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Kawasaki MULE 3010 TRANS 4 × 4 Service Manual

Other manuals for MULE 3010 TRANS 4 × 4: Service Manual

Summary of MULE 3010 TRANS 4 × 4

  • Page 1

    Mule 3010 trans 4 × 4 utility vehicle service manual.

  • Page 3: Quick Reference Guide

    This quick reference guide will assist you in locating a desired topic or pro- cedure. •bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •refer to the sectional table of contents for the exact pages to locate th...

  • Page 5: Mule 3010 Trans 4 × 4

    Mule 3010 trans 4 × 4 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 qual...

  • Page 6

    List of abbreviations 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 bottom dead center ps horsepower btdc before top dead center psi pound(s) per square inc...

  • Page 7

    Emission control information to protect the environment in which we all live, kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the united states environmental protection agency and california air resources board. 1...

  • Page 8

    Note ○ 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 de- vices or elements of design in order to perform maintenance. 2. Tampering could include: a.M...

  • Page 9: Foreword

    Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the prope...

  • Page 11: General Information

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 12

    1-2 general information before servicing before starting to perform an inspection service or carry out a disassembly and reassembly oper- ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions ha...

  • Page 13

    General information 1-3 before servicing 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 subas...

  • Page 14

    1-4 general information before servicing tightening sequence generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can l...

  • Page 15

    General information 1-5 before servicing press for items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball bearing and needle bearing do not remove presse...

  • Page 16

    1-6 general information before servicing lubrication it is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of engine rotati...

  • Page 17

    General information 1-7 model identification kaf620-j1 left side view kaf620-j1 right side view the kaf620-k1 is a camouflage-surface-treated model and identical to the kaf620-j1, the base model, in every other aspect: controls, features, and specifications..

  • Page 18

    1-8 general information general specifications items kaf620-j1/k1 dimensions overall length 3 169 mm (124.76 in.) overall width 1 449 mm (57.05 in.) overall height 1 933 mm (76.10 in.) wheelbase 2 165 mm (85.24 in.) track: front 1 160 mm (45.67 in.) rear 1 180 mm (46.46 in.) ground clearance 177 mm ...

  • Page 19

    General information 1-9 general specifications items kaf620-j1/k1 duration 322° lubrication system forced lubrication (wet sump) engine oil: grade api sf or sg, api sh or sj with jaso ma viscosity 10w-40 capacity 1.8 l (1.9 us qt) coolant capacity 4.6 l (4.9 us qt) drive train primary reduction syst...

  • Page 20

    1-10 general information general specifications items kaf620-j1/k1 suspension: front: type macpherson strut wheel travel 100 mm (3.9 in.) rear: type de dion axle wheel travel 70 mm (2.8 in.) brake type: front and rear drum (hydraulic) parking brake type drum (mechanical internal expansion) electrica...

  • Page 21

    General information 1-11 unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 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 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 23: Periodic Maintenance

    Periodic maintenance 2-1 2 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 procedur...

  • Page 24

    2-2 periodic maintenance periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected. Frequency whichever comes first first service regular servic...

  • Page 25

    Periodic maintenance 2-3 periodic maintenance chart frequency whichever comes first first service regular service → ↓ operation every after 50 h, or 1 000 km of use every 250 h, or 5 000 km of use every 500 h, or 10 000 km of use see page chassis steering - check • • 2-34 steering and axle shaft joi...

  • Page 26

    2-4 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “remarks” column mean: l: apply a non-permanent locking agent to the threads. ...

  • Page 27

    Periodic maintenance 2-5 torque and locking agent torque fastener n·m kgf·m ft·lb remarks 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) 25 2.5 18 oil pressure switch 9.8 1.0 87 in·lb ss oil filter – – – see text ...

  • Page 28

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks 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 valve...

  • Page 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks 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 4.4 0.45 39 in·lb l screen fixing lever screw 4.4 0.4...

  • Page 30

    2-8 periodic maintenance 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 permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor ...

  • Page 31

    Periodic maintenance 2-9 specifications item standard service limit brakes brake fluid: type dot3 – – – fluid level between upper and lower level lines – – – brake pedal play 2 ∼ 10 mm (0.08 ∼ 0.39 in.) – – – brake drum inside diameter 180.000 ∼ 180.160 mm (7.0866 ∼ 7.0929 in.) 180.75 mm (7.116 in.)...

  • Page 32

    2-10 periodic maintenance special tools inside circlip pliers: 57001-143 rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 valve adjusting screw holder: 57001-1217 oil filter wrench: 57001-1249 brake drum remover: 57001-1260 brake drum pusher, m18 × 1.5: 57001-1261 brake drum holder: 57001-1325 brake ...

  • Page 33

    Periodic maintenance 2-11 periodic maintenance procedures fuel system throttle pedal free play inspection • check that the throttle pedal moves smoothly from full open to close. If the throttle pedal does not return properly, lubricate the throttle cable. • check the throttle pedal free play [a]. If...

  • Page 34

    2-12 periodic maintenance periodic maintenance procedures full throttle pedal position adjustment • loosen the locknut [a]. • screw in the throttle pedal stop bolt [b]. • depress the throttle pedal until the throttle lever on the carburetor is in the fully opened position, and keep its position. • t...

  • Page 35

    Periodic maintenance 2-13 periodic maintenance procedures fuel filter inspection • visually inspect the fuel filter [a]. If the filter is clear with no signs of dirt or other contami- nation, it is ok and need not be replaced. If the filter is dark or looks dirty, replace it. Also, check the rest of...

  • Page 36

    2-14 periodic maintenance periodic maintenance procedures fuel hoses replacement • tilt up the cargo bed. • slide out the plate clamps [a]. • remove the hoses [b] (see exploded view in fuel system chapter). • when installing, route the hoses according to cable, wire, and hose routing section in the ...

  • Page 37

    Periodic maintenance 2-15 periodic maintenance procedures • install the cover [a] and lock the clamps. ○ face the top mark [b] upward. • reset the air filter restriction gauge [a] (push [b] its reset button). Air cleaner housing dust and/or water inspection • push open the drain tube [a] on the bott...

  • Page 38

    2-16 periodic maintenance periodic maintenance procedures caution when cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. Keep the steam gun [a] away more than 0.5 m (1.6 ft) [b] from the radiator core . Hold the steam gun perpendicular to the core sur-...

  • Page 39

    Periodic maintenance 2-17 periodic maintenance procedures • remove: torque converter coolant drain plug [a] at rear cylinder ○ place a container under the drain plug. • remove: front final gear case skid plate coolant drain plugs [a] at water pipes ○ place a container under the drain plugs. Coolant ...

  • Page 40

    2-18 periodic maintenance periodic maintenance procedures • fill the cooling system up to the filler neck [a] in the radi- ator cap fitting with coolant. • install the radiator cap. • fill the reservoir tank up to the f (full) mark with coolant. • bleed the air from the cooling system as follows. ○ ...

  • Page 41

    Periodic maintenance 2-19 periodic maintenance procedures • check the belt for wear, cracks, breaks or peeling. If necessary, replace the belt with a new one. Belt [a] crack [b] broken [c] note ○ whenever the belt is replaced, inspect the drive and the driven pulleys. Converter driven pulley shoe in...

  • Page 42

    2-20 periodic maintenance periodic maintenance procedures • remove the air cleaner element, and separate the foam element [a] from the paper element [b]. • clean the foam element in a bath of a high flash-point solvent, and then dry it with compressed air or by shaking it. Caution do not use compres...

  • Page 43

    Periodic maintenance 2-21 periodic maintenance procedures • turn the alternator rotor clockwise so that the mark "1" [a] or "2" [b] on the rotor aligns with the mark [c] on the crankcase breather cover. Check both rocker arms are free. If not, turn the rotor more one turn and free both rocker arms. ...

  • Page 44

    2-22 periodic maintenance periodic maintenance procedures spark arrester cleaning warning to avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run dur- ing this procedure, the muffler will become hot. • remove the drain plug [a] from the muffler [b]. • apply the pa...

  • Page 45

    Periodic maintenance 2-23 periodic maintenance procedures note ○ depending on the atmospheric temperature of your rid- ing area, the engine oil viscosity should be changed ac- cording to the chart: oil filter removal • tilt up the cargo bed. • remove the oil filter [a]. ○ when unscrewing the oil fil...

  • Page 46

    2-24 periodic maintenance periodic maintenance procedures transmission transmission oil change • warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle. • place an oil pan beneath the transmission case. • remove the transmission oil d...

  • Page 47

    Periodic maintenance 2-25 periodic maintenance procedures tire inspection • examine the tire for damage and wear. If the tire is cut or cracked, replace it. ○ lumps or high spots on the tread or sidewalls indicate internal damage, requiring tire replacement. ○ remove any foreign objects from the tre...

  • Page 48

    2-26 periodic maintenance periodic maintenance procedures brakes brake fluid level inspection • with the vehicle on level ground, check that, through the inspection hole [a], the fluid level in the reservoir is be- tween the upper (max) and lower (min) level lines. If the fluid level is lower than t...

  • Page 49

    Periodic maintenance 2-27 periodic maintenance procedures brake fluid changing • remove the maintenance cover. • check that there is plenty of fluid in the reservoir. Note ○ the fluid level must be checked several times during the fluid changing and replenished as necessary. If the fluid in the rese...

  • Page 50

    2-28 periodic maintenance periodic maintenance procedures • loosen the locknut [a] and turn the push rod [b] to obtain the correct amount of free play. • tighten: torque - push rod locknut: 18 n·m (1.8 kgf·m, 13 ft·lb) • check for brake drag and braking effectiveness. Warning incorrect adjustment wi...

  • Page 51

    Periodic maintenance 2-29 periodic maintenance procedures brake hose and pipe inspection • the high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not properly main- tained. Bend and twist the rubber hose while examining it. Replace it if any cracks or bul...

  • Page 52

    2-30 periodic maintenance periodic maintenance procedures [a] metal pipes [b] nipples [c] hoses [e] retainers brake wear inspection • remove the brake drum (see brake drum removal in the brakes chapter). • measure the inside diameter of the drum at several points. If any measurement is greater than ...

  • Page 53

    Periodic maintenance 2-31 periodic maintenance procedures brake wheel cylinder assembly replacement • remove: brake drum (see brake drum removal) brake pipe nipple [a] ○ immediately wipe up any brake fluid that spills. Caution brake fluid quickly ruins painted surfaces; any spilled fluid should be c...

  • Page 54

    2-32 periodic maintenance periodic maintenance procedures (rear brake panel) ○ pry the ratchet lever [a] with a screwdriver [b] to reset the shoe clearance adjuster in its original position [c] • grease (amoco rykon premium grease no. 2 ep green): brake panel seating surface • apply a non-permanent ...

  • Page 55

    Periodic maintenance 2-33 periodic maintenance procedures parking brake lever travel adjustment • check parking brake lever travel [a]. ○ pull the parking brake lever [b] upward slowly all way. Count the number of notches (clicks) during lever travel. If lever travel is not correct, adjust it. Parki...

  • Page 56

    2-34 periodic maintenance periodic maintenance procedures steering steering wheel free play inspection • check steering wheel free play [a]. ○ set the front wheels straight ahead. Gently turn [b] the steering wheel left and right. The steering wheel free play is the amount of travel in the steering ...

  • Page 57

    Periodic maintenance 2-35 periodic maintenance procedures electrical system brake light switch adjustment • check the operation of the brake light switch by depress- ing the brake pedal. The brake light should go on after 10 mm (0.4 in.) of pedal travel [a]. If it does not, adjust the brake light sw...

  • Page 58

    2-36 periodic maintenance periodic maintenance procedures pivots and points: lubricate with grease. Seat brackets cargo bed mounting pins throttle pedal pivot brake pedal pivot transmission shift control lever pivot differential shift cable upper end 2wd/4wd shift lever pivot propeller shaft bearing...

  • Page 59

    Periodic maintenance 2-37 periodic maintenance procedures bolts, nuts, and fasteners tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ check the engine fastener tightness when the engine is ...

  • Page 60

    2-38 periodic maintenance periodic maintenance procedures steering: steering wheel mounting nut intermediate shaft clamp bolts tie-rod end nuts and cotter pins tie-rod end locknuts suspension arm joint nuts and cotter pins main shaft mounting bolts and nuts frame: front and rear bar mounting bolts a...

  • Page 61: Fuel System

    Fuel system 3-1 3 fuel system 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 p...

  • Page 62

    3-2 fuel system exploded view.

  • Page 63

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner housing mounting bolts 20 2.0 14 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..

  • Page 64

    3-4 fuel system exploded view.

  • Page 65

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 float bowl screws 2.0 0.20 18 in·lb 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 leve...

  • Page 66

    3-6 fuel system 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 ∼ 1 mm (0 ∼ 0.04 in...

  • Page 67

    Fuel system 3-7 throttle pedal and cable throttle pedal free play inspection • refer to throttle pedal free play inspection in the peri- odic maintenance chapter. Throttle pedal free play adjustment • refer to throttle pedal free play adjustment in the peri- odic maintenance chapter. Full throttle p...

  • Page 68

    3-8 fuel system governor link mechanism control panel assembly removal • remove: cargo bed • drill out the pop rivets [a] holding the control panel as- sembly shroud [b] with a drill bit of the 5 mm (0.02 in.) diameter. ○ drill only until the rivet head comes off. Do not drill through the hole. • re...

  • Page 69

    Fuel system 3-9 governor link mechanism 1. Governor arm 2. Pivot arm 3. Link 4. Hole 5. Turn the pivot arm. 6. Turn the governor arm. 7. Carburetor throttle full open 8. Throttle full open 9. Governor arm clamp nut 10. Pin 11. Front-reverse shift cable.

  • Page 70

    3-10 fuel system governor link mechanism • turn the bushings [a] counterclockwise until fitting on the link with click [b]. • fit the 4 bosses on the intake pipe of the engine with the carburetor cover after pass the link into the hole of the carburetor cover. • insert a suitable rod in the hole on ...

  • Page 71

    Fuel system 3-11 governor link mechanism governor arm and throttle link removal • remove: cargo bed control panel assembly shroud carburetor cover bolts [a] carburetor cover [b] • remove: throttle link [a] governer arm [b] governor arm installation • adjust the governor arm on the shaft. ○ loosen th...

  • Page 72

    3-12 fuel system governor link mechanism governor assembly removal • remove: transmission case (split) governor arm governor shaft snap pin [a] governor shaft [b] washer (thin) [c] washer (thick) [d] • remove the governor assembly [a] with the sleeve [b] by prying the gear [c] with two suitable leve...

  • Page 73

    Fuel system 3-13 governor link mechanism throttle link lever installation • measure the clearance [a] between the seating surface of the bolt head and shims. Throttle link lever bolt/shim clearance standard: 0.05 ∼ 0.3 mm (0.002 ∼ 0.012 in.) if the clearance is not within the specified range, adjust...

  • Page 74

    3-14 fuel system choke cable choke cable free play inspection • push in the choke knob all the way. • check the choke cable free play [a]. ○ determine the amount of free play at the choke knob. Pull the choke knob until the starter lever [b] on the carburetor begins to turn; the amount of choke knob...

  • Page 75

    Fuel system 3-15 choke cable choke cable inspection • with the choke cable disconnected at both ends, the ca- ble should move freely [a] within the cable housing. If the cable does not move freely after lubricating, if the cable is frayed, or if the housing is kinked, replace the cable..

  • Page 76

    3-16 fuel system carburetor idle speed inspection • refer to idle speed inspection in the periodic mainte- nance chapter. Idle speed adjustment • refer to idle speed adjustment in the periodic mainte- nance chapter. Fuel system cleanliness inspection • refer to fuel system cleanliness inspection in ...

  • Page 77

    Fuel system 3-17 carburetor • remove: carburetor [a] choke link [b] • after removing the carburetor, stuff pieces of lint-free, clean cloth into the carburetor holder and the air cleaner duct to keep dirt out of the engine and air cleaner. Caution if dirt gets through into the engine, excessive en- ...

  • Page 78

    3-18 fuel system 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) • when installing the air duct [a] to the tube [b] on the cham- ber case cover, note the following. ○ strip off the old sealant around the tube and...

  • Page 79

    Fuel system 3-19 carburetor • remove: pin [a] float [b] • remove: pilot jets [a] • remove: main jets [a] carburetor assembly • tighten: torque - float bowl screws: 2.0 n·m (0.20 kgf·m, 18 in·lb).

  • Page 80

    3-20 fuel system carburetor carburetor cleaning warning clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline...

  • Page 81

    Fuel system 3-21 carburetor • check that the gasket [a] on the float bowl is in good condition. If the gasket is not in good condition, replace it. • check the float [a] for cracks. If there are any cracks, replace the float. Note ○ float height can not be adjusted. • check the tip [a] of the float ...

  • Page 82

    3-22 fuel system air cleaner air cleaner element 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 housi...

  • Page 83

    Fuel system 3-23 fuel pump and fuel filter fuel pump and fuel filter removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this in...

  • Page 84

    3-24 fuel system fuel tank fuel tank removal warning fuel is extremely flammable and can be explosive under certain conditions. Turn the main switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. •...

  • Page 85

    Fuel system 3-25 fuel tank • remove the fuel tank [a]. Fuel tank installation if the rubber dampers [a] were removed, install them onto the fuel tank with an adhesive. • install the dampers on the collars, as shown. ○ position the damper [a] so that its thicker side [b] faces the front side. ○ posit...

  • Page 86

    3-26 fuel system fuel tank ○ push down the gasket [a] into the bottom of fuel tank cap [b], and insert the flange portions [c] of gasket to the cap threads..

  • Page 87: Cooling System

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 specifications ................................................................................................

  • Page 88

    4-2 cooling system exploded view.

  • Page 89

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coolant reservoir mounting bolt 4.4 0.45 39 in·lb 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 25 2.5 18 5 water pipe bolts 8.8 0.90 78 in·lb 6 coolant temper...

  • Page 90

    4-4 cooling system specifications item standard service limit coolant type permanent type of antifreeze – – – (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) color green – – – mixed ratio soft water 50%, coolant 50% – – – freezing point...

  • Page 91

    Cooling system 4-5 sealant kawasaki bond (silicone sealant): 56019-120

  • Page 92

    4-6 cooling system flow chart.

  • Page 93

    Cooling system 4-7 flow chart 1. Radiator 2. Radiator fan 3. Radiator cap 4. Reservoir tank 5. Water pump 6. Cylinder 7. Thermostat 8. Coolant temperature warning light switch 9. Air bleeder bolt (water pipe) 10. Filter 11. Carburetor 12. Thermo valve 13. Air bleeder bolt (intake manifold) 14. Cylin...

  • Page 94

    4-8 cooling system flow chart 1. Filter 2. Thermo valve 3. White mark 4. Coolant inlet 5. Coolant outlet 6. Level the tube to the inlet pipe. 7. Do not bulge the tube as a dotted line. 8. Face the projection on the valve body to the carburetor..

  • Page 95

    Cooling system 4-9 coolant coolant level inspection note ○ check the level when the engine is cold (room of ambi- ent temperature). Caution do not check the level through the coolant filler by removing the radiator cap. If the cap is removed, the coolant will flow out from the reservoir tank. • chec...

  • Page 96

    4-10 cooling system water pump water pump removal • remove: torque converter coolant (drain) water hoses [a] water pump cover bolts [b] water pump cover [c] • remove: water pump housing bolt [a] water pump housing [b] • remove: water pump drive gear [a] • remove: pin [a] washer [b] • remove: water p...

  • Page 97

    Cooling system 4-11 water pump • remove: mechanical seal [a] oil seal [b] water pump installation • clean the sliding surface of a new mechanical seal with a high-flash point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion. • apply coolant...

  • Page 98

    4-12 cooling system water pump water pump inspection • check the drainage outlet passage [a] at the bottom of the water pump body for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passages. Re- place the mechanical seal [a] or o-ring [b...

  • Page 99

    Cooling system 4-13 radiator and radiator fan radiator removal warning the radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is dis- connected. Touching the fan before the ...

  • Page 100

    4-14 cooling system radiator and radiator fan radiator inspection • check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [a] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstr...

  • Page 101

    Cooling system 4-15 radiator cap the radiator cap at the reservoir tank has the pressure relief valve, and must be inspected. The cap at the radiator has no valve. Caution do not change the positions of the radiator cap at the reservoir tank and the cap at the radiator. Radiator cap inspection • che...

  • Page 102

    4-16 cooling system thermostat thermostat removal • remove: coolant (drain) hose [a] • remove: thermostat housing cap bolts [a] thermostat housing cap [b] thermostat installation • install the thermostat [a] so that the jiggle valve [b] is on top. • adjust: coolant thermostat inspection • remove the...

  • Page 103

    Cooling system 4-17 thermostat • to check valve opening temperature, suspend the ther- mostat in a container of water and raise the temperature of the water. If the measurement is out of the specified range, replace the thermostat. Thermostat valve opening temperature standard: 80.5 ∼ 83.5°c (177 ∼ ...

  • Page 104

    4-18 cooling system hoses and pipes hose and pipe installation • install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • install the clamps [a] as near as possible to the hose end to clear the raised rib or the fit...

  • Page 105

    Cooling system 4-19 radiator fan switch, coolant temperature warning light switch radiator fan switch, coolant temperature warning light switch removal caution the fan switch or the coolant temperature warning light switch should never be allowed to fall on a hard surface. Such a shock to their part...

  • Page 107: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view........................................................................................................................ 5-2 specifications ................................................................................................

  • Page 108

    5-2 engine top end exploded view.

  • Page 109

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 intake pipe bolts 8.8 0.90 78 in·lb l (2) 2 valve adjusting screw locknuts 9.8 1.0 87 in·lb 3 cylinder head bolts 22 2.2 16 s 4 coolant temperature warning light switch 23 2.3 17 ss l: apply a non-permanent locking agent....

  • Page 110

    5-4 engine top end specifications item standard service limit cylinder head cylinder compression (usable range) 1 000 ∼ 1 520 kpa (10.2 ∼ 15.5 kgf/cm², 145 ∼ 220 psi) @490 r/min (rpm) – – – cylinder head warp – – – 0.03 mm (0.001 in.) valves valve clearance (when cold) 0.25 mm (0.010 in.) – – – valv...

  • Page 111

    Engine top end 5-5 special tools outside circlip pliers: 57001-144 valve seat cutter, 45° - 35: 57001-1116 valve seat cutter, 32° - 30: 57001-1120 valve seat cutter holder bar: 57001-1128 valve seat cutter, 45° - 30: 57001-1187 valve seat cutter, 32° - 33: 57001-1199 valve adjusting screw holder: 57...

  • Page 112

    5-6 engine top end cylinder head cylinder compression measurement • tilt up the cargo bed. • thoroughly warm up the engine so that the engine oil be- tween the piston and the cylinder wall will help seal com- pression as it does during normal running. • stop the engine, remove the spark plugs, and a...

  • Page 113

    Engine top end 5-7 cylinder head • remove: choke cable bracket bolt [a] choke cable bracket [b] breather hose [c] coolant hose [d] • remove: bands [a] intake manifold bolts [b] intake manifold [c] muffler and exhaust pipe alternator cover [d] • remove: hoses [a] coolant temperature warning light swi...

  • Page 114

    5-8 engine top end cylinder head • remove: cylinder head bolts [a] cylinder head [b] cylinder head gasket rocker arm push rods cylinder head installation • clean the mating surface of the cylinder head and the cylinder. • replace the gasket with a new one. • check to see that the cylinder head knock...

  • Page 115

    Engine top end 5-9 cylinder head • tighten the cylinder head bolts in the order shown. Torque - cylinder head bolts: 22 n·m (2.2 kgf·m, 16 ft·lb) • tighten the intake manifold bolts in the order shown. • adjust: valve clearance adjustment • route the electric wires [a], and tighten the bands [b] as ...

  • Page 116

    5-10 engine top end cylinder head • remove: valve spring retainers [a] split keepers [b] valve springs valves ○ press down the valve spring retainer holding the valve head, and remove the split keepers. • remove: oil seals [a] spring seats [b] • check to see that the valve moves smoothly up and down...

  • Page 117

    Engine top end 5-11 valves valve clearance inspection • refer to valve clearance inspection in the periodic main- tenance chapter valve clearance adjustment • refer to valve clearance adjustment in the periodic maintenance chapter valve seat inspection • remove the valve. • check the valve seating s...

  • Page 118

    5-12 engine top end valves seat cutter operating cares 1. The valve seat cutter [a] is designed only for valve seat repair. Therefore the cutter must not be used for other purposes. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil...

  • Page 119

    Engine top end 5-13 valves operating procedures • clean the seat area carefully. • coat the seat with machinist’s dye. • fit a 45° cutter to the holder and slide it into the valve guide. • press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth. ...

  • Page 120

    5-14 engine top end valves.

  • Page 121

    Engine top end 5-15 valves valve spring free length • measure the valve spring free length. If the free length is less than the service limit, replace the valve spring with a new one. Valve spring free length standard: 34.3 mm (1.35 in.) service limit: 32.6 mm (1.28 in.) valve head thickness • measu...

  • Page 122

    5-16 engine top end valves valve guide inside diameter • measure the inside diameter [a] of the valve guide. If the valve guide has worn past the service limit, replace the cylinder head. Valve guide inside diameter standard: 6.000 ∼ 6.015 mm (0.2362 ∼ 0.2368 in.) service limit: 6.08 mm (0.239 in.) ...

  • Page 123

    Engine top end 5-17 valves • measure the inside diameter [a] of the rocker arm. If the bearing has worn past the service limit, replace the rocker arm with a new one. Rocker arm inside diameter standard: 12.006 ∼ 12.024 mm (0.4727 ∼ 0.4734 in.) service limit: 12.05 mm (0.474 in.) rocker arm push rod...

  • Page 124

    5-18 engine top end exhaust pipe and muffler exhaust pipe removal • remove: exhaust pipe cover screws [a] exhaust pipe cover [b] • remove: exhaust pipe holder nuts [a] exhaust pipe clamp bolts [b] exhaust pipes [c] muffler removal • remove: exhaust pipe clamp bolts [a] muffler mounting bolts [b] muf...

  • Page 125

    Engine top end 5-19 exhaust pipe and muffler exhaust pipe and muffler inspection • before removing, check for signs of leakage at the ex- haust pipe gasket in the cylinder head and at the muffler clamp. If there are signs of leakage around the exhaust pipe gas- ket, it should be replaced. If the muf...

  • Page 127: Converter System

    Converter system 6-1 6 converter system table of contents exploded view........................................................................................................................ 6-2 specifications ............................................................................................

  • Page 128

    6-2 converter system exploded view.

  • Page 129

    Converter system 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 driven pulley bolt 93 9.5 69 l 2 wear shoe mounting screws 1.1 0.11 10 in·lb 3 drive pulley bolt (new) 76 7.7 56 r 4 cooling fan cover bolts 8.8 0.90 78 in·lb 5 drive pulley cover bolts 13 1.3 113 in·lb 6 spider 275 28 ...

  • Page 130

    6-4 converter system exploded view.

  • Page 131

    Converter system 6-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 converter cover botls 1.5 0.15 13 in·lb 2. Fit the joint location of the seal with the top of the case. 3. Fit the seal into groove of the case. Do not twist the seal..

  • Page 132

    6-6 converter system specifications item standard service limit drive belt belt deflection 28 ∼ 33 mm (1.1 ∼ 1.3 in.) – – – belt width 30.3 mm (1.19 in.) 28.8 mm (1.13 in.) drive pulley spider wear guide clearance 0 ∼ 0.4 mm (0 ∼ 0.16 in.) – – – cover bushing inside diameter 28.075 ∼ 28.175 mm (1.10...

  • Page 133

    Converter system 6-7 special tools outside circlip pliers: 57001-144 drive pulley wrench: 57001-1411 drive & driven pulley holder: 57001-1412 drive pulley puller bolt: 57001-1429 driven pulley holder: 57001-1465.

  • Page 134

    6-8 converter system air cleaner air cleaner housing removal • loosen: clamps [a] • remove: air duct [b] bracket bolt [c], collar and nut air cleaner housing [d] • after removing the housing, stuff pieces of lint-free, clean cloth into the torque converter cover duct to keep dirt out of the torque c...

  • Page 135

    Converter system 6-9 torque converter torque converter removal • remove: left rear shock absorber [a] (see suspension chapter) air cleaner housing for torque converter (see air cleaner housing removal) exhaust pipe (see engine top end chapter) outer cover bolts torque converter cover [b] • remove: c...

  • Page 136

    6-10 converter system torque converter torque converter installation • clean the following portions with an oil-less cleaning fluid such as trichloroethylene or acetone. Fixed sheave tapered portion [a] crankshaft tapered portion [b] warning these cleaning fluids are usually highly flammable and har...

  • Page 137

    Converter system 6-11 torque converter when installing the new trim seal [a], install it according to the following procedure. ○ fit the joint [b] of the trim seal with the top of the case [c]. ○ fit the seal into the groove of the case. Note ○ do not twist the trim seal. • tighten: torque - convert...

  • Page 138

    6-12 converter system drive belt drive belt removal • remove the torque converter cover (see torque con- verter removal). • pull the parking brake lever up and to the rear to apply the parking brake. Warning wear gloves to protect your hands from sharp edges during the following steps. Note ○ before...

  • Page 139

    Converter system 6-13 drive belt drive belt deflection inspection • remove the torque converter cover (see torque con- verter removal). • put the transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley. • measure the b...

  • Page 140

    6-14 converter system drive pulley drive pulley disassembly • hold the drive pulley with the drive & driven pulley holder [a] in a vise. Special tool - drive & driven pulley holder: 57001-1412 ○ mount the pulley holder base plate chamfered side up in a vise, with the short guide (l = 41 mm) (1.614 i...

  • Page 141

    Converter system 6-15 drive pulley drive pulley assembly • install the ramp weight [a] as shown. • tighten: torque - ramp weight nuts [b]: 6.9 n·m (0.70 kgf·m, 61 in·lb) • check the ramp weights swing smoothly. • install: roller [a] spacers [b] pin [c] ○ press in the pin as shown, so that the pin en...

  • Page 142

    6-16 converter system drive pulley • tighten: special tool - drive pulley wrench [a]: 57001-1411 torque - spider: 275 n·m (28 kgf·m, 203 ft·lb) • put the spring [a] in the groove of the spider. • align the arrows [b] on the drive pulley cover and spider. • tighten: torque - drive pulley cover bolts:...

  • Page 143

    Converter system 6-17 drive pulley • replace any sheave which has uneven wear on the belt contacting surface. [a] sheave surface [b] straight edge if the guide bushings are damaged or worn, replace them. Cover bushing inside diameter [a] standard: 28.075 ∼ 28.175 mm (1.105 ∼ 1.109 in.) service limit...

  • Page 144

    6-18 converter system drive pulley if the spring is damaged, replace the spring. Spring free length [a] standard: 65.02 mm (2.56 in.) bushing installation • press the cover bushing [a] into the cover [b] with a suit- able driver until it stops at the shoulder in the hole. • press the sheave bushing ...

  • Page 145

    Converter system 6-19 driven pulley driven pulley disassembly • hold the driven pulley [a] with the drive & driven pulley holder and driven pulley holder in a vise. Special tools - drive & driven pulley holder: 57001-1412 driven pulley holder: 57001-1465 ○ install: base plate [b] stopper pins [c] gu...

  • Page 146

    6-20 converter system driven pulley • remove: circlip [a] spacer [b] ramp [c] spring [d] movable sheave [e] spacers [f] fixed sheave [g] • remove: screws [a] wear shoes [b] driven pulley assembly • install the wear shoe [a] on the movable sheave [b] as shown. • tighten: torque - wear shoe mounting s...

  • Page 147

    Converter system 6-21 driven pulley • install: movable sheave [a] spring [b] ○ insert the spring end into the hole “c”. Note ○ the fixed/movable sheave assembly has several differ- ent spring locations which affect shifting characteristics of the torque converter. • install the ramp [a] on the fixed...

  • Page 148

    6-22 converter system driven pulley if the splines [a] are damaged or worn, replace them. If the spring is damaged, replace the spring. Spring free length [a] standard: 112.6 mm (4.43 in.) if the tabs on the spring are misaligned or the spring coils are distorted, replace the spring. Bushing install...

  • Page 149: Engine Lubrication System

    Engine lubrication system 7-1 7 engine lubrication system table of contents exploded view........................................................................................................................ 7-2 specifications ..........................................................................

  • Page 150

    7-2 engine lubrication system exploded view.

  • Page 151

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil pressure switch 9.8 1.0 87 in·lb ss 2 engine oil drain plug (m16) 25 2.5 18 3 engine oil drain plug (m14) 22 2.2 16 4 crankcase cover bolt 25 2.5 18 g: apply grease to the wire terminal. O: apply engine oil...

  • Page 152

    7-4 engine lubrication system specifications item standard service limit engine oil and oil filter engine oil: grade api sf or sg – – – api sh or sj with jaso ma viscosity sae 10w-40 – – – capacity 1.5 l (1.6 us qt) (when filter is not removed) – – – 1.8 l (1.9 us qt) (when filter is removed) – – – ...

  • Page 153

    Engine lubrication system 7-5 special tools and sealant oil filter wrench: 57001-1249 kawasaki bond (silicone sealant): 56019-120

  • Page 154

    7-6 engine lubrication system engine oil flow chart 1. Oil screen 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil pressure switch 6. Crankshaft 7. Camshaft 8. Rocker arm.

  • Page 155

    Engine lubrication system 7-7 engine oil and oil filter warning vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Oil level inspection note ○ if the vehicle has just been used, wait severa...

  • Page 156

    7-8 engine lubrication system engine oil and oil filter • apply engine oil to the rubber seal lip [a] on the dipstick. • face the recess side [a] of the dipstick upward, and insert it. Caution do not insert the dipstick except the specified di- rection. This can damage the plate of the dipstick gaug...

  • Page 157

    Engine lubrication system 7-9 engine oil and oil filter if the oil level is too high, remove the excess oil, using a syringe or some other suitable device, or removing the engine oil drain plug, drain the excess oil. If the oil level is too low, add the correct amount of oil through the oil filler o...

  • Page 158

    7-10 engine lubrication system oil pump and relief valve oil pump and relief valve removal • remove: engine crankcase cover oil pump cover bolts [a] oil pump gear [b] and oil pump cover [c] oil pump inner rotor [d] oil pump outer rotor [e] relief valve spring [f] steel ball [g] oil pump and relief v...

  • Page 159

    Engine lubrication system 7-11 oil pump and relief valve • visually inspect the relief valve spring [a], and steel ball [b]. If any rough spots are found during the above inspection, wash the valve clean with a high flash-point solvent and blow out any foreign particles that may be in the valve with...

  • Page 160

    7-12 engine lubrication system oil pump and relief valve inner rotor shaft bearing inside diameter [a] standard: 11.000 ∼ 11.011 mm (0.4331 ∼ 0.4335 in.) service limit: 11.07 mm (0.436 in.) outer rotor housing inside diameter [b] standard: 40.680 ∼ 40.701 mm (1.6016 ∼ 1.6024 in.) service limit: 40.8...

  • Page 161

    Engine lubrication system 7-13 oil screen oil screen removal • remove: engine crankcase cover oil screen cover screws [a] oil screen cover [b] • remove: oil screen [a] oil screen installation • clean the oil screen thoroughly whenever it is removed. Oil screen cleaning/inspection • clean the oil scr...

  • Page 162

    7-14 engine lubrication system oil pressure switch oil pressure switch removal • remove: engine oil (drain, see engine oil change) switch wire terminal [a] oil pressure switch [b] oil pressure switch installation • apply silicone sealant to the threads of the oil pressure switch and tighten it. Seal...

  • Page 163: Engine Removal/installation

    Engine removal/installation 8-1 8 engine removal/installation table of contents exploded view........................................................................................................................ 8-2 engine removal/installation .........................................................

  • Page 164

    8-2 engine removal/installation exploded view.

  • Page 165

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine positioning plate bolts 20 2.0 14.

  • Page 166

    8-4 engine removal/installation engine removal/installation engine removal • disconnect: battery terminal wires (see electrical system chapter) • remove: engine oil (drain) coolant (drain) cargo bed (see frame chapter) exhaust pipe (see engine top end chapter) torque converter and case (see torque c...

  • Page 167

    Engine removal/installation 8-5 engine removal/installation engine installation • adjust the engine mounting position for alignment of the torque converter. ○ mount the engine and install the engine mounting bolts loosely. ○ install the engine positioning plate [a] onto the transmis- sion case and c...

  • Page 169: Engine Bottom End

    Engine bottom end 9-1 9 engine bottom end table of contents exploded view........................................................................................................................ 9-2 specifications ..........................................................................................

  • Page 170

    9-2 engine bottom end exploded view.

  • Page 171

    Engine bottom end 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 connecting rod big end cap bolts 21 2.1 15 2 oil filter stud bolt 18 1.8 13 3 crankcase cover bolts 25 2.5 18 4 coolant drain plugs (cylinder) 17 1.7 12 g: apply grease. O: apply engine oil..

  • Page 172

    9-4 engine bottom end specifications item standard service limit camshaft and tappets cam height: inlet 25.719 ∼ 25.809 mm (1.0126 ∼ 1.0161 in.) 25.62 mm (1.009 in.) exhaust 25.962 ∼ 26.052 mm (1.0221 ∼ 1.0257 in.) 25.86 mm (1.018 in.) camshaft journal diameter 15.957 ∼ 15.975 mm (0.6282 ∼ 0.6289 in...

  • Page 173

    Engine bottom end 9-5 specifications item standard service limit 34.004 ∼ 34.015 mm 34.05 mm connecting rod big end bearing inside diameter (1.3387 ∼ 1.3392 in.) (1.341 in.) crankshaft runout less than 0.02 mm (0.0008 in.) tir 0.05 mm (0.002 in.) tir crankshaft main journal diameter 33.959 ∼ 33.975 ...

  • Page 174

    9-6 engine bottom end special tools piston pin puller assembly: 57001-910 piston ring compressor grip: 57001-1095 piston ring compressor belt, 67 ∼ 79: 57001-1097.

  • Page 175

    Engine bottom end 9-7 crankcase cover crankcase cover removal • remove: engine water pump crankcase cover bolts [a] crankcase cover [b] note ○ if the crankcase cover sticks, tap lightly with a mallet on the alternator side near the knock pins. Crankcase cover installation • be sure to replace the oi...

  • Page 176

    9-8 engine bottom end camshaft and tappets camshaft removal • remove: engine cylinder heads crankcase cover camshaft [a] tappets [b] ○ turn the engine upside down to keep the tappets from catching the cam lobes. Camshaft installation • apply engine oil: tappets camshaft journals cam surfaces • align...

  • Page 177

    Engine bottom end 9-9 camshaft and tappets camshaft bearing/journal wear • measure the diameter [a] of the camshaft journals. If any journal has worn past the service limit, replace the camshaft with a new one. Camshaft journal diameter standard: 15.957 ∼ 15.975 mm (0.6282 ∼ 0.6289 in.) service limi...

  • Page 178

    9-10 engine bottom end cylinders and pistons piston removal • remove: engine cylinder heads crankcase cover camshaft • turn the crankshaft to expose the two connecting rod big end cap bolts. • remove: connecting rod big end cap bolts [a] connecting rod big end caps [b] • push the connecting rod ends...

  • Page 179

    Engine bottom end 9-11 cylinders and pistons • carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. • remove the 3-piece oil ring with your thumbs in the same manner. Piston installation • apply engine oil: piston pin piston skirt cyl...

  • Page 180

    9-12 engine bottom end cylinders and pistons • assemble the pistons onto the connecting rods as shown. ○ no. 1 cylinder piston, align the arrow on the top of the piston with "made in japan" on the connecting rod. ○ no. 2 cylinder piston, align the arrow on the top of the piston with opposite "made i...

  • Page 181

    Engine bottom end 9-13 cylinders and pistons piston ring, piston ring groove wear • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to the groove sur- faces. If not, the piston must be replaced. • with the piston rings in their grooves, make sev...

  • Page 182

    9-14 engine bottom end cylinders and pistons boring, honing when boring and honing a cylinder, note the following. ○ oversize piston requires oversize rings. Oversize piston and rings 0.50 mm (0.02 in.) oversize ○ before boring a cylinder, first measure the exact diame- ter of the oversize piston, a...

  • Page 183

    Engine bottom end 9-15 crankshaft and connecting rods connecting rod removal • remove the connecting rods during the piston removal. Connecting rod installation • install the connecting rods during the piston installation. Crankshaft removal • remove: engine cylinder head alternator rotor and stator...

  • Page 184

    9-16 engine bottom end crankshaft and connecting rods • measure the connecting rod twist. ○ with the big-end arbor [a] still on the v blocks [c], hold the connecting rod horizontally and measure the amount that the small end arbor [b] varies from being parallel with the surface plate over a 100 mm (...

  • Page 185

    Engine bottom end 9-17 crankshaft and connecting rods ○ remove the connecting rod big end cap, and measure the plastigauge width [a] to determine the bearing/crankpin clearance. Connecting rod big end bearing/crankpin clearance standard: 0.024 ∼ 0.048 mm (0.0009 ∼ 0.0019 in.) service limit: 0.08 mm ...

  • Page 186

    9-18 engine bottom end crankshaft and connecting rods crankshaft main bearing/journal wear • measure the diameter [a] of the crankshaft main journal. If the journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft main journal diameter standard: 33.959 ∼ 33.975 mm (...

  • Page 187

    Engine bottom end 9-19 breather valve breather valve removal • remove: alternator and stator breather cover bolts [a] breather cover [b] • remove: breather valve [a] breather valve installation • place the reed valve on the seat so that there is a slight gap between the valve and the seat. Mounting ...

  • Page 189: Transmission

    Transmission 10-1 10 transmission table of contents exploded view................................... 10-2 specifications .................................... 10-8 special tools and sealant ................. 10-9 transmission oil................................ 10-10 transmission oil level inspection...

  • Page 190

    10-2 transmission exploded view.

  • Page 191

    Transmission 10-3 exploded view g: apply grease..

  • Page 192

    10-4 transmission exploded view.

  • Page 193

    Transmission 10-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 shift shaft stop bolts 7.8 0.80 69 in·lb 2 differential gear housing bolts 57 5.8 42 3 shift arm positioning bolt 37 3.8 27 g: apply grease. L: apply a non-permanent locking agent. O: apply engine oil..

  • Page 194

    10-6 transmission exploded view.

  • Page 195

    Transmission 10-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 transmission case bolts 8.8 0.90 78 in·lb 2 transmission oil drain plug 15 1.5 11 3 engine positioning plate bolts 20 2.0 14 4 governor pivot arm stopper bolt 15 1.5 11 5 shift shaft lever clamp bolts 12 1.2 104 in·lb 6 hi...

  • Page 196

    10-8 transmission specifications item standard service limit transmission oil type api "gl-5" hypoid gear oil – – – viscosity sae 90: above 5°c (41°f) – – – sae 80: below 5°c (41°f) – – – capacity: 2.5 l (2.6 us qt) – – – oil level between h and l lines on dipstick – – – transmission and shift mecha...

  • Page 197

    Transmission 10-9 special tools and sealant outside circlip pliers: 57001-144 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 hexagon wrench, hex 32: 57001-1194 kawasaki bond (liquid gasket - silver): 92104-002.

  • Page 198

    10-10 transmission transmission oil caution vehicle operation with insufficient, deteriorated or contaminated transmission oil will cause acceler- ated wear and may result in transmission failure. Transmission oil level inspection note ○ if the vehicle has just been used wait several minutes for all...

  • Page 199

    Transmission 10-11 transmission case transmission case removal • remove: transmission oil (drain) cargo bed propeller shafts (see final drive chapter) torque converter case (see converter system) drive shafts and axles (see final drive chapter) neutral switch terminal lead (disconnect) transmission ...

  • Page 200

    10-12 transmission transmission case transmission case splitting • remove: cable bracket transmission case bolts [a] transmission case (left) [b] transmission case assembly • check to see that the transmission case knock pins [a] are in place. If any one of them has been removed, re- place it with a...

  • Page 201

    Transmission 10-13 transmission and shift mechanism transmission and hi/low shift cables installation • remove one side of the spring [a] from the shift shaft lever assembly. • put the shift lever [a] in the "l" (low) position. • using the shift shaft lever [b] temporarily set the shift arm [a] in f...

  • Page 202

    10-14 transmission transmission and shift mechanism • screw the joint [a] of the shift shaft lever [b] fully into the hi/low shift cable [c] end, and install the cable onto the bracket [d]. • line up the punch mark [a] on the shift arm, projection [b] on the transmission case and slit opening in the...

  • Page 203

    Transmission 10-15 transmission and shift mechanism • screw the joint [a] of the shift shaft lever [b] fully into the transmission shift cable [c] end, and install the cable onto the bracket [d]. • line up the punch mark [a] on the shift arm, projection [b] on the transmission case and slit opening ...

  • Page 204

    10-16 transmission transmission and shift mechanism shift lever position inspection • start the engine and put the shift lever in "n" (neutral) or "l" (low) position. • move the shift lever [a] slowly to the direction of the arrow on the figure. At this time, increase the engine speed slightly. • ch...

  • Page 205

    Transmission 10-17 transmission and shift mechanism transmission shift cable inspection • with the cable disconnected at both ends, the cable should move freely within the cable housing. If the cable movement is not free, if the cable is frayed, or if the housing is kinked, replace the cable. Transm...

  • Page 206

    10-18 transmission transmission and shift mechanism • remove: circlips [a] driven shaft reverse sprocket [b] driven shaft forward gear [c] driven shaft [d] special tool - outside circlip pliers: 57001-144 transmission installation • replace all circlips that were removed with new ones. Note ○ always...

  • Page 207

    Transmission 10-19 transmission and shift mechanism transmission and shift mechanism inspection • visually inspect the forward gears, reverse sprockets, gear and shaft bushings [a], drive chains, and shifter. • replace parts worn beyond the service limit. Shift arm pin diameter [a] standard: 7.95 ∼ ...

  • Page 208

    10-20 transmission hi/low gears and shift mechanism hi/low shift cable installation • see transmission and hi/low shift cables installation. Hi/low shift cable inspection • with the cable disconnected at both ends, the cable should move freely within the cable housing. If the cable movement is not f...

  • Page 209

    Transmission 10-21 hi/low gears and shift mechanism • remove: circlip [a] washer [b] low gear [c] collar special tool - outside circlip pliers: 57001-144 • remove: bolt [a] holder [b] • remove: retaining pin [a] shift shaft and arm [b] hi/low gear and shift mechanism installation • apply transmissio...

  • Page 210

    10-22 transmission hi/low gears and shift mechanism • install: reduction gear [a] high gear [b] washer [c] shifter [d] • check to see that the hi/low gear case knock pins [e] are in place on the transmission case. If any one of them has been removed, replace it with a new one. • fit the shift arm pi...

  • Page 211

    Transmission 10-23 2wd/4wd shift mechanism 2wd/4wd shift cable adjustment • put the shift lever [a] in the 2wd position. • install the 2wd/4wd shift cable [a] to the shift shaft lever [b] and cable bracket [c]. • put the shift lever [a] in the 4wd position. • turn the shift shaft lever [a] countercl...

  • Page 212

    10-24 transmission 2wd/4wd shift mechanism note ○ if the 2wd/4wd shift cable cannot be adjusted by using the adjuster at the shift shaft lever, use the adjuster [a] at the shift lever. Do not forget to tighten the adjuster nuts [b]. 2wd/4wd shift cable lubrication whenever the shift cable is removed...

  • Page 213

    Transmission 10-25 2wd/4wd shift mechanism • remove: shifter [a] circlip [b] speedometer gear [c] collar special tool - outside circlip pliers: 57001-144 2wd/4wd shift mechanism installation • apply grease: shift shaft o-ring • install the shift shaft lever [a] to the shift shaft arm [b] as shown. T...

  • Page 214

    10-26 transmission differential gears and shift mechanism differential shift cable adjustment • put the shift lever [a] in the unlock position. • set the shift shaft lever [a] in the unlock position. • loosen the adjuster nut [b] until the inner cable is slightly loosened. • tighten the adjuster nut...

  • Page 215

    Transmission 10-27 differential gears and shift mechanism differential shift mechanism installation • apply grease: shift shaft o-ring • install the shift shaft lever [a] to the shift arm [b] as shown. Torque - shift shaft stop bolt: 7.8 n·m (0.80 kgf·m, 69 in·lb) differential shift mechanism inspec...

  • Page 216

    10-28 transmission differential gears and shift mechanism • remove: differential gear housing bolts [a] final gear [b] • remove: housing cover [a] knock pin [b] side gear [c] spacer [d] • remove: knock pins [a] retaining pin [b] pinion gear shaft [c] pinion gears [d] spacers side gear [e] spacer dif...

  • Page 217

    Transmission 10-29 bearings and oil seal bearing replacement • using a press, a puller, the oil seal & bearing remover, or the bearing driver set, remove the bearings. Special tools - oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 • using the hexagon wrench [a], remove the bea...

  • Page 218

    10-30 transmission transmission sectional figure.

  • Page 219

    Transmission 10-31 transmission sectional figure.

  • Page 221: Wheels/tires

    Wheels/tires 11-1 11 wheels/tires table of contents exploded view........................................................................................................................ 11-2 specifications .................................................................................................

  • Page 222

    11-2 wheels/tires exploded view.

  • Page 223

    Wheels/tires 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 wheel nuts 137 14 101.

  • Page 224

    11-4 wheels/tires specifications item standard service limit wheel alignment caster 7.5° (non-adjustable) – – – camber 0.8° (non-adjustable) – – – toe-in 0 ∼ 20 mm (0 ∼ 0.79 in.) – – – tires standard tire: front and rear 23 × 11.00-10 dunlop kt869 tubeless – – – – – – tire air pressure (when cold): ...

  • Page 225

    Wheels/tires 11-5 wheel alignment toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance a (rear) is greater than b (front) as shown. The purpose of toe-in is to prevent the front wheels from getting out of para...

  • Page 226

    11-6 wheels/tires wheel alignment note ○ the toe-in will be near the specified range, if the length of the tie-rod distance between the dust boot end [a] of steering gear assembly and the locknut [b] is 43.5 mm (1.71 in.) [c] on both the left and right tie-rods. • check the toe-in again. • tighten: ...

  • Page 227

    Wheels/tires 11-7 wheels (rims) wheel removal • loosen the wheel nuts [a] (do not remove). • lift the wheel(s) off the ground. • remove: wheel nuts wheel(s) wheel installation • position the wheel so that the valve stem [a] is toward the outside of the vehicle. • tighten: torque - wheel nuts: 137 n·...

  • Page 228

    11-8 wheels/tires wheels (rims) • install a new air valve in the new rim. ○ remove the valve cap, lubricate the stem with a soap and water solution, and pull the stem [a] through the rim from the inside out until it snaps into place. Caution do not use engine oil or petroleum distillates to lu- bric...

  • Page 229

    Wheels/tires 11-9 tires tire removal • remove: wheel (see wheel removal) valve core (let out the air) • lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water [a]. This helps the tire beads slip off the rim flanges. Caution do not lubricate the t...

  • Page 230

    11-10 wheels/tires tires • check to see that the rim lines [a] on both sides of the tire are parallel with the rim flanges [b]. If the rim lines and the rim flanges are not parallel, deflate the tire, lubricate the sealing surfaces again, and reinflate the tire. • after the beads are properly seated...

  • Page 231: Final Drive

    Final drive 12-1 12 final drive table of contents exploded view................................... 12-2 specifications .................................... 12-6 special tools ..................................... 12-7 front final gear case ....................... 12-8 front final gear case oil level...

  • Page 232

    12-2 final drive exploded view.

  • Page 233

    Final drive 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 gear case bracket bolts 44 4.5 33 l 2 gear case mounting nuts 44 4.5 33 3 oil filler cap 29 3.0 22 4 oil drain plug 20 2.0 14 5 front axle cap bolts 8.8 0.90 78 in·lb 6 differential case torx bolts 32 3.3 24 l 7 pinion gear...

  • Page 234

    12-4 final drive exploded view.

  • Page 235

    Final drive 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bevel gear case holder nuts 25 2.5 18 2 housing locknut 120 12 87 l 3 bearing holder 120 12 87 l 4 driven gear shaft nut 110 11 80 l 5 bevel gear case bolts 22 2.2 16 6 drive gear nut 120 12 87 mo 7 drive shaft cap bolts 20...

  • Page 236

    12-6 final drive specifications item standard service limit front final gear case gear case oil: type api "gl-5 or gl-6" hypoid gear oil for lsd (limited slip differential gears) – – – viscosity sae85w-140, sae90, or sae140 – – – capacity 0.4 l (0.4 us qt) – – – oil level filler opening level – – – ...

  • Page 237

    Final drive 12-7 special tools bearing puller: 57001-135 outside circlip pliers: 57001-144 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 pinion gear holder: 57001-1281 socket wrench: 57001-1283 pinion gear holder: 57001-1285 hexagon wrench, hex 40: 57001-1324 socket wrench: 5...

  • Page 238

    12-8 final drive front final gear case front final gear case oil level inspection • park the vehicle so that it is level, both side-to-side and front-to-rear. • remove: front final gear case skid plate bolts [a] front final gear case skid plate [b] • remove: filler cap [a] caution be careful not to ...

  • Page 239

    Final drive 12-9 front final gear case front final gear case removal • remove: front final gear case oil (drain) radiator (see cooling system chapter) propeller shafts (see propeller shaft removal) front axles (see front axle removal) front final gear case mounting bolts [a] and nuts [b] collar [c] ...

  • Page 240

    12-10 final drive front final gear case front final gear case disassembly • remove: front final gear case (see front final gear case re- moval) bearing housing nuts [a] pinion gear unit [b] • remove: spacers [a] (both sides) • remove the ring gear cover bolts, starting with the smaller bolts [b]. La...

  • Page 241

    Final drive 12-11 front final gear case • install the pinion gear unit with the ring gear side of the case facing down. • align the air vent passage [a] with the hose nipple [b]. ○ first tighten the 10 mm (0.39 in.) bolts, then tighten the 8 mm (0.31 in.) bolts. Torque - 10 mm ring gear cover bolts:...

  • Page 242

    12-12 final drive front final gear case • be sure to assemble the differential unit and inspect the clutch torque (see lsd clutch torque inspection). Tapped holes [a] for ring gear mark [b] for assembly • install the front axles [c] to center the steel plates. • apply a non-permanent locking agent: ...

  • Page 243

    Final drive 12-13 front final gear case lsd clutch plate inspection • visually inspect the friction plates and steel plates to see if they show any signs of seizure, overheating, or uneven wear. If any plates show signs of damage, or if the friction plates have worn past the service limit, replace t...

  • Page 244

    12-14 final drive front final gear case • fit the toothed washer claw [a] into the shaft. • apply molybdenum disulfide oil to the threads and seating surface of the pinion gear slotted nut, and tighten it. Torque - pinion gear slotted nut: 120 n·m (12 kgf·m, 87 ft·lb) if none of the toothed washer t...

  • Page 245

    Final drive 12-15 front final gear case bearing preload adjustment: • check and adjust the bearing preload in the following cases. ○ when any of the parts listed below are replaced with new ones. Pinion gear collar shim tapered roller bearings pinion gear bearing housing [a] oil seal collar ○ when t...

  • Page 246

    12-16 final drive front final gear case.

  • Page 247

    Final drive 12-17 front final gear case if the preload is out of the specified range, replace the collar and/or shim(s). ○ to increase preload, decrease the size of the shim(s) or collar. To decrease preload, increase the size of the shim(s) or collar. ○ change the thickness a little at a time. • re...

  • Page 248

    12-18 final drive front final gear case • move the front axle back and forth [a]. Special tool - pinion gear holder: 57001-1285 [b] dial gauge [c] bevel gear backlash standard: 0.09 ∼ 0.20 mm (0.035 ∼ 0.0079 in.) (at ring gear tooth) tooth contact adjustment • clean any dirt and oil off the bevel ge...

  • Page 249

    Final drive 12-19 front final gear case.

  • Page 250

    12-20 final drive front final gear case bevel gear inspection • visually check the bevel gears [a] for scoring, chipping, or other damage. Replace the bevel gears as a set if either gear is dam- aged. Differential gear inspection • visually check the differential gears [a] for scoring, chip- ping, o...

  • Page 251

    Final drive 12-21 bevel gear case bevel gear case removal • remove: transmission oil (drain) cargo bed (see frame chapter) propeller shafts (see propeller shaft removal) bevel gear case bolts [a] bevel gear case [b] bevel gear case installation • check and adjust the bevel gear backlash and tooth co...

  • Page 252

    12-22 final drive bevel gear case • remove: housing locknut bearing housing [a] special tools - pinion gear holder: 57001-1281 [c] socket wrench: 57001-1363 [b] • remove: driven gear shaft nut [a] special tool - pinion gear holder: 57001-1281 [b] ○ pressing the spring seat [c], remove the driven gea...

  • Page 253

    Final drive 12-23 bevel gear case drive bevel gear removal • remove: hi/low gear case drive gear nut [a] special tool - transmission gear holder [b]: 57001-1364 • remove: drive gear [a] drive gear shim(s) [b] drive gear shaft [c] drive bevel gear installation • check and adjust the bevel gear backla...

  • Page 254

    12-24 final drive bevel gear case • set up a dial gauge [a] against one of the grooves in the locknut [b]. • to measure the backlash, turn the shaft clockwise and counterclockwise while holding the drive bevel gear steady. The difference between the highest and lowest gauge readings is the amount of...

  • Page 255

    Final drive 12-25 bevel gear case tooth contact adjustment • clean any dirt and oil off the bevel gear teeth. • apply checking compound to 4 or 5 teeth on the driven bevel gear. Note ○ apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, ...

  • Page 256

    12-26 final drive bevel gear case incorrect tooth contact patterns example 1: increase the thickness of the drive bevel gear shim(s) by 0.05 mm (0.002 in.), and/or increase the thick- ness of the driven bevel gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown below. Repeat in 0.05 mm (...

  • Page 257

    Final drive 12-27 bevel gear case bevel gear inspection • visually check the bevel gears [a] for scoring, chipping, or other damage. Replace the bevel gears as a set if either gear is dam- aged. Ball bearing inspection • since the ball bearings are made to extremely close toler- ances, the wear must...

  • Page 258

    12-28 final drive propeller shafts propeller shaft removal • remove: fuel tank (see fuel system chapter) plate screws [a] plate [b] • remove: water pipe bracket bolts [a] • remove: propeller shaft bearing housing mounting bolts [a] and nuts • move the water pipe [a] and the propeller shaft bearing h...

  • Page 259

    Final drive 12-29 propeller shafts propeller shaft installation • wipe the old grease off the splines of the propeller shafts, and grease to them. • inspect the propeller shafts. • apply grease to the o-ring [a] on the front pinion gear. • install the front propeller shaft [b] on the front pinion ge...

  • Page 260

    12-30 final drive propeller shafts propeller shaft inspection • visually inspect the splines of the propeller shafts. If they are twisted, badly worn, or chipped, replace the shafts. • check that the universal joint works smoothly without rat- tling or sticking. If it does not, the bearings of the j...

  • Page 261

    Final drive 12-31 drive shaft and axles front axle removal • remove: steering knuckle (see steering chapter) radiator side cover front axle cap bolts [a] front axle [b] front axle installation • wipe the old grease off the splines of the axle and cap oil seal, and grease them. • inspect the axle. • ...

  • Page 262

    12-32 final drive drive shaft and axles • remove: drive shaft cap bolts [a] drive shaft [b] and cap [c] ○ set the differential shift lever into the un-lock position. Rear drive shaft and axle installation • wipe the old grease off the splines of the drive shafts, axles, and cap oil seals, and grease...

  • Page 263

    Final drive 12-33 drive shaft and axles dust boot inspection • visually inspect the boots [a] in accordance with the peri- odic maintenance chart or if the drive shafts or axles are noisy during operation. If the dust boot is torn, worn, deteriorated, or leaks grease, replace it. Front axle joint bo...

  • Page 264

    12-34 final drive drive shaft and axles • remove the steel balls [a] with a screwdriver [b]. • wipe the old grease. Caution do not reuse the old grease. • move the steel ball holder [c] toward the outboard joint. • remove: circlip [a] special tool - outside circlip pliers [b]: 57001-144 • remove: st...

  • Page 265

    Final drive 12-35 drive shaft and axles • check the universal joints. If any joint does not work smoothly without rattling or stick- ing, the joint bearing is damaged. Replace the axle. • visually inspect the splines on the shaft. If they are badly worn or chipped, replace the axle. • clean off the ...

  • Page 266

    12-36 final drive drive shaft and axles • install: small boot band [a] inboard boot [b] steel ball holder [c] steel ball base [d] ○ install the steel ball holder [a] as shown. ○ face the chamfered side [b] of the steel ball base [c] to the boot. [d] outboard shaft • install: circlip [a] special tool...

  • Page 267

    Final drive 12-37 drive shaft and axles • install the retaining ring [a] so that the opening [b] is aligned with one of the projections [c]. • install the inboard boot [a] on the outboard joint and shaft [b] properly as shown. [c] 119 mm (4.69 in.) • clamp the small boot band [d] and bend the tang s...

  • Page 268

    12-38 final drive drive shaft and axles grease seal inspection • visually inspect the grease seals. Replace if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been oth- erwise damage..

  • Page 269: Brakes

    Brakes 13-1 13 brakes table of contents exploded view........................................................................................................................ 13-2 specifications .............................................................................................................

  • Page 270

    13-2 brakes exploded view.

  • Page 271

    Brakes 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 5.9 0.60 52 in·lb 2 wheel cylinder mounting bolts 11 1.1 95 in·lb 3 brake panel mounting bolts 44 4.5 33 l 4 front axle nuts 200 20 140 5 brake pipe nipples 18 1.8 13 f 6 brake hose banjo bolts 25 2.5 18 7 piston st...

  • Page 272

    13-4 brakes exploded view.

  • Page 273

    Brakes 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 5.9 0.60 52 in·lb 2 wheel cylinder mounting nuts 7.8 0.80 69 in·lb 3 brake panel mounting bolts 44 4.5 33 l 4 rear axle nuts 300 31 220 5 brake pipe nipples 18 1.8 13 f f: apply brake fluid. G: apply grease. Hg: app...

  • Page 274

    13-6 brakes specifications item standard service limit brake fluid type dot3 – – – fluid level between upper and lower level lines – – – brake pedal brake pedal free play 2 ∼ 10 mm (0.08 ∼ 0.39 in.) – – – brake drums brake drum inside diameter 180.000 ∼ 180.160 mm (7.0866 ∼ 7.0929 in.) 180.75 mm (7....

  • Page 275

    Brakes 13-7 special tools inside circlip pliers: 57001-143 rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 brake drum remover: 57001-1260 brake drum pusher, m18 × 1.5: 57001-1261 brake drum holder: 57001-1325 brake drum remover nuts: 57001-1326.

  • Page 276

    13-8 brakes brake fluid brake fluid recommendation use extra heavy-duty brake fluid only from a container marked dot3. Recommended brake fluid type: dot3 warning never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not m...

  • Page 277

    Brakes 13-9 brake fluid brake line air bleeding • remove the maintenance cover. • check that there is plenty of fluid in the reservoir. Note ○ the fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservoir runs completely out a...

  • Page 278

    13-10 brakes brake pedal and master cylinder brake pedal free play adjustment • refer to brake pedal free play adjustment in the periodic maintenance chapter. Master cylinder removal • remove: front fender upper (see frame chapter) brake hose banjo bolts [a] brake pipe nipple [b] (unscrew) • immedia...

  • Page 279

    Brakes 13-11 brake pedal and master cylinder master cylinder inspection • check that there are no scratches, rust or pitting on the inside of the cylinder and on the outside of the piston. If the cylinder or piston shows any damage, replace them. • inspect the primary cups and secondary cups. If a c...

  • Page 280

    13-12 brakes brake hoses and pipes brake hose and pipe inspection • refer to brake hose and pipe inspection in the periodic maintenance chapter. Brake hose and pipe replacement • refer to brake hose and pipe replacement in the peri- odic maintenance chapter..

  • Page 281

    Brakes 13-13 brake drums brake drum removal • remove: wheel (see wheel removal) cotter pin [a] axle nut [b] ○ loosen the axle nut, while applying the brake, and release the brake. • the brake drums are press-fitted on the axles. Use the brake drum remover, stud nuts, and rotor puller (special tools)...

  • Page 282

    13-14 brakes brake drums • grease (amoco rykon premium grease no.2 ep green): front brake drum grease seal lips [a] • tighten: • do not press the drum bolts out. If a drum bolt is damaged, replace the drum. Torque - front axle nuts: 200 n·m (20 kgf·m, 140 ft·lb) rear axle nuts: 300 n·m (31 kgf·m, 22...

  • Page 283

    Brakes 13-15 brake panel assemblies brake panel removal • remove: brake drum (see brake drum removal) brake pipe nipple [a] ○ immediately wipe up any brake fluid that spills. Caution brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up imme- diately. Loosen the...

  • Page 284

    13-16 brakes brake panel assemblies • remove the following for the rear brake panel removal. Cotter pin [a] clevis pin [b] parking brake lever linkage [c] • remove: brake panel mounting bolts [a] brake panel [b] brake panel installation • set the brake shoe clearance adjuster so that the drum can be...

  • Page 285

    Brakes 13-17 brake panel assemblies • grease (amoco rykon premium grease no. 2 ep green): brake panel seating surface • apply a non-permanent locking agent: brake panel mounting bolts • apply brake fluid: brake pipe nipple threads • tighten: torque - wheel cylinder mounting bolts: 11 n·m (1.1 kgf·m,...

  • Page 286

    13-18 brakes brake panel assemblies wheel cylinder assembly • before assembly, clean all parts including the wheel cylin- der with brake fluid or alcohol, and apply brake fluid to the removed parts and the inner wall of the cylinder. Caution use only brake fluid, isopropyl alcohol, or ethyl al- coho...

  • Page 287

    Brakes 13-19 brake panel assemblies brake shoe spring inspection • visually inspect the brake shoe springs [a] for breaks or distortion. If the springs are damaged in any way, replace them..

  • Page 288

    13-20 brakes parking brake lever and cables parking brake lever travel adjustment • refer to parking brake lever and cables in the periodic maintenance chapter. Parking brake cable lubrication whenever the parking brake cables are removed, lubri- cate the cables as follows. • apply a thin coating of...

  • Page 289: Suspension

    Suspension 14-1 14 suspension table of contents exploded view........................................................................................................................ 14-2 specifications .....................................................................................................

  • Page 290

    14-2 suspension exploded view.

  • Page 291

    Suspension 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 strut locknut 49 5.0 36 2 strut mounting nuts 44 4.5 33 3 strut clamp nut 98 10 72 4 tie-rod end nuts 34 3.5 25 5 front suspension arm pivot bolts 98 10 72 6 front suspension arm joint nut 78 8.0 58 7 leaf spring mounting nu...

  • Page 292

    14-4 suspension specifications item standard service limit rear shock absorbers (usable range) spring preload setting position 3rd position 1 ∼ 5 positions.

  • Page 293

    Suspension 14-5 special tool steering stem nut wrench: 57001-1100

  • Page 294

    14-6 suspension struts and rear shock absorbers strut (front shock absorber) removal • remove: front fender upper (see frame chapter) front wheel (see wheels/tires chapter) brake panel (see brakes chapter) brake hose retainer [a] brake hose [b] (from bracket) strut clamp bolt and nut [c] • remove: s...

  • Page 295

    Suspension 14-7 struts and rear shock absorbers • bend the cotter pin [a] over the nut [b]. Strut spring replacement in addition to the standard springs, hard springs are avail- able. The hard springs stiffen the strut action and accelerate the rebound damping. • remove: strut (see strut removal) • ...

  • Page 296

    14-8 suspension struts and rear shock absorbers • apply grease to the upper and lower side on the following parts, and install them. Dust seal [a] thrust washer [b] ○ face the projection on the thrust washer downward. • install: holder [a] large washer [b] small washer [c] lock nut [d] ○ push down t...

  • Page 297

    Suspension 14-9 struts and rear shock absorbers rear shock absorber removal • remove: rear wheel (see wheels/tires chapter) • remove: rear shock absorber mounting bolts and nuts [a] (while moving the frame up or down with a jack) rear shock absorber [b] rear shock absorber installation • install the...

  • Page 298

    14-10 suspension front suspension arms front suspension arm removal • remove: front wheel (see wheels/tires chapter) • hold the front brake drum and panel assembly in position. • remove: front suspension arm pivot bolts [a] • remove: front suspension arm joint nut [a] front suspension arm joint from...

  • Page 299

    Suspension 14-11 front suspension arms • bend the cotter pin [a] over the nut [b]. Front suspension arm inspection • visually inspect the front suspension arm for breaks or distortion. If the front suspension arm is damaged in any way, re- place it. • check the rubber bushings in the pivots. Replace...

  • Page 300

    14-12 suspension leaf springs and dampers leaf spring removal • remove: rear wheel (see wheels/tires chapter) • hold the rear brake drum and panel assembly in position. • free the brake hose [a], pipe, and cable from the leaf spring. ○ immediately wipe up any brake fluid that spills. Caution brake f...

  • Page 301

    Suspension 14-13 leaf springs and dampers leaf spring inspection • visually inspect the leaf spring for breaks or distortion. If the leaf spring is damaged in any way, replace it. • check the rubber bushings in the mounts and the damper. Replace any bushings or damper that are worn, cracked, hardene...

  • Page 303: Steering

    Steering 15-1 15 steering table of contents exploded view........................................................................................................................ 15-2 specifications .........................................................................................................

  • Page 304

    15-2 steering exploded view.

  • Page 305

    Steering 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 steering wheel mounting nut 52 5.3 38 2 intermediate shaft clamp bolts 20 2.0 14 3 tie-rod end locknuts 49 5.0 36 4 rack guide spring cap locknut 39 4.0 29 5 steering gear assembly bracket bolts 52 5.3 38 l 6 strut clamp nut 9...

  • Page 306

    15-4 steering specifications item standard service limit steering wheel steering wheel free play 0 ∼ 20 mm (0 ∼ 0.79 in.) – – – steering gear assembly tie-rod length 43.5 mm (1.71in.) – – – (distance between boot end and locknut).

  • Page 307

    Steering 15-5 steering wheel and main shaft assembly steering wheel position adjustment • loosen the steering main shaft bracket mounting nuts [a]. • adjust the steering wheel position. • tighten the main shaft bracket mounting nuts securely. Steering wheel free play inspection • refer to steering w...

  • Page 308

    15-6 steering steering wheel and main shaft assembly • remove: steering gear shaft clamp bolt [a] intermediate shaft [b] steering wheel and main shaft installation • grease: dust cover lips [a] • connect the intermediate shaft [a] to the main shaft and the steering gear pinion in any position. Mount...

  • Page 309

    Steering 15-7 steering gear assembly steering gear assembly removal • remove: front fender upper (see frame chapter) steering wheel and main shaft assembly front radiator (see cooling system chapter) tie-rod end nuts [a] tie-rod ends [b] from steering knuckles ○ install a suitable nut on the stud of...

  • Page 310

    15-8 steering steering gear assembly • install the boot [a] so that the mark (f, arrow) [b] faces forward. • tighten: torque - steering gear assembly bracket bolts: 52 n·m (5.3 kgf·m, 38 ft·lb) tie-rod end nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) • insert a new cotter pin [a]. Note ○ when inserting the co...

  • Page 311

    Steering 15-9 steering gear assembly tie-rod length adjustment • check the length [a] of the tie-rod distance between the dust boot end [b] of steering gear assembly and the lock- nut [c]. This distance should be the specified value for both the left and right tie-rods. Tie- rod length (distance bet...

  • Page 312

    15-10 steering steering knuckles steering knuckle removal • remove: front wheel (see wheels/tires chapter) front brake drum (see brakes chapter) front brake panel assembly (see brakes chapter) tie-rod end nut [a] tie-rod end [b] from steering knuckle ○ install a suitable nut on the stud of the tie-r...

  • Page 313

    Steering 15-11 steering knuckles • bend the cotter pin [a] over the nut [b]. • check: toe-in of front wheels (see wheels/tires chapter).

  • Page 315: Frame

    Frame 16-1 16 frame table of contents exploded view........................................................................................................................ 16-2 seat and seat belts...........................................................................................................

  • Page 316

    16-2 frame exploded view.

  • Page 317

    Frame 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 hood latch lever mounting bolt 39 4.0 29 2. Damper 3. Carburetor cover 4. 10 mm (0.39 in.) ad: apply adhesive agent. G: apply grease..

  • Page 318

    16-4 frame exploded view.

  • Page 319

    Frame 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 seat belt mounting bolts 34 3.5 25 2 seat belt buckle mounting bolts 34 3.5 25 3 front bar mounting bolts (lower) 98 10 72 4 front bar mounting bolts (upper) 44 4.5 33 5 top bar mounting bolts 44 4.5 33 6 center bar mounting bolt...

  • Page 320

    16-6 frame exploded view.

  • Page 321

    Frame 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 tail gate fixing lever screw 4.4 0.45 39 in·lb l 2. Large corner side 3. Fix the bolt to inside from outside. Ad: apply adhesive agent. G: apply grease. L: apply a non-permanent locking agent..

  • Page 322

    16-8 frame seat and seat belts front seat removal • remove: seat bracket nuts [a] seat brackets [b] seat [c] • remove: seat back mounting nuts [a] seat back [b] front seat installation • grease: seat bracket inside surfaces [a] • be careful not to overtighten the seat bracket nuts. After tightening ...

  • Page 323

    Frame 16-9 seat and seat belts rear seat removal • fold the rear seat and push its assembly into the stored position. • tilt up the cargo bed. • remove the pivot bolt [a] and nut [b]. • remove the rear seat [c]. • remove: rear seat back mounting nuts [a] rear seat stay [b] rear seat back [c] • remov...

  • Page 324

    16-10 frame seat and seat belts rear seat installation • install the rear seat back [a] so that its thicker side [b] faces upward. Seat belt removal • remove: front seat belt mounting bolts [a] front seat belts [b] • remove: front seat belt buckle mounting bolts [a] front seat belt buckles [b] • rem...

  • Page 325

    Frame 16-11 seat and seat belts seat belt installation • tighten: torque - seat belt mounting bolts: 34 n·m (3.5 kgf·m, 25 ft·lb) ○ install the front [a] and rear seat belts so that their instal- lation angle is 40° ∼ 60° [b]. • tighten: torque - seat belt buckle mounting bolts: 34 n·m (3.5 kgf·m, 2...

  • Page 326

    16-12 frame control panel control panel removal • remove: front cargo compartment (see front cargo compart- ment removal) • disconnect: light switch wire connector hour meter wire connector ignition switch wire connector power outlet connector wire connector coolant temperature warning/parking brake...

  • Page 327

    Frame 16-13 front cargo compartment front cargo hood removal • remove: rear snap pins [a] mounting pins [b] front snap pins [c] • slide the front cargo hood [d] to the right and remove it. • remove: arm assembly bolts [a] arm assembly [b] stay front cargo compartment removal • remove: front cargo ho...

  • Page 328

    16-14 frame cargo bed cargo bed removal • unlock the hooks [a] • raise the rear seat and push it toward the front seat back to store. • remove: rear fenders mounting screws [a] rear fenders [b] • remove: tail/brake light wires [a] tail/brake light mounting bolts [b] tail/brake light assemblies [c] •...

  • Page 329

    Frame 16-15 cargo bed cargo bed installation • grease: cargo bed mounting pins • apply adhesive agent: cargo bed rubber dampers (bottom) [a] frame rubber dampers (upper) [b] tail gate pivot rubber dampers (left and right) • when the cargo bed is disassembled, note the following when installing the p...

  • Page 330

    16-16 frame front, center and rear bars front bar removal • remove: front bar mounting bolts [a] front bar [b] front bar installation • tighten: torque - front bar mounting bolts (lower): 98 n·m (10 kgf·m, 72 ft·lb) front bar mounting bolts (upper): 44 n·m (4.5 kgf·m, 33 ft·lb) rear bar removal • re...

  • Page 331

    Frame 16-17 front, center and rear bars rear bar installation • be sure the rubber plates [a] are in position. ○ plug one hole [b] and plug only half about another hole [c], using the rubber plate. • tighten: torque - rear bar mounting bolts and nuts: 44 n·m (4.5 kgf·m, 33 ft·lb) center bar removal ...

  • Page 332

    16-18 frame front, center and rear bars cargo bed latch position inspection • cargo bed must be latched securely on the cargo bed or the rear seat hooks [b] without rattling. [a] latch if there is rattling or not snug enough, adjust the latch positions. Cargo bed latch position adjustment • release ...

  • Page 333

    Frame 16-19 front fender assembly front cover removal • remove: front cargo hood (see front cargo hood removal) guard bolts [a] collars [b] guard [c] • remove: screws [a] guard [b] • remove: screws [a] • remove: rivets [a] • remove: rivets [a] screws [b] front cover [c].

  • Page 334

    16-20 frame front fender assembly front fender removal • remove: screws [a] guard [b] • remove: coolant reserve tank from frame rivets [a] • remove: screws [a] plugs [b] and screws screws [c] and nuts front fender [d] radiator side cover removal • remove: screws [a] guard [b] • remove: screws [a] ra...

  • Page 335

    Frame 16-21 front fender assembly radiator side cover installation • apply adhesive agent: radiator side cover trims [a] radiator side cover flap removal • remove: radiator side cover (see radiator side cover removal) screw [a], nut and washer radiator side cover flap [b] floor center panel removal ...

  • Page 336

    16-22 frame front fender assembly • remove: screws [a] floor center panel (rear side) [b].

  • Page 337

    Frame 16-23 rear end sub-frame rear end sub-frame removal • remove: engine (see engine removal/installation chapter) transmission case (see transmission chapter) rear end sub-frame mounting bolts [a] and nuts rear end sub-frame [b] rear end sub-frame installation • tighten: torque - rear end sub-fra...

  • Page 339: Electrical System

    Electrical system 17-1 17 electrical system table of contents exploded view................................... 17-2 specifications .................................... 17-6 special tools ..................................... 17-7 parts location.................................... 17-8 precautions......

  • Page 340

    17-2 electrical system exploded view.

  • Page 341

    Electrical system 17-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 igniter mounting bolts 8.8 0.90 78 in·lb 2 regulator/rectifier mounting bolts 8.8 0.90 78 in·lb 3 spark plugs 17 1.7 12 4 alternator rotor nut 120 12 87 5 starter motor mounting bolts 22 2.2 16 l: apply a non-permanen...

  • Page 342

    17-4 electrical system exploded view.

  • Page 343

    Electrical system 17-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil pressure switch 9.8 1.0 87 in·lb ss 2 neutral switch 15 1.5 11 3 radiator fan switch 25 2.5 18 4 coolant temperature warning light switch 23 2.3 17 ss 5 battery holder nuts 17 1.7 12 6. Battery holder 7. Damper 8....

  • Page 344

    17-6 electrical system specifications item standard service limit battery type sealed battery – – – capacity 12 v 18 ah – – – voltage 12.8 v or more – – – charging system type three-phase ac – – – regulator/rectifier output voltage battery voltage ∼ 15 v – – – stator coil resistance 0.2 ∼ 0.4 Ω – – ...

  • Page 345

    Electrical system 17-7 special tools crankcase splitting tool assembly: 57001-1098 hand tester: 57001-1394 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457.

  • Page 346

    17-8 electrical system parts location horn [a] radiator fan switch [b] radiator fan [c] brake light switch [a] horn button [a] light switch [b] hour meter [c] ignition switch [d] coolant temperature warning indicator light [e] parking brake indicator light [f] battery [a] starter circuit relay [a] r...

  • Page 347

    Electrical system 17-9 parts location fuse box [a] ground wire (frame) [b] coolant temperature warning indicator light switch [a] spark plugs [a] ignition coils [b] ground wire (engine) [a] starter motor [b] neutral switch [a].

  • Page 348

    17-10 electrical system parts location oil pressure switch [a] alternator [a] pickup coil [b] fuel pump [c].

  • Page 349

    Electrical system 17-11 precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○ always check battery cond...

  • Page 350

    17-12 electrical system precautions male connectors [b].

  • Page 351

    Electrical system 17-13 battery battery removal • remove: mounting rivets [a] screws [b] battery cover [c] • remove: left side cover (see frame chapter) battery holder nuts [a] battery holder [b] • disconnect the negative terminal wire [a] first, and then positive terminal wire [b]. Caution be sure ...

  • Page 352

    17-14 electrical system battery • put the battery in place on the rubber damper. • connect the three positive wires [a] first, and then con- nect the negative wire [b]. • put a light coat of grease on the terminals to prevent cor- rosion. • install the battery holder. • tighten: torque - battery hol...

  • Page 353

    Electrical system 17-15 battery • place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill. Note ○ do not tilt ...

  • Page 354

    17-16 electrical system battery • after charging is completed, press down firmly with both hands to seat the strip of caps [a] into the battery (don’t pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery. Caution once the strip of the caps [a] is...

  • Page 355

    Electrical system 17-17 battery a sealed battery. Be careful, if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened. Charging condition inspection battery charging condition can be checked by measuring battery t...

  • Page 356

    17-18 electrical system battery note ○ increase the charging voltage to a maximum voltage of 25 v if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current [d], decreas...

  • Page 357

    Electrical system 17-19 charging system alternator rotor and stator removal • remove, if the engine is mounted on the frame: cargo bed propeller shafts • remove: alternator cover bolts [a] alternator cover [b] • remove: pickup coil (see pickup coil removal) alternator rotor nut [a] ○ hold the altern...

  • Page 358

    17-20 electrical system charging system • disconnect the alternator wire connector [a]. • remove: alternator stator mounting screws [a] alternator stator [b] alternator rotor and stator installation • apply non-permanent locking agent: alternator stator mounting screws • clean [a] the inside of the ...

  • Page 359

    Electrical system 17-21 charging system • install: pickup coil (see pickup coil installation) • route the electrical wires as shown. Alternator wire [a] pickup coil wires [b] bands [c] charging system operational inspection • check battery condition. Note ○ always check battery condition before cond...

  • Page 360

    17-22 electrical system charging system stator coil resistance • disconnect the alternator wire connector. • measure the stator coil resistance. ○ connect an ohmmeter between the alternator wires. Stator coil resistance standard: 0.2 ∼ 0.4 Ω if the meter does not read as specified, replace the alter...

  • Page 361

    Electrical system 17-23 charging system regulator circuit test-1st step: • connect the test light and the 12 v battery to the regula- tor/rectifier as shown. • check bk1, bk2, and bk3 terminals respectively. Caution the test light limits the current flow through the reg- ulator/rectifier. Do not use...

  • Page 362

    17-24 electrical system charging system charging system circuit 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Battery 5. 30 a fuse 6. Load.

  • Page 363

    Electrical system 17-25 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, high tension coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. Caution do not disconnect the battery leads or any ot...

  • Page 364

    17-26 electrical system ignition system ignition coil installation • install: tube [a] (for rear ignition coil wire) ignition coil inspection • measure the ignition coil [c] resistance. Measure primary winding resistance [a] measure secondary winding resistance [b] ignition coil winding resistance p...

  • Page 365

    Electrical system 17-27 ignition system • turn the ignition switch on, and run the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage. • repeat the measurements 5 times for one ignition coil. Ignition coil primary peak voltage standard: 264 v or more • repeat t...

  • Page 366

    17-28 electrical system ignition system pickup coil peak voltage inspection note ○ be sure the battery is fully charged. • remove the spark plug caps, but do not the spark plugs. • remove: pickup coil wire connector [a] • set the hand tester [b] to the 10 v dc range. • connect the peak voltage adapt...

  • Page 367

    Electrical system 17-29 ignition system ignition system inspection.

  • Page 368

    17-30 electrical system ignition system ignition system circuit 1. Ignition switch 2. 30 a fuse 3. Battery 4. Igniter 5. Ignition coils 6. Spark plugs 7. Pickup coil.

  • Page 369

    Electrical system 17-31 electric starter system starter motor removal • remove: torque converter case (see converter system chapter) starter motor wires (from starter motor) [a] starter motor mounting bolts [b] starter motor [c] starter motor installation • clean the mating surface [a] of the starte...

  • Page 370

    17-32 electrical system electric starter system • remove: armature [a] positive brushes [b] brush plate [c] • remove: drive end cover screws [a] drive end cover [b] • remove: starter clutch [a] idle gear [b] steel ball [c] • remove: retainer [a] and rollers [b] • remove: return spring [a].

  • Page 371

    Electrical system 17-33 electric starter system starter motor assembly • grease: retainer and rollers starter clutch steel ball return spring armature bearing • install the retainer [a] and rollers [b] on the drive end cover shaft [c]. • install: starter clutch [a] idle gear [b] • install: steel bal...

  • Page 372

    17-34 electrical system electric starter system • fit the projection [a] on the yoke [b] into the notch [c] in the magnetic switch [d]. • install the magnetic switch wire and tighten the nut se- curely. Carbon brush inspection • measure the carbon brush length [a]. If the brush length is less than t...

  • Page 373

    Electrical system 17-35 electric starter system • measure the diameter [a] of the commutator. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator diameter standard: 30 mm (1.18 in.) service limit: 29 mm (1.14 in.) armature inspection • usi...

  • Page 374

    17-36 electrical system electric starter system starter circuit relay inspection • remove: starter circuit relay [a] starter circuit relay connector [b] • connect the hand tester [a] and 12 v battery [b] to the starter circuit relay [c] as shown. If the relay does not work as specified, the relay is...

  • Page 375

    Electrical system 17-37 electric starter system electric starter circuit 1. Starter motor 2. Starter circuit relay 3. Neutral switch 4. Battery 5. 30 a fuse 6. Ignition switch.

  • Page 376

    17-38 electrical system fuel pump and relay the fuel pump does not operate when the ignition switch is turned on alone. The pump operates when the engine is running. When fuel level in the float chamber is low, the fuel pump operates to supply fuel into the float chamber. When the fuel reaches a cer...

  • Page 377

    Electrical system 17-39 fuel pump and relay fuel pump and relay circuit 1. Ignition switch 2. Battery 3. 30 a fuse 4. Fuel pump relay 5. Fuel pump 6. Igniter.

  • Page 378

    17-40 electrical system radiator fan radiator fan circuit inspection • disconnect the wires from the radiator fan switch [a]. • using an auxiliary wire [b], connect the radiator fan switch wires. If the radiator fan rotates, inspect the radiator fan switch. If the radiator fan does not rotate, inspe...

  • Page 379

    Electrical system 17-41 lighting system headlight beam adjustment • turn the adjusting screw [a] on each headlight rim in or out to adjust the headlight vertically. Headlight bulb replacement • remove: front cargo bed compartment (see frame chapter) dust cover [a] • turn the bulb holder [b] counterc...

  • Page 380

    17-42 electrical system lighting system tail/brake light replacement • remove the lock pin type bulb [a]. ○ remove the tail/brake light lens. ○ push the bulb in, turn it counterclockwise, and pull it out of the socket. Caution do not use bulbs rated for greater wattage than the specified value. ○ be...

  • Page 381

    Electrical system 17-43 lighting system lighting system circuit 1. Headlights 2. Tail/brake lights 3. Light switch 4. Brake light switch 5. Coolant temperature warning light switch 6. Parking brake light switch 7. Parking brake indicator light 8. Coolant temperature warning indicator light 9. Batter...

  • Page 382

    17-44 electrical system switches brake light switch adjustment • refer to brake light switch adjustment in the periodic maintenance chapter. Switch inspection • using a hand tester, check to see that only the connec- tions shown in the table (see wiring diagram) have con- tinuity (about zero ohms). ...

  • Page 383

    Electrical system 17-45 switches coolant temperature warning light switch inspection • remove: coolant temperature warning light switch (see cooling system chapter) • suspend the switch [a] in a container of coolant so that the temperature sensing projection and threaded portion are submerged. • sus...

  • Page 384

    17-46 electrical system fuses fuse removal • unlock the hook to lift up the lid [a]. • pull the fuses [b] straight out of the fuse box with a needle nose pliers. Fuse installation if a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new...

  • Page 385

    Electrical system 17-47 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 386

    17-48 electrical system wiring diagram.

  • Page 387

    Electrical system 17-49 wiring diagram.

  • Page 389: Appendix

    Appendix 18-1 18 appendix table of contents troubleshooting guide ........................................................................................................... 18-2 cable, wire, and hose routing ..............................................................................................

  • Page 390

    18-2 appendix troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine doesn’t start, starting difficulty: starter motor not rot...

  • Page 391

    Appendix 18-3 troubleshooting guide poor running or no power at high speed: firing incorrect: spark plug dirty, broken, or maladjusted spark plug cap shorted or not in good con- tact spark plug incorrect igniter trouble ignition coil trouble pickup coil trouble fuel/air mixture incorrect: choke valv...

  • Page 392

    18-4 appendix troubleshooting guide shifting too quickly: drive pulley spring weak driven pulley spring weak or incorrectly in- stalled (too loose) shifting too slowly: belt dirty or worn drive or driven pulley sheave dirty or worn drive pulley weight doesn’t move smoothly drive pulley movable sheav...

  • Page 393

    Appendix 18-5 troubleshooting guide brown smoke: main jet too small fuel level too low air cleaner poorly sealed or missing handling and/or stability unsatisfactory: steering wheel hard to turn: steering shaft bearing damaged steering shaft lubrication inadequate steering shaft bent steering gear as...

  • Page 394

    18-6 appendix cable, wire, and hose routing 1. Headlight wire 2. Main harness 3. Band (do not tighten band on wire connector joint.) 4. Black/yellow wire 5. Red/black wire 6. Red/yellow wire.

  • Page 395

    Appendix 18-7 cable, wire, and hose routing 1. Water temperature warning/parking brake indicator lights 2. Oil pressure warning indicator light wire (for option) 3. Power outlet connector 4. Ignition switch 5. Hour meter 6. Speedometer cable (option) 7. Horn switch wire 8. Speedometer light (option)...

  • Page 396

    18-8 appendix cable, wire, and hose routing 1. Radiator fan motor 2. Radiator fan motor wire 3. Radiator fan switch 4. Horn wire 5. Front final gear case breather hose 6. Radiator fan motor tube 7. Brake light switch 8. Speedometer cable (option) 9. Main harness 10. Front final gear case 11. Clamp 1...

  • Page 397

    Appendix 18-9 cable, wire, and hose routing 1. Brake master cylinder 2. Keep hose away from steering intermediate shaft. 3. Install clamp in this direction. 4. Brake hose (left).

  • Page 398

    18-10 appendix cable, wire, and hose routing 1. Main harness 2. Choke cable 3. Differential shift cable 4. Brake light switch 5. Radiator fan motor tube 6. Throttle cable 7. Transmission shift cable 8. 2wd/4wd shift cable 9. Hi/low shift cable 10. Radiator fan switch wire 11. Horn wires 12. Front fi...

  • Page 399

    Appendix 18-11 cable, wire, and hose routing 1. Ignition switch wire 2. Headlight wire (left) 3. Headlight wire (right) 4. Main harness 5. Band 6. 110 mm (4.3 in.) 7. 80 mm (3.2 in.) 8. 170 mm (6.7 in.) 9. 300 mm (11.8 in.) 10. 140 mm (5.5 in.).

  • Page 400

    18-12 appendix cable, wire, and hose routing 1. Breather tube 2. Brake hose 3. Brake pipe 4. Clamp 5. Band.

  • Page 401

    Appendix 18-13 cable, wire, and hose routing 1. Front brake master cylinder 2. Brake hose 3. Harness 4. Clamp 5. Band 6. Parking brake lever boot.

  • Page 402

    18-14 appendix cable, wire, and hose routing 1. Right brake drum 2. Right frame 3. Breather tube 4. Brake pipe 5. Brake cable 6. Left brake drum 7. Left frame 8. Band.

  • Page 403

    Appendix 18-15 cable, wire, and hose routing 1. Run the cables straight to front. 2. Trims 3. Run the cables under the main harness and fuel hose. 4. Run the cables on the damper of right rear brake pipe. 5. Choke cable 6. Fix the differential shift cable, 2wd/4wd shift cable and throttle cable with...

  • Page 404

    18-16 appendix cable, wire, and hose routing 1. Right parking brake cable 2. Left parking brake cable 3. Clamp 4. Right side round pipe end of frame 5. Plug.

  • Page 405

    Appendix 18-17 cable, wire, and hose routing 1. Accessory connectors 2. Headlight wire (left) 3. Ground wire (steering gear assembly) 4. Radiator fan motor wire 5. Radiator fan switch wire 6. Horn wire 7. Headlight wire (right) 8. Oil pressure warning indicator light wire (for option) 9. Power outle...

  • Page 406

    18-18 appendix cable, wire, and hose routing 1. Brake/tail light wire 2. Clamp 3. Band 4. Neutral switch wire 5. 80 mm (3.2 in.) 6. Neutral switch cap 7. 0 ∼ 20° 8. Frame pipe 9. Carburetor 10. Carburetor air vent tube 11. Insert the air vent tube into the hole in frame pipe to inside wall of frame ...

  • Page 407

    Appendix 18-19 cable, wire, and hose routing 1. Floor center covers 2. Position the rubber protector for the (+) wire lead. 3. Fuel pump wire 4. Band 5. Cover 6. Alternator wire 7. (–) wire lead 8. (+) wire lead 9. Position the white tape on the harness. 10. Ground wire (frame) 11. Main harness 12. ...

  • Page 408

    18-20 appendix cable, wire, and hose routing 1. Regulator/rectifier 2. Starter circuit relay 3. Fuel pump relay 4. Igniter 5. Fuel filter 6. Run the harness between the frame and the fuel filter. 7. Fuel pump 8. (–) wire lead 9. (+) wire lead 10. Run the (+) (–) wire leads on the damper of left rear...

  • Page 409

    Appendix 18-21 cable, wire, and hose routing 1. Fuel tank 2. Cross pipe 3. Fuel hose 4. Protector 5. To fuel filter 6. 150 mm (5.91 in.) 7. Fuel hose end (fuel filter side) 8. Protector end 9. All cables 10. Fuel hose with protector 11. Brake pipe 12. Main harness and wire leads 13. Frame 14. Breath...

  • Page 410

    18-22 appendix cable, wire, and hose routing 1. Horn button 2. Horn switch contact 3. Ground wire 4. To main harness 5. Band 6. Front 7. Installation condition of horn switch contact.

  • Page 411

    Appendix 18-23 cable, wire, and hose routing 1. Speedometer cable 2. Clamp the speedometer cable with other cables, harness and brake pipe. 3. Clamp the speedometer cable with other cables. 4. Clamp the speedometer cable with the parking brake cable. 5. Band 6. Bolt 7. Remove plastic cover. 8. Speed...

  • Page 412

    18-24 appendix cable, wire, and hose routing 1. Differential shift cable 2. Cable bracket 3. 100 mm (3.9 in.) 4. Cable clamp 5. 2wd/4wd shift cable.

  • Page 413

    Model application year model beginning frame no. 2005 kaf620-j1 jk1afcj1 □ 5b500001 2005 kaf620-k1 jk1afck1 □ 5b500001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1350-01 printed in japan.