warning Light Switch Installation ................. 4-19

Radiator Fan Switch, Coolant Temperature Warning Light Switch Inspection.................. 4-19

4-2 COOLING SYSTEM

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Exploded View

Property of www.SmallEngineDiscount.com - Not for Resale

COOLING SYSTEM 4-3

No. Fastener

Coolant Reservoir Mounting Bolt 2 Radiator Screen Bolts 8.8 0.90 78 in·lb 3 Radiator Mounting Bolts 8.8 0.90 78 in·lb 4

Radiator Fan Switch 5 Water Pipe Bolts 8.8 0.90 78 in·lb 6 Coolant Temperature Warning Light Switch 23 2.3 17 SS 7

Coolant Drain Plugs (Cylinder ) 8 Water Pump Cover Bolts (M6) 8.8 0.90 78 in·lb S 9 Water Pump Cover Bolts (M8) 25 2.5 18 S

S: Follow specified tightening sequence.

SS: Apply silicone sealant.

N·m kgf·m ft·lb

4.4 0.45 39 in·lb

25 2.5 18

17 1.7 12

Torque

Remarks

4-4 COOLING SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

Specifications

Item Standard Service Limit

Coolant

Type

Color Green ––– Mixed ratio Freezing point Total amount

Water Pump

Water pump shaft diameter 9.975 ∼ 9.990 mm 9.94 mm

Water pump shaft bearing inside diameter

Radiator Cap

Relief pressure 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼

Thermostat

Valve opening temperature 80.5 ∼ 83.5°C (177 ∼ 182°F) ––– Valve full opening lift 8 mm (0.3 in.) or more @95°C (203°F) –––

Permanent type of antifreeze

(Soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Soft water 50%, coolant 50% –35°C (–31°F)

4.6 L (4.9 US qt)

(0.392 ∼ 0.393 in.) (0.39 in.)

10.020 ∼ 10.038 mm 10.09 mm (0.394 ∼ 0.395 in.) (0.40 in.)

18 psi)

–––

––– ––– –––

–––

Sealant

Property of www.SmallEngineDiscount.com - Not for Resale

Kawasaki Bond (Silicone Sealant): 56019-120

COOLING SYSTEM 4-5

4-6 COOLING SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

Flow Chart

Property of www.SmallEngineDiscount.com - Not for Resale

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. Air Bleeder Bolt (Intake M anifold)

14. Cylinder Head

15. Radiator Fan Switch

COOLING SYSTEM 4-7

4-8 COOLING SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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.

Coolant

Property of www.SmallEngineDiscount.com - Not for Resale

Coolant Level Inspection

NOTE

Check the level when the engine iscold (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.

Check the coolant level in the reservoir tank [A] with the

•

vehicle held perpendicularly. If the coolant level is lower than the L (Low) [B] mark, remove the reservoir tank cap [C], then add coolant to the F (Full) [D] mark.

CAUTION

For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack thealuminum engine parts. In an emergency, soft water can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often, or the reservoirtank has run completely dry; there is probably leakage in the cooling system. Check the system for leaks.

COOLING SYSTEM 4-9

Coolant Draining

Refer to Coolant Draining in the Periodic Maintenance

•

chapter.

Coolant Filling

Referto Coolant Filling in thePeriodic Maintenancechap-

•

ter.

Pressure Testing

Remove the radiator cap, and install a cooling system

•

pressure tester [A] and adapter [B] on the radiator filler neck [C].

NOTE

Wet the cap sealing surfaces with water or coolant to

○

prevent pressure leakage.

Builduppressureinthesystemcarefullyuntilthepres-

•

sure reaches 123 kPa (1.25 kgf/cm², 18 psi).

CAUTION

During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi).

Watch the gauge for at least 6 seconds.

•

If the pressure holds steady, the system is all right. If the pressure drops soon, check for leaks.

4-10 COOLING SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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]

Remove:

•

Pin [A] Washer [B]

Remove:

•

Water Pump Impeller [A] Shaft [B] Pin [C] and O-ring [D]

Water Pump

Property of www.SmallEngineDiscount.com - Not for Resale

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 lubrication. Apply coolant to the surfaces of the rubber seal and seal-

•

ing seat [A], and press the rubber seal [B] and sealing seat into the impeller by hand until the seat bottoms out.

COOLING SYSTEM 4-11

Fit the washer tab [A] to the notch [B] of the housing.

•

Fit the drive gear notches [C] to the pin [D].

•

Installthe water pump housing turning the i mpeller so that

•

the drive gear [A] engages with the camshaft gear [B].

Tighten the water pump cover bolts in the order shown.

•

Torque - Water Pump Cover Bolts (M6): 8.8 N·m (0.90

kgf·m, 78 in·lb)

Water P ump Cover Bolt (M8): 25 N·m (2.5 kgf·m,

18 ft·lb)

4-12 COOLING SYSTEM

Property of www.SmallEngineDiscount.com - Not for Resale

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. Replace the mechanical seal [A] or O-ring [B].

Measure the diameter [A] of the water pump shaft.

•

If the shaft has worn past the service limit, replace the shaft with a new one.

Water Pump Shaft Diameter

Standard: 9.975 ∼ 9.990 mm (0.392 ∼ 0.393 in.) Service Limit: 9.94 mm (0.39 in.)

Measure the inside diameter [A] of the water pump shaft

•

bearing. If the bearing has worn past the service limit, replace the crankcase with a new one.

Water Pump Shaft Bearing Inside Diameter

Standard: 10.020 ∼ 10.038 mm (0.394 ∼ 0.395 in.) Service Limit: 10.09 mm (0.40 in.)

Radiator and Radiator Fan

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Radiator Removal

WARNING

The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.

Remove:

•

Front Cover (see Frame chapter) Coolant (drain) Water Hoses [A]

COOLING SYSTEM 4-13

Remove:

•

Water Hose [A] Radiator Fan Switch Wires [B] Fan Motor Wire Connector

Remove:

•

Radiator Mounting Bolts [A] Radiator [B]

CAUTION

Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.

4-14 COOLING SYSTEM

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Radiator and Radiator Fan

Radiator Inspection

Check the radiator core.

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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 deformed fins, replace the radiator with a new one.

Radiator Cleaning

Refer to Radiator Cleaning in the Periodic Maintenance

•

chapter.

Kawasaki MULE 3010 TRANS 4 × 4, MULE 3010 TRANS 4x4 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual